Ranger Drifter Repair Manual F161!10!99a
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RANG.DRFT.REPAIR MANUAL
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Ranger / Drifter Repair Manual FOREWORD This Manual has been prepared to provide information covering normal service repairs and maintenance for the RANGER / DRIFTER SERIES. As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information.
Ford/Mazda Motor Company
WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford/Mazda-trained technicians in mind. This manual may be useful to non-Ford/Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are excepted at least to know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools, which are not recommended by Ford/Mazda Motor Corporation, must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford/Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation. Parts should be replaced with genuine Ford/Mazda replacement parts or with parts, which match the quality of genuine Ford/Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. Ford/Mazda Motor Corporation is not responsible for any problems, which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts, or not being aware of any revision of this manual.
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CONTENTS Title
Section
General Information
Ranger / Drifter Repair Manual
G6 Engine
B1
F8/FE WL, WL Turbo
B2
F2
B3
Lubrication System
D
Cooling System
E
Fuel and Emission Control Systems
APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page.
GI GI
G6
F1
WL, WL Turbo
F2
F2 CIS
F3
F2 CARB
F4
Engine Electrical System
G
Clutch
H
Manual Transmission
M15M–D M15MX–D R15M–D R15MX–D
J2
Transfer
J3
J1
Propeller Shaft
L
Front and Rear Axles
M
Steering System
N
Braking System
P
Suspension
R
Body
S
Body Electrical System
T
Heater and Air Conditioner Systems
U
Technical Data
TD
Special Tools
ST ST
1999 Ford/Mazda Motor Company All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford/Mazda Motor Company. PRINTED IN JAPAN, JAN.1999 F161–10–99A
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VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs. JMZ JMZ JMZ
UN1B320W UN8B320W UN8F420W
100001– 100001– 100001–
European specs. JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ
UN1*620W UN1*62WW UN1*320W UN1*32WW UN8*720W UN8*72WW UN8*320W UN8*32WW
100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001–
General specs. (L.H.D.) MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7
UNY02100 UNY021WW UNYOW100 UNYOW1 WW UN2*6*00 UN2*6*WW UN3*6*00 UN3*6*WW UN2*2*00 UN2*2*WW
100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001–
General specs. (R.H.D.) MM6 UNY02100 MM6 UNYOW100
100001– 100001–
RELATED MATERIALS B Series Training Manual .......................................... 3333-10-99A Engine Workshop Manual WL, WL Turbo ................ 1532-10-96C Engine Workshop Manual G6 .................................... 1640-10-99A Engine Workshop Manual F2 .................................... 1641-10-99A Manual Transmission Workshop Manual M15M-D M15MX-D .............................................................. 1645-10-99A
Manual Transmission Workshop Manual R15M-D R15MX-D.................................................... 1642-10-99A B Series Wiring Diagrams (European, General specs. (L.H.D.)) ..................... 5449-10-99A B Series Wiring Diagrams (European, General specs. (R.H.D.)) .................... 5450-10-99A
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GENERAL INFORMATION HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . . SERVICING PROCEDURE . . . . . . . . . . . . . . . SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADVISORY MESSAGES . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES . . . . . . . . . . . . PROTECTION OF THE VEHICLE . . . . . . . . . . PREPARATION OF TOOLS AND MEASURING EQUIPMENT . . . . . . . . . . . . . . SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . DISCONNECTION OF THE NEGATIVE BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION DURING REMOVAL, DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF PARTS . . . . . . . . . . . . . . CLEANING OF PARTS . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER PARTS AND TUBING . . . . . . . . . . . HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . . VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GI-1 GI-1 GI-1/2 GI-3 GI-3 GI-3/6 GI-6 GI-7 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8/9 GI-9 GI-9 GI-9 GI–19 GI–19 GI–10 GI–10
HOW TO USE THIS MANUAL RANGE OF TOPICS This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment Simple operations which can be performed easily just by looking at the vehicle, such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.
DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . GI–10 INSTALLATION OF RADIO SYSTEM . . . . . . . . GI–10 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . GI–11 ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . GI–11 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–11/13 ELECTRICAL TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–13 JACKING POSITIONS . . . . . . . . . . . . . . . . . . . . . . GI–14 VEHICLE LIFT (2 SUPPORTS) POSITIONS . . . GI–14 SAFETY STAND POSITIONS . . . . . . . . . . . . . . . GI–14 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–15 TOWING HOOKS . . . . . . . . . . . . . . . . . . . . . . . . GI–16 TIEDOWN HOOKS . . . . . . . . . . . . . . . . . . . . . . . GI–16 IDENTIFICATION NUMBER LOCATIONS . . . . . GI–16 VEHICLE IDENTIFICATION NUMBER . . . . . . GI–16 ENGINE IDENTIFICATION NUMBER . . . . . . . GI–16 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI–17/19 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–19 PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI-20 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20
SERVICING PROCEDURE Inspection, Adjustment The procedures for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.
SHOWS PROCEDURE ORDER FOR SERVICE
SHOWS TIGHTENING TORQUE SPECIFICATIONS
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HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part. SHOWS SERVICE ITEM (S)
Procedure
Indicates any relevant references which need to be followed during installation.
“Removal/Installation” Portion “Inspection After Installation” Portion
SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION
SHOWS PROCEDURE ORDER FOR SERVICE Install the parts by performing Steps 1—3 in reverse order
SHOWS APPLICATION POINTS OF GREASE, ETC. SHOWS TIGHTENING TORQUE SPECIFICATIONS
SHOWS EXPENDABLE PARTS
SHOWS DETAILS SHOWS TIGHTENING TORQUE UNITS
SHOWS THERE ARE REFERRAL NOTES FOR SERVICE
SHOWS SPECIAL SERVICE TOOL (SST) NO.
SHOWS REFERRAL NOTES FOR SERVICE
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HOW TO USE THIS MANUAL SYMBOLS There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such materials during service. Symbol
Meaning
TROUBLESHOOTING PROCEDURE Basic Flow of Troubleshooting
Kind SECTION F ONLY
Apply oil
R
SST
Appropriate new engine oil or gear oil
Apply brake fluid
Appropriate new brake fluid
Apply automatic transaxle/ transmission fluid
Appropriate new automatic transaxle/ transmission fluid
Apply grease
Appropriate grease
Apply sealant
Appropriate sealant
Apply petroleum jelly
Appropriate petroleum jelly
Replace part
O-ring, gasket, etc.
Use SST
Appropriate SST
ADVISORY MESSAGES You’ll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual.
ACTUAL TROUBLESHOOTING PROCEDURES SECTION K ONLY
IF MENTIONED
SECTION F ONLY
On-board diagnosis The service codes are important hints for repairing malfunctions that are difficult to simulate. By following the service code, perform the inspection to quickly and accurately diagnose the malfunction. The self-diagnostic function is used during inspection. When a service code is shown, specifying the cause of a malfunction, continue the inspection according to the items indicated by the self-diagnostic function. Engine tune-up (Section F) Any necessary adjustments are made after starting the engine.
Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Basic inspection (Section K) The basic inspection is performed to quickly narrow down the possible causes after a malfunction occurs regardless of the symptoms. ST The basic inspection is performed to also locate the region of many malfunction symptoms.
Caution A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored.
Diagnostic index The diagnostic index lists the symptoms of the malfunctions. Select the symptoms pertaining or most closely pertaining to the actual malfunction.
Note A Note provides added information that will help you to complete a particular procedure.
Quick diagnosis chart (If mentioned) The quick diagnosis chart lists the diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction.
Specification The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
Symptom troubleshooting Symptom troubleshooting quickly determines the location of the malfunction according to the type of symptoms.
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HOW TO USE THIS MANUAL Procedures For Use Using the basic inspection
Perform the basic inspection before the symptom troubleshooting. Perform each step in the order shown. The reference column lists the location of the detailed procedure for each basic inspection. Although inspection and adjustment are performed as according to the procedures referred to in the reference column, if the cause of the malfunction is discovered during the basic inspection, continue the procedures as indicated in the remarks column. SHOWS INSPECTION ORDER
SHOWS ITEM NAMES FOR THE DETAILED PROCEDURES
SHOW POINTS REQUIRING ATTENTION IN REGARD TO INSPECTION RESULTS
Perform malfunction diagnosis according to No. 26 “HOLD INDICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON” or No. 27 “HOLD INDICATOR LIGHT ILLUMINATES WHEN HOLD SWITCH IS NOT TURNED ON”
Using the diagnostic index The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting. The exact malfunction symptoms can be selected using the details.
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HOW TO USE THIS MANUAL Using the quick diagnosis chart The chart lists the relation between the symptoms and cause of the malfunction. The chart is effective in quickly narrowing down the relation between the symptoms and cause of the malfunction and specifying the region of the common cause when multiple malfunction symptoms occur. The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart.
PARTS WHICH MAY BE THE CAUSE OF PROBLEMS ENGINE QUICK DIAGNOSTIC CHART
PART WHICH MAY BE THE SYMPTOM
CHOOSE THE ACTUAL SYMPTOM
ST
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HOW TO USE THIS MANUAL Using the symptom troubleshooting Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for each
trouble symptom.
TROUBLESHOOTING HINTS describes possible point of malfunction.
TROUBLE SYMPTOM
STEP shows the order of troubleshooting.
ACTION describes the appropriate action to take as a result (Yes/No) of INSPECTION.
INSPECTION describes an inspection (method) to quickly determine the failed part.
Reference page(s) for the detailed procedure to perform INSPECTION is shown. How to perform ACTION is described in the relative material shown.
TEXT SEQUENCE The text sequence is as indicated by the arrows shown below. Example:
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UNITS
UNITS
The actual converted values for 2.7 kgf/cm2 are
Electric current
A (ampere)
Electric power
W (watt)
Electric resistance
(ohm)
Electric voltage
V (volt)
Length
264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2.7 is used as a lower limit, so its converted values are rounded up to 270 and 39.
mm (millimeter) in (inch) kPa (kilo pascal)
Negative pressure
mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal)
Positive pressure
kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch)
Number of revolutions
rpm (revolutions per minute) N·m (Newton meter) kgf·m (kilogram force per meter)
Torque
kgf·cm (kilogram force per centimeter) ft·lbf (foot pound) force in·lbf (inch pound) force L (liter) US qt (U.S. quart) Imp qt (Imperial quart)
Volume
ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce)
Weight
g (gram) oz (ounce)
Conversion to SI Units (Système International d’Unités) All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values.
ST
Rounding off Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and lower limits When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
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FUNDAMENTAL PROCEDURES REMOVAL OF PARTS While correcting a problem, try also to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering.
FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas before starting work.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting any work.
DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
SPECIAL SERVICE TOOLS Use special tools when they are required.
INSPECTION DURING REMOVAL, DISASSEMBLY When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.
DISCONNECTION OF THE NEGATIVE BATTERY CABLE Before beginning any work, turn the ignition switch to LOCK, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS unit to deplete its stored power. Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is neccessary to verify those memories before disconnecting the cable.
ARRANGEMENT OF PARTS All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
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FUNDAMENTAL PROCEDURES Oil should be applied to the moving components of
parts. Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before reassembly.
CLEANING OF PARTS All parts to be reused should be carefully and thoroughly cleaned using the appropriate method. SXU00012
Warning Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
ADJUSTMENT Use suitable gauges and/or testers when making adjustments.
SXU00013
RUBBER PARTS AND TUBING Prevent gasoline or oil from spilling on rubber parts or tubing.
REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones: 1
Oil seals
2
Gaskets
3
O-rings
4
Lockwashers
5
Cotter pins
6
Nylon nuts
ST SXU00014
HOSE CLAMPS When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.
SXU00011
Sealant, a gasket, or both should be applied to the
specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks.
SXU00015
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FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM TORQUE FORMULAS When using a torque wrench-SST combination, the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque using the following formulas. Choose the formula that applies to you. Torque Unit
Formula
kgf·m
kgf·m [L/(L+A) ]
kgf·cm
kgf·cm [L/(L+A) ]
ft·lbf
ft·lbf [L/(L+A) ]
in·lbf
in·lbf [L/(L+A) ]
A: The length of the SST past the torque wrench drive. L: The length of the torque wrench.
INSTALLATION OF RADIO SYSTEM If a radio system is installed improprerly or if a highpowered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions. 1. Install the antenna at the farthest point from control modules. 2. Install the antenna feeder as far as possible from the control modules harness, and perpendicular to wiring harnesses. 3. Do not install a high-powered radio system. 4. After installing the radio system, start and idle the engine, then confirm that the engine is not influenced by output waves from the system.
SXU00016
VISE When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
SXU00017
DYNAMOMETER When test-running a vehicle on dynamometer : Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle uncluttered. Watch the water temperature gauge.
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ELECTRICAL SYSTEM Disconnecting Connectors When disconnecting two connectors, grasp the connectors, not the wires.
ELECTRICAL SYSTEM ELECTRICAL PARTS Battery Cable Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable.
SXU00020
Connectors can be disconnected by pressing or
pulling the lock lever as shown. SXU00018
Wiring Harness To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
SXU00021
Locking Connector When locking connectors, listen for a click that will indicate they are securely locked.
CONNECTORS Data Link Connector Insert the probe into the service hole when connecting a jumper wire to the data link connector. Caution Inserting a jumper wire probe into the data link connector terminal may damage the terminal.
SXU00022
Inspection 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring harness side.
SXU00019
SXU00023
2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.
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ELECTRICAL SYSTEM Caution To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal.
SXU00027
SXU00024
Terminals Inspection Pull lightly on individual wires to check that they are secured in the terminal.
Wiring Harness Wiring color codes Two-color wires are indicated by a two-color code symbol. The first letter indicates the base color of the wire and the second the color of the stripe. CODE
COLOR
CODE
COLOR
B
Black
O
Orange
BR
Brown
P
Pink
G
Green
R
Red
GY
Gray
V
Violet
L
Blue
W
White
LB
Light Blue
Y
Yellow
LG
Light Green
B/R
BR/Y BLACK
SXU00025
Replacement Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. Insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down, pull the terminal out from the connector.
RED
BROWN
YELLOW
SXU00028
Fuse Replacement 1. When replacing a fuse, be sure to replace it with one of the specified capacity. If a fuse again fails after it has been replaced, the circuit probably has a short and the wiring should be checked. 2. Be sure the negative battery terminal is disconnected before replacing a main fuse.
TYPE A TYPE B
SXU00026
Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.
SXU00029
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ELECTRICAL SYSTEM 3. When replacing a pullout fuse, use the fuse puller. PULLER
Ohmmeter The ohmmeter is used to measure the resistance between two points in a circuit, and to check for continuity and short circuits. Caution Do not connect the ohmmeter to any circuit to which voltage is applied. This will damage the ohmmeter. POWER SOURCE LINE
FUSE SXU00030
ELECTRICAL TROUBLESHOOTING TOOLS Jumper Wire A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or other damage to wiring harnesses or electronic components.
GROUND LINE
OHMMETER
SXU00034
SXU00032
Voltmeter The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (–) probe (black lead wire) to a body ground. VOLTMETER
POWER SOURCE LINE
BLACK LEAD
RED LEAD GROUND
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JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS, SAFETY STAND POSITIONS REAR
JACKING POSITIONS Warning Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle after it has been lifted. FRONT
SAFETY STAND POSITIONS FRONT
REAR
REAR
VEHICLE LIFT (2 SUPPORTS) POSITIONS FRONT
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TOWING (With Manual Transmission) If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use wheel dollies.
TOWING Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed.
(With Automatic Transmission) If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies. If all four wheels are on the ground, the vehicle may be towed only forward. Do not exceed 45 km/h (28 mph) and a distance of 15 km (9.3 miles); you could damage the transmission.
Wheel dollies
If speed must exceed 45 km/h (28 mph) or a towing distance of 15 km (9.3 miles), use one of these methods: Place the rear wheels on dollies. Tow with the rear wheels off the ground. Disconnect the propeller shaft.
Wheel dollies
If the transmission or rear axle is inoperative, tow with the rear wheels off the ground. Caution Follow these instructions when towing the vehicle with all wheels on the ground or with the front wheels on the ground and the rear wheels raised.
Caution Do not tow with sling-type equipment. This could damage your vehicle. Use wheel-lift or flatbed equipment.
(44 Model) 1. Put the transfer case in 2H. 2. Set the transfer case at 2H and the hubs at FREE. (All Models) 1. Set the transmission in neutral. 2. Turn the engine switch to ACC position. 3. Release the parking brake. Remember that power assist for the brakes
and steering will not be available when the engine is not running. If your Ford/Mazda has 44, change to 2-wheel drive before having the vehicle towed. If this is not possible, tow with all four wheels raised.
CONTINUED
GI–15
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TOWING, IDENTIFICATION NUMBER LOCATIONS TOWING HOOKS Caution The towing hooks should be used only in an emergency (e.g. to get the vehicle out of a ditch or a snow bank). When using the towing hooks, always pull the cable or chain in a straight direction with respect to the hook. Apply no sideways force.
IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER
FRONT 44
ENGINE IDENTIFICATION NUMBER G6
TIEDOWN HOOKS Caution Do not use the hook loops under the front for towing. They are designed ONLY for tying down the vehicle when it is being transported. Using them for towing will damage the bumper.
WL, WL Turbo
FRONT 42
F2 CIS F2 CARB 44
CONTINUED
GI–16
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NEW STANDARDS
NEW STANDARDS Following is a comparison of the previous standard and the new standard. New Standard Abbreviation AP
Name
Previous Standard Abbreviation
Accelerator Pedal
—
Accelerator Pedal
ACL
Air Cleaner
—
Air Cleaner
A/C
Air Conditioning
—
Air Conditioning
Barometric Pressure
—
Atmospheric Pressure
Battery Positive Voltage
VB
Battery Voltage
—
Brake Switch
—
Stoplight Switch
—
Calibration Resistor
—
Corrected Resistance
Camshaft Position Sensor
—
Crank Angle Sensor
CAC
Charge Air Cooler
—
Intercooler
CLS
Closed Loop System
—
Feedback System
CTP
Closed Throttle Position
—
Fully Closed
Closed Throttle Position Switch
—
Idle Switch
—
Clutch Position
BARO B
CMP sensor
— CPP
Clutch Pedal Position
CIS
Continuous Fuel Injection System
CS sensor CKP sensor
Control Sleeve Sensor
EGI CSP sensor
Remark
Name
#6
Electronic Gasoline Injection System Control Sleeve Position Sensor
Crankshaft Position Sensor
—
Crank Angle Sensor 2
DLC
Data Link Connector
—
Diagnosis Connector
DTM
Diagnostic Test Mode
—
Test Mode
DTC
#6
#1
Diagnostic Trouble Code(s)
—
Service Code(s)
DI
Distributor Ignition
—
Spark Ignition
DLI
Distributorless Ignition
—
Direct Ignition
Electronic Ignition
—
Electronic Spark Ignition
ECT
Engine Coolant Temperature
—
Water Thermo
EM
Engine Modification
—
Engine Modification
—
Engine Speed Input Signal
—
Engine RPM Signal
EVAP
Evaporative Emission
—
Evaporative Emission
EGR
Exhaust Gas Recirculation
—
Exhaust Gas Recirculation
FC
Fan Control
—
Fan Control
FF
Flexible Fuel
—
Flexible Fuel
4GR
Fourth Gear
—
Overdrive
Fuel Pump Relay
—
Circuit Opening Relay
#3
Fuel Cut Valve
#6
EI
— FSO solenoid
Fuel Shut Off Solenoid
FCV
GEN
Generator
—
Alternator
GND
Ground
—
Ground/Earth
HO2S
Heated Oxygen Sensor
—
Oxygen Sensor
Idle Air Control
—
Idle Speed Control
Incorrect Gear Ratio
—
—
IAC —
#2
With heater
#1: Diagnostic trouble codes depend on the diagnostic test mode #2: Controlled by the PCM #3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #6: Part name of diesel engine
CONTINUED
GI–17
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NEW STANDARDS
New Standard Name
Abbreviation
Previous Standard
—
Injection Pump
FIP
Fuel Injection Pump
—
Input/Turbine Speed Sensor
—
Pulse Generator
IAT
Intake Air Temperature
—
Intake Air Thermo
KS
Knock Sensor
—
Knock Sensor
MIL
Malfunction Indicator Lamp
—
Malfunction Indicator Light
MAP
Manifold Absolute Pressure
—
Intake Air Pressure
MAF sensor
Mass Air Flow Sensor
—
Airflow Sensor
MFL
Multiport Fuel Injection
—
Multiport Fuel Injection
OBD
On-Board Diagnostic
—
Diagnosis/Self-Diagnosis
OL
Open Loop
—
Open Loop
—
Output Speed Sensor
—
Vehicle Speed Sensor 1
OC
Oxidation Catalytic Converter
—
Catalytic Converter
O2S
Oxygen Sensor
—
Oxygen Sensor
PNP
Park/Neutral Position
—
Park/Neutral Range
—
Remark
Name
Abbreviation
#6
PCM Control Relay
—
Main Relay
PSP
Power Steering Pressure
—
Power Steering Pressure
PCM
Powertrain Control Module
ECU
—
Pressure Control Solenoid
—
Line Pressure Solenoid Valve
Pulsed Secondary Air Injection
—
Secondary Air Injection System
Pulsed injection
Pump Speed Sensor
—
NE Sensor
#6
Secondary Air Injection
—
Secondary Air Injection System
Injection with air pump
Secondary Air Pulse Valve
—
Reed Valve
Sequential Multipoint Fuel Injection
—
Sequential Fuel Injection
—
1–2 Shift Solenoid Valve
—
Shift A Solenoid Valve
—
2–3 Shift Solenoid Valve
—
Shift B Solenoid Valve
PAIR — AIR SAPV SFI —
Shift Solenoid A
—
Shift Solenoid B
—
Engine Control Unit
Shift Solenoid C
—
3–4 Shift Solenoid Valve
3GR
Third Gear
—
3rd Gear
TWC
Three Way Catalytic Converter
—
Catalytic Converter
Throttle Body
—
Throttle Body
Throttle Position Sensor
—
Throttle Sensor
TB TP sensor TCV
Timer Control Valve
TCC
Torque Converter Clutch
—
Lock-up Position
TCM
Transmission (Transaxle) Control Module
—
EC-AT Control Unit
—
Transmission (Transaxle) Fluid Temperature Sensor
—
ATF Thermosensor
TR
Transmission (Transaxle) Range
—
Inhibitor Position
TC
Turbocharger
—
Turbocharger
Vehicle Speed Sensor
—
Vehicle Speed Sensor
Voltage Regulator
—
IC Regulator
VSS VR
TCV
#4: Device that controls engine and powertrain #6: Part name of diesel engine
Timing Control Valve
#6 #4
#6
CONTINUED
GI–18
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NEW STANDARDS, ABBREVIATIONS
New Standard Abbreviation VAF sensor WU-TWC WOT
Name
Previous Standard Remark
Name
Abbreviation
Volume Air Flow Sensor
—
Air flow Sensor
Warm Up Three Way Catalytic Converter
—
Catalytic Converter
Wide Open Throttle
—
Fully Open
#5
#5: Directly connected to exhaust manifold
ABBREVIATIONS ACC . . . . . . . . . . . . . . ATDC . . . . . . . . . . . . . ATF . . . . . . . . . . . . . . . BTDC . . . . . . . . . . . . . CARB . . . . . . . . . . . . . ELR . . . . . . . . . . . . . . EX . . . . . . . . . . . . . . . FIP . . . . . . . . . . . . . . . HI . . . . . . . . . . . . . . . . HLA . . . . . . . . . . . . . . IG . . . . . . . . . . . . . . . . IN . . . . . . . . . . . . . . . . INT . . . . . . . . . . . . . . . LH . . . . . . . . . . . . . . . . L.H.D. . . . . . . . . . . . . . LO . . . . . . . . . . . . . . . LSD . . . . . . . . . . . . . . LSPV . . . . . . . . . . . . . M ................ MAX . . . . . . . . . . . . . . MFW . . . . . . . . . . . . . MIN . . . . . . . . . . . . . . P/S . . . . . . . . . . . . . . . RFW . . . . . . . . . . . . . . RH . . . . . . . . . . . . . . . R.H.D. . . . . . . . . . . . . SAS . . . . . . . . . . . . . . SST . . . . . . . . . . . . . . TNS . . . . . . . . . . . . . . 2WD . . . . . . . . . . . . . . 4WD . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . 44 . . . . . . . . . . . . . .
Accessories After top dead center Automatic transmission fluid Before top dead center Carburetor Emergency locking retractor Exhaust Fuel injection pump High Hydraulic lash adjuster Ignition Intake Intermittent Left hand Left hand drive Low Limited slip differential Load sensing proportioning valve Motor Maximum Manual freewheel Minimum Power steering Remote freewheel Right hand Right hand drive Sophisticated air bag sensor Special service tool Tail number side lights 2 wheel drive 4 wheel drive 4 wheel – 2 drive 4 wheel – 4 drive
CONTINUED
GI–19
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PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. UNDER BONNET-ENGINE RUNNING AT OPERATING TEMPERATURE CHECK the following items: Operation of dashpot Initial ignition timing Injection timing Idle speed Operation of throttle position sensor
EXTERIOR INSPECT and ADJUST, if necessary, the following items to the specifications: Glass, exterior bright metal and paint for damage Wheel lug nuts Tire pressures All weatherstrips for damage or detachment Operation of bonnet release and lock Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps UNDER BONNET-ENGINE OFF INSPECT and ADJUST, if necessary, the following items to the specifications: Fuel, coolant and hydraulic lines, fittings, connections and components for leaks Engine oil level Power steering fluid level (if equipped) Brake and clutch master cylinder fluid levels Windshield washer reservoir fluid level Radiator coolant and specific gravity Tightness of water hose clamps Tightness of battery terminals, electrolyte level and specific gravity Drive belt tensions Accelerator cable and linkage for free movement CLEAN the spark plugs INTERIOR INSTALL the following parts Fuse for accessories CHECK the operation of the following items: Seat controls (sliding and reclining) and headrest Door locks Ignition switch (Engine switch) and steering lock All lights including warning and indicator lights Horn, windshield wipers and washers (if equipped) Wiper blades performance Clean the wiper blades and windshield Antenna Cigarette lighter and clock Tilt steering (if equipped) Air conditioner at various modes (if equipped) CHECK the following items: Presence of spare fuse Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: Operation and fit of windows Pedal height and free play of brake and clutch pedals Parking brake
ON HOIST CHECK the following items: Operation of freewheel hubs Manual transmission oil level Transfer oil level Front differential oil level Rear differential oil level Underside fuel, coolant and hydraulic lines, fittings, connections and components for leaks Tires for cuts or bruises Steering linkage, suspension, exhaust system and all underside hardware for looseness or damage ROAD TEST CHECK the following items: Brake operation Clutch operation Steering control Operation of meters and gauges 3 Squeaks, rattles or unusual noise Engine general performance Emergency locking retractors Operation of transfer AFTER ROAD TEST REMOVE seat and floor mat protective covers CHECK for necessary owner's information material, tools and spare tire in vehicle
Gl-20
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ENGINE (G6) DRIVE BELT ................................................................B1-1 DRIVE BELT INSPECTION ................................B1-1/2 DRIVE BELT ADJUSTMENT .............................B1-2 COMPRESSION INSPECTION ..................................B1-2 TIMING CHAIN .............................................................B1-3 TIMING CHAIN REMOVAL/ INSTALLATION ....................................................B1-3/5 CYLINDER HEAD GASKET ..................................B1-6 CYLINDER HEAD GASKET REPLACEMENT .................................................B1-6/9 HYDRAULIC LASH ADJUSTER (HLA).................B1-10 DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has been stopped. Apply pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys.
HLA REMOVAL/INSTALLATION .....................B1-10/11 HLA TROUBLESHOOTING .............................B1-12 FRONT OIL SEAL.......................................................B1-13 FRONT OIL SEAL REPLACEMENT.................B1-13 REAR OIL SEAL .........................................................B1-14 REAR OIL SEAL REPLACEMENT ..................B1-14 ENGINE .......................................................................B1-15 ENGINE REMOVAL/INSTALLATION ..............B1-15/16 ENGINE DISASSEMBLY/ASSEMBLY ..............B1-17
Deflection Drive belt Generator P/S A/C
mm {in} *New
Used
10.0—12.0 {0.40—0.47} 6.6—7.2 {0.26—0.28}
12.0—14.0 {0.48—0.55} 7.2—8.0 {0.29—0.31}
8.5—10.0 {0.34—0.39}
10.0—11.5 {0.40—0.45}
*: A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has been stopped. Using the SST, check the belt tension between any two pulleys.
N {kgf, Ibf} Drive belt Generator P/S
A/C
*New
Used
491-588 {50-60,110-132} 412—470 {42-48,93—105}
393-490 {40-50,88-110} 354—402 {36-41, 80—90}
557—641 {56.7—65.4, 125—143}
471—556 {48.0—56.7, 106—124}
* A belt that has been on a running engine for less than five minutes.
CONTINUED
B1-1
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DRIVE BELT, COMPRESSION INSPECTION 2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten mounting bolts A and B and locknut C.
COMPRESSION INSPECTION Warning • When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during removal/installation of each component. 1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool off for about 10 minutes. 4. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 5. Disconnect the igniter connector. (Refer to section G, IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) 6. Remove the spark plugs. 7. Connect a compression gauge into the No.1 spark plug hole. 8. Fully depress the accelerator pedal and crank the engine. 9. Note the maximum gauge reading. 10. Inspect compression of each cylinder. Compression Item Standard Minimum Maximum difference between
kPa {kgf/cm2, psi} [rpm] Engine type G6 1255 {12.8, 182} [270] 882.6 {9.0, 128} [270] 196 kPa {2.0 kgf/cm 2, 28 psi}
11. If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. (2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required. (3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. 12. Disconnect the compression gauge. 13. Install the spark plugs. Tightening torque 15—22 N.m {1.5—2.3 kgf.m, 11—l6ft.lbf} 14. Connect the igniter connector. 15. Install the fuel pump relay.
CONTINUED B1-2
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TIMING CHAIN
TIMING CHAIN TIMING CHAIN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 4. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 5. Remove the cylinder head. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 6. Remove the water pump. (Refer to section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 7. Remove the oil pan. (Refer to section D, OIL PAN, OIL PAN REMOVAL/INSTALLATION.) 8. Disconnect the oil strainer stay. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Start the engine and check for engine oil and engine coolant leakage.
1
A/C compressor bracket
10
2 3 4
Generator strap P/S oil pump bracket Generator bracket
11
5 6
Pulley lock bolt ☞ Removal/Installation Note Crankshaft pulley
13
7
Chain cover
8
Spacer
9
Balancer chain guide ☞ Installation Note
12
14 15
Balancer chain, idler sprocket, crankshaft sprocket ☞ Installation Note Timing chain, timing sprocket, camshaft sprocket ☞ Installation Note Chain adjuster ☞ Installation Note Key Timing chain lever ☞ Installation Note Timing chain guide
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TIMING CHAIN Pulley Lock Bolt Removal/Installation Note • Hold the crankshaft using the SST.
Timing Chain Lever Installation Note • Install the chain lever and verify that it moves smoothly in the direction indicated.
2. Assemble the camshaft sprocket to the timing chain so that the timing mark of camshaft sprocket is aligned with the white link of timing chain as shown.
3. Secure the camshaft sprocket and the timing chain with a wire to prevent disengagement. Balancer Chain, Idler Sprocket, Crankshaft Sprocket Installation Note 1. Install the crankshaft sprocket as shown.
2. Assemble the idler sprocket on to the idler shaft. Chain Adjuster Installation Note • Push the chain adjuster sleeve in (toward the left) and insert the pin as shown into the lever to hold the sleeve.
3. Set the balancer chain on the idler sprocket so that the timing mark of the idler sprocket is aligned with the brown link of the balancer chain as shown. Timing Chain, Timing Sprocket, Camshaft Sprocket Installation Note 1. Install the timing chain and timing sprocket so that the white link of the timing chain is aligned with the timing mark of the timing sprocket as shown.
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TIMING CHAIN 4. Install the balancer chain so that the five alignment marks on the chain, sprocket and cylinder block align, and attach the idler sprocket to the cylinder block.
4. Loosen the chain guide C by adjusting bolt E. 5. Push the chain guide C with a force of 49 N {5.0 kgf, 11 Ibf} in the direction of the arrow, then pull back the chain guide 3.2—3.8 mm {0.13—0.14 in] and tighten the adjusting bolt E.
5. Hand-tighten the idler sprocket lock bolt. Balancer Chain Guide Installation Note 1. Install the chain guide A and B.
Note • The balancer chain must be replaced if chain guide C bottoms when adjusting. 6. Measure the timing chain slack. Specification Approx. 3.0 mm {0.12 in}
2. Install the chain guide C, and tighten the bolt D and hand-tighten the adjusting bolt E.
3. Tighten the idler sprocket lock bolt.
CONTINUED
B1-5
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CYLINDER HEAD GASKET
CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan. 5. Remove the front pipe. 6. Remove the air intake pipe and resonance chamber. 7. Disconnect the accelerator cable and bracket. 8. S. Disconnect the vacuum hoses, water hoses, and engine harness connectors. 9. Disconnect the fuel hoses. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the intake manifold bracket. 11. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 12. Remove the high-tension lead. (Refer to section G, IGNITION SYSTEM, HIGH-TENSION LEAD REMOVAL/INSTALLATION.) 13. Remove the spark plug. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Inspect for fuel leakage. 17. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 18. Start the engine and (1) check the pulleys and drive belt for runout and contact. (2) check the ignition timing and idle speed. (Refer to section F1, ENGINE TUNE-UP.)
CONTINUED
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CYLINDER HEAD GASKET
1
Upper radiator hose
2
Cylinder head cover ☞ Installation Note
3
Distributor drive gear ☞ Removal Note ☞ Installation Note Camshaft sprocket ☞ Removal Note ☞ Installation Note
4
5
Cylinder head ☞ Removal Note ☞ Installation Note
6
Cylinder head gasket ☞ Installation Note
CONTINUED
B1-7
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CYLINDER HEAD GASKET Distributor Drive Gear Removal Note 1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
2. Verify that the camshaft sprocket mark is aligned with the horizontal surface on the cylinder head.
3. Remove the seal cover. 4. Hold the crankshaft using the SST.
5. Remove the lock bolt. Camshaft Sprocket Removal Note 1. Remove the service cover on the chain cover.
3. Secure the camshaft sprocket and the chain with a wire as shown.
4. Remove the camshaft sprocket off the camshaft dowel pin. Cylinder Head Removal Note 1. Remove the bolts A. 2. Loosen the cylinder head bolts a few turns in the order shown.
Cylinder Head Gasket Installation Note • Apply silicone sealant to the areas shown. Thickness Ø3.0 mm {0.12 in}
2. Push the chain adjuster sleeve in (toward the left) and insert a pin as shown into the lever hole to hold the sleeve.
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CYLINDER HEAD GASKET Cylinder Head Installation Note 1. Tighten the cylinder head bolts a few turns in the order shown.
Distributor Drive Gear Installation Note 1. Install the distributor drive gear with a new washer and lock bolt. 2. Hold the camshaft with a screwdriver as shown.
2. Tighten the bolts A. Camshaft Sprocket Installation Note 1. Install the camshaft sprocket onto the camshaft dowel pin. 2. Remove the wire securing the camshaft sprocket and chain.
3. Tighten the lock bolt. 4. Apply silicone sealant to the areas shown.
3. Remove the retaining pin from the chain adjuster. 4. Install the service cover with a new gasket. Tightening torque 7.9—10.7 N.m {80—110 kgf.cm, 69.5—95.4 in.lbf}
5. Install the new seal cover. Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover are free of oil, water, and other foreign material. 2. Coat a new gasket with silicone sealant, and install it onto the cylinder head cover. 3. Apply silicone sealant to the cylinder head as shown.
4. Install the cylinder head cover.
CONTINUED
B1-9
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HYDRAULIC LASH ADJUSTER (HLA)
HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL / INSTALLATION •
Caution Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1. Disconnect the negative battery cable. 2. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 3. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Check the engine oil level, (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) 7. Start the engine and (1) check the engine oil. (2) check the idle speed, (Refer to section F1, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 8. Check the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1
Distributor drive gear ☞ CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Removal Note ☞ CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Installation Note
2
Rocker arm ☞ Removal Note & Installation Note
3
HLA ☞ Installation Note
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HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Removal Note 1. Loosen the bolts a few turns in the order shown.
Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed. 3. Remove the rocker arm and shaft assembly together with the bolts. HLA Installation Note 1. Place each HLA in a container filled with clean engine oil. Caution • Do not push the pin too hard. It may damage the HLA. 2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.
Rocker Arm Installation Note Note • The intake side shaft has twice as many oil holes as the exhaust side shaft. 1. Assemble the rocker arm and shaft assembly as shown in the figure according to the cap number and mark.
2.
2. Install the rocker arm and shaft. 3. Tighten the bolts a few turns in the order shown.
3. Pour engine oil into the oil reservoir in the rocker arm.
4. Apply clean engine oil to HLA O-ring
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HYDRAULIC LASH ADJUSTER (HLA) HLA TROUBLESHOOTING Problem
Possible Cause
Action
1.
Noise when engine is started immediately after oil is changed.
2.
Noise when engine is started after sitting one day or more.
3.
Noise when engine is started after new HLA is installed.
Oil leakage in HLA
4.
Noise continues more than 10 minutes.
Insufficient oil pressure
Check oil pressure. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION)
Faulty HLA
Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HLA, HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Incorrect oil amount
Check oil level. (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) Replace new engine oil. (Refer to section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
5.
Noise during idle after high speed running.
Oil leakage in oil passage or in HLA
Deteriorated oil
Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Valve Clearance Inspection 1. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 2. Measure valve clearance. Valve clearance 0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in}, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) 4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
B1-12
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FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and water pump pulley. 5. Remove the radiator cowling. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
1
2 3
Pulley lock bolt ☞ TIMING CHAIN, TIMING CHAIN ☞ REMOVAL/INSTALLATION, Pulley Lock Bolt ☞ Removal/Installation Note Crankshaft pulley Front oil seal ☞ Removal Note ☞ Installation Note
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
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REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Rear oil seal ☞ Removal Note ☞ Installation Note Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
CONTINUED
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ENGINE ENGINE ENGINE REMOVAL/INSTALLATION Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and fresh-air duct. 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket, heater hoses, and vacuum hoses. 6. Remove the radiator. (Refer to section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 8. Disconnect the fuel hoses. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 9. Remove the transmission. (Refer to section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 10. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 11. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 12. Remove in the order indicated in the table. 13. Install in the reverse order of removal. 14. Start the engine and (1) check the engine oil, engine coolant, transmission oil, and fuel leakage. (2) check the ignition timing, idle speed and idle mixture. (Refer to section F1, ENGINE TUNE-UP.) 15. Perform a road test.
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ENGINE
1
Engine mount nut
2
Engine
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ENGINE ENGINE DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
1 2 3 4 5
Remove the oil cooler. (Refer to section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) Remove the thermostat. (Refer to section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) Remove the spark plug. Remove the oil pressure switch. (Refer to section D, OIL PRESSURE INSPECTION.) Remove the intake-air system. (Refer to section F1, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) Remove the exhaust system. (Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Remove the oil filter. (Refer to section D, OIL FILTER, OIL FILTER REPLACEMENT) Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) Remove the generator. Disassemble in the order indicated in the table. Assemble in the reverse order of disassembly.
Water bypass pipe Water inlet pipe A/C compressor bracket Generator bracket P/S oil pump bracket
6 7 8 9 10
A/C idler P/S idler Oil cooler bypass pipe Generator strap Engine mount
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Engine Workshop Manual F8 FE
CONTENTS
FOREWORD This manual explains the disassembly, inspection, repair, and reassembly procedures for the above-indicated engines. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully. The information in this manual is current up to April, 1997. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing.
© 2001 Ford/Mazda Motor Corporation PRINTED IN JAPAN, APR. 1997 1570-10-97D
Title
Section
General Information
GI
Engine
B
Technical Data
TD
Special Tools
ST
Mazda Motor Corporation HIROSHIMA, JAPAN
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GENERAL INFORMATION HOW TO USE THIS MANUAL .............. ................ Gl- 1 RANGE OF TOPICS .................... .................... Gl- 1 SERVICING PROCEDURE .............. ................ Gl- 1/2 SYMBOLS ............................. .......................... Gl- 3 ADVISORY MESSAGES .................................. Gl- 3 TEXT SEQUENCE ........................................... Gl- 3 UNITS ................................................................... Gl- 4 NEW STANDARDS ............................................... Gl- 5 FUNDAMENTAL PROCEDURES ........... .............. Gl- 7 PREPARATION OF TOOLS AND MEASURING EQUIPMENT .......................... Gl- 7 SPECIAL TOOLS ............................................. Gl- 7 DISASSEMBLY ................................................ Gl- 7
INSPECTION DURING REMOVAL, DISASSEMBLY ............................................. Gl- 7 ARRANGEMENT OF PARTS ........................... Gl- 7 CLEANING OF PARTS .................................... Gl- 7 REASSEMBLY ................................................. Gl- 7 ADJUSTMENT ................................................. Gl- 8 RUBBER PARTS AND TUBING ....................... Gl- 8 HOSE CLAMPS ............................................... Gl- 8 TORQUE FORMULAS ...................................... Gl- 8 VISE ................................................................ Gl- 8 ELECTRICAL SYSTEM ........................................ Gl- 9 CONNECTORS ................................................ Gl- 9 ABBREVIATIONS.................................................. Gl- 10
HOW TO USE THIS MANUAL
SERVICING PROCEDURE Inspection, Adjustment • The procedures .for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.
RANGE OF TOPICS • This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment • Simple operations which can be performed easily just by looking at the vehicle such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.
CONTINUED
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HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration, It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions, 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part.
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HOW TO USE THIS MANUAL SYMBOLS • There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such Symbol
Meaning
TEXT SEQUENCE • The text sequence is as indicated by the arrows shown below. Example:
Kind
Apply oil
New appropriate engine oil or gear oil
Apply brake fluid
New appropriate brake fluid
Apply automatic transaxle / transmission fluid
New appropriate automatic transaxle/transmi ssion fluid
Apply grease
Appropriate grease
Apply sealant
Appropriate sealant
Apply petroleum jelly
Appropriate petroleum jelly
Replace part
O-ring, gasket, etc.
Use SST
Appropriate SST
ADVISORY MESSAGES You'll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual. Warning • A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution • A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note • A Note provides added information that will help you to complete a particular procedure. Specification • The values indicates the allowable range when performing inspections or adjustments. Upper and lower limits • The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
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HOW TO USE THIS MANUAL UNITS Electrical current
A (ampere)
Electric potential
V (volt)
Electric power
W (watt)
Length
2 • The actual converted values for 2.7 kgf/cm are 264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2,7 is used as a lower limit, so its converted values are rounded up to 270 and 39.
mm (millimeter) in (inch) kPa (kilo pascal)
Negative pressure
mmHg (millimeters of mercury) inHg (inches of mercury)
Positive pressure
kPa (kilo pascal) kgf/cm 2 (kilogram force per square centimeter) psi (pounds per square inch)
Resistance
Ω (ohm)
Speed
rpm (revolution per minute) N•m (Newton meter) kgf•m (kilogram force per meter)
Torque
kgf•cm (kilogram force per centimeter) ft•lbf (foot pound) in•lbf (inch pound) L (liter) US qt (U.S. quart) Imp qt (Imperial quart)
Volume
ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce)
Weight
9 (gram) oz (ounce)
Conversion to Sl Units (Système International d'Unités) • All numerical values in this manual are based on 81 units. Numbers shown In conventional units are converted from these values, Rounding off • Converted values are rounded off to the same number of places are the Sl unit value. For example, if the 81 unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and lower limits • When the data indicates upper and lower limits, the converted values are rounded down if the Sl unit value is an upper limit and rounded up if the Sl unit value is a lower limit. Therefore, converted values for the same Sl unit value may differ after 2 conversion. For example, consider 2.7 kgf/cm in the following specifications: 210—260 kPa { 2.1—2.7 kgf/cm2 , 30—38 psi } 270—310 kPa { 2.7—3.2 kgf/cm2 , 39—45 psi }
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NEW STANDARDS NEW STANDARDS • Following is a comparison of the previous standard and the new standard. Previous Standard Abbreviation
Name
New Standard Abbreviation AP
Name
—
Accelerator Pedal
—
Air Cleaner
ACL
—
Air Conditioning
A/C
Air Conditioning
—
Airflow Meter
VAF
Volume Air Flow Sensor
Air Cleaner
—
Airflow Sensor
MAF
Mass Air Flow Sensor
—
Alternator
GEN
Generator
—
ATF Thermosensor
—
Atmospheric Pressure
VB
Battery Voltage
Catalytic Converter
— BARO B+ OC TWC
Transmission (Transaxle) Fluid Temperature Sensor Barometric Pressure Battery Positive Voltage Oxidation Catalytic Converter Three Way Catalytic Converter
FPR
Warm Up Three Way Catalytic Converter Fuel Pump Relay
Clutch Position
CPP
Clutch Pedal Position
Crank Angle Sensor
CMP
Camshaft Position Sensor
Crank Angle Sensor 2
CKP
Crankshaft Position Sensor
WU-TWC —
Circuit Opening Relay
— — — —
Diagnosis Connector
DLC
Data Link Connector
—
Diagnosis/Self-Diagnosis
OBD
On-Board Diagnostic
—
Direct Ignition
DLI
Distributorless Ignition
—
EC-AT Control Unit
TCM
Electronic Gasoline Injection System
CIS
EGI —
Electronic Spark Ignition
ECU
Engine Control Unit
—
Engine Modification
El
Electronic Ignition
#3
Powertrain Control Module
#4
ECM
Engine Control Module
EM
Engine Modification
—
Engine Speed Input Signal
Engine RPM Signal Evaporative Emission
EVAP
Evaporative Emission
—
Exhaust Gas Recirculation
EGR
Exhaust Gas Recirculation
Fan Control Feedback System
—
Flexible Fuel
#2
PCM
—
—
#1
Transmission (Transaxle) Control Module Continuous Fuel Injection System
—
—
Remark
Accelerator Pedal
FC CLS FF
Fan Control Closed Loop System Flexible Fuel
—
Fuel Pump
FP
—
Fully Closed
CTP
Closed Throttle Position
Fuel Pump
—
Fully Open
WOT
Wide Open Throttle
—
Ground/Earth
GND
Ground
—
1C Regulator
VR
Voltage Regulator
#1: Directly connected to exhaust manifold #2: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #3: Controlled by the ECM/PCM #4: Device that controls engine and powertrain
CONTINUED
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NEW STANDARDS Previous Standard Abbreviation
Name
New Standard Abbreviation IAC
Name
—
Idle Speed Control
—
Idle Switch
—
Igniter
ICM
Ignition Control Module
—
Inhibitor Position
TR
Transmission (Transaxle) Range
—
Intake Air Pressure
MAP
—
Intake Air Thermo
IAT
—
Intercooler
—
Knock Sensor
—
Line Pressure Solenoid Valve
—
Lock-up Position
TCC
Torque Converter Clutch
—
Malfunction Indicator Light
MIL
Malfunction Indicator Lamp
—
Multiport Fuel Injection
MFI
Multiport Fuel Injection
—
Open Loop
OL
Open Loop
—
Overdrive
4GR
Fourth Gear
—
Oxygen Sensor
—
—
CAC
Closed Throttle Position Switch
Manifold Absolute Pressure Intake Air Temperature Charge Air Cooler
KS
Knock Sensor
—
Pressure Control Solenoid
HO2S
Heated Oxygen Sensor
O2S
Oxygen Sensor
Park/Neutral Range
PNP
Park/Neutral Position
—
Power Steering Pressure
PSP
—
Pulse Generator
—
Reed Valve
—
Secondary Air Injection System
—
—
Power Steering Pressure Secondary Air Pulse Valve
PAIR
Pulsed Secondary Air Injection
AIR
Secondary Air Injection
Sequential Fuel Injection
SFI
Sequential Multipoint Fuel Injection
—
Service Code(s)
DTC
—
Spark Ignition
Dl
Distributor Ignition
—
Stoplight Switch
—
Brake Switch
—
Test Mode
—
Throttle Body
—
Throttle Sensor
TP
Throttle Position Sensor
—
Turbocharger
TC
Turbocharger
—
Vehicle Speed Sensor
—
Vehicle Speed Sensor 1
—
Water Thermo
TB
VSS — ECT
1—2 Shift Solenoid Valve
Shift+B Solenoid Valve —
3—4 Shift Solenoid Valve
—
3rd Gear
—
—
Pulsed injection Inject with compressor
Diagnostic Trouble Code(s)
Diagnostic Test Mode
#5
Throttle Body
Vehicle Speed Sensor Output Speed Sensor Engine Coolant Temperature Shift Solenoid A
Shift+A Solenoid Valve 2—3 Shift Solenoid Valve
With heater
Input/Turbine Speed Sensor
SAPV
DTM
Remark
Idle Air Control
—
Shift Solenoid B
—
Shift Solenoid C
3GR —
Third Gear Incorrect Gear Ratio
#5: Diagnostic trouble codes depend on the diagnostic test mode
CONTINUED
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FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MESURING EQUIPMENT • Be sure that all necessary tools and measuring equipment are available before starting any work.
ARRANGEMENT OF PARTS • All disassembled parts should be carefully arranged for reassembly. • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
SPECIAL TOOLS
• Use special tools when they are required.
CLEANING OF PARTS
• All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
DISASSEMBLY
• If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear " whenever using compressed air.
INSPECTION DURING REMOVAL, DISASSEMBLY • When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.
REASSEMBLY
• Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones: 1
Oil seals
2
Gaskets
3
O-rings
4
Lockwashers
5
Cotter pins
6
Nylon nuts
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FUNDAMENTAL PROCEDURES HOSE CLAMPS
• When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.
1. Sealant, gasket, or both should be applied to the specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.
TORQUE FORMULAS
• When using a torque wrench-SST combination, the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you. Torque Unit N•m kgf• m kgf•cm ft•lbf in•lbf
ADJUSTMENT
• Use suitable gauges and testers when making adjustments.
Formula N•m x [L/(L+A) ] kgf•m x [L/(L+A) ] kgf•cm x [L/(L+A) ] ft•lbf x [L/(L+A) ] in•lbf x [L/(L+A) ]
A: The length of the SST past the torque wrench drive. L: The length of the torque wrench.
VISE RUBBER PARTS AND TUBING
• Prevent gasoline or oil from getting on rubber parts or tubing.
• When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
I
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ELECTRICAL SYSTEM ELECTRICAL SYSTEM
2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.
CONNECTORS Disconnecting Connectors • When disconnecting two connectors, grasp the connectors, not the wires.
Caution
• To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal.
• Connectors can be disconnected by pressing or pulling the lock lever as shown.
Locking Connector
• When locking connectors, listen for a click that will indicate they are securely locked.
Inspection 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring harness side.
GI-9
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ABBREVIATIONS ABBREVIATIONS EX ............................................ HLA ......................................... IN ............................................. MAX ......................................... SST .........................................
Exhaust Hydraulic lash adjuster lntake Maximum Special service tool
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ENGINE ENGINE OVERHAUL SERVICE WARNING .......... ENGINE MOUNTING/DISMOUNTING ................... MOUNTING ....................................................... DISMOUNTING .................................................. ENGINE DISASSEMBLY/ASSEMBLY .................. TIMING BELT DISASSEMBLY/ASSEMBLY......... CYLINDER HEAD (I) DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER HEAD (II) DISASSEMBLY/ ASSEMBLY .................................................... TIMING CHAIN DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER BLOCK (I) DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER BLOCK (II) DISASSEMBLY/ ASSEMBLY .................................................... ENGINE INSPECTION/REPAIR ............................ CYLINDER HEAD INSPECTION/REPAIR ........... VALVE INSPECTION ......................................... VALVE GUIDE INSPECTION ............................. VALVE GUIDE REPLACEMENT ......................... VALVE SEAT INSPECTION/REPAIR ................. VALVE SPRING INSPECTION ........................... CAMSHAFT INSPECTION ................................. CAMSHAFT OIL CLEARANCE INSPECTION ..................................................
B- 1 B- 1 B- 1/2 B- 2 B- 3 B- 3/5
CAMSHAFT END PLAY INSPECTION ................... B-26 ROCKER ARM AND ROCKER ARM SHAFT INSPECTION ..................................................... B-26/27 CYLINDER BLOCK INSPECTION/ REPAIR ............................................................. B-27 PISTON INSPECTION ........................................... B-27 PISTON CLEARANCE INSPECTION/ REPAIR ............................................................. B-28 PISTON RING CLEARANCE INSPECTION ........... B-28 PISTON PIN CLEARANCE INSPECTION .............. B-28/29 CRANKSHAFT INSPECTION ................................. B-29 CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR ........................................ B-29/30 CRANKSHAFT END PLAY INSPECTION/REPAIR ........................................ B-30 CONNECTING ROD INSPECTION ........................ B-30 CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR ........................................ B-31 CONNECTING ROD SIDE CLEARANCE INSPECTION ..................................................... B-31 PISTON AND CONNECTING ROD INSPECTION ..................................................... B-31 TENSIONER SPRING INSPECTION ..................... B-31 GEAR CLEARANCE INSPECTION ........................ B-31/32 ROTOR CLEARANCE INSPECTION ..................... B-32/33 PLUNGER SPRING INSPECTION ......................... B-33
B- 6/12 B-12/13 B-14/16 B-17/19 B-20/22 B-23 B-23 B-23/24 B-24 B-24 B-25 B-25 B-26 B-26
ENGINE OVERHAUL SERVICE WARNING Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
ENGINE MOUNTING/DISMOUNTING MOUNTING 1. Install the SST (arms and attachment) to the cylinder block holes as shown, and hand-tighten the SST (bolts).
2. Assemble the SST (bolts, nuts, and plate) to the specified positions.
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ENGINE MOUNTING/DISMOUNTING 3. Adjust the SST (bolts) so that less than 20 mm {0.79 in } of thread is exposed. 4. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 5. Tighten the SST (bolts and nuts) to affix the SST firmly.
Warning
• The self-locking brake system of the engine stand may not be effective when the engine is held In an unbalanced position. This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).
7. Drain the engine oil. 8. Install the oil drain plug. Tightening torque 30–41 N.m {3.0–4.2 kgf.m, 22–30 ft.lbf }
DISMOUNTING
• Dismount in the reverse order of mounting.
CONTINUED
B-2
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ENGINE MOUNTING/DISMOUNTING ENGINE DISASSEMBLY/ASSEMBLY TIMING BELT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2
Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note Upper timing belt cover
3 4 5
Lower timing belt cover Guide plate Spark plug
1
6
7 8
Timing belt • Refer to Disassembly Note • Refer to Assembly Note Tensioner, tensioner spring • Refer to Assembly Note Idler
CONTINUED
B-3
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ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.
Timing Belt Disassembly Note 1. Turn the crankshaft clockwise and align the timing marks as shown.
Timing Belt Assembly Note 1. Turn the crankshaft clockwise and align the timing marks as shown. Camshaft pulley timing mark F8: 4 FE: 2
Camshaft pulley timing mark F8: 4 FE: 2
2. Remove the spark plug. Caution • The following will damage the belt and shorten its life; forcefully twisting it. Turning it inside out, or allowing oil or grease on It. 3. Mark the timing belt rotation on the belt for proper reinstallation.
2. Install the timing belt. 3. Turn the crankshaft clockwise twice and align the timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Assembly Note step 1. 4. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring. 5. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation. 6. Turn the crankshaft clockwise twice and check the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf , 22 Ibf } If it is incorrect repeat from Timing Belt Disassembly Note. Timing belt deflection New : 4.0―5.0 mm {0.16―0.19 In } Used : 5.5―6.5 mm {0.22―0.25 in }
Tensioner, Tensioner Spring Assembly Note 1. Install the tensioner and tensioner spring. 2. Position the tensioner all the way to the intake side and temporarily secure it by tightening the lock bolt.
B-4
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ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Assembly note • Hold the crankshaft by using the SST.
CONTINUED
B-5
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ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD(I) DISASSEMBLY/ASSEMBLY Timing belt drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
3
4
Cylinder head cover • Refer to Assembly Note Rocker arm • Refer to Disassembly Note • Refer to Assembly Note Camshaft pulley • Refer to Disassembly Note • Refer to Assembly Note
5 6
7
Front housing • Refer to Assembly Note Camshaft • Refer to Assembly Note Cylinder head • Refer to Disassembly Note • Refer to Assembly Note Cylinder head gasket
CONTINUED
B-6
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ENGINE DISASSEMBLY/ASSEMBLY Rocker Arm Disassembly Note • Loosen the bolts in two or three steps in the order shown.
Camshaft pulley Disassembly Note • Hold the camshaft by using a screwdriver.
Cylinder Head Disassembly Note • Loosen the cylinder head bolts in two or three steps in the order shown.
Front Housing Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Camshaft Pulley Assembly Note • Install the camshaft pulley on the camshaft with the knock pin fit into the hole at the timing mark. Camshaft pulley timing mark F8: 4 FE: 2
Cylinder Head Assembly Note • Tighten the bolts in two or three steps in the order shown. Rocker Arm Assembly Note 1. Assemble the rocker arms, rocker arm shafts, and camshaft bearing cap as shown in the figure.
Camshaft Assembly Note • Be certain that the knock pin of the camshaft faces straight up. 2. Tighten the bolts in two or three steps in the order shown.
CONTINUED B-7
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ENGINE DISASSEMBLY/ASSEMBLY
3. Tap in the seal cap by using a plastic hammer.
Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the shaded areas. Thickness ∅1.5―2.0 mm {0.060―0.078 in }
2. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
CONTINUED
B-8
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ENGINE DISASSEMBLY/ASSEMBLY Timing chain drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
3 4
5
6
Cylinder head cover • Refer to Assembly Note Chain adjuster • Refer to Disassembly Note • Refer to Assembly Note Camshaft gear • Refer to Disassembly Note Rocker arm • Refer to Disassembly Note • Refer to Assembly Note Camshaft
7
8
B-9
Camshaft sprocket • Refer to Disassembly Note • Refer to Assembly Note Cylinder head • Refer to Disassembly Note • Refer to Assembly Note Cylinder head gasket • Refer to Assembly Note
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ENGINE DISASSEMBLY/ASSEMBLY Chain Adjuster Disassembly Note 1. Turn the crankshaft until the FE mark of the camshaft pulley is at the top as shown. 2. Check that the crankshaft pulley timing mark is aligned with the indicator pin.
3. Remove the chain adjuster.
Cylinder Head Disassembly Note 1. Remove the bolt A. 2. Loosen the remaining cylinder head bolts in two or three steps in the order shown.
Cylinder Head Gasket Assembly Note 1. Apply silicone sealant to the shaded area.
Camshaft Gear Disassembly Note 1. Pry up the washer tab.
2. Install the cylinder head gasket. 3. Apply silicone sealant to the shaded area of the cylinder head gasket. 2. Hold the camshaft with a screwdriver as shown.
Rocker Arm Disassembly Note • Loosen the rocker arm shaft bolts in two or three steps in the order shown.
Cylinder Head Assembly Note 1. Tighten the cylinder head bolts in two or three steps in the order shown.
2. Tighten the remaining small cylinder head bolts.
B-10
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ENGINE DISASSEMBLY/ASSEMBLY Rocker Arm Assembly Note 1. Apply silicone sealant to the shaded area.
Camshaft Sproket Assembly Note 1. Install the camshaft sprocket to the camshaft, aligning mark on the camshaft sprocket and timing chain.
2. Tighten the bolt in two or three steps in the order shown.
3. Tap in the new seal cap by using a plastic hammer.
2. Hold the camshaft with a screwdriver as shown.
3. Bent the washer tab to lock the locknut.
Chain Adjuster Assembly Note 1. Lift the ratchet pawl and compress the chain adjuster sleeve fully, then lock it with the pin lock.
CONTINUED
B-11
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ENGINE DISASSEMBLY/ASSEMBLY Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the seal cap as shown.
CYLINDER HEAD (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2. Apply silicone sealant to the shaded areas.
1 3. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
2 3
Valve keeper • Refer to Disassembly Note • Refer to Assembly Note Upper valve spring seat Valve spring (FE CIS: Single spring type) • Refer to Assembly Note
4
Lower valve spring seat
5 6
Valve Valve seal • Refer to Disassembly Note • Refer to Assembly Note
Valve Keeper Disassembly Note • Remove the valve keeper by using the SST.
Valve Seal Disassembly Note • Remove the valve seal by using the SST.
CONTINUED
B-12
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ENGINE DISASSEMBLY/ASSEMBLY Valve Spring Assembly Note • Install the valve spring with the closer pitch toward the cylinder head.
Valve Seal Assembly Note 1. Assemble the SST so that depth L is as specified. Depth L F8, FE CARB: 19.2―19.6 mm {0.756―0.771 in } FE CIS: 21.4―22.2 mm {0.843―0.874 in }
Valve Keeper Assembly Note • Install the valve keeper by using the SST.
2. Press the valve seal onto the valve guide by hand. 3. Tap the SST by using a plastic hammer until its lower end touches the cylinder head.
CONTINUED
B-13
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ENGINE DISASSEMBLY/ASSEMBLY TIMING CHAIN DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the order of disassembly.
1 2
3
4 5 6 7
Water pump Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note Timing chain cover • Refer to Disassembly Note • Refer to Assembly Note Timing chain • Refer to Assembly Note Timing gear Crankshaft key Timing chain lever
8 9 10
11 12
Timing chain guide Oil strainer Oil pan • Refer to Disassembly Note • Refer to Assembly Note Oil pump cover Inner rotor
13 14
Outer rotor Spring seat
15
Pressure spring
16
Control plunger
CONTINUED
B-14
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ENGINE DISASSEMBLY/ASSEMBLY Timing Chain Assembly Note 1. Install the timing chain as shown in the figure.
Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.
Oil Pan Disassembly Note • Remove the oil pan by using the separator tool.
2. Support the timing chain by using a magnetic base. Timing Chain Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Oil Pan Assembly Note • Apply silicone sealant to the oil pan as shown. Thickness ∅2.5―3.5 mm {0.099―0.137 in }
4. Apply silicone sealant to the mounting surface along the inside of the bolt holes as shown.
_
Timing Chain Cover Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.
5. Tighten the timing chain cover installation bolt.
Tightening torque A: 19―25 N.m {1.9―2.6 kgf.m , 14―18 ft.lbf } B: 38―51 N.m {3.8―5.3 kgf.m , 28―38 ft.lbf }
B-15
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ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Assembly Note • Hold the crankshaft by using the SST.
CONTINUED
B-16
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ENGINE DISASSEMBLY/ASSEMBLY CYLINDER BLOCK (I) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2
1
Oil pan (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note
2 3
Oil strainer (Timing belt drive type) Oil baffle (FE CIS) • Refer to Disassembly Note • Refer to Assembly Note Timing belt pulley (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note Flywheel • Refer to Disassembly Note • Refer to Assembly Note End plate Oil pump (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note
4
5
6 7
8 9
Oil pump body (Timing belt drive type) Outer gear (Timing belt drive type)
10
Inner gear (Timing belt drive type)
11 12 13 14 15
Oil pump cover (Timing belt drive type) Spring seat (Timing belt drive type) . Pressure spring (Timing belt drive type) Control plunger (Timing belt drive type) Rear cover • Refer to Disassembly Note • Refer to Assembly Note Water pump • Refer to Assembly Note
16
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ENGINE DISASSEMBLY/ASSEMBLY Oil Pan Disassembly Note Note • Do not insert the separator tool between the oil baffle and cylinder block.
Oil Pump Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.
• Remove the oil pan by using the separator tool.
Oil Baffle Disassembly Note • Remove the oil baffle by using the separator tool.
Timing Belt Pulley Disassembly Note • Hold the crankshaft by using the SST.
Flywheel Disassembly Note • Hold the crankshaft by using the SST.
Rear Cover Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.
Water Pump Assembly Note 1. Verify that the rubber seal is securely fixed onto the water pump. 2. If not, replace the rubber seal and reapply the bonding agent. 3. Install the water pump.
Rear Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
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ENGINE DISASSEMBLY/ASSEMBLY Oil Pan Assembly Note • Apply Silicone sealant to the oil pan as shown.
Oil Pump Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Thickness ∅2.0―3.0 mm {0.079―0.118 in }
Flywheel Assembly Note 1. Hold the crankshaft by using the SST. 2. Tighten the flywheel bolt in the order shown.
Timing Belt Pulley Assembly Note • Hold the crankshaft by using the SST.
Oil Baffle Assembly Note • Apply silicone sealant to the oil baffle as shown. Thickness ∅2.0―3.0 mm {0.079―0.118 in }
CONTINUED
B-19
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ENGINE DISASSEMBLY/ASSEMBLY CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 3
4 5 6 7 8
Connecting rod cap Lower connecting rod bearing Piston and connecting rod • Refer to Disassembly Note • Refer to Assembly Note Upper connecting rod bearing Piston ring Piston pin Piston Connecting rod
9
10 11
12 13 14
Main bearing cap • Refer to Disassembly Note • Refer to Assembly Note Lower main bearing Pilot bearing • Refer to Disassembly Note • Refer to Assembly Note Crankshaft Upper main bearing Cylinder block
CONTINUED
B-20
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ENGINE DISASSEMBLY/ASSEMBLY Pilot Bearing Disassembly Note • Remove the pilot bearing by using the SST.
Piston and Connecting Rod Disassembly Note 1. Assemble the SST as shown.
Pilot Bearing Assembly Note • Install the pilot bearing by using a suitable pipe.
2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.
Main Bearing Cap Assembly Note 1. Tighten the bolts in two or three steps in the order shown.
3. Set the piston and connecting rod on the SST as shown.
Piston and Connecting Rod Assembly Note 1. Assemble the SST as shown.
4. Press out the piston pin. Main Bearing Cap Disassembly Note • Loosen the main bearing cap bolts in two or three steps in the order shown.
CONTINUED
B-21
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ENGINE DISASSEMBLY/ASSEMBLY 2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.
8. Verify that the second ring is installed with the scraper face downward. 9. Position the end gap of the oil ring as shown.
3. Set the SST (stopper bolt) so that dimension L is as specified. Dimension L 60.0 mm {2.36 in }
10. F mark facing the front of the engine.
4. Apply clean engine oil to the piston pin. 5. Insert the piston pin and the SST assembled in step 2 into the piston and connecting rod.
6. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt). 7. While inserting the piston pin, check the pressure force. If it is less than the specification, replace the piston pin or the connecting rod. Pressure force 2.94―14.70 KN {300―1500 kgf , 660―3300 Ibf }
CONTINUED
B-22
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ENGINE INSPECTION/REPAIR ENGINE INSPECTION/REPAIR CYLINDER HEAD INSPECTION/REPAIR 1. Carry out cooling flaw detection on the cylinder head surface. Replace the cylinder head if necessary. 2. Inspect for the following and repair or replace if necessary. (1) Sunken valve seats (2) Excessive camshaft oil clearance and end play 3. Measure the cylinder head for distortion in the six directions as shown.
VALVE INSPECTION 1. Measure the valve head margin thickness of each valve. Replace the valve if necessary. Margin thickness FE CIS IN: 1.80―2.20 mm {0.071―0.086 in } EX: 1.30―1.70 mm {0.052―0.006 in } F8, FE CARB IN: 0.8―1.2 mm {0.032―0.047 in } EX: 1.3―1.7 mm {0.052―0.066 in }
Distortion 0.15 mm {0.006 in} max.
2. Measure the length of each valve. Replace the valve if necessary. Standard length FE CIS IN: 115.61―116.01 mm {4.552―4.567 in } EX: 116.01―116.41mm {4.568―4.583 in } F8, FE CARB IN: 111.69―112.09 mm {4.398―4.412} EX: 111.49―111.89 mm {4.390―4.405 in }
4. If the cylinder head distortion exceeds the maximum, repair by grinding the height or replace the cylinder head. If the cylinder head height is not within the specification, replace it. Standard height 91.95―92.05 mm {3.621―3.624 in }
Minimum length
Grinding 0.20 mm {0.008 in } max.
FE CIS
IN: 115.51 mm {4.548 in} EX: 115.71 mm {4.556 in} F8, FE CARB IN: 111.39 mm {4.386 in} EX: 111.19 mm {4.378 in}
5. Measure the manifold contact surface distortion as shown. Distortion 0.15 mm {0.006 in } max. 6. If the distortion exceeds the specification, grind the surface or replace the cylinder head .
3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) shown. Replace the valve if necessary. Standard diameter FE CIS IN: 6.970―6.985 mm {0.2745―0.2749 in } EX: 6.965―6.980 mm {0.2743―0.2748 in } F8, FE CARB IN: 8.030―8.045 mm {0.3162―0.3167 in } EX: 8.025―8.040 mm {0.3160―0.3165 in }
Grinding 0.20 mm {0.008 in } max.
Minimum diameter FE CIS IN: 6.920 mm {0.2724 in } EX: 6.915 mm {0.2722 in } F8, FE CARB IN: 7.980 mm {0.3142 in } EX: 7.975 mm {0.3140 in }
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ENGINE INSPECTION/REPAIR
VALVE GUIDE INSPECTION 1. Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) shown. Replace the valve guide if necessary. Standard inner diameter FE CIS IN: 7.010―7.030 mm {0.2760―0.2767 in } EX: 7.010―7.030 mm {0.2760―0.2767 in } F8, FE CARB IN: 8.030―8.045 mm {0.3162―0.3167 in } EX: 8.025―8.040 mm {0.3160―0.3165 in }
Valve Guide Installation 1. Assemble the SSTs so that depth L is as specified. Depth L FE CIS: 19.8―20.3 mm {0.780―0.799 in } F8, FE CARB: 19.1―19.6 mm {0.752―0.771 in }
2. Tap the valve guide in from the side opposite the combustion chamber until! the SST contacts the cylinder head. 3. Verify that the valve guide projection height (dimension) is within the specification.
2. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat. Replace the valve guide if necessary.
Standard height FE CIS: 19.8―20.3 mm {0.780―0.799 in } FB, FE CARB: 19.1―19.6mm {0.752―0.771 in }
Standard height FE CIS: 19.8―20.3 mm {0.780―0.799 in } F8, FE CARB: 19.1―19.6mm {0.752―0.711 in }
VALVE GUIDE REPLACEMENT Valve Guide Removal • Remove the valve guide from the combustion chamber side by using the SST.
CONTINUED
B-24
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ENGINE INSPECTION/REPAIR VALVE SEAT INSPECTION/REPAIR 1. Measure the seat contact width. If necessary, resurface the valve seat by using a 45° valve seat cutter and/or resurface the valve face.
VALVE SPRING INSPECTION 1. Apply pressing force to the pressure spring and check the spring height. Replace the valve spring if necessary. Pressing force FE CIS IN: 203.10―229.86 N {20.71―23.44 kgf , 45.57― 51.56 Ibf } EX: 240.37―272.03 N {24.51―27.74 kgf , 53.93―61.02 Ibf } F8, FE CARB Inner: 117.19―136.01 N {11.95―13.87 kgf , 26.29―30.51 Ibf } Outer: 243.70―267.03 N {24.85―27.23 kgf , 54.67―59.90 Ibf }
Standard width IN: 1.2―1.6 mm {0.048―0.062 in } EX: 1.2―1.6 mm {0.048―0.062 in }
Standard height FE CIS IN: 41 mm {1.614 in } EX: 41 mm {1.614 in } F8, FE CARB Inner: 36.5 mm {1.437 in } Outer: 41.0 mm {1.614 in }
2. Verify that the valve seating position is at the center of the valve face. (1) If the seating position is too high, correct the valve seat by using a 75° (FE CIS) or 60° (F8, FE CARB) cutter, and a 45° cutter. (2) If the seating position is too low, correct the valve seat by using a 35° (IN) or 15° (EX) cutter and a 45° cutter.
2. Measure the out-of-square of the valve spring. Replace the valve spring if necessary. Valve spring out-or-square FE CIS IN: 1.70 mm {0.067 in } EX: 1.76 mm {0.069 in } FB, FE CARB Inner: 1.5 mm {0.059 in } Outer: 1.8 mm {0.071 in }
3. Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. Replace the cylinder head if necessary. Standard dimension L F8, FE CARB: 46.5 mm {1.831 in } FE CIS: 49.7 mm {1.957 in } Maximum dimension L F8, FE CARB: 47.0 mm {1.850 in } FE CIS: 51.2 mm {2.016 in }
CONTINUED
B-25
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ENGINE INSPECTION/REPAIR CAMSHAFT INSPECTION
2. Install the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD (II) Camshaft Cap Assembly Note.) 3. Remove the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER HEAD (II) Camshaft Cap Assembly Note.) 4. Measure the oil clearance. Replace the cylinder head if necessary.
1. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary. Runout 0.03 mm {0.0012 in } max. 2. Measure the cam lobe height at the two points as shown. Replace the camshaft if necessary.
Standard clearance No.1, 5: 0.035―0.085 mm {0.00138―0.00334 in } No.2, 3, 4: 0.065―0.115 mm {0.00256―0.00453 in }
Standard height FE CIS IN: 41.340 mm {1.6276 in } EX: 41.847 mm {1.6475 in } F8, FE CARB IN: 38.202 mm {1.5040 in } EX: 38.202 mm {1.5040 in } Fuel pump cam: 39.900 mm {1.5709 in }
3. Measure the journal diameters in X and Y directions at the two points (A and B) as shown. Replace the camshaft if necessary.
Maximum clearance 0.15 mm {0.006 in }
CAMSHAFT END PLAY INSPECTION 1. Install the camshaft and thrust plate. 2. Measure the camshaft end play. Replace the camshaft and/or thrust plate if necessary. Standard end play 0.08―0.16 mm {0.00315―0.00629 in }
Standard diameter No.1, 5: 31.940―31.965 mm {1.2575―1.2585 in } No.2, 3, 4: 31.910―31.935 mm {1 .2563―1.2572 in } Minimum diameter No.1, 5: 31.910 mm {1.2563 in } No.2, 3, 4: 31.880 mm {1.2551 in }
Maximum end play 0.20 mm {0.008 in } ROCKER ARM AND ROCKER ARM SHAFT INSPECTION 1. Measure the rocker arm inner diameter. Diameter FE CIS: 19.000―19.033 mm {0.7481―0.7493 in } F8, FE CARB: 15.966―15.984 mm {0.6286―0.6292 in }
CAMSHAFT OIL CLEARANCE INSPECTION 1. Position a plastigage atop the journals in the axial direction. 2. Measure the rocker arm shaft diameter.
CONTINUED B-26
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ENGINE INSPECTION/REPAIR Diameter FE CIS: 18.959―18.980 mm {0.7465―0.7472 in } F8, FE CARB: 15.966―15.984 mm {0.6286―0.6292 in }
3. If the cylinder bore exceeds the wear limit, replace the cylinder block or rebore the cylinder and install the oversize pistons so that the specified piston-to-cylinder clearance is obtained. Note • Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter.
3. Calculate the rocker arm-to-shaft clearance. Replace the rocker arm and/or rocker arm shaft if necessary. Standard clearance FE CIS: 0.020―0.074 mm {0.00079―0.00291 in } F8, FE CARB: 0.016―0.061 mm {0.00063―0.00240 in }
Cylinder bore Size
86.000―86.019
Standard
CYLINDER BLOCK INSPECTION/REPAIR 1. Measure the distortion of the cylinder block top surface in the six directions as shown. Repair by grinding or replace if necessary.
{3.3859―3.3865}
0.25 {0.01} oversize 0.50 {0.02} oversize
Cylinder block distortion 0.15 mm {0.006 in } max.
mm { in } Diameter
86.250―86.269 {3.3957―3.3964} 86.500―86.519 {3.4056―3.4062}
Wear limit 0.15 mm {0.006 in }
Cylinder block height FE: 288.93―289.07 mm {11.376―11.380 in } F8: 268.43―268.57 mm {10.569―10.573 in }
PISTON INSPECTION • Measure the outer diameter of each piston at a right angle (90°) to the piston pin, 18.0 mm {0.709 in } below oil ring groove. Piston diameter mm { in }
Grinding 0.20 mm {0.008 in } max.
Size Standard 0.25 {0.01} oversize 0.50 {0.02} oversize
Diameter 85.943―85.965 {3.38358―3.38444} 86.193―86.215 {3.39342―3.39428} 86.443―86.465 {3.40327―3.40412}
2. Measure the cylinder bores in X and Y directions at 65 mm {2.56 in } (F8), 70 mm {2.76 in } (FE) below the top surface.
CONTINUED B-27
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ENGINE INSPECTION/REPAIR PISTON CLEARANCE INSPECTION/REPAIR 1. Calculate the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit an oversized piston if necessary.
PISTON PIN CLEARANCE INSPECTION 1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown. Standard diameter 21.988―21.998 mm {0.8657―0.8660 in }
Standard clearance 0.035―0.076 mm {0.0014―0.0029 in } Maximum clearance 0.15 mm {0.006 in } 2. If the piston is replaced, the piston rings must also be replaced. PISTON RING CLEARANCE INSPECTION 1. Measure the piston ring-to-ring land clearance around the entire circumference. Replace the piston and piston ring if necessary. Standard clearance Top : 0.03―0.07 mm {0.0012―0.0027 in } Second : 0.03―0.07 mm {0.0012―0.0027 in } Oil : 0.03―0.07 mm {0.0012―0.0027 in }
2. Measure each connecting rod small end inner diameter in X and Y directions as shown. Standard diameter 21.943―21.961 mm {0.8639―0.8646 in }
Maximum clearance 0.15 mm {0.006 in }
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. 3. Measure each piston ring end gap by using a feeler gauge. Replace the piston ring if necessary.
3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown. Standard diameter 21.974―21.980 mm {0.8652―0.8653 in }
Standard end gap Top : 0.20―0.35 mm {0.008―0.013 in } Second : 0.15―0.30 mm {0.006―0.011 in } Oil rail : 0.20―0.70 mm {0.008―0.027 in } Maximum end gap 1.0 mm {0.039 in }
4. Calculate the piston pin-to-piston pin bore clearance. Replace the piston and/or piston pin if necessary.
CONTINUED B-28
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ENGINE INSPECTION/REPAIR Standard clearance 0.008―0.024 mm {0.00032―0.00094 in } 5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin. Standard clearance - 0.037―0.013 mm {-0.0014―0.0006 in } CRANKSHAFT INSPECTION 1. Measure the crankshaft runout. Replace the crankshaft if necessary.
Crank pin Bearing size Standard
50.940―50.955 {2.0056―2.0060}
0.25 {0.01} undersize
50.690―50.705 {1.9957―1.9962}
0.50 {0.02} undersize
50.440―50.455 {1.9859―1.9864}
0.75 {0.03} undersize
50.190―50.205 {1.9760―1.9765}
Runout 0.03 mm {0.0012 in }
Out-of-round 0.05 mm {0.002 in } max.
2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersize bearing if necessary. Main journal
mm { in }
Bearing size
mm { in } Diameter
Diameter
Standard
No.1, 2, 4, 5 : 59.937―59.955 {2.3598―2.3604} No.3 : 59.937―59.955 {2.3598―2.3604}
0.25 {0.01} undersize
No.1, 2, 4, 5 : 59.687―59.697 {2.3499―2.3502} No.3 : 59.687―59.691 {2.3499―2.3500}
0.50 {0.02} undersize
No.1, 2, 4, 5 : 59.437―59.447 {2.3401―2.3404} No.3 : 59.437―59.455 {2.3401―2.3407}
0.75 {0.03} undersize
No.1, 2, 4, 5 : 59.187―59.197 {2.3302―2.3305} No.3 : 59.187―59.205 {2.3302―2.3309}
CRANKSHAFT OIL CLEARANCE INSPECTION/ REPAIR . 1. Position a plastigauge atop the journals in the axial direction. 2. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.) 3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.) 4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained. Standard oil clearance No.1, 2, 4, 5: 0.025―0.074 mm {0.00099―0.00291 in } No.3: 0.031―0.074 mm {0.00123―0.00291 in } Maximum oil clearance 0.10 mm {0.004 in }
Out-of-round 0.05 mm {0.002 in } max.
CONTINUED
B-29
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ENGINE INSPECTION/REPAIR mm { in } Bearing size
Bearing thickness
Standard
2.004―2.007 {0.07890―0.07901}
0.25 {0.01} undersize
2.129―2.139 {0.08382―0.08421}
0.50 {0.02} undersize
No.1, 2, 4, 5 : 2.254―2.264 {0.08874―0.08913} No.3 : 2.254―2.257 {0.08874―0.08885}
0.75 {0.03} undersize
No.1, 2, 4, 5 : 2.379―2.389 {0.09367―0.09405} No.3 : 2.379―2.382 {0.09367―0.09377}
CRANKSHAFT END PLAY INSPECTION/REPAIR 1. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.) 2. Measure the crankshaft end play. If the end play exceeds the maximum, replace the crankshaft bearing or grind the crankshaft and Install an undersize bearing so that the specified end play is obtained.
3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.) CONNECTING ROD INSPECTION • Measure each connecting rod for bending and distortion. Replace the connecting rod if necessary. Bending 0.15 mm {0.006 in } max. /100 mm {3.937 in }
Standard end play 0.08―0.18 mm {0.00315―0.00708 in }
Distortion 0.180 mm {0.0071 in } max. /50 mm {1.97 in }
Maximum end play 0.30 mm {0.012 in }
Center-to-center distance FE: 151.95―152.05 {5.983―5.986 in } F8: 135.95―136.05 {5.353―5.356 in }
Note • When replacing the No.3 crankshaft bearing replace all of the bearing as a set. mm { in } Bearing size
Bearing thickness
Standard
27.94―27.99 {1.1000―1.1019}
0.25 {0.01} undersize
28.04―28.09 {1.1 040―1.1 060}
0.50 {0.02} undersize
28.12―28.17 {1.1071―1.1090}
0.75 {0.03} undersize
28.20―28.25 {1.1103―1.1122}
CONTINUED B-30
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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ENGINE INSPECTION/REPAIR CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR 1. Position a plastigauge atop the journals in the axial direction. 2. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BlOCK(II) DISASSEMBLY/ASSEMBLY, Piston and Connecting Rod Assembly Note.) 3. Remove the connecting rod cap. 4. Measure the crankpin oil clearance. If the clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained.
PISTON AND CONNECTING ROD INSPECTION • Check the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.
Standard oil clearance 0.027―0.067 mm {0.0011―0.0026 in } Maximum oil clearance 0.10 mm {0.004 in } Bearing size
3. Remove the connecting rod cap.
mm { in } Bearing thickness
Standard
1.505―1.510 {0.0593―0.0594}
0.25 {0.01} undersize
1.630―1.635 {0.0642―0.0643}
0.50 {0.02} undersize
1.755―1.760 {0.0691―0.0692}
0.75 {0.03} undersize
1.880―1.885 {0.0741―0.0742}
TENSIONER SPRING INSPECTION • Measure the free length of the tensioner spring. Replace the tensioner spring if necessary. Free length F8: 63.0 mm {2.48 in } FE CARB: 56.9 mm {2.24 in } FE CIS: 53.9 mm {2.12 in }
CONNECTING ROD SIDE CLEARANCE INSPECTION 1. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY. Piston and Connecting Rod Assembly Note.) 2. Measure the connecting rod large end side clearance. Replace the connecting rod and cap if necessary. Standard clearance 0.110―0.262 mm {0.005―0.010 in }
GEAR CLEARANCE INSPECTION F8, FE CARB Timing Belt Drive Type • Measure the following clearance. Replace the gear and/or pump body if necessary. Standard innergear tooth tip to cresent clearance 0.267―0.380 mm {0.0106―0.0149 in }
Maximum clearance 0.30 mm {0.012 in }
Maximum innergear tooth tip to cresent crearance 0.400 mm {0.0157 in }
B-31
CONTINUED
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ENGINE INSPECTION/REPAIR
Standard outer gear tooth tip to cresent clearance 0.200―0.320 mm {0.0079―0.0125 in }
ROTOR CLEARANCE INSPECTION FE CIS • Measure the following clearance. Replace the rotor and/or pump body if necessary.
Maximum outer gear tooth tip to cresent clearance 0.350 mm {0.0138 in }
Maximum Inner rotor tooth tip to outer rotor clearance 0.18 mm {0.007 in }
Standard side clearance 0.030―0.063 mm {0.00119―0.00248 in }
Standard outer gear to pump body clearance 0.090―0.176 mm {0.0036―0.0069 in }
Maximum side clearance 0.10 mm {0.004 in }
Maximum outer gear to pump body clearance 0.20 mm {0.008 in }
Standard outer rotor to body clearance 0.030―0.063 mm {0.00119―0.00248 in }
Standard side clearance 0.03―0.09 mm {0.0012―0.0035 in }
Maximum body clearance 0.10 mm {0.004 in }
Maximum side clearance 0.10 mm {0.004 in }
CONTINUED
B-32
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ENGINE INSPECTION/REPAIR
FE CARB Timing Chain Drive Type • Measure the following clearance. Replace the rotor and/or pump body if necessary.
PLUNGER SPRING INSPECTION • Measure the free length of the plunger spring. Replace the plunger spring if necessary. Free length 46.4 mm {1.827 in }
Standard Inner rotor tooth tip to outer rotor clearance 0.044―0.084 mm {0.0017―0.0033 in } Maximum Inner rotor tooth tip to outer rotor clearance 0.18 mm {0.007 in }
Standard outer gear to pump body clearance 0.090―0.176 mm {0.0035―0.0069 in } Maximum outer gear to pump body clearance 0.20 mm {0.008 in }
Standard side clearance 0.03―0.09 mm {0.0012―0.0035 in } Maximum side clearance 0.10 mm {0.004 in }
CONTINUED B-33
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TECHNICAL DATA TECHNICAL DATA ......................................... TD-1/4
TECHNICAL DATA Item Cylinder head Height mm Distortion mm Grinding mm Valve clearance (F8, FE CARB) mm { in }
Specification { in } { in } { in }
91.95—92.05 {3.621—3.624} 0.15 {0.006} max. 0.20 {0.008} max.
IN
0.30 {0.012} (Engine hot)
EX
0.30 {0.012} (Engine hot)
IN
FE CIS: 1.80—2.20 {0.071—0.086} F8, FE CARB: 0.8—1.2 {0.032—0.047}
EX
FE CIS: 1.30—1.70 {0.052—0.066} F8, FE CARB: 1.3—1.7 {0.052—0.066}
Valve and valve guide Margin thickness mm { in }
IN Valve length mm { in } EX
IN Valve stem diameter mm { in }
Standard
FE CIS: 115.61—116.01 {4.552—4.567} F8, FE CARB: 111.69—112.09 {4.398—4.412}
Minimum
FE CIS: 115.51 {4.548}, F8, FE CARB: 111.39 {4.386}
Standard
FE CIS: 116.01—116.41 {4.568—4.583} F8, FE CARB: 111.49—111.89 {4.390—4.405}
Minimum
FE CIS: 115.71 {4.556}, F8, FE CARB: 111.19{4.378}
Standard
FE CIS: 6.970—6.985 {0.2745—0.2749} F8, FE CARB: 8.030—8.045 {0.3162—0.3167}
Minimum
FE CIS: 6.920 {0.2724} F8, FE CARB: 7.980 {0.3142}
Standard
FE CIS: 6.965—6.980 {0.2743—0.2748} F8, FE CARB: 8.025—8.040 {0.3160—0.3165}
Minimum
FE CIS: 6.915 {0.2722} F8, FE CARB: 7.975 {0.3140}
EX
Guide inner diameter
IN
FE CIS: 7.010—7.030 {0.2760—0.2767} F8, FE CARB: 8.030—8.045 {0.3162—0.3167}
EX
FE CIS: 7.010—7.030 {0.2760—0.2767} F8, FE CARB: 8.025—8.040 {0.3160—0.3165}
IN
FE CIS: 19.8—20.3 {0.780—0.799} F8, FE CARB: 19.1—19.6 {0.752—0.771}
EX
FE CIS: 19.8—20.3 {0.780—0.799} F8, FE CARB: 19.1—19.6 {0.752—0.771}
IN
1.2—1.6 {0.048—0.062}
EX
1.2—1.6 {0.048—0.062}
IN
45°
Valve guide protrusion height mm { in }
Valve seat Seat contact width mm { in } Seat angle
EX IN
Seat sinking mm { in } (Valve protrusion height) EX
45°
Standard
F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957}
Maximum
F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016}
Standard
F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957}
Maximum
F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016}
CONTINUED
TD-1
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TECHNICAL DATA Item
Specification
Valve spring H: 41.0 mm {1.614 in } (FE CIS) IN
Pressing force at Valve spring height H N { kgf, lbf }
H Inner: 36.5 mm {1.437 in } Outer: 41.0 mm {1.614 in } (F8, FE CARB)
Inner: 117.19—136,01 {11,95—13.87, 26.29—30,51} Outer: 243.70—267.03 {24.85—27.23, 54.67—59.90}
H: 41.0 mm {1.614 in } (FE CIS) EX
Out-of-square mm { in }
H Inner: 36.5 mm {1.437 in} Outer: 41.0 mm {1.614 in } (F8, FE CARB)
Inner: 117.19—136.01 {11.95—13.87, 26,29—30.51} Outer: 243.70—267.03 {24.85—27.23, 54.67—59.90}
FE CIS: 1.70 {0.067} F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071}
EX
FE CIS: 1.76 {0.069} F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071} mm { in }
mm { in } No.1, 5
Journal diameter mm { in }
No.2, 3, 4
Camshaft bearing oil clearance mm { in } Camshaft end play
mm { in }
240.37—272.03 {24.51—27.74, 53.93—61.02}
IN
Camshaft Camshaft runout Lobe height
203.10—229.86 {20.71—23.44, 45.57—51.56}
0.03 {0.0012} max.
IN
FE CIS: 41,340 {1.6276} F8, FE CARB: 38.202 {1.5040}
EX
FE CIS: 41.847 {1.6475} F8, FE CARB: 38.202 {1.5040}
Standard
31.940—31.965 {1.2575—1.2585}
Minimum
31.910 {1.2563}
Standard
31.910—31.935 {1.2563—1.2572}
Minimum
31.880 {1.2551}
No.1, 5
0.035—0.085 {0.00138—0,00334}
No.2, 3, 4
0.065—0.115 {0.00256—0.00453}
Maximum
0.15 {0.006}
Standard
0.08—0.16 {0.00315—0.00629}
Maximum
0.20 {0.008}
Rocker arm and rocker arm shaft Rocker arm inner diameter
mm { in }
FE CIS: 19.000—19.033 {0.7481—0.7493} F8, FE CARB: 15.966—15.984 {0.6286—0.6292}
Rocker arm shaft diameter
mm { in }
FE CIS: 18.959—18.980 {0.7465—0.7472} F8, FE CARB: 15.966—15.984 {0.6286—0.6292}
Rocker arm to shaft clearance
mm { in }
FE CIS: 0.020—0.074 {0.00079—0.00291} F8, FE CARB: 0.016—0.061 {0,00063—0.00240}
Height
mm { in }
FE; 288.93—289.07 {11.376—11.380} F8: 268.43—268.57 {10.569—10.573}
Distortion
mm { in }
0.15 {0.006} max.
Cylinder block
Grinding Cylinder bore diameter mm { in }
mm { in }
86.000—86.019 {3.3859—3,3865}
0.25 {0.01} oversize
86.250—86.269 {3.3957—3.3964}
0.50 {0.02} oversize Wear limit
0.20 {0.008} max.
Standard
86.500—86.519 {3.4056—3.4062} mm { in }
0.15 {0,006}
CONTINUED
TD-2
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TECHNICAL DATA Item
Specification
Piston Piston diameter Measured at 90° to pin bore axis and 18.0 mm {0.709 in } below oil ring groove mm { in }
Standard
85.943—85.965 {3.38358—3.38444}
0.25 {0.01} oversize
86.193—86.215 {3.39342—3.39428}
0.50 {0.02} oversize
86.443—86.465 {3.40327—3.40412}
Piston-to-cylinder clearance mm { in }
Standard
0.035—0.076 {0.0014—0.0029}
Maximum
0.15 {0.006}
Piston ring Top Piston ring-to-ring groove clearance mm { in }
0.03—0.07 {0.0012—0.0027}
Second
0.03—0.07 {0.0012—0.0027}
Oil
0.03—0.07 {0.0012—0.0027}
Maximum End gap (Measured in cylinder) mm { in }
0.15 {0.006}
Top
0.20—0.35 {0.008—0.013}
Second
0.15—0.30 {0.006—0.011}
Oil (rail)
0.20—0.70 {0.008—0.027}
Maximum
1.0 {0.039}
Piston pin Diameter Connecting rod small end-to-piston pin clearance Piston-to-piston pin clearance Crankshaft
mm { in }
21.974—21.980 {0.8652—0.8653}
mm { in }
- 0.037— - 0.013 { -0.0014— - 0.0006}
mm { in }
0.008—0.024 {0.00032—0.00094}
Crankshaft runout
mm { in }
Main journal diameter mm { in }
Standard 0.25 {0.01} undersize
No.1, 2, 4, 5: 59.687—59.697 {2.3499—2.3502} No.3: 59.687—59.691 {2.3499—2.3500}
0.50 {0.02} undersize
No.1, 2, 4. 5: 59.437—59.447 {2.3401—2.3404} No.3: 59.437—59.455 {2.3401—2.3407}
0.75 {0.03} undersize
No.1, 2, 4, 5: 59,187—59.197 {2.3302—2.3305} No.3: 59.187—59.205 {2.3302—2.3309}
Out-of-round Crankpin diameter mm { in }
mm { in }
0.05 {0.002} max.
Standard
50.940—50.955 {2.0056—2.0060}
0.25 {0.01} undersize
50.690—50.705 {1.9957—1.9962}
0.50 {0.02} undersize
50.440—50.455 {1.9859—1.9864}
0.75 {0.03} undersize Out-of-round
50.190—50.205 {1.9760—1.9765} mm { in }
mm { in } mm { in }
0.05 {0.002} max. No.1, 2, 4, 5: 0.025—0.074 {0.00099—0.00291} No.3: 0.031—0.074 {0.00123—0.00291}
Standard
Main journal oil clearance
Crankshaft end play
0.03 {0.0012} max. No.1, 2, 4, 5: 59.937—59.955 {2.3598—2.3604} No.3: 59.937—59.955 {2.3598—2.3604}
Maximum
0.10 {0.004}
Standard
0.08—0.18 {0.00315—0.00708}
Maximum
0.30 {0.012}
CONTINUED
TD-3
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TECHNICAL DATA Item Connecting rod and connecting rod bearing
Specification
Length (Center to center)
mm { in }
F8: 135.95—136.05 {5,353—5.356} FE: 151.95—152.05 {5.983—5.986}
Bending
mm { in }
0.15 {0.006} max./100 mm {3.937 in}
mm { in }
0.180 {0.0071} max./50 mm {1.97 in }
Distortion Connecting rod side clearance mm { in }
Standard
0.110—0.262 {0.005—0.010}
Maximum
0.30 {0.012}
Connecting rod bearing oil clearance mm { in }
Standard
0.027—0.067 {0.0011—0.0026}
Maximum
0.10 {0.004}
Tensioner spring Free length
mm { in }
F8: 63.0 {2.48}, FE CARB: 56.9 {2.24}, FE CIS: 53.9 {2.12}
Oil pump Inner rotor tooth tip to outer rotor clearance mm { in }
Standard
FE CARB Timing chain drive type: 0.044—0.084 {0.0017—0.0033}
Maximum
0.18 {0.007} (FE CIS, FE CARB Timing chain type)
Outer rotor to body clearance mm { in }
Standard
FE CIS, CARB Timing chain type: 0.090—0.176 {0.0035—0.0069}
Maximum
FE CIS, CARB Timing chain type: 0.20 {0.008}
Standard
F8, FE CARB Timing belt drive type: 0.267—0.380 {0.0106—0.0149}
Maximum
F8, FE CARB Timing belt drive type: 0.400 {0.0157}
Outer gear tooth tip to crescent clearance mm { in }
Standard
P8, FE CARB Timing belt drive type: 0.200—0.320 {0.0079—0.0125}
Maximum
F8, FE CARB Timing belt drive type: 0.350 {0.0138}
Outer gear to pump body clearance mm { in }
Standard
0.030—0.063 {0.00119—0.00248}
Maximum
0.10 {0.004}
Standard
F8, FE CARB Timing belt drive type: 0.030—0.063 {0.00120—0.0024} FE CIS, FE CARB Timing chain drive type: 0.03—0.09 {0.0012—0.0035}
Maximum
0.10 {0.004}
Inner gear tooth tip to crescent clearance mm { in }
Side clearance
mm { in }
Plunger spring Free length
mm { in }
46.4 {1.827}
CONTINUED
TD-4
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SPECIAL TOOLS SPECIAL TOOLS ........................................... ST-1
SPECIAL TOOLS 49 0107 680A
49 L010 1A0
49 0636 100B
Engine stand
Engine hanger set
Valve spring lifter arm
49 B012 0A2
49 0221 251A
49 S120 170
Pivot
Valve guide remover and installer
Valve seal remover
49 L012 0A2
49 L011 0A0B
49 E011 1A0
Valve seal and guide installer
Piston pin setting tool set
Ring gear brake set
49 1285 071
49 P005 204
49 S011 103
Needle bearing puller
Oil seal installer
Oil seal installer
CONTINUED
ST-1
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ENGINE (WL, WL Turbo) DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–1 DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . B2–1/2 DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . B2–2 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . B2–2 VALVE CLEARANCE INSPECTION/ADJUSTMENT . . . . . . . . . . . . . B2–2 COMPRESSION INSPECTION . . . . . . . . . . . . . . . B2–3 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–4 TIMING BELT REMOVAL/INSTALLATION . . . . B2–4/5 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . B2–6 CYLINDER HEAD GASKET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . B2–6/8
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . B2– 9 ROCKER ARM REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . B2– 9/11 FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . B2–11 FRONT OIL SEAL REPLACEMENT . . . . . . . . B2–11/12 REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . B2–12 REAR OIL SEAL REPLACEMENT . . . . . . . . B2–12 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–13 ENGINE REMOVAL/INSTALLATION . . . . . . B2–13/14 ENGINE DISASSEMBLY/ASSEMBLY . . . . . B2–14
DRIVE BELT
Deflection
DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N {10 kgf, 22 lbf} midway between the specified pulleys. GENERATOR
*New
Used
Limit
Generator
7.0—9.0 {0.28—0.35}
8.0—10.0 {0.32—0.39}
16.0 {0.63}
a
5.0—6.2 {0.20—0.24}
6.0—6.5 {0.24—0.25}
11.3 {0.44}
b
9.5—11.8 {0.38—0.46}
11.0—12.5 {0.44—0.49}
18.0 {0.71}
A/C
MEASURING POINT
(mm {in})
Drive belt
* A belt that has been on a running engine for less than five minutes. WATER PUMP
2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) GENERATOR
CRANKSHAFT PULLEY MEASURING POINT a
A/C
CRANKSHAFT PULLEY
Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.
A/C COMPRESSOR
49 9200 020A
MEASURING POINT b WHEN MEASURED
WHEN SET
CONTINUED
B2–1
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DRIVE BELT, VALVE CLEARANCE Tension
(N {kgf, lbf})
Drive belt
*New
Used
Limit
Generator
442—637 {45—65, 99—143}
383—539 {39—55, 86—121}
177 {18, 40}
A/C
403—519 {41—53, 91—116}
354—431 {36—44, 80—96}
181 {18.5, 41}
VALVE CLEARANCE VALVE CLEARANCE INSPECTION/ADJUSTMENT 1. Remove the cylinder head cover. 2. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinder is at TDC of compression. 3. Measure the valve clearances A with the No.1 cylinder at TDC of compression, and those of B with the No.4 cylinder at TDC of compression.
* A belt that has been on a running engine for less than five minutes.
2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen the mounting bolt and locknut A. 2. Adjust the belt deflection or tension by turning adjusting bolt B. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten the mounting bolt and locknut A.
Valve clearance IN: 0.05—0.15 mm {0.0020—0.0059 in} [Engine cold] 0.15 mm {0.0059 in} [Engine hot (Reference)] EX:0.15—0.25 mm {0.0060—0.0098 in} [Engine cold] 0.25 mm {0.0098 in} [Engine hot (Reference)] A
A
A
GENERATOR
ENGINE FRONT
B A 19—25 {1.9—2.6, 14—18}
WATER PUMP
B
B
B
GENERATOR
4. If not within the specification, adjust and recheck the valve clearance. 5. Turn the crankshaft one full turn and measure the remaining valve clearances. Adjust if necessary.
32—46
A {3.2—4.7,
CRANKSHAFT PULLEY
24—33}
B a
A/C
38—51 {3.8—5.3, A 28—38}
Tightening torque (locknut) 16—20 N·m {1.6—2.1 kgf·m, 12—15 ft·lbf} A/C COMPRESSOR
CRANKSHAFT PULLEY
FEELER GAUGE
ADJUST SCREW
LOCKNUT b
N·m {kgf·m, ft·lbf}
4. Inspect the belt deflection or tension. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
6. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
CONTINUED
B2–2
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COMPRESSION INSPECTION
COMPRESSION INSPECTION Warning When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they are cool. 1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool off for about 10 minutes. Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent fuel from spurting out of the injection nozzle hole, do not ground the FCV (fuel cut valve) terminal.
(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. 10. Remove the SST. 11. Install the glow plug. (Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.) 12. Connect the FCV (fuel cut valve) connector.
4. Disconnect the FCV (fuel cut valve) connector. 5. Remove all the glow plugs. (Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.) 6. Install the SSTs into the glow plug hole. 49 S010 1A0 49 S013 102
7. Crank the engine and note the maximum gauge reading. 8. Check each cylinder as above. Compression (kPa {kgf/cm2, psi} [rpm]) Item
Engine WL, WL Turbo
Standard
2942 {30, 427} [200]
Minimum
2648 {27, 384} [200]
9. If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. (2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
CONTINUED
B2–3
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TIMING BELT 3. Remove the tensioner and tensioner spring.
TIMING BELT TIMING BELT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Timing Belt Installation Note 1. Measure the tensioner spring free length. Replace the tensioner spring if necessary. Free length 63.0 mm {2.48 in}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
38—51 {3.8—5.3, 28—38} N·m {kgf·m, ft·lbf}
FREE LENGTH
1
Timing belt cover + Installation Note
2
Tensioner, tensioner spring
3
Timing belt + Removal Note + Installation Note
2. Turn the crankshaft clockwise and align the timing marks as shown. TIMING MARK TENSIONER LOCK BOLT
Timing Belt Removal Note
CAMSHAFT PULLEY
Caution Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life.
TENSIONER SPRING TENSIONER TIMING MARK
FAULTY
FAULTY
Caution Overtensioning of the timing belt can cause breakage of the belt and the camshaft.
FAULTY
ROTATION ARROW
25 mm {1.0 in} MIN.
3. Verify that the FIP attaching bolts and nuts are tightened to the specified torque. This must be done to prevent overtensioning of the timing belt after it has been installed. 4. Install the timing belt. 5. Install the tensioner, tensioner spring, and hand-tighten the lock bolt. 6. Turn the crankshaft clockwise twice, and align the timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Installation Note Step 2. 7. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring. 8. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation. 9. Turn the crankshaft clockwise twice, and check the timing belt deflection as shown. If it is incorrect, repeat from Timing Belt Removal Note.
FAULTY
1. Mark the timing belt rotation on the belt for proper reinstallation. 2. Turn the crankshaft clockwise and align the timing marks as shown. TIMING MARK
CAMSHAFT PULLEY TENSIONER SPRING TENSIONER TIMING MARK
FIP PULLEY
FIP PULLEY
CONTINUED
B2–4
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TIMING BELT Timing belt deflection 9.0—10.0 mm {0.36—0.39 in} at 98 N {10 kgf, 22 lbf} TENSIONER LOCK BOLT
DEFLECTION CHECKING POINT
CAMSHAFT PULLEY TENSIONER SPRING TENSIONER FIP PULLEY
Timing Belt Cover Installation Note Tighten the timing belt cover bolts in the order shown.
CONTINUED
ST
B2–5
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CYLINDER HEAD GASKET
CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E,ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the intake manifold, air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 4. Remove the injection nozzle. (Refer to Section F2, FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 5. Remove the turbocharger. (WL Turbo) (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 7. Remove in the order indicated in the table. 8. Install in the reverse order of removal. 9. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 10. Check the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 11. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 12. Start the engine and (1) Inspect for engine oil, engine coolant, and fuel leakage. (2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, PREPARATION, Idle Speed Adjustment.) 13. Inspect the compression. (Refer to COMPRESSION INSPECTION.)
5.0—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf} 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
18—19 {1.8—2.0, 13.1—14.4} 29 {3.0, 22} + (90°—105°) + (90°—105°)
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
38—51 {3.8—5.3, 28—38}
CONTINUED N·m {kgf·m, ft·lbf}
B2–6
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CYLINDER HEAD GASKET
1
Drive belt
2
Cylinder head cover + Installation Note
3
Cylinder head bolt + Removal Note + Installation Note
4
Cylinder head
5
Cylinder head gasket + Installation Note
LENGTH
Cylinder Head Bolt Removal Note 1. Remove bolts A. 2. Loosen the cylinder head bolts in two or three steps in the order shown.
2. Apply clean engine oil to the threads and the seat face of each bolt and install them. 3. Tighten the bolts in two or three steps in the order shown in the figure.
A
Tightening torque 29 N·m {3.0 kgf·m, 22 ft·lbf} A
A
Cylinder Head Gasket Installation Note Apply silicone sealant to the cylinder head as shown.
A
Thickness ø2.0—3.0 mm {0.08—0.11 in}
4. Put a paint mark on each bolt head. 5. Using the marks as a reference, tighten the bolts by turning each 90°—105° in the sequence shown. 6. Further tighten each bolt by turning another 90°—105°.
16.0 mm {0.63 in} 40.5 mm {1.59 in}
ENGINE FRONT
PAINT MARK 90°—105°
48.5 mm {1.91 in}
90°—105°
9.0 mm {0.35 in}
ST Cylinder Head Bolt Installation Note 1. Measure the length of each bolt. Replace the bolt if necessary.
PAINT MARK
7. Tighten bolts A.
Cylinder head bolt
(mm {in})
Bolt head mark
Standard length
Maximum length
W
101.2—101.8 {3.985—4.007}
102.5 {4.035}
N
113.2—113.8 {4.457—4.480}
114.5 {4.508}
Tightening torque 18—19 N·m {1.8—2.0 kgf·m, 13.1—14.4 ft·lbf}
CONTINUED
B2–7
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CYLINDER HEAD GASKET Cylinder Head Cover Installation Note 1. Apply silicone sealant to the cylinder head as shown. Thickness ø1.5—2.5 mm {0.060—0.098 in}
2. Tighten cylinder head cover bolts A and B. Tightening torque 1.5—2.9 N·m {15—30 kgf·cm, 14—26 in·lbf}
A ENGINE FRONT B
3. Tighten the cylinder head cover bolts in the order shown. Tightening torque 5.0—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf}
CONTINUED
B2–8
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ROCKER ARM
ROCKER ARM ROCKER ARM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
5.0—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf}
R
11.3—14.2 N·m {115—145 kgf·cm, 100—125 in·lbf} 16—20 {1.6—2.1, 12—15}
R SST
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 30—41 {3.0—4.2, 22—30}
123—140 {12.5—14.3, 91—103}
N·m {kgf·m, ft·lbf}
1
2
Cylinder head cover + VALVE CLEARANCE, VALVE CLEARANCE INSPECTION/ADJUSTMENT + CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note
3
Seal plate + Installation Note
4
Camshaft + Removal Note + Installation Note
ST
Camshaft pulley + Removal Note + Installation Note
5
Rocker arm + Installation Note
6
Pivot
CONTINUED
B2–9
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ROCKER ARM Camshaft Pulley Removal Note Hold the camshaft by using a wrench on the cast hexagon.
2. Tighten the camshaft cap bolts gradually in three or four steps in the order shown. Camshaft Removal Note Note Mark the camshaft caps so that they can be reinstalled in the position from which they were removed.
ENGINE FRONT
Loosen the camshaft cap bolts in three or four
steps in the order shown.
ENGINE FRONT
3. Apply clean engine oil to the new oil seal. 4. Push the oil seal slightly in by hand. 5. Tap the oil seal into the cylinder head by using the SST and a hammer. 6. To ensure that the oil seal is installed accurately, measure distance between the end of the cylinder head and the face of the oil seal. 49 S010 001
Rocker Arm Installation Note If a new rocker arm is used, set dimension follows.
as 0.5—1.0 mm {0.02—0.03 in}
Dimension A 0—4 mm {0—0.1 in} HAMMER
CYLINDER HEAD
OIL SEAL
Seal Plate Installation Note Tighten the seal plate bolts in the order shown. A
Camshaft Installation Note 1. Apply silicone sealant to the front camshaft cap mounting surfaces as shown. Prevent sealant from getting onto the camshaft journal, oil seal surface, and camshaft thrust surface.
B2–10
CONTINUED
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ROCKER ARM, FRONT OIL SEAL Camshaft Pulley Installation Note Hold the camshaft by using a wrench on the cast hexagon and tighten the pulley lock bolt.
FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the upper radiator hose. 4. Remove the radiator cowling and cooling fan. (Refer to Section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Inspect the engine oil level. 8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) SST R SST 350—390 {35—40, 260—280}
N·m {kgf·m, ft·lbf}
1
Drive belt
2
Crankshaft pulley + Removal Note + Installation Note
3
Front oil seal + Removal Note + Installation Note
Crankshaft Pulley Removal Note Hold the crankshaft by using the SST. Caution Turning the crankshaft after the crankshaft pulley is removed can cause the timing gear to become dislocated. Removing the key can cause the key groove to become misaligned.
49 S011 102A
CONTINUED
B2–11
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FRONT OIL SEAL, REAR OIL SEAL Front Oil Seal Removal Note 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag.
REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
RAG
Front Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly by using the SST and a hammer. 4. To ensure that the oil seal is installed accurately, measure the distance between the end of the gear case cover and the face of the front oil seal.
SST
1
GEAR CASE COVER
49 S010 301
0—0.4 mm {0—0.01 in}
HAMMER
R
Rear oil seal + Removal Note + Installation Note
Rear Oil Seal Removal Note 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag.
FRONT OIL SEAL
Crankshaft Pulley Installation Note Hold the crankshaft by using the SST.
RAG
49 S011 102A
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly by using the SST and a hammer. 4. To ensure that the oil seal is installed accurately, measure the distance between the end of the rear cover and the face of the rear oil seal. 49 S011 103
REAR COVER
0—0.5 mm {0—0.01 in}
HAMMER
REAR OIL SEAL
CONTINUED
B2–12
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ENGINE
ENGINE ENGINE REMOVAL/INSTALLATION Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.) 1. Remove the air intake pipe. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.) 3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 4. Remove the front pipe. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the transmission. (Refer to section J2, TRANSMISSION, TRANSMISSION REMOVAL/INSTALLATION.) 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal. 8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 10. Start the engine and (1) Inspect the engine oil, engine coolant, and fuel leakage. (2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed Adjustment.) 11. Perform a road test.
19—25 {1.9—2.6, 14—18}
9.9—14.7 N·m {100—150 kgf·cm, 86.8—130 in·lbf}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
32—46 {3.2—4.7, 24—33}
20—30 {2.0—3.1, 15—22} N·m {kgf·m, ft·lbf}
1
Cooling fan
2
Drive belt
3 4
5
P/S oil pump + Removal Note
Accelerator cable
6
Engine mount nut
A/C compressor + Removal Note
7
Engine + Removal/Installation Note
CONTINUED
B2–13
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ENGINE A/C Compressor Removal Note Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. P/S Oil Pump Removal Note Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. Engine Removal/Installation Note Install the engine hanger (JE48 10 561C) to the cylinder head by using bolt (99794 0820) or (M8 1.25, 6T, length 20 mm {0.79 in}) as shown.
ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the intake-air system. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the exhaust system. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Remove the oil cooler. (Refer to Section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) 4. Disassemble in the ordre indicated in the table. 5. Assemble in the reverse order of disassembly.
12—17 {1.2—1.8, 9—13}
Tightening torque 19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf} 38—51 {3.8—5.3, 28—38}
ENGINE FRONT
32—46 {3.2—4.7, 24—33}
19—25 {1.9—2.6, 14—18}
38—51 {3.8—5.3, 28—38}
N·m {kgf·m, ft·lbf}
1
Drive belt
2
Generator
3
Idler
4
A/C compressor bracket
5
Engine mount bracket
6
Oil pressure switch + Section D, OIL PRESSURE INSPECTION
7
Water pump pulley
CONTINUED
B2–14
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ENGINE (F2) DRIVE BELT .................................................... B3- 1 DRIVE BELT INSPECTION .......................... B3- 1 DRIVE BELT ADJUSTMENT ........................ B3- 2 COMPRESSION INSPECTION ........................ B3- 2/3 TIMING BELT .................................................. B3- 4 TIMING BELT REMOVAL/INSTALLATION ... B3-4/6 CYLINDER HEAD GASKET ............................. B3- 7 CYLINDER HEAD GASKET REPLACEMENT ......................................... B3- 7/9 HYDRAULIC LASH ADJUSTER (HLA) ............ B3-10
DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys.
HLA REMOVAL/INSTALLATION ................ B3-10/12 HLA TROUBLESHOOTING ........................ B3-13 FRONT OIL SEAL ......................................... B3-14 FRONT OIL SEAL REPLACEMENT ........... B3-14 REAR OIL SEAL ............................................. B3-15 REAR OIL SEAL REPLACEMENT ............. B3-15 ENGINE .......................................................... B3-16 ENGINE REMOVAL/INSTALLATION ......... B3-16/17 ENGINE DISASSEMBLY/ASSEMBLY ........ B3-18
Deflection Drive belt Generator P/S A/C
*New
mm {in} Used
7.0—8.0 {0.28—0.31}
8.0—9.0 {0.32—0.35}
5.0—6.0 {0.20—0.23} 10.0—12.0 {0.40—0.47}
5.5—6.5 {0.22—0.25} 12.0—14.0 {0.48—0.55}
* A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.
CONTINUED
B3-1
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DRIVE BELT, COMPRESSION INSPECTION N {kgf, Ibf}
Tension Drive belt
*New
Used
Generator
510—588 {52—60, 115—132}
432—509 44—52, 97—114}
P/S
393—490 {40—50, 88—110}
344—441 {35—45, 77—99}
A/C
373—490 {38—50, 84—110}
275—372 {28—38, 62—83}
* A belt that has been on a running engine for less than five minutes. 2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the generator or adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten mounting bolts A and B, and locknut C.
COMPRESSION INSPECTION
•
• • •
• • • • • •
Warning • When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during removal/installation of each component. Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) Warm up the engine to the normal operating temperature. Stop the engine and allow it to cool off for about 10 minutes. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB). Remove the spark plugs. Connect a compression gauge into the No.1 spark plug hole. Fully depress the accelerator pedal and crank the engine. Note the maximum gauge reading. Inspect compression of each cylinder.
Compression Item Standard Minimum Maximum difference between cylinders
kPa {kgf/cm2, psi} [rpm] Engine type F2 CARB F2CIS 1196 {12.2, 173} 1226 {12.5, 178} [300] [300] 837 {8.54, 121} [300]
858 {8.75, 124} [300]
2 196 kPa {2.0 kgf/cm , 28 psi}
•
If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. • If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. • If the compression stays low, a valve may be stuck or improperly seated and overhaul is required. • If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. • Disconnect the compression gauge. • Install the spark plugs. Tightening torque 15—22 N-m {1.5—2.3 kgf-m, 11—16 ft-lbf}
B3-2
CONTINUED
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COMPRESSION INSPECTION • •
Connect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB). Install the fuel pump relay.
CONTINUED
B3-3
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TIMING BELT TIMING BELT TIMING BELT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the spark plugs. 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and cooling fan pulley. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Start the engine and (1) Inspect the pulleys and drive belt for runout and contact. (2) Inspect the ignition timing. (Refer to Section F3-F4, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
1 2 3 4 5
Generator strap Cooling fan bracket Timing belt cover ☞ Installation Note Crankshaft pulley Guide plate
6
7
Timing belt ☞ Removal Note ☞ Installation Note Tensioner, tensioner spring ☞ Installation Note
CONTINUED
B3-4
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TIMING BELT Timing Belt Removal Note 1. Turn the crankshaft clockwise and align the timing marks. Camshaft pulley timing mark 1 2. Install the tensioner. 3. Temporarily secure the tensioner with the spring fully extended.
2. Loosen the tensioner lock bolt. 3. Push the tensioner in the direction of the ar reduce tension of the timing belt and handrow to tighten the tensioner lock bolt. Timing Belt Installation Note 1. Verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks as shown. Camshaft pulley timing mark 1
Caution • Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life. Note • Mark the timing belt rotation on the belt for proper reinstallation. 2. Install the timing belt so that there is no looseness at the tension side.
Tensioner, Tensioner Spring Installation Note 1. Measure the tensioner spring free length. If not as specified, replace the tensioner spring. Free length 63.0 mm {2.48 in}
CONTINUED
B3-5
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TIMING BELT Caution • Applying excessive tension can break the timing belt. Be sure not to apply tension other than that of the tensioner spring. 3. Loosen the tensioner lock bolt to apply tension to the timing belt. 4. Turn the crankshaft clockwise twice and verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks. 5. If not, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.) Caution • Prevent the tensioner from moving with the tensioner lock bolt as it is turned. Otherwise tension will become very high and the timing belt may break. 6. Tighten the tensioner lock bolt. 7. Inspect the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf, 22 Ibf}. Timing belt deflection New : 8.0—9.0 mm {0.32—0.35 in} Used : 9.0—10.0 mm {0.36—0.39 in}
8. If not as specified, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.) Timing Belt Cover Installation Note • Tighten the timing belt cover bolts in the order shown.
CONTINUED
B3-6
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CYLINDER HEAD GASKET CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the timing belt, (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove the front pipe. (Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the air cleaner. (F2 CARB) 6. Remove the air hose. (F2 CIS) 7. Disconnect the PCV hose. 8. Disconnect the accelerator cable and bracket (F2 CIS). 9. Disconnect the vacuum hoses, and engine harness connector. 10. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, AFTER REPAIR PROCEDURE.) 11. Remove the dynamic chamber bracket. (F2 CIS) 12. Disconnect the heater hoses. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Inspect for fuel leakage. 16. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 17. Start the engine and inspect the idle speed. (Refer to Section F3-F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
CONTINUED B3-7
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CYLINDER HEAD GASKET
1
Cylinder head cover ☞ Installation Note
2
Cylinder head ☞ Removal Note ☞ Installation Note
3
Cylinder head gasket
CONTINUED
B3-8
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CYLINDER HEAD GASKET Cylinder Head Bolt Removal Note • Loosen the cylinder head bolts a few turns in the order shown.
Cylinder Head Bolt Installation Note • Tighten the cylinder head bolts a few turns in the order shown.
Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material. 2. Apply sealant all around the cylinder head cover side of the cylinder head cover gasket surface. 3. Install the cylinder head cover gasket into the cylinder head cover. 4. Apply silicone sealant to the shaded area as shown.
CONTINUED
B3-9
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HYDRAULIC LASH ADJUSTER (HLA) HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL/INSTALLATION Caution • Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.) 1. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 2. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 6. Start the engine and (1) inspect the engine oil (2) inspect the idle speed. (Refer to Section F3—F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 7. Inspect the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1
Rocker arm component ☞ Removal Note ☞ Installation Note
2
Camshaft cap (F2 CARB) ☞ Installation Note
3
Hydraulic lash adjuster (HLA) ☞ Installation Note
CONTINUED
B3-10
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HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Component Removal Note 1. Loosen the bolts a few turns in the order shown.
4. Apply clean engine oil to HLA 0-ring. Camshaft Cap (F2 CARS) Installation Note • Apply silicone sealant to the shaded areas of the cylinder head as shown.
Rocker Arm Component Installation Note Note • The intake side shaft has twice as many oil holes as the exhaust side shaft. (F2 CARB)
2. Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed. 3. Remove the rocker arm and shaft assembly together with the bolts.
1. Assemble the rocker arms and shaft assembly as shown in the figure.
Hydraulic Lash Adjuster (HLA) Installation Note 1. Place each HLA in a container filled with clean engine oil. Caution • Do not push the pin too hard. It may damage the HLA. 2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.
3. Pour engine oil into the oil reservoir in the rocker arm.
CONTINUED
B3-11
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HYDRAULIC LASH ADJUSTER (HLA)
2. Apply silicone sealant to the shaded areas of the cylinder head as shown.
3. Install the rocker arm component. 4. Tighten the bolts a few turns in the order shown.
CONTINUED
B3-12
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HYDRAULIC LASH ADJUSTER (HLA) HLA TROUBLESHOOTING Problem Possible Cause 1. Noise when engine is started Oil leakage in oil immediately after oil is passage or in HLA changed. 2. 3.
4.
5.
Action Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. * Time required for engine oil to circulate within HLA Noise when engine is started includes tolerance for engine oil condition and after sitting one day or more. ambient temperature. Noise when engine is started Oil leakage in HLA (Refer to HYDRAULIC LASH ADJUSTER (HLA), after new HLA is installed. HLA TROUBLESHOOTING, Valve Clearance Inspection.) Noise continues more than Insufficient oil pressure Check oil pressure. 10 minutes. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION.) Faulty HLA Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.) Noise during idle after high Incorrect oil amount Check oil level. speed running. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) Deteriorated oil Replace new engine oil. (Refer to Section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
Valve Clearance Inspection 1. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 2. Measure valve clearance. Valve clearance 0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in}, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) 4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
CONTINUED
B3-13
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FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
1 2 3
Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
Timing belt pulley ☞ Removal/Installation Note Key Front oil seal ☞ Removal Note ☞ Installation Note
Timing Belt Pulley Removal/Installation Note • Hold the crankshaft using the SST.
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
CONTINUED B3-14
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REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/ INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Rear oil seal • Refer to Removal Note • Refer to Installation Note
Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
CONTINUED
B3-15
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ENGINE ENGINE ENGINE REMOVAL/INSTALLATION Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and air hose (F2, CIS). 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket (F2 CIS), heater hoses, high-tension leads, and vacuum hoses. 6. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the cooling fan and cooling fan pulley. 8. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the transmission. (Refer to Section J1-J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 11. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to Section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 12. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Start the engine and (1) Inspect the engine oil, engine coolant, transmission oil, and fuel leakage. (2) Inspect the ignition timing, idle speed and idle mixture. (Refer to Section F3-F4, ENGINE TUNE-UP.) 16. Perform a road test.
CONTINUED
B3-16
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ENGINE
1
Engine mount nut
2
Engine
CONTINUED
B3-17
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ENGINE ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the distributor. (Refer to Section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 2. Remove the generator. 3. Remove the thermostat. (Refer to Section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) 4. Remove the intake-air system. (Refer to Section F3-F4, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Remove the exhaust system. (Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the oil filter. (Refer to Section D, OIL FILTER, OIL FILTER REPLACEMENT.) 7. Remove the oil pressure switch. (Refer to Section D, OIL PRESSURE INSPECTION.) 8. Disassemble in the order indicated in the table. 9. Assemble in the reverse order of disassembly.
1 2 3 4 5
Generator strap Cooling fan bracket Generator bracket Water inlet pipe Water bypass pipe
6 7 8 9
Dipstick P/S oil pump bracket Gusset plate Engine mount
CONTINUED
B3-18
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LUBRICATION SYSTEM OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL INSPECTION . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . .
D–1 D–2 D–2 D–2 D–2 D–2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER REMOVAL/INSTALLATION . . . . . OIL COOLER BODY INSPECTION . . . . . . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL/INSTALLATION . . . . . . . . .
D–3 D–3/4 D–4 D–4 D–4/5
G6
OIL PRESSURE INSPECTION Warning Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they are cool.
: 305—402 kPa {3.1—4.1 kgf/cm2, 45—58 psi} [3,000 rpm] WL : 452—529 kPa {4.6—5.4 kgf/cm2, 66—76 psi} [3,000 rpm] WL Turbo : 402—480 kPa {4.1—4.9 kgf/cm2, 59—69 psi} [3,000 rpm]
5. If the pressure is not as specified, inspect for the cause and repair or replace as necessary. 6. Stop the engine and wait until it becomes cool. 7. Remove the SST. 8. Apply silicone sealant to the oil pressure switch threads as shown.
1. Remove the oil pressure switch. 2. Screw the SST into the oil pressure switch installation hole. F2, G6
1.0—2.0 mm {0.040—0.078 in}
49 0187 280
4.0—6.0 mm {0.16—0.23 in} WL, WL TURBO
9. Install the oil pressure switch before the sealant hardens. Tightening torque 12—17 N·m {1.2—1.8 kgf·m, 9—13 ft·lbf} 10. Start the engine and inspect for oil leakage. 49 0187 280
3. Warm up the engine to normal operating temperature. 4. Run the engine at the specified speed, and note the gauge readings. Note The oil pressure can vary with viscosity and temperature. Oil pressure F2 : 295—392 kPa {3.0—4.0 kgf/cm2, 43—56 psi} [3,000 rpm]
CONTINUED
D–1
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ENGINE OIL, OIL FILTER
ENGINE OIL
OIL FILTER
ENGINE OIL INSPECTION 1. Position the vehicle on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and inspect for oil level and condition. Verify that the oil level is within the F and L marks on the dipstick. 5. Add or replace oil if necessary.
OIL FILTER REPLACEMENT 1. Remove the oil filter by using the SST or the filter wrench.
49 9014 001
ENGINE OIL REPLACEMENT Warning When the engine and the engine oil are hot, they can badly burn. Don’t burn yourself with either. A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands. Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
2. Use a clean rag to wipe off the mounting surface on the oil filter body. 3. Apply engine oil to the O-ring and tighten the filter according to the installation directions on the side of the oil filter using the SST or the filter wrench. 4. Start the engine and inspect for oil leakage. 5. Inspect for the oil level and add oil if necessary. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
1. Position the vehicle on level ground. 2. Remove the oil filler cap and the oil pan drain plug. 3. Drain the oil into a container. 4. Install the drain plug by using a new washer. Tightening torque 30—41 N·m {3.0—4.2 kgf·m, 22—30 ft·lbf} 5. Refill the engine oil with the specified type and amount of engine oil. 6. Refit the oil filler cap. 7. Run the engine and inspect for oil leakage. 8. Inspect the oil level and add oil if necessary. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.) Note The actual oil level may vary from the specified capacity in some cases. Oil capacity
(L {US qt, Imp qt}) Engine
Item
F2
G6
WL, WL Turbo
Oil replacement
3.9 {4.1, 3.4}
4.5 {4.8, 4.0}
5.6 {5.9, 4.9}
Oil and oil filter replacement
4.2 {4.4, 3.7}
4.7 {5.0, 4.4}
6.3 {6.7, 5.5}
Total (dry engine)
4.6 {4.9, 4.0}
5.5 {5.8, 4.8}
6.7 {7.1, 5.9}
CONTINUED
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OIL COOLER
OIL COOLER OIL COOLER REMOVAL/INSTALLATION G6, WL, WL Turbo 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the turbocharger. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) (WL Turbo model.) 4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.) 5. Remove in the order shown in the figure. 6. Install in the reverse order of removal. 7. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E, ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.) 8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.) 9. Start the engine and inspect for engine coolant leakage. G6
30—39 {3.0—4.0, 22—28} N·m {kgf·m, ft·lbf}
1
Water hose
2
Nut
3
Oil cooler
WL, WL TURBO R 30—49 {3.0—5.0, 22—36}
R
R
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 19—25 {1.9—2.6, 14—18}
R 19—25 {1.9—2.6, 14—18}
R N·m {kgf·m, ft·lbf}
1
Dipstick pipe
2
Radiator hose
3
Thermostat case
4
Insulator
5
Oil cooler body + Installation Note
6
Oil cooler
CONTINUED
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OIL COOLER, OIL PAN Oil Cooler Body Installation Note WL, WL Turbo Tighten the mounting bolts and nuts in the order shown.
OIL PAN OIL PAN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. 5. Fill with the specified amount and type of engine oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.) 6. Start the engine and inspect for engine oil leakage. F2, G6
OIL COOLER BODY INSPECTION WL, WL Turbo Measure the spring free length. Replace the spring if necessary. Standard free length Bypass valve spring: 36.7 mm {1.44 in} Pressure control valve spring: 54.7 mm {2.15 in} BYPASS VALVE SPRING
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 30—41 {3.0—4.2, 22—30}
38—51 {3.8—5.3, 28—38}
38—51 {3.8—5.3, 28—38}
PRESSURE CONTROL VALVE SPRING
N·m {kgf·m, ft·lbf}
1
Gusset plate
2
Oil pan + Removal Note + Installation Note
CONTINUED
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OIL PAN Oil Pan Installation Note
WL, WL TURBO
Caution If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause bolt hole damage.
94—115 {9.5—11.8, 69—85}
CRACKS
OLD SEALANT
55—80 {5.6—8.2, 41—59}
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf}
1
Crossmember (4WD)
2
Oil pan + Removal Note + Installation Note
1. Apply silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. N·m {kgf·m, ft·lbf}
Thickness Ø2.0—3.0 mm {0.08—0.11 in}
OIL PAN
Oil Pan Removal Note 1. Remove the oil pan mounting bolts. Caution Pry tools can easily scratch the cylinder block or oil baffle and oil pan contact surfaces. Prying off the oil pan can also easily bend the oil pan flange.
2. Install the oil pan before the sealant hardens.
2. Use a separator tool to separate the oil pan. SEPARATOR TOOL
CONTINUED
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COOLING SYSTEM ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT LEVEL INSPECTION . . . . ENGINE COOLANT REPLACEMENT . . . . . . . . ENGINE COOLANT LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP INSPECTION . . . . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR REMOVAL/INSTALLATION . . . . . . .
E–1 E–1 E–1/2 E–2 E–3 E–3 E–3 E–3
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT REMOVAL/INSTALLATION . . . . THERMOSTAT INSPECTION . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP REMOVAL/INSTALLATION . . . . COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING FAN REMOVAL/INSTALLATION . . . COOLING FAN INSPECTION . . . . . . . . . . . . . . .
E–4 E–4/5 E–5 E–6 E–6 E–7 E–7 E–7
ENGINE COOLANT Warning Removing the radiator cap or loosening the radiator drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you’re sure all the pressure is gone, press down on the cap –still using a cloth– turn it, and remove it. When the engine and the engine coolant are hot, they can badly burn. Turn off the engine and wait until they are cool before draining the engine coolant. ENGINE COOLANT LEVEL INSPECTION 1. Remove the radiator cap. 2. Verify that the coolant level is near the radiator filler neck. 3. Verify that the coolant level in the radiator reservoir is between the FULL and LOW marks. 4. Add coolant if necessary. ENGINE COOLANT REPLACEMENT 1. Drain the coolant in the radiator reservoir. 2. Remove the radiator cap and loosen the radiator drain plug.
TYPE A
DRAIN PLUG TYPE B
3. Drain the coolant into a container. 4. Flush the cooling system with water until all traces of color are gone. 5. Let the system drain completely. 6. Tighten the radiator drain plug. Tightening torque Type A: 1.5—2.9 N·m {15—30 kgf·cm, 14—26 in·lbf} Type B: 0.9—1.1 N·m {9.0—12 kgf·cm, 7.9—10 in·lbf} Caution The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant’s effectiveness. 7. Referring to the following graph and chart, select proper gravity of the coolant. Slowly pour the coolant into the radiator up to the coolant filler port. Filling pace 1.0 L {1.1 US qt, 0.88 Imp qt}/min. [max]
CONTINUED
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ENGINE COOLANT
SPECIFIC GRAVITY
Caution Applying more than 103 kPa {1.05 kgf/cm2, 14.9 psi} (F2) or 122 kPa {1.25 kgf/cm2, 17.7 psi} (G6, WL, WL Turbo) can damage the hoses, fittings, and other components, and cause leakage.
COOLANT PROTECTION
1,100 1,090 1,080
49 9200 147
1,070 1,060
50% 40%
1,050 30% 1,040 1,030
49 9200 146
1,020 1,010 1,000 0
5. Verify that the pressure is held. If not, inspect the system for coolant leakage.
–10 0 10 20 30 40 50 60 70 80 90 { 14 } { 32 } { 50 } { 68 } { 86 } { 104 }{ 122 } { 140 } { 158 } { 176 } { 194 } COOLANT TEMPERATURE °C { °F }
Antifreeze solution mixture percentage
Water
Coolant
Gravity at 20°C {68°F}
Above –16°C {3°F}
65
35
1,054
Above –26°C {–15°F}
55
45
1,066
Above –40°C {–40°F}
45
55
1,078
Volume percentage Coolant protection
8. Fill the coolant into the reservoir up to the FULL mark. 9. Fully install the radiator cap. 10. Start the engine and let it idle for approx. 10 minutes. If the coolant temperature becomes too high, stop the engine to prevent it from overheating. 11. After the engine warms up, run it at approx. 2,500 rpm for five minutes. 12. Increase the engine speed to approx. 3,000 rpm for five seconds, then return to idle. Repeat several times. 13. Stop the engine and wait until it is cool. 14. Inspect the coolant level. If it is low, repeat Steps 7—12. 15. Inspect for coolant leakage. ENGINE COOLANT LEAKAGE INSPECTION 1. Inspect the coolant level. (Refer to ENGINE COOLANT, ENGINE COOLANT LEVEL INSPECTION.) 2. Remove the radiator cap. 3. Connect a radiator cap tester and the SST to the radiator filler neck. 4. Apply pressure to the radiator. Pressure F2: 103 kPa {1.05 kgf/cm2, 14.9 psi} G6, WL, WL Turbo: 122 kPa {1.25 kgf/cm2, 17.7 psi}
CONTINUED
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RADIATOR CAP, RADIATOR
RADIATOR CAP
RADIATOR
RADIATOR CAP INSPECTION Warning Removing the radiator cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you’re sure all the pressure is gone, press down on the cap –still using a cloth– turn it, and remove it.
RADIATOR REMOVAL/INSTALLATION 1. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove in the order indiacted in the table. 3. Install in the reverse order of removal. 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 18—26 {1.8—2.7, 14—19} 18—26 {1.8—2.7, 14—19}
1. Attach the radiator cap to a radiator cap tester with the SST. Apply pressure gradually. 2. Verify that the pressure becomes stable within the specification. Pressure F2: 74—102 kPa {0.75—1.05 kgf/cm2, 10.7—14.9 psi} G6, WL, WL Turbo: 94—122 kPa {0.95—1.25 kgf/cm2, 13.5—17.7 psi} 3. If the pressure is held for 10 seconds, the radiator cap is normal. 49 9200 147
N·m {kgf·m, ft·lbf}
1
Radiator hose
2
Lower radiator cowling
3
Radiator cowling
4
Radiator
CONTINUED ST
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THERMOSTAT
THERMOSTAT
1
Upper radiator hose
2
Thermostat cover THERMOSTAT REMOVAL/INSTALLATION 3 Thermostat 1. Drain the engine coolant. (Refer to ENGINE + Installation Note COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. WL, WL TURBO 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) F2
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R
19—25 {1.9—2.6, 14—18}
R 19—25 {1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
1
Upper radiator hose
2
Thermostat cover
3
Thermostat + Installation Note
1
Dipstick pipe
2
Lower radiator hose
3
Thermostat cover
4
Thermostat + Installation Note
Thermostat Installation Note F2, G6 1. Install the thermostat into the cylinder head with the jiggle pin at the top. 2. Install a new gasket with the seal print side facing the cylinder head.
G6
JIGGLE PIN 19—25 {1.9—2.6, 14—18}
A
A–A
R
A
PRINT
19—25 {1.9—2.6, 14—18}
WL, WL Turbo Install the thermostat into the thermostat cover, aligning the projection on the gasket to the thermostat cover as shown.
CONTINUED
N·m {kgf·m, ft·lbf}
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THERMOSTAT
GASKET PROJECTION
THERMOSTAT COVER
THERMOSTAT INSPECTION Warning During inspection, the thermostat and water are extremely hot and they can badly burn. Do not touch the thermostat and water directly. Inspect the thermostat for the following and replace as necessary. Open valve in room temperature Opening temperature and lift of the valve Initial-opening temperature F2: 83.5—89.5 °C {183—193 °F} G6: 86.5—89.5 °C {188—193 °F} (Main valve) 83.5—86.5 °C {183—187 °F} (Sub valve) WL, WL Turbo: 80—84 °C {176—183 °F} Full open temperature F2, G6 : 100 °C {212 °F} WL, WL Turbo : 95 °C {203 °F} Full open lift G6 : 8.0 mm {0.31 in} min. (Main valve) 1.5 mm {0.06 in} min. (Sub valve) F2, WL, WL Turbo: 8.5 mm {0.33 in} min.
CONTINUED
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WATER PUMP
WATER PUMP
WL, WL TURBO
WATER PUMP REMOVAL/INSTALLATION 1. Remove the cooling fan. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.) 19—25 2. Remove the timing belt (F2). {1.9—2.6, 14—18} (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 3. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
R
F2 19—22 {1.9—2.3, 14—16}
N·m {kgf·m, ft·lbf} 19—25 {1.9—2.6, 14—18}
1
Water pump
2
Idler
R
38—51 {3.8—5.3, 28—38} N·m {kgf·m, ft·lbf}
G6
R
19—22 {1.9—2.2, 14—16} N·m {kgf·m, ft·lbf}
CONTINUED
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COOLING FAN
COOLING FAN COOLING FAN REMOVAL/INSTALLATION 1. Remove the drive belt. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the drive belt (generator) deflection. (Refer to Section B2,DRIVE BELT, DRIVE BELT ADJUSTMENT.)
F2, G6: 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} WL, WL TURBO: 19—25 {1.9—2.6, 14—18} N·m {kgf·m, ft·lbf}
1
Cooling fan
2
Water pump pulley
COOLING FAN INSPECTION 1. Rotate the cooling fan by hand and inspect for abnormal noise and looseness. Replace the cooling fan if necessary. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)
CONTINUED
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FUEL AND EMISSION CONTROL SYSTEMS (G6)
Page 1 of 2
ENGINE TUNE-UP ...............................................................F1-2 ENGINE TUNE-UP PREPARATION............................F1-2 IGNITION TIMING ADJUSTMENT...............................F1-2/3 IDLE SPEED ADJUSTMENT .......................................F1-4 IDLE-UP SPEED INSPECTION ..................................F1-4/5 IDLE MIXTURE INSPECTION .....................................F1-5 INTAKE-AIR SYSTEM ........................................................F1-6 VACUUM HOSE ROUTING DIAGRAM .......................F1-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .................................F1-6/7 BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION .................................F1-8 AIR VALVE INSPECTION ........................................... F1-8 IDLE AIR CONTROL (lAC) VALVE INSPECTION ........................................................F1-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ................................ F1-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT ..............................F1-9 FUEL SYSTEM .................................................................. F1-10 BEFORE REPAIR PROCEDURE ............................. F1-10 AFTER REPAIR PROCEDURE ................................. F1-10 FUEL TANK REMOVAL/INSTALLATION ............................... F1-11/13 NONRETURN VALVE INSPECTION ........................ F1-13 FUEL PUMP UNIT REMOVAL/INSTALLATION ............................... F1-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY .............................. F1-13/14 FUEL PUMP UNIT INSPECTION .............................. F1-14/16 FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION ............................... F1-16/17 FUEL INJECTOR REMOVAL/INSTALLATION ............................... F1-18/19 FUEL INJECTOR INSPECTION ................................ F1-19/21 PRESSURE REGULATOR REMOVAL/INSTALLATION ............................... F1-21 PRESSURE REGULATOR INSPECTION ...................................................... F1-21/22 PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION ................................................. F1-22 PULSATION DAMPER REMOVAL/INSTALLATION ............................... F1-22 PULSATION DAMPER INSPECTION ....................... F1-22 FUEL PUMP RELAY INSPECTION .......................... F1-23 EXHAUST SYSTEM .......................................................... F1-24 EXHAUST SYSTEM INSPECTION ........................... F1-24 EXHAUST SYSTEM REMOVAL/INSTALLATION ............................... F1-24 EMISSION SYSTEM .......................................................... F1-25 EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION .......................................................... F1-25 ROLLOVER VALVE INSPECTION ........................... F1-25 EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION ................................ F1-25
CHECK VALVE (TWO-WAY) INSPECTION ....................................................... F1-25/26 EVAPORATIVE CHAMBER INSPECTION ....................................................... F1-26 CHARCOAL CANISTER INSPECTION ................... F1-26 PURGE SOLENOID VALVE INSPECTION ....................................................... F1-26/27 POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION .............................. F1-27 CONTROL SYSTEM .......................................................... F1-28 CONTROL SYSTEM COMPONENT LOCATION............................................................ F1-28 PCM REMOVAL/INSTALLATION ............................. F1-29 PCM INSPECTION .............................................. F1-29/37 MASS AIR FLOW (MAF) SENSOR INSPECTION........................................................ F1-37 THROTTLE POSITION (TP) SENSOR INSPECTION ....................................................... F1-37/38 THROTTLE POSITION (TP) SENSOR ADJUSTMENT .................................................... F1-38 THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION ................................ F1-38/39 CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION ....................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION ....................................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION ................................ F1-40 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION ............... F1-40 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION ...................................... F1-40/41 CAMSHAFT POSITION (CMP) SENSOR INSPECTION ....................................................... F1-41 OXYGEN SENSOR O2S) INSPECTION ....................................................... F1-41/42 OXYGEN SENSOR O2S) REMOVAL/INSTALLATION................................. F1-42 VARIABLE RESISTOR INSPECTION........................ F1-42 CLUTCH SWITCH INSPECTION .............................. F1-42/43 CLUTCH SWITCH REMOVAL/INSTALLATION ............................... F1-43 NEUTRAL SWITCH INSPECTION ............................ F1-43 NEUTRAL SWITCH REMOVAL/INSTALLATION ................................ F1-43/44 POWER STEERING PRESSURE (PSP) SWITCH INSPECTION ............................ F1-44 MAIN RELAY INSPECTION ....................................... F1-44/45 MAIN RELAY REMOVAL/INSTALLATION ................ F1-45 ON-BOARD DIAGNOSTIC SYSTEM ............................... F1-45 READ/CLEAR DIAGNOSTIC TEST RESULTS ............................................................. F1-45 PARAMETER IDENTIFICATION (PID) ACCESS ............................................................... F1-45 DIAGNOSTIC SUPPORT PROCEDURE .................. F1-45 SIMULATION TEST..................................................... F1-45 ON-BOARD DIAGNOSTIC TEST .............................. F1-45/46 DTC READING PROCEDURE .................................. F1-46/48
F1-1
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FUEL AND EMISSION CONTROL SYSTEMS (G6 ) Page 2 of 2
PID/DATA MONITOR AND RECORD PROCEDURE ...................................................... F1-48 PLAYBACK OF STORED PIDS PROCEDURE ...................................................... F1-48/49 DIAGNOSTIC SUPPORT PROCEDURE .......... F1-49 SIMULATION TEST PROCEDURE ........................ F1-50/51 AFTER REPAIR PROCEDURE ............................. F1-51 DTC INSPECTION .................................................. F1-52/69
ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION Using the SSTs (NGS Tester) 1. Warm up the engine to normal operating temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads. • A/C switch 4. Verify that the steering wheel is at straight ahead position. 5. Connect the SSTs (NQS tester) to the DLC and select "PID/DATA MONITOR AND RECORD". (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.)
6. Access RPM PID. Press the trigger key to enter this selection. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.) 7. Press SETUP (Key 8) and turn the test mode on. 8. Press CANCEL. 9. Press START.
TROUBLESHOOTING ...................................................F1-70 FOREWORD ............................................................F1-70 TROUBLESHOOTING ITEM TABLE .....................F1-70 QUICK DIAGNOSTIC CHART ...............................F1-71/74 SYMPTOM TROUBLESHOOTING .......................F1-75/114 DIAGNOSTIC INSPECTION..................................F1-115/120 ENGINE SYSTEM INSPECTION .........................F1-120/127
Not Using the SSTs (NGS tester) 1. Warm up the engine to normal operating temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads. • A/C switch 4. Verify that the steering wheel is at straight ahead position. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. 5. Connect a dwell tachometer to the DLC terminal IG-.
IGNITION TIMING ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNEUP PREPARATION.) 2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ±20) rpm 3. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 4. Connect the timing light to the high-tension lead of the No. 1 cylinder. 5. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 4°—6°(5° ± 1°)
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ENGINE TUNE-UP 6. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment. 7. Tighten the distributor lock bolts to the specified torque. Tightening torque 19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf} 8. Press SETUP (Key 8) and turn the test mode off. 9. Press CANCEL. 10. Verify that the timing mark on the crankshaft pulley is within the specification.
4. Verify that the idle speed is within the specification. Specification 730—770 (750 ± 20) RPM 5. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 6. Connect the timing light to the high-tension lead of the No.1 cylinder. 7. Verify that the timing mark on the crankshaft pulley is within the specification.
Specification BTDC 1°—30° Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
Specification BTDC 4°—6° (5° ± 1°) 8. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment. 9. Tighten the distributor lock bolts to the specified torque. Tightening torque 19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf} 10. Disconnect the SST or jumper wire. 11. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 1°—30°
3. If using a jumper wire to turn on the test mode, perform the following: Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. • Use a jumper wire to short terminal TEN of the DLC to body GND.
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ENGINE TUNE-UP IDLE SPEED ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not be adjusted. Any adjustment will negatively affect the engine performance. 3. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT", then adjust the idle speed by turning the AAS.
Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. • Use a jumper wire to short terminal TEN of the DLC to body GND.
4. Verify that the idle speed is within the specification using the dwell tachometer. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not be adjusted. Any adjustment will negatively affect the engine performance. 5. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT', then adjust the idle speed by turning the AAS.
4. Press SETUP (Key 8) to turn the test mode off. 5. Press CLEAR to clear previously selected items. 6. Disconnect the SSTs. Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
3. If using a jumper wire to turn on the test mode, perform the following:
6. Disconnect the SST or a jumper wire. 7. Disconnect the dwell tachometer. IDLE-UP SPEED INSPECTION Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Press SETUP (Key 8) and turn the test mode off. 3. Press CANCEL. 4. Press START. 5. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 6. Verify that the RPM PID is within the specification.
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ENGINE TUNE-UP Specification Load condition P/S ON*2 A/C ON*3
Idle-up speed (RPM)*1
•
700—800 (750 ± 50)
1
* : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. : A/C switch and fan switch are on. 7. If not as specified with all load conditions, inspect the IAC valve. 8. If not as specified with some load condition, inspect the related input switches, harnesses, and connectors. Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 3. Verify that the idle-up speed is within the specification. Specification 1 Load condition Idle-up speed (rpm)* P/S ON*2 700—800 (750 ± 50) A/C ON*3 1 * : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. 3 * : A/C switch and fan switch are on. 4. If not as specified with all load conditions, inspect the IAC valve. 5. If not as specified with some load conditions, inspect the related input switches, harnesses, and connectors. IDLE MIXTURE INSPECTION Vehicles With Oxygen Sensor (O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the idle speed and ignition timing are within the specification. (Refer to ENGINE TUNE-UP, IGNITION TIMING INSPECTION.) (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 3. Turn the test mode off. 4. Warm up the engine by holding the engine speed at 2500—3000 rpm for approx. 3 minutes. 5. Insert an exhaust gas analyzer to the tailpipe. 6. Verify that the CO and HC concentrations are within the regulation. 7. If not within the regulation, inspect the following: • On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.) • O2S (Refer to CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION.)
•
•
•
Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Intake Manifold Vacuum Inspection.) Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.) Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.) If the systems and devices are normal, replace the TWC. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
Vehicles Without Oxygen Sensor O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". 2. Verify that the idle speed and ignition timing are within the specification. (Refer to IGNITION TIMING INSPECTION.) (Refer to IDLE SPEED ADJUSTMENT.) 3. Insert an exhaust gas analyzer to the tailpipe. 4. Verify that the CO and HC concentrations are within the regulation. 5. If not, turn the adjust screw to adjust CO and HC concentration using the SST.
6. If not adjusted, inspect the following: • On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.) • Variable resistor (Refer to CONTROL SYSTEM, VARIABLE RESISTOR INSPECTION.) • Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM, INSPECTION, Intake Manifold Vacuum Inspection.) • Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel line Pressure Inspection.) • Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.)
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INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning • When the engine and intake-air system are hot, they can badly burn. Turn off engine and wait until they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Disconnect the negative battery cable. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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INTAKE-AIR SYSTEM
1 2 3 4
Air cleaner component Air intake hose MAP sensor Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ ADJUSTMENT
5 6 7
Throttle body component Dynamic chamber Fuel injector ☞ FUEL SYSTEM, FUEL INJECTOR REMOVAL/ INSTALLATION
8
Intake manifold
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INTAKE-AIR SYSTEM BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAC valve connector. 3. Drain the engine coolant from the radiator. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 4. Remove the BAC valve.
6. If not as specified, replace the BAC valve. (Refer to BAC VALVE REMOVAL/INSTALLATION.) If as specified, but IAC valve is failed, inspect for the following: Open circuit • Power circuit (IAC valve connector terminal A and main relay terminal D) 5. Install in the reverse order of removal. AIR VALVE INSPECTION Operation Inspection Note 1. Perform the following test only when directed. 1. Carry out the "Idle Air Control (IAC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.) 2. Remove the BAC valve. (Refer to INTAKE-AIR SYSTEM, BAC VALVE REMOVAL/INSTALLATION.) 3. Add cold water into the engine coolant passage of the BAC valve to reduce the air valve temperature. 4. Verify that the air valve operates when hot water is added into the engine coolant passage of the BAC valve. 5. If not as specified, replace the BAC valve, 6. Install the BAC valve. IDLE AIR CONTROL (IAC) VALVE INSPECTION Resistance Inspection Note 2. Perform the following test only when directed, 1. Carry out the "Idle Air Control (IAC) Inspection", (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.) 2. If not as specified, perform the further inspection for the IAC valve. 3. Disconnect the negative battery cable. 4. Disconnect the IAC valve connector. 5. Measure the resistance between the IAC valve terminals using an ohmmeter.
•
GND circuit (IAC valve connector terminal B and PCM connector terminal 2W) Short circuit • IAC valve connector terminal B and PCM connector terminal 2W to GND 7. Repair or replace faulty areas. 8. Connect the IAC valve connector. 9. Connect the negative battery cable.
Resistance 7.7—9.3 Ω [23 °C {73 °F}]
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INTAKE-AIR SYSTEM ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1
2
Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Measure the free play of the accelerator cable.
Free play 1—3 mm {0.04—0.11 in} 2. If not as specified, adjust by turning the locknut,
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FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". Note • Fuel in the fuel system is under high pressure when the engine is not running. Fuel Line Safety Procedures 1. Remove the fuel-filler cap and release the pressure in the fuel tank. 2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.
3. Start the engine. 4. After the engine stalls, crank the engine several times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and "Fuel Leakage Inspection" described below. Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit the hose onto the pipe over 25 mm {0.98 in}. When the pipe has a stopper, fit the hose until it contacts the stopper.
3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position. CLAMP INSTALLATION RANGE
Fuel Leakage Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 1. Short the DLC terminal F/P to body GND using a jumper wire.
2. Turn the ignition switch on to operate the fuel pump body. 3. Pressurize the system this way for at least 5 minutes to be sure of no leakage. 4. If there is fuel leakage, inspect for damaged fuel hoses, hose clamps, and fuel pipe sealing surface and replace as necessary. 5. After repair, assemble the system and repeat Steps 1 to 3.
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FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Level the vehicle. 2. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Drain the fuel from the drain plug. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) STRETCH CAB 2WD, DOUBLE CAB 2WD
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FUEL SYSTEM STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1 2 3 4 5 6 7
Joint hose ☞ Installation Note Breather hose ☞ Installation Note Under guard Fuel hose Fuel tank Evaporative hose ☞ Installation Note Rollover valve
8 Fuel pump unit 9 Fuel-filler pipe 10 Dust cover 11 Fuel inlet pipe 12 Nonreturn valve 13 Evaporative gas check valve (two-way) ☞ Installation Note 14 Check valve (two-way) 15 Evaporative chamber
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FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note • Install the arrow mark of the evaporative gas check valve (two-way) facing the charcoal canister. Evaporative Hose Installation Note • Fit each hose onto the respective fittings within the specification, and install clamps as shown. Length Evaporative hose: 25—30 mm {0.99—1.18 in}
Breather Hose Installation Note • Fit each hose onto the respective fittings within the specification, and install clamp as shown.
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet pipe. 2. Verify that the nonreturn valve opening angle is 50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm {0.06 in} when the nonreturn valve is returned to the closed position.
Length Breather hose: 25—30 mm {0.99—1.18 in}
Joint Hose Installation Note • Fit the joint hose onto the respective fittings within the specification, and install clamps as shown. Length Joint hose: 35—40 mm {1.4—1.5 in}
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAL/INSTALLATION 1. Remove the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) 2. Install the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
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FUEL SYSTEM STRETCH CAB 2WD, DOUBLE CAB 2WD
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1 2 3 4 5 6
Rubber mount Fuel filter (low-pressure) Clamp Fuel hose Fuel pump body Fuel gauge sender unit
FUEL PUMP UNIT INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.)
2. If not as specified, perform the further inspection for the fuel pump unit. Continuity Inspection Note • Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit connector terminals C and D.
5. If there is no continuity, replace the fuel pump body. If as specified but the "Simulation Test" is failed, inspect the following: Fuel pump relay malfunction Open circuit • GND circuit (fuel pump unit connector terminal D and body GND) • Power circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)
Short circuit • Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 6. Repair or replace faulty areas. 7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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FUEL SYSTEM Fuel Pump Maximum Pressure Inspection Warning •
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note •
8. If not as specified, inspect the following: • Fuel pump relay • Fuel filter (low-pressure, high-pressure) for clogging • Fuel line for clogging or leakage 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 10. Disconnect the negative battery cable.
Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose, then plug the opening as shown.
11. Disconnect the fuel pressure gauge. 12. Connect the negative battery cable. 13. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) Fuel Pump Hold Pressure Inspection Warning •
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note •
Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 4. Connect the negative battery cable.
2. Disconnect the negative battery cable.
Caution •
Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only.
3. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose, then plug the opening as shown.
5. Short the DLC terminal F/P to body GND using a jumper wire.
4. Connect the negative battery cable. Caution 6. Turn the ignition switch on to operate the fuel pump body. Measure the fuel pump maximum pressure. Fuel pump maximum pressure 500—630 kPa {5.0—6.5 kgf/cm2, 72—92 psi} 7. Turn the ignition switch off and disconnect the jumper wire.
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•
Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only.
5. Short the DLC terminal F/P to body GND using a jumper wire.
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FUEL SYSTEM
6. Turn the ignition switch on for 10 seconds to operate the fuel pump body. 7. Turn the ignition switch off. Measure the fuel pump hold pressure after 5 minutes. Fuel pump hold pressure More than 340 kPa {3.5 kgf/cm2, 50 psi} 8. Disconnect the jumper wire. 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the negative battery cable. 13. If not as specified, carry out the "PRESSURE REGULATOR INSPECTION", "FUEL INJECTOR INSPECTION" (Refer to FUEL SYSTEM, PRESSURE REGULATOR INSPECTION.) (Refer to FUEL SYSTEM, FUEL INJECTOR INSPECTION.) 14. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order or removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 2
Fuel hose Protector
3
Fuel filter (high-pressure) ☞ Removal Note ☞ Installation Note
Fuel Filter (High-pressure) Removal Note • Before removing the fuel filter (high-pressure), paint marks on the fuel filter (high-pressure) and fuel filter bracket for correct reassembly.
Fuel Filter (High-pressure) Installation Note Replacing the fuel filter (high-pressure) 1. Paint a mark on the new fuel filter (high-pressure) at the same spot as the removed fuel filter (highpressure). 2. Align the paint marks and install the fuel filter (high-pressure) as shown.
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FUEL SYSTEM
Replacing the fuel filter bracket 1. Paint a mark on the new fuel filter bracket at the same spot as the removed fuel filter bracket. 2. Align the paint marks and install the fuel filter bracket as shown.
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FUEL SYSTEM FUEL INJECTOR REMOVAL/INSTALLATION Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2. 3. 4. 5. 6.
Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Disconnect the fuel injector connectors and remove the harness from the fuel distributor. Remove in the order indicated in the table. Install in the reverse order of removal. Complete the "AFTER REPAIR PROCEDURE." (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 Dynamic chamber 2 Dynamic chamber gasket
6 Fuel injector ☞ Installation note 7 Grommet 8 Fuel injector insulator
3 Fuel injector connector 4 Fuel hose 5 Fuel distributor
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FUEL SYSTEM Fuel Injector Installation Note 1. Use new fuel injector O-rings. 2. Verify that the O-rings and the fuel injector sealing surfaces are free of foreign materials. Clean with gasoline if necessary. 3. Apply a small amount of engine oil to the O-rings and into the fuel distributor. 4. Install the fuel injectors in the fuel distributor with a light twisting motion so that the O-rings will not be folded.
FUEL INJECTOR INSPECTION Simulation Test 1. Carry out the "Fuel Injector Operation Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Injector Operation Inspection.) 2. If not as specified, perform the further inspection for the fuel injectors. Resistance Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the fuel injector connectors. 3. Measure the resistance of the fuel injector using an ohmmeter.
Resistance 12—16Ω[20°C {68°F}] 4. If not as specified, replace the fuel injector. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) If as specified but "Simulation Test" is failed, inspect for the following:
Open circuit • GND circuit (No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U) • GND circuit (No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2V) • GND circuit (No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U) • GND circuit (No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V) • Power circuit (No.1 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No.2 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No.3 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No.4 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)
Short circuit • No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND • No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND • No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND • No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND 5. Repair or replace faulty areas. 6. Reconnect the fuel injector connectors. 7. Reconnect the negative battery cable. Fuel Leakage Test Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note • Perform the following test only when directed.
CONTINUED F1-19
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FUEL SYSTEM 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel injectors together with the fuel distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) 4. Fasten the fuel injectors firmly to the fuel distributor with wire.
5. Connect the negative battery cable. Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 6. Short the DLC terminal F/P to body GND using a jumper wire.
9. Turn the ignition switch off and remove the jumper wire. 10. If not as specified, replace the fuel injector. 11. Complete the "AFTER REPAIR PROCEDURE", (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) Volume Test Warning •
1.
2. 3.
4. 5.
7. Turn the ignition switch on to operate the fuel pump body. 8. Tilt the fuel injectors approx. 60 degrees and verify that fuel leakage from the fuel injector nozzles is within the specification.
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note • Perform the following test only when directed. Complete the "BEFORE REPAIR PROCEDURE", (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Remove the fuel injectors together with the fuel distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) Fasten the fuel injectors firmly to the fuel distributor with wire. Connect the SST as shown in the figure.
6. Connect the negative battery cable. Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 7. Short the DLC terminal F/P to body GND using a jumper wire.
Fuel leakage Less than 1 drop/2 minutes 8. Turn the ignition switch on to operate the fuel pump body. 9. Measure the injection volume of each fuel injector using a graduated container.
F1-20
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FUEL SYSTEM Injection volume 55—71 ml {55—71 cc, 1.9—2.3 fl oz}/15 sec. 10. Turn the ignition switch off and disconnect the jumper wire. 11. If not as specified, replace the fuel injector. 12. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) PRESSURE REGULATOR REMOVAL/INSTALLATION Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
O 1 Vacuum hose 2 Fuel hose 3 Pressure regulator PRESSURE REGULATOR INSPECTION Simulation Test 1. Carry out the "Fuel Line Pressure Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.) 2. If not as specified, perform the further inspection for the pressure regulator. Operation Inspection Note •
Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE".) 2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge between the pulsation damper and fuel main hose.
4. Connect the negative battery cable. 5. Start the engine and let it idle. 6. Measure the fuel line pressure after approx. 2 minutes. Fuel line pressure 2 210—250 kPa {2.1—2.6 kgf/cm , 30—36 psi} 7. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure.
Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi} 8. Turn the ignition switch off. 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.") 10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the fuel main hose to the fuel distributor. 13. Reconnect the negative battery cable. 14. If not as specified, inspect the following: • Fuel pump maximum pressure • Fuel pump hold pressure • Fuel filter for clogging • Fuel injector for leakage • Fuel pump relay • Fuel line for improper routing, clogging, kinks or leakage
CONTINUED F1-21
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FUEL SYSTEM If all items above are okay, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.) 15. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Pressure Regulator Control (PRC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Pressure Regulator Control (PRC) Inspection.) 2. If not as specified, perform the further inspection for the PRC solenoid valve, Airflow Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the PRC solenoid valve. (Refer to INTAKE-AIR SYSTEM, VACUUM HOSE ROUTING DIAGRAM.) 3. Inspect airflow between the ports under the following conditions.
4. If not as spec tied, replace the PRC solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage Open circuit • GND circuit (PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector) • Power circuit (PRC solenoid valve connector terminal A and main relay connector terminal D through common connector)
Short circuit • PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector to GND) 5. Repair or replace faulty areas. 6. Install the PRC solenoid valve. 7. Reconnect the negative battery cable. PULSATION DAMPER REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the pulsation damper. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1
Fuel hose
2 3
Bolt Pulsation damper
PULSATION DAMPER INSPECTION 1. Remove the pulsation damper. (Refer to FUEL SYSTEM, PULSATION DAMPER REMOVAL/INSTALLATION.) 2. Visually inspect the pulsation damper for damage and cracks. Also inspect that there is no extreme rust, which will cause fuel leakage. 3. If either is observed, replace the pulsation damper.
F1-22
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FUEL SYSTEM •
FUEL PUMP RELAY INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.) 2. If not as specified, perform the further inspection for the fuel pump relay. Continuity Inspection Note • Perform the following test only when directed.
Power circuit (fuel pump relay connector terminal A or C and IG switch connector terminal IG1 through common connector)
1. Disconnect the negative battery cable. 2. Remove the fuel pump relay located under the passenger's side front side trim.
3. Inspect for continuity between the fuel pump relay terminals using an ohmmeter.
Short circuit • Fuel pump relay connector terminal B and PCM connector terminal 1H through common connector to GND • Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 5. Repair or replace faulty areas. 6. Install the fuel pump relay. 7. Reconnect the negative battery cable.
4. If not as specified, replace the fuel pump relay. If as specified but the "Simulation Test" is failed, inspect for the following: Fuel pump unit malfunction Open circuit • GND circuit (fuel pump relay connector terminal B and PCM connector terminal 1H through common connector) • GND circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)
CONTINUED F1-23
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EXHAUST SYSTEM
EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 2 3
After silencer Main silencer TWO (Europe) Presilencer (Except Europe)
4 5 6
Front pipe Insulator Exhaust manifold
CONTINUED
F1-24
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EMISSION SYSTEM
EMISSION SYSTEM EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION
4. If not as specified, replace the rollover valve. EVAPORATIVE GAS CHECK VALVE (TWOWAY) INSPECTION 1. Remove the evaporative gas check valve (twoway). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Inspect airflow of the valve under the following conditions. Apply pressure below +2.9 kPa {+22 mmHg, +0.87 inHg} to port A
1
Charcoal canister
2 3
Purge solenoid valve PCV valve
Apply pressure over +5.9 kPa {+44 mmHg, +1.7 inHg} to port A Apply pressure over -0.98 kPa {-7.36 mmHg, -0.29 inHg} to port A
No airflow Airflow Airflow
ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Hold the valve as shown. Blow air into port A and verify that there is airflow.
3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow.
3. If not as specified, replace the evaporative gas check valve (two-way). CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Inspect airflow of the valve under the following conditions. Apply pressure of -0.98—1-13.7 kPa {-7.3—1-102 mmHg, -0.28— + 4.0 inHg} to port A Apply pressure over +18.6 kPa {+140 mmHg, +5.5 inHg} to port A Apply pressure over -4.9 kPa {-36.8 mmHg, -1.4 inHg} to port B
No airflow Airflow Airflow
CONTINUED
F1-25
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EMISSION SYSTEM
3. If not as specified, replace the check valve (twoway). EVAPORATIVE CHAMBER INSPECTION 1. Remove the evaporative chamber. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow air into port A and verify that air flows out from the holes B on the evaporative chamber.
PURGE SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Purge Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection.) 2. If not as specified, perform the further inspection for the purge solenoid valve, Airflow Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the purge solenoid valve. 3. Inspect airflow between the ports under the following conditions.
3. Visually inspect that there is no damage nor crack on the evaporative chamber. 4. If not as specified, replace the evaporative chamber. 5. Install the evaporative chamber. CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Plug the atmosphere side port and purge solenoid valve side port of the charcoal canister. 3. Blow air into the charcoal canister from the fuel tank side port and verify that there is no air leakage.
4. If not as specified, replace the purge solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage. Open circuit • GND circuit (purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector) • Power circuit (purge solenoid valve connector terminal A and main relay connector terminal D through common connector)
4. If there is air leakage, replace the charcoal canister.
CONTINUED
F1-26
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EMISSION SYSTEM Short circuit • Purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector to GND 5. Repair or replace faulty areas. 6. Install the purge solenoid valve. 7. Reconnect the negative battery cable. POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION
1. Remove the PCV valve. 2. Blow through the valve and verify that air flows as specified. Specification Condition Air applied from port A
Airflow Yes
Air applied from port B
No
3. If not as specified, replace the PCV valve.
CONTINUED
F1-27
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CONTROL SYSTEM
CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION
1 2 3 4 5 6 7
PCM MAF sensor TP sensor CTP switch IAT sensor ECT sensor CMP sensor (In distributor)
8 9 10 11 12 13
O2S (Europe only) Variable resistor (Except Europe) Clutch switch Neutral switch PSP switch Main relay
CONTINUED
F1-28
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CONTROL SYSTEM •
PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the cowl side panel (driver's side). 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
• •
For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM terminal voltage. When measuring the following PID value, perform the following: TP V PID (Refer to Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection.) (Refer to Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection.)
6. If PID value is not within the specification, follow the instruction in action column.
1 PCM 2 PCM connector PCM INSPECTION Using SSTs (NGS tester) Note • PIDs for the following parts are not available on this model. Go to the appropriate part inspection page. 1. Water temperature sender unit (Integrated with ECT sensor) (Refer to CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION.) 2. CMP sensor (Refer to CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION.) 3. Main relay (Refer to CONTROL SYSTEM, MAIN RELAY INSPECTION.) 1. Connect the SSTs (NGS tester) to the DLC. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ONBOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.) 2. Turn the ignition switch on. 3. Select the "PID/DATA MONITOR AND RECORD" function on the NGS tester display and press TRIGGER. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.) 4. Select the appropriate PID on the NGS tester display and press START. 5. Measure the PID value. Note • The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. If a monitored value of an output device is out of specification, inspect the monitored value of the input device related to the output control.
F1-29
Note • Perform the SIMULATION TEST for the output device (A/C RLY, FP RLY, IACV, PRGV) after PID/DATA measurement is completed.
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CONTROL SYSTEM PID MONITOR Table Monitor item (Definition)
Unit/ Condition
A/C RLY (A/C relay)
ON/OFF
Ignition switch on: OFF A/C switch on and fan switch on at idle: ON
A/C SW (A/C switch)
ON/OFF
A/C switch and fan switch on at ignition Inspect A/C switch. switch on: ON ☞ Section U A/C switch off at ignition switch on: OFF
Condition/Specification
Action
PCM terminal
Inspect following PIDs: RPM, TP V, ECT V, A/C SW. Inspect A/C relay. ☞ Section U
1J
1Q
Constant: B+
Inspect main relay. ☞ CONTROL SYSTEM, MAIN RELAY INSPECTION Inspect battery. ☞ Section G
kPa
Below 400 m {0.25 mile} above sea level: 100—103 kPa {1.01—1.05 kgf/cm2}
DTC P1195 is indicated. Follow DTC Troubleshooting ☞ ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION
-
BARO V*2 (Barometric pressure signal voltage)
V
Below 400 m {0.25 mile} above sea level: 3.9—4.0 V
DTC P1195 is indicated. Follow DTC Troubleshooting ☞ ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION
-
BRKSW (Brake switch)
ON/OFF
Brake pedal depressed: ON Brake pedal released: OFF
Inspect brake switch. ☞ Section P
1O
ON/OFF
Accelerator depressed: OFF Accelerator released: ON
Inspect CTP switch ☞ CONTROL SYSTEM, CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION
1N
°C
Engine coolant temperature 20 °C {68°F}: 20°C {68°F} Engine coolant temperature 60 °C {140°F}: 60°C {140°F}
B+ (Battery positive voltage)
V
BARO*2 (Barometric pressure)
CTP SW (Idle switch)
ECT (Engine coolant temperature) ECT V (ECT signal voltage)
FHO2S*1 (Oxygen sensor)
FPRLY (Fuel pump relay)
IACV (Idle air control valve)
°F
1B
Inspect engine coolant temperature sensor. w CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
2Q
V
Engine coolant temperature 20 °C {68 °F}; 2.2—2.4V After warms up: Below 1.0 V
Inspect engine coolant temperature sensor. ☞ CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
2Q
V
Ignition switch on: 0,1—1.0 V After warm up: 0.1—1.0 V Acceleration (after warm up): 0.5—1.0 V Deceleration (after warm up): 0—0.5V
Inspect O2S. ☞ CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION
2N
Ignition switch on: OFF Idle: ON Cranking: ON
Inspect following PID: RPM. Inspect fuel pump relay. ☞ FUEL SYSTEM, FUEL PUMP RELAY INSPECTION
1H
Idle: 2.4—2.7 ms
Inspect following PIDs: IATV, RPM, ECT V, MAF V, TP V, NL SW, CLT SW, PSP SW, A/C SW, TEN. Inspect idle air control valve. ☞ INTAKE-AIR SYSTEM, IDLE AIR CONTROL (IAC) VALVE INSPECTION
2W
ON/OFF
ms
1
: Europe only *2: Except Europe
CONTINUED F1-30
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CONTROL SYSTEM Monitor item (Definition) IATDC (Intake air temperature (Dynamic chamber)) IATDC V (IAT signal voltage (Dymanic chamber))
IGT (Ignition timing)
Unit/ Condition °C
V
BTC
MAFV (Mass air flow signal voltage) MT/AT*1 (MT/AT distinction signal)
V
Intake air temperature 20 °C {68 °F}: 2.5—2.7 V
Inspect IAT sensor -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
short to ground: A—6 BTC
PCM terminal
2L
2L
Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, PSP SW, NL SW, A/C SW, TEN, Inspect CMP sensor. -CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect idle speed and ignition timing. - ENGINE TUNE-UP. Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, NL SW, FHO2S, PSP SW, BRK SW, A/C SW, B+. Inspect CMP sensor. - CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION
Ignition switch on: 0.0 ms Idle: 3.0—5.0 ms
Ignition switch on: 1.0—2.0 V Idle: 1.9—2.8 V
ON/OFF
Constant: ON
ON/OFF
Neutral position and clutch pedal depressed: ON
NLSW (Load/no load condition signal)
Intake air temperature 20 °C {68 °F}:20°C{68 °F}
Idle: 1—30 BTC
ms
Action Inspect IAT sensor rar -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
Terminal TEN (DLC)
INJ (Fuel injection duration)
Condition/Specification
Inspect mass air flow sensor. CONTROL SYSTEM, MASS AIR FLOW (MAF) SENSOR INSPECTION -
Others: OFF
Inspect neutral switch. - CONTROL SYSTEM, NEUTRAL SWITCH INSPECTION Inspect clutch switch. -CONTROL SYSTEM, CLUTCH SWITCH INSPECTION
2F
2U 2V
20
1L
1V
CONTINUED
*1: Europe only
F1-31
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CONTROL SYSTEM Monitor item (Definition)
Unit/ Condition
Action
PGM terminal
Inspect following PIDs: ECTV, IAT V, RPM,TP V, B+. Inspect PRC solenoid valve. ☞ FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION
2T
Inspect following PIDs: IATV, RPM, ECT V, MAP V, TP V, FHO2S, B+. Inspect purge solenoid valve. ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION
2X
Steering wheel fully turned: ON Steering wheel straight ahead position: OFF
Inspect PSP switch. ☞ CONTROL SYSTEM, POWER STEERING PRESSURE (PSP) SWITCH INSPECTION
1P
Idle: 700—770 RPM
Inspect CMP sensor. ☞ CONTROL SYSTEM, CRANKSHAFT POSITION SENSOR INSPECTION
2E
Inspect wiring from DLC terminal TEN to PCM terminal 1L
1K
V
Closed throttle position: 0.4—0.6 V Wide open throttle: 3.4—4.7 V
Inspect TP sensor. ☞ CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR INSPECTION
2M
V
Turned fully clockwise: below 1.0 V Turned fully counterclockwise: Approx 4.0 V
Inspect variable resistor ☞ VARIABLE RESISTOR INSPECTION
2N
Vehicle speed 20 km/h {mph}: 20 km/h {mph}
☞ Section T, WARNING AND
Ignition switch on: OFF
PRCV (Pressure regulator control)
Condition/Specification
ON/OFF
Idle: OFF Engine start at hot condition: ON
PRGV (Purge solenoid valve duty value)
PSP SW (PSP switch)
RPM (Engine speed)
%
ON/OFF
RPM
TEN (TEN terminal (DLC))
ON/OFF
VRV*2 (Variable resistor)
VS (Vehicle speed)
Idle: 0%
Terminal TEN (DLC) short to ground: ON Terminal TEN (DLC) open: OFF
TP V (TP sensor signal voltage)
Ignition switch on: 0%
KPH
Vehicle speed 40 km/h {mph}: 40 km/h {mph}
Inspect vehicle speedometer sensor INDICATOR SYSTEM, INSTRUMENT CLUSTER INSPECTION Inspect vehicle speed sensor
1M
CONTINUED
*2: Except Europe
F1 -32
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CONTROL SYSTEM Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection 1. 2.
Turn the ignition switch on. Measure the voltage between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal A and body GND using a voltmeter. (1) When measurement voltage is 0 V. ① Turn the ignition switch off. ② Disconnect the TP sensor and variable resistor (Except Europe) connector (applied to constant voltage).
4.
If there is no continuity, repair the related harnesses. Not Using the SSTs (NGS Tester) at Power Supply Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Measure the voltage between the PCM battery power terminal connectors and body GND using an ohmmeter. Power supply terminal 1A Power supply terminal voltage: B+ 4. If not as specified, repair the related harnesses and replace the faulty fuses.
③
④ ⑤
⑥ (2)
(3)
Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and body GND using an ohmmeter. If there is continuity, repair the related harnesses. Using an ohmmeter, inspect for continuity between the PCM connector (vehicle side) terminal 2D and TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C which is applied to constant voltage. If there is continuity, repair the related harness.
When measurement voltage is B+. ① Turn the ignition switch off. ② Disconnect the battery positive harness, then battery negative harness. ③ Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and battery positive harness using an ohmmeter. ④ If there is continuity, repair the related harnesses. When measurement voltage is approx. 5V. • Constant voltage terminal of PCM is okay.
Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Inspect for continuity between the PCM GND terminals and body GND using an ohmmeter.
Not Using the SSTs (NGS Tester) at Serial Communication Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Verify there is continuity between PCM connector terminal 1 D and DLC KLN terminal.
4.
If there is no continuity, repair the related harnesses.
Not Using the SSTs (NGS Tester) at Instrument Cluster (Engine speed signal) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connector and instrument cluster connector (26 pin). 3. Verify there is continuity between PCM connector terminal 2F and instrument cluster connector (20 pin) terminal 3B.
4.
If there is no continuity, repair the related harnesses.
PCM GND terminal 2A 2B 2C
CONTINUED F1-33
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CONTROL SYSTEM Using voltmeter Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made.
Note • With the PCM connector connected, body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage at PCM terminal using a voltmeter. 4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the action column in the terminal voltage list.
1. Remove the PCM. 2. Reconnect PCM connector and battery negative terminal. PCM Terminal Voltage (Reference)
Terminal
Signal
Connected to
1A
Back-up power supply
Battery
1B
Power supply
Main relay
1C
1D
1E
—
Test condition Constant
Voltage (V) B+
Ignition switch off
0
Ignition switch on
B+
—
—
Action • •
Inspect ROOM fuse. Inspect related harness.
•
Inspect related harness.
—
Serial communication
Carry out inspection according to DTC. DTC output is a part of serial DLC communication. (Terminal KLN) Judgement by terminal voltage is not possible.
DTC output
Ignition switch on DLC and terminal TEN (Terminal FEN) (in DLC) short to chassis ground
No DTC stored DTC stored
—
Below 1.0
—
•
Inspect related harness.
•
Inspect related harness.
0-B+
1F
—
—
—
—
—
1G
—
—-
—
—
—
Ignition switch on 1H
Fuel pump control Fuel pump relay
1I
1J
1K
1L*1
—
— A/C relay
B+
Cranking
Below 1.0
Idle
Below 1.0 — A/C switch on
B+
A/C switch off
B+
Ignition switch off
A/C switch on
Diagnostic test mode
DLC Ignition switch (Terminal TEN) on
Transmission distinction
Ground
A/C switch off Terminal TEN (DLC) open Terminal TEN (DLC) short to ground
*1: Europe only
Inspect fuel pump relay. ☞ FUEL SYSTEM,FUEL PUMP INSPECTION Inspect related harness. —
•
Below 1.0 • Below 1.0
Inspect A/C relay. ☞ section U Inspect related harness.
B+ •
Inspect related harness.
•
Inspect related harness.
Below 1.0 0
Constant
•
—
Ignition switch on
A/C control
•
CONTINUED F1-34
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CONTROL SYSTEM Terminal 1M
Signal Vehicle speed
Connected to
Test condition
Vehicle running
1N
CTP
CTP switch
Ignition switch on
Accelerator pedal depressed
B+
Accelerator pedal released
Below 1.0
Brake pedal depressed 1O
Brake
Brake switch Brake pedal released
1P
1Q
Power steering pressure
A/C
PSP switch
A/C switch
Action
• Inspect VSS. 0 or Approx. 5.0 ☞ section T Approx. 5.0 • Inspect related harness.
Vehicle stopped
VSS
Voltage (V)
Steering wheel straight ahead position
Idle
Ignition switch on
•
•
Inspect CTP switch. ☞ CLOSED THROTLE POSITION (CTP) SWITCH INSPECTION Inspect related harness.
• Inspect brake switch. ☞ section P Below 1.0 • Inspect related harness. B+
• B+
Steering wheel fully turned
Below 1.0 •
A/C switch and fan switch on
Below 1.0
•
A/C switch off
B+
•
Inspect PSP switch. ☞ POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Inspect related harness. Inspect A/C switch. ☞ section U Inspect related harness.
1R
—
—
—
—
—
1S
—
—
—
—
—
1T
—
—
—
—
—
1U
—
—
—
—
—
1V
Load/no load distinction
Transmission neutral position or clutch pedal depressed
Below 1.0 •
•
Inspect neutral switch. ☞ NEUTRAL SWITCH INSPECTION Inspect clutch switch. ☞ CLUTCH SWITCH INSPECTION Inspect related harness.
Constant
Below 1.0 •
Inspect related harness.
Neutral/clutch Ignition switch switch on
Other than transmission neutral or clutch pedal released
• B+
2B
Fuel injector ground Power ground
Ground
Constant
Below 1.0 •
Inspect related harness.
2C
System ground
Ground
Constant
Below 1.0 •
Inspect related harness.
Analog ground
MAF sensor, IAT sensor, ECT sensor, O2S,TP sensor
Constant
Below 1.0 •
Inspect related harness.
SGT
Ignition switch on CMP sensor (integrated into distributor) Idle
1.8—2.3
Ignition switch on
Below 1.0
Idle
0.35—0.5
2A
2D
2E
2F
IGT control
Ground
Ignition control module
5.0
•
• •
•
Inspect CMP sensor. ☞ CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect related harness. Inspect ignition control module. ☞ section G Inspect related harness.
2G
—
—
—
—
—
2H 2I 2J
— — —
— — —
— — —
— — —
— — —
2K
Constant voltage TP sensor (Vref)
Ignition switch on
F1-35
4.5—5.5
•
Inspect related harness.
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CONTROL SYSTEM Terminal
Signal
Connected to
Test condition
Voltage (V)
Action •
2L
IAT
IAT sensor
Ignition switch on
IAT 20° C {68°F}
2.15 •
2M
TP
TP sensor
Ignition switch on
Accelerator pedal released
0.4—0.6
•
Accelerator pedal depressed
3,4—4.7
•
Engine cold
0.0—1.0
After warm up
0.5—1.0
Ignition switch on 2N*
1
O2S
•
0.0—1.0
Acceleration Deceleration
•
2N*
Varies according to the variable Variable resistor Variable resistor resistor adjustment
0—4 •
2O
Mass airflow
2P
2Q
—
ECT
MAP sensor
Ignition switch on
1.45
Idle (after warm up)
2.15
Engine speed 3000 rpm (after warm up)
2.73
—
ECT sensor
Inspect O2S. ☞ OXYGEN SENSOR (O2S) INSPECTION Inspect related harness.
0.0—0.5 •
2
Inspect TP sensor. ☞ THROTTLE POSITION (TP) SENSOR INSPECTION Inspect related harness.
0.55
Idle
O2S
Inspect IAT sensor. ☞ INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect related harness.
—
• •
—
Inspect variable resistor. ☞ VARIABLE RESISTOR INSPECTION Inspect related harness. Inspect MAF sensor. ☞ MASS AIR FLOW (MAF) SENSOR INSPECTION Inspect related harness. —
IAT 20°C {68°F}
1.02
•
After warm up
0.58
•
Ignition switch on
Inspect ECT sensor. ☞ ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Inspect related harness.
2R
—
—
—
—
—
2S
—
—
—
—
—
2T
Pressure PRC solenoid regulator control valve
For 120 sec. after ignition switch on
0
For 120 sec. after engine start
0
Ignition switch on
B+
•
Ignition switch on
B+
•
Idle
B+
•
Ignition switch on
B+
•
Idle
B+
•
Ignition switch on
0.2
•
Approx 1.0
•
ECT above 90°C {194°F} (Hot condition) Others
Fuel injector No.1,No.3
2U Fuel injector control
Fuel injector No.2, No.4
2V
2W
IAC
•
IAC valve Idle (after warm up)
*1: Europe only *2: Except Europe
Inspect PRC solenoid valve. ☞ FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION Inspect related harness. Inspect fuel injector. ☞ FUEL SYSTEM,FUEL INJECTOR INSPECTION Inspect related harness. Inspect fuel injector. ☞ FUEL SYSTEM,FUEL INJECTOR INSPECTION Inspect related harness. Inspect IAC valve. ☞ INTAKE-AIR SYSTEM, IAC VALVE INSPECTION Inspect related harness.
CONTINUED F1-36
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CONTROL SYSTEM Terminal
2X
Signal
Purge control
Connected to
Purge solenoid valve
Test condition
Voltage (V)
Ignition switch on
B+
Idle
B+
2Z
— Engine speed output
—
—
—
Short circuit • MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20 to GND) • Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector to GND) 4. Repair or replace faulty areas. 5. Reconnect the MAF sensor connector.
B+ 4.9—7.0
Inspect purge solenoid valve. ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Inspect related harness. —
•
Tachometer Ignition switch on (integrated into instrument cluster) Idle
MASS AIR FLOW (MAF) SENSOR INSPECTION Note • Perform the following test only when directed. MAF Sensor Inspection 1. Visually inspect for the following on the MAF sensor. • Damage • Cracks • Terminal bends • Terminal rust 2. If any of the above are found, replace the MAF sensor. If the MAF sensor PID value is out of specification, inspect as follows and repair or replace as necessary: 3. Disconnect the MAF sensor connector. Open circuit • MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20) • Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector) • GND circuit (MAF sensor connector terminal A and PCM connector terminal 2D through common connector)
•
•
Driving in gear 2Y
Action
•
Inspect instrument cluster. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION Inspect related harness.
THROTTLE POSITION (TP) SENSOR INSPECTION Note • Perform the following test only when directed. Resistance Inspection 1. Verify that the throttle valve is at closed throttle position. 2. Inspect that the accelerator cable free play is within the specification. (Refer to INTAKE-AIR SYSTEM, ACCELERATOR CABLE INSPECTION / ADJUSTMENT.) 3. If as specified but PID valve is out of specification, measure the resistance between TP sensor terminals A and C using an ohmmeter. Specification 4—6KΩ
4. Disconnect the TP sensor connector. 5. If not as specified, replace the TP sensor. If as specified, inspect for the following: Open circuit • Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) • TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M) • GND circuit (TP sensor connector terminal C and PCM connector terminal 2D) Short circuit • Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) • TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M)
CONTINUED F1-37
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CONTROL SYSTEM 6. Repair or replace faulty areas. 7. Reconnect the TP sensor connector. THROTTLE POSITION (TP) SENSOR ADJUSTMENT Caution • Adjusting the TP sensor with the throttle adjusting screw (TAS) can adversely affect the engine. Do not adjust the TP sensor with the TAS. • Since the TP sensor is adjusted by the manufacturer, adjusting the TP sensor excessively can adversely affect the engine. Do not adjust the TP sensor excessively. 1. Verify that the throttle valve is at closed throttle position. 2. Disconnect the TP sensor connector. 3. Turn ignition switch on. 4. Measure and record the voltage of the disconnected harness side connector terminal C using a voltmeter.
Specification 4.5—5.5 V 5. Reconnect the TP sensor connector. 6. Loosen the TP sensor screw.
7. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to adjust the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is at the closed throttle position.
Specification (CTP) TP sensor terminal C voltage (V)
PCM terminal 2M voltage TP V (NGS tester) (V)
4.5—4.9 4.9—5.1 5.1—5.5 8. Tighten the TP sensor screw.
0.4—0.6 0.4—0.6 0.4—0.6
Tightening torque 1.6—2.3 N.m {16—24 kgf.cm, 14—20 in.lbf} 9. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to verify the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is wide open. Specification (WOT) TP sensor terminal C voltage (V)
PCM terminal 2M voltage TP V (NGS tester) (V)
4.5—4.7 4.7—4.8 4.8—4.9 4.9—5.0 5.0—5.1 5.1—5.3 5.3—5.4 5.4—5.5
3.4—4.4 3.6—4.5 3.7—4.6 3.7—4.8 3.8—4.9 4.0—5.0 4.1—5.1 4.2—5.2
10. If not as specified, replace the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR REMOVAL / INSTALLATION.) THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION 1. Disconnect the TP sensor connector. 2. Remove the TP sensor screws. 3. Remove the TP sensor from the throttle body.
4. Verify that the throttle valve is fully closed. 5. Install the TP sensor to the throttle body. 6. tighten the TP sensor screws. Tightening torque 1.6—2.3 N.m {16—24 kgf.cm, 14—20 in.lbf } 7. Verify that the throttle valve moves smoothly. 8. Reconnect the TP sensor connector.
F1-38
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CONTROL SYSTEM 9. Adjust the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR ADJUSTMENT.) CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION Caution • The CTP switch is set at the factory. Do not try to adjust it. • Removing the closed throttle position switch can negatively affect the engine. Note • Perform the following test only when directed. 1. Disconnect the CTP switch connector. 2. Inspect for continuity between the CTP switch terminal and a GND using an ohmmeter.
Specification Measuring condition Closed throttle position Others
Continuity Yes No
3. If not as specified, replace the throttle body. If the CTP switch is okay, but PI D value is out of specification, inspect as follows and repair or replace as necessary. Open circuit • CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1N) • GND circuit (CTP switch body to GND)
Short circuit • CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1 N to GND) 4. Reconnect CTP switch connector. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Resistance inspection Note • Perform the following test only when directed. 1. Remove the IAT sensor. 2. Heat the IAT sensor using the lamp. 3. Measure the resistance of the IAT sensor using an ohmmeter
Specification Water temperature (°C {°F}) 20 {68} 80 {176}
Resistance (kΩ) 2.09— 2.81 0.274 —0.802
4. If not as specified, replace the IAT sensor. If IAT sensor is okay, but PID value is out of specification, inspect as follows and repair or replace as necessary. Open circuit • IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2L) • GND circuit (IAT sensor connector terminal B and PCM connector terminal 2D)
Short circuit • IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2Lto GND) 5. Reconnect the IAT sensor connector.
CONTINUED
F1-39
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CONTROL SYSTEM INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor connector. 3. Remove the IAT sensor. 4. Install the IAT sensor.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Note • Perform the following test only when directed. ECT Sensor Resistance Inspection 1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove the ECT sensor. 3. Place the ECT sensor in water with a thermometer, and heat the water gradually.
Tightening torque 7.9—11.7 N.m {80—120 kgf.cm, 70—104 in.lbf} 5. Connect the IAT sensor connector. 6. Connect the negative battery cable. ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION Warning • When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before removing or installing the ECT sensor. 1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor.
4. Replace the gasket. 5. Install in the reverse order of removal, Tightening torque 25—29 N.m {2.5—3.0 kgf.m, 19—21 ft.lbf} 6. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
4. Measure the resistance between the ECT sensor terminals A and B using an ohmmeter. Specification Water temperature (°C {°F}) Resistance (kΩ) 20 {68} 2.2—2.8 80 {176} 0.29—0.4 5. If not as specified, replace the ECT sensor. If the ECT sensor is okay, but PID value is out of specification, inspect for the following: Open circuit • ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector) • GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector) Short circuit • ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector to GND) • GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector to GND) 6. Repair or replace faulty areas.
F1-40
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CONTROL SYSTEM 7. Install the ECT sensor. 8. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) CAMSHAFT POSITION (CMP) SENSOR INSPECTION Note • Perform the following test only when directed. Voltage Inspection 1. Remove the distributor. 2. Disconnect the fuel injector connectors. 3. Disconnect the high-tension lead. 4. Connect the distributor connector. Warning • Turning the ignition switch on with the fuel injector connector still connected will actuate the fuel injector. • Turning the ignition switch on with the distributor connector still connected will generate sparks, which can cause electrical shock. Disconnect the connector and prevent it from grounding to the vehicle body. 5. Turn the ignition switch on. 6. Verify the following signal (voltage) from the PCM 2E terminal using a voltmeter when the distributor is rotated by hand. Specification Signal Terminal SGT
2E
Voltage 4 pulses/rev. (Approx. 5.0 V)
7. If not as specified, inspect as follows and repair or replace as necessary. 8. Disconnect the distributor connector. Open circuit • SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E) • Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D) • GND circuit (Distributor harness side connector terminal A and engine GND)
Short circuit • SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E to GND) • Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D to GND) 9. If the harnesses are okay, replace the distributor and adjust the ignition timing. (Refer to ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.) OXYGEN SENSOR (O2S) INSPECTION O2S Voltage Inspection Note • Perform the following test only when directed. 1. Warm up the engine and run it at idle. 2. Disconnect the O2S connector. 3. Connect the voltmeter test leads to the following O2S terminals: • (+) lead-O2S terminal A • (-) lead-O2S terminal B
4. Run the engine at 3000 rpm until the voltmeter increases 0.5—0.7 V. 5. Verify that the voltmeter needle moves when racing the engine several times. Specification Engine condition Voltage (V) Acceleration 0.5—1.0 Deceleration 0—0.5 6. If not as specified, replace the O2S. If the O2S is okay, but PID value is out of specification, inspect for following:
F1-41
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CONTROL SYSTEM Open circuit • O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N) • GND circuit (O2S connector terminal B and PCM connector terminal 2D)
Short circuit • O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N to GND) 7. Repair or replace faulty areas. 8. Reconnect the O2S connector. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION 1. Disconnect the battery negative terminal. 2. Disconnect the O2S connector. 3. Remove the O2S. 4. Install in the reverse order of removal. Tightening torque 29-49 N.m {3—5 kgf.m, 22—36 ft.lbf} VARIABLE RESISTOR INSPECTION 1. Disconnect the connector from the variable resistor. 2. Connect an ohmmeter between the variable resistor terminal B and C.
3. Using the SST, verify that the resistance increases in relation to the turning amount of the variable resistor.
Variable resistor condition
Resistance (kΩ)
Turned fully clockwise Turned fully counterclockwise
4-6 Below 0.1
4. If not as specified, replace the variable resistor. 5. Adjust idle mixture. 6. If the variable resistor is okay, but PCM terminal 2N or 2K voltage is out of specification, inspect for the following: Open circuit • Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) • Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) • GND circuit (Variable resistor connector terminal C and PCM connector terminal 2D) Short circuit • Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) • Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) 7. If there is an open or short circuit, repair or replace wiring harness. 8. If there is no open or short circuit, replace variable resistor. 9. Reconnect the variable resistor connector. CLUTCH SWITCH INSPECTION Continuity Inspection Note • Perform the following test only when directed. 1. Verify that the clutch switch is installed properly. 2. Disconnect the negative battery cable. 3. Remove the clutch switch. (Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLATION.) 4. Inspect the continuity between the clutch switch terminals A and B using an ohmmeter.
CONTINUED F1-42
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CONTROL SYSTEM
Specification Specification Transmission In neutral Others
5. If not as specified, replace the clutch switch. If the clutch switch is okay, but PID value is out of specification, inspect for the following: Open circuit • Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V through common connector) • GND circuit (Clutch switch connector terminal A and GND) Short circuit • Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V to GND) Neutral switch • The neutral switch operation and related harnesses continuity (Refer to NEUTRAL SWITCH INSPECTION. 6. Repair or replace faulty areas. 7. Install the clutch switch. (Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLTION.) 8. Connect the negative battery cable. CLUTCH SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the clutch switch connector. 3. Loosen the nuts and remove the clutch switch. 4. Install the clutch switch. 5. Adjust the clutch pedal height referring to the above and the height specification. (Refer to Section H, CLUTCH PEDAL, CLUTCH PEDAL INSPECTION/ADJUSTMENT.) 6. Connect the clutch switch connector. 7. Connect the negative battery cable. NEUTRAL SWITCH INSPECTION Continuity inspection Note • Perform the following test only when directed. 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Measure the continuity between the neutral switch terminals A and B using an ohmmeter.
Continuity Yes No
4. If not as specified, replace the neutral switch. If the neutral switch is okay, but PID value is out of specification, inspect for the following: Open circuit • Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector) • GND circuit (neutral switch connector terminal B and GND)
Short circuit • Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector to GND) Clutch switch • The clutch switch operation and related harness continuity. (Refer to CONTROL SYSTEM, CLUTCH SWITCH INSPECTION.) 5. Repair or replace faulty areas. 6. Reconnect the neutral switch connector. NEUTRAL SWITCH REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Remove the neutral switch. 4. Install the new washer and neutral switch.
F1-43
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CONTROL SYSTEM
Tightening torque 25—34 N.m {2.5—3.5 kgf.m, 19—25 ft.lbf} 5. Connect the neutral switch connector. 6. Connect the battery negative cable. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Continuity inspection Note • Perform the following test only when directed. 1. Disconnect the PSP switch connector. 2. Start the engine. 3. Inspect for continuity between the PSP switch terminal and GND using an ohmmeter.
Specification Condition Steering wheel in straight ahead Steering wheel fully turned
Continuity Yes No
4. If not as specified, replace the PSP switch. If the PSP switch is okay, but PID value is out of specification, inspect for the following: Open circuit •
PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector)
•
GND circuit (PSP switch body and GND)
Short circuit • PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector to GND) Power steering fluid (Refer to Section N, engine speed sensing power steering system.) • Fluid level • Fluid leakage • Fluid pressure 5. Repair or replace faulty areas. 6. Reconnect the PSP switch connector. MAIN RELAY INSPECTION Continuity Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the main relay connector. 3. Inspect for continuity between terminals of the relay using an ohmmeter.
Specification
4. If not as specified, replace the main relay. If the main relay is okay, inspect for the following: Open circuit • Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector) •
PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector)
CONTINUED F1-44
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CONTROL SYSTEM, ON-BOARD DIAGNOSTIC SYSTEM •
GND circuit (Main relay connector terminal B and GND) Short circuit • Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector to GND) • PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector to GND) 5. Repair or replace faulty areas. 6. Reconnect the main relay. 7. Reconnect the negative battery cable. MAIN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the main relay connector. 3. Remove the main relay. 4. Install the reverse order of removal. Tightening torque 7.9—10.7 N.m {80—110 kgf.cm, 69.5—95.4 in-Ibf}
ON-BOARD DIAGNOSTIC SYSTEM READ/CLEAR DIAGNOSTIC TEST RESULTS • This retrieves all stored DTCs in the PCM and clears the DTC. PARAMETER IDENTIFICATION (PID) ACCESS • The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values and system status information. Since PID values for output devices are PCM internal data values, perform the Simulation Test to identify which output devices are malfunctioning. Note • PID monitor item "PRCV" can be selected and "ON" or "OFF' is displayed for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped. DIAGNOSTIC SUPPORT PROCEDURE • These tests are the ability of the powertrain control system to detect a change in certain input devices by following the instructions on the NGS tester. There are two options: ALL TEST and SINGLE TEST. ALL TEST takes you through all diagnostic support tests. SINGLE TEST enables you to perform specific tests that relate to the particular diagnosis that you are conducting. This test MUST follow the instructions on the NGS tester. If not, a "TEST CONDITIONS NOT CORRECT' message will appear, or else the test result will be FAULTY. SIMULATION TEST • Output devices can be turned on and off by sending simulation command signals from the NGS tester to the PCM. The "Idling Test" and "Ignition ON Test" are available in this test. These tests will verify the PCM status, output devices, and related circuit wiring harnesses. Note • "PRCV" of the simulation item can be selected for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped. ON-BOARD DIAGNOSTIC TEST NGS Tester Hook-up Procedure Note • Make sure the ignition switch is at LOCK position. 1. Insert the vehicle interface module and latest program card into the hand-held NGS control unit.
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ON-BOARD DIAGNOSTIC SYSTEM
3. Move the cursor to SELECT NEW VEHICLE YEAR & MODEL Press the TRIGGER key to enter this selection. 2. Plug the adapter harness connector into the vehicle interface module and the DLC located at the engine compartment. 3. Plug the NGS tester power connector into the cigarette lighter. Alternatively, use a battery hook-up adapter.
4. Listen to the double beep. The NGS tester is now initialized. Begin the powertrain control system functional test. DTC READING PROCEDURE Using the SSTs (NGS Tester) Note
4. Move the cursor to B-SERIES (UN). Press the TRIGGER key to enter this selection. EUROPE
•
Start engine and keep it running. If the engine will not start, turn the ignition switch on during the procedure. 1. Perform the necessary vehicle preparation and visual inspection. Hook the NGS tester up to the vehicle.
2. Move the cursor to VEHICLE & ENGINE SELECTION. Press the TRIGGER key to enter this function.
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ON-BOARD DIAGNOSTIC SYSTEM EXCEPT EUROPE
Note • Make sure the selected vehicle is correct. 5. A vehicle selection screen showing the selected vehicle will be displayed. Move the cursor to the vehicle selected. Press the TRIGGER key. 6. Move the cursor to DIAGNOSTIC DATA LINK on the main menu screen. Press the TRIGGER key to enter into menu system diagnostics.
9. Move the cursor to READ/CLEAR DIAGNOSTIC TEST RESULTS. Press the TRIGGER key to enter this selection.
10. Press START. 11. Retrieve DTCs. Not Using the SSTs (NGS Tester) Using the SST (self-diagnosis checker) 1. Connect the SSTs to the DLC located in the engine compartment and ground the black (negative) lead to the body.
7. Move the cursor to PCM-POWERTRAIN CONTROL MODULE. Press the TRIGGER key to enter this selection.
8. Move the cursor to DIAGNOSTIC TEST MODES. Press the TRIGGER key to enter this selection.
2. Set the select switch on the SST (self-diagnosis checker) to A. 3. Turn the dial switch on the SST (system selector) to 1, and the test switch to SELF TEST. 4. Turn the ignition switch on. 5. Verify that the buzzer sounds for approximately 3 seconds and code "88" flashes for 5 seconds. If DTC is not detected, "00" will then be indicated. Note • If the "88" does not flash, inspect +B terminal of the DLC, and the related harnesses and connectors. • If the "88" flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect. 6. If any DTCs is indicated, inspect the appropriate area and repair as necessary. Note • A DTC consists of four numbers. They are flashed one by one in the right window on the display. ("1" is always shown on the left window.)
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ON-BOARD DIAGNOSTIC SYSTEM 7. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS tester).) 8. Remove the SSTs.
7. If any DTCs is indicated, inspect the appropriate area and repair as necessary. 8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS Tester).) 9. Remove the voltmeter and jumper wire PID/DATA MONITOR AND RECORD PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 7 from the DTC READING PROCEDURE. 3. Turn the ignition switch on or run the engine. 4. Move the cursor to PID/DATA MONITOR AND RECORD. Press the TRIGGER key to enter this selection.
Using the Voltmeter 1. Turn the ignition switch off. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. 2. Using a jumper wire to short terminal TEN of the DLC to body GND. 3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B.
5. Move the cursor to PID values to view. Press the TRIGGER key. A star symbol will appear next to the item when it is selected. Note • Press the TRIGGER key once again to deselect a PID. • Press the CLEAR to deselect all PIDs. 6. Press START to begin. 7. When ready to capture and store the selected PIDs, press the TRIGGER key. 8. Press the TRIGGER key again when ready to save information. 9. Move the cursor to STORE RECORDING AREA 1. Press the TRIGGER key.
4. Turn the ignition switch on. 5. The voltmeter indicates B+ for approximately 3 seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the voltmeter's needle. If DTC is not detected, the needle does not move. Note • The DTC will be output as shown.
10. Follow the instructions displayed on the NGS tester to save the recording data. PLAYBACK OF STORED PIDS PROCEDURE Note • Look for abnormal behavior or values that are clearly incorrect. Inspect the signals for abrupt or unexpected changes.
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ON-BOARD DIAGNOSTIC SYSTEM • •
Look for agreement in related signals. Make sure signals act in proper sequence.
1. Select VIEW RECORDER AREAS.
2. Select up to four PIDs to review in the table format or two PIDs to review in the graph mode. (1) Table format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the values.
4. Move the cursor to ALL TEST or SINGLE TEST. Press the TRIGGER key. Note • ALL TEST inspects each item according to an established programmed order. With SINGLE TEST, enable to select and inspect any test item in any order, one at a time.
5. Follow the instructions displayed on the NGS tester and press the TRIGGER key. Note • To skip a test item, press OMIT. • Before performing the test, the basic condition on the test vehicle must be set up in order to get exact data. Press BASIC to view the basic condition instruction screen. • If the screen shows PASSED, the system operates correctly. • If the screen shows FAULTY, the system operates incorrectly.
(2) Graph format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the linear lines showing the transformation of values to the line graph.
DIAGNOSTIC SUPPORT PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 8 from the DTC READING PROCEDURE. 3. Move the cursor to DIAGNOSTIC SUPPORT PROCEDURE. Press the TRIGGER key to enter this selection.
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ON-BOARD DIAGNOSTIC SYSTEM SIMULATION TEST PROCEDURE Idling Test 1. Perform the NGS tester hook-up procedure. 2. Perform the Steps 1 through 7 from the DTC READING PROCEDURE. 3. Start the engine and run it at idle. 4. Move the cursor to SIMULATION TEST. Press the TRIGGER key to enter this selection.
8. Press the TRIGGER key.
9. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
5. Move the cursor to IDLING TEST. Press the TRIGGER key to enter this selection. 10. To perform the simulation again, press the TRIGGER key. To exit the idling test, press the CANCEL key.
6. The screen will display a list of simulation items. Select the appropriate simulation item for testing, then press the TRIGGER key.
Ignition ON Test 1. Perform Steps 1 through 7 from the DTCs READING PROCEDURE. 2. Turn the ignition switch on. Move the cursor to SIMULATION TEST. Press the TRIGGER key to enter this selection.
Note • Only one simulation item can be selected at a time.
3. Move the cursor to IGNITION ON TEST. Press the TRIGGER key to enter this selection. 7. Press START. Note • If the screen displays "TEST CONDITION NOT CORRECT", inspect the following signal conditions and determine whether or not they are normal: • NLSW: ON • RPM; above 550
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ON-BOARD DIAGNOSTIC SYSTEM
4. The screen will display a list of simulation items. Select the appropriate simulation item for testing, then press the TRIGGER key.
AFTER REPAIR PROCEDURE Using the SSTs (NGS Tester) 1. After repairs have been made, perform the DTCs READING PROCEDURE. 2. Press CLEAR. 3. Press the TRIGGER key. 4. Press the CANCEL key. 5. Ensure that the customer's concern has been resolved. Not Using the SSTs (NGS Tester) 1. After repairs, disconnect the negative battery cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable. 2. Warm up the engine to normal operating temperature. Note • If the engine will not start, continue to operate the starter for 5-6 seconds.
5. Press START. 6. Press the TRIGGER key.
3. Perform the "DTC READING PROCEDURE" again. 4. Verify that the DTC is not detected.
7. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
8. To perform the simulation again, press the TRIGGER key. To exit the ignition on test, press the CANCEL key.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table DTC No.
Output pattern
Display on the NGS tester
Condition
P0100
MAF/VAF-CIRCUIT MALFUNCTION
MAF sensor circuit malfunction
P0115
ECT-CIRCUIT MALFUNCTION
ECT sensor circuit malfunction
P0120
TP-CIRCUIT MALFUNCTION TP sensor circuit malfunction
P0134
O2S 11-CIRCUITNO ACTIVITY DETECTED
O2S circuit no activity detected
P0340
CAMSHAFT POS SENSORCKT MALFUNCTION
SGT signal is not detected
P0443
EVAP SYSTEM-PURGE CTRL VALVE CKT MALF
Purge solenoid valve circuit malfunction
P0505
IDLE CONTROL SYSTEMMALFUNCTION
IAC valve circuit malfunction
P1110
IATS (D/C)-OPEN OR SHORT IAT sensor circuit malfunction
P1170
HO2S 11-INVERSION
O2S is stuck
P1195
EGRBS-OPEN OR SHORT
Barometric pressure sensor (in PCM) malfunction
P1250
PRC-OPEN OR SHORT
PRC solenoid valve circuit malfunction
P1608
PCM (CPU)-MALFUNCTION
PCM internal circuit malfunction
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ON-BOARD DIAGNOSTIC SYSTEM DTC Troubleshooting DTC P0100
Mass air flow (MAP) sensor circuit malfunction
DETECTION CONDITION
Input voltage from MAF sensor is below 0.7 V or above 5.4 V when ignition switch is turned on.
POSSIBLE CAUSE
• • • • • • • • • •
MAF sensor malfunction Blockage at MAP sensor Poor connection of connectors at MAF sensor and/or PCM Leakage in intake-air system Short to power supply circuit in wiring from MAF sensor terminal B to PCM terminal 20 Short to ground in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal C to main relay terminal D Open circuit in wiring from MAF sensor terminal A to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground.
STEP INSPECTION 1 Verify stored DTC. Have DTCs P0115, P0120, P0134, P0340, P0443, P0505, P1110, P1170, and/or P1250 been stored?
Yes
No
ACTION Inspect for open circuit in following wiring harnesses, then go to Step 12. • Main relay terminal D-purge solenoid valve, PRC solenoid valve, IAC valve CMP sensor • PCM terminal 2D-throttle position sensor, intake-air temperature sensor, engine coolant temperature sensor, oxygen sensor • Between PCM terminal 2C and engine ground Go to next step
2
Does MAP sensor connector or PCM connector have poor connection?
Yes Repair or replace connector, then go to Step 12. No
Go to next step.
3
Is intake-air system okay?
Yes
Go to next step
No
Repair or replace faulty parts, then go to Step 12.
4
Disconnect MAF sensor connector. Turn ignition switch on. Is there battery positive voltage at MAF sensor harness side connector terminal C?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and MAF sensor terminal C), then go to Step 12.
5
6
7 8 9 10
Disconnect PCM connector. MAF sensor connector is Yes disconnected. Is there continuity between MAF sensor harness side No connector terminal A and PCM harness side connector terminal 2D?
Go to next step.
Is there continuity between MAF sensor harness side connector terminal B and PCM harness side connector terminal 20
Yes
Go to next step
No
Repair open circuit, then go to Step 12.
Is there continuity from PCM harness side connector terminals 20 to 1B?
Yes Repair short to power circuit, then go to Step 12.
Is there continuity from PCM harness side connector terminals 20 to body ground.
Yes Repair short to ground circuit, then go to Step 12.
Remove MAF sensor. Is there any foreign material at MAF sensor screen?
Yes Clean MAF sensor screen, then go to Step 12.
Connect MAF sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access MAF V PID. Does MAF V PID change when air is blown into mass airflow sensor? Note • If NGS tester is not used, measure PCM 20 terminal voltage with circuit tester.
No No
Repair open circuit, then go to Step 12.
Go to next step Go to next step.
No Yes
Go to next step. Go to next step.
No
Replace MAF sensor, then go to Step 12.
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ON-BOARD DIAGNOSTIC SYSTEM STEP 11
12
INSPECTION Yes
Go to Step 1.
Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
DTC P0115
Engine coolant temperature (ECT) sensor circuit malfunction
DETECTION CONDITION
Input voltage from ECT sensor is below 0.07 V or above 4.58 V when ignition switch is turned on.
POSSIBLE CAUSE
STEP 1
ACTION
Clear DTC from memory.
• • • • • • •
ECT sensor malfunction Poor connection of connectors at ECT sensor terminal and/or PCM Short to power supply circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Short to ground in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground INSPECTION
ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 9. • PCM terminal 2D-MAF sensor, O2S, IAT sensor, and/or TP sensor • PCM terminal 2C-engine ground
No
Go to next step
Does ECT sensor connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 9.
No
Go to next step
Disconnect ECT sensor connector. Turn ignition switch on. Is there 5V at engine coolant temperature sensor harness side connector terminal A
Yes
Go to next step
No
Disconnect PCM connector. ECT sensor connector is disconnected. Is there continuity between ECT sensor harness side connector terminal B and PCM harness side connector terminal 2D Is there continuity from PCM harness side connector terminals 2Q to 1B?
Yes
Inspect for open or short circuit in wiring harness (between PCM terminal 2Q and ECT sensor terminal A), then go to Step 9. Go to next step.
No
Repair open circuit, then go to Step 9
Yes
Repair short to power circuit, then go to Step 9
No
Go to next step.
6
Is there continuity from PCM harness side connector terminals 2Q to body ground?
Yes
Repair short to ground circuit, then go to Step 9.
No
Go to next step
7
Is ECT sensor okay? ☞ CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
Yes
Go to next step
No
Replace ECT sensor, then go to Step 9. ☞ CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION.
2 3
4
5
Verify stored DTC. Have DTCs P0100, P0120, P0134, P1110, and/or P1170 been stored?
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ON-BOARD DIAGNOSTIC SYSTEM STEP 8
9
INSPECTION Yes
Go to Step 1.
No
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step.
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
DTC P0120
Throttle position (TP) sensor circuit malfunction
DETECTION CONDITION
Input voltage from TP sensor is below 0.09 V or above 4.78 V when ignition switch is turned on.
POSSIBLE CAUSE
STEP 1
2 3
4
5
ACTION
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
• • • • • • • • • • •
TP sensor malfunction Poor connection of connectors at TP sensor and/or PCM Short to power supply circuit in wiring from TP sensor terminal A to PCM terminal 2K Short to power supply circuit in wiring from TP sensor terminal C to PCM terminal 2D Short to power supply circuit in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal C to PCM terminal 2D Open circuit in wiring from TP sensor terminal B to PCM terminal 2M Open circuit in wiring from TP sensor terminal 2C to engine ground INSPECTION
Verify stored DTC. Have DTC P0100, P0115, P0134, P1110 and/or P1170 been stored.
ACTION Yes
No
Inspect for open or short circuit in following wiring harnesses, then go to Step 11. • PCM terminal 2D -MAP sensor, O2S, IAT sensor, and/or ECT sensor • Between PCM terminal 2C and engine ground Go to next step
Does TP sensor connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 11
No
Go to next step.
Disconnect TP sensor connector. Turn ignition switch on. Is there 5V at TP sensor harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2K and TP sensor terminal A), then go to Step 11
Disconnect PCM connector. Yes TP sensor is disconnected. Is there continuity between TP sensor harness side connector terminal No C and PCM harness side connector terminal 2D. Is there continuity between TP sensor harness side connector terminal B and PCM harness side connector terminal 2M.
Go to next step. Repair open circuit, then go to Step 11.
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 11.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM STEP 6
INSPECTION
ACTION
Is there continuity from PCM harness side connector terminals 2D to 1B?
Yes No
Repair short to power supply circuit, then go to Step 11 Go to next step.
7
Is there continuity from PCM harness side connector terminal 2M to 1B
Yes No
Repair short to power supply circuit, then go to Step 11. Go to next step.
8
Is there continuity from PCM harness side connector terminals 2M to body ground?
Yes
Repair short to ground circuit, then go to Step 11.
No
Go to next step.
Connect TP sensor and PCM connectors. Connect NGS tester to DLC. Turn ignition switch on. Access TP V PID. Does TP V increase linear according to throttle valve opening angle?
Yes
Go to next step.
No
Verify TP sensor, then go to Step 11.
Yes
Go to Step 1.
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes
Go to applicable DTC inspection
No
Troubleshooting completed.
9
Note
•
10
11
If NGS tester is not used, measure PCM 2M terminal voltage with circuit tester. Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM DTC P0134
Oxygen sensor (O2S) circuit no activity detected
DETECTION CONDITION
O2S signal does not exceed 0.45 V after the engine is started, or stays below 0.45 V for 180 seconds after the engine has reached normal operating temperature.
POSSIBLE CAUSE
• • • • • • • • • • • • • • •
O2S malfunction Open or short circuit in wiring harness Open or short circuit in wiring harness Poor connection of connector Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose and/or fuel filter clogging or leakage Leakage in intake-air system Leakage in exhaust system Ignition coil and/or igniter malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Vacuum hose damage or looseness
Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
ACTION
1
Verify stored DTC. Have DTC P0100 P0120, P0115 and/or P1110 been stored?
Yes
2
Clear DTC. Verify RPM, ECT and VS PIDs. Drive in normal mode for approx. 2 minutes under same condition. Is DTC P0134 stored? Note • If NGS tester is not used, measure follow PCM terminal voltages with circuit tester. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1M)
Yes
Trouble is in process. Go to next step.
No
Go to 'TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent concerns".
Implement PID/DATA MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK by using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle? Note • If NGS tester is not used, measure following PCM terminal voltages with circuit tester. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2M)
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.
No
Go to next step.
3
No
Inspect and repair DTC P0100, P0115, P0120 or P1110 then go to Step 22. Go to next step
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ON-BOARD DIAGNOSTIC SYSTEM STEP 4
ACTION
INSPECTION Continue monitoring items in previous step. Is there any input signal, which causes drastic changes when it is set to be in trouble condition?
Yes
Implement 'TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.
No
Go to next step.
5
Inspect exhaust system upstream from oxygen sensor. Is there any gas leakage?
Yes
Repair or replace faulty exhaust parts, then go to Step 22. ☞ EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.
No
Go to next step
6
Inspect installation of O2S. Is it okay?
Yes
Go to next step.
No
Implement PID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on oxygen sensor as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean condition Note • If NGS tester is not used, measure PCM 2N terminal voltage with circuit tester.
Yes
Install O2S properly, then go to Step 22. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION. Go to next step.
No
Inspect and repair or replace faulty oxygen sensor harness, connector or terminal, then go to Step 22. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) INSPECTION.
Inspect for open, poor connection, and other problems on following harnesses, connectors and terminals (for fuel injector at each cylinder): • Front main relay to fuel injector Are there any problems?
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 22.
No
Go to next step.
Inspect injection amount of each fuel injector. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION, Fuel Injection Volume Test. Are there any fuel injectors in abnormal condition for amount or condition of injection?
Yes
Replace faulty fuel injectors, then go to Step 22. ☞ FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.
No
Go to next step.
Inspect for air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. Can air suction be confirmed? Inspect for suction in vacuum hose which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed?
Yes
Repair or replace source of air suction, then go to Step 22.
No
Go to next step.
Yes
Repair or replace source of air suction, then go to Step 22.
No
Go to next step.
Inspect fuel line pressure under trouble condition. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pressure Inspection. Is fuel line pressure okay? Inspect fuel pump maximum pressure. ☞ FUEL SYSTEM, FUEL PUMP UNIT INSPECTION, Fuel Pump Maximum Pressure Inspection. Is it okay? Inspect for clogging in fuel filter (high-pressure). Are there foreign materials on fuel side of fuel filter?
Yes
Go to Step 17.
No
Go to next step.
Yes
Go to next step
No
Replace fuel pump, then go to Step 22. ☞ FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/INSTALLATION.
7
8
9
10
11
12
13
14
Yes
Go to next step.
No
Go to Step 16.
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TO. MODEL .INDEX
ON-BOARD DIAGNOSTIC SYSTEM STEP 15
16
17
18
19
20
INSPECTION
ACTION
Inspect inside of fuel tank for foreign materials and stains. Is inside of fuel tank okay?
22
Replace fuel filter (high-pressure), then go to Step 22. - FUEL SYSTEM, FUEL FILTER (HIGHPRESSURE) REMOVAL/INSTALLATION.
No
Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter (high-pressure), then go to Step 22. -FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION.
Inspect for leakage and clogging in fuel line from fuel Yes distributor to fuel pump. No Is it okay?
Repair or replace necessary, then go to Step 22.
Inspect for leakage in fuel line fuel filter (highpressure) to fuel tank (return side). Is it okay?
Yes
Replace pressure regulator, then go to Step 22. -FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.
No
Repair or replace as necessary, the go to Step 22.
Go to next step.
Verify blinking condition on each cylinder by setting Yes timing light on high-tension lead under trouble condition. No Does it blink regularly and stably?
Go to Step 19.
Inspect resistance of ignition coil. ☞ Section G, IGNITION COIL INSPECTION. Is it okay?
Yes
Go to next step.
No
Replace ignition coil, then go to Step 22.
Yes
Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 22.
No
Go to next step.
Yes
Go to next step
No
Implement engine overhaul, the go to next step.
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
Warning • Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing the radiator cap, wrap a thick cloth around and turn it slowly. Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles which make engine coolant white at filling opening?
21
Yes
Note • Large bubbles are normal since they are remaining air coming out from engine coolant passage. Inspect engine compression. ☞ Section B1, COMPRESSION INSPECTION. Is it okay? Clear DTC. Verify DTC after running vehicle. Is there any DTC stored?
Go to next step.
CONTINUED F1-59
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ON-BOARD DIAGNOSTIC SYSTEM DTC P0340
SGT signal is not detected
DETECTION CONDITION
No SGT signal input from CMP sensor when engine is started and 2.1 seconds have passed
POSSIBLE CAUSE
STEP
• • • • • • • •
CMP sensor malfunction CMP sensor air gap incorrect Short to power supply circuit in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal C to PCM terminal 2E Open circuit in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal A to body ground INSPECTION
1
Verify stored DTC. Have DTC PP0100, P0443, P0505, and/or P1250 been stored?
2
Does CMP sensor or PCM connector have poor connection?
3
4
5
Disconnect CMP sensor connector. Turn ignition switch on. Is there battery positive voltage at CMP sensor harness side connector terminal B? Disconnect CMP sensor connector. Turn ignition switch on. Is there 5 V at CMP sensor harness side connector terminal C? Disconnect PCM connector and CMP sensor connector. Is there continuity between CMP sensor harness side connector terminal C and PCM harness side connector terminal 2E?
ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 11. • Main relay terminal D-purg solenoid valve, PRC solenoid valve, IAC solenoid valve, MAF sensor
No
Go to next step.
Yes
Repair or replace connector, then go to Step 11.
No
Go to next step
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and CMP sensor terminal B), then go to Step 11.
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2E and CMP terminal C), then go to Step 11.
Yes
Go to next step.
No
Repair open circuit, then go to Step 11.
6
Is there continuity from PCM harness side connector Yes terminal 2E to 1B? No
Repair short to power circuit, then go to Step 11.
7
Is there continuity from PCM harness side connector Yes terminal 2E to body ground? No
Repair short to ground circuit, then go to Step 11.
8
Is there continuity from CMP sensor harness side terminal A to body ground?
Yes
Go to next step.
No
Repair open circuit, then go to Step 11.
9
Connect CMP sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access RPM PID. Does RPM PID change when engine is running?
Yes
Go to next step.
No
Replace distributor and adjust ignition timing, then go to Step 11.
Yes
Go to Step 1
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
10
11
Note • If NGS tester is not used, measure PCM 2E terminal voltage with circuit tester. Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Go to next step. Go to next step.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P0443 DETECTION CONDITION
POSSIBLE CAUSE
STEP
Purge solenoid valve circuit malfunction Open or short circuit is observed in purge solenoid valve system when ignition switch is turned on. • • • • • • •
Purge solenoid valve malfunction Poor connection of connectors at purge solenoid valve and/or PCM Short to power supply circuit in wiring from purge solenoid valve B to PCM terminal 2X Short to ground in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from purge solenoid valve terminal A to main relay terminal D INSPECTION
ACTION
1
Verify stored DTC. Have DTC P0100, P0505, P0340, and/or P1250 been stored?
Yes
No
Go to next step
2
Does purge solenoid valve connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 9.
No
Go to next step.
Disconnect purge solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at purge solenoid valve harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and purge solenoid valve terminal A), then go to Step 9.
Disconnect PCM connector Purge solenoid valve is disconnected. Is there continuity between purge solenoid valve harness side connector terminal B and PCM harness side connector terminal 2X?
Yes
Go to next step.
No
Repair open circuit, then go to step 9.
Is there continuity from PCM harness side connector terminal 2X to 1B?
Yes No
Repair short to power supply circuit, then go to Step 9. Go to next step.
3
4
5
Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, IAC solenoid valve, MAF sensor, CMP sensor • Between PCM terminal 2C and engine ground
6
Is there continuity from PCM harness side connector terminal 2X to body ground?
Yes No
Repair short to ground circuit, then go to Step 9. Go to next step.
7
Is purge solenoid valve okay? ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION
Yes
Go to next step
No
Replace purge solenoid valve, then go to Step 9.
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to Step 1.
No
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection.
No
Troubleshooting completed.
8
9
F1-61
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P0505
Idle air control (IAC) valve circuit malfunction
DETECTION CONDITION
Open or short circuit is observed in idle air control, system
POSSIBLE CAUSE
STEP
IAC valve malfunction Poor connection of connectors at IAC valve and/or PCM Short to ground in wiring from IAC valve terminal B to PCM terminal 2W Short to power supply circuit in wiring from IAC valve terminal B to PCM terminal 2W Short to ground in wiring from IAC valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from IAC valve terminal B to PCM terminal 2W Open circuit in wiring from IAC valve terminal A to main relay terminal D
INSPECTION
ACTION
1
Verify stored DTC. Have DTC P0100, P0340, P0443, and/or P1250 been stored.
Yes
No
Go to next step
2
Does IAC valve connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 9.
3
Disconnect IAC valve connector. Yes Turn ignition switch on. No Is there battery positive voltage at IAC valve harness side connector terminal A?
Go to next step.
Disconnect PCM connector IAC valve is disconnected. Is there continuity between IAC valve harness side connector terminal B and PCM harness side connector terminal 2W?
Yes
Go to next step.
No
Repair open circuit, then go to step 9.
4
No
Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, MAF sensor, CMP sensor, purge solenoid valve • Between PCM terminal 2C and engine ground
Go to next step Inspect for open or short circuit in wiring harness (between main relay terminal D and IAC valve terminal A), then go to Step 9.
5
Is there continuity from PCM harness side connector Yes terminal 2W to 1B? No
Repair short to power supply circuit, then go to Step 9.
6
Is there continuity from PCM harness side connector Yes terminal 2W to body ground? No
Repair short to ground circuit, then go to Step 9,
Is resistance between IAC valve component side connector A and B as specified?
Yes
Go to next step.
No
Replace IAC valve, then go to Step 9.
Yes
Go to Step 1
No
Yes
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection
No
Troubleshooting completed
7
8
9
Specification 8.7—10.5 Ω [23 °C {73.4 °F}] Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
F1-62
Go to next step. Go to next step
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P1110
Intake air temperature (IAT) sensor circuit malfunction
DETECTION CONDITION
Input from IAT sensor is below 0.1 V or above 4.9 V when ignition switch is turned on
POSSIBLE CAUSE
STEP 1
• • • • • • •
IAT sensor malfunction Poor connection of connectors at IAT sensor terminal and/or PCM Short to power supply circuit in wiring from IAT sensor terminal A to PCM terminal 2L Short to GND in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine GND INSPECTION
ACTION
Verify stored DTC. Have DTC P0100, P0115, P0120, P0134, P0335, and/or P1170 been stored?
Yes
No
Inspect for open circuit in following wiring harnesses, then go to Step 7. • PCM terminal 2D-ECT sensor, MAP sensor, O2S, CMP sensor and/or TP sensor • PCM terminal 2C-engine GND Go to next step. Repair or replace connector, then go to Step 9.
2
Does IAT sensor connector or PCM connector have poor connection?
Yes No
Go to next step.
3
Disconnect IAT sensor connector. Turn ignition switch on. Is there 5V at IAT sensor harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2L and IAT sensor terminal A), then go to Step 9.
Disconnect PCM connector. IAT sensor connector is disconnected. Is there continuity between IAT sensor harness side connector terminal B and PCM harness side connector terminal 2D?
Yes
Go to next step.
No
Repair open circuit, then go to Step 9.
Is there continuity from PCM harness side connector terminals 2L to 1B?
Yes
Repair short to power circuit, then go to Step 9.
No
Go to next step.
Is there continuity from PCM harness side connector terminal 2D to body GND?
Yes
Repair short to ground circuit, then go to Step 9.
No
Go to next step.
Is IAT sensor okay? ☞ CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
Yes
Go to next step.
No
Replace IAT sensor, then go to Step 9. ☞ CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to Step 1.
No
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection.
No
Troubleshooting completed.
4
5 6 7
8
9
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ON-BOARD DIAGNOSTIC SYSTEM
DTCP1170 DETECTION CONDITION
POSSIBLE CAUSE
Oxygen sensor (O2S) is stuck When O2S signal stays above 0.45V for 20 seconds after engine has reached normal operating temperature. • • • • • • • • • • • • • • •
O2S deterioration Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose clogging or leakage Fuel return hose and/or fuel filter clogging Leakage in intake-air system or exhaust system PCV valve malfunction Purge solenoid valve malfunction or purge solenoid hoses are hooked up incorrectly Ignition coil malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Open or short circuit in wiring harness Poor connection of connector Vacuum hose damage or looseness
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1
INSPECTION Verify stored DTC. Have DTCs P0100, P0110 P0115, and/or P0120 been stored?
ACTION Yes
No
Inspect and repair DTC P0100, P0110, P0115, or P0120. Go to Step 26. Go to next step.
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ON-BOARD DIAGNOSTIC SYSTEM STEP 2
3
INSPECTION
ACTION
Clear DTC. Verify RPM, ECT and VS PIDS. Drive vehicle approx. 1 minute under same condition. Is DTC P1170 stored?
Yes
Trouble is in process. Go to next step.
Note • If NGS tester is not used, measure following PCM terminal voltage with voltmeter. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1 M) Implement PID/DATA.MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle?
No
Go to TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent Concerns.
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace then go to Step 26.
No
Go to next step.
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace, then go to Step 26.
Note • If NGS tester is not used, measure following PCM terminal voltage with voltmeter. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2K) 4
Continue monitoring items on previous PIDs. Is there any input signal which causes drastic changes when it is set to be in trouble condition?
Yes
No
Go to next step.
5
Inspect exhaust system, upstream from O2S. Is there any gas leakage?
Yes
Repair or replace faulty exhaust parts, then go to Step 26. ☞ EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.
No
Go to next step.
Yes
Go to next step.
No
Install heated oxygen sensor properly, then go to Step 26. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION.
Implement FID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on O2S as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean condition Note • If NGS tester is not used, measure PCM 2N voltages with voltmeter.
Yes
Go to next step.
No
Inspect and repair or replace faulty O2S, harnesses, connector or terminals, then go to Step 26. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) INSPECTION.
Inspect for open, poor connection and other problems on the following harnesses, connectors, and terminals (for fuel injector at each cylinder): • From main relay to fuel injector • From fuel injector to PCM Is there any trouble?
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 26.
No
Go to next step.
6
7
8
Is O2S installed properly?
F1-65
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ON-BOARD DIAGNOSTIC SYSTEM STEP 9
INSPECTION
ACTION
Inspect injection amount of each injector. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION, Volume Test. Are there any injectors operating abnormally? (e.g. injection amount, injection condition) Inspect purge control system. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection. Is it okay?
Yes
Replace faulty fuel injectors, then go to Step 26. ☞ FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.
No
Go to next step.
Yes
Go to next step.
No
By following system inspection, repair or replace faulty parts, then go to Step 26.
Inspect PCV valve operation. ☞ EMISSION SYSTEM, POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION. Is it okay?
Yes
Go to next step.
No
Replace PCV valve, then go to Step 26,
12
Inspect fuel line pressure under trouble condition. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay?
Yes
No
Inspect for leakage and injection amount. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION. Replace faulty fuel injector, then go to Step 26. Go to next step.
13
Inspect pressure regulator. ☞ FUEL SYSTEM, PRESSURE REGULATOR INSPECTION. Is it okay?
Yes
Go to next step.
No
Inspect air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. • Can air suction confirmed? Inspect for air suction in vacuum hose, which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed?
Yes
Replace pressure regulator, then go to Step 26. ☞ FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION, Repair or replace source of air suction, then go to Step 26.
10
11
14
15
16
17
18
19
20
No
Go to next step.
Yes
Repair or replace source of air suction, then go to Step 26.
No
Go to next step,
Inspect fuel line pressure under trouble condition. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay? Inspect fuel pump maximum pressure. ☞ FUEL SYSTEM, FUEL PUMP UNIT INSPECTION, Fuel Pump Maximum Pressure Inspection. Is it okay?
Yes
Go to Step 22.
No
Go to next step.
Yes
Go to next step.
No
Replace fuel pump body, then go to Step 26. ☞ FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/ INSTALLATION.
Inspect for clogging in fuel filter (high-pressure). Is there foreign material in fuel on fuel pump side of filter?
Yes
Go to next step.
No
Go to Step 20.
Inspect inside of fuel tank for foreign material and stains. Is inside of fuel tank okay?
Yes
Replace fuel filter (high-pressure), then go to Step 26. ☞ FUEL SYSTEM, FUEL FILTER (HIGHPRESSURE) REMOVAL/INSTALLATION.
No
Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter, then go to Step 26.
Yes
Go to next step.
No
Repair or replace source of fuel leakage or clogging, then go to Step 26.
Inspect for leakage and clogging in fuel line from distributor to fuel pump. Is it okay?
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ON-BOARD DIAGNOSTIC SYSTEM STEP 21
INSPECTION
ACTION
Inspect for leakage in fuel line from fuel filter (highpressure) to fuel tank (return side). Is it okay?
Yes
No 22
23
24
Replace pressure regulator, then go to Step 26. ☞ FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION. Repair or replace source of fuel leakage, then go to Step 26
Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. Does it blink regularly and stably?
Yes
Go to Step 24
No
Go to next step.
Inspect resistance of ignition coil. ☞Section G, IGNITION COIL INSPECTION. Is it okay?
Yes
Go to next step.
No
Replace ignition coil, then go to Step 26.
Warning • Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing the radiator cap, wrap a thick cloth around and turn it slowly. Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles, which make engine coolant white at filling opening?
Yes
Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 26.
No
Go to next step.
Yes
Go to next step.
No
Implement engine overhaul, then go to next step.
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
Note • Large bubbles are normal since they are remaining air coming out from engine coolant passage. 25
Inspect engine compression. ☞Section B1, COMPRESSION INSPECTION. Is it okay? Clear DTC. Verify DTC after running vehicle. Is there any DTC stored?
26
DTC P1195 DETECTION CONDITION POSSIBLE CAUSE STEP _
Barometric pressure (BARO) sensor (in PCM) Input voltage from barometric pressure sensor is below 1.5 V or above 4.5 V when ignition switch is turned on. • Barometric pressure sensor (in PCM) malfunction. INSPECTION _
ACTION _
Replace PCM ☞ CONTROL SYSTEM, PCM REMOVAL/INSTALLATION
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM DTC P1250
PRESSURE REGULATOR CONTROL (PRC) solenoid valve circuit malfunction
DETECTION CONDITION
Open or short circuit is observed in PRC solenoid valve when Ignition switch is turned on
POSSIBLE CAUSE
STEP
• • • • • • • •
PRC solenoid valve malfunction Poor connection of connectors at PRC solenoid valve and/or PCM Short to power supply circuit in wiring from PRC solenoid valve B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2T and/or 2C to engine GND Open circuit in wiring from PRC solenoid valve terminal B to PCM terminal 2T Open circuit in wiring from PRC solenoid valve terminal A to man relay terminal D INSPECTION
ACTION
1
Verify stored DTC. Have DTCs P0100, P0335, P0443 and/or P0505 been stored?
Yes
No
Inspect for open circuit in following wiring harnesses, then go to Step 9. • Main relay terminal D-IAC valve, PRC solenoid valve, MAF sensor, CMP sensor, purge solenoid valve • Between PCM terminal 2C and engine ground. Go to next step.
2
Does PRC solenoid valve connector or PCM connector have poor connection?
Yes No
Repair or replace connector, then go to Step 9. Go to next step.
3
Disconnect PRC solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness. (between main relay terminal D and PRC solenoid valve terminal A), then go to Step 9.
Disconnect PCM connector. PRC solenoid valve is disconnected. Is there continuity between PRC solenoid valve harness side connector terminal B and PCM harness side connector terminal 2T?
Yes
Go to next step.
No
Repair open circuit, then go to Step 9.
Is there continuity between PCM harness side connector terminals 2T and 1B?
Yes No
Repair short to power supply circuit, then go to Step 9. Go to next step.
Is there continuity from PCM harness side connector terminal 2T to body GND?
Yes
Repair short to GND circuit, then go to Step 9.
No
Go to next step.
Is PRC solenoid valve okay? ☞ FUEL SYSTEM, PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION
Yes
Go to next step.
No
Replace PRC solenoid valve, then go to Step 9.
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to Step 1.
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
4
5
6 7
8
9
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ON-BOARD DIAGNOSTIC SYSTEM DTCP1608 DETECTION CONDITION POSSIBLE CAUSE
PCM internal circuit malfunction PCM does not read DTC from output devices. • •
PCM does not read DTC from output devices. Short to power supply circuit in wiring from output devices (purge solenoid valve, PRC solenoid valve, IAC solenoid valve and/or fuel injectors) to PCM
STEP INSPECTION 1 Disconnect output devices and PCM connector. Is there continuity between the following connectors? • PCM harness side connector terminal 2X-1B • PCM harness side connector terminal 2E-1B • PCM harness side connector terminal 2W-1B • PCM harness side connector terminal 2U-1B • PCM harness side connector terminal 2V-1B
Yes
No
ACTION Repair short to power supply circuit. Replace PCM. ☞ CONTROL SYSTEM, PCM REMOVAL/INSTALLATION Replace PCM ☞ CONTROL SYSTEM, PCM REMOVAL/INSTALLATION
CONTINUED
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TROUBLESHOOTING
TROUBLESHOOTING FOREWORD • Before proceeding with the following troubleshooting. (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If the diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP". TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. No.
TROUBLESHOOTING ITEM
DESCRIPTION
1
Melting of main or other fuses
2
Will not crank
Starter does not work.
4 5 6
Hard to start/long crank/erratic start/erratic crank Engine stalls After start/at idle Cranks normally but will not start Slow return to idle
Starter cranks engine at normal speed but engine requires excessive cranking time before starting. Engine stops unexpectedly at idle and/or after start. Starter cranks engine at normal speed but engine will not run. Engine takes more time than normal to return to idle speed.
7
Engine runs rough/rolling idle
Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.
8
Fast idle/runs on
Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off.
9
Low idle/stalls during deceleration
3
10
Engine stalls/quits
Acceleration/cruise
Engine runs rough Misses
Acceleration/cruise Acceleration/cruise
—
Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. Engine stops unexpectedly at beginning of acceleration or during acceleration. Engine stops unexpectedly while cruising. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising.
11
Hesitation/stumble Surges Lack/loss of power
Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise
12
Knocking/pinging
Acceleration/cruise
13 14 15
Poor fuel economy Emissions compliance High oil consumption/leakage
Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber). Fuel economy is unsatisfactory. Emission compliance test is failed. Oil consumption is excessive.
16
Cooling system concerns
Overheating
Engine runs at higher than normal temperature/overheats.
17
Cooling system concerns
Runs cold
Engine takes excessive period for reaching normal operating temperature.
18
Exhaust smoke
Buck/jerk
Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output. Performance is poor under load (e.g. power down when climbing hills).
Blue, black, or white smoke from exhaust system
19
Fuel odor (in engine compartment)
Gasoline fuel smell or visible leakage
20
Engine noise
Engine noise from under hood
21
Vibration concerns (engine)
Vibration from under hood or driveline
22
A/C does not work sufficiently
A/C compressor magnetic clutch does not engage when A/C is turned on.
23 24 25 26 27
A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions Exhaust sulphur smell Intermittent concerns Constant voltage
A/C compressor magnetic clutch does not disengage. A/C compressor magnetic clutch does not disengage under WOT. Rotten egg smell (sulphur) from exhaust. Symptom occurs randomly and is difficult to diagnose. Incorrect constant voltage.
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TROUBLESHOOTING QUICK DIAGNOSTIC CHART Engine or transmission mounts improperly installed
Cooling system malfunction (Radiator, hoses, overflow system, thermostat, etc.)
Water and anti-freeze mixed improperly
Improper engine coolant level
Improper tension or damaged drive belts
Flywheel seized
Base engine malfunction
Improper dipstick
Improper engine oil viscosity
Hydrolocked engine
x
Improper valve timing
x
Improper engine compression
Charging system malfunction
x
Low or dead battery
x
Improper engine oil level
Starter circuit including ignition switch open
Troubleshooting item
Starter motor malfunction (Mechanical or electrical)
Possible factor
1 Melting of main or other fuses 2 Will not crank
x
x
3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls After start/at idle 5 Cranks normally but will not start
X X
x x
x
x
x x x
x x x
x x
6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10
Acceleration/cruise Acceleration/cruise Acceleration/cruise
x
x
Hesitation/stumble Surges 11 Lack/loss of power
Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise
x x x
x x x
12 Knocking/pinging
Acceleration/cruise
x
Buck/jerk
x
13 Poor fuel economy
x
x
14 Emissions compliance
x
x
15 High oil consumption/leakage
x x x
x
19 Fuel odor (in engine compartment) 20 Engine noise
x
x
x
x
X
x x x
x
21 Vibration concerns (engine) 22 A/C does not work sufficiently. 23
x
x
16 Cooling system concerns Overheating 17 Cooling system concerns Runs cold 18 Exhaust smoke
x
x x
x
A/C is always on/A/C compressor runs continuously
24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns
x
27 Constant voltage
F1-71
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TROUBLESHOOTING
High-tension leads malfunction (Cracks , open, low resistance)
CMP sensor damaged (e.g. open or short circuits)
x
Spark plug malfunction
x
Initial ignition timing misadjustment (CMP & crankshaft pulley misadjustment
x
Ignition coil malfunction (e.g. open short or cracks)
x
Vacuum leakage (Vacuum hose damaged, mis-routing)
Air leakage from intake-air system (Tubes looseness, crack, gaskets broken) x
x
Throttle body malfunction
Air cleaner element clogged or restriction x
x
IAC valve improper operation
Engine overheating
Fuel quality
Troubleshooting item
Accelerator cable free play misadjustment
Cooling fan seated improperly
Possible factor
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic star/erratic crank
x
4 Engine stalls
x
5 Cranks normally but will not start 6 Slow return to idle
x
x
7 Engine runs rough/rolling idle 8 Fast idle/runs on
x
After start/at idle
x
x x
x
x
x
x
x
x
9 Low idle/stalls during deceleration Engine stalls/quits
Acceleration/cruise
x
x
x
x
x
x
x
x
Engine runs rough
Acceleration/cruise
x
x
x
x
x
x
x
x
Misses
Acceleration/cruise
x
x
x
x
x
x
x
x
10
x
x
x
x
x
x
x
x
Hesitation/stumble
Acceleration/cruise/ deceleration Acceleration
x
x
x
x
x
x
x
x
Surges
Acceleration/cruise
x
x
x
x
x
x
x
x
11 Lack/loss of power
Acceleration/cruise
x
x
x
x
x
x
x
12 Knocking/pinging 13 Poor fuel economy
Acceleration/cruise
Buck/jerk
x x
14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns
Overheating
17 Cooling system concerns 18 Exhaust smoke
Runs cold
x x
x
x
x
x
x
x
x
x
x
x
x
19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently.
x
x
x
A/C is always on/A/C compressor runs 23 continuously 24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell
x
26 Intermittent concerns
x
x
x
x
27 Constant voltage
F1-72
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ECT sensor malfunction
Main relay malfunction (Mechanical or electrical)
V-reference supply circuit malfunction
PCV valve malfunction
Evaporative emission control system malfunction
Catalytic converter malfunction
Exhaust system restricted or clogged
Improper air/fuel mixture ratio control
PRC solenoid valve improper operation
Fuel filters restricted or clogged
Fuel leakage from fuel system (Including insulator, injector O-ring)
Injectors malfunction (Leakage or clogging, inoperative)
Fuel hoses restricted or clogged
Possible factor
Pressure regulator malfunction
Fuel pump body malfunction (Mechanical or electrical
TROUBLESHOOTING
Troubleshooting item Melting of main or other fuses Will not crank
x x
x x
x x
x
x
x x
x x
x x
x x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Hard to start/long crank/erratic start/erratic crank 3 After start/at idle Engine stalls 4
x x
1 2
x x
Cranks normally but will not start Slow return to idle
5 6
Engine runs rough/rolling idle
7
x
Fast idle/runs on
8
Low idle/stalls during deceleration
9
x
x
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Engine stalls/quits
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Engine runs rough
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Misses
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Lack/loss of power
11
x x
x x
Knocking/pinging
x
x
12 13
x
x
x
x
x
x
x
x
x
x
x
x
x x
x
x
x
x
Hesitation/stumble
x
Acceleration/cruise
Surges
x x
Emissions compliance
x
High oil consumption/leakage
15
Overheating
Cooling system concerns
16
Runs cold
Cooling system concerns
17
x
x
x
Buck/jerk
Acceleration/cruise Poor fuel economy
x
x
x
x
10
Acceleration/cruise/ deceleration Acceleration
x x
x
x
14
Exhaust smoke
18
Fuel odor (in engine compartment)
19
Engine noise
20
Vibration concerns (engine)
21
A/C does not work sufficiently.
22
A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions
24
Exhaust sulphur smell Intermittent concerns Constant voltage
25 26 27
23
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x
Suspension malfunction
x
Drive line malfunction
x
Wheels and tires improper balance
x
Loose parts
x
Brake dragging
x
Improper ATF level
x
VSS and related circuit malfunction
A/C relay (A/C control signal) circuit malfunction
x
Clutch slippage
Improper refrigerant charging amount
PSP switch and related circuit malfunction
Variable resistor and related circuit malfunction (Except Europe)
TP sensor misadjustment (Including looseness)
TP sensor and related circuit malfunction
Troubleshooting item
MAF sensor and related circuit malfunction
Brake switch and related circuit malfunction
Possible factor
Neutral or clutch switch and related circuit malfunction
TROUBLESHOOTING
x
x
1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank
x
4 Engine stalls after start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle
x
8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits
10
x
x
acceleration/cruise
x
x
x
x
x
x
x
Engine runs rough
acceleration/cruise
x
x
x
x
x
x
x
Misses
acceleration/cruise
x
x
x
x
x
x
x
Buck/jerk Hesitation/stumble Surges
acceleration/cruise/ deceleration acceleration
x
x
x
x
x
x
x
x
x
x
x
x
x
x
acceleration/cruise
x
x
x
x
x
x
x
x
x
x
x
11 Lack/loss of power
acceleration/cruise
12 Knocking/pinging 13 Poor fuel economy
acceleration/cruise
x
x x
x
14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns
overheating
17 Cooling system concerns
runs cold
x
x
18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine)
x x
22 A/C does not work sufficiently. 23
x
A/C is always on/A/C compressor runs continuously
x x
24 A/C is not cut off under WOT conditions
x
x
25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage
x
x
x
x x
x
x
x
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SYMPTOM TROUBLESHOOTING: Symptom 1-Melting of main or other fuses
FI-75
Symptom 2-Will not crank
FI-76
Symptom 3-Hard to start/long crank/erratic crank
FI-77-78
Symptom 4-Engine stalls-after start/at idle
FI-79-81
Symptom 5-Cranks normally but will not start
FI-82-84
Symptom 6-Slow return to idle
FI-85
Symptom 7-Engine runs rough/rolling idle
FI-86-88
Symptom 8-Fast idle/runs on
FI-89
Symptom 9-Low idle/stalls during deceleration
FI-90
Symptom 10-Engie stalls/quits-acceleration/cruise - Engine runs rough – acceleration/cruise - Misses-acceleration/cruise - Buck/jerk – acceleration/cruise/deceleration - Hesitation/stumble – acceleration - Surges – acceleration/cruise
FI-91-93
Symptom 11-Lack/loss of power-acceleration/cruise
FI-94-96
Symptom 12-Knocking/pinging-acceleration/cruise
FI-97
Symptom 13-Poor fuel economy
FI-98-99
Symptom 14-Emission compliance
FI-100-101
Symptom 15-High oil consumption/leakage
FI-101
Symptom 16-Cooling system concerns-overheating
FI-102-103
Symptom 17-Cooling system concerns-runs cold
FI-103
Symptom 18-Exhaust smoke
FI-104-105
Symptom 19-Fuel odor (in engine compartment)
FI-106
Symptom 20-Engine noise
FI-107
Symptom 21-Vibration concerns (engine)
FI-107
Symptom 22-A/C does not work sufficiently
FI-108
Symptom 23-A/C is always on (a/c compressor runs continuously
FI-109
Symptom 24-A/C does not cut off under wide open throttle (wot) conditions
FI-110
Symptom 25-Exhaust sulphur smell
FI-111
Symptom 26-Intermittent concerns
FI-112
Symptom 27-Constant voltage
FI-113-114
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TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1
MELTING OF MAIN OR OTHER FUSES
Damaged Fuse MAIN (80 A)
HEAD (30 A) A/C (10A) WIPER (15 A)
STOP (15 A) FUEL INJ (30 A)
ROOM (10 A) ENGINE (15 A)
METER (15 A)
Related Wiring Harness MAIN fuse Generator Ignition switch Starter Ignition coil Condenser HEAD fuse • Generator A/C relay • Generator WIPER fuse • A/C relay • A/C switch STOP fuse • Brake switch Main relay • Fuel injector • PCM • PRC solenoid valve • Purge solenoid valve • IAC valve • MAF sensor • CMP sensor ROOM fuse • PCM ENGINE fuse • Main relay • Fuel pump relay Fuel pump relay • Fuel pump METER fuse • PCM
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TROUBLESHOOTING SYMPTOM 2 WILL NOT CRANK DESCRIPTION • Starter does not work. • Open circuit between ignition switch and starter POSSIBLE • Starter malfunction CAUSE • Seized/hydrolocked engine or flywheel STEP INSPECTION RESULTS ACTION 1 Inspect for following: Yes Go to next step. • Battery connection No Service as necessary. • Battery condition Repeat Step 1. • Fuses Are all items okay? 2
Is clicking sound heard from starter when ignition switch is turned to START?
3
Inspect starting system. ☞ Section G, STARTING SYSTEM, STARTER INSPECTION Is starting system okay?
Yes No Yes
Go to next step. Go to Step 4. Inspect for seized/hydrolocked engine or flywheel. ☞ Section H, FLYWHEEL, FLYWHEEL INSPECTION
No
Repair or replace components as required. Go to next step. Inspect charging system. ☞ Section G, CHARGING SYSTEM, GENERATOR INSPECTION No DTC is displayed: Inspect following: • START circuit in ignition switch • Open circuit between ignition switch and starter
4
Do any other electrical accessories work?
Yes No
5
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
6
No
DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay is stuck open. • Open or poor GND circuit at PCM • Poor connection of vehicle body GND
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 3 DESCRIPTION
POSSIBLE CAUSE
HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK • •
Starter cranks engine at normal speed but engine requires excessive cranking time before starting. Battery in normal condition.
• • • • • • • • • • • •
Spark leakage from high-tension leads Vacuum leakage Poor fuel quality Starting system malfunction Spark plug malfunction Air leakage from intake-air system Erratic signal from CMP sensor Air cleaner restriction PCV valve malfunction Inadequate fuel pressure Purge solenoid valve malfunction MAF sensor contamination Restriction in exhaust system Pressure regulator control (PRC) system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
RESULTS
1
Inspect for following: • Vacuum leakage • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • Loose bands on intake-air system • Cracks on intake-air system parts • Air cleaner restriction Are all items okay?
Yes
Go to next step.
No
Service as necessary.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
3
Is engine overheating?
Yes No
Go to symptom troubleshooting No.16 for "Cooling system concerns - Overheating". Go to next step.
4
Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads?
Yes
Repair suspected high-tension leads.
No
Go to next step.
Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?
Yes
2
5
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Replace malfunctioning parts.
Remove PCV valve and inspect PCV valve. Does PCV valve rattle?
Yes No
Go to next step. Replace PCV valve.
No 6 7
ACTION
F1-77
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TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 8 Install fuel pressure gauge between fuel filter Yes Go to next step. and fuel distributor. No Zero or low: Connect a jumper wire between F/P terminal at Inspect fuel pump circuit. DLC in engine compartment and GND. Inspect for open fuel pump relief valve. ☞ TROUBLESHOOTING, ENGINE SYSTEM Inspect for fuel leakage inside pressure regulator. INSPECTION, Fuel Line Pressure Inspect for clogged main fuel line. Inspection Inspect PRC solenoid valve and related vacuum hose Turn ignition switch on. and harnesses. Is fuel line pressure correct? High: Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 39—45 psi} Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. 9
Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2,21 psi} for 5 min.
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Disconnect vacuum hose from pressure regulator and plug hose. Start engine. Does fuel line pressure remain within ± 20 kPa 2 {0.21 kgf/cm , 3 psi} while driving vehicle?
Yes
Go to next step.
No
Inspect for clogged fuel filter.
Connect vacuum hose to pressure regulator. Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or fuel pressure gauge reading decrease as vacuum gauge reading increases?
Yes
Go to next step.
No
Connect vacuum hose to pressure regulator. Start engine. Verify fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Disconnect a vacuum hose from purge solenoid valve and plug opening end of vacuum hose. Start engine. Is starting condition improved?
Yes
Inspect if purge solenoid valve sticks to open.
No
Go to next step.
13
Inspect for contaminated MAP sensor. Is there any contamination?
Yes
Replace MAP sensor.
No
Go to next step.
14
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
15
Inspect starting system. Yes Inspect for loose connectors or poor terminal contact. ☞ Section G, STARTING SYSTEM, STARTER INSPECTION No Repair or replace components as required. Is starting system normal? Verify test results. If okay, return to diagnostic index to service any additional symptoms.
10
11
12
16
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TROUBLESHOOTING SYMPTOM 4
ENGINE STALLS - AFTER START / AT IDLE
DESCRIPTION
•
Engine stops unexpectedly at idle and/or after start.
• • • • • • • • • • • • • • • • • • • •
A/C system operation is improper. Air leakage from intake-air system parts Purge solenoid valve malfunction Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or wrong installation Vacuum leakage Low engine compression Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Electrical connector disconnection Open or short circuit in fuel pump body and related harness No battery power supply to PCM or poor GND Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Pressure regulator control (PRC) system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always • keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death • and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE • REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION Verify following: 1 • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Ignition wiring • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay? 2
Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?
RESULTS Yes Go to next step.
No
ACTION
Service as necessary. Repeat Step 11.
Yes
Go to next step.
No
Go to symptom troubleshooting No.27 "Constant voltage".
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TROUBLESHOOTING STEP 3
4 5
6 7 8
9
INSPECTION
RESULTS
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC Is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (terminal 2A, 2B or 2C) • Poor connection of vehicle body GND
Attempt to start engine at part throttle. Does engine run smoothly at part throttle?
Yes
Inspect IAC valve and wiring harness.
No Yes
Go to next step. Go to next step.
No
Inspect for following: • Open or short circuit In CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness okay, go to next step.
Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed during cranking of engine?
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
Inspect for cracks on high-tension leads Are there any cracks on high-tension leads?
Yes
Repair suspected high-tension lead.
No
Go to next step.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Go to next step. If symptom occurs with A/C on, go to Step 14.
No
Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F
Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?
Yes
Remove and shake PCV valve. Does PCV valve rattle?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Replace PCV valve.
Is there any restriction in the exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
No 10 11
ACTION
CONTINUED
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TROUBLESHOOTING STEP INSPECTION 12 Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
13
14
15
16
17 18
RESULTS Yes Go to next step. No
ACTION
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid valve, related vacuum hose and related harnesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2,21 psi} for 5 min. Note • The following test is for stall concerns with A/C on. If other symptoms exist, go to next step. Connect pressure gauges to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURE, REFRIGERANT PRESSURE CHECK Is pressure within specifications?
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid side. Plug opening end of vacuum hose. Start engine. Is engine stall now eliminated? Is air leakage felt or heard at intake-air system components while racing engine to higher speed?
Yes
Inspect if purge solenoid valve sticks to open. Inspect evaporative emission control system.
No
Go to next step.
Yes
Repair or replace.
No
Go to next step.
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for cause.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 5
DESCRIPTION
POSSIBLE CAUSE
CRANKS NORMALLY BUT WILL NOT START • • • •
Starter cranks engine at normal speed but engine will not run. Refer to "Engine stalls" if this symptom appears after engine stall. Fuel in tank. Battery in normal condition.
• • • • • • • • • • • • • • • • • • • •
No battery power supply to PCM Air leakage from intake-air system Open PCM GND or vehicle body GND Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or incorrect installation Low engine compression Vacuum leakage Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connector Open or short circuit in fuel pump body and related harness Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from injector Fuel injector is clogged. Purge solenoid valve malfunction Pressure regulator control (PRO) system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • • ☞ ☞
Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Verify following: • Vacuum connection • External fuel shut off or accessory (kill switch, alarm etc.) • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve
Yes
Go to next step.
ACTION
No
Service as necessary. Repeat Step 11.
Are all items okay?
CONTINUED
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TROUBLESHOOTING STEP 2
3
4 5 6
7 8 9
10
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?
Yes
DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (PCM terminal 2A, 2B or 2C) • Poor connection of vehicle body GND Go to next step.
No
Go to symptom troubleshooting No.27 "Constant voltage",
Does engine start with throttle closed?
Yes
Go to Step 18.
No
Go to next step.
Will engine start and run smoothly at part throttle?
Yes
Inspect IAC valve and wiring harness.
No
Go to next step.
Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed when cranking engine?
Yes
Go to next step.
No
Inspect for following: • Open or short circuit in CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness are okay, go to next step.
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
Inspect for cracks on high-tension leads. Is there any cracks on high-tension leads?
Yes
Repair suspected high-tension leads.
No
Go to next step.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Go to next step.
No
Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F
Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?
Yes
If spark plug is wet or covered with carbon, inspect for fuel leakage from injector. If spark plug is grayish white, inspect for clogged fuel injector.
No
Install spark plugs on original cylinders. Go to next step. Go to next step.
11
Remove and shake PCV valve. Does PCV valve rattle?
Yes No
Replace PCV valve.
12
Is there any restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
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TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 13 Install fuel pressure gauge between fuel main Yes Go to next step. pipe and fuel distributor. No Zero or low: Connect jumper wire between F/P terminal at Inspect fuel pump circuit. DLC in engine compartment and GND. Inspect for open fuel pump relief valve. Turn ignition switch on. Inspect for fuel leakage inside pressure regulator. Is fuel line pressure correct when ignition switch Inspect for clogged main fuel line. is cycled on/off five times? Inspect PRC solenoid, related vacuum hose, and harFuel line pressure nesses. High: 270—3-10 kPa Inspect pressure regulator for high pressure cause. {2.7—3.2 kgf/cm 2, 39—45 psi} Inspect for clogged fuel return line. 14
15
16
17 18
Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2, 21 psi} for 5 min. Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Is starting condition improved? Is air leakage felt or heard at intake-air system components while racing engine to higher speed?
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Inspect if purge solenoid valve sticks to open mechanically. Inspect evaporative emission control system.
No
Go to next step.
Yes
Repair or replace.
No
Go to next step.
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for causes.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 6 DESCRIPTION POSSIBLE CAUSE STEP 1
2
3
SLOW RETURN TO IDLE • Engine takes more time than normal to return to idle speed. • • • •
ECT sensor malfunction Thermostat is stuck open. Throttle body malfunction Air leakage from intake-air system INSPECTION
RESULTS
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Remove thermostat and inspect operation. ☞ Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is throttle body free of contamination?
Yes
Yes No
No 4
ACTION
Engine coolant temperature and thermostat are okay. Go to next step. Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT V PID is normal, inspect temperature gauge and heat gauge unit. Inspect for air leakage from intake-air system components while racing engine to higher speed. Clean or replace throttle body.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 7 DESCRIPTION
POSSIBLE CAUSE
ENGINE RUNS ROUGH/ROLLING IDLE • •
Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively. Idle speed is too slow and engine shakes excessively.
• • • • • • • • • • • • • • • • • • •
Air leakage from intake-air system parts A/C system operation is improper. Spark leakage from high-tension leads Purge solenoid valve malfunction (if equipped) Improper operation of IAC valve Low engine compression Erratic signal from CMP sensor Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connectors Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Engine overheating Vacuum leakage Pressure regulator control (PRC) system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1
2
3
INSPECTION Verify following: • External fuel shut off or accessory • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve. Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display? Is engine overheating?
RESULTS
ACTION
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Yes
Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating".
No
Go to next step.
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
4
Note • Following test is for engine running rough idle with A/C on concerns. If other symptoms exist, go to next step. Connect pressure gauge to A/C low and high pressure side lines. Start engine and run it at idle. Turn A/C switch on. Measure low side and high side pressures. ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURE, REFRIGERANT PRESSURE CHECK Are reading pressures within specification?
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Note • Following test is for engine running rough with P/S on. If other symptoms exist, go to next step. Start engine and run it at idle. Access PSP SW PID. Inspect if PSP SW PID is on while turning steering wheel right to left. Is PSP SW PID okay? Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Inspect power steering pressure switch operation and wiring harness between power steering pressure switch connector and PCM connector terminal 1P.
No
Go to next step.
Yes
Go to next step.
No
Replace malfunctioning parts.
7
Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads?
Yes
Repair suspected high-tension leads.
No
Go to next step.
8
Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?
Yes
5
6
Start engine and disconnect IAC valve connector. Does rpm drop or engine stall?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Inspect IAC valve and wiring harness.
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step.
No
Zero or low Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line Inspect PRC solenoid valve, related vacuum hose and harnesses High • Inspect pressure regulator for high pressure cause • Inspect for clogged fuel return line
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1.5 kgf/cm ,21 psi} for 5 min.
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
No 9
10
11
ACTION
CONTINUED
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TROUBLESHOOTING STEP 12
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC, Start the engine and run it at idle. Access FHO2S PID. Is FHO2S PID okay? • More than 0.45 V when accelerator pedal is suddenly depressed: rich condition • Less than 0.45 V during fuel cut: lean condition
Yes
Go to next step.
No
Inspect and repair or replace faulty O2S, harness, connector or terminal, then go to next step.
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Does engine condition improve?
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No
Go to next step.
14
Remove and shake PCV valve. Does PCV valve rattle?
Yes
Go to next step.
No
Replace PCV valve.
15
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
16
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for causes.
17
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
13
CONTINUED
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TROUBLESHOOTING SYMPTOM 8
FAST IDLE/RUNS ON
DESCRIPTION
• •
POSSIBLE CAUSE
• • •
Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off.
ECT malfunction Air leakage from intake-air system Throttle body malfunction STEP INSPECTION RESULTS 1 Connect NGS tester to DLC. Yes Access ECT PID. No Start and warm up engine to normal operating temperature. Is ECT PID reading between 112°C {234°F} and 82°C {180°F}?
2
3
4
ACTION Go to next step. ECT PID is higher than 112°C {234°F}: Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". ECT PID is less than 82°C {180°F}: Go to symptom troubleshooting No.17 "Cooling system concerns - Runs cold".
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is there air leakage felt or heard at intake-air system components while racing engine to higher speed?
Yes
Repair or replace parts as necessary.
No
Verify accelerator cable free play.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 9 DESCRIPTION
•
Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
POSSIBLE CAUSE
• • • • • • •
Vacuum leakage IAC valve malfunction Air leakage from intake-air system MAF sensor or related circuit malfunction TP sensor or related circuit malfunction Brake switch or related circuit malfunction Neutral/clutch switch or related circuit malfunction
STEP 1
2
3
4
5
6
7
LOW IDLE/STALLS DURING DECELERATION
INSPECTION Does engine idle roughly?
RESULTS Yes
ACTION
No
Go to symptom troubleshooting No.7 for "Engine runs rough/Rolling idle". Go to next step.
Verify following: • Proper routing and no damage of vacuum lines • IAC valve is connected properly. • No air leakage from intake-air system Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 2.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Does idle speed drop or stall when disconnecting IAC valve?
Yes
Go to next step.
No
Inspect following: • Circuit from IAC valve to PCM connector terminal 2W for open and short • IAC valve for sticking If okay, go to next step.
Disconnect vacuum hose between purge Yes solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. No Drive vehicle. Does engine condition improve? Connect NGS tester to DLC. Yes Access TP V, MAP V, VS, BRK SW and NL SW PIDs. Monitor each PID while driving vehicle. No • TP V PID • MAF V PID • VS PID BRK • SW PID • NL SW PID Are PIDs okay? ☞ CONTROL SYSTEM, PCM INSPECTION
Inspect evaporative emission control system.
Go to next step. Go to symptom troubleshooting No.26 for "Intermittent concerns".
TP V PID: Inspect TP sensor. MAF V PID: Inspect MAF sensor. VS PID: Inspect VSS. BRK SW PID: Inspect brake switch. NL SW PID: Inspect neutral switch and clutch switch.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING
SYMPTOM 10
DESCRIPTION
POSSIBLE CAUSE
ENGINE STALLS/QUITS - ACCELERATION/CRUISE ENGINE RUNS ROUGH - ACCELERATION/CRUISE MISSES - ACCELERATION/CRUISE BUCK/JERK - ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE - ACCELERATION SURGES - ACCELERATION/CRUISE • Engine stops unexpectedly at beginning of acceleration or during acceleration. • Engine stops unexpectedly while cruising. • Engine speed fluctuates during acceleration or cruising. • Engine misses during acceleration or cruising. • Vehicle bucks/jerks during acceleration, cruising or deceleration. • Momentary pause at beginning of acceleration or during acceleration. • Momentary minor irregularity in engine output. • A/C system operation is improper. • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • Erratic signal from CMP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Spark leakage from high-tension leads • Air cleaner restriction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system • Intermittent open or short in fuel pump circuit • Inadequate fuel pressure • Fuel pump mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Intermittent open or short of MAF sensor, TP sensor and VSS • Clutch slippage Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ ☞
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS Verify following: Go to next step. 1 Yes • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) No Service as necessary. • Ignition wiring Repeat Step 1. • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay?
F1-91
ACTION
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TROUBLESHOOTING STEP 2
3
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is engine overheating?
Yes No
Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". Go to next step.
Connect NGS tester to DLC. Access RPM PID, B+ PID, TP V PID, MAF V PID, and VS PID. • RPM PID • B+PID • TP V PID • MAF V PID • VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? ☞ CONTROL SYSTEM, PCM INSPECTION
Yes
Go to next step.
No
RPM PID: Inspect CMP sensor and related harness for vibration, intermittent open/short circuit. B+ PID: Inspect for open circuit intermittently. MAF V PID: Inspect for open circuit of MAF sensor and related wire harness intermittently. TP V PID: Inspect if output signal from TP sensor changes smoothly. VS PID: Inspect for open circuit of VSS and related wire harness intermittently.
5
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
6
Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?
Yes
4
Remove and shake PCV valve. Does PCV valve rattle?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Replace PCV valve.
Verify that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug. Is lever in correct position?
Yes
Go to next step.
No
Adjust as necessary.
Are there restrictions in the exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1.5 kgf/cm , 21 psi} for 5 min.
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
No 7 8
9 10
11
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TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 12 Install vacuum gauge to intake manifold. Yes Go to next step. Start engine. No Connect vacuum hose to pressure regulator. Does fuel pressure gauge reading increase as Start engine. vacuum gauge reading decreases and/or does Verify that fuel pressure gauge reading changes as vacuum fuel pressure gauge reading decrease as changes. vacuum reading increases? If it changes, inspect vacuum line. If it does not change, replace pressure regulator. 13
14
15
16
Note • The following test is for engine stalling with A/C on. If other symptoms exist, go to next step. Connect a pressure gauge to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Is pressure within specifications? ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? Is engine compression correct?
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No
Go to next step.
Yes
Inspect following: • Valve timing • Clutch
No
Inspect for cause.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 11
LACK/LOSS OF POWER - ACCELERATION/CRUISE
DESCRIPTION
• • • • • • • • • • • • • • •
POSSIBLE CAUSE
Performance is poor under load e.g. power down when climbing hills).
• •
Improper A/C system operation Air leakage from intake-air system parts Purge control solenoid malfunction Brake dragging Erratic signal from CMP sensor Low engine compression Vacuum leakage Poor fuel quality Spark leakage from high-tension leads Air cleaner restriction PCV valve malfunction Improper valve timing due to jumping out of timing belt Restriction in exhaust system Intermittent open or short in fuel pump circuit Inadequate fuel pressure Fuel pump mechanical malfunction
• • • •
Fuel leakage from fuel injector Fuel injector clogging Intermittent open or short of MAP sensor, TP sensor and VSS Clutch slippage
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
RESULTS
1
Verify following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Fuel quality (e.g. proper octane, contamination, winter/summer blend) Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTCs. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC Is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is engine overheating?
Yes
Go to symptom troubleshooting No. 16 "Cooling system concerns - Overheating".
No
Go to next step.
2
3
ACTION
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TROUBLESHOOTING STEP INSPECTION 4 Connect NGS tester to DLC. Access RPM PID, MAF V PID, TP V PID, and VS PID. • RPM PID • MAP V PID • TP V PID • VS PID
RESULTS Yes Go to next step. No
Drive vehicle while monitoring PIDs. Are PIDs within specification? ☞ CONTROL SYSTEM, PCM INSPECTION
ACTION
RPM PID: Inspect CMP sensor and related harness for vibration and/or intermittent open/short circuit. MAF V PID: Inspect for intermittent open circuit of MAF sensor and related wire harness. TP V PID: Inspect if TP sensor output increases smoothly. VS PID: Inspect for intermittent open circuit of VSS and related wire harness.
5
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
6
Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No 7
Remove and shake PCV valve. Does PCV valve rattle?
Yes No
Replace PCV valve.
8
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
9
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
Yes
Go to next step.
No
Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
Yes
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Go to next step.
No
Connect vacuum hose to pressure-regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Note • Following test is for engine stalling with A/C on concern. If other symptoms exist, go to next step. Connect pressure gauge to A/C low and high side pressure lines. Turn A/C on and measure low side and high side pressure. Is the pressure within specifications? ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK Inspect for A/C cut off operation. Does A/C cut-off work properly?
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C always on/ A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
10
11
12
Yes
Go to next step.
No
Inspect A/C cut-off system components.
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TROUBLESHOOTING STEP 13
14
15
INSPECTION Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? Is engine compression correct?
RESULTS
ACTION
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No
Go to next step.
Yes
Inspect following: • Valve timing • Clutch • Brake system for dragging
No
Inspect for cause.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 12 DESCRIPTION
POSSIBLE CAUSE
STEP 1
KNOCKING/PINGING - ACCELERATION/CRUISE •
Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber).
• • •
Engine overheating due to cooling system malfunction Inadequate engine compression Inadequate fuel pressure
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Access ECT P1D. Verify ECT PID is less than 116°C {241 °F} while driving. Is ECT PID less than specification?
Yes
Go to next step.
No
Inspect cooling system for cause of overheating.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
3
Is engine compression correct?
Yes
Go to next step.
No
Inspect for cause.
4
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Inspect ignition timing.
2
5
6
Install vacuum gauge to intake manifold. Yes Start engine. No Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
Connect vacuum hose to pressure regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 13
POOR FUEL ECONOMY
DESCRIPTION
•
Fuel economy is unsatisfactory.
• • • • • • • • • • • • • •
Contaminated air cleaner element Engine cooling system malfunction Improper automatic transmission fluid level Weak spark Poor fuel quality Improper coolant level Inadequate fuel pressure Spark plug malfunction PCV valve malfunction Brake dragging Improper valve timing due to jumping out of timing belt Contaminated MAF sensor Improper engine compression Exhaust system clogging
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS ACTION 1 Yes Go to next step. Inspect following: • Air cleaner element for contamination • Automatic transmission fluid level No Service as necessary. • Fuel quality • Coolant level Are all items okay? Repeat Step 1. Connect NGS tester to DLC. Yes No DTC is displayed: 2 Turn ignition switch on. Go to next step. Retrieve any DTCs. No DTC is displayed: Is "NO CODES RECEIVED" or "SYSTEM Go to appropriate DTC test. PASSED" display? 3
4
Connect NGS tester to DLC. Access ECT PID. Drive vehicle while monitoring PID. ☞ CONTROL SYSTEM, PCM INSPECTION Is PID within specification?
Yes
Go to next step.
No
Inspect for coolant leakage, cooling fan operation, or thermostat operation.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step. Inspect the following: • High-tension leads • Ignition coil and connector
No
5
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING STEP INSPECTION 6 Remove and shake PCV valve. Does PCV valve rattle?
RESULTS Yes Go to next step. No
Replace PCV valve.
ACTION
7
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
8
Is brake system functioning properly?
Yes
Go to next step.
No
Inspect for cause.
9
Inspect for contaminated MAF sensor. Is there any contamination?
Yes
Replace MAP sensor.
No
Go to next step.
10
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for cause.
11
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 14 DESCRIPTION
POSSIBLE CAUSE
EMISSION COMPLIANCE • Emission compliance test is failed. • • • • • • • • • • •
Vacuum line leakage or blockage Cooling system malfunction Spark plug malfunction Leakage from intake manifold Inadequate fuel pressure PCV valve malfunction or incorrect valve installation Exhaust system clogging Fuel tank ventilation system malfunction Charcoal canister damage Excessive carbon built up in combustion chamber Improper engine compression Improper valve timing
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
RESULTS
1
Inspect following: • Vacuum lines for leakage or blockage • Electrical connections • Proper maintenance schedule followed • Intake-air system and air cleaner element concerns: obstructions, leakage or dirt Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is any other drivability concern present?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
2
3 4
5
6
ACTION
Yes
Go to appropriate symptom troubleshooting.
No
Go to next step.
Connect NGS tester to DLC. Access ECT PID. Warm up engine and run it at idle. Is ECT PID correct?
Yes
Go to next step.
No
Inspect for coolant leakage, cooling fan operation or thermostat operation.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step.
No
Inspect following: • High-tension leads • Ignition coil and connector Go to next step.
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa { 2.1—2.6 kgf/cm2, 30—36 psi}
Yes No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
7
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi} Remove and shake PCV valve. Does PCV valve rattle?
Yes
Go to next step.
No
Inspect pressure regulator for high pressure cause.
Yes
Go to next step.
No
Replace PCV valve.
Is there restriction in the exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
Yes
Replace charcoal canister.
No
Inspect fuel tank vent system.
8 9 10
11
Inspect for fuel saturation inside charcoal canister. Is excessive amount of liquid fuel present in canister?
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 15 DESCRIPTION POSSIBLE CAUSE
HIGH OIL CONSUMPTION/LEAKAGE • Oil consumption is excessive. • PCV valve malfunction • Improper dipstick • Improper engine oil viscosity • Engine internal parts malfunction
STEP INSPECTION 1 Remove and shake PCV valve. Does PCV valve rattle? 2
3
ACTION
Inspect for following: • External leakage • Proper dipstick • Proper engine oil viscosity Are all items okay?
RESULTS Yes Go to next step.
ACTION
No
Replace PCV valve.
Yes
Inspect internal engine parts such as valves, valve guides, valve stem seals, cylinder head drain passage, piston rings.
No
Service as necessary. Repeat Step 2.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 16
COOLING SYSTEM CONCERNS - OVERHEATING
DESCRIPTION
•
Engine runs at higher than normal temperature/overheats.
POSSIBLE CAUSE
• • • • • • • • • • • • •
Improper coolant level Blown fuses Coolant leakage/Improper coolant level Excessive A/C system pressure Improper water/anti-freeze mixture Fans reverse rotation Poor radiator condition Thermostat malfunction Radiator hose damage Improper or damaged radiator cap Main cooling fan is inoperative. Coolant overflow system malfunction Improper tension of drive belt Drive belt damage INSPECTION RESULTS
STEP 1
ACTION
Inspect following: • Engine coolant level • Coolant leakage • Water and anti-freeze mixture • Radiator condition • Collapsed or restricted radiator hoses • Radiator pressure cap • Overflow system • Fan rotational direction • Fuses Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Start engine and run it at idle speed. Turn A/C switch on. Does A/C compressor engage?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine and run it at idle speed. Turn A/C switch on. Does A/C SW PID read ON?
Yes
Go to next step.
No
Inspect for following: • Refrigerant pressure switch operation • A/C switch stuck open • Open or short circuit between refrigerant pressure switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier
5
Is drive belt okay?
Yes No
Go to next step. Replace drive belt.
6
Is there any leakage around heater unit in passenger compartment?
Yes No
Inspect and service heater for leakage. Go to next step.
7
Is there any leakage at coolant hoses and/or radiator?
Yes
Replace malfunctioning parts.
No
Go to next step.
2
3
4
Yes
Go to Step 5.
No
Inspect for following and repair or replace as necessary: • Refrigerant charging amount • Open circuit between A/C relay and PCM terminal 1J • Seized A/C magnetic clutch • A/C magnetic clutch malfunction If all Items are okay, go to next step.
CONTINUED
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TROUBLESHOOTING STEP 8
9
INSPECTION Cool down engine. Remove thermostat and inspect operation. ☞ Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay?
RESULTS
ACTION
Yes
Engine coolant temperature and thermostat are okay, inspect engine block for leakage or blockage.
No
Access ECT V PID on NGS tester. Inspect for both ECT V and temperature gauge readings. If temperature gauge on instrument cluster indicates normal range but ECT V is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates overheating but ECT V is normal, inspect temperature gauge and heat gauge unit.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 17
COOLING SYSTEM CONCERNS - RUNS COLD
DESCRIPTION
•
Engine takes excessive period for reaching normal operating temperature.
POSSIBLE CAUSE STEP
• •
Thermostat malfunction Cooling fan system malfunction INSPECTION RESULTS
ACTION
1
Is customer complaint "Lack of passenger compartment heat" only?
Yes No
Go to next step.
2
Does engine speed continue at fast idle?
Yes
Go to symptom troubleshooting No.8 "Fast idle/runs on".
No
Go to next step.
3
Remove thermostat and inspect operation. ☞ Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay?
Yes
Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT voltage is normal, inspect temperature gauge and heat gauge unit.
No
Replace thermostat.
4
Inspect A/C and heater system.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 18 DESCRIPTION
POSSIBLE CAUSE
EXHAUST SMOKE • Blue, black, or white smoke from exhaust system. Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system (coolant loss) malfunction • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted. • Fuel return line is restricted. • Excessive fuel pressure • Improper engine compression • Injector fuel leakage • Ignition system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP 1
2
INSPECTION What color is smoke coming from exhaust system?
Remove and shake PCV valve. Does PCV valve rattle?
RESULTS Blue
ACTION Burning oil is indicated. Go to next step.
White
Water in combustion is indicated. Go to Step 3.
Black
Rich fuel mixture is indicated. Go to Step 4.
Yes
No
Inspect for following: • Damaged valve guide, stems or valve seals • Blocked oil drain passage in cylinder head • Piston rings are not seated, seized or worn • Damaged cylinder bore If other drivability symptoms are present, return to diagnostic index to service any additional symptoms. Replace PCV valve.
3
Does cooling system hold pressure?
Yes
Inspect for following: • Cylinder head gasket leakage • Intake manifold gasket leakage • Cracked or porous engine block If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
No
Inspect for cause.
4
Inspect for following: • Air cleaner restriction • Collapsed or restricted intake-air system • Restricted fuel return line Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
Go to next step.
No
Service as necessary, Repeat Step 4.
Yes
No DTC Is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
5
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TROUBLESHOOTING STEP INSPECTION 6 Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa {2.1—2.6 kgf/cm 2,30—36 psi} 7
8
9
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2,30—36 psi} Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
RESULTS Yes Go to next step.
ACTION
No
Zero or low: Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High: Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line
Yes
Go to next step.
No
Inspect pressure regulator for high pressure cause.
Yes
Inspect spark plugs.
No
Inspect following: • High-tension leads • Ignition coil and connector
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 19
FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIPTION
•
Gasoline fuel smell or visible leakage,
• • •
Excessive fuel pressure Fuel tank vent system blockage Charcoal canister malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Then stop engine. Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on and off? Fuel line pressure 210—250 kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step,
No
Inspect pressure regulator for high pressure cause.
Inspect for blockage/restriction or open between engine vacuum port and charcoal canister. Inspect for blockage in fuel tank vent system. Is fault indicated?
Yes
Replace vacuum hose.
No
Go to next step.
Inspect purge solenoid valve. ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Is solenoid operating properly?
Yes
Go to next step.
No
Replace purge solenoid valve.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
2
3
4
5
ACTION
No DTC is displayed: Inspect charcoal canister for fuel saturation. If excessive amount of liquid fuel is present, replace charcoal canister. No DTC is displayed: Go to appropriate DTC test. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 20
ENGINE NOISE
DESCRIPTION
•
POSSIBLE CAUSE
Engine noise from under hood
Squealing, clicking or chirping noise: • Improper engine oil level • Improper drive belt tension Rattling noise: • Loose parts Hissing sound noise: • Vacuum leakage • Loose spark plug • Air leakage from intake-air system Rumbling or grinding noise: • Improper drive belt tension Rapping or roar noise: • Exhaust system looseness Other noise: • Camshaft friction gear noise
STEP INSPECTION 1 Is squealing, clicking or chirping sound present? 2 3
Is rumbling or grinding sound present? Is rattling sound present?
RESULTS ACTION Yes Inspect engine oil level or drive belts. No
Go to next step.
Yes
Inspect drive belt.
No
Go to next step.
Yes
Inspect location of rattle for loose parts.
No
Go to next step. Inspect following: • Vacuum leakage • Spark plug looseness • Intake-air system leakage
4
Is hissing sound present?
Yes
No
Go to next step.
5
Is rapping or roaring sound present?
Yes
Inspect exhaust system for loose parts.
No
Go to next step.
Yes
Go to symptom troubleshooting No.12 "Knocking/ pinging".
6
Is knocking sound present?
No
7
If noise comes from inside engine, inspect for friction gear noise. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 21 DESCRIPTION
VIBRATION CONCERNS (ENGINE) • Vibration from under hood or driveline
POSSIBLECAU SE
• Loose attaching bolts or worn parts • Component malfunctions such as worn parts
STEP 1
2
INSPECTION Inspect following components for loose attaching bolts or worn parts: • Cooling fan • Drive belt and pulleys • Engine mounts Are all items okay?
RESULTS Yes
ACTION Inspect following systems: • Wheels • Driveline • Suspension
No
Readjust or retighten engine mount installation position. Service as necessary for other parts. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING SYMPTOM 22
A/C DOES NOT WORK SUFFICIENTLY.
DESCRIPTION
•
A/C compressor magnetic clutch does not engage when A/C switch is turned on.
POSSIBLE CAUSE
• • • • • • • •
Improper refrigerant charging amount Open A/C magnetic clutch Open circuit between A/C relay and A/C magnetic clutch Poor GND of A/C magnetic clutch Refrigerant pressure switch is struck open. A/C relay is stuck open. Seized A/C compressor Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
STEP 1
2
3
4
5
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Disconnect A/C compressor connector. Start engine and turn A/C switch on. Is there correct voltage at terminal of A/C compressor magnetic clutch connector? Specification More than 10.5V
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test,
Yes
Inspect for GND condition of magnetic clutch on A/C compressor. If GND condition is okay, inspect for open circuit of magnetic clutch coil.
No
Go to next step.
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine. Turn A/C switch on and set blower fan at any speed. Does A/C SW PI Dread ON?
Yes
Inspect for stuck open A/C relay. Replace as necessary.
No
Go to next step.
Disconnect refrigerant pressure switch connector. Connect a jumper wire between terminals of refrigerant pressure switch connector. Start engine and turn A/C switch on. Does A/C work?
Yes
Inspect for following: • Refrigerant charging amount • Refrigerant pressure switch operation
No
Inspect for following: • A/C switch is stuck open. • Open circuit between refrigerant pressure switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier • Open circuit between A/C amplifier and refrigerant pressure switch
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 23
A/C IS ALWAYS ON /A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION
• • • • • •
POSSIBLE CAUSE
STEP 1
2
3
4
5
A/C compressor magnetic clutch does not disengage. Stuck engagement A/C relay is stuck closed. Short to GND between A/C switch and PCM Short to GND circuit between A/C relay and PCM A/C relay to magnetic clutch circuit shorts to battery power INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Start engine and run it at idle. Turn A/C switch on. Remove A/C relay. Does A/C magnetic clutch disengage?
Yes
Inspect for following: • A/C relay is stuck closed. • Short to GND circuit between A/C relay and PCM terminal 1J If both items okay, go to next step.
No
Inspect if circuit between A/C relay and magnetic clutch shorts to battery power circuit. If circuit is okay, inspect magnetic clutch engagement or clearance.
Yes
Inspect for short to GND circuit between refrigerant pressure switch and PCM terminal 10.
No
Go to next step.
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start the engine and turn A/C switch on. Read A/C SW PID while disconnecting refrigerant pressure switch connector. Note • A/C SW PID should read OFF when disconnecting connector. If A/C SW PID reading remains ON, short to GND circuit may be present. Does A/C SW PID reading remain ON?
Reconnect refrigerant pressure switch Yes Inspect for following: connector. • Short to GND circuit between A/C switch and A/C Read A/C SW PID while turning off A/C switch. amplifier Note • Short to GND circuit between A/C amplifier and • A/C SW PID should read OFF when turnrefrigerant pressure switch ing A/C switch off. If A/C SW PID reading remains ON, short to GND circuit may be No Inspect for stuck closed A/C switch. present. Does A/C SW PID reading remain ON? Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 24 DESCRIPTION POSSIBLE CAUSE
A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE (WOT) CONDITIONS • A/C compressor magnetic clutch does not disengage under WOT. • TP sensor malfunction • TP sensor misadjustment • TP sensor is loosely installed.
STEP INSPECTION 1 Does A/C compressor disengage when A/C switch is turned off? 2
3
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
RESULTS Yes Go to next step.
ACTION
No
Go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously".
Yes
No DTC is displayed: Inspect TP sensor for proper adjustment.
No
DTC is displayed: Go to appropriate DTC test.
Verify test results. If okay, return to diagnostic index to service any additional symptoms,
CONTINUED
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TROUBLESHOOTING SYMPTOM 25
EXHAUST SULPHUR SMELL
DESCRIPTION • • • • •
POSSIBLE CAUSE
Rotten egg smell (sulphur) from exhaust Electrical connectors are disconnected or connected poorly Charcoal canister malfunction Vacuum lines are disconnected or connected improperly. Improper fuel pressure
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Are any drivability or exhaust smoke concerns present?
Yes
Go to appropriate flow chart.
No
Go to next step.
2
Inspect following: • Electrical connections • Vacuum lines Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 2.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Install fuel pressure gauge between fuel filter and fuel distributor. Start engine and run it at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2,30—36 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi} Inspect charcoal canister for fuel saturation. Is excessive amount of liquid fuel present in canister?
Yes
Go to next step.
No
Inspect pressure regulator for high pressure cause.
Yes
Replace charcoal canister.
3
4
5
6
7
ACTION
No
Inspect fuel tank vent system. If fuel tank vent system is okay, since sulfur content can vary in different fuels, suggest trying a different brand. If fuel tank vent system is not okay, repair or replace malfunctioning parts. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 26 INTERMITTENT CONCERNS Symptom occurs randomly and is difficult to diagnose. DESCRIPTION • STEP
INSPECTION
RESULTS
1
Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous repairs and components replaced for a certain symptom?
Yes
Go to next step.
No
Go to Symptom Index.
Connect NGS tester to DLC. If input is switch-type component, turn on manually. Turn ignition switch on. Access PIDs for suspect component. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal crimps.
No
Go to next step.
Start engine. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal crimps.
No
Go to next step.
Start engine. Accurately spray water on suspect component wire, component or vacuum line related to possible fault area. Are any PID values out of range, or do they suddenly change and go back into range, or was there a noticeable engine misfire/ stumble?
Yes
Fault occurred while spraying component: Replace part and verify repair. Fault occurred while spraying wiring: Inspect each wire for corrosion, bent or loose terminals and poor wire terminal crimps. Fault occurred while spraying vacuum line: Repair vacuum hoses. Inspect wire and connector at suspect component for corrosion, bent or loose terminals, poor wire terminal crimps and high tension of wire. Repair as necessary.
2
3
4
No
ACTION
CONTINUED
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TROUBLESHOOTING SYMPTOM 27 CONSTANT VOLTAGE DESCRIPTION Incorrect constant voltage POSSIBLE CAUSE
• Constant voltage circuit malfunction Note • TP sensor and variable resistor (Except Europe) use constant voltage.
STEP
INSPECTION
RESULTS
1
Disconnect TP sensor connector. Turn ignition switch on. Measure voltage between following TP sensor and variable resistor (Except Europe) connector terminals: • Constant voltage terminal - GND terminal Is constant voltage greater than 6.0 volts?
Yes
Repair constant voltage circuit short to power in harness.
No
Go to next step.
Is voltage across battery terminals greater than 10.5 volts?
Yes
Go to next step.
No
Inspect charging system.
Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Measure voltage between battery positive terminal and GND circuit at TP sensor connector. Is voltage greater than 10.5 volts and within 1.0 volt of battery voltage?
Yes
Go to next step.
No
Go to Step 8.
Note • The purpose of this step is to determine if NGS tester is communicating with PCM. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed? Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Turn ignition switch on. Measure voltage between PCM connector terminals 1B and 2B. Is voltage greater than 10.5 volts?
Yes
Go to Step 7.
No
Go to next step.
Yes
Go to next step.
No
Repair open circuit between PCM terminal 1B and main relay.
2 3
4
5
6
7
8
ACTION
Leave TP sensor, variable resistor (Except Europe) and PCM connectors disconnected. Disconnect NGS tester from DLC. Measure resistance between PCM connector terminals 2K and 2B. Is resistance greater than 10,000 ohms?
Yes
Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.
No
Repair constant voltage circuit short to GND.
Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Measure resistance between PCM connector terminal 2K and constant voltage circuit at appropriate sensor connector. Is resistance less than 5.0 ohms? Note • The purpose of this step is to determine if NGS tester is communicating with PCM. Reconnect TP sensor and variable resistor (Except Europe) connector. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed?
Yes
Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.
No
Repair open constant voltage circuit.
Yes
Go to next step.
No
Go to Step 10.
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TROUBLESHOOTING STEP 9
10
11
INSPECTION
RESULTS
ACTION
Turn ignition switch off. Disconnect NGS tester from DLC. Disconnect PCM connector. Measure resistance between GND circuit at appropriate sensor connector and PCM connector terminal 2D. Is resistance less than 5.0 ohms?
Yes
Reconnect sensor connector. Go to appropriate DTC test.
No
Repair open GND circuit.
Turn ignition switch off. Disconnect PCM connector. Measure resistance between battery negative terminal and PCM terminals 2A, 2B and 2C. Is each resistance less than 5.0 ohms?
Yes
Go to next step.
No
Repair open GND circuit.
Turn ignition switch off. Measure resistance between GND circuit at following sensor connector and GND: • ECT sensor • O2S • IAT sensor • MAF sensor • TP sensor • Variable resistor (Except Europe) Is each resistance less than 5.0 ohms?
Yes
GND circuits are okay. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again.
No
Inspect for open GND circuit.
CONTINUED
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TROUBLESHOOTING DIAGNOSTIC INSPECTION Spark Plug Condition Inspection Purpose Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or to all cylinders.
Procedure 1. Remove the spark plug. 2. Inspect spark plug condition. 3. Go to appropriate troubleshooting chart for further information.
Spark plug condition Specific plug is wet or covered with carbon.
Symptom 1
Troubleshooting chart Wet/carbon stuck on specific plug
Specific plug looks grayish white.
Symptom 2
Grayish white with specific plug
All plugs are wet or covered with carbon.
Symptom 3
Wet/carbon stuck on all plugs
All plugs look grayish white.
Symptom 4
Grayish white with all plugs
SYMPTOM 1
Wet/carbon stuck on specific plug • • • •
POSSIBLE CAUSE
Spark—No spark visible or spark weak Air/fuel mixture—Excessive fuel injection volume Compression—No compression, low compression Faulty spark plug
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Is spark plug wet/covered with carbon by engine oil? 2
3
4
5
RESULTS ACTION Yes Working up and down inspect all areas related to oil. No
Go to next step.
Inspect spark plug for following: • Cracked insulator • Heating value • Air gap • Worn electrode Is spark plug okay?
Yes
Go to next step.
No
Replace spark plug.
Inspect compression pressure at suspected faulty cylinder. ☞ Section B1, COMPRESSION INSPECTION Is compression pressure correct? Install all spark plugs. Carry out spark test at suspected faulty cylinder. Is strong blue spark visible? (Compare with normal cylinder) Carry out fuel line pressure inspection. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Yes
Inspect fuel injector for following: • Open or short in injector • Leakage • Injection volume
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING SYMPTOM 2 POSSIBLE CAUSE
Grayish white with specific plug • •
STEP 1
2
INSPECTION
RESULTS
ACTION
Inspect spark plug for following: • Heating value • Air gap Is spark plug okay?
Yes
Go to next step.
No
Replace spark plug.
Remove suspected fuel injector. Inspect for following: ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION • Resistance • Fuel injection volume Are all above items okay?
Yes
Inspect for open circuit between suspected fuel injector terminal and PCM connector terminal.
No
Replace fuel injector.
SYMPTOM 3
Wet/carbon stuck on all plugs • • • •
POSSIBLE CAUSE
STEP
Air/fuel mixture—Insufficient fuel injection volume Faulty spark plug
Spark—Spark weak Air/fuel mixture—Too rich Compression—Low compression Clogging in intake/exhaust system
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
1
Is air cleaner element free of restriction?
Yes
Go to next step.
No
Replace air cleaner element.
2
Carry out spark test. Is strong blue spark visible at each cylinder?
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
3
Carry out fuel line pressure inspection. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 37—45 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Inspect following PIDs: ☞ CONTROL SYSTEM, PID/DATA MONITOR INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Are PIDs okay?
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Carry out purge control inspection. (When engine can be started) Is purge control correct?
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Carry out compression inspection. Is compression correct?
Yes
Inspect for clogging in exhaust system.
No
Repair or replace malfunctioning parts.
4
5
6
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TROUBLESHOOTING SYMPTOM 4
Grayish white with all plugs •
POSSIBLE CAUSE
Air/fuel mixture—Too lean
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
When engine cannot be started, inspect intake-air system for air leakage. When engine can be started, carry out intake manifold vacuum inspection. Is air sucked in from intake-air system?
Yes
Repair or replace malfunctioning parts.
No
Go to next step.
Carry out fuel line pressure inspection. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 37—45 psi}
Yes
Inspect following PIDs: ☞ CONTROL SYSTEM, PID/DATA MONITOR INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Inspect for PCM GND condition.
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
2
ACTION
CONTINUED
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TROUBLESHOOTING Inspection Using an Oscilloscope (Reference) Purpose Using an oscilloscope, inspection such as stuck solenoid valve is made possible without actually removing parts.
Finding unusual signals While referring to the diagnostic trouble code inspection section of the on-board diagnostic system, use the PID/DATA MONITOR AND RECORD function to inspect the input signal system relating to the problem. 1. Turn the ignition on and run it at idle. You can assume that any signals that are out of specifications by a wide margin are unusual. 2. When recreating the problem, any sudden change in monitor input signals that is not consciously created by the driver can be judged as unusual. Locating the source of unusual signals Caution:
When normal Counter electromotive voltage A, generated when the threeway solenoid valve or the fuel injector is turned off from on, shows irregular convergence because induced electromotive voltage B, generated by the plunger return operation, is added to it.
•
Compare the NGS monitor voltage with the measurement voltage using the DIGITAL MEASUREMENT SYSTEM function. If you use another tester, misreading may occur.
•
When measuring voltage, attach the tester GND to the GND of the PCM that is being tested, or to the engine itself. If this is not done, the measured voltage and actual voltage may differ. After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage, inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do this may result in deterioration of the harness or terminal from water damage, leading to problems with the vehicle.
•
When plunger is stuck When the plunger is stuck, pulse convergence is smooth because no induced electromotive voltage B is generated.
Input Signal System Investigation Procedure 1. Find an unusual signal. (Refer to procedures below) 2. Locate its source. (Refer to procedures below) 3. Repair or replace the defective part. 4. Confirm that the unusual signal has been erased.
Variable resistance type 1 (Throttle position (TP) sensor and variable resistor (Except Europe))
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector.
2.
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•
Female terminal opening loose
•
Coupler (pin holder) damage
•
Pin discoloration (blackness)
• Harness/pin crimp is loose or disconnected. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
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TROUBLESHOOTING (2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. Investigate the standard power supply system (1) Confirm that the #3 terminal is at 5 V. (1) If the measured voltage on the #3 terminal is 5 V, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. (3) Female terminal opening looseness (4) Coupler (pin holder) damage (5) Pin discoloration (blackness) (2) If the #3 terminal measures other than 5 V, inspect for the following. • Open or short circuit in harness • Harness/pin crimp is loose or disconnected. Investigate the GND system 1. Confirm that terminal sensor #5 is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. Open or short circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
(2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. Investigate the electrical supply system 1. Confirm that the sensor #3 terminal is B+. (1) If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) (2) If the #3 terminal measures other than B+, inspect for the following. • Open or short circuit in harness • Harness/pin crimp is loose or disconnected. Investigate the GND system
1. Confirm that terminal sensor #4 is at 0 V. (1) (2)
Variable resistance type 2 (Mass air flow (MAP) sensor)
If it is at 0 V, inspect the sensor. If necessary, replace the sensor. If not at 0 V, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
Thermistor type (Intake air temperature (IAT) and engine coolant temperature (ECT) sensors)
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. 2. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (2) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (3) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. (1) Female terminal opening looseness (2) Coupler (pin holder) damage (3) Pin discoloration (blackness) (4) Harness/pin crimp is loose or disconnected. 2. When you get an unusual signal, measure the #2 sensor terminal voltage. (3) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
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TROUBLESHOOTING (2)
• •
If the sensor and NGS voltages are the same, inspect for the following points concerning the sensor connector. If there are no problems, proceed to next investigation below, • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
ENGINE SYSTEM INSPECTION Main Relay Operation Inspection 1. Verify that the main relay clicks when the ignition switch is turned to on and off.
Investigate the GND system 1. Confirm that terminal sensor #3 is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Vehicle speed sensor (VSS) 2.
1.
Measure the #1 PCM terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine is at idle. (1) If it is at 0 V or 5 V, proceed to symptom troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the PCM connector. If there are no problem, proceed to next step. • Female terminal opening loose • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
2.
Measure the #2 sensor terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine at idle. (1) If it is at 0 V or 5 V, proceed to symptom troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the sensor connector. If there are no problems, proceed to next step. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
3.
If there is no operating sound, inspect the following. • Main relay • Harness and connector between ignition switch and main relay
Intake Manifold Vacuum Inspection 1. Verify air intake hoses are installed properly. 2. Start the engine and run it at idle. 3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve on the intake manifold side. 4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.
Specification More than 60 kPa {450 mmHg, 18 inHg} 5.
If not as specified, inspect for the following: Air suction at throttle body, intake manifold and • PCV valve installation points Fuel injector insulator • Accelerator cable free play • Engine compression (Refer to section B1.) • Note
Confirm that the #3 terminal switch voltage is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. • Open circuit in harness • Female terminal opening looseness • Coupler (pin holder) damage
•
Air suction can be located by engine speed change when lubricant is sprayed on the area where suction is occurring.
CONTINUED F1-120
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TROUBLESHOOTING (3)
Idle Air Control (IAC) Inspection Engine coolant temperature (ECT) compensation inspection 1. Connect the SSTs (NQS tester) to DLC.
4. 2. 3.
4. 5. 6.
Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select the following PIDs. • ECT • IACV • RPM Verify that the engine is cold, then start the engine. Verify that the engine speed decreases as the engine warms up. If the engine speed does not decrease or decreases slowly, carry out the following. • ECT sensor inspection • IAC valve inspection
Load compensation inspection 1. Start the engine and run at idle. 2. Disconnect the IAC valve connector and verify that the engine rotation changes.
5. 6.
Verify that DTC P0505 is not displayed. If DTC P0505 is shown, carry out DTC inspection. (4) Select the SIMULATION TEST function on the NGS display. (5) Change the duty value of the IAC valve to 100% using the IACV PID. (6) Verify that the idle speed increases. ① If the idle speed increases, replace the PCM. ② If the idle speed does not change, inspect the following. • IAC valve air passage • Open or short circuit between IAC valve connector terminals and PCM connector terminal 2W Warm up the engine to normal operating temperature and run it at idle. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select the following PIDs. • A/C SW • IAC V • PSP SW • RPM
7.
Turn the electrical loads on and verify that the engine speed is within the specification.
Engine speed (rpm) Load condition
Idle-up speed (rpm)*
1
2
P/S ON* 700—800 (750 ± 50) A/CON*3 *1 Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. 3 * : A/C switch and fan switch are on. Note • Excludes temporary idle speed drop just after the electrical loads are turned on. 8.
3.
If the engine condition does not change, do as follows. (1) Connect the IAC valve connector. (2) Connect the SSTs (NGS tester) to DLC.
If not as specified, carry out the following. • A/C switch inspection • PSP switch inspection • IAC valve inspection Fuel Line Pressure Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. • To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2.
Disconnect the negative battery cable. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
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TROUBLESHOOTING •
3.
Connect the negative battery cable. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
4.
Short the DLC terminal F/P to body GND using a jumper wire.
5.
Turn the ignition switch on and measure the fuel line pressure.
Fuel Pressure Hold Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. • To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2.
Disconnect the negative battery cable. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
3.
Connect the negative battery cable. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
Specification 2 270—310 kPa {2.7—3.2 kgf/cm , 39—45 psi} 6. 7.
8.
Turn off the ignition switch and disconnect the jumper wire. If the pressure is higher than specified, inspect the fuel pump maximum pressure. If normal, inspect fuel return hose or the pressure regulator for clogging. If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.
4.
Short the DLC terminal F/P to body GND using a jumper wire.
5. 6. 7.
•
If the fuel line pressure quickly increases, inspect the pressure regulator and PRC solenoid valve.
If fuel line pressure gradually increases, inspect the fuel pump maximum pressure. If the fuel pump maximum pressure is normal, inspect for clogging between fuel pump body and pressure regulator.
Turn the ignition switch on for approx. 10 sec. to operate the fuel pump body. Turn off the ignition switch and disconnect the jumper wire. Observe the fuel pressure after 5 min. Specification 2 More than 150 kPa {1.5 kgf/cm , 21 psi}
8.
F1-122
If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.
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TROUBLESHOOTING Inspection 1 1. Connect the SSTs (NGS tester) to the DLC.
•
If the fuel line pressure holds, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.) • If fuel line pressure does not hold, inspect the fuel leakage from fuel line and fuel injector. Pressure Regulator Control Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. • To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
3. 4.
2. 3.
Start the engine and let it idle. Select the SIMULATION TEST function on the NGS display. 4. Select IDLING TEST mode. 5. Select PRCV PID. 6. Press START. 7. Turn the PRC solenoid valve from off to on and inspect if the fuel pressure changes. (1) If the pressure changes, inspect the following. • ECT, IATDC and TP V PIDs (Refer to CONTROL SYSTEM, PID/DATA MONITOR INSPECTION.) (2) If the pressure does not change, do as follows. ① Select the SIMULATION TEST function on the NGS display. ② Select IDLING TEST mode. ③ Select PRCV PID. ④ Press START. ⑤ Turn the PRC solenoid valve from off to on and inspect if the operation sound of the valve is heard. ⑥ If the operating sound is heard, inspect the pressure regulator. ⑦ It the operating sound is not heard, inspect the PRC solenoid valve. Inspection 2 1. Connect the SSTs (NGS tester) to the DLC.
Connect the negative battery cable. Measure the fuel line pressure under the following conditions.
Specifications Condition Idling
Fuel pressure [kPa {kgf/cm 2, psi}] 210—250 {2.1—2.6, 30—36}
During 120 sec. of hot start
270—310 {2.7—3.2, 39—45}
After 120 sec. of hot start
210—250 {2.1—2.6, 30—36}
Judgment
Normal
210—250 {2.1—2.6, 30—36}
270—310 {2.7—3.2, 3&—45}
2. 3. 4.
Not Normal (Perform Inspection 1)
Not Normal (Perform Inspection 2)
Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Turn the PRC solenoid valve from off to on using the PRCV PID and inspect if the operating sound is heard. (1) If the operating sound is heard, inspect for a loose or damaged vacuum hose. (Pressure regulator—PRC solenoid valve—intake manifold) (2) If the operating sound is not heard, inspect the PRC solenoid valve)
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TROUBLESHOOTING Fuel Injector Operation Inspection STEP INSPECTION 1 While cranking engine, inspect for fuel injector operating sound at each cylinder using a soundscope. Is operating sound heard?
2
3
4
Carry out main relay operation inspection. Is main relay operation okay?
Yes
Inspect following: • Fuel injector power system related wiring harnesses and connectors • PCM connectors • Fuel injector GND and related wiring harnesses and connectors
No
Repair or replace malfunctioning parts.
Change fuel injector connector of not operating fuel injector and operating fuel injector. Is operating sound heard?
Yes
Go to next step.
No
Replace fuel injector.
Are wiring harnesses and connectors of not operating fuel injector okay? (Open or short)
Yes
Inspect PCM terminal voltage of fuel injector signal.
No
Repair or replace malfunctioning parts.
Fuel Cut Control Inspection 1. Warm up engine and let it idle. 2. Turn off the electrical loads and A/C switch. 3. Connect the SSTs (NGS tester) to the DLC.
4. 5. 6. 7.
8.
RESULTS ACTION Yes Fuel injector operation is okay. Not heard at all cylinders: No Go to next step. Not heard at some cylinders: Go to Step 3.
Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select RPM and INJ PIDs. Press START. Monitor both PIDs while performing the following steps. (1) Depress the accelerator pedal and increase the engine speed to 4000 rpm. (2) Release the accelerator pedal (brake pedal is not depressed) and inspect that the fuel injector duration time is 0 msec., and 2—5 msec. when the engine speed drops below 1200 rpm. If not as specified, carry out the following. • ECT sensor inspection • Neutral/clutch switch inspection
Fuel Pump Operation Inspection 1. Connect the SSTs (NGS tester) to the DLC.
2. 3. 4. 5. 6.
Remove the fuel-filler cap. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Turn the fuel pump relay from off to on using the FP RLY PID and inspect if the operating sound is heard. If no operating sound is heard, measure the voltage at harness side fuel pump unit connector terminal B. Specification Battery positive voltage (Ignition switch on)
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TROUBLESHOOTING 7.
8.
If the voltage is as specified, inspect the following. • Fuel pump continuity • Fuel pump GND • Wiring harness between fuel pump relay and PCM terminal 1 H If not as specified, inspect the following. 1. Fuel pump relay 2. Wiring harness and connector (Main relay—fuel pump relay—fuel pump unit)
Fuel Pump Control Inspection 1. Connect the SSTs (NGS tester) to the DLC.
4. 5.
2. 3. 4. 5. 6. 7.
8. 9.
Increase the engine speed and verify the ignition timing is advanced. If the ignition timing is not advanced, carry out the following. • CMP sensor inspection • MAP sensor inspection
Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Select IG ON TEST mode. Select FP RLY PID. Press START. Turn the fuel pump relay from off to on and inspect if the operating sound of the fuel pump relay is heard.
If no operating sound is heard, inspect the fuel pump relay. If the fuel pump relay is normal, inspect the following. • Wiring harnesses and connectors (Main relay—fuel pump relay—PCM)
Ignition Timing Control Inspection 1. Connect a timing light to the engine. 2. Crank the engine. 3. Verify that the timing mark (yellow) on the crankshaft pulley is within the specification. Specification BTDC 9°—11°(10° ± 1°)
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TROUBLESHOOTING Spark Test 1. Remove the fuel pump relay. 2. Verify that each high-tension lead and connector is connected properly. 3. Inspect the ignition system in the following procedure. Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test. STEP INSPECTION 1 Remove high-tension lead from spark plug. Hold high-tension lead with pliers installed 5—10 mm {0.20—0.39 in} from GND. Crank the engine and verify that there is a strong blue spark. (Inspect each cylinder.) 2
3 4 5 6 7
RESULTS ACTION Yes Ignition system is okay.
No
Some cylinders do not spark: Go to next step. All cylinders do not spark: Go to Step 3. Inspect for cracks or damage of high-tension lead, distributor and Ignition coil. Replace the high-tension lead.
Does PCM or ignition coil connector have poor connection?
Yes
Repair or replace connector.
No
Go to next step.
Is igniter okay?
Yes
Go to next step.
No
Replace igniter.
Is high-tension lead resistance correct?
Is ignition coil winding resistance okay? Are distributor cap and rotor okay? Are following parts okay? • CMP sensor • PCM terminal 2F voltage Specification Approx. 1.5 V
No
Yes
Yes
Go to next step.
No
Replace ignition coil.
Yes
Go to next step.
No
Replace distributor cap or rotor.
Yes
Inspect for open or short in wiring harness and connector of CMP sensor.
No
Repair or replace malfunctioning part.
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TROUBLESHOOTING Purge Control Inspection 1. Start the engine. 2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister. 3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold. 4. If there is a vacuum, inspect the following. • Wiring harness and connectors (Purge solenoid valve—PCM terminal 2X) • Purge solenoid valve 5. Warm up the engine to the normal operating temperature. 6. Stop the engine. 7. Connect the SSTs (NGS tester) to DLC.
8. 9. 10. 11. 12. 13. 14. 15. 16.
A/C CUT-OFF CONTROL INSPECTION 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch actuates. 4. If it does not actuate, go to symptom troubleshooting No.22 "A/C does not work sufficiently".
5.
6.
Turn the ignition switch on. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select ECT PID. Verify that the engine coolant temperature is above 60°C {140°F}. If the SSTs (NGS tester) indicates below 60 °C {140 °F}, carry out the ECT sensor inspection. Select the SIMULATION TEST function on the NGS display. Select PRGV PID. Press START. Increase the duty value of the purge solenoid valve to 50% and inspect if the operating sound of the valve is heard. (1) If the operating sound is heard, inspect the loose or damaged vacuum hose. (Intake manifold— purge solenoid valve—charcoal canister) (2) If the operating sound is not heard, carry out the purge solenoid valve inspection.
F1-127
Note • Specification of A/C cut-off control time is from 2 to 5 seconds. Fully open the throttle valve in a short period and verify that the A/C compressor magnetic clutch does not actuate. If it actuates, inspect the following. (1) Connect the SSTs (NGS tester) to DLC.
(2) (3) (4)
Turn the A/C switch off. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. (5) Select IG ON TEST mode. (6) Select A/C RLY PID (7) Press START. (8) Turn the A/C relay from off to on and inspect if the operating sound of the relay is heard. (9) If the operating sound is heard, inspect TP V PID. (10) If the operating sound is not heard, inspect the following. • /C relay • Open or short to GND circuit in wiring harnesses and connectors (Main relay—A/C relay—PCM terminal 1J) • A/C related parts
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FUEL AND EMISSION CONTROL SYSTEMS (WL, WL Turbo) ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . F2– 2 ENGINE TUNE-UP PREPARATION . . . . . . . . F2– 2 IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . F2– 2 IDLE-UP SPEED ADJUSTMENT . . . . . . . . . . . F2– 2 INJECTION TIMING ADJUSTMENT . . . . . . . . F2– 3 INTAKE-AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . F2– 4 VACUUM HOSE ROUTING DIAGRAM . . . . . F2– 4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 5/7 TURBOCHARGER INSPECTION . . . . . . . . . . F2– 8/9 GLOW PLUG REMOVAL/INSTALLATION . . . F2– 9 GLOW PLUG INSPECTION . . . . . . . . . . . . . . . F2– 9 GLOW PLUG RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 9 GLOW PLUG RELAY INSPECTION . . . . . . . . F2–10 GLOW PLUG CORD INSPECTION . . . . . . . . F2–10 ACCELERATOR PEDAL REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . F2–10/11 ACCELERATOR CABLE INSPECTION/ADJUSTMENT . . . . . . . . . . . . F2–11 IDLING KNOB, IDLING CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–11 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–12 BEFORE REPAIR PROCEDURE . . . . . . . . . . F2–12 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–12 FUEL TANK REMOVAL/INSTALLATION . . . . F2–13/15 FUEL FILTER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–15/16 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–16 FUEL GAUGE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–16 FUEL FILTER AIR BLEEDING . . . . . . . . . . . . . F2–16 SEDIMENTOR WATER DRAINING . . . . . . . . . F2–16 SEDIMENTOR SWITCH INSPECTION . . . . . F2–16/17 FUEL WARMER INSPECTION . . . . . . . . . . . . F2–17 FUEL INJECTION PUMP (FIP) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–17 FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–17/18 INJECTION NOZZLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–18
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . F2–19 INJECTION NOZZLE INSPECTION . . . . . . . . F2–19/20 FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–20 FUEL CUT VALVE (FCV) INSPECTION . . . . . F2–20/21 FICD SOLENOID VALVE NO.1, NO.2 INSPECTION F2–21 TIMER CONTROL VALVE (TCV) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–22 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . F2–23 EXHAUST SYSTEM INSPECTION . . . . . . . . . F2–23 EXHAUST SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–23/25 EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–25 ROLLOVER VALVE INSPECTION . . . . . . . . . F2–25 EVAPORATIVE CHAMBER INSPECTION . . . F2–25 EGR VALVE INSPECTION . . . . . . . . . . . . . . . . F2–26 EGR SOLENOID VALVE INSPECTION . . . . . F2–26 EGR PIPE, EGR VALVE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . F2–26 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–27 COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . F2–27 POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–28 POWERTRAIN CONTROL MODULE (PCM) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–28/31 NE SENSOR INSPECTION . . . . . . . . . . . . . . . F2–32 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION . . . . . . . . . . . . . . . . . F2–32/33 IDLE SWITCH INSPECTION . . . . . . . . . . . . . . F2–33 CONTROL LEVER POSITION SENSOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–33/34 ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . F2–35 DTC READING PROCEDURE . . . . . . . . . . . . . F2–35 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–35 DTC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . F2–36/38 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . F2–39 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–39 TROUBLESHOOTING ITEM TABLE . . . . . . . . F2–39 SYMPTOM TROUBLESHOOTING . . . . . . . . . F2–40/60 SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . F2–61/64
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ENGINE TUNE-UP 4. After adjusting the idle speed, tighten the locknut securely.
ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating temperature. 2. Turn the all electrical loads off. 3. Connect a tachometer. IDLE SPEED ADJUSTMENT WL 1. Perform “Engine tune-up preparation”. 2. Verify that the idle speed is within the specification.
IDLE-UP SPEED ADJUSTMENT 1. Perform “Engine tune-up preparation”. 2. Turn all electrical loads off in neutral shift position. 3. Apply vacuum of –53.3 kPa {–400 mmHg, –15.8 inHg} or over to actuator B, and measure the idle-up speed. WL
ADJUSTING SCREW B ADJUSTING SCREW C
Specification 700—740 (72020) rpm LOCKNUT B
3. If not within the specification, adjust the idle speed by turning the IAS (idle adjustment screw). ACTUATOR A
LOCKNUT 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
ACTUATOR B
WL, WL Turbo IAS
ADJUSTING SCREW B
ADJUSTING SCREW C
LOCKNUT B
4. After adjusting the idle speed, tighten the locknut securely.
ACTUATOR A ACTUATOR B
WL Turbo 1. Perform “Engine tune-up preparation”. 2. Verify that the idle speed is within the specification. Specification General (L.H.D.) : 760—800 (78020) rpm Europe and UK : 700—740 (72020) rpm
Specification 1200—1500 (1,350150) rpm 4. If not within the specification, do as follows; (1) Loosen the locknut B. (2) Adjust the idle-up speed by turning the adjusting screw B. (3) Tighten the locknut B.
Caution Turning the idle switch (Europe and UK only) with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation.
Tightening torque 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
3. If not as specified, loosen the idle switch locknut and adjust the idle speed by turning the idle switch.
5. Release actuator B to atmosphere and apply vacuum of –53.3 kPa {–400 mmHg, –15.8 inHg} or over to actuator A, and measure the idle-up speed. Specification WL vehicle: 805—855 (83025) rpm WL Turbo, WL (Europe only): 825—875 (85025) rpm
LOCKNUT 11.8—14.7 N·m {120—150 kgf·cm, 104—130 in·lbf}
6. If not as specified, adjust the idle-up speed by turning adjusting screw C.
IDLE SWITCH
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ENGINE TUNE-UP INJECTION TIMING ADJUSTMENT
6. Turn the crankshaft counterclockwise to approx. 30° BTDC. (Align the SST installation hole on the crankshaft pulley.) 7. Turn the crankshaft lightly right and left, and verify that the dial gauge indicator does not move. Then set the indicator to 0 mm {0 in}. 8. Turn the crankshaft clockwise to position the indicator pin to 10° ATDC (white mark) and read the dial indicator.
Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always observe the “Fuel Line Safety Procedures”, “Fuel Hose Installation”.
INDICATOR PIN BTDC 0° (YELLOW MARK)
Caution After tightening the FIP mounting nuts and bolt after loosening them, be sure to inspect the timing belt tension. If the belt tension is not inspected, the timing belt and the camshaft may become damaged. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
ATDC 10° (WHITE MARK)
Specification 0.95—1.05 mm {0.038—0.041 in} (1.00.05 mm {0.0390.019 in})
1. Remove the injection pipes (Refer to FUEL SYSTEM, FUEL INJECTION PUMP (FIP) 9. If not as specified, adjust by loosening the FIP REMOVAL/INSTALLATION.) mounting nut and bolt and turn the FIP. 2. Remove the cooling fan 10. Tighten the FIP mounting nuts and then the bolt. (Refer to Section E, COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.) Tightening torque 3. Turn the crankshaft pulley at slow rotation to align 19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf} the timing mark (BTDC 0° : yellow mark) with MOUNTING NUT indicator pin. INDICATOR PIN
BTDC 0 ° (YELLOW MARK)
MOUNTING BOLT ATDC 10 ° (WHITE MARK)
4. Remove the hydraulic head plug from the injection pump. 5. Mount the SST into the plug hole on the hydraulic head so that the dial indicator probe touches the plunger end of the pump and the dial indicator indicates approx. 2.0 mm {0.079 in}. 49 9140 074
11. Remove the SST. 12. Install the hydraulic head plug and a new gasket. Tightening torque 14—19 N·m {1.4—2.0 kgf·m, 11—14 ft·lbf} 13. Connect the injection pipes. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 14. Bleed the air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 15. Inspect for fuel leakage. 16. Check the timing belt tension. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
CONTINUED
F2–3
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INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM TO POWER BRAKE UNIT
WL
FICD SOLENOID VALVE No.1 FICD SOLENOID VALVE No.2
FICD ACTUATOR
VACUUM PUMP
WL TURBO
TO POWER BRAKE UNIT FICD SOLENOID VALVE No.2
TO RFW ACTUATOR
4WD ONLY FICD SOLENOID VALVE No.1
EGR VALVE
EGR SOLENOID VALVE
FICD ACTUATOR
VACUUM PUMP
CONTINUED
F2–4
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INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system. WL 1. Disconnect the negative battery cable. 2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf}
18.7—25.4 {1.9—2.6, 13.8—18.8} 2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}
2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf} 7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
18.7—25.4 {1.9—2.6, 13.8—18.8}
R
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf} N·m {kgf·m, ft·lbf}
1
Fresh-air duct
6
FICD solenoid valve No.1
2
Air cleaner
7
FICD solenoid valve No.2
3
Air hose
8
FICD solenoid valve bracket
4
Resonance chamber
9
Intake manifold
5
Air intake pipe
CONTINUED
F2–5
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INTAKE-AIR SYSTEM WL Turbo 1. Disconnect the negative battery cable. 2. Drain the engine coolant from radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 3. Remove the front mud guard. (Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Refill the engine coolant to radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) STEP 1
A
4.9 N·m {50 kgf·cm, 43 in·lbf}
4.9 N·m {50 kgf·cm, 43 in·lbf}
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf} 4.9 N·m {50 kgf·cm, 43 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
A
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf} 8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
1
Fresh-air duct
5
Air intake pipe
2
Air cleaner
6
Air hose
3
Air intake hose
7
Charge air cooler
4
Air hose
8
Air hose
CONTINUED
F2–6
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INTAKE-AIR SYSTEM
STEP 2
19—25 {1.9—2.6, 14—18}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
19—25 {1.9—2.6, 14—18}
R
19—25 {1.9—2.6, 14—18} 19—25 {1.9—2.6, 14—18}
R
N·m {kgf·m, ft·lbf}
1
FICD solenoid valve No.1
4
FICD solenoid valve bracket
2
FICD solenoid valve No.2
5
Air intake pipe
3
EGR solenoid valve
6
Intake manifold
CONTINUED
F2–7
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INTAKE-AIR SYSTEM TURBOCHARGER INSPECTION Wastegate Actuator Inspection Caution Compressed air used in the workshop is highly pressurized and can damage the actuator. Adjust the air pressure with a transformer, and inspect the actual pressure by using an air blower before actual use. Stop blowing air if the rod moved.
A
MIRROR TURBOCHARGER
4. Inspect all fins of compressor wheel while rotating the compressor wheel by hand. 5. If the compressor wheel is interfering with the housing, it is likely that more than two fins are damaged, cracked or bent. Replace the turbocharger. Note If scratches are found inside the housing but the fins are okay, the turbocharger is okay. Scratches are made in the turbocharger made by factory.
1. Disconnect the air hose of the wastegate actuator on the compressor housing side. 2. Apply the compressed air using the air gun. 3. Note the air pressure when the wastegate actuator is moved. Specification 107—115 kPa {1.09—1.18 kgf/cm2, 15.5—16.8 psi} WASTEGATE ACTUATOR
Turbine Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the turbine wheel from view B.
ROD
4. If not within the specification, replace the turbocharger. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Compressor Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the compressor wheel from view A.
Note To make work accurate, use a penlight to inspect.
B
MIRROR
Note To make work accurate, use a penlight to inspect.
TURBOCHARGER
4. Inspect all fins of turbine wheel while rotating the turbine wheel by hand.
CONTINUED
F2–8
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INTAKE-AIR SYSTEM 5. If the turbine wheel is interfering with the housing, it is likely that one or more fins are damaged, cracked or bent. Replace the turbocharger.
GLOW PLUG INSPECTION 1. Remove the glow plug cord. 2. Inspect the resistance between the glow plug terminal and the cylinder head.
Note Grinding marks on the shaft are normal. This mark is for adjusting the shaft balance at the factory.
Specification Glow plug resistance Approx. 0.75 Ω [20 °C {68 °F}] GLOW PLUG
GRINDING MARK
GLOW PLUG REMOVAL/INSTALLATION 3. If not as specified, replace the glow plug. Caution Do not damage the heated section of the glow plug. Do not reuse a glow plug that has been dropped over a height of 10 cm {0.4 in}. When removing the glow plug, first loosen it over one pitch by using a tool, then loosen by hand.
GLOW PLUG RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove glow plug relay. 3. Install the glow plug relay. 8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
GLOW PLUG RELAY
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 0.8—15 N·m {8—15 kgf·cm, 7—13 in·lbf}
4. Connect the negative battery cable.
1
Glow plug cord
2
Glow plug
CONTINUED
F2–9
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INTAKE-AIR SYSTEM GLOW PLUG RELAY INSPECTION System Inspection 1. Carry out the “Glow system inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Glow System Inspection.) 2. If not as specified, perform the further inspection for the glow plug relay.
GLOW PLUG CORD INSPECTION 1. Remove the glow plug cord. (Refer to GLOW PLUG REMOVAL/INSTALLATION.) 2. Verify that the glow plug cord is not broken or bent. 3. Verify there is continuity at both ends of the glow plug cord. 4. If there is no continuity, replace the glow plug cord.
Continuity Inspection Note Perform the following test only when directed.
ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. (Refer to Section N, MANUAL STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. General (R.H.D.)
1. Remove the glow plug relay. 2. Inspect for continuity between terminals C and D of the glow plug relay under the following conditions. C
D C
D R
A
B
19—25 {1.9—2.6, 14—18}
B
A
: Continuity Step
A
B
1
B+
GND
C
D
2 19—25 {1.9—2.6, 14—18}
3. If there is no continuity, replace the glow plug relay. (Refer to GLOW PLUG RELAY REMOVAL/INSTALLATION.) If as specified but the System Inspection is failed, inspect following: Open circuit Power circuit (Glow plug relay connector terminal A (1-pin: R/B) and battery) Power circuit (Glow plug relay connector terminal A 123456567 (2-pin) and PCM connector terminal O) GND circuit (Glow plug relay connector terminal A (1-pin: R) and glow plug cord) GND circuit (Glow plug relay connector terminal B (2-pin) and engine GND) Signal circuit (Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I) Short circuit Glow plug relay connector terminal A (1-pin: R/B) and battery to GND. Glow plug relay connector terminal A (2-pin) and PCM connector terminal O to GND. Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I to GND. 4. Repair or replace faulty areas. 5. Install the glow plug relay.
R 5.0 N·m {50 kgf·cm, 44 in·lbf}
1
Idling knob
2
Idling cable
3
Brake switch connector
4
Accelerator cable + Installation Note
5
Spring pin
6
Clevis pin
7
E clip
8
Pin
9
Bushing
10
Push rod
11
Clevis
12
Nut
13
Nut
14
Pedal component + Installation Note
N·m {kgf·m, ft·lbf}
CONTINUED
F2–10
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INTAKE-AIR SYSTEM Except General (R.H.D.)
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Warm up the engine, then turn the engine switch off. 2. Measure the free play of the accelerator cable.
LOCKNUT
Free play 1—3 mm {0.04—0.11 in}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
3. If not as specified, adjust by turning locknut. IDLING KNOB, IDLING CABLE INSPECTION General (R.H.D.) 1 Accelerator cable 1. Verify that the accelerator pedal is in the idling + Installation Note position, when the idling knob is not turned. 2 Accelerator pedal 2. Verify that the accelerator pedal moves in the direction that engine speed increases, when the Pedal Component Installation Note idling knob is turned to the right. Carry out the “BRAKE PEDAL HEIGHT 3. Verify that the accelerator pedal returns to the INSPECTION” procedure after installing the pedal idling position when the idling knob is turned to the component. left. (Refer to Section P, BRAKE PEDAL HEIGHT INSPECTION.) Carry out the “CLUTCH PEDAL INSPECTION” procedure after installing the pedal component. (Refer to Section H, CLUTH PEDAL INSPECTION/ADJUSTMENT.) Accelerator Cable Installation Note Carry out the “ACCELERATOR CABLE INSPECTION/ADJUSTMENT” procedure after installing the accelerator cable. (Refer to ACCELERATOR CABLE INSPECTION/ADJUSTMENT.)
IDLING KNOB
CONTINUED
F2–11
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FUEL SYSTEM
FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure
when the engine is not running. Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel Line Safety Procedures”. Fuel Line Safety Procedures Avoid fuel line spills and leaks by completing the following procedures. (1) Remove the fuel-filler cap and release the pressure in the fuel tank. (2) When disconnecting a fuel hose, wrap a rag around it to protect against fuel leakage. (3) Plug the fuel hose after removal. AFTER REPAIR PROCEDURE Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe “Fuel Hose Installation” described below. Fuel Hose Installation Verify that there is no damage or deformation on the fuel hose and fuel pipe when installing.
CONTINUED
F2–12
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FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the drain plug and drain the fuel from the fuel tank. 4. Remove the rear flap. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) STRETCH CAB 2WD, DOUBLE CAB 2WD 1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
7.9–10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R
WITH BOX
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
A
B
R
R
SEAL RUBBER R
2.5—4.6 N·m {25—47 kgf·cm, 22—40 in·lbf} 2.5—3.5 N·m {25—36 kgf·cm, 22—26 in·lbf}
11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf} 11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
1.1—2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
WITHOUT BOX
R
32—46 {3.2—4.7, 24—33}
EUROPE
DRAIN PLUG 26—32 {2.6—3.3, 19—23} 32—46 {3.2—4.7, 24—33}
EXCEPT EUROPE N·m {kgf·m, ft·lbf}
CONTINUED
F2–13
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FUEL SYSTEM
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf} 1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
SEAL R RUBBER 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R WITH BOX
A
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
B
R 2.5—4.6 N·m {25—47 kgf·cm, 22—40 in·lbf} 2.5—3.5 N·m {25—36 kgf·cm, 22—26 in·lbf}
11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf} 11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf}
16—22 {1.6—2.3, 12—16} 1.1—2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
WITHOUT BOX
16—22 {1.6—2.3, 12—16}
R
32—46 {3.2—4.7, 24—33}
EUROPE DRAIN HOSE 26—32 {2.6—3.3, 19—23}
32—46 {3.2—4.7, 24—33}
EXCEPT EUROPE N·m {kgf·m, ft·lbf}
1
Evaporative chamber (If equipped)
7
2
Joint hose + Installation Note
Evaporative hose + Installation Note
8
Fuel gauge sender unit
Breather hose + Installation Note
9
Rollover valve
10
Fuel-filler pipe
3 4
Under guard
11
Dust cover
5
Fuel hose + Installation Note
12
Fuel inlet pipe
6
Fuel tank
13
Check valve (two–way)
14
Evaporative chamber
CONTINUED
F2–14
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FUEL SYSTEM Evaporative Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamps as shown. Length Evaporative hose: 25 mm {0.98 in}
9—12 mm {0.36—0.47 in}
10 mm {0.39 in}
9—12 mm {0.36—0.47 in}
VIEW A
EVAPORATIVE HOSE
Fuel Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamp as shown. Length Fuel hose: 25 mm {0.98 in}
VIEW B
FUEL FILTER DISASSEMBLY/ASSEMBLY 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disassemble in the order indicated in the table. 4. Assemble in the reverse order of removal. 5. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 6. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 7. Start the engine and verify that fuel does not leak from the fuel system. 8. If fuel leaks, reassemble the fuel filter. WITH FUEL WARMER
10 mm {0.39 in}
19—25 {1.9—2.6, 14—18}
WITHOUT FUEL WARMER
FUEL HOSE
Breather Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamp as shown.
N·m {kgf·m, ft·lbf}
Length Breather hose: 25 mm {0.98 in}
R
10 mm {0.39 in}
BREATHER HOSE
Joint Hose Installation Note Fit the joint hose onto the respective fittings within the specification, and install clamps as shown. Length Joint hose: 35 {1.4 in}
CONTINUED
F2–15
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FUEL SYSTEM
1
Connector
2
Fuel hose
3
Priming pump
4
Fuel filter + Assembly Note
5
Sedimentor switch + Assembly Note
6
Drain plug
7
Fuel warmer
SEDIMENTOR SWITCH INSPECTION Continuity Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Drain fuel from the fuel filter. (Refer to FUEL SYSTEM, SEDIMENTOR WATER DRAINING.) 3. Remove the sedimentor switch. 4. Inspect continuity of the sedimentor switch by using an ohmmeter.
Sedimentor Switch Assembly Note Apply a small amount of fuel to a new O-ring. Tighten the sedimentor switch enough to the fuel filter by hand. Fuel Filter Assembly Note Apply a small amount of fuel to the fuel filter O-ring. Tighten the fuel filter approx. 3/4 by hand after the O-ring contacts the priming pump.
Float
Continuity
Up
Yes
Down
No UP DOWN
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION)
FLOAT
FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.) FUEL FILTER AIR BLEEDING Caution Continuously cranking the engine for over 30 seconds can damage the battery and the starter.
5. If not as specified, replace the sedimentor switch. If as specified, inspect following: Open circuit GND circuit (Sedimentor switch connector terminal B and body GND) Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C)
Repeat cranking the engine for 30 seconds and
stop for 5—10 seconds until the engine starts.
SEDIMENTOR SWITCH
SEDIMENTOR WATER DRAINING 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Loosen the drain plug located at the bottom of the fuel filter. 4. Pump the priming pump and drain the water. 5. After all the water has been drained, tighten the drain plug. 6. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 7. Reconnect the negative battery cable.
B
A
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
ENGINE SWITCH A
B
A
C
B
D
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–16
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FUEL SYSTEM Short circuit GND circuit (Sedimentor switch connector terminal B and body GND to power circuit) Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C to GND)
FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION Caution After removing/installing the FIP, be sure to inspect the timing belt tension. If the belt tension is not inspected, the timing belt and the camshaft may become damaged. (Refer to section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
6. Repair or replace faulty areas. 7. Install the sedimentor switch. 8. Reconnect the negative battery cable. 9. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 1. Disconnect the negative battery cable. FUEL WARMER INSPECTION 2. Complete the “BEFORE REPAIR PROCEDURE”. With fuel warmer (Refer to FUEL SYSTEM, BEFORE REPAIR 1. Disconnect the negative battery cable. PROCEDURE.) 2. Complete the “BEFORE REPAIR PROCEDURE”. 3. Remove the FICD solenoid valve bracket. (Refer to FUEL SYSTEM, BEFORE REPAIR (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM PROCEDURE.) REMOVAL/INSTALLATION.) 3. Remove the fuel warmer. 4. Remove the air intake pipe. (Refer to FUEL SYSTEM, FUEL FILTER (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM DISASSEMBLY/ASSEMBLY.) REMOVAL/INSTALLATION.) 4. Verify that the resistance between terminal A and 5. Set the No.1 cylinder to TDC. the fuel warmer body is within the specification 6. Remove in the order indicated in the table. when vacuum of –26.6—–40.0 kPa 7. Install in the reverse order of removal. {–200—–300mmHg, –7.9—–11.8 inHg} is applied 8. Complete the “AFTER REPAIR PROCEDURE”. to port A of the fuel warmer. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 9. Inspect injection timing. (Refer to ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT.) 10. Check the timing belt tension. (Refer to Section B2,TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
Specification Water temperature °C {°F}
Resistance (Ω)
20 {68}
0.5—1.5
2.4—3.4 N·m {25—35 kgf·cm, 22—30 in·lbf}
A 19—25 {1.9—2.6, 14—18}
5. If not as specified, replace the fuel warmer.
59—68 {6.0—7.0, 44—50}
FUEL INJECTION PUMP (FIP) INSPECTION Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. Consult your distributor for disassembly if any FIP
internal parts are possibly malfunctioning.
A R
25—29 {2.5—3.0, 19—21}
19—25 {1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf}
CONTINUED
F2–17
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FUEL SYSTEM
59—68 {6.0—7.0, 44—50}
1
Injection pipe
2
Accelerator cable
3
Fuel hose
4
Connector
5
Vacuum hose
6
Timing belt cover + Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Cover Installation Note.
7
FIP mounting bolt
8
FIP mounting nut
9
FIP + Removal Note
10
Key
27—32 {2.7—3.3, 20—23}
R
R R
2.4—3.4 N·m {25—35 kgf·cm, 22—30 in·lbf}
FIP Removal Note 1. Remove the two FIP pulley mounting bolts. 2. Loosen the FIP pulley locknut. 3. Remove the pulley with the SST.
25—29 {2.5—3.0, 19—21}
N·m {kgf·m, ft·lbf}
49 S120 215A
FIP PULLY LOCKNUT
1
Injection pipe
2
Fuel leak pipe
3
Fuel leak washer
4
Injection nozzle + Installation Note
5
Nozzle washer
6
Corrugated gasket + Installation Note
Corrugated Gasket Installation Note Install the bead side facing combustion chamber.
INJECTION NOZZLE REMOVAL/INSTALLATION Caution Cover the outlet of the injection pipe and fuel hose with a rag. Catch the fuel with a rag.
Injection Nozzle Installation Note Install each injection nozzle onto the FIP, matching their identification color rings as shown. INJECTION NOZZLE
1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
FIP
COLOR RING
CONTINUED
F2–18
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FUEL SYSTEM Injection Starting Pressure 1. Connect the injection nozzle to a nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Slowly lower the nozzle tester handle and note the pressure when injection starts.
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY Caution The injection port is very small so it must be kept clean. Otherwise, foreign material may get stuck in the injection nozzle, causing damage.
Injection starting pressure 11.4—12.1 MPa {116—124 kgf/cm2, 1650—1760 psi} (New) More than 10.0 MPa {102 kgf/cm2, 1450 psi} (Inspection)
1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
4. If the injection starting pressure is not within the specification, adjust it by installing the correct shim. Note Adding/subtracting 0.02 mm {0.0008 in} thickness shim increases/decreases the starting pressure approx. 470 kPa {4.8 kgf/cm2, 68 psi}.
29—49 {3.0—5.0, 22—36} N·m {kgf·m, ft·lbf}
1
Nozzle holder body + Disassembly Note
2
Ring
3
Shim
4
Nozzle spring
5
Spring seat
6
Spacer
7
Needle valve + Assembly Note
8
Nozzle body
9
Retaining nut
ADJUSTING SHIM
Atomization 1. Connect the injection nozzle to the nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Lower the handle several times as quickly as possible so that a pulsating whistling sound is heard, and note the atomization pattern. (1) Uniform, proper atomization (2) Incorrect injection angle and direction
Nozzle Holder Body Disassembly Note Secure the retaining nut in a vise and remove the nozzle holder body. Needle Valve Assembly Note When the nozzle body or the needle valve is damaged, replace them as a set.
(1)
(2)
INJECTION NOZZLE INSPECTION Caution Fuel and fuel tank used for the nozzle tester must be kept clean. Otherwise, foreign material may get stuck between the nozzle and the nozzle tester, causing damage. NORMAL
FAULTY ANGLE
FAULTY DIRECTION
4. If necessary, disassemble and clean or replace the injection nozzle.
CONTINUED
F2–19
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FUEL SYSTEM Nozzle Leakage 1. Connect the injection nozzle to the nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Apply 8.8 MPa {90 kgf/cm2, 1,280 psi} pressure to the injection nozzle, and inspect for fuel leakage from the nozzle spray port.
CORRECT
4. Remove the needle valve from the nozzle body. 5. Clean the needle valve and the nozzle body with clean light oil. 6. Verify that the needle valve moves smoothly in the nozzle body. 7. If not, replace the nozzle assembly.
WRONG
4. If fuel leaks, disassemble and clean or replace the injection nozzle. Operating Inspection 1. Verify that the needle valve and nozzle body are not damaged. 2. Verify that the nozzle body is not damaged. Hold the nozzle body upright and insert approximately two thirds of the needle valve; then see if the needle valve drops to the valve seat by its own weight when released.
FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION Without immobilizer system 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the FCV. 4. Install in the reverse order of removal. NUT 2.0—2.4 N·m {20—25 kgf·cm, 18—21 in·lbf}
NEEDLE VALVE
FCV 15—25 {1.5—2.6, 11—18}
N·m {kgf·m, ft·lbf}
FUEL CUT VALVE (FCV) INSPECTION Without immobilizer system On-vehicle Inspection
NOZZLE BODY
Injection Nozzle Cleaning 1. Inspect the outer and inner surfaces of the injection nozzle for carbon accumulation. 2. If carbon is observed on the outer surface, remove it by using a hard wood chip. 3. If carbon is observed inside of the nozzle, remove it by using a toothpick.
Note Perform the following test only when directed. 1. With the engine idling, disconnect the FCV connector and verify that the engine stops. 2. If the engine does not stop, carry out the following inspection. Off-vehicle Inspection 1. Disconnect the negative battery cable. 2. Remove the FCV. 3. Connect the battery positive voltage to the FCV terminal and GND the FCV body, 4. Verify that the FCV stem is drawn into the FCV.
CONTINUED
F2–20
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FUEL SYSTEM : Continuity Terminal
Step
: Airflow Port
A
B
A
B+
GND
B
C
1 2
B GND
5. Replace the FCV if not as specified. If as specified, inspect following: Open circuit GND circuit (FCV body and engine switch connector terminal IG1) Power circuit (FCV connector terminal and engine switch connector terminal IG1)
B
A
C
B
D
A 123456567
AIR FILTER
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Short circuit GND circuit (FCV body and engine switch connector terminal IG1 to GND) Power circuit (FCV connector terminal and engine switch connector terminal IG1 to GND)
4. If not as specified, replace the faulty FICD solenoid valve. If as specified but the “System Inspection” is failed, inspect following: Vacuum hose improper routing, kinks or leakage. Open circuit GND circuit (FICD solenoid valve No.1 connector terminal B and PCM connector terminal C) GND circuit (FICD solenoid valve No.2 connector terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector terminal A and engine switch connector terminal IG1) Power circuit (FICD solenoid valve No.2 connector terminal A and engine switch connector terminal IG1) ENGINE SWITCH
6. Repair or replace faulty areas. 7. Install the FCV. 8. Reconnect the negative battery cable. FICD SOLENOID VALVE NO.1, NO.2 INSPECTION System Inspection 1. Carry out the “FICD System Inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, FICD System Inspection.) 2. If not as specified, perform the further inspection for the FICD solenoid valve No.1, No.2. Airflow Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the FICD solenoid valve No.1, No.2. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Inspect for airflow between ports of the solenoid valve.
B
B+
C
ENGINE SWITCH A
A
A
B
A
C
B
D
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Short circuit GND circuit (FICD solenoid valve No.1 connector terminal B and PCM connector terminal IG1) GND circuit (FICD solenoid valve No.2 connector terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector terminal A and engine switch connector terminal IG1 to GND) Power circuit (FICD solenoid valve No.2 connector terminal A and engine switch connector terminal IG1 to GND) 5. Repair or replace faulty areas. 6. Install the FICD solenoid valve No.1, No.2. 7. Reconnect the negative battery cable.
CONTINUED
F2–21
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FUEL SYSTEM TIMER CONTROL VALVE (TCV) INSPECTION Europe and UK 1. Carry out the “Timer Control Valve (TCV) Control Inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Timer Control Valve (TCV) Control Inspection.) 2. If not as specified, perform the further inspection for the TCV. Continuity Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the FIP connector (8–pin terminal). 3. Verify that there is continuity between the FIP connector terminal D and TCV body. FIP
A
C
E
G
B
D
F
H
COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
4. If not as specified, send TCV to a distributor for replacement. If the TCV is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. Open circuit Power circuit (FIP connector terminal D and PCM connector terminal H) Short circuit FIP connector terminal D and PCM connector terminal H to GND 5. Repair or replace faulty areas. 6. Reconnect the FIP connector.
F2–22
CONTINUED
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EXHAUST SYSTEM
EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. WL
TURKEY and GENERAL (R.H.D., L.H.D.)
EUROPE and UK
N·m {kgf·m, ft·lbf}
1
Tail pipe
4
Front pipe
2
Main silencer
5
Exhaust manifold insulator
6
Exhaust manifold
3
Middle pipe (Turkey and General (R.H.D.,
L.H.D.) OC (Europe and UK)
CONTINUED
F2–23
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EXHAUST SYSTEM
WL TURBO
EUROPE and UK
TURKEY and GENERAL (R.H.D., L.H.D.)
N·m {kgf·m, ft·lbf}
1
Tail pipe
6
Joint pipe
2
Main silencer
7
Turbocharger + Removal Note
8
Oil pipe + Installation Note
9
Exhaust manifold
3
Middle pipe (General (L.H.D.)) OC (Europe and UK)
4
Front pipe
5
Exhaust manifold insulator
CONTINUED
F2–24
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EXHAUST SYSTEM, EMISSION SYSTEM Oil Pipe Installation Note Be sure to confirm that the turbocharger is installed correctly, then install the oil pipe. Water pipe Install the water pipe and tighten to the specified torque.
EMISSION SYSTEM ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow from port A and verify that there is airflow.
Tightening torque 24—35 N·m {2.4—3.6 kgf·m, 18—26 ft·lbf} OIL PIPE
WATER PIPE
A
3. Turn the valve over and blow from port A. Verify that there is no airflow.
Turbocharger Removal Note Do not drop the turbocharger. Do not bend the wastegate actuator mounting or rod. Cover the intake, exhaust and oil passages to prevent dirt or other objects from entering. A
4. If not as specified, replace the rollover valve. EVAPORATIVE CHAMBER INSPECTION If equipped 1. Remove the evaporative chamber. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow from port A and verify that there is airflow from port B.
A
B
3. If not as specified, replace the evaporative chamber.
CONTINUED
F2–25
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EMISSION SYSTEM EGR VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection Note Perform the following test only when directed. 1. Remove the EGR valve. 2. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the figure.
4. If not as specified, replace the EGR solenoid valve. If the EGR solenoid valve is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. Vacuum hose improper routing, kinks or leakage. Open circuit Power circuit (EGR solenoid valve connector terminal A and PCM connector terminal 1R) GND circuit (EGR solenoid valve connector terminal B and body GND through common connector) EGR SOLENOID VALVE
A
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Vacuum (kPa {mmHg, inHg})
Airflow
Below –21.3—–25.3 {–160— –190, –6.3— –7.4}
Yes
Except above
No
Short circuit EGR solenoid valve connector terminal A and PCM connector terminal 1R. 5. Repair or replace faulty areas. 6. Install the EGR solenoid valve connector.
3. If not as specified, replace the EGR valve.
EGR PIPE, EGR VALVE REMOVAL/INSTALLATION WL Turbo for Europe and UK 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
EGR SOLENOID VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the EGR solenoid valve (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION, WL Turbo.) 3. Inspect for airflow between ports of the solenoid valve. : Continuity Terminal
Step
A
19—25 {1.9—2.6, 14—18}
: Airflow N·m {kgf·m, ft·lbf}
A
B
C
1 2
B+
B GND
35—40 {3.5—4.0, 25—29}
Port
B
19—25 {1.9—2.6, 14—18}
GND
1
EGR pipe
2
EGR valve
A B
B+
A
C 123456567
CONTINUED
AIR FILTER
F2–26
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CONTROL SYSTEM
CONTROL SYSTEM COMPONENT PARTS
WL TURBO
WL TURBO
*1: *2:
1
Glow indicator light
10
A/C relay
2
Temperature control dial
11
TCV*2
3
Engine switch
12
Control lever position sensor*2
4
PCM
13
Glow plug
5
FICD solenoid valve No.2
14
NE sensor
6
FICD solenoid valve No.1
15
Idle switch*2
16
Starter
17
Glow plug relay
7
EGR solenoid
8
ECT sensor
9
DLC
valve*1
CONTINUED
WL Turbo for Europe and UK Europe and UK
F2–27
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CONTROL SYSTEM POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Remove the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
8.9—12.7 N·m {90—130 kgf·cm, 78—112 in·lbf}
1
PCM connector
2
PCM installation nut
3
PCM
POWERTRAIN CONTROL MODULE (PCM) INSPECTION Caution The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. 1. Remove the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 2. Remove the PCM with the connector connected. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.) Note With the PCM connector connected, body ground the voltmeter negative (–) lead and measure the voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage of each PCM terminals by using a voltmeter. 4. If the output voltage is not normal while each input voltage is normal, inspect the related device systems. When they are normal, replace the PCM. 5. Install the PCM. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.) 6. Install the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
F2–28
CONTINUED
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CONTROL SYSTEM Terminal Voltage (Reference) Europe and UK S T Terminal
A A*1
B C
Q R
Signal – Constant voltage
System ground FICD control
O P
Turkey and General (R.H.D. ,L.H.D.)
M
K
I
G
E C
A
N
L
J
H
F
B
Connected to – Control lever position osition sensor EGR valve position sensor
D
O M K I G E C A P N L J H F D B
Test condition – Engine switch
ON OFF
Idle
Ground
Constant
FICD solenoid valve No.1
Idle
E
Start
ECT
ECT is below 20°C {68°F}.
Engine switch (Starter)
Engine switch is on.
ECT sensor
Engine switch is on.
While cranking ECT is 20°C {68°F}. After warm-up
F
G
Engine speed (Input)
NE sensor
A/C (With A/C)
Temperature control dial
Engine switch is on. Idle Engine switch is on.
Temperature control dial is off and fan switch is off.
Temperature control dial is at position other than off and fan switch is on.
H H*1
*1:
– Idle (Control lever open or close)
– Idle switch
Engine switch is on.
Below 1.0
Action – Inspect related harness.
Inspect PCM. Inspect related harness.
Approx. 5.0
ECT is above 20°C {68°F}. D
Voltage (V) – Approx. 5.0
– Accelerator pedal is depressed. Accelerator pedal is released.
Below 1.0 Below 1.0 B+ Below 1.0 Approx. 10 Approx. 3.1 Approx. 0.8 Approx. 0 Approx. 0.05 B+
Below 1.0
– B+ Below 1.0
Inspect related harness. Inspect FICD solenoid
valve No.1. + FUEL SYSTEM, FICD SOLENOID VALVE No No.1, 1 No.2 INSPECTION Inspect related harness Inspect related harness
Inspect engine coolant
temperature sensor. + ECT SENSOR INSPECTION Inspect related harness Inspect NE sensor. + NE SENSOR INSPECTION Inspect related harness Inspect microswitch. + Section U, CONTROL SYSTEM, HEATER CONTROL UNIT INSPECTION Inspect fan switch. + Section U, CONTROL SYSTEM, HEATER CONTROL UNIT INSPECTION Inspect related harness – Inspect idle switch. + IDLE SWITCH INSPECTION Inspect related harness.
Europe and UK
CONTINUED
F2–29
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CONTROL SYSTEM
Terminal
I
Signal Glow plug voltage
Connected to Glow plug
Test condition ECT is below 60°C {140°F}.
For less than approx. 15 seconds after turning engine switch on. Over approx. 15 seconds after turning engine switch on.
ECT is above 60°C {140°F}.
For less than 10 minutes after starting engine. Over 10 minutes after starting engine. While cranking For less than approx. 2 seconds after turning engine switch on. Over approx. 2 seconds after turning engine switch on. While cranking
J
J*1
K
L*1
L*2
Power supply
Control lever position ((Detection))
Engine switch
Control lever position sensor
Engine switch
Engine switch is on.
Approx. 4.2
Accelerator pedal is fully closed.
Approx. 0.8—1.5
Engine switch
Engine switch
N*1
Glow indicator light g control
A/C control (With A/C)
Glow indicator light g
B+
Idle OFF
Below 1.0
ON
B+
Engine switch is on.
B+
Idle
B+
A/C is not operating
Engine switch is off.
–
Below 1.0 Below 1.0
Engine switch is on and within approx. 4.5 sec. (25 °C {77 °F}).
A/C relay
Over 4.5 seconds (25 °C {77 °F}) after turning engine switch on.
B+
Engine switch is on.
B+
Idle
B+
–
Inspect engine switch. + Section T, POWER SYSTEM,, IGNITION SWITCH INSPECTION Inspect related harness. Inspect control lever posi-
tion sensor. + CONTROL LEVER POSITION SENSOR INSPECTION Inspect related harness. Inspect related harness.
6.9—7.1
A/C is not operating A/C is operating
N*2
B+
Accelerator pedal is fully open.
A/C is operating M
Below 1.0
B+
Power supply
A/C relay
Below 1.0 B+ B+
ON
Engine switch is on.
Inspect related harness
B+
Below 1.0
Instrument cluster
Action
Below 1.0
OFF
Engine speed (Out(Out put)
A/C control (With A/C)
Voltage (V) B+
–
Below 1.0 –
Inspect engine switch. + Section T, POWER SYSTEM,, IGNITION SWITCH INSPECTION Inspect related harness. Inspect A/C relay. + S Section ti U, U CONTROL SYSTEM, A/C RELAY INSPECTION Inspect related harness. Inspect glow indicator
g light + Section T, WARNING AND INDICATOR SYSTEM, WARNING AND INDICATOR LIGHT BULB REPLACEMENT Inspect related harness. Inspect A/C relay. + S Section ti U, U CONTROL SYSTEM, A/C RELAY INSPECTION Inspect related harness.
–
*1:
Europe and UK *2: Turkey and General (R.H.D., L.H.D.)
CONTINUED
F2–30
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CONTROL SYSTEM
Terminal
O
Signal Glow system
Connected to Glow plug relay
Test condition Engine coolant temperature is below 60°C {140°F}.
For less than approx. 15 seconds after turning engine switch on. Over approx. 15 seconds after turning engine switch on. For less than 10 minutes after starting engine. Over 10 minutes after starting engine.
Engine coolant temperature is above 60°C {140°F}.
FICD control
FICD solenoid valve No.2
Idle
B+
Below 1.0
B+ B+
Over approx. 2 seconds after turning engine switch on.
Below 1.0
is not at OFF Engine coolant temperature is below 60°C {140°F}. Temperature control dial
Inspect glow plug relay. + INTAKE-AIR SYSTEM, GLOW PLUG RELAY INSPECTION Inspect related harness.
Below 1.0
For less than approx. 2 seconds after turning engine switch on.
Temperature control dial
Action
B+
While cranking
While cranking P
Voltage (V)
B+ Below 1.0
Inspect FICD solenoid
B+
valve No.2. + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION Inspect related harness.
–
–
B+
Inspect TCV. + CONTROL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION Inspect related harness.
is not at OFF Engine coolant temperature is above 60°C {140°F}. Q Q*1
– Timer control
– TCV
– Engine switch is on. Idle
R
–
R*3
EGR valve control
S S*1
– Diagnostic test mode
Below 1.0
– EGR solenoid valve
– Engine switch is on. Idle
– Data link connector (DLC) (Terminal TEN)
T
–
–
T*1
DTC output
Data link connector (DLC) (Ter (Terminal FEN)
Below 1.0 –
Engine switch is on on.
– B+
–
Open terminal TEN
B+
Short terminal TEN
Below 1.0
–
–
No DTC output
Below 1.0
DTC output
0—B+
– Inspect EGR solenoid
valve. + EMISSION SYSTEM, SYSTEM EGR SOLENOID VALVE INSPECTION Inspect related harness. – Inspect related harness.
– Inspect related harness.
*1:
Europe and UK Turkey and General (R.H.D., L.H.D.) *3: WL Turbo for Europe and UK
CONTINUED
*2:
F2–31
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CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
NE SENSOR INSPECTION Note Perform the following test only when directed. 1. Disconnect the NE sensor connector. 2. Measure the resistance between the NE sensor connector terminals A and B by using an ohmmeter.
A
Note Perform the following test only when directed. 1. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor. 4. Place the sensor in water with a thermometer, and heat the water gradually.
B
Specification 800—920 Ω 3. If not as specified, replace the NE sensor. Tightening torque 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
A
4. If NE sensor is okay, but PCM terminal F voltage is out of specification, inspect the following: Open circuit Engine speed (input) circuit (NE sensor connector terminal A and PCM connector terminal F) GND circuit (NE sensor connector terminal B and PCM connector terminal B) Short circuit NE sensor connector terminal A and PCM connector terminal F to GND 5. Repair or replace faulty areas. 6. Reconnect the NE sensor connector.
B
5. Measure the resistance between engine coolant temperature sensor terminals A and B by using an ohmmeter. Specification Water temperature (°C {°F})
Resistance (kΩ)
20 {68}
2.27—2.73
80 {176}
0.29—0.34
6. If not as specified, replace the ECT sensor. 7. Refill the radiator with the specified engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 8. Install the ECT sensor. Tightening torque 16—23 N·m {1.6—2.4 kgf·m, 12—17 in·lbf} 9. If ECT sensor is okay, but PCM terminal E voltage is out of specification, inspect as follows:
CONTINUED
F2–32
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CONTROL SYSTEM Open circuit Reference voltage circuit (ECT sensor connector terminal A and PCM connector terminal E through common connector) GND circuit (ECT sensor connector terminal B and PCM connector terminal B through common connector) Short circuit ECT sensor connector terminal A and PCM connector terminal E through common connector to GND 10. Repair or replace faulty areas. 11. Reconnect the ECT sensor connector.
Open circuit Power supply circuit (Idle switch connector terminal E and PCM connector terminal 2H through common connector) GND circuit (Idle switch connector terminal and body GND)
IDLE SWITCH INSPECTION Europe and UK Continuity Inspection
E
C
A
H
F
D
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the 8-pin connector of FIP. 3. Inspect for continuity between the idle switch terminal E and ground using an ohmmeter.
A
C
E
G
B
D
F
H
Short circuit Power supply circuit (Idle switch connector terminal E and PCM connector terminal H through common connector to GND) 6. Repair or replace faulty areas. 7. Reconnect the 8-pin connector of FIP. CONTROL LEVER POSITION SENSOR INSPECTION Europe and UK Output Voltage Inspection Note Perform the following test only when directed.
COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
1. Verify that the FIP control lever is fully closed. 2. Turn the engine switch on and measure the PCM terminal J voltage.
Specification
Specification : Continuity
Measuring g condition
G
Terminal E
GND
Not accelerated Other
Measuring condition
Voltage (V)
Accelerator pedal is fully open.
Approx. 4.2
Accelerator pedal is fully closed.
Approx. 0.8—1.5
3. If not as specified, replace the control lever position sensor. When the reading is out of specification, send the FIP with the control lever position sensor to a distributor to repair. If the PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary.
Caution Turning the idle switch with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation. 4. If not as specified, loosen the idle switch locknut and adjust the continuity by turning the idle switch. 5. If not as specified, replace the idle switch. If the idle switch is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary.
Open circuit Constant voltage circuit (Control lever position sensor connector terminal B and PCM connector terminal A through common connector) Control lever position signal circuit (Control lever position sensor connector terminal A and PCM connector terminal J through common connector) GND circuit (Control lever position sensor connector terminal C and PCM connector terminal B through common connector)
CONTINUED
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CONTROL SYSTEM
G
E
C
A
H
F
D
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Short circuit Control lever position sensor connector terminal B and PCM connector terminal A through common connector to GND Control lever position sensor connector terminal A and PCM connector terminal J through common connector to GND 4. Repair or replace faulty areas. 5. Reconnect the 8-pin connector of FIP.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM Using the Voltmeter 1. Turn the engine switch off. 2. Connect the DLC located in the engine compartment terminal TEN and GND using a jumper wire.
ON-BOARD DIAGNOSTIC SYSTEM Europe and UK only DTC READING PROCEDURE Using the SST (Self-Diagnosis Checker) 1. Connect the SSTs to the DLC located in the engine compartment and GND the black (negative) lead to the body.
Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
49 B019 9A0 DLC
3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B. 49 H018 9A1A
FEN
2. Set the select switch on the SST (self-diagnosis checker) to A. 3. Turn the dial switch on the SST (system selector) to 1, and the test switch to SELF TEST. 4. Turn the engine switch on. 5. Verify that the buzzer sounds for approximately 3 seconds and code “88” flashes for 5 seconds. If DTC is not detected, “00” will then be indicated. Note If the “88” does not flash, inspect +B terminal of the data link connector, and the related harnesses and connectors. If the “88” flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect. 6. If any DTCs are indicated, inspect the appropriate areas and repair as necessary. Note A DTC consists of four numbers. They are flashed one by one in the right window on the display. (“1” is always shown on the left window.) When there are multiple malfunctions, the codes are displayed in numerical order. 7. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE.) 8. Remove the SSTs.
DLC TEN
+B
GND
4. turn the engine switch on. 5. The voltmeter indicates the battery positive voltage for approximately 3 seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the voltmeter’s needle. If DTC is not detected, the needle does not move. 7. If any DTCs are indicated, inspect the appropriate areas and repair as necessary. 8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE.) 9. Remove the voltmeter and the jumper wire. AFTER REPAIR PROCEDURE 1. After repairs, disconnect the negative battery cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable. 2. Warm up the engine to normal operating temperature. Note If the engine will not start, keep the starter operated for 5-6 seconds. 3. Perform the “DTC READING PROCEDURE” again. 4. Verify that the DTC is not detected.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table DTC No.
Indicator Pattern
09
Engine coolant temperature (ECT) sensor malfunction
12
Control lever position sensor malfunction
36
Glow plug relay malfunction
DTC 09 DETECTION CONDITION POSSIBLE CAUSE
ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION Input value to PCM is excessively high or low for more than 2.0 sec. ECT sensor malfunction Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B
STEP 1 2
3 4
5
6
Condition
INSPECTION
ACTION
Does ECT sensor or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 6.
No
Go to next step.
Disconnect ECT sensor connector. Turn engine switch on. Is there 5 V at connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness. (PCM terminal B–ECT sensor terminal B)
Is there continuity between connector terminal A and PCM terminal E?
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 6.
Is ECT sensor okay? + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
Yes
Go to next step.
No
Replace ECT sensor, then go to Step 6.
Clear DTC from memory. Is same code No. present after performing “After Repair Procedure”?
Yes
Go to Step 1.
No
Intermittent poor connection in harnesses or connector. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing “After Repair Procedure”?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
PCM (20 PIN) ECT SENSOR E J
A
B
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM
DTC 12 DETECTION CONDITION
CONTROL LEVER POSITION SENSOR MALFUNCTION Input voltage from control lever positIon sensor is below 0.1 V or above 4.75 V when continued for 1.0
sec. When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V. Control lever position sensor malfunction Idle switch malfunction Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-
POSSIBLE CAUSE
nal B Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to
PCM terminal J Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to
PCM terminal A Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H
STEP 1
INSPECTION
ACTION
Does control lever position sensor connector or PCM connector have poor connection?
Yes
Repair or replace connectors, then go to Step 7.
No
Go to next step.
Disconnect control lever position sensor connector. Turn engine switch on. Is there 5 V at connector terminal B?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness. (PCM terminal A–control lever position sensor terminal B)
Is there continuity between connector terminal A and PCM terminal J?
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 7.
Is there continuity between connector terminal C and PCM terminal B?
Yes
Replace control lever position sensor, then go to Step 7.
No
Repair or replace wiring harness, then go to Step 7.
5
Is there continuity between connector terminal E and PCM terminal H?
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 7.
6
Is idle switch okay? + CONTROL SYSTEM SYSTEM, IDLE SWITCH INSPECTION
Yes
Go to next step.
No
Replace idle switch.
Clear DTC from memory. Is same code No. present after performing “After Repair Procedure”?
Yes
Go to Step 1.
No
Intermittent poor connection in harness or connector. Repair connector and/or harness, then go to next step.
Clear DTC from memory. Is there any DTC present after performing “After Repair Procedure”?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
2
3 4
7
8
CONTROL LEVER POSITION SENSOR PCM (20 PIN) A J
B
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
G
E
C
A
H
F
D
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM
DTC 36
GLOW PLUG RELAY MALFUNCTION When the glow plug relay is on, current voltage signal of the relay below 1.0 V is inputted to the PCM
DETECTION CONDITION
continuously for more than 1.0 sec. When the glow plug relay is off, signal of the relay current voltage above 4.0 V is inputted to the PCM
continuously for more than 1.0 sec. POSSIBLE CAUSE STEP 1 2
3 4 5
6
7
Glow plug relay malfunction Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR) Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B) Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse INSPECTION
ACTION
Does glow plug relay connector or PCM connector have poor connection?
Yes
Repair or replace connectors, then go to Step 5.
No
Go to next step.
Remove glow plug relay. Is there continuity between connector terminal A and PCM terminal O? Is there continuity between connector terminal A (B) and PCM terminal I?
Yes
Go to next step.
No
Repair or replace wiring harness.
Is there continuity between connector terminal B and body GND?
Yes
Go to next step.
No
Repair or replace wiring harness.
Is there continuity between connector terminal A (R) and glow fuse?
Yes
Go to next step.
No
Repair or replace wiring harness.
Is glow plug relay okay? + INTAKE-AIR INTAKE AIR SYSTEM, SYSTEM GLOW PLUG RELAY INSPECTION
Yes
Go to next step.
No
Replace glow plug relay.
Clear DTC from memory. Is same code No. present after performing “After Repair Procedure”?
Yes
Go to Step 1.
No
Intermittent poor connection in harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing “After Repair Procedure”?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed. GLOW PLUG RELAY
PCM (20 PIN)
A A O
A B
I
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
(WIRE COLOR: R)
(WIRE COLOR: B)
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–38
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TROUBLESHOOTING
TROUBLESHOOTING FOREWORD Before processing with the following troubleshooting, refer to section GI to understand the basic troubleshooting procedure. No.
TROUBLESHOOTING ITEM TABLE Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart. If a diagnostic trouble code is displayed, proceed with inspection steps for the code.
TROUBLESHOOTING ITEMS
DESCRIPTION
1
Melts main or other fuse
2
Will not crank
Starter does not work.
—
3
Hard start/long crank/erratic start/erratic crank
Starter cranks engine at normal speed but engine requires excessive cranking. Battery is in normal condition.
4
Engine stalls
Engine stops unexpectedly at idle and/or after start.
5
Cranks normally but will not start
Starter cranks engine at normal speed but engine will not run. Refer to “ENGINE STALLS” if this symptom appears after engine stall. Fuel is in tank Battery is in normal condition.
6
Slow return to idle/fast idle
Engine takes more time than normal to return to idle speed. Engine speed continues at fast idle after warm-up.
7
Engine runs rough/rolling idle
Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. Idle speed is too slow and engine shakes excessively.
8
Runs on
Engine runs after engine switch is turned off.
9
Engine stalls/quits
Acceleration/cruise
Engine stops unexpectedly at beginning of acceleration during acceleration or while cruising.
Engine runs rough
Acceleration/cruise
Engine speed fluctuates during acceleration or cruising.
Misses
Acceleration/cruise
Engine misses during acceleration or cruising.
Buck/jerk
Acceleration/cruise/ deceleration
Vehicle bucks/jerks during acceleration, cruising, or deceleration.
Hesitation/stumble
Acceleration
Momentary pause at beginning of acceleration or during acceleration.
After start At idle
Surges
Acceleration/cruise
Momentary minor irregularity in engine output.
10
Lack/loss of power
Acceleration/cruise
Performance is poor under load (i.e. power down when climbing hills).
11
Poor fuel economy
Fuel economy is unsatisfactory.
12
High oil consumption/leaks
Oil consumption is excessive.
13
Cooling system concerns
Overheating
Engine runs at higher than normal temperature/overheats.
14
Cooling system concerns
Runs cold
Engine does not reach normal operating temperature.
15
Excessive black smoke
Excessive black smoke is observed in exhaust gas.
16
Engine noise
Engine noise from under hood.
17
Vibration concerns (engine)
Vibration from under hood or driveline.
18
A/C does not work.
A/C compressor magnetic clutch does not engage when A/C is turned on.
19
A/C always on/A/C compressor runs continuously.
A/C compressor magnetic clutch does not disengage.
20
Intermittent concerns
Symptom occurs randomly and is difficult to diagnose.
CONTINUED
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SYMPTOM TROUBLESHOOTING: Symptom 1-Melts main or other fuse
F2-40
Symptom 2-Will not crank
F2-41
Symptom 3-Hard start/long crank/erratic start/erratic crank
F2-42-43
Symptom 4-Engine stalls-after start/at idle
F2-43-44
Symptom 5-Cranks normally but will not start
F2-45-46
Symptom 6-Slow return to idle/fast idle
F2-46
Symptom 7-Engine runs rough/rolling idle
F2-47-48
Symptom 8-Runs on
F2-49
Symptom 9-Engie stalls/quits-acceleration/cruise -
Engine runs rough – acceleration/cruise
-
Misses-acceleration/cruise
-
Buck/jerk – acceleration/cruise/deceleration
-
Hesitation/stumble – acceleration
-
Surges – acceleration/cruise
F2-49-50
Symptom 10-Lack/loss of power-acceleration/cruise
F2-51-52
Symptom 11-Poor fuel economy
F2-53
Symptom 12-High oil consumption/leaks
F2-54
Symptom 13-Cooling system concerns-overheating
F2-55
Symptom 14-Cooling system concerns-runs cold
F2-55
Symptom 15-Excessive black smoke
F2-56
Symptom 16-Engine noise
F2-56-58
Symptom 17-Vibration concerns (engine)
F2-58
Symptom 18-A/C does not work
F2-58-59
Symptom 19-A/C is always on/a/c compressor runs continuously
F2-59-60
Symptom 20-Intermittent concerns
F2-60
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TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1
MELTS MAIN OR OTHER FUSE
TROUBLESHOOTING HINTS Inspect the condition of the fuse.
Deterioration
Shorted harness
Repair shorted harness and replace fuse
fuse
Damaged Fuse
Replace fuse
Related Wiring Harness
MAIN (100 A)
Main fuse Engine switch Generator PCM Blower relay Blower fan motor A/C relay Refrigerant pressure switch
HEAD (30 A)
HEAD fuse Generator Glow plug relay Glow plugs
GLOW (60 A) ENGINE (15 A)
Engine fuse PCM FICD solenoid valve No.1 FICD solenoid valve No.2 FCV
CONTINUED
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TROUBLESHOOTING
SYMPTOM 2 DESCRIPTION
WILL NOT CRANK Starter does not work. Open starter circuit between battery and starter through engine switch Starter malfunction Seized/hydrolocked engine, flywheel
POSSIBLE CAUSE STEP 1
INSPECTION
ACTION
RESULTS
Verify the following: Battery condition Battery connection Fuses Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
2
Turn engine switch to START. Is clicking sound heard from starter?
Yes
Go to next step.
No
Go to Step 6.
3
Do any other electrical accessories work?
Yes
Go to next step.
No
Inspect the charging system. + Section G, CHARGING SYSTEM
Disconnect battery negative cable. Disconnect engine switch and starter connectors. Inspect for electrical connections, loose wire, bent or corroded terminals. Inspect Ins ect for continuity on following circuits: Engine switch connector terminal STA and starter terminal S Battery positive cable and starter magnet switch terminal B. Are all circuits okay?
Yes
Go to next step.
No
Repair or replace open circuit.
Inspect engine switch. + Section T, POWER SYSTEM, IGNITION SWITCH INSPECTION. Is engine switch okay?
Yes
Go to next step.
No
Replace engine switch.
Inspect starting system. Is starting system okay?
Yes
Inspect for seized/hydrolocked engine, flywheel. + Section H, CLUTCH, FLYWHEEL INSPECTION
No
Service as required. + Section G, STARTING SYSTEM, STARTER INSPECTION
4
5
6
CONTINUED
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TROUBLESHOOTING
SYMPTOM 3 DESCRIPTION
HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK Starter cranks engine at normal speed but engine requires excessive cranking. Battery is in normal condition.
POSSIBLE CAUSE
STEP 1
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating Glow system malfunction
INSPECTION
Fuel leakage Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Fuel line clogging ACTION
RESULTS
Verify the following: Fuel quality including water contamination Loose bands on intake-air system y Cracks on intake-air system parts Air cleaner element restriction Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
2
Is engine overheating?
Yes
Go to flowchart No.13 for “COOLING SYSTEM CONCERNS OVERHEATING”.
No
Go to next step.
3
Does engine start normally after warm-up?
Yes
Inspect glow system operation. + SYSTEM INSPECTION, Glow System Inspection Replace any defective parts as necessary. If quick start system is okay, go to next step.
No
Go to next step.
Yes
Go to next step.
No
Adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect for fuel leakage from fuel pipe. Is any fuel leakage found in fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
7
Measure engine compression. Is compression okay?
Yes
Go to Step 9.
No
Go to next step.
8
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat. Worn valve stem or valve guide. Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace the timing belt.
Yes
Go to next step.
No
Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
4
5 6
9
Is idle speed correct?
Is there any restriction in exhaust system?
Inspect injection timing. Is injection timing okay?
CONTINUED
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TROUBLESHOOTING
STEP 10
INSPECTION Remove and inspect injection nozzle as follows: Clogged nozzle Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
SYMPTOM 4 DESCRIPTION POSSIBLE CAUSE
STEP 1
ACTION
RESULTS Yes
Remove FIP. Inspect FIP. If FIP okay, inspect fuel line for clogging.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
ENGINE STALLS – AFTER START/AT IDLE Engine stops unexpectedly at idle and/or after start.
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction
INSPECTION Note: The following test should be performed on vehicles with immobilizer system. Go to next step for vehicles without immobilizer system. system
Fuel leakage Fuel filter clogging Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction ACTION
RESULTS Yes
Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.
No
Go to next step.
Verify the following: Fuel quality including water contamination Loose bands on intake-air system y Cracks on intake-air system parts Air cleaner element restriction Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 2.
3
Is engine overheating?
Yes
Go to flowchart No.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”.
No
Go to next step.
4
Does engine run normally after warm-up?
Yes
Go to next step.
No
Go to Step 6
5
Inspect glow system operation, + SYSTEM INSPECTION, Glow System Inspection. Is quick start system operation normal?
Yes
Go to next step.
No
Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C always ON/A/C compressor runs continuously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
Does immobilizer indicator light flash and indicate? 2
6
Note: If the following test cannot be performed due to engine stalls, go to step. next ste Connect the pressure gauge to A/C lines. Turn the fan switch on. Is pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
CONTINUED
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TROUBLESHOOTING
STEP 7
INSPECTION
ACTION
RESULTS
Inspect FICD system operation. + SYSTEM INSPECTION, FICD System Inspection Is FICD operation normal?
Yes
Go to next step.
No
Inspect the following: Engine coolant temperature sensor + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE SENSOR INSPECTION Vacuum pump Vacuum leakage around vacuum pump or fittings FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION FICD actuator PCM terminal voltage, J Open circuit between FICD solenoid No.1 connector terminal B and PCM connector terminal C Open circuit between FICD solenoid No.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. If FICD system is okay, go to next step.
Depress accelerator pedal slightly. Crank the engine.
Yes
Inspect and adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT If symptom still appears, go to next step.
Does engine start now?
No
Go to next step.
9
Inspect fuel leakage from fuel pipe. Is any fuel leakage found in fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
10
Measure engine compression. Is compression okay?
Yes
Go to Step 12.
No
Go to next step.
11
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve seat or valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt.
Inspect injection timing. Is injection timing okay?
Yes
Go to next step.
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Inspect fuel filter for clogging. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
Is valve clearance correct?
Yes
Remove FIP. Inspect FIP.
No
Adjust valve clearance.
8
12
13 14
15
CONTINUED
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TROUBLESHOOTING
SYMPTOM 5
POSSIBLE CAUSE
STEP 1
CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION
Starter cranks engine at normal speed but engine will not run. Refer to “ENGINE STALLS” if this symptom appears after engine stall. Fuel is in tank. Battery is in normal condition. Poor fuel quality Fuel filter clogged Air cleaner restriction Incorrect injection timing FCV malfunction FIP malfunction Low engine compression Injection nozzle malfunction Fuel leakage
INSPECTION Note: The following test should be performed on vehicles with immobilizer system. Go to next step for vehicles without immobilizer system. system
ACTION
RESULTS Yes
Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.
No
Go to next step.
Verify the following: Fuel quality including water contamination Loose bands on intake-air system Cracks on intake-air system parts Air cleaner element restriction Fuses Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 2.
3
Turn engine switch to ON. Is FCV operation sound heard?
Yes No
4
Measure engine compression. Is compression okay?
5
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes No Yes
Go to next step. Inspect for the following: Stuck FCV Open circuit in FCV Open wiring harness between engine switch and FCV. Poor ground of FCV. Go to step 6. Go to next step. Inspect for the following: Burnt valve Worn piston, piston ring or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve stem or valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt. Go to next step. Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Does immobilizer indicator light flash and indicate? 2
No
6
Inspect injection timing. Is injection timing okay?
Yes No
7
Inspect fuel filter for clogging. Is fuel filter okay?
8
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
Yes No Yes No
Go to next step. Replace fuel filter cartridge. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
CONTINUED
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TROUBLESHOOTING
STEP 9
INSPECTION Is valve clearance correct?
RESULTS Yes No
SYMPTOM 6
Engine takes more time than normal to return to idle speed. Engine speed continues at fast idle after warm-up. Malfunction of ECT sensor Thermostat stuck open FICD malfunction
POSSIBLE CAUSE
1
2
3
Remove FIP. Inspect FIP. Adjust valve clearance.
SLOW RETURN TO IDLE/FAST IDLE
DESCRIPTION
STEP
ACTION
INSPECTION
Injection timing is incorrect. Accelerator cable free play incorrect adjustment Idle speed incorrect adjustment
ACTION
RESULTS
Inspect FICD system operation. + SYSTEM INSPECTION, FICD System Inspection. Is FICD operation normal?
Yes
Go to next step.
No
Inspect the following: ECT sensor + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION FICD actuators. PCM terminal voltage (J) + CONTROL SYSTEM, PCM INSPECTION Short to ground circuit between FICD solenoid valve No.1 connector terminal B and PCM connector terminal C. Short to ground circuit between FICD solenoid valve No.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. If FICD system is okay, go to next step.
Inspect injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT. Is injection timing okay?
Yes
Go to next step.
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Remove thermostat and inspect operation. + section E, THERMOSTAT, THERMOSTAT INSPECTION.
Yes
Inspect for free play of accelerator cable. Adjust free play as necessary. If free play is okay, inspect and adjust idle and/or idleup speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
No
Replace thermostat.
Is thermostat okay?
CONTINUED
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TROUBLESHOOTING
SYMPTOM 7 DESCRIPTION
POSSIBLE CAUSE
STEP 1
2
3 4
ENGINE RUNS ROUGH/ROLLING IDLE Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. Idle speed is too slow and engine shakes excessively.
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction
INSPECTION
ACTION
Verify the following: Fuel quality including water contamination Air cleaner element restriction
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
Is engine overheating?
Yes
Go to flowchart No.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”.
No
Go to next step.
Yes
Go to next step.
No
Go to Step 5.
Yes
Go to Step 6.
No
Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C always ON/ A/C compressor runs continuously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
Yes
Go to next step.
No
Inspect the following: Engine coolant temperature sensor + CONTROL SYSTEM, ECT SENSOR INSPECTION Vacuum pump Vacuum leaks around vacuum pump or fittings FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION Inspection FICD actuators PCM terminal voltage (J) + CONTROL SYSTEM, PCM INSPECTION Open circuit between FICD solenoid valve No.1 connector terminal B and PCM connector terminal C. Open circuit between FICD solenoid valve No.2 connector terminal B and PCM connector terminal P. Repair or replace any defective part as necessary. If FICD system is okay, go to next step.
Does engine run normally after warm-up? Inspect glow system operation. + SYSTEM INSPECTION INSPECTION, Glow System Inspection.
Note: If the following test cannot be performed due to engine stalls, go to step. next ste Connect the pressure gauge to A/C (if equipped) lines. Turn the blower switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
6
Fuel leakage Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction
RESULTS
Is glow system operation normal? 5
Inspect for FICD system operation. + SYSTEM INSPECTION, FICD System Inspection Is FICD operation normal?
CONTINUED
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TROUBLESHOOTING
STEP 7
8 9
INSPECTION
ACTION
RESULTS
Depress accelerator pedal slightly. Crank the engine.
Yes
Inspect and adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT. If symptom still appears, go to next step.
Does engine start now?
No
Go to next step.
Inspect fuel leakage from fuel pipe. Is any fuel leakage found on fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
Yes
Go to next step.
No
Repair or replace as necessary.
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
10
Measure engine compression. Is compression okay?
Yes
Go to Step12.
No
Go to next step.
11
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect follows: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem or valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace timing belt.
Inspect injection timing. Is injection timing okay?
Yes
Go to next step.
No
Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
13
Inspect fuel filter for clogging. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
14
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the fuel injection nozzle. Incorrect valve opening pressure: Adjust fuel injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
Is valve clearance correct?
Yes
Remove fuel injection pump. Inspect fuel injection pump.
No
Adjust valve clearance.
12
15
CONTINUED
F2–48
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TROUBLESHOOTING
SYMPTOM 8
RUNS ON
DESCRIPTION
Engine runs after engine switch is turned off. FCV malfunction
POSSIBLE CAUSE STEP 1
INSPECTION Run the engine at idle speed. Disconnect the FCV connector. Verify that the engine stops. Does the engine stop?
POSSIBLE CAUSE
2
3 4
5
6
Inspect for the following: Short to power line between engine switch and FCV. Repair or replace wire harness.
No
Inspect for FCV stuck to open.
Engine stops unexpectedly at beginning of acceleration, during acceleration or while cruis-
DESCRIPTION
1
Yes
ENGINE STALLS/QUITS-ACCELERATION/CRUISE ENGINE RUNS ROUGH-ACCELERATION/CRUISE MISSES-ACCELERATION/ CRUISE BUCK/JERK-ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE-ACCELERATION SURGES-ACCELERATION/CRUISE
SYMPTOM 9
STEP
ACTION
RESULTS
ing. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output.
Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Fuel leakage
INSPECTION Is idle speed stable?
Glow system malfunction Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression Clutch slippage ACTION
RESULTS Yes
Go to next step.
No
Go to flowchart No.7 “ENGINE RUNS ROUGH/ROLLING IDLE”.
Yes
Go to flowchart No.13 “COOLING SYSTEM CONCERNS OVERHEATING”.
No
Go to next step.
Yes
Go to next step.
No
Go to Step 5.
Inspect for glow system operation. + SYSTEM INSPECTION, Glow System Inspection. Is glow system operation normal?
Yes
Go to next step.
No
Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection
Connect the pressure gauge to A/C lines. Turn the blower switch on. Is the pressure within specifications? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
Inspect air cleaner for clogging. Is air cleaner okay?
Yes
Go to next step.
No
Clean or replace air cleaner element.
Is engine overheating?
Does symptom disappear after warm-up?
CONTINUED
F2–49
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TROUBLESHOOTING
STEP 7
INSPECTION Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 9.
ACTION
RESULTS Yes
Retighten the hose band. If the concern is resolved, complete the inspection. If the concern still exists, go to next step.
No
Go to next step.
Inspect for improper operation, kinks, clogs, or disconnection on the wastegate actuator. + INTAKE-AIR SYSTEM, WASTEGATE ACTUATOR INSPECTION. Is actuator okay?
Yes
Turbocharger is okay. Go to next step.
No
Repair or replace as necessary. If the concern is resolved, complete the inspection. If the concern still exists, the turbocharger is okay. Go to next step.
Remove injection nozzle. Inspect injection nozzle for the following Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket. Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
Is there any restriction in exhaust system?
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect for fuel leakage from pipe. Is any fuel leakage found in fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect fuel filter for clogs. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
13
Measure engine compression. Is compression okay?
Yes
Go to Step 15.
No
Go to next step.
14
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace timing belt.
Yes
Inspect follows: Clutch slippage FIP
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Inspect the hose band between the following parts: T b h i and d air i Turbocharger compressor h housing cleaner Turbocharger compressor housing and charge air cooler. Is the hose band loose? 8
9
10 11 12
15
Inspect injection timing. Is injection timing okay?
CONTINUED
F2–50
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TROUBLESHOOTING
SYMPTOM 10
LACK/LOSS OF POWER-ACCELERATION/CRUISE
DESCRIPTION
Performance is poor under load (i.e. power down when climbing hills).
POSSIBLE CAUSE
STEP 1
Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Clutch slippage Fuel leakage
INSPECTION Is idle speed stable?
Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Turbocharger malfunction Brake system drags EGR system malfunction (WL Turbo) ACTION
RESULTS Yes
Go to next step.
No
Go to flowchart No.7 “ENGINE RUNS ROUGH/ROLLING IDLE”.
2
Is engine overheating?
Yes
Go to flowchart No. 13 “COOLING CONCERNS OVERHEATING”.
No
Go to next step.
3
Connect the pressure gauge to A/C lines. Turn the fan switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”. For other symptoms, inspect the following: Refrigerant charging amount. Cooling fan operation.
Inspect air cleaner for clogging. Is air cleaner okay?
Yes
Go to next step.
No
Clean or replace air cleaner element.
Yes
Retighten the hose band. If the concern is resolved, complete the inspection. If the concern still exists, go to next step.
No
Go to next step.
Inspect the wastegate actuator for improper operation, kinks, clogs, or disconnection. + INTAKE-AIR SYSTEM, WASTEGATE ACTUATOR INSPECTION. Is actuator okay?
Yes
Go to next step.
No
Repair or replace as necessary. If the concern is resolved, complete the inspection. If the concern still exists, the turbocharger is okay. Go to next step.
Remove the parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger primary compressor wheel is bent,, damaged, g , or interfering g with the housing on the vehicle. + INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Turn the turbocharger compressor wheel by hand hand. Does the wheel turn easily and smoothly?
Yes
Go to next step.
No
Replace the turbocharger.
4 5
Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 13. Inspect the hose band between the following parts: Turbocharger T b h compressor h housing i and d air i cleaner Turbocharger compressor housing and charge air cooler. Is the hose band loose?
6
7
8
9
CONTINUED
F2–51
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TROUBLESHOOTING
STEP 10
INSPECTION Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicles. Note: Inspect all fins on each turbine wheel.
ACTION
RESULTS Yes
Replace the turbocharger.
No
Go to next step.
Is there any problem? 11
Is any engine oil found inside the turbocharger turbine housing?
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step.
No
Go to next step.
12
Is any engine oil found inside the turbocharger compressor housing?
Yes
Wipe the oil off the vehicle and install all removed parts in Step 7. Then, go to next step.
No
The turbocharger is okay. Install all removed parts in Step 7. Then, go to next step.
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket. Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
14
Is there any restriction in exhaust system?
Yes
Repair or replace as necessary.
No
Go to next step.
15
Inspect fuel leakage from pipe. Is any fuel leakage found on fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect fuel filter for clogging. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
Yes
Go to next step.
Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
No
Repair or replace as necessary.
Measure engine compression. Is compression okay?
Yes
Go to Step 20.
No
Go to next step.
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt.
Yes
Inspect follows: Brake system dragging Clutch slippage FIP
No
Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
13
16 17
18 19
20
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system.
Inspect injection timing. Is injection timing okay?
F2–52
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TROUBLESHOOTING
SYMPTOM 11 DESCRIPTION POSSIBLE CAUSE
STEP 1
2
POOR FUEL ECONOMY Fuel economy is unsatisfactory. Idle speed or idle-up speed incorrect adjustment Accelerator cable free play incorrect adjustment Air cleaner restriction Engine cooling system malfunction Improper transmission fluid level Poor fuel quality Improper coolant level Improper engine compression INSPECTION
Inspect the following: Fuel quality including water contamination Air cleaner element for restriction Transmission fluid level Coolant level Are all items okay? Inspect for idle speed and idle-up speed. + ENGINE TUNE-UP, TUNE-UP IDLE-UP SPEED ADJUSTMENT. Is idle-up speed within specifications?
3
Inspect fuel leakage from pipe. Is any ffuel leakage ffound in ffuel pipe? ?
4
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket. Is injection nozzle okay?
5
Is there restriction in exhaust system?
6
Is brake system functioning properly?
7
8 9
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay? Measure engine compression. Is compression okay? ? Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
RESULTS Yes
Inspect injection timing. Is injection timing okay?
Exhaust system clogged Injection timing incorrect Injection nozzle malfunction FIP malfunction High idle speed High idle-up speed FICD malfunction Fuel leakage Brake dragging EGR system malfunction (WL Turbo) ACTION
Go to next step.
No
Service as necessary and repeat Step 1.
Yes
Go to next step.
No
Go to flowchart No.6 “SLOW RETURN TO IDLE/FAST IDLE”.
Yes No Yes No
Yes No Yes No Yes
Repair or replace as necessary. Go to next step. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Inspect exhaust system. Go to next step. Go to next step. Inspect for cause. Go to next step.
No
Repair or replace as necessary.
Yes No Yes
Go to Step 10. Go to next step. Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing belt . If timing belt is broken, damaged or cracked, replace timing belt.
No
10
Yes
Inspect for the following: FIP
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
F2–53
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TROUBLESHOOTING
SYMPTOM 12
HIGH OIL CONSUMPTION/LEAKS
DESCRIPTION
Oil consumption is excessive. Improper engine oil level Improper dipstick Improper engine oil viscosity
POSSIBLE CAUSE STEP 1
2
INSPECTION Inspect the following: Proper dipstick Pro Proper er engine viscosity Engine oil level Are all items okay?
4
5
ACTION
RESULTS Yes
Go to next step.
No
Service as necessary and repeat Step 1.
Yes
Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Turn the turbocharger compressor wheel by hand hand. Does the wheel turn easily and smoothly?
Yes
Go to next step.
No
Replace the turbocharger.
Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicles.
Yes
Replace the turbocharger.
No
Go to next step.
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step.
No
Go to next step.
Is any engine oil found inside the turbocharger compressor housing?
Yes
Wipe the oil off the vehicle. Then, go to next step.
No
Go to next step.
Is any engine oil found around oil pipes attached on the turbocharger center housing?
Yes
If the oil leaked from the damaged pipe, replace the oil pipe. Then, go to next step.
No
Go to next step.
Is any engine oil found inside the air intake pipes or Hoses?
Yes
Wipe the engine oil off.
No
The turbocharger is okay. Install all parts removed in step 2. Then, go to next step.
Measure engine compression. Is compression okay?
Yes
Inspect oil leakage from outside of engine.
No
Inspect for the following: Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder. Service as necessary.
Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 10. Remove the parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger primary compressor wheel is bent, damaged, or interfering with the housing on the vehicle. + INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION Is there any problem?
3
Engine internal part malfunction Oil leak Turbocharger malfunction
Note: Inspect all fins on each turbine wheel. Is there any problem? 6
7 8
9
10
Is any engine oil found inside the turbocharger turbine housing?
F2–54
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TROUBLESHOOTING
SYMPTOM 13
COOLING SYSTEM CONCERNS—OVERHEATING
DESCRIPTION
Engine runs at higher than normal temperature/overheats.
POSSIBLE CAUSE
STEP 1
2
3
Water temperature gauge or sender unit malfunc-
Cooling fan malfunction Low drive belt tension Drive belt damage Improper coolant level Thermostat malfunction Radiator clogging A/C system malfunction
INSPECTION
tion Improper or damaged radiator cap Radiator hose damage Coolant leakage (engine internal, turbocharger, ex-
ternal) ACTION
RESULTS
Inspect the following: Engine coolant level Coolant leakage Radiator condition Collapsed or restricted radiator hoses Radiator pressure cap Drive belt tension Drive belt Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
Connect the pressure gauge to A/C lines. Turn the blower switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”. For other symptoms, inspect the following: Refrigerant charging amount Cooling fan operation
Inspect water temperature sender unit. Is water temperature sender unit okay?
Yes
Inspect thermostat. + section E, THERMOSTAT, THERMOSTAT INSPECTION
No
Replace water temperature sender unit.
SYMPTOM 14
COOLING SYSTEM CONCERNS—RUNS COLD
DESCRIPTION
Engine does not reach normal operating temperature.
POSSIBLE CAUSE STEP 1
Thermostat malfunction
INSPECTION Remove the thermostat from vehicle. Inspect thermostat. + section E, THERMOSTAT, THERMOSTAT INSPECTION INSPECTION. Is thermostat okay?
RESULTS
ACTION
Yes
Inspect water temperature sender unit operation. + section T, INSTRUMENT CLUSTER, WATER TEMPERATURE SENDER UNIT INSPECTION
No
Replace thermostat.
CONTINUED
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TROUBLESHOOTING
SYMPTOM 15
EXCESSIVE BLACK SMOKE
DESCRIPTION
Excessive black smoke is observed in exhaust gas.
POSSIBLE CAUSE STEP
Air cleaner element restriction Incorrect fuel injection timing Injection nozzle malfunction
INSPECTION
1
Does any other symptom exist?
2
Inspect air cleaner element for clogging. Is air cleaner element okay?
3
Inspect injection timing. Is injection timing okay?
4
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
5
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
6
Measure engine compression. Is compression okay?
RESULTS Yes No Yes No Yes No
Yes
No
Repair or replace as necessary.
Yes No
Inspect fuel injection pump. Inspect for the following: Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder. Service as necessary.
Yes No
ENGINE NOISE
DESCRIPTION
Engine noise from under hood.
ACTION Go to appropriate flow chart. Go to next step. Go to next step. Repair or replace air cleaner element. Go to next step. Inspect TCV (if equipped). + FUEL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Go to next step.
SYMPTOM 16 POSSIBLE CAUSE
FIP malfunction Low engine compression EGR system malfunction (WL Turbo)
Engine internal damage Timing belt displacement Injection nozzle malfunction Loose attaching bolts or worn parts
Improper drive belt tension Air leaks from intake-air system Turbocharger operating noise EGR system malfunction (WL Turbo)
CONTINUED
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TROUBLESHOOTING
STEP 1
INSPECTION Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 9. Remove the necessary parts arts to inspect ins ect the turbocharger. Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with the housing on the vehicle. Is there any problem?
2
3
4
5
ACTION Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Turn the turbocharger compressor wheel by hand hand. Does wheel turn easily and smoothly?
Yes
Go to next step.
No
Replace the turbocharger.
Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicle. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Is any engine oil found inside the turbocharger turbine housing?
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step. Go to next step. Wipe the oil off of the vehicle. Then, go to next step. Go to next step. Remove turbocharger. Inspect for cracks on center housing inlet surface. If cracks are found, replace turbocharger. If no cracks are found, DO NOT replace turbocharger. Replace gaskets, bolts, and nuts only. Then, go to next step. Go to next step. Retighten the loose bolts. If any bolt is missing, attach the appropriate new bolt. Turbocharger is okay. Install all removed parts in Step1. Go to next step. Inspect engine oil level or drive belt. Go to next step. Inspect drive belt. Go to next step. Inspect location of rattle for loose parts. Go to next step. Inspect for the following: Vacuum leaks Intake-air system leaks
6
Is any engine oil found inside the turbocharger compressor housing?
7
Is any exhaust gas leakage found around the location where the turbocharger is attached to the exhaust manifold?
8
RESULTS Yes
Are any of the attaching bolts of center housing and turbine housing loose?
No Yes No Yes
No Yes No
9
Is squeal, click, or chirp sound present?
10
Is rumble or grind sound present?
11
Is rattle sound present?
12
Is hiss sound present?
13
Is rap or roar sound present?
Yes No Yes No Yes No Yes
No Yes No
Go to next step. Inspect exhaust system for loose parts. Go to next step.
CONTINUED
F2–57
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TROUBLESHOOTING
STEP
INSPECTION
RESULTS Yes No
ACTION
14
Inspect the injection timing. Is injection timing okay?
15
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
Yes
Go to next step. Inspect TCV (if equipped) + FUEL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step.
No
Repair or replace as necessary.
Remove the fuel injection nozzle. Inspect for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Fuel dripping (fuel leakage) Is injection nozzle okay?
Yes
Inspect for the following: Metal flow Bent connecting rod Damaged valve seat After-leakege, clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
16
SYMPTOM 17
VIBRATION COCNERNS (ENGINE)
DESCRIPTION
Vibration from under hood or driveline.
POSSIBLE CAUSE STEP 1
No
Loose attaching bolts or worn parts Components malfunctions such as worn parts
INSPECTION Inspect the following components for loose attaching bolts or worn parts: Cooling fan Drive belt and pulley Engine mounts Exhaust system Are all items okay?
ACTION
RESULTS Yes
Inspect the following: Wheels Transmission and mounts Driveline Suspension Service as necessary.
No
Readjust or retighten engine mount installation position. Service as necessary for other parts.
SYMPTOM 18
A/C DOES NOT WORK.
DESCRIPTION
A/C compressor magnetic clutch does not engage when A/C is turned on.
POSSIBLE CAUSE
Improper refrigerant charging
amount Microswitch is stuck open. Open A/C magnetic clutch Open circuit in related wire harnesses Poor ground of A/C magnetic clutch A/C low/high pressure switch is stuck open.
A/C relay is stuck open. Seized A/C compressor Frost switch is stuck open. Open circuit in blower resistor Poor blower switch ground ECT sensor malfunction Improper magnet clutch clearance
CONTINUED
F2–58
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TROUBLESHOOTING
STEP
INSPECTION
RESULTS
1
Turn engine switch on. Set the fan switch to 1st, 2nd, 3rd, or 4th position. Verify the blower motor is operating. Is blower motor okay?
Yes
Go to next step.
No
Inspect for the following: Poor ground of fan switch Open circuit in blower resistor Poor contact of fan switch Blower relay is stuck open. Open circuit in blower relay coil Seized blower motor Open circuit in blower motor coil. Open circuit between blower motor and resistor Open circuit between fan switch and resistor Repair or replace as necessary.
Turn the engine switch on. Set the fan switch to 1st, 2nd, 3rd, or 4th position. Measure the voltage at PCM connector terminal G. + CONTROL SYSTEM, PCM INSPECTION Specification: Less than 2.7 V Is voltage correct?
Yes
Go to next step.
No
Inspect for the following: Frost switch is stuck open. Poor contact of microswitch in heater control unit Open circuit between PCM connector terminal G and frost switch connector terminal. Open circuit between frost switch connector terminal and fan switch connector terminal. Repair or replace as necessary.
Start the engine and run it at idle speed. Set the fan switch to 1st position. Measure the voltage at terminal of A/C relay connector terminal C. Specification: More than 10.5 V Is voltage correct?
Yes
Go to next step.
No
Inspect for the following: Open circuit in A/C relay coil Poor contact in A/C relay A/C relay stuck open Open circuit between PCM connector terminal L and A/C relay connector terminal. Open circuit in battery supply line Open circuit between engine switch and A/C relay connector terminal Engine coolant temperature sensor malfunction Repair or replace as necessary.
Disconnect the A/C magnetic clutch connector, Measure the A/C magnetic clutch connector terminal voltage. Specification: More than 10.5 V Is voltage okay?
Yes
Inspect for the following: Poor ground of A/C magnetic is clutch Open circuit in magnet is clutch coil Refrigerant charging amount Repair or replace as necessary.
No
Inspect for the following: Open circuit between pressure switch connector terminal and A/C magnetic clutch connector terminal Refrigerant charging amount A/C pressure switch is stuck open. Magnetic clutch clearance A/C compressor is seized. Repair or replace as necessary.
2
3
4
ACTION
SYMPTOM 19
A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION
A/C compressor magnetic clutch does not disengage.
POSSIBLE CAUSE
Improper magnetic clutch clear-
Short to power line between A/C relay and pressure
ance Short to ground circuit between PCM and frost switch Short to ground circuit between PCM and A/C relay
A/C low/high pressure switch is stuck to close. A/C relay is stuck to close. Frost switch is stuck to close.
switch
CONTINUED
F2–59
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TROUBLESHOOTING
STEP
INSPECTION
RESULTS
1
Turn the engine switch on. Turn the blower switch off. Measure the voltage at PCM connector terminal G. Specification: More than 2.7 V Is voltage correct?
Yes
Go to next step.
No
Inspect for the following: Short to ground circuit between PCM connector terminal G and frost switch Short to ground circuit between frost switch and blower switch connector terminal Repair or replace as necessary.
Start the engine and run it at idle speed. Turn the blower switch off. Measure the voltage at terminal of A/C relay connector terminal C. Specification: 0V Is voltage correct?
Yes
Inspect for magnetic is clutch clearance. Adjust it as necessary.
No
Inspect for the following: Short to ground circuit between PCM connector terminal L and A/C relay terminal C A/C relay is stuck to close. Short to power line between A/C relay connector terminal C and A/C pressure switch Short to power line between pressure switch and A/C compressor magnetic is clutch connector Repair or replace as necessary.
2
SYMPTOM 20
INTERMITTENT CONCERNS
DESCRIPTION
Symptom occurs randomly and is difficult to diagnose.
STEP 1
2
3
4
ACTION
INSPECTION
ACTION
RESULTS
Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous revious repairs and components replaced for a certain symptom?
Yes
Go to next step.
No
Go to symptom index.
Key off. If input is switch-type component, turn on manually. Turn engine switch off. Connect the voltmeter to the PCM terminals. Lightly ta tap on sus suspect ect com component onent, wiggle and pull each wire/connector at suspect component or PCM. Is any voltage out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal clamps.
No
Go to next step.
Start the engine and run it at idle speed. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM PCM. Are any voltages out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal clamps.
No
Go to next step.
Accurately spray water on suspect component wire, component, or vacuum line related to possible fault area. Is any voltage out of range, or suddenly change and go back into range, or was there a noticeable engine stumble?
Yes
Fault area is identified. If fault occurred while spraying on component: Replace part and verify repair. If fault occurred while spraying water: Inspect each wire for corrosion, bent, loose terminals, or poor wire terminal clamps. If fault occurred while spraying vacuum line: Repair vacuum hoses.
No
Inspect wire and connector at suspect component for corrosion, bent, loose terminals, or poor wire terminal crimps and high tension wire. Repair as necessary.
CONTINUED
F2–60
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TROUBLESHOOTING SYSTEM INSPECTION FICD System Inspection Fast-Idle Function 1. Verify that the FICD actuator rod is not pulled. 2. Verify that the engine is cold (ECT is below 20 °C {68 °F}). 3. Turn fan switch off. 4. Start the engine. 5. Verify that the FICD actuator rod is pulled.
11. If not, disconnect vacuum hose A from the FICD actuator and inspect if there is vacuum. VACUUM HOSE A
6. If not, disconnect the vacuum hoses from the FICD actuator and inspect if there is vacuum as shown. FICD ACTUATOR
Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction.
Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 7. If there is vacuum, consult your distributor for replacement of the FICD actuator. 8. If there is no vacuum, inspect the following. FICD solenoid valve No.1 and No.2 Loose or damaged vacuum hoses between FICD actuator, FICD solenoid valve No.1 and No.2, and vacuum pump. PCM terminal C, E and P voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wiring harness between FICD solenoid valve No.1 and PCM terminal C. Wiring harness between FICD solenoid valve No.2 and PCM terminal P. 9. Warm up the engine. (ECT above 20 °C {68 °F}). 10. Verify that the FICD actuator rod returns for one notch.
12. If there is no vacuum, consult your distributor for replacement of the FICD actuator. 13. If there is vacuum, inspect the following. FICD solenoid valve No.1 PCM terminal C, E voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wire harness between FICD solenoid valve No.1 and PCM terminal C 14. Warm up the engine (ECT is above 60 °C {140 °F}). 15. Verify that the FICD actuator rod returns completely.
16. If not, disconnect vacuum hose B from the FICD actuator and inspect if there is vacuum.
CONTINUED
F2–61
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TROUBLESHOOTING 7. If there is no vacuum, inspect the following: FICD solenoid valve No.2 PCM terminal G and P voltages
VACUUM HOSE B
(Refer to CONTROL SYSTEM,POWERTRAIN CONTROL MODULE (PCM) INSPECTION) Wiring harness between FICD solenoid valve No.2 connector terminal B and PCM terminal P Turbocharger Boost Pressure 1. Disconnect the air hose between the intake pipe and the boost compensator. 2. Connect a pressure gauge (range of measurement is 93.3 kPa {700 mmHg, 27.6 inHg}). BOOST COMPENSATOR PRESSURE GAUGE
Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 17. If there is no vacuum, consult your distributor for replacement of the FICD actuator. 18. If there is vacuum, inspect the following. FICD solenoid valve No.2 PCM terminal E, G and P voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wiring harness between FICD solenoid valve No.2 and PCM terminal P. A/C Idle-up Function 1. Start the engine. 2. Warm up the engine to normal operating temperature and run it at idle speed. 3. Set the fan switch at 1st position. 4. Verify that the FICD rod is pulled for one notch. 5. If not, disconnect the vacuum hose B from the FICD actuator and inspect if there is vacuum as shown.
TO INTAKE PIPE
3. Warm up the engine. 4. With the accelerator at the wide open throttle, increase the engine speed to 4800—5000 rpm and verify that the boost pressure is within the specification. Specification 60.0—73.3 kPa {0.62—0.74 kgf/cm2, 8.82—10.52 psi} 5. If not as specified, inspect the exhaust system. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM INSPECTION.) 6. If the exhaust system is normal, inspect the wastegate actuator. (Refer to INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION, Wastegate Actuator Inspection.) 7. If the wastegate actuator is normal, inspect the turbocharger. (Refer to INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION.)
VACUUM HOSE B
TCV Control Inspection (Europe and UK) 1. Crank the engine and verify that the TCV operation sound is heard. WL Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction.
TCV
6. If there is vacuum, consult your distributor for replacement of the FICD actuator.
CONTINUED
F2–62
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TROUBLESHOOTING WL Turbo
TCV
2. If no operation sound is heard, inspect the TCV (in the FIP). 3. If the TCV is normal, inspect the following: PCM terminal Q voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION) Wire harness between TCV and PCM terminal Q EGR System Inspection (if equipped) 1. Make sure that all hoses are securely connected in the proper position. 2. Disconnect the vacuum hose from the EGR valve. 3. Start the engine at cold condition. 4. Verify that there is no vacuum at vacuum hose. 5. If there is vacuum, inspect the following: EGR solenoid valve PCM terminal R voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wire harness between EGR solenoid valve and PCM terminal R 6. Warm up the engine to the normal operating temperature and run it at idle speed. 7. Verify that there is vacuum at vacuum hose. 8. If there is no vacuum, inspect the following: EGR solenoid valve PCM terminal R voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wire harness between EGR solenoid valve and PCM terminal R 9. Connect the vacuum pump to the EGR valve. 10. Apply the vacuum to the EGR valve and inspect if the engine speed becomes unstable or the engine stalls. 11. If the engine speed does not change, stop the engine and inspect the EGR valve.
F2–63
CONTINUED
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TROUBLESHOOTING Glow System Inspection STEP 1
2
3
4
5
6
INSPECTION
ACTION
RESULTS
Connect NGS tester to DTC. Turn engine switch on and retrieve DTC. Are any of the following DTCs displayed? 09 (ECT sensor) 12 (Control lever position sensor) 36 (Glow plug relay)
Yes
Go the appropriate DTC test. After repair is completed, go to next step.
No
Go to next step.
Turn engine switch on while engine is cold. Does glow indicator light illuminate for approx. 1—9 seconds.?
Yes
Go to next step.
No
Inspect the following according to indication condition of glow indicator light: 1. Will not go out Short circuit between glow indicator light and PCM connector terminal M Short circuit in instrument cluster print plate 2. Illuminates for approx. 1 second (same condition after engine is warmed up and cold) Extremely low resistance of engine coolant temperature sensor Short circuit between engine coolant temperature sensor and PCM connector terminal E 3. Will not illuminate Glow indicator light Open circuit between glow indicator light and PCM connector terminal M Open circuit in instrument cluster print plate 4. Illuminates for approx. 9 seconds (same condition after engine is warmed up and cold) Extremely high resistance of engine coolant temperature sensor Open circuit between engine coolant temperature sensor and PCM connector terminal E
Leave engine switch on while engine is cold. Does glow plug voltage indicate B+ for approx. 15 seconds.?
Yes
Go to next step.
No
Inspect for open or short circuit in harnesses and connectors between battery, glow plug relay, and glow plug. Inspect if glow plug relay is stuck open or closed. Inspect glow plug relay ground circuit. Inspect for open circuit between glow relay and PCM terminal O.
Does glow plug voltage indicate B+ while cranking engine?
Yes
Go to next step.
No
Inspect for open or short to ground circuit in harness and connectors between engine switch (starter) and PCM connector terminal D.
Is power supplied to the glow plug for maximum 10 minutes after engine started when engine is cold?
Yes
Go to next step.
No
Inspect for open or short circuit in harnesses and connectors between NE sensor and PCM connector terminal F.
Remove the glow plug wire from glow plugs. Measure resistance between glow plug and body ground. yg Is glow plug resistance approx. 1 Ω or less? + INTAKE-AIR SYSTEM, GLOW PLUG INSPECTION
Yes
Glow system is okay.
No
Replace glow plug.
CONTINUED
F2–64
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FUEL AND EMISSION CONTROL SYSTEMS (F2 CARB) ENGINE TUNE-UP .........................................................F4-2 ENGINE TUNE-UP PREPARATION ........................F4-2 IGNITION TIMING ADJUSTMENT ...........................F4-2 IDLE SPEED ADJUSTMENT ...................................F4-2 IDLE MIXTURE ADJUSTMENT ...............................F4-2/3 DASHPOT (D/P) ADJUSTMENT ..............................F4-3 THROTTLE POSITIONER (T/P) ADJUSTMENT ........................................................F4-3/4 A/C IDLE-UP ADJUSTMENT ...................................F4-4/5 INTAKE-AIR SYSTEM .................................................F4-6 VACUUM HOSE ROUTING DIAGRAM ...................F4-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION ..................................F4-7 AIR CLEANER ELEMENT INSPECTION ..........................................................F4-8 IDLE COMPENSATOR INSPECTION ....................F4-8 AIR THERMO VALVE INSPECTION ..........................................................F4-8 VACUUM CONTROL DIAPHRAGM INSPECTION ..........................................................F4-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ..................................F4-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT .............................. F4-9 FUEL SYSTEM ..............................................................F4-10 BEFORE REPAIR PROCEDURE.............................F4-10 AFTER REPAIR PROCEDURE ...............................F4-10 FUEL TANK REMOVAL/INSTALLATION ...............F4-11/13 NONRETURN VALVE INSPECTION ......................F4-13 FUEL PUMP UNIT REMOVAL/INSTALLATION...................................F4-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY ................................F4-13/14 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION ..................................F4-14 FUEL GAUGE SENDER UNIT INSPECTION ..........................................................F4-14 FUEL PUMP INSPECTION ......................................F4-14/15 FUEL LINE PRESSURE INSPECTION ..................F4-15 FUEL LINE FLOW AMOUNT INSPECTION ..........................................................F4-15/16 FAST IDLE SPEED ADJUSTMENT ........................F4-16 DASHPOT (D/P) INSPECTION ................................F4-16 FUEL PUMP RELAY INSPECTION ........................F4-16/17 SERVO DIAPHRAGM REMOVAL/INSTALLATION ..................................F4-17 CARBURETOR REMOVAL/INSTALLATION ..................................F4-17
CARBURETOR DISASSEMBLY/ASSEMBLY ............................... F4-18/21 CARBURETOR INSPECTION/ADJUSTMENT .............................. F4-21/24 HIGH-ALTITUDE COMPENSATOR INSPECTION ......................................................... F4-24 PTC HEATER INSPECTION ................................... F4-24 SLOW FUEL CUT SOLENOID VALVE INSPECTION ......................................................... F4-24 EXHAUST SYSTEM .................................................... F4-25 EXHAUST SYSTEM INSPECTION ........................ F4-25 EXHAUST SYSTEM REMOVAL/INSTALLATION ................................. F4-25 EMISSION SYSTEM .................................................... F4-26 N0.1 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26 N0.2 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26 WATER THERMO VALVE INSPECTION .............. F4-26 AIR VENT SOLENOID INSPECTION ...................... F4-26 CHECK VALVE (TWO-WAY) INSPECTION ......................................................... F4-26 CHARCOAL CANISTER INSPECTION ................. F4-26 ROLLOVER VALVE INSPECTION ......................... F4-26/27 WATER THERMO VALVE REMOVAL/INSTALLATION ................................. F4-27 PCV VALVE INSPECTION ...................................... F4-27 CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT ...................................... F4-27 FLANGE THERMOSWITCH INSPECTION ......................................................... F4-27 CONTROL SYSTEM .................................................... F4-28 COMPONENT LOCATION ...................................... F4-28 PCM REMOVAL/INSTALLATION ........................... F4-29 PCM INSPECTION .................................................... F4-29 PTC HEATER RELAY INSPECTION ..................... F4-30 THROTTLE POSITIONER T/P) SOLENOID VALVE INSPECTION ........................................... F4-30 WATER THERMOSWITCH (INTAKE MANIFOLD SIDE) INSPECTION ......................... F4-30/31 WATER THERMOSWITCH REMOVAL/INSTALLATION ................................. F4-31 TROUBLESHOOTING ................................................ F4-32 FOREWORD ............................................................. F4-32 TROUBLESHOOTING ITEM TABLE ...................... F4-32 QUICK DIAGNOSTIC CHART ................................. F4-33 SYMPTOM TROUBLESHOOTING ......................... F4-34/47
CONTINUED
F4-1
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ENGINE TUNE-UP ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1. Check the condition of the engine (plugs, leaks in hoses, etc.) 2. Make sure all accessories are OFF. 3. Connect a tacho dwell tacho tester to the engine. 4. Warm up the engine and run it for three minutes at 2,500—3,000 rpm in neutral. IGNITION TIMING ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION. 2. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it.
3.
While checking the ignition timing by using a timing light, adjust the crankshaft pulley alignment mark position (yellow paint) by turning the distributor as specified. Specification BTDC: 5°—7°(6°±1°)
IDLE MIXTURE ADJUSTMENT 1. Attach an exhaust gas analyzer and measure the CO concentration.
2. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 3. Verify that CO concentration in exhaust gas at the tail pipe during idling is as specified in the table below. For GULF General
CO concentration (%) 2.0—2.5 (2.0 ) 2.0—3.0 (2.5 ±0.5)
5.
If not within the specification, adjust the CO concentration by turning the MAS (mixture adjust screw). Remove the blind cap. (GULF)
6.
Remove the spring pin.
4.
Reconnect the proper vacuum hose to the port. IDLE SPEED ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION. 2. Verify that the idle speed is within the specification. 4.
3.
If not within the specification, adjust the idle speed by turning the TAS (throttle adjust screw)
CONTINUED F4-2
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ENGINE TUNE-UP DASHPOT (D/P) ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT" 2. Increase the engine speed to 2,500 rpm. 3. Pull the throttle lever until the rod and arm of the dashpot separate. 4. Slowly return the throttle lever from the position above, then verify that the engine speed is as specified when the arm contacts the rod. Specification 1,900—2,100 (2,000 ± 100) rpm 5. If not as specified, loosen the dashpot locknut and turn the dashpot body to adjust.
Reconfirm that the engine speed is within the specification. 8. If not within the specification, adjust the idle speed by turning the TAS (throttle adjust screw). Note GULF only • Run the engine at idle for 3—5 seconds, then fit a blind cap to the MAS (mixture adjust screw) of the vehicles for the following markets. 7.
•
6. After adjustment, tighten the locknut. Tightening torque 9.8—17.6 N.m {100—180 kgf.cm, 87—156 in.lbf} 7. Race the engine and again verify that the engine speed returns smoothly to idle speed. 8. If not, repeat the above procedure to adjust the idle speed or D/P inspect (Refer to FUEL SYSTEM, DASHPOT (D/P) INSPECTION) THROTTLE POSITIONER (T/P) ADJUSTMENT GULF only 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. 3. Disconnect the vacuum hose from the servo diaphragm.
Run the engine at idle for 3—5 seconds, then tap in the spring pin as shown.
4. Connect the intake manifold vacuum directly to the servo diaphragm, and verify that the engine speed is as specified. Specification 1,050—1,250 (1,150 ± 100) rpm
CONTINUED F4-3
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ENGINE TUNE-UP 5. If not within the specification, adjust the engine speed by the adjust screw.
6. After adjusting the engine speed, reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the engine speed is raced at 2,000 rpm or more. 7. If the servo diaphragm does not operate, inspect the T/P solenoid valve. 8. If the solenoid valve is okay, replace the servo diaphragm. A/C IDLE-UP ADJUSTMENT GULF only with, A/C 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from port A.
3. Connect the intake manifold vacuum directly to port A, and verify that the engine speed is as specified. Specification 1,400—1,600 (1,500 ± 100) rpm 4. If not within the specification, adjust the engine speed by the adjust screw.
6. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. 7. Disconnect the vacuum hose from port B.
8. Connect the intake manifold vacuum directly to port B, and verify that the engine speed is as specified. Specification 1,050—1,250 (1,150 ±100) rpm 9. If not within the specification, adjust the engine speed by the adjust locknut on the dual servo diaphragm head.
10. Reconnect the proper vacuum hose to port B. 11. After adjusting the engine speed reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated. 12. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve or T/P solenoid valve. 13. If the solenoid valve is okay, replace the dual servo diaphragm. Except GULF, with A/C 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from the servo diaphragm. 3. Connect the intake manifold vacuum directly to the servo diaphragm, and verify that the engine speed is as spec tied.
5. Reconnect the proper vacuum hose to port A.
CONTINUED F4-4
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ENGINE TUNE-UP
Specification 1,400—1,600 (1,500 ± 100) rpm 4. If not within the specification, adjust the engine speed by adjust screw.
5. Reconnect the proper vacuum hose to port. 6. After adjusting the engine speed reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated. 7. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve. 8. If the solenoid valve is okay, replace the servo diaphragm.
CONTINUED
F4-5
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INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM
1
Air cleaner
12 Distributor
2 3 4 5 6 7 8 9 10 11
Carburetor Vacuum control diaphragm Idle compensator Air thermos sensor FICB solenoid valve High-altitude compensator FICB diaphragm Charcoal canister No.1 purge control valve Water thermo valve
13 14 15 16 17 18 19 20 21 22
T/P solenoid valve Servo diaphragm A/C idle-up solenoid valve Dual servo diaphragm To intake manifold Fuel main line (to fuel tank) Fuel return line (to fuel tank) To charcoal canister or ventilation To carburetor To check valve (two-way)
CONTINUED
F4-6
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INTAKE-AIR SYSTEM INTAKE - AIR SYSTEM REMOVAL/INSTALLATION Warning • When the engine and intake-air system are hot, they can badly bum. Turn off the engine and wait until they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant from the radiator. (Refer to Section E.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 2
Air cleaner (in idle compensator, vacuum control diaphragm, shutter valve, air thermo sensor) Air cleaner element
8
Intake manifold
9
Water thermoswitch ☞ CONTROL SYSTEM, WATER THERMOSWITCH REMOVAL/INSTALLATION
3
Carburetor
4
Fuel hose
10
Intake manifold gasket
5
Accelerator cable
11
6 7
PTC heater gasket PTC heater
12
Water thermo valve ☞ FUEL SYSTEM, WATER THERMO VALVE REMOVAL/INSTALLATION Servo diaphragm
CONTINUED F4-7
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INTAKE-AIR SYSTEM AIR CLEANER ELEMENT INSPECTION • Visually check the air cleaner element for excessive dirt, damage or oil, replace if necessary. IDLE COMPENSATOR INSPECTION 1. Confirm that the valve is in the closed position when the bimetal temperature is lower than the specified temperature. Opening temperature 63—71 °C {145.4—159.8 °F}
AIR THERMO VALVE INSPECTION Note Perform the following test only when directed. • 1. Disconnect the vacuum hose from the vacuum control diaphragm. 2. Verify that vacuum is felt at the vacuum hose when the engine is cold (below 30 °C {86 °F}) and idling. 3. Warm up (above 30 °C {86 °F}) the engine and verify that vacuum is not felt.
2. To check, suck air from the tube A. If excessive air leakage is found, replace the idle compensator.
4. If vacuum condition is not as specified in Steps 2 and 3, replace the air thermo valve. VACUUM CONTROL DIAPHRAGM INSPECTION 1. Disconnect the vacuum hose from the vacuum control diaphragm. 2. Connect a vacuum pump to the vacuum control diaphragm. 3. Apply more than 24 KPa {180 mmHg, 7.087 inHg} vacuum and verify that the shutter valve is opened to the hot position.
3. When the bimetal temperature is more than approx. 71 °C {159.8 °F}, confirm that the valve is in the open position. If the valve is not open, replace the idle compensator as an assembly.
4. Replace the vacuum control diaphragm if not as specified.
CONTINUED
F4-8
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INTAKE-AIR SYSTEM ACCELERATOR PEDAL REMOVAL/INSTALLATION
1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1
2
Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Verify that the throttle valve is entirely closed. 2. Measure the free play of the accelerator cable. Free play 1—3 mm {0.04—0.11 in} 3. If not as specified, adjust by turning locknut A.
CONTINUED
F4-9
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FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". Fuel Line Safety Procedures Note Fuel in the fuel system is under high • pressure also when the engine is not running. 1. Remove the fuel-filler cap and release the pressure in the fuel tank. 2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.
3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position.
3. Start the engine. 4. After the engine stalls, crank the engine several times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and described below. Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit the hose onto the pipe over 25 mm {0.98 in}. When the pipe has a stopper, fit the hose until it contacts the stopper.
F4-10
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FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. 2. 3. 4. 5. 6. 7.
Level the vehicle. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Drain the fuel from the drain plug. Remove in the order indicated in the table. Install in the reverse order of removal. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
DOUBLE CAB
CONTINUED
F4-11
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FUEL SYSTEM REGULAR CAB
1
Joint hose ☞ Installation Note
2
Breather hose w Installation Note
3
Under guard
4 5
Fuel hose Fuel tank
6
Evaporative hose - Installation Note
7 8
Rollover valve Fuel pump unit
9
Fuel-filler pipe
10 Dust cover 11 Fuel inlet pipe 12 Non return valve Evaporative gas check valve (two-way) 13 ☞ Installation Note
CONTINUED
F4-12
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FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note Install the arrow mark of the evaporative gas • check valve (two-way) facing the charcoal canister. Evaporative Hose Installation Note Fit each hose onto the respective fittings within • the specification, and install clamps as shown. Length Evaporative hose: 25 mm {0.98 in}
Breather Hose Installation Note Fit each hose onto the respective fittings within • the specification, and install clamp as shown.
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet pipe. 2. Verify that the nonreturn valve opening angle is 50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm {0.06 in} when the nonreturn valve is returned to the closed position.
Length Breather hose: 25—30 mm {0.99—1.18 in}
Joint Hose Installation Note Fit the joint hose onto the respective fittings • within the specification, and install clamps as shown. Length Joint hose: 35—40 mm {1.4—1.5 in}
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAUINSTALLATION 1. Remove the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Install the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
F4-13
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FUEL SYSTEM DOUBLE CAB
Fuel Pump Assembly Note After installing the fuel pump body to the • bracket; pull the pump down so that it is tight against the bracket.
Fuel Hose Assembly Note 1. Do not apply excessive side force when pushing the fuel hose onto the fuel pump nipple. 2. Install the clamps as shown. REGULAR CAB
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.)
1 2 3 4 5 6 7
Fuel pump unit connector Rubber mount Fuel filter (low-pressure) Clamp Fuel hose ☞ Assembly Note Fuel pump body ☞ Assembly Note Fuel gauge sender unit
FUEL PUMP INSPECTION Continuity Inspection Note Perform the following test only when • directed, 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit connector terminals C and D.
F4-14
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FUEL SYSTEM 4. Connect the C and D terminals of the fuel pump relay with a jumper wire.
5. If there is no continuity, replace the fuel pump body. If there is continuity in the fuel pump but the fuel pump does not operate, inspect as follows and repair or replace as necessary. Open circuit • GND circuit (fuel pump unit connector terminal C and body GND) • Power circuit (fuel pump relay connector terminal C and fuel pump unit connector terminal D through common connector)
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit Fuel pump relay connector terminal C and • fuel pump unit connector terminal D through common connector to GND 6. Repair or replace faulty areas. If the harnesses are okay, inspect the fuel pump relay. (Refer to FUEL SYSTEM, FUEL PUMP RELAY INSPECTION.) 7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) FUEL LINE PRESSURE INSPECTION Note • Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and connect a fuel pressure gauge to it.
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) 5. Connect the negative battery cable. 6. Turn the ignition switch ON, and verify that fuel pressure is as specified. Specification 2 20—25kPa {0.20—0.25 kgf/cm , 2.8—3.6 psi} 7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.) FUEL LINE FLOW AMOUNT INSPECTION Note • Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and insert the end into a measuring beaker. 4. Connect the C and D terminals of the fuel pump relay with a jumper wire.
CONTINUED F4-15
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FUEL SYSTEM
5. Connect the negative battery cable. 6. Turn the ignition switch on. Drive the fuel pump for a minute and verify that the fuel flow amount is within the specification. Specification More than 1.150 cc {70.2 cu in} min. 7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.) FAST IDLE SPEED ADJUSTMENT 1. Warm up the engine to normal operation temperature. 2. Stop the engine. 3. Plug the hoses of the idle compensator. 4. While holding the throttle valve slightly open, push the choke fully closed; then release the choke valve after releasing the throttle valve. 5. Start the engine, but do not touch the accelerator pedal. 6. Verify that the engine speed is 3,000—4,000 rpm. If the engine speed is not as specified, turn the adjust screw to adjust.
DASHPOT (D/P) INSPECTION 1. Open the throttle valve fully then push the dash pot rod with a finger and make sure the rod goes into the dash pot slowly. 2. Release the finger and make sure the rod comes out quickly.
FUEL PUMP RELAY INSPECTION On-Vehicle Inspection Note • Perform the following test only when directed. 1. Remove the front left side trim. 2. Crank the engine while touching the fuel pump relay by hand. 3. Verify that clicking sound is heard or vibration is felt from the fuel pump relay white cranking the engine. 4. If there is no clicking sound or vibration, inspect the harness for the following, Open circuit •
Power circuit (fuel pump relay connector terminal A, D and ignition switch IG1)
•
GND circuit (fuel pump relay connector terminal B and PCM terminal H)
Short circuit Fuel pump relay connector terminal A, D • and ignition switch IG1 to GND. 5. If the harnesses are okay, perform the following off-vehicle inspection. Off-Vehicle Inspection 1. Remove the fuel pump relay. 2. Inspect for continuity between the fuel pump relay terminals by using an ohmmeter.
CONTINUED
F4-16
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FUEL SYSTEM Tightening torque 9.8—24 N.m {100—250 kgf.cm-cm, 87—216 in.lbf} CARBURETOR REMOVAL/INSTALLATION (Refer to INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. If not as specified, replace the fuel pump relay. SERVO DIAPHRAGM REMOVAL/INSTALLATION 1. Loosen the servo diaphragm installation nut.
2. Remove the servo diaphragm and the servo diaphragm bracket from the intake manifold.
3. Separate the servo diaphragm from the bracket. 4. Install the servo diaphragm onto the bracket, then hand-tighten the installation nut. 5. Install the servo diaphragm bracket to the intake manifold. Tightening torque 19—25N.m {1.9—2.6 kgf.m, 14—18ft.lbf} 6. Tighten the installation nut to the specification.
CONTINUED F4-17
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FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. (Refer to Carburetor After Assembly Note.) •
Caution Replace the O-rings, gaskets, and washers when assembling the carburetor. If not, it will possibly cause a malfunction.
CONTINUED
F4-18
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FUEL SYSTEM 1
Accelerator pump connecting rod
2
Connect spring
3
Air vent solenoid valve
4
Choke rod
5
Air horn
6
Float
7
Needle valve assembly
8
Accelerator pump plunger
9
Closed throttle position (CTP) switch (GENERAL (LH.D.), high-altitude models)
4
Air vent solenoid valve lead (separate from the connector)
5
Disconnect choke rod
10 Slow fuel cut solenoid valve 11 Accelerator pump outlet check ball and spring 12 Accelerator pump inlet check ball 13 Primary slow jet 14 Secondary slow jet 15 Primary main jet 16 Secondary main jet 17 Primary venturi and nozzle 18 Secondary venturi and nozzle 19 Primary main air bleed 20 Secondary main air bleed 21 Main body
6
Air horn and automatic choke assembly (separate from main body)
7
Air vent solenoid valve, spring, and gasket, if necessary
22 Vacuum diaphragm 23 Throttle body 24 Mixture adjust screw 25 Bimetal 26 Choke breaker diaphragm 27 Power jet
Needle Valve and Float Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Air Horn and Automatic Choke Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Vacuum hose
2
Accelerator pump connecting rod, spring, and lever
3
Connect spring
1
Float and pin
2
Needle valve assembly
CONTINUED
F4-19
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FUEL SYSTEM Air Bleeds and Jets Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
Secondary slow jet Secondary slow air bleed (No.1)
3
Secondary main air bleed
4
Secondary main jet
5
Primary main air bleed
6
Slow jet and plug
7
Primary slow air bleed (No.1)
8
Primary main jet
9
Primary slow air bleed (No.2)
1
CTP switch and spring
2
Slow fuel cut solenoid valve, needle valve, spring, and gasket.
3
Accelerator pump plunger assembly and spring
4
Retaining clip
5
Strainer and accelerator pump inlet check ball
6 7
Check valve plug Accelerator pump outlet check ball and spring
10 Power jet
•
Caution Note the size of all jets and air bleeds so that they will be reassembled in the correct position
Note • One bolt is inside the throttle body
11 Coasting richer air bleed (No.2) 12 Secondary slow air bleed (No.2) 13 Coasting richer air bleed (No.1) 14 Coasting richer jet
Main Body Disassembly/Assembly Caution • After installing the idle switch, be sure to adjust it. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
8 9
Disconnect vacuum diaphragm connecting rod Throttle body (separate from main body)
10 Vacuum diaphragm assembly and gasket
CONTINUED
F4-20
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FUEL SYSTEM
11 Diaphragm cover screws and cover 12 Spring and diaphragm 13 Accelerator cable hanger Throttle Body Disassembly/Assembly Caution • Do not remove the throttle valve and shaft, the Venturis, or the choke valve and shaft. 1. Disassemble in the following order. 2. Assemble in the reverse order of disassembly. (1) When removing the mixture adjust screw, tap out the spring pin as shown in the figure.
(4) Adjust the CTP switch. (5) After the idle adjustment has been completed, check the fast idle speed as follows. CARBURETOR INSPECTION/ADJUSTMENT Body, Valve, Jet 1. Check for cracks on the air horn, distortion on the installing surface attached to the main body, and wear on the contact surface of the choke valve shaft. If necessary, replace it. 2. Check for cracks and distortion on the throttle body, and wear on the contact surface of the throttle valve shaft. If necessary, replace it. 3. Check for deformity, bends, and wear on the levers, arms, and connecting rods. If necessary, replace it. Caution • Do not use a piece of wire to clean the jets. The wire may scratch, crack, or deform the port of the jets and become the cause of malfunctions. 4. Check for clogging in jets and air bleeds. If necessary, clean with clean gasoline or kerosene and dry with compressed air. 5. Check the taper part of the MAS, solenoid valves, and needle valve (float) for cracks and dents, and wear. If necessary, replace it. 6. Check the rubber part of the accelerator pump for cracks and damage. If necessary, replace it.
Carburetor After Assembly Note • Install the carburetor in the reverse order of removal. After installation, note the following. (1) Start the engine and check for leaks. (2) Make the idle adjustment. (3) After the idle adjustment is completed, press in the spring pin.
CONTINUED F4-21
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FUEL SYSTEM Diaphragms 1. Push the rod fully and plug the port by hand. 2. Verify that the rod does not return when the port is plugged.
Clearance L 44—45 mm {1.732—1.772 in} 4. If not as specified, bend the float stopper B until the proper clearance is obtained. 3. If the rod returns to the original position, replace the diaphragm. Float Level Adjusting 1. Measure the clearance H between the float and air horn. Choke Valve 1. Use a vacuum pump to apply approximately 53 kPa {400 mmHg, 15.7 inHg} vacuum to the choke diaphragm. 2. Push the choke valve lightly to close it, and check the clearance R,
Clearance H 8—9 mm {0.315—0.354 in} 2. If not as specified, bend the float seat lip A until the proper clearance is obtained.
Clearance R 1.72—2.22 mm {0.068—0.087 In} 3. Measure the clearance L between the bottom of the float and air horn.
3. If the clearance is not as specified, adjust by bending the choke lever D.
CONTINUED
F4-22
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FUEL SYSTEM Fast-idle cam 1. Set the fast-idle cam to the second highest position. 2. Adjust the throttle valve clearance G by turning the adjust screw. (The clearance becomes larger as the screw is turned clockwise.)
Clearance G 0.64—0.84 mm {0.025—0.033 in} 3. Set the fast idle cam at the second highest position. 4. Check the choke valve clearance R. Clearance R 2.82—3.70 mm {0.111—0.146 in} 3. If the clearance is not as specified, adjust by bending tab A. Secondary throttle valve 1. The secondary throttle valve should start to open when the primary throttle valve opens 48 ° —52 ° and should be completely open at the same time the primary throttle valve is fully open. 2. Check the clearance between the primary throttle valve and the throttle bore when the secondary throttle valve starts to open. 3. If the clearance is not as specified, bend tab B to adjust.
Clearance R 0.60—1.20 mm {0.024—0.047 in} 5. If necessary, adjust the choke valve clearance R by bending the starting arm B. If large adjustments are required, the choke rod should be bent. Unloader system 1. Open the primary throttle valve fully. 2. Measure the choke valve clearance R.
CONTINUED
F4-23
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FUEL SYSTEM Clearance R 7.35—8.25 mm {0.289—0.325 in} HIGH-ALTITUDE COMPENSATOR INSPECTION 1. Disconnect each air hose from the carburetor. 2. Check the high-altitude compensator by blowing through each hose.
500m {1,640 ft} or higher (High altitude): Air passes. Less than 500 m {1,640 ft } (Low altitude): Air does not pass. 3. If not as specified, replace the high-altitude compensator. PTC HEATER INSPECTION 1. Disconnect the PTC heater connector. 2. Connect an ohmmeter between the connector and the intake manifold, and verify continuity. 3. If it is not correct, replace the PTC heater. SLOW FUEL CUT SOLENOID VALVE INSPECTION Operation Inspection
1. 2. 3. 4.
Note • Perform the following test only when directed. Run the engine at idle speed. Disconnect the carburetor connector (6-pin). Disconnect the carburetor connector and verify that the engine stops. If the engine does not stop, replace the slow fuel cut solenoid valve.
CONTINUED
F4-24
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EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1 2
After pipe Main silencer
3
Pre-silencer
4 5
Front pipe Exhaust manifold
CONTINUED
F1-25
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EMISSION SYSTEM 3. Turn the ignition switch to "ON" and "OFF". If there is a "clicking" noise, the air vent solenoid valve is working properly.
EMISSION SYSTEM N0.1 PURGE CONTROL VALVE INSPECTION 1. Blow through port A and verify that air does not flow. 2. Connect a vacuum pump and apply vacuum of -14.7 KPa {-110 mmHg, -4.33 inHg} or above and blow through port A again. 3. Verify that air flows from port A.
CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). 2. Inspect airflow of the valve under the following conditions. Condition
N0.2 PURGE CONTROL VALVE INSPECTION 1. Disconnect vacuum hose B from the pipe. 2. Blow into the hose and make sure air flows freely.
Apply pressure below +2.9 kPa {+22 mmHg, +0.87 inHg} to port A Apply pressure over +5.9 kPa {+44 mmHg, +1.7 inHg} to port A Apply pressure over -0.98 KPa {-7.36 mmHg, -0.29 inHg} to port A
3. If not as specified, replace the charcoal canister. WATER THERMO VALVE INSPECTION 1. Remove the water thermo valve. 2. Put the threaded part in a water-filled container and slowly increase the water temperature. 3. Check the airflow of the valve under the following conditions.
Port A-B C-D
Condition Below 50°C {122°F} Above50°C {122°F} No Airflow Airflow Airflow No Airflow
Airflow No Yes Yes
3. If not as specified, replace the check valve (twoway). CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Visually check the charcoal canister for damage and leakage. 3. Shake the charcoal canister upside down and verify that no pieces of charcoal falls from either nipple. 4. Replace the charcoal canister if necessary. ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) 2. Hold the valve as shown. Blow air into port A and verify that there is airflow.
4. If not as specified, replace the water thermo valve. AIR VENT SOLENOID INSPECTION 1. Remove the air cleaner. 2. Touch the finger onto the air vent solenoid valve.
CONTINUED F4-26
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EMISSION SYSTEM CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT 1. Warm up the engine and run it at idle. 2. Connect a dwell tacho tester to the engine. 3. Connect a voltmeter to the CTP switch terminal. 4. Increase the engine speed to more than 2,000 rpm; decelerate gradually and verify that the volt meter indicates as follows.
3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow.
4. If not as specified, replace the rollover valve. WATER THERMO VALVE REMOVAL/NSTALLATION 1. Drain the engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove the water thermo valve from the intake manifold. 3. Wrap sealing tape two or three times around the threaded part of the valve before installing.
4. Use a new washer and install in the reverse order of removal. Tightening torque 25—39 N.m {2.5—4.0 kgf.m-m, 19—28 ft.lbf} PCV VALVE INSPECTION 1. Remove the PCV valve. 2. Check the airflow of the valve under the following conditions.
Condition Blow from port A
Engine speed At idle 1,000—1,200 (1,100 ±100) rpm
Voltage Approx. 12 V Less than 1.5 V
5. If not as specified, turn the adjust screw to adjust.
FLANGE THERMOSWITCH INSPECTION Note • Perform the following test only when directed. Continuity Inspection 1. Drain the coolant into a container. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 2. Remove the flange thermoswitch from the carburetor. 3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
Airflow Yes
Blow from port B No 3. If not as specified, replace the PCV valve.
4. Inspect the thermoswitch terminals by using an ohmmeter. Specification Water temperature (°C {°F}) Below 67 {153} Above 67 {153}
Continuity Yes No
5. If not as specified, replace the flange thermoswitch.
CONTINUED F4-27
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CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION
1 2 3
Ignition coil Water thermoswitch PCM
4 5 6
T/P solenoid valve (GULF only) PTC heater relay Fuel pump relay
CONTINUED
F4-28
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CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front left side trim. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1. Remove the PCM. 2. Reconnect PCM connector and battery negative terminal. Note •
With the PCM connector connected, body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage at PCM terminal using a voltmeter. 4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the Action column in the terminal voltage list.
PCM INSPECTION Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. PCM Terminal Voltage (Reference)
Terminal *A
Signal Throttle positioner control
B
C
—
FICB control
Connected to
Test condition
T/P solenoid valve
Engine speed
GND
Constant
FICB solenoid valve
Coolant temperature Ignition SW
B+
•
Above 1500 rpm
Below 1.0
•
Below 1.0
•
Related wiring harnesses
•
FICB solenoid valve
•
Related wiring harnesses
Approx 11V •
Igniter Related wiring harnesses —
Below 40°C {104°F}
Below 1.0
Igniter Ignition SW ON
E F
— IG1
G
H
I
J
B+
ON
Idle Ignition
— Ignition SW
—
Fuel pump relay
•
PTC heater control
•
PTC heater relay
Fuel pump control
•
PTC heater control
—
ON
B+
OFF
Below 1.0
Ignition SW
ON
•
•
—
—
Fuel pump control
Coolant temperature
Below 1.0
—
•
Water thermoswitch
•
Fuel pump relay
•
PTC heater relay
Action
Below 1500 rpm
Other D
Voltage (V)
Coolant temperature
• •
Ignition SW Related wiring harnesses —
• •
Fuel pump relay
•
Related wiring
— B+
Ignition SW OFF
•
Below 1.0
T/P solenoid valve Related wiring harnesses
PTC heater relay
Below 40°C {104°F}
B+
•
Water thermoswitch
Above 40°C {104°F}
0V
•
Related wiring harnesses
ON
B+
• •
OFF
Below 1.0
•
Fuel pump relay PTC heater relay Related wiring harnesses
Ignition SW
*: GULF only
F4-29
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CONTROL SYSTEM PTC HEATER RELAY INSPECTION 1. Remove the PTC heater relay. 2. Inspect for continuity between the PTC heater relay terminals by using an ohmmeter.
3. If not as specified, replace the PTC heater relay. THROTTLE POSITIONER (T/P) SOLENOID VALVE INSPECTION Voltage Inspection Note • Perform the following test only when directed. 1. Run the engine at idle. 2. Connect a voltmeter to terminals of the T/P solenoid valve as shown. 3. Measure the voltage as shown.
Engine speed (rpm) Below 1,500 Above 1,500
4. If not as specified, replace the T/P solenoid valve. If as specified, inspect the following: Vacuum hose improper routing, kinks or leakage. Open circuit • Power circuit (T/P solenoid valve connector terminal A and ignition switch IG1 through common connector.) • GND circuit (T/P solenoid valve connector terminal B and PCM connector terminal A.) Short circuit • T/P solenoid valve connector terminal A and ignition switch IG1 through common connector to GND 5. Repair or replace faulty areas. 6. Install the T/P solenoid valve. 7. Connect the negative battery cable. WATER THERMOSWITCH INSPECTION Note • Perform the following test only when directed. Continuity Inspection 1. Drain the coolant into a container. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 2. Remove the water thermoswitch from the under side of the intake manifold. 3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
Voltage (V) B+ Below 1.0
8. If output voltage is as shown in the table above but there is no airflow in the T/P solenoid valve, perform the following airflow inspection. Airflow Inspection 1. Disconnect the negative battery cable. 2. Remove the T/P solenoid valve. 3. Inspect for airflow between each port under the following condition.
4. Inspect the thermoswitch terminals by using an ohmmeter.
F4-30
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CONTROL SYSTEM Specification Water temperature (°C {°F}) Below 40 {104} Above 40 {104}
Continuity Yes No
5. If not as specified, replace the water thermoswitch. WATER THERMOSWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the water thermoswitch from the radiator. 4. The wrap sealing tape two or three times around the threaded part of the switch before installing.
5. Use a new washer and install in the reverse order of removal. Tightening torque 5.9—8.8 N.m {60—90 kgf.cm-cm, 53—78 in.lbf}
F4-31
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TROUBLESHOOTING TROUBLESHOOTING FOREWORD • Before proceeding with the following troubleshooting; (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If a diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP". TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart. No. 1
TROUBLESHOOTING ITEM Cranks normally but won't start or hard start
DESCRIPTION No combustion
2
Cranks normally but won't start or hard start (always) Requires excessive cranking time (more than 5 seconds)
3
Cranks normally but won't start or hard start (engine Requires excessive cranking of longer than 5 seconds for cold) more than 3 times for engine to start.
4 5
Cranks normally but won't start or hard start (engine Requires excessive cranking time (more than 5 seconds) warm) Rough idle/engine stalls at idle (always) —
6
Rough idle/engine stalls at idle (engine cold)
Idling is stable when engine is warm.
7
Rough idle/engine stalls at idle (engine warm)
Idling is stable when engine is cold.
8 9
Rough idle/engine stalls at idle when A/C or P/S ON Engine runs normally at idle with no load, but stalls or vibrates (if equipped) excessively when load (A/C or P/S) is ON. Engine suddenly stalls often —
10
High idle speed after warm-up
—
11
Engine stalls at drive away
—
12
Engine stalls on deceleration
—
13
Hesitation
—
14
Poor acceleration
—
15
No power, fastest speed is low
—
16
Knocking
—
17
Afterburn occurs during deceleration
—
18
Poor fuel economy
—
CONTINUED
F4-32
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TROUBLESHOOTING
Emission system
Carburetor
Engine
Item
Fuel system
Control system
Engine electrical system
1
Cranks normally but won't start or hard start
O
O O
O O
O O
O
O O O O
2
Cranks normally but won't start or hard start (always)
O
O O
O O
O O
O
O O O O
3
Cranks normally but won't start or hard start (engine cold)
O
O O O
O O
O O
O
O O O O
4
Cranks normally but won't start or hard start (engine warm)
O O
O
O O
O O O
5
Rough idle/engine stalls at idle (always)
O O O
O
O O O
6
Rough idle/engine stalls at idle (engine cold)
O
O
7
Rough idle/engine stalls at idle (engine warm)
O
O O
8
Rough idle/engine stalls at idle when A/C or P/S ON (If equipped)
9
Engine suddenly stalls often
O
O
O
O O
O O O
O O O O
10 High idle speed after warm-up
O O
O O O
O
O
O
O O
12 Engine stalls on deceleration 13 Hesitation
O O O
O O O O O
14 Poor acceleration
O O O
O
O O O O
O O
15 No power, fastest speed is low
O O O
O
O
O O
O
O
O
O
O O O
16 Knocking
Measure compression pressure Spark inspection
O O
O
O
O
O
O
O
O O O O O
Lower than specification No spark
Malfunctioning spark plug
Malfunctioning ignition coil
Malfunctioning distributor
Malfunctioning slow cut solenoid valve
O O
Malfunctioning air vent solenoid valve
Engine internal damage
Malfunctioning water switch
O
Malfunctioning fuel pump
Malfunctioning fuel line
Misadjusted CO, HC concentration
Malfunctioning choke system
Float lever
O O O O
Manufacturing accelerator pump
Clogged secondary main
O
Clogged secondary slow
Clogged primary main
O
Clogged primary slow
Malfunctioning hoses
Misadjusted accelerator cable
O O O
Clogged air cleaner
17 Afterburn occurs during deceleration 18 Poor fuel economy
O
Battery
11 Engine stalls at drive away
O O
Malfunctioning starter
No
Intake-air system
QUICK DIAGNOSTIC CHART
O O O O
F4-33
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SYMPTOM TROUBLESHOOTING: Symptom 1-Cranks normally but will not start or hard start
F4-34
Symptom 2-Cranks normally but will not start or hard start (always)
F4-35
Symptom 3-Cranks normally but will not start or hard start (engine cold)
F4-36-37
Symptom 4-Cranks normally but will not start or hard start (engine warm)
F4-37
Symptom 5-Rough idle/engine stalls at idle (always)
F4-38
Symptom 6-Rough idle/engine stalls at idle (engine cold)
F4-39
Symptom 7-Rough idle/engine stalls at idle (engine warm)
F4-39
Symptom 8-Rough idle/engine stalls at idle-when a/c or p/s on (if equipped)
F4-40
Symptom 9-Engine suddenly stalls often
F4-40
Symptom 10-High idle speed after warm-up
F4-41
Symptom 11-Engine stalls at drive away
F4-41-42
Symptom 12-Engine stalls on deceleration
F4-42
Symptom 13-Hesitation
F4-42-43
Symptom 14-Poor acceleration
F4-43-44
Symptom 15-No power, fastest speed is low
F4-44-45
Symptom 16-Knocking
F4-46
Symptom 17-Afterburn occurs during deceleration
F4-46
Symptom 18-Poor fuel economy
F4-47
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TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1
CRANKS NORMALLY BUT WON'T START OR HARD START 1.
POSSIBLE CAUSE
Air/Fuel mixture too lean Air leak • 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and teaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check if there is any air leakage. Is there any?
RESULTS ACTION Yes Repair or replace appropriate parts. No
Go to next step.
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder?
Yes
Go to next step.
No
Refer to section G.
Check float level. Is it okay?
Yes
Go to next step.
No
4
Open and close throttle valve 2-3 times. Does engine start?
Yes No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step.
5
Check each spark plug. Are they okay?
Yes
Go to next step.
No
Repair or replace spark plug.
Check ignition timing at idle. Is it okay?
Yes
Go to step 8.
No
Go to next step.
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
8
Check slow fuel cut solenoid. Is it okay?
Yes
Go to step 10.
No
Go to next step.
9
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.
2
3
6 7
No 10 11
12
Check compression pressure. Is it okay?
Yes
Go to step 12.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear,
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Check primary main, slow system. Is it okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each jet and air bleed.
No
F4-34
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TROUBLESHOOTING SYMPTOM 2
POSSIBLE CAUSE
CRANKS NORMALLY BUT WON'T START OR HARD START (ALWAYS) 1. Air/Fuel mixture too lean • Air leak • Fuel level incorrect • Restricted primary main, slow system 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich • Float level incorrect • Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. " ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Check if there is any air leakage. Is there any?
2
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder?
Yes No Yes
3
Check ignition timing at idle. Is it okay?
4
Perform ignition timing adjustment. Can timing be adjusted?
5
Check float level. Is it okay?
6
Open and close throttle valve 2-3 times. Does engine start?
7
Check each spark plug. Are they okay?
8
Check slow fuel cut solenoid. Is it okay?
9
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
10
Check compression pressure. Is it okay?
11
Add oil through plug hole. Does engine start?
12
Check primary main, slow system. Is it okay?
ACTION Repair or replace appropriate parts. Go to next step. Go to next step.
No
Refer to Section G.
Yes No Yes No Yes
Go to Step 8. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step.
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Yes No Yes No Yes No
Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to Step 10. Go to next step.
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to Step 12. Go to next step. Check pistons and cylinders for wear.
No Yes No Yes No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace each jet and air bleed.
F4-35
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TROUBLESHOOTING SYMPTOM 3
CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE COLD) 1.
POSSIBLE CAUSE
Air/Fuel mixture too lean • Air leak 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich • Choke system malfunction • Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check if there is any air leakage. Is there any?
RESULTS ACTION Yes Repair or replace appropriate parts. No
Go to next step.
Disconnect high-tension lead at idle, then check engine speed, Does it decrease equally at each cylinder?
Yes
Go to next step.
No
Refer to Section G.
Check float level. Is it okay?
Yes
Go to next step.
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Open and close throttle valve 2-3 times. Does engine start?
Yes
Check each jet and air bleed for clogging.
No
Go to next step.
5
Check each spark plug. Are they okay?
Yes
Go to next step.
No
Repair or replace spark plug.
6
Check ignition timing at idle. Is it okay?
Yes
Go to Step 9.
No
Go to next step.
7
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
8
Check choke system. Is it okay?
Yes
Go to next step.
No
Repair or replace choke system.
9
Check slow fuel cut solenoid. Is it okay?
Yes
Go to Step 11.
No
Go to next step.
10
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.
2
3
4
No 11 12
Check compression pressure. Is it okay?
Yes
Go to Step 13.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
F4-36
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TROUBLESHOOTING STEP 13
INSPECTION Check primary main, slow system. Is it okay?
SYMPTOM 4
POSSIBLE CAUSE
ACTION
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace each jet and air bleed.
CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE WARM) 1. Percolation • Air vent solenoid valve malfunction 2. Air/Fuel mixture too rich • High float level • Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Inspect spark plugs. 2
RESULTS
RESULTS Yes Repair or replace
Are spark plugs wet or covered with carbon?
No
Go to next step.
Check choke system.
Yes
Go to next step.
ACTION
Is it okay?
No
Repair or replace choke system.
3
Check air vent solenoid valve.
Yes
Go to next step.
Is it okay?
No
Replace air vent solenoid valve.
4
Check float level? Is it okay? (float level is high.)
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Inspect both float and needle valve.
No
CONTINUED
F4-37
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TROUBLESHOOTING SYMPTOM 5
ROUGH IDLE/ENGINE STALLS AT IDLE (ALWAYS) 1.
POSSIBLE CAUSE
Air/Fuel mixture too rich • High float level • Loose primary main jet • Restricted primary slow air bleed 2. Poor ignition or misfire 3. Air/Fuel mixture too lean • Air leakage • Restricted primary main jet 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check if there is any air leakage. Is there any?
RESULTS ACTION Yes Repair or replace appropriate parts. No
Go to next step.
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder?
Yes
Go to next step.
No
Refer to Section G.
Check idle-up system. Is it okay?
Yes
Go to next step.
No
Repair or adjust system.
Check ignition timing at idle. Is it okay?
Yes
Go to Step 6.
No
Go to next step.
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
Check idling speed. Is it okay?
Yes
Go to Step 8.
No
Go to next step.
7
Perform idling speed adjustment. Can idling speed be adjusted?
Yes
Adjust idling speed.
No
Adjust or inspect idling mixture.
8
Check pcv valve. Is it okay?
Yes
Go to next step.
No
Repair or replace pcv valve.
9
Check compression pressure? Is it okay?
Yes
Go to Step 11.
No
Go to next step.
Drive vehicle. Does engine stop at takeoff?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Check primary main, slow system. Is it okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace each jet and air bleed.
2
3 4 5 6
10
11
CONTINUED F4-38
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TROUBLESHOOTING SYMPTOM 6
POSSIBLE CAUSE
STEP 1
ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE COLD) Choke system malfunction • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
Check choke system (quick release). Is it okay?
SYMPTOM 7
POSSIBLE CAUSE
3 4 5
ACTION
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Repair or replace choke system.
ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE WARM) 1. Choke system malfunction 2. Float level incorrect 3. Air vent solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Start and warm engine. Check choke valve. Is it fully open? 2
RESULTS
RESULTS Yes Go to next step. No
ACTION
Repair or replace choke system.
Inspect spark plugs. re spark plugs wet or covered with carbon?
Yes
Repair or replace spark plugs.
No
Go to next step.
Check air vent solenoid valve. Is it okay?
Yes
Go to next step.
No
Replace valve.
Check fuel check valve. Is it okay?
Yes
Go to next step.
No
Repair or replace valve.
Check float level. Is it okay? (float level is high.)
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Inspect both float and needle valve.
No
F4-39
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TROUBLESHOOTING SYMPTOM 8
ROUGH IDLE/ENGINE STALLS AT IDLE - WHEN A/C OR P/S ON (IF EQUIPPED 1.
POSSIBLE CAUSE
STEP 1
Idle-up system malfunction • Solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious Injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
Inspect idle-up system. Is it okay?
SYMPTOM 9
POSSIBLE CAUSE
Follow steps for troubleshooting item "Rough idle/engine stalls at idle (Always)".
No
Adjust or repair system,
ENGINE SUDDERLY STALLS OFTEN 1. Disconnected starter connector 2. Poor connection of starter connector Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check starter connector. Is it disconnected or is it not properly connected? 2 Check slow fuel cut valve. Is it okay?
RESULTS Yes Go to next step.
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
ACTION
No
Properly connect connector, or repair or replace if necessary.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Go to next step.
No 3
ACTION
Yes
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
No
Repair or replace slow fuel cut solenoid valve.
CONTINUED
F4-40
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TROUBLESHOOTING SYMPTOM 10
POSSIBLE CAUSE
HIGH IDLE SPEED AFTER WARM-UP • Idle-up system malfunction • Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check throttle wiring. Is there sufficient slack in wiring? 2 3 4
RESULTS Yes Go to next step.
ACTION
No
Adjust or repair accelerator cable.
Check idle-up system. Is it okay?
Yes
Go to next step.
No
Adjust or repair.
Check secondary throttle valve. Is it closed?
Yes
Go to next step.
No
Repair or inspect secondary diaphragm link.
Check float level. Is it okay? (float level is high.)
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Inspect both float and needle valve.
SYMPTOM 11
POSSIBLE CAUSE
ENGINE STALLS AT DRIVE AWAY • Restricted primary main system • Accelerator pump malfunction • Poor ignition or misfire • Malfunctioning unloader system Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check system for air leakage. Is there any?
RESULTS ACTION Yes Repair or replace parts as necessary. No
Go to next step.
2
Check throttle wiring. Is there sufficient slack in wiring?
Yes
Go to next step.
No
Adjust or repair accelerator cable.
3
Check accelerator pump. Is fuel pumped out when accelerator pump is depressed?
Yes
Go to next step.
No
Repair or replace accelerator pump.
4
Check distributor's vacuum advance. Is it correct?
Yes
Go to next step.
No
Replace distributor vacuum control unit.
5
Check unloader system. Is it okay?
Yes
Go to next step.
No
Repair or replace unloader system.
F4-41
CONTINUED
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TROUBLESHOOTING STEP 6
INSPECTION
RESULTS
Check primary main, slow system. Is it okay?
Yes
No SYMPTOM 12
POSSIBLE CAUSE
ENGINE STALLS ON DECELERATION Slow fuel cut solenoid valve malfunction • Throttle positioner (T/P) malfunction (GULF only) • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check idle-up system. Is it okay? 2 3
4
No
ACTION Go to next step. Repair or replace any parts as necessary.
Yes
Go to Step 4.
No
Go to next step.
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
No
Repair or replace slow fuel cut solenoid valve.
Check dashpot's touch speed. Is it correct?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Adjust dashpot.
POSSIBLE CAUSE
2
RESULTS Yes
Check slow fuel cut valve. Is it okay?
SYMPTOM 13
STEP 1
ACTION Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each Jet and air bleed.
HESITATION Spark advance control malfunction • Restricted jets • Air leakage • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
INSPECTION Check system for air leakage. Is there any? Check throttle wiring. Is there sufficient slack in wiring?
RESULTS ACTION Yes Repair or replace any parts as necessary. No Go to next step. Yes
Go to next step.
No
Adjust or repair accelerator cable.
CONTINUED F4-42
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TROUBLESHOOTING STEP 3
INSPECTION
RESULTS
ACTION
Check centrifugal spark advance control. Is it okay?
Yes
Go to next step.
No
Check accelerator pump. Is fuel pumped out when accelerator pump is depressed?
Yes
Check for the following: • Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op eration.) Go to next step.
No
Repair or replace pump.
Check secondary diaphragm. Is it okay?
Yes
Go to next step.
No
Replace secondary diaphragm.
6
Inspect spark plugs? Are they okay?
Yes
Go to next step.
No
Clean or replace spark plugs.
7
Is linkage of primary and secondary valve smooth?
Yes
Go to next step.
No
Repair or replace any parts as necessary.
Inspect every jet. Are they okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace jets. Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
4
5
8
No
SYMPTOM 14
POOR ACCELERATION 1. 2. 3.
POSSIBLE CAUSE
STEP
Spark advance control malfunction Restricted intake/exhaust system Air/Fuel mixture too lean • Low float level • Restricted jets, air bleeds • Accelerator pump malfunction 4. Secondary diaphragm malfunction • RPM limiter malfunction 5. Low engine compression 6. Poor ignition Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
1
Check throttle wiring. Is there sufficient slack in wiring?
Yes No
Adjust or repair accelerator cable.
2
Inspect intake system. Is it restricted? (especially air cleaner)
Yes
Go to next step.
No
Repair or replace intake system.
3
Check choke valve. Is it fully open after warm-up?
Yes No
Go to next step. Repair or replace choke system.
4
Check distributor, (centrifugal spark advance, vacuum spark advance) It is okay?
Yes
Go to next step.
No
Repair or replace distributor.
F4-43
Go to next step.
CONTINUED
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
ACTION
5
Inspect exhaust system. Is it okay?
Yes No
Repair or replace exhaust system.
6
Inspect accelerator pump. It is okay?
Yes
Go to next step.
No
Repair or replace accelerator pump.
7
Check float level. Is it okay?
Yes
Go to next step.
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
8
Inspect spark plugs. Are they okay?
Yes
Go to next step.
No
Clean or replace spark plugs.
9
Check secondary diaphragm. Is it okay?
Yes
Go to next step.
No
Replace secondary diaphragm.
10
Check compression pressure. Is it okay?
Yes
Go to Step 12.
No
Go to next step.
11
Add oil through plug hole. Does engine start?
Yes
Check pistons, rings, and cylinders for wear.
No
Check the following: • Cylinder heads, gaskets • Valve clearance
Inspect all jets and air bleeds (including high speed richer) of both primary and secondary main passage. Is there blockage?
Yes
Clean or replace each jet and air bleed.
No
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
12
SYMPTOM 15
POSSIBLE CAUSE
STEP 1
Go to next step.
NO POWER, FASTEST SPEED IS LOW • Restricted primary main, slow system • Centrifugal spark advance malfunction • Restricted exhaust system • Restricted air cleaner Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can Ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
Check system for air leakage. Is there any
Yes
Go to next step.
No
Repair or replace any part as necessary.
2
Check engine. Does it seem to be overheating?
Yes
Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil.
No
Go to next step.
3
Check throttle wiring. Is there sufficient slack in wiring?
Yes
Go to next step.
No
Adjust or repair accelerator cable.
4
Check choke valve. Is it fully open after warm-up?
Yes
Go to next step.
No
Repair or replace choke valve.
5
Check intake system. Is it restricted? (especially air cleaner)
Yes No
Go to next step. Repair or replace intake system.
CONTINUED F4-44
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
ACTION
6
Check exhaust system. Is it restricted?
Yes No
Repair or replace exhaust system.
7
Check float level. Is it okay? (float level is low.)
Yes
Go to next step.
No
If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Inspect spark plugs. Are they okay?
Yes
Go to next step.
No
Clean or replace spark plugs.
Check secondary diaphragm. Is it okay?
Yes
Go to next step.
No
Replace secondary diaphragm.
Check centrifugal spark advance control. Is it okay?
Yes
Go to next step.
No
Check compression pressure. Is it okay?
Yes
Check for the following: Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op• eration.) Go to Step 13.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Check main (primary) system. Is it okay?
Yes
Go to next step.
No
Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
Check main (secondary) system. Is it okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
8 9 10
11 12
13
14
No
Go to next step.
CONTINUED
F4-45
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TROUBLESHOOTING SYMPTOM 16 KNOCKING 1. Air/Fuel mixture too lean • Restricted primary main, slow system • Poor ignition or misfire • Insufficient engine coolant Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1
2
INSPECTION Check engine Does it seem to be overheating? Inspect spark plugs. Are spark plugs electrode free of carbon accumulation?
RESULTS Yes
ACTION
No
Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil, Go to next step.
Yes
Replace fuel,
No
Clean or replace spark plugs.
SYMPTOM 17 AFTERBURN OCCURS DURING DECELERATION • Poor ignition or misfire • Slow fuel cut solenoid valve malfunction • Throttle position (T/P) malfunction (GULF only) • Dashpot malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. CAUSE Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION 1 Check ignition timing at idle. Is it okay? 2
Perform ignition timing adjustment. Can timing be adjusted?
3
Inspect distributor, (centrifugal spark advance, vacuum spark advance) It is okay?
4
Check thermostat. Is it okay?
5
Inspect every jet. Are they okay?
RESULTS Yes No Yes No Yes
ACTION Go to Step 3. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step.
No
Repair or replace distributor.
Yes No Yes
Go to next step. Repair or replace thermostat. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace jets.
CONTINUED
F4-46
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TROUBLESHOOTING SYMPTOM 18
POSSIBLE CAUSE
STEP 1
POOR FUEL ECONOMY • Incorrect adjustment of main adjust screw • Incorrect adjustment of idle speed • High float level • Poor ignition or misfire Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
Check system for air leakage. Is there any?
Yes
Go to next step.
No
Repair or replace any part as necessary.
Check ignition timing at idle. Is it okay?
Yes
Go to Step 4.
No
Go to next step.
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
Check idling speed. Is it correct?
Yes
Go to Step 6.
No
Go to next step.
Perform idling speed adjustment. Can it be adjusted?
Yes
Adjust idling speed.
No
Adjust or repair any part as necessary.
Check slow fuel cut solenoid valve. Is it okay?
Yes
Go to Step 8.
No
Go to next step.
7
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes No
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.
8
Check both CO and HC concentration. Are they okay?
Yes
Go to next step.
No
Adjust CO and HC concentrations.
Check choke valve. Is it fully open after warm-up?
Yes
Go to next step.
No
Repair or replace choke system.
Check float level. Is it okay? (float level is high.)
Yes
Go to next step.
No
Check the following: • Float • Needle valve
Check distributor, (centrifugal spark advance, vacuum spark advance) Is it okay?
Yes
Go to next step.
No
Repair or replace distributor.
Check compression pressure. Is it normal?
Yes
Go to Step 14.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Is main jet loose?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace jets.
2 3 4 5 6
9 10
11
12 13
14
No
F4-47
CONTINUED
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ENGINE ELECTRICAL SYSTEM CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . BATTERY REMOVAL/INSTALLATION . . . . . . BATTERY INSPECTION . . . . . . . . . . . . . . . . . . BATTERY RECHARGING . . . . . . . . . . . . . . . . . GENERATOR REMOVAL/INSTALLATION . . . GENERATOR INSPECTION . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . IGNITER INSPECTION . . . . . . . . . . . . . . . . . . . IGNITION COIL REMOVAL/INSTALLATION .
G– 1 G– 1 G– 1/2 G– 2 G– 2/3 G– 3/4 G– 5 G– 5 G– 5
IGNITION COIL INSPECTION . . . . . . . . . . . . . DISTRIBUTOR REMOVAL/INSTALLATION . . DISTRIBUTOR DISASSEMBLY/ASSEMBLY . DISTRIBUTOR INSPECTION (F2 CARB) . . . HIGH-TENSION LEAD REMOVAL/INSTALLATION . . . . . . . . . . . . . . STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . STARTER REMOVAL/INSTALLATION . . . . . . STARTER INSPECTION . . . . . . . . . . . . . . . . . .
G–5/6 G–6/7 G–8 G–9 G–9 G–10 G–10 G–10/11
Battery Clamp Installation Note (RH) Install the battery clamp as shown.
CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
3.5—4.9 {35—50, 31—43}
FRONT
75D26R
FRONT N·m {kgf·cm, in·lbf}
1
Negative battery cable
2
Positive battery cable
3
Battery clamp + Installation Note (RH)
4
Battery
5
Battery tray
BATTERY INSPECTION Battery ST Inspect the battery in the following procedure. Step
Inspection
1
Measure open circuit voltage of battery.
2
Quick charge for 30 minutes and recheck voltage.
3
Apply test load (see test load chart) to battery using a battery y load tester and record battery voltage after 15 seconds. Is voltage more than specification?
Action Above 12.4 V
Go to Step 3.
Below 12.4 V
Go to next step.
Above 12.4 V
Go to next step.
Below 12.4 V
Replace battery.
Yes
Battery is okay.
No
Replace battery.
CONTINUED
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CHARGING SYSTEM 1. Place a battery in a pan of water to prevent it from overheating. The water level should come up about halfway on the battery. Keep water off the top of the battery.
Test load chart Battery
Load (A)
34B19R
110
55D23R
180
75D26L
195
75D26R
195
80D26R
195
95D31R
250
BATTERY
Battery positive voltage with load Approximate battery temp.
Minimum voltage(V)
21 °C {70 °F}
9.6
15 °C {60 °F}
9.5
10 °C {50 °F}
9.4
4 °C {40 °F}
9.3
– 1 °C {30 °F}
9.1
Battery type (5–hour rate)
Slow charge (A)
Quick charge (A)/(30 min.)
– 7 °C {20 °F}
8.9
34B19R (27)
3.0—4.0
20
–12 °C {10 °F}
8.7
55D23R (48)
4.5—5.5
30
–18 °C { 0 °F}
8.5
2. Connect a battery charger to the battery. 3. Adjust the charging current as follows.
Back-up Current 1. Verify that the ignition switch (engine switch) is at the OFF position and that the key has been removed. 2. Disconnect the negative battery cable.
5.5—6.5
35
5.5—6.5
35
80D26R (55)
5.5—6.5
35
95D31R (64)
6.5—8.0
40
4. After the battery has been recharged, measure the battery positive voltage and verify that the battery keeps specified voltage for more than 1 hour.
Caution Operating electrical loads while measuring the back-up current can damage the circuit tester.
Specification Above 12.4 V
3. Measure the back-up current between the negative battery terminal and the negative battery cable. Back-up current 20 mA max.
75D26L (52) 75D26R (52)
5. If not as specified, replace the battery. GENERATOR REMOVAL/INSTALLATION Warning When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery before performing the following operation.
4. If the current exceeds the maximum, remove the fuse in the main fuse block and the fuse block one by one while measuring the back-up current. 5. Inspect and repair harnesses and connectors of the fuse at which the current reduces. BATTERY RECHARGING
1. Disconnect the negative battery cable. 2. Remove the fresh-air duct, air intake pipe and air hose. (WL, WL Turbo) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the drive belt deflection/tension. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.)
Caution When disconnecting the battery, remove the negative cable first and install it last to prevent damage to electrical components or the battery. To avoid deformation or damage to the battery, remove the battery plugs while charging the battery. Do not quick charge for over 30 minutes. It will damage the battery.
CONTINUED
G–2
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CHARGING SYSTEM
G6
WL, WL Turbo
5.0—6.8 N·m {50—70 kgf·cm, 44—60 in·lbf}
20—30 {2.0—3.1, 15—22}
A B C 19—25 {1.9—2.6, 14—18}
38—51 {3.8—5.3, 28—38}
A 5.0—6.8 N·m {50—70 kgf·cm, 44—60 in·lbf}
B
38—51 {3.8—5.3, 28—38}
C 38—51 {3.8—5.3, 28—38} N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
F2 CARB, F2 CIS 5.0—6.8 N·m {50—70 kgf·cm, 44—60 in·lbf} 16—22 {1.6—2.3, 12—16}
1
Terminal B wire
2
Connector
3
Drive belt (generator)
4
Generator strap (G6)
5
Generator
GENERATOR INSPECTION Generator Warning Light 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is correct. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Turn the ignition switch (engine switch) on and verify that the generator warning light illuminates. 4. If not, inspect the generator warning light and wiring harnesses between the battery and generator warning light and between the battery and generator terminal L (G6, F2 CARB, F2 CIS), I (WL, WL Turbo). 38—51 {3.8—5.3, 28—38}
ST G6, F2 CARB, F2 CIS
N·m {kgf·m, ft·lbf}
S
G–3
L
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CHARGING SYSTEM Standard voltage
WL, WL Turbo
Engine switch ON (V)
Idle (V) [20°C {68°F}]
WL, WL Turbo
WL, WL Turbo
B
B+
14.05—14.85
A
B+
14.05—14.85
S
0
7.025—7.425
I
2.0—4.0
13.00—14.85
Terminal
A
S
I
6. If not as specified, disassemble and inspect the generator. 5. Verify that the generator warning light goes out after engine starts. 6. If not, inspect the wiring harness between the S terminals of the generator (WL, WL Turbo) and the generator. Generator Voltage 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is within the specification. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Turn off all electrical loads. 4. Turn the ignition switch (engine switch) to START position and verify that the generator turns smoothly without any noise while the engine is running. 5. Measure the voltage at the terminals shown in the table.
Current 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is correct. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Disconnect the negative battery cable. 4. Connect an ammeter, capable of reading 120 A or over, between generator terminal B and the wiring harness. 5. Connect the negative battery cable. 6. Turn all electrical loads off. 7. Start the engine and increase the engine speed to 2,000—2,500 rpm. 8. Turn the following electrical loads on and verify that the current reading increases. Headlights Blower motor Rear window defroster Note Current required for generating power varies with electrical loads applied.
G6, F2 CARB, F2 CIS
Standard current (Reference) S
L
Measuring conditions Room temperature: 20 °C {68 °F} Voltage: 13.5 V Engine hot Engine speed (rpm)
Standard voltage Ignition switch ON (V)
Idle [20°C {68°F}] (V)
G6, F2 CARB, F2 CIS
G6, F2 CARB, F2 CIS
B
B+
14.1—14.7
L
Approx. 1
13.0—14.0
S
B+
14.1—14.7
Terminal
*:
S
G6, F2 CARB, F2 CIS
WL, WL Turbo
1,000
Approx. 0—43
Approx. 0—58
2,000
Approx. 0—62
Approx. 0—74
Must not be 0 A.
9. If generator terminal B current will not increase, disassemble and inspect the generator.
WL, WL Turbo
A
Terminal B current (A)*
I
CONTINUED
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IGNITION SYSTEM
IGNITION SYSTEM
G6, F2 CIS 8.9—12.7 {90—130, 79—112}
IGNITER INSPECTION G6, F2 CIS 1. Disconnect the igniter connector. 2. Turn the ignition switch on and measure the voltage at connector terminal A using the voltmeter.
1.5—1.9 {15—20, 14—17}
G6, F2 CIS
Specification Battery positive voltage
6.87—9.80 {70—100, 60.8—86.8] N·m {kgf·cm, in·lbf}
3. Turn the ignition switch off and verify that there is continuity between terminal B and the body ground. 4. While cranking the engine, measure the voltage at terminal C using the voltmeter.
F2 CARB 8.9—12.7 {90—130, 79—112}
Specification Approx. 0.5 V 5. If voltage and continuity are okay, replace the igniter. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.)
2.0—2.9 {20—30, 18—26}
IGNITION COIL REMOVAL/INSTALLATION G6, F2 CARB, F2 CIS 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
6.87—9.80 {70—100, 60.8—86.8]
ST N·m {kgf·cm, in·lbf}
1
Center lead
2
Connector
3
Ignition coil bracket
4
Condenser
5
Ignition coil
6
Igniter
IGNITION COIL INSPECTION G6, F2 CARB, F2 CIS Primary Coil Winding 1. Disconnect the ignition coil connector.
CONTINUED
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IGNITION SYSTEM 2. Measure the resistance at the primary coil using an ohmmeter.
F2 CARB
Specification [20 °C {68 °F}] G6, F2 CIS: 0.81—0.99 Ω F2 CARB: 1.035—1.265 Ω
(+)
G6, F2 CIS
4. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) DISTRIBUTOR REMOVAL/INSTALLATION G6, F2 CARB, F2 CIS 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the ignition timing. (Refer to Section F2, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
F2 CARB
G6
3. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) Secondary Coil Winding 1. Disconnect the ignition coil connector. 2. Disconnect the center lead. 3. Measure the resistance at the secondary coil using an ohmmeter. Specification 10—16 k [20 °C {68 °F}] 19—25 {1.9—2.6, 14—18} G6, F2 CIS N·m {kgf·m, ft·lbf}
CONTINUED
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IGNITION SYSTEM Distributor Installation Note Verify that the No.1 cylinder is at top dead center, and align the distributor matching marks.
F2 CARB
MATCHING MARKS
19—25 {1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf}
F2 CIS
19—25 {1.9—2.6, 14—18}
ST N·m {kgf·m, ft·lbf}
1
Vacuum hose
2
High-tension lead + HIGH-TENSION LEAD REMOVAL/INSTALLATION
3
Connector
4
Distributor + Installation Note
CONTINUED
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IGNITION SYSTEM DISTRIBUTOR DISASSEMBLY/ASSEMBLY G6, F2 CARB, F2 CIS 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. F2 CIS
G6
R
R
F2 CARB
R
1
Cap
8
Coupling set
2
Rotor
9
Governor set
3
Cover
10
Oil seal
4
Signal rotor
11
Bearing
5
Pick-up coil with igniter
12
Distributor body
6
Vacuum control unit
13
O-ring
7
Breaker
CONTINUED
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IGNITION SYSTEM DISTRIBUTOR INSPECTION (F2 CARB) Centrifugal Spark Advance Control 1. Warm up the engine to the normal operating temperature. 2. Check to be sure that the idle speed and ignition timing are correct. (Refer to Section F2, ENGINE TUNE-UP.) 3. Turn off all electrical loads. 4. Disconnect the vacuum hose to the vacuum control unit, and plug the end of the hose.
TIMING LIGHT DIAPHRAGM A
( ° ) 11—15
VACUUM HOSE
0—2 0
5. While gradually increasing the engine speed, use the timing light to check the advance angle on crankshaft pulley.
20 53.3 {150, 5.9} {400, 15.7}
ADVANCE (DEGREE) VACUUM ( kPa { mmHg , inHg })
6. If necessary, disassemble and inspect the distributor.
19—23
Pick-up Coil With Igniter Inspection 1. Connect an ohmmeter to the pick-up coil.
(°) 9—13
0—2 ADVANCE (DEGREE) 0
1,200 2,200 6,000 ENGINE SPEED ( rpm )
(1) Excess advance . . . weak governor spring (if the governor spring is broken, the advance will rise very high) (2) Insufficient advance . governor weight or cam malfunction 6. If necessary, disassemble and inspect the distributor.
2. Measure the resistance.
ST Resistance 900—1,200 Ω
Vacuum Spark Advance Control 1. Warm up the engine to normal operating temperature. 2. Check to be sure that the idle speed and ignition timing are correct. (Refer to section F2, ENGINE TUNE-UP.) 3. Turn off all electrical loads. 4. Disconnect the vacuum hose to the vacuum control unit, and plug the end of the hose. 5. Attach a vacuum pump to the diaphragm A and check using the timing light while applying vacuum.
3. If it is not within specification, replace it. HIGH-TENSION LEAD REMOVAL/INSTALLATION Caution D The high-tension leads must be reinstalled to their original positions. Incorrect installation can damage the leads and cause power loss, and negatively affect the electronic components.
CONTINUED
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STARTING SYSTEM
STARTING SYSTEM WL, WL Turbo
STARTER REMOVAL/INSTALLATION 9.9—11.7 N·m {100—120 kgf·cm, 87—104 in·lbf}
Warning When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery before performing the following operation. 1. Disconnect the negative battery cable. 2. Remove the battery. (WL, WL Turbo) (Refer to CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.) 3. Remove the intake manifold bracket. (G6) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. G6, F2 CARB, F2 CIS 38—51 {3.8—5.3, 28—38}
38—51 {3.8—5.3, 28—38}
9.9—11.7 N·m {100—120 kgf·cm, 87—104 in·lbf}
N·m {kgf·m, ft·lbf}
1
Terminal B wire
2
Terminal S wire
3
Starter
STARTER INSPECTION On-vehicle Inspection 1. Verify that the battery is fully charged. 2. Crank the engine and verify that the starter turns smoothly without any noise. 3. If not as specified, measure the voltage at terminals S and B when the ignition switch (engine switch) is at START position. Specification Above 8 V 4. If the voltage is within the specification, remove the starter and inspect the magnetic switch and the starter. 5. If the voltage is not as specified, inspect the wiring harness, ignition switch (engine switch).
N·m {kgf·m, ft·lbf}
No Load Test 1. Verify that the battery is fully charged. 2. Connect the starter, battery, voltmeter, and ammeter as shown. A B M
IGNITION SWITCH (ENGINE SWITCH)
V STARTER BATTERY
TERMINAL S
CONTINUED
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STARTING SYSTEM 3. Operate the starter and verify that it turns smoothly. 4. Measure the voltage and current while the starter is operating. Specification Engine type Item
G6
F2 CARB, F2 CIS
WL, WL Turbo
Voltage (V)
11.5
11.5
11
Current (A)
Below 100
Below 60
Below 130
5. If not as specified, repair or replace the inner parts as necessary.
G–11
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CLUTCH GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH FLUID INSPECTION . . . . . . . . . . . . . CLUTCH FLUID REPLACEMENT/AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL INSPECTION/ ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
H– 1 H– 1 H– 1 H– 1/2 H– 2 H– 2/3 H– 3 H– 4 H– 5
CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . H– 7 CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . H– 7 CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . H– 7 CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 8 CLUTCH UNIT REMOVAL/INSTALLATION . . . H– 8/10 CLUTCH COVER INSPECTION . . . . . . . . . . . . H–10 CLUTCH DISC INSPECTION . . . . . . . . . . . . . . . H–11 CLUTCH RELEASE COLLAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . H–11 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–11 PILOT BEARING INSPECTION . . . . . . . . . . . . . H–11 FLYWHEEL INSPECTION . . . . . . . . . . . . . . . . . H–11
H– 5 H– 5/6
GENERAL PROCEDURES
CLUTCH FLUID
Clutch Pipe Removal/Installation 1. If any clutch pipe has been disconnected any time during the procedure, add brake fluid, bleed the air, and inspect for leakage after the procedure has been completed. 2. If removing the clutch pipe, remove it using the SST (49 0259 770B). If installing the clutch pipe, modify the clutch pipe tightening torque to allow for the use of a torque wrench–SST (49 0259 770B) combination, and then tighten the clutch pipe using the SST (49 0259 770B).
CLUTCH FLUID INSPECTION Note The fluid in the reservoir must be maintained between the MIN/MAX level during replacement. CLUTCH FLUID REPLACEMENT/AIR BLEEDING Caution Clutch fluid will damage painted surfaces, be careful not to spill clutch fluid on a painted surface. If this should happen, wash it off immediately. Do not mix different brands of clutch fluid. Do not reuse the clutch fluid that was drained out. 1. Draw the fluid from the reserve tank with a suction pump. 2. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug. 3. Place the other end of the vinyl hose into a container. 4. Slowly pump the clutch pedal several times. 5. With the clutch pedal depressed, loosen the bleeder screw using the SST to let fluid escape. Close the bleeder screw using the SST. BLEEDER SCREW
49 0259 770B
CONTINUED
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CLUTCH FLUID, CLUTCH PEDAL 1.Repeat steps 4 and 5 until only clean fluid is seen. 2.Tighten the bleeder screw. Tightening torque 5.9—8.8 N·m {60—90 kgf·cm, 52—78 in·lbf}
CLUTCH PEDAL CLUTCH PEDAL INSPECTION/ADJUSTMENT Clutch Pedal Height 1. Measure the distance from the upper surface of the pedal pad to the carpet.
3.Add fluid to the MAX mark. 4.Check for correct clutch operation.
Pedal height 241.6—246.6 mm {9.52—9.70 in}
B
A 14—17 {1.4—1.8, 11—13}
PEDAL HEIGHT
CARPET
N·m {kgf·m, ft·lbf}
2.If necessary, adjust the pedal height by turning stopper bolt A and clutch switch (or adjust bolt) B.
CONTINUED
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CLUTCH PEDAL CLUTCH PEDAL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2.Remove in the order indicated in the table. 3.Install in the reverse order of removal. 4.After installation, adjust the clutch pedal. (Refer to CLUTCH PEDAL INSPECTION/ADJUSTMENT)
Clutch Pedal Free Play 1. Depress the clutch pedal by hand until clutch resistance is felt, and measure the pedal free play. Pedal free play 3.0—8.0 mm {0.12—0.31 in}
L.H.D. D 19—25 {1.9—2.6, 14—18}
C 12—16 {1.2—1.7, 8.7—12.3}
19—25 {1.9—2.6, 14—18}
PEDAL FREE PLAY N·m {kgf·m, ft·lbf}
6.9—9.80 N·m {70—100 kgf·cm, 61—86.8 in·lbf}
2.If necessary, adjust the pedal free play by turning locknut C and adjusting push rod D. Clutch Release Point Inspection 1. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. 2.Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position.
1
Clutch switch connector (G6, F2 CIS)
2
Spring pin
3
Clevis pin
4
Nut
5
Clutch pedal component
R.H.D. G6, F2 CIS, F2 Carb Refer to section F2, INTAKE-AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION.
Standard distance A: 14.6—37.5 mm {0.58—1.47 in} (reference value) A
WL, WL Turbo Refer to section F2, INTAKE-AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION.
RELEASE POINT FULL STROKE END POSITION
N·m {kgf·m, ft·lbf}
PEDAL STROKE
3.If the clutch pedal disengagement stroke is outside of the specification, adjust the pedal height and pedal free play, and verify the pedal stroke. Pedal stroke 146.5—151.5 mm {5.8—5.9 in} (reference value)
CONTINUED
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CLUTCH PEDAL CLUTCH PEDAL DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. Note Apply lithium-based grease to the spring and bush when assembling. 2. Assemble in the reverse order of disassembly.
12—16 {1.2—1.7, 8.7—12.3}
14—17 {1.4—1.8, 11—13}
R
N·m {kgf·m, ft·lbf}
1
Clutch switch (G6, F2 CIS)
2
Adjustment bolt (WL, WL Turbo, F2 Carb)
3
Nut
4
Stopper rubber
5
Retaining ring
6
Washer
7
Bush
8
Pin
9
Fork
10
Push rod
11
Nut
12
Pedal pad
13
Clutch pedal component
CONTINUED
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CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 6.9—9.8 {70—100, 60.8—86.7}
R
SST * 12.8—21.5 {130—220, 113—190}
* 49 0259 770B
N·m {kgf·cm, in·lbf}
1
Clutch pipe
3
Clutch master cylinder
2
Nut
4
Gasket
CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R
R
R
84—112 N·m {8.5—11.5 kgf·m, 61.5—83.1 ft·lbf}
CONTINUED
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CLUTCH MASTER CYLINDER
1
Snap ring + Disassembly Note + Assembly Note
2
Piston
3
Protector
4
Primary cap
5
Return spring
6
Tank cap
7
Reservoir
8
Bushing
9
Joint bolt
10
Gasket
11
One-way valve piston
12
Return spring
13
One way valve pin
14
Clutch master cylinder body
Snap Ring Disassembly Note Hold the piston down using a cloth-wrapped pin punch.
Snap Ring Assembly Note Hold the piston down using a cloth-wrapped pin punch.
CONTINUED
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CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
22—26 {2.2—2.7, 16—19}
16—22 {1.6—2.3, 12—16}
(LITHIUM BASED GREASE)
1
E-clip
3
Bolt
2
Clutch hose
4
Clutch release cylinder
N·m {kgf·m, ft·lbf}
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
G6
R
5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
EXCEPT G6
1
Boot
5
Bleeder cap
2
Push rod
6
Bleeder screw
3
Piston and cap
7
Steel ball
4
Return spring
8
Clutch release cylinder body
CONTINUED
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CLUTCH UNIT
CLUTCH UNIT CLUTCH UNIT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
G6 :92—98 {9.3—10.0, 67.3—72.3} EXCEPT G6 :97—102 {9.8—10.5, 70.9—75.9} ENGINE SIDE
TRANSMISSION SIDE
SST
18—26 {1.8—2.7, 14—19}
SST SST SST
(MOLYBDENUM SULFIDE) N·m {kgf·m, ft·lbf}
1
2
Transmission + Section J1, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION + Section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION Clutch release collar
3
Clutch release fork
4
Clutch cover + Removal Note + Installation Note
5
Clutch disc + Installation Note
6
Pilot bearing + Removal Note + Installation Note
7
Flywheel + Removal Note + Installation Note
CONTINUED
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CLUTCH UNIT Clutch Cover Removal Note 1. Install the SSTs. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released. 49 E011 1A0
Flywheel Installation Note 1. Install the flywheel to the crankshaft. 2. Hand-tighten the flywheel lock bolts. 3. Install the SST to the flywheel. 4. Apply sealant to the bolt threads before installing the bolt to prevent oil leakage from the bolt. 5. Gradually tighten the flywheel lock bolts in a crisscross pattern. G6 1
5
49 SE01 310A
7
3
49 E011 1A0
4 6
8
2
Pilot Bearing Removal Note Note The pilot bearing does not need to be removed unless you are replacing it.
EXCEPT G6
Use the SSTs to remove the pilot bearing. 3
1 6
49 E011 1A0 4
5 2
49 1285 071
Flywheel Removal Note 1. Hold the flywheel using the SST. 2. Remove the bolts evenly and gradually in a crisscross pattern.
Pilot Bearing Installation Note G6, F2 CIS, F2 Carb Install a new pilot bearing using a pipe until depth is as follows: Depth 4.0 mm {0.16 in}
G6 PILOT BEARING CRANK SHAFT
Ä ÀÆ Â Ã Å Ç Á
49 E011 1A0
EXCEPT G6
3
1 6
49 E011 1A0
4
5 2
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CLUTCH UNIT WL, WL Turbo Install a new pilot bearing using a pipe until protrusion height is as follows:
CLUTCH COVER INSPECTION 1. Measure the wear of the diaphragm spring figures. Depth 0.6 mm {0.024 in} min.
Protrusion height 0—0.2 mm {0—0.008 in}
DEPTH PILOT BEARING FLY WHEEL
2. Measure the flatness of the pressure plate using a straight edge and a feeler gauge.
Clutch Disc Installation Note Hold the clutch disc in position using the SST.
Clearance 0.5 mm {0.020 in} max.
49 SE01 310A
Clutch Cover Installation Note 1. Install the SSTs. 2. Tighten the bolts evenly and gradually in a crisscross pattern.
3. When checking the diaphragm spring fingers, mount a dial indicator on the cylinder block. 4. Rotate the flywheel and check for misaligned diaphragm spring fingers.
49 E011 1A0
Misalignment 0.6 mm {0.030 in} max.
49 SE01 310A
5. Replace the clutch cover if not as specified.
CONTINUED
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CLUTCH UNIT CLUTCH DISC INSPECTION 1. Using vernier calipers, measure the thickness of the lining at a rivet head on both sides. 2. If clutch disc thickness is less than the minimum, replace the clutch disc.
FLYWHEEL PILOT BEARING INSPECTION 1. Without removing the pilot bearing from the flywheel, turn the bearing while applying force in the axial direction.
Thickness 0.3 mm {0.012 in} min. 0.3 mm {0.012 in}
2. If the bearing sticks or has excessive resistance, replace it. 3. Measure the clutch disc runout using a dial indicator.
FLYWHEEL INSPECTION 1. Install a dial indicator on the cylinder block. 2. Measure the flywheel runout using a dial indicator.
Runout 0.7 mm {0.027 in} max.
Runout 0.2 mm {0.079 in} max.
4. If runout is excessive, replace the clutch disc. CLUTCH RELEASE COLLAR INSPECTION
3. If runout is excessive, replace the flywheel.
Caution Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing. Otherwise, clutch release collar may not operate properly. 1. Turn the collar while applying force in the axial direction.
2. If the collar sticks or has excessive resistance, replace the clutch release collar.
CONTINUED
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MANUAL TRANSMISSION (M15M-D, M15MX-D) MANUAL TRANSMISSION .............................. J1-1 TRANSMISSION OIL INSPECTION ................ J1-1 TRANSMISSION OIL REPLACEMENT ........... J1-1/2 OIL SEAL (M15M-D) REPLACEMENT............. J1-2 VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION ........................ J1-2
VEHICLE SPEEDOMETER SENSOR INSPECTION .....................................................J1-2 MANUAL TRANSMISSION REMOVAL/INSTALLATION ................................J1-3/7
MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. Remove the check plug A.
2.
Verify that the oil is at the brim of the check plug hole as shown. If it is low, add the specified oil from the check plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D) 2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D) 3. Install a new check plug A.
2. 3. 4.
5.
Drain the oil into a container. Clean the drain plug B. Install the drain plug B with new washer. Tightening torque B: 40—58 N.m {4.0—6.0 kgf.m, 29—43 ft.lbf} Add the specified oil from check plug A port until the level reaches the brim of check plug hole.
Tightening torque A: 25—39 N.m {2.5-4.0 kgf.m, 19—28 ft.lbf} TRANSMISSION OIL REPLACEMENT 1. Remove the drain plug B with washer and the check plug A.
Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D) 2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D)
6. Install a new check plug A. Tightening torque A: 25—39 N.m {2.5—4.0 kgf.m, 19—28 ft.lbf}
CONTINUED J1-1
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MANUAL TRANSMISSION 6.
Install the vehicle speedometer sensor. Tightening torque 7.9—10.7 N.m {80—110 kgf.cm, 69.5—95.4 in.Ibf}
7. 8.
9.
OIL SEAL (M15M-D) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.) 3. Remove the oil seal using a screwdriver.
Connect the vehicle speedometer sensor connector. Add the specified type and amount of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) Connect the negative battery cable.
VEHICLE SPEEDOMETER SENSOR INSPECTION 1. Remove the vehicle speedometer sensor. (Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.) 2. Measure voltage between terminals of the vehicle speedometer sensor while the gear is turning. Meter needle
4. 5.
Action
Moves slightly under 5 V
Speedometer sensor is normal. Inspect wiring harness. (Instrument cluster-Vehicle speedometer sensor)
Does not move
Replace vehicle speedometer sensor.
Apply the specified oil to new oil seal. Install the oil seal until it touches the case using a suitable piece of pipe.
3.
Install the vehicle speedometer sensor. (Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.)
6.
Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.) 7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the transmission oil. 3. Disconnect the vehicle speedometer sensor connector. 4. Remove the vehicle speedometer sensor. 5. Apply transmission oil to new O-ring and install it on new vehicle speedometer sensor.
J1-2
CONTINUED
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MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 4x2(M15M-D) 1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1
Shift lever knob
12
Speedometer sensor connector
2
Console
13
Back-up light switch connector
3
Dust boot
14
Neutral switch connector (F2 CIS)
4
Change boot upper plate
15
Front pipe bracket
5
Boot
16
Clutch release cylinder
6
Dust boot
17
7
Gasket
Crossmember ☞ Removal Note
8
Wave washer
9
Change bush
18 19
10
Change lever
Transmission lower mount Transmission ☞ Removal Note ☞ Installation Note
11
Change seat
CONTINUED J1-3
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MANUAL TRANSMISSION
1
Shift lever knob
12
Speedometer sensor connector
2
Console
13
Back-up light switch connector
3
Dust boot
14
Front pipe bracket
4
Change boot upper plate
15
Clutch release cylinder
5
Boot
16
6
Dust boot
Crossmember ☞ Removal Note
7
Gasket
17
Dynamic damper
8
Wave washer
18
Transmission lower mount
19
Transmission ☞ Removal Note & Installation Note
9
Change bush
10
Change lever
11
Change seat
CONTINUED
J1-4
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MANUAL TRANSMISSION Crossmember removal note • Securely support the transmission on a transmission jack, then remove the crossmember. Transmission removal note • Maintain the stability of the transmission while removing it.
Transmission installation note Warning • A transmission that is not securely supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. 2.
Place the transmission on a transmission jack. Maintain the stability of the transmission while installing it.
CONTINUED
J1-5
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MANUAL TRANSMISSION 4x4(M15MX-D) 1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft, (Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission and transfer oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1
Shift lever knob
12
Transfer under cover
2
Console
13
Speedometer sensor connector
3
Dust boot
14
Back-up light switch connector
4
Change boot upper mount
15
4x4 indicator switch connector
5
Boot
16
Front pipe bracket
6
Dust boot
17
Clutch release cylinder
7
Gasket
18
8
Wave washer
9
Change bush
Crossmember ☞ MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 4x2 (M15M-D), Crossmember removal Note
10
Change lever
11
Change seat
CONTINUED
J1-6
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MANUAL TRANSMISSION 19
Transmission lower mount
20
Transmission and transfer ☞ Removal Note & Installation Note
Transmission and transfer removal note • Maintain the stability of the transmission and transfer while removing them .
Transmission and transfer installation note Warning • A transmission and transfer that are not securely supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while installing them.
CONTINUED
J1-7
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MANUAL TRANSMISSION (R15M–D, R15MX–D) MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . TRANSMISSION OIL INSPECTION . . . . . . . . . TRANSMISSION OIL REPLACEMENT . . . . . . OIL SEAL (R15M–D) REPLACEMENT . . . . . . VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
J2–1 J2–1 J2–1/2 J2–2
VEHICLE SPEEDOMETER SENSOR INSPECTION...J2–2 MANUAL TRANSMISSION REMOVAL/INSTALLATION . . . . . . . . . . . . . . . J2–3/9
J2–2 TRANSMISSION OIL REPLACEMENT 1. Remove drain plugs A and B, and drain the oil into a container. 2. Clean the drain plug A. 3. Install the drain plug A with new washer and a new drain plug B.
MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. Remove the filler plug. FILLER PLUG
Tightening torque A: 40—58 N·m {4.0—6.0 kgf·m, 29—43 ft·lbf} B: 21—31 N·m {2.1—3.2 kgf·m, 16—23 ft·lbf} FILLER PLUG
2. Verify that the oil is at the brim of the filler plug hole as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL–4 or GL–5 Viscosity: SAE 75W–90 (All season) or SAE 80W–90 (Above 10°C {50°F})
DRAIN PLUG A
DRAIN PLUG B
4. Remove the filler plug and add the specified oil through the filler plug port until the level rises to the bottom of the port. Specified oil Grade: API service GL–4 or GL–5 Viscosity: SAE 75W–90 (All season) or SAE 80W–90 (Above 10°C {50°F}) Capacity: 2.8 L {3.0 US qt, 2.5 lmp qt} (R15M–D) 3.2 L {3.4 US qt, 2.8 lmp qt} (R15MX–D)
FILLER PLUG HOLE
3. Install a new filler plug. Tightening torque 25—39 N·m {2.6—4.0 kgf·m, 19—28 ft·lbf}
FILLER PLUG HOLE
CONTINUED
J2–1
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MANUAL TRANSMISSION 1. Install a new filler plug. Tightening torque 25—39 N·m {2.6—4.0 kgf·m, 19—28 ft·lbf} OIL SEAL (R15M–D) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove the oil seal using a screwdriver.
4. Apply the specified oil to the new oil seal. 5. Install the oil seal until it touches the case using a suitable piece of pipe.
PIPE
6. Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION (Refer to section J1, MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION.) VEHICLE SPEEDOMETER SENSOR INSPECTION (Refer to section J1, MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR INSPECTION.)
CONTINUED
J2–2
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MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 42 (R15M–D) 1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified amount and type of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation. 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
F2
R
69—88 {7.0—9.0, 51—65}
19—25 {1.9—2.6, 14—18}
A
69—88 {7.0—9.0, 51—65} 16—22 {1.6—2.3, 12—16}
38—51 {3.8—5.3, 28—38}
69—88 {7.0—9.0, 51—65} 69—88 {7.0—9.0, 51—65}
16—22 {1.6—2.3, 12—16}
A
ST 38—51 {3.8—5.3, 28—38}
38—51 {3.8—5.3, 28—38}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
38—46 {3.8—4.7, 28—33}
32—46 {3.2—4.7, 24—33} 22—28 {2.2—2.9, 16—20}
N·m {kgf·m, ft·lbf}
1
Shift lever knob
12
Vehicle speedometer sensor connector
2
Console
13
Back–up light switch connector
3
Dust boot
14
Neutral switch connector (F2 CIS)
4
Change boot upper plate
15
Front pipe bracket
5
Boot
16
Clutch release cylinder
6
Dust boot
17
7
Gasket
Crossmember + Removal Note
8
Wave washer
18
Transmission lower mount
9
Change bush
19
10
Change lever
Transmission + Removal note + Installation note
11
Change seat
CONTINUED
J2–3
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MANUAL TRANSMISSION G6
1
Shift lever knob
12
Vehicle speedometer sensor connector
2
Console
13
Back-up light switch connector
3
Dust boot
14
Neutral switch connector
4
Change boot upper plate
15
Front pipe bracket
5
Boot
16
Clutch release cylinder
6
Dust boot
17
7
Gasket
Crossmember ☞ Removal Note
8
Wave washer
18
Transmission lower mount
9
Change bush
19
10
Change lever
Transmission ☞ Removal note ☞ Installation note
11
Change seat
CONTINUED
J2-4
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MANUAL TRANSMISSION WL, WL TURBO 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R
38—51 {3.8—5.3, 28—38}
19—25 {1.9—2.6, 14—18}
38—51 {3.8—5.3, 28—38}
A 16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
A
32—46 {3.2—4.7, 24—33} 22—28 {2.2—2.9, 16—20}
38—46 {3.8—4.7, 28—33}
N·m {kgf·m, ft·lbf}
1
Shift lever knob
11
Change seat
2
Console
12
Vehicle speedometer sensor connector
3
Dust boot
13
Back-up light switch connector
4
Change boot upper plate
14
Front pipe bracket
5
Boot
15
Clutch release cylinder
6
Dust boot
16
7
Gasket
Crossmember + Removal Note
8
Wave washer
17
Transmission lower mount
9
Change bush
18
10
Change lever
Transmission + Removal note + Installation note
CONTINUED
J2–5
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MANUAL TRANSMISSION Crossmember removal note Securely support the transmission on a transmission jack, then remove the crossmember. Transmission removal note Warning Do not allow the transmission to fall from the transmission jack. Maintain the stability of the transmission while
removing it.
Transmission installation note Warning A transmission that is not securely supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission on a transmission jack. 2. Maintain the stability of the transmission while installing them.
ST
CONTINUED
J2–6
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MANUAL TRANSMISSION 44 (R15MX–D) 1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the front pipe. (G6 engine) (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal. 8. Add the specified type and amount of transmission and transfer oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.) 9. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation. G6 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R R
38—51 {3.8—5.3, 28—38}
19—25 {1.9—2.6, 14—18}
A 38—51 {3.8—5.3, 28—38}
16—22 {1.6—2.3, 12—16}
69—88 {7.0—9.0, 51—65}
38—51 {3.8—5.3, 28—38}
32—46 {3.2—4.7, 24—33}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
A
37—50 {3.7—5.1, 27—36}
44—53 {4.4—5.3, 32—39}
38—51 {3.8—5.3, 28—38}
N·m {kgf·m, ft·lbf}
CONTINUED
J2–7
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MANUAL TRANSMISSION 1
Shift lever knob
14
Back–up light switch connector
2
Console
15
Neutral switch connector
3
Dust boot
16
4x4 indicator switch connector
4
Change boot upper mount
17
Transfer neutral switch connector (RFW model)
5
Boot
18
Front pipe bracket
6
Dust boot
19
Clutch release cylinder
7
Gasket
20
8
Wave washer
Crossmember + MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 42 (R15M–D), Crossmember removal note
9
Change bush
10
Change lever
21
Transmission lower mount
11
Change seat
22
12
Transfer under cover
13
Vehicle speedometer sensor connector
Transmission and transfer + Removal note + Installation note
WL, WL TURBO
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R R
38—51 {3.8—5.3, 28—38}
19—25 {1.9—2.6, 14—18}
ST
38—51 {3.8—5.3, 28—38}
A 32—46 {3.2—4.7, 24—33} 16—22 {1.6—2.3, 12—16}
A
37—50 {3.7—5.1, 27—36}
44—53 {4.4—5.3, 32—39} 22—28 {2.2—2.9, 16—20}
N·m {kgf·m, ft·lbf}
CONTINUED
J2–8
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MANUAL TRANSMISSION 1
Shift lever knob
2
Console
3
Dust boot
4
Change boot upper mount
5
Boot
6
Dust boot
7
Gasket
8
Wave washer
9
Change bush
10
Change lever
11
Change seat
12
Transfer under cover
13
Vehicle speedometer sensor connector
14
Back–up light switch connector
15
Transfer neutral switch connector (RFW model)
16
4x4 indicator switch connector
17
Front pipe bracket
18
Clutch release cylinder
19
Crossmember + MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 42 (R15M–D), Crossmember removal note
20
Transmission lower mount
21
Transmission and transfer + Removal note + Installation note
Transmission and transfer removal note Warning Do not allow the transmission to fall from the transmission jack. Maintain the stability of the transmission and
transfer while removing them.
Transmission and transfer installation note Warning A transmission and transfer that are not securely supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while installing them.
CONTINUED
J2–9
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TRANSFER TRANSFER ..................................................................J3-1 TRANSFER OIL INSPECTION ...............................J3-1 TRANSFER TRANSFER OIL INSPECTION 1. Remove the filler plug with washer.
2.
Verify that the oil is at the brim of the filler plug hole as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 USqt,1.8 lmp qt}
TRANSFER OIL REPLACEMENT................ J3-1
TRANSFER OIL REPLACEMENT 1. Remove the filler plug with washer and drain plug with washer.
2. 3. 4.
Drain the oil into a container. Clean the filler and drain plugs. Install the drain plug with new washer. Tightening torque 40—58 N.m {4.0—6.0 kgf.m, 29—43 ft.lbf}
5.
Add the specified oil from filler plug port until the level reaches the brim of filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 USqt,1.8lmpqt}
3. 4.
Clean the filler plug. Install the filler plug with new washer. Tightening torque 40—58 N-m {4.0—6.0 kgf.m, 29—43 ft.lbf} 6.
Install the filler plug with new washer. Tightening torque 40—58 N-m {4.0-6.0 kgf.m, 29—43 ft.lbf}
CONTINUED
J3-1
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PROPELLER SHAFT PROPELLER SHAFT (42) . . . . . . . . . . . . . . . . . . PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT INSPECTION . . . . . . . . . . FRONT PROPELLER SHAFT (44) . . . . . . . . . . . FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
L–1 L–1 L–2 L–2 L–2
FRONT PROPELLER SHAFT INSPECTION . . FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . REAR PROPELLER SHAFT (44) . . . . . . . . . . . . REAR PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR PROPELLER SHAFT INSPECTION . . . .
L–3 L–3/4 L–5 L–5 L–5
PROPELLER SHAFT (42) PROPELLER SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 50—58 {5.0—6.0, 37—43}
SST
37—52 {3.7—5.4, 27—39} N·m {kgf·m, ft·lbf}
1
Bolt, nut
2
Nut + Installation Note
3
Propeller shaft + Removal Note + Installation Note
WL TURBO, G6:
49 S120 440
WL, F2 CIS, F2 CARB:
49 0259 440
Propeller Shaft Installation Note Align the marks made during removal, and install the propeller shaft. If installing a new propeller shaft, align the differential companion flange precast marking with the tag on the propeller shaft. TAG
MARK
Propeller Shaft Removal Note 1. Before removing the propeller shaft, put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation. TAG
MARK
Nut Installation Note ST Tighten the center bearing installation nuts with the vehicle *unloaded. *unloaded...Fuel tank is full; engine coolant and engine oil are at specified levels; spare tire, jack and tools are in designated position.
2. Remove the propeller shaft from the extension housing and immediately install the SST to prevent oil leakage.
CONTINUED
L–1
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PROPELLER SHAFT (42), FRONT PROPELLER SHAFT (44) PROPELLER SHAFT INSPECTION 1. Measure the propeller shaft runout using a dial indicator.
FRONT PROPELLER SHAFT (44) FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
Runout 0.4 mm {0.016 in} max.
28—30 {2.8—3.1, 21—22}
2. If the runout is excessive, replace the propeller shaft. 3. Move the universal joint in the direction shown, and inspect joint play. Note Starting torque 0.3—1.1 N·m {3.0—12.0 kgf·cm, 2.7—10.4 in·lbf}
N·m {kgf·m, ft·lbf}
1
Bolt, nut
2
Front propeller shaft + Removal Note + Installation Note
Front Propeller Shaft Removal Note Before removing the front propeller shaft, put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation. 4. If there is excessive play or the starting torque is not within the specification, replace the propeller shaft.
TAG
MARK
Front Propeller Shaft Installation Note Align the marks made during removal, and install the front propeller shaft. If installing a new propeller shaft, align the precast marking with the tag on the front propeller shaft.
CONTINUED
L–2
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FRONT PROPELLER SHAFT (44)
TAG
MARK
FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. R
R
R
FRONT PROPELLER SHAFT INSPECTION 1. Measure the front propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.
R
1
Snap ring + Disassembly Note
2
Universal joint yoke
3
Universal joint + Disassembly Note + Assembly Note
4
Sliding yoke
5
Propeller shaft
Snap ring Disassembly Note 1. Mark the yoke and propeller shaft for proper reassembly. 2. If the runout is excessive, replace the front propeller shaft. 3. Move the universal joint in the direction shown, and inspect the joint play.
MARK
Note Starting torque 0.3—0.7 N·m {3.0—8.0 kgf·cm, 2.7—6.9 in·lbf}
2. Clamp the propeller shaft in a vise. 3. Remove the snap ring.
ST
Universal joint Disassembly Note 1. Push one bearing cup out of the propeller shaft by tapping the yoke with a plastic hammer.
BEARING CUP
4. If there is excessive play or the starting torque is not within the specification, repair the front propeller shaft. (Refer to FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY.) YOKE
CONTINUED
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FRONT PROPELLER SHAFT (44) 1. Remove the opposite bearing cup in the same manner. 2. Separate the propeller shaft and yoke. 3. Clamp the yoke in a vise. 4. Remove the bearing cups and the spider from the yoke in the same manner as in Steps 1 and 2. Universal joint Assembly Note 1. Verify that the inside of the bearing cup is filled with 1.15—1.45g {0.04—0.05 oz} grease. Add the specified amount of disulphide molybdem grease as necessary. 2. Set the new spider into the yoke and tap in a new bearing cup until the snap ring groove is exposed.
6. If there is excessive play or the starting torque is not within the specification, replace the front propeller shaft.
SPIDER
3. Measure the snap ring clearance, then select and install two new snap rings of equal thickness. Snap ring thicknesses mm {in} 1.22 {0.0480}
1.32 {0.0520}
1.24 {0.0488}
1.34 {0.0528}
1.26 {0.0496}
1.36 {0.0536}
1.28 {0.0504}
1.38 {0.0543}
1.30 {0.0512} BEARING CUP YOKE
SNAP RING CLEARANCE
SPIDER
4. Install the remaining bearing cups and snap rings as in Steps 1—3. 5. Move the universal joint in the direction shown, and inspect joint play. Note Starting torque 0.3—0.7 N·m {3.0—8.0 kgf·cm, 2.7—6.9 in ·lbf}
CONTINUED
L–4
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REAR PROPELLER SHAFT (44)
REAR PROPELLER SHAFT (44)
TAG
MARK
REAR PROPELLER SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
50—58 {5.0—6.0, 37—43}
REAR PROPELLER SHAFT INSPECTION 1. Measure the rear propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.
37—52 {3.7—5.4, 27—39} 50—58 {5.0—6.0, 37—43} N·m {kgf·m, ft·lbf}
1
Bolt, nut
2
Nut + PROPELLER SHAFT (42), PROPELLER SHAFT REMOVAL/INSTALLATION, Nut Installation Note
3
Rear propeller shaft + Removal Note + Installation Note
4
Dynamic damper (WL Turbo)
2. If the runout is excessive, replace the rear propeller shaft. 3. Move the universal joint in the direction shown. Inspect starting torque and joint play. Note Starting torque 0.3—1.1 N·m {3.0—12.0 kgf·cm, 2.7—10.4 in·lbf}
Rear Propeller Shaft Removal Note 1. Before removing the rear propeller shaft, put marks on the yoke and the companion flange on the rear propeller shaft tag side for proper reinstallation. TAG
ST
MARK
4. If there is excessive play or the starting torque is not within the specification, replace the rear propeller shaft.
Rear Propeller Shaft Installation Note Align the marks made during removal, and install the rear propeller shaft. If installing a new propeller shaft, align precast marking with the tag on the rear propeller shaft.
CONTINUED
L–5
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FRONT AND REAR AXLES GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . FRONT AXLE (42) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . FRONT AXLE (44) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE INSPECTION . . . . . . . . . . . . . . . . AXLE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION . . . . . . . . . . . . . . OUTPUT SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL OIL INSPECTION . . . . REAR DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL ASSEMBLY . . .
M– 2 M– 2 M– 2 M– 3/5 M– 5 M– 5 M– 6/8 M– 9 M– 9 M– 9/11 M–12 M–12 M–13/15 M–16 M–17/18 M–19 M–19 M–19 M–20 M–21/23 M–24/27
MANUAL FREEEWHEEL (MFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–32 ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . M–32
REMOTE FREEWHEEL (RFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 INDICATOR SWITCH INSPECTION . . . TRANSFER NEUTRAL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW SWITCH INSPECTION . . . . . . . . . . . . . . RFW MAIN SWITCH REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . RFW MAIN SWITCH INSPECTION . . . . . . . . ONE-WAY CHECK VALVE INSPECTION . . . LOCK AND FREE SOLENOID VALVES INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW ACTUATOR INSPECTION . . . . . . . . . . . RFW CONTROL MODULE INSPECTION . . . . RFW CONTROL MODULE REMOVAL/ INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT REMOVAL/INSTALLATION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . JOINT SHAFT INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT ASSEMBLY . . . CONTROL BOX REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL BOX DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT FORK INSPECTION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL DISASSEMBLY . . . . FRONT DIFFERENTIAL ASSEMBLY . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . REMOTE FREEWHEEL (RFW) . . . . . . . . . . . .
M–32 M–32 M–32/33 M–33 M–33 M–33 M–34 M–34 M–34 M–35 M–35/36 M–37 M–38/39 M–39 M–40/42 M–42 M–43/44 M–44 M–45 M–45 M–45 M–45 M–46/47 M–48/50 M–51/55 M–56 M–56/62
CONTINUED
M–1
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GENERAL PROCEDURES, FRONT AXLE (42)
GENERAL PROCEDURES
FRONT AXLE (42)
Wheel and tire removal/installation The removal and installation procedure for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to the specified torque. (Refer to section TD, SUSPENSION, Wheels and Tires.)
WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection After jacking up the vehicle and supporting it at the specified places with safety stands, inspect for noticeable bearing play by holding the top and bottom of the tire.
Suspension arm removal/installation Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and unloaded.*
Wheel bearing axial play 0 mm {0 in} Preload Adjustment 1. Verify that the tire rotates smoothly when rotated strongly, and that there is no rough feeling or is abnormal noise from the bearing. 2. Remove the brake caliper component and suspend it by a rope. 3. Remove the hub cap, pull out the cotter pin and remove the set cover. 4. Loosen the locknut to the extent that it can be turned by hand. 5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount.
*Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Brake line disconnection/connection Caution Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off immediately. Tighten the brake pipe flare nut using the
SST (49 0259 770B). Be sure to modify the brake pipe fIare nut tightening torque to allow use of a torque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.) If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and inspect leakage after the procedure has been completed.
Preload Frictional force plus 5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf} 7. Install the set cover, and secure with a new cotter pin. 8. Install the hub cap and brake caliper component.
Connectors disconnection/connection Disconnect the negative battery cable before doing any work that requires the handling of connectors. Reconnect the negative battery cable only after the work is completed.
M–2
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FRONT AXLE (42) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
54—68 {5.5—7.0, 40—50}
SST
108—127 {11—13, 80—94}
R
SST
R
30—50 {3.0—5.2, 22—50} 80—100 {8.1—10.2, 59—73}
R SST
R SST R R
R SST
SST
R
R
45—58 {4.5—6.0, 33—43} 118—156 {12—16, 87—115}
19—25 {1.9—2.6, 14—18}
R
R
N·m {kgf·m, ft·lbf}
1
Hub cap
2
Cotter pin
11
Lower arm ball joint + section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note
3
Set cover
4
Locknut
5
Washer
12
Hub and disc plate component + Installation Note
Upper arm ball joint + section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note
6
Brake caliper component + Removal Note
7
13
Steering knuckle
8
Dust cover
14
9
Tie-rod end ball joint + section N, MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note
Disc plate + Removal Note
15
Wheel hub + Removal Note
16
Hub bolt + Removal Note + Installation Note
10
Knuckle arm
CONTINUED
M–3
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FRONT AXLE (42)
17
Outer bearing inner race
18
Oil seal + Installation Note
19
Inner bearing inner race
20
Inner bearing outer race + Removal Note + Installation Note
21
Outer bearing outer race + Removal Note + Installation Note
Brake Caliper Component Removal Note Remove the brake caliper component, and suspend it by a rope.
Outer Bearing Outer Race, Inner Bearing Outer Race Installation Note Install the bearing outer race using the SSTs and a press. For the other side, reverse the wheel hub and install the outer race.
OUTSIDE BEARING
49 H033 101 INSIDE BEARING
49 B025 001
Disc Plate, Wheel Hub, Hub Bolt Removal Note Note The hub bolt does not need to be removed unless it is being replaced. 1. After putting markings on the disc plate and the wheel hub, remove the bolt and disassemble the plate and hub.
Oil Seal Installation 1. After inserting the bearing in the hub, use the SST to tap in the oil seal until it is flush with the hub end surface. 2. Apply grease to the oil seal lip.
49 F019 001 MARK
2. Remove the hub bolt using a press as necessary.
Hub Bolt Installation Note Press new hub bolts into the wheel hub using a press.
Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note Note When the inner bearing outer race is removed, the inner race and oil seal are removed together. Remove the bearing outer race using a suitable
round bar and a hammer. For the other side, reverse the wheel hub and remove the outer race.
CONTINUED
M–4
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FRONT AXLE (42), FRONT AXLE (44) Hub and Disc Plate Component Installation Note 1. Apply grease to the areas indicated in the figure.
FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Wheel Bearing Play Inspection.) Preload Adjustment Caution When replacing the locknut, tighten it using the SST and turn the wheel hub a few times to seat the bearing. Then, perform the preload adjustment.
2. Install the hub and disc plate component, then adjust the preload. (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment.)
1. For RFW model, remove the hub cap and drive shaft end flange. For MFW model, remove the freewheel hub component. 2. Remove the spacer and set plate. 3. Remove the brake caliper component, and suspend it by a rope. 4. Loosen the locknut to the extent that it can be turned by hand using the SST. 49 S231 635
5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount. Preload Frictional force plus 5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf} 7. Install the set plate, spacer, freewheel hub or drive shaft end flange, hub cap and brake caliper component.
CONTINUED
M–5
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FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
55—80 {5.6—8.2, 41—59}
R SST
R SST
SST
55—67 {5.6—6.9, 41—49}
54—68 {5.5—7.0}
R
R
R
SST
30—51 {3.0—5.2, 22—37}
R SST R
R R
SST SST SST
R SST R
R
19—25 {1.9—2.6, 14—18} 118—156 {12—16, 87—115} 40—44 {4.0—4.5, 29—32} 45—58 {4.5—6.0, 33—43}
(RFW MODEL)
(MFW MODEL) 25—29 {2.5—3.0, 19—21}
N·m {kgf·m, ft·lbf}
1
Hub cap
9
Dust cover
2
Drive shaft end flange
10
3
Freewheel hub component
4
Spacer
5
Set plate
Tie-rod end ball joint + Section N, MANUAL STEERING, STEERIG GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note
6
Locknut + Removal Note + Installation Note
11
7
Brake caliper component + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Brake Caliper Component Removal Note.
Disc plate + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Disc Plate Removal Note
12
Wheel hub + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Wheel Hub Removal Note
8
Hub and disc plate component
CONTINUED
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FRONT AXLE (44)
13
Hub bolt + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Removal Note + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Installation Note
14
Outer bearing inner race
15
Oil seal + Installation Note
16
Inner bearing inner race
17
Inner bearing outer race + FRONT AXLE (42) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note
18
Outer bearing outer race + FRONT AXLE (42) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note
19
Nut + Section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Nut Installation Note
20
Shock absorber bolt
21
Upper arm ball joint + Section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note
22
Steering knuckle component + Removal Note
23
Lower arm ball joint
24
Oil seal + Removal Note + Installation Note
25
Spacer
26
Needle bearing + Removal Note + Installation Note
27
Steering Knuckle Component Removal Note 1. Remove the lower arm ball joint from the knuckle using the SST. (Refer to section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note.) 2. Remove the lower arm installation bolt and remove the lower arm with the knuckle. Oil Seal Removal Note Remove the oil seal using a screwdriver.
Needle Bearing Removal Note Remove the needle bearing using the SST. 49 S231 660
Needle Bearing Installation Note 1. Install the needle bearing using the SST and a press. 2. Apply grease to the needle bearing.
49 S033 108
Steering knuckle
Locknut Removal Note Remove the locknut using the SST. 49 S231 635
CONTINUED
M–7
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FRONT AXLE (44) Oil Seal Installation Note 1. Install the new oil seal using the SST and a press. 2. Apply grease to the oil seal lip.
Locknut Installation Note 1. Install the locknut using the SST. 49 S231 635
49 S033 107
2. Adjust the preload. (Refer to FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment)
Outer Bearing Outer Race Installation Note Install the outer bearing outer race using the SST and press.
49 F027 005
Inner Bearing Outer Race Installation Note Install the inner bearing outer race using the SST and a press.
49 F027 007
Oil Seal Installation Note Install the new oil seal using the SST and a press.
49 S033 106
CONTINUED
M–8
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REAR AXLE 4. If not as specified, adjust the bearing play. (Refer to REAR AXLE, AXLE SHAFT REMOVAL/INSTALLATION, Bearing Inner Race, Bearing Locknut Installation Note, Bearing play adjustment.)
REAR AXLE REAR AXLE INSPECTION Wheel Bearing Play Inspection 1. Jack up the rear end and support it with safety stands. 2. Verify that there is no abnormal noise and that the tire rotates smoothly when forcefully rotated by hand. 3. With a hand on top of the tire, inspect the bearing play. Wheel bearing axial play 0.05—0.25 mm {0.002—0.010 in} AXLE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
SST *
SST
16—21 N·m {1.6—2.2 kgf·cm, 12—15 in·lbf}
275—313 {28—32, 203—231}
R
R
SST
R SST SST
SST R
108—127 {11—13, 80—94}
SST R
CONTINUED *49
0259 770B N·m {kgf·m, ft·lbf}
M–9
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REAR AXLE Bearing Housing Removal Note Remove the bearing and bearing housing using the SSTs.
1
Brake drum
2
Parking brake connecting pin
3
Brake pipe
4
Nut
5
Axle shaft and back plate component
6
Shim
7
Bearing locknut + Removal Note + Installation Note
8
Lock washer
9
Bearing housing + Removal Note
10
Bearing inner race + Installation Note
11
Bearing spacer
12
Oil seal (bearing housing side) + Installation Note
13
Bearing outer race + Removal Note + Installation Note
14
Back plate component
15
Axle shaft
16
Hub bolt
17
Baffle
18
Oil seal (axle casing side) + Removal Note + Installation Note
49 S026 204 49 S026 205
49 S026 208
Bearing Outer Race Removal Note After removing the bearing inner race and oil seal from the rear wheel hub, tap lightly using a suitable round bar to force out the outer race.
Oil Seal (Axle Casing Side) Removal Note Remove the oil seal from the axle casing using a screwdriver.
Bearing Locknut Removal Note Note Be careful when removing or installing the bearing locknuts for the left wheels because they are left threaded (tightened by turning counterclockwise).
OIL SEAL
Set the SSTs as shown in the figure, and remove
the bearing locknut from the rear axle shaft. AXLE CASING
49 0603 635A 49 S120 645A
Oil Seal (Axle Casing Side) Installation Note 1. Use the SST to tap the oil seal in until it is flush with the end of the axle casing. 2. After installation, apply grease to the oil seal lip. OIL SEAL
49 H025 001
AXLE CASING
CONTINUED
M–10
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REAR AXLE Bearing Outer Race, Oil Seal (Bearing Housing Side) Installation Note Press the bearing outer race and the oil seal using the SSTs. OIL SEAL
BEARING OUTER RACE
49 U027 003 49 F027 004
Bearing play adjustment Adjust the bearing play in the axial direction (only when the bearing is replaced). (1) First insert one side of the rear axle shaft component and push the end of the shaft to the thrust block, then insert a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.65—0.95 mm {0.026—0.037 in}. (2) Next insert the opposite shaft component and push the end of the shaft to the thrust block. (3) Use a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.05—0.25 mm {0.002—0.010 in}. Bearing play in axial direction 0.05—0.25 mm {0.002—0.010 in}
Bearing Inner Race, Bearing Locknut Installation Note Caution The torque wrench must be attached perpendicular to the SST.
PINION SHAFT A
1. Set the SST and then press the bearing inner race in until 3 to 5 threads of the bearing locknut mounting screw of the axle shaft are visible above the top of the bearing outer race.
SHIM
THRUST BLOCK
49 S120 748
2. Remove the SST, and then install the bearing locknut to the axle shaft. 3. Tighten the bearing locknut using the SST to press in the bearing inner race. 4. Remove the SST and install the lock washer so that its tab fits into the groove of the axle shaft. 5. Tighten the bearing locknut to the specified torque. Bearing locknut tightening torque 275—313 N·m {28.0—32.0 kgf·m, 203—231 ft·lbf}
49 0603 635A 49 S120 645A
CONTINUED
M–11
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DRIVE SHAFT
DRIVE SHAFT DRIVE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
R
1
2
Wheel hub, steering knuckle + FRONT AXLE (44), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
3
Snap ring
4
Clip + Installation Note
Drive shaft + Removal Note + Installation Note
Drive Shaft Removal Note Caution Do not damage the dust cover or oil seal. Remove the drive shaft by prying with a bar
inserted between the differential casing and the drive shaft.
Clip Installation Note Left side Install a new clip to the output shaft clip groove with the opening facing upward. Right side Install a new clip to the clip groove of the drive shaft end with the opening facing upward. CLIP
OPENING 28 mm {1.1 in}
Drive Shaft Installation Note Be careful not to damage the oil seal with the shaft spline when installing the drive shaft.
CONTINUED
M–12
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DRIVE SHAFT DRIVE SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of removal.
R RIGHT SIDE
R
R R
R R
LEFT SIDE
1
Boot band + Disassembly Note + Assembly Note
6
Inner ring + Disassembly Note + Assembly Note
2
Clip
7
3
Outer ring + Disassembly Note + Assembly Note
Cage + Disassembly Note + Assembly Note
8
Boot + Disassembly Note + Assembly Note
9
Bell joint component
10
Drive shaft
4
Snap ring + Assembly Note
5
Balls + Disassembly Note + Assembly Note
CONTINUED
M–13
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DRIVE SHAFT Boot Band Disassembly Note
3. Disassemble the balls, inner ring, cage from the drive shaft as component. 4. Turn the cage by approximately 30 degrees and pull the cage and balls away from the inner ring.
Note D The wheel side boot band does not need to be removed unless replacing it.
30_
1. Pry up the locking clip using a screwdriver and remove the band using pliers. 2. Slide the boot along the shaft to expose the joint.
Boot Disassembly Note Note D The wheel side boot does not need to be removed unless it is being replaced. Outer Ring Disassembly Note 1. Wrap the shaft splines with tape. 2. Remove the boot.
Caution D Mark with paint; do not use a punch. 1. Mark the cage and outer ring for proper assembly. 2. Remove the clip using a screwdriver. 3. Remove the outer ring from the inner ring and the balls. 4. Clean the grease away.
TAPE
MARKS
Boot Assembly Note Note D The wheel side and differential side boots are different. Balls, Inner Ring, Cage Disassembly Note Caution D Mark with paint; do not use a punch. 100.5 mm {4.0 in}
1. Mark the drive shaft and inner ring for proper assembly.
WHEEL SIDE
99.2 mm {3.9 in}
DIFFERENTIAL SIDE
1. With the splines of the shaft still wrapped in tape from disassembly, assemble the boot. 2. Temporarily assemble the wheel side boot, new boot bands, and differential side boot to the drive shaft. 3. Remove the tape.
MARKS
2. Disassemble the snap ring from the drive shaft using a snap-ring pliers.
CONTINUED
M–14
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DRIVE SHAFT Cage, Inner Ring, Balls, Snap Ring Assembly Note 1. Align the marks, and install the balls and cage to the inner ring in the direction shown in the figure. Caution Install the cage with the offset facing the snap ring groove. If incorrectly installed, the drive shaft may become disengaged.
LEFT SIDE
RIGHT SIDE
2. Install a new snap ring. BALLS CAGE
Standard length Right side : 619.0—629.0 mm {24.4—24.7 in} Left side : 551.0—561.0 mm {21.7—22.0 in} 3. Release trapped air from inside the boot using a screwdriver covered with a rag. SNAP RING GROOVE
INNER RING
Outer Ring Assembly Note Note Use the specified grease supplied in the boot kit. 1. Apply grease to the cage, inner ring, balls, and the outer ring. 4. Set the new boot band to the boot groove. 5. Fold the band back and use pliers to pull it tight. 6. Lock the end of the band by bending the locking clips.
Wheel side : 110—130 g {3.8—4.6 oz} Differential side : 95—105 g {3.4—3.7 oz} 2. Align the marks, and install the outer ring onto the shaft. 3. Install a new clip. MARKS
Boot Band Assembly Note Caution Do not damage the boot. For wheel side, apply grease only when assembling the boot. 1. Apply grease to the inside of the boot. 2. Set the drive shaft to the standard length.
CONTINUED
M–15
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DRIVE SHAFT OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
37—57 {3.7—5.5, 27—39}
N·m {kgf·m, ft·lbf}
1
2
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION
3
Screw
4
Output shaft component + Removal Note
Bolt
Output Shaft Component Removal Note Remove the output shaft by prying with a bar inserted between the bearing housing of the output shaft and the differential casing.
CONTINUED
M–16
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DRIVE SHAFT OUTPUT SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R SST R R R
R
1
Clip + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Clip Assembly Note
4
Bearing + Disassembly Note + Assembly Note
2
Output shaft component + Disassembly Note + Assembly Note
5
Output shaft
6
Bearing housing
7
Oil seal + Assembly Note
8
O-ring
3
Oil seal + Assembly Note
Output Shaft Component Disassembly Note Disassemble the output shaft component using a press.
CONTINUED
M–17
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DRIVE SHAFT Bearing Disassembly Note Remove the bearing from the output shaft component using a press.
Oil Seal Assembly Note Assemble the new oil seal by lightly tapping it using a plastic hammer.
Oil Seal Assembly Note Use the SST to assemble the new oil seal until it is flush with the bearing housing end using the SST.
Output Shaft Component Assmebly Note Press the output shaft and bearing to the bearing housing.
49 M005 796
Bearing Assembly Note Caution Press the bearing center and shaft center vertically. Press the new bearing to the output shaft.
CONTINUED
M–18
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REAR DIFFERENTIAL Specified oil Type Standard differential: API service GL–5, SAE 90 LSD: API service GL–6, SAE 90 Capacity: 42: 1.40 L {1.48 US qt, 1.23 lmp qt} 44: 1.85 L {1.96 US qt, 1.63 lmp qt}
REAR DIFFERENTIAL REAR DIFFERENTIAL OIL INSPECTION Caution Position the vehicle level. 1. Remove the filler plug. 2. Verify that the oil is at the brim of the filler plug hole. If it is low, add the specified oil. Specified oil Type Standard differential: API service GL–5, SAE 90 LSD: API service GL–6, SAE 90 Capacity 42: 1.40 L {1.48 US qt, 1.23 lmp qt} 44: 1.85 L {1.96 US qt, 1.63 lmp qt}
6. Install a new washer and the filler plug. Tightening torque 40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf}
FILLER PLUG
WASHER
3. Install a new washer and the filler plug. Tightening torque 40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf} REAR DIFFERENTIAL OIL REPLACEMENT 1. Remove the filler and drain plugs. 2. Drain the differential oil into a container.
3. Wipe the plugs clean. 4. Install a new washer and the drain plug. Tightening torque 40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf} 5. Add the specified oil from the filler plug hole until it reaches the brim of the hole.
M–19
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REAR DIFFERENTIAL REAR DIFFERENTIAL REMOVAL/INSTALLATION Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil. 1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) 2. Remove the rear propeller shaft. (Refer to section L, REAR PROPELLER SHAFT (44), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
26—28 {2.6—2.9, 19—20}
50—58 {5.0—6.0, 37—43}
N·m {kgf·m, ft·lbf}
1
Axle shaft and back plate component + REAR AXLE, AXLE SHAFT REMOVAL/ INSTALLATION
2
Differential + Removal Note
Differential Removal Note To prevent the differential from dropping, leave the two bolts loosely tightened. Then hit the differential carrier using a wooden hammer.
CONTINUED
M–20
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REAR DIFFERENTIAL STANDARD DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table.
SST SST
SST SST
SST
1
Differential component + Disassembly Note
14
Adjusting shim
15
Front bearing cup + Disassembly Note
2
Bearing cap + Disassembly Note
16
Oil buffle
3
Adjusting shim
17
4
Side bearing cup
Rear bearing cup + Disassembly Note
5
Side bearing cone + Disassembly Note
18
Carrier
19
Hex screw
6
Pinion nut + Disassembly Note
20
Ring gear
21
Roll pin + Disassembly Note
22
Pinion shaft
23
Thrust block
7
Companion flange + Disassembly Note
8
Oil seal + Disassembly Note
9
Thrust washer
24
Pinion gear
10
Drive pinion + Disassembly Note
25
Pinion gear thrust washer
26
Side gear
11
Front bearing cone
27
Side gear thrust washer
12
Collapsible spacer
28
Case
13
Rear bearing cone + Disassembly Note
CONTINUED
M–21
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REAR DIFFERENTIAL Differential Component Disassembly Note Mount a carrier component to the SST or equivalent.
Pinion Nut Removal Note Hold the companion frange and remove the pinion nut.
T57L–500–B
Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that the left and right bearing caps won’t get mixed up. Use the mark for matching at the time of assembly.
Companion Flange Disassembly Note Remove the companion flange using universal puller.
MARK
Oil Seal Disassembly Note Pull out the oil seal using the SST.
Side Bearing Cone Disassembly Note Warning When pulling the side bearing cone, do not allow differential component to fall. It can strike legs or feet and may cause serious injury. Caution Mark the left bearing in order to install in the same position.
308–047 T77F–1102–A
Remove the side bearing cone using a press and
the SST.
Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic hammer. 205–D064 D84L–1123–A
CONTINUED
M–22
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REAR DIFFERENTIAL Rear Bearing Cone Disassembly Note Note Mark or otherwise distinguish between the front and rear cones so that they are not mixed up at the time of reassembly. Remove the rear bearing cone using the SST.
205–D064 D84L–1123–A
Front Bearing Cup, Rear Bearing Cup Disassembly Note Note Mark or otherwise distinguish between the front and rear cups so that they are not mixed up at the time of reassembly. Remove the bearing races using the SSTs (308 047 T77F–1102A and 100 001 T50T–100–A).
Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note Note • Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the time of reassembly. • Remove the bearing outer races by using the two grooves on the carrier and tapping the outer races alternately.
100–001 T50T–100–A
3308–047 T77F–1102–A
Knock Pin Disassembly Note Caution • Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. • Secure the gear case in a vise and remove the knock pin by using a 4 mm {0.16 in} diameter bar.
Roll Pin Disassembly Note Caution Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. Secure the gear case in a vise and remove the roll
pin using a small drift.
CONTINUED
M–23
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REAR DIFFERENTIAL STANDARD DIFFERENTIAL ASSEMBLY Assemble in the order indicated in the table.
75—95 {7.6—9.7, 55—70}
SST
SST
R
SST 130—150 {13.2—15.3, 96—110}
R SST
R R
SST
R
R
R SST
R R
SST
298—500 {30.3—50.9, 220—368}
N·m {kgf·m, ft·lbf}
1
Case + Assembly Note
16
Adjusting shim + Assembly Note
2
Side gear thrust washer + Assembly Note
17
Rear bearing cone + Assembly Note
3
Side gear
18
4
Pinion gear thrust washer
Drive pinion + Assembly Note
5
Pinion gear
19
Collapsible spacer
6
Thrust block
20
Front bearing cone
7
Pinion shaft
21
Thrust washer
8
Roll pin
22
9
Ring gear
Oil seal + Assembly Note
10
Hex screw
23
Companion flange
11
Side bearing cone + Assembly Note
24
Pinion nut
25
12
Carrier
Side bearing cup + Assembly Note
13
Oil buffle
26
Adjusting shim + Assembly Note
14
Front bearing cup + Assembly Note
27
Bearing cap + Assembly Note
15
Rear bearing cup + Assembly Note
CONTINUED
M–24
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REAR DIFFERENTIAL Adjusting Shim Assembly Note Pinion height Adjustment 1. Assemble the rear bearing cone over the SST and insert it into the rear bearing cup of the carrier. 2. Assemble the front bearing cone into the front bearing cup and assemble the SSTs.
6. This measurement is the thickness needed for the selective shim if there was no marking on the drive pinion. If the drive pinion is marked with a plus (+) reading, the amount marked should be subtracted from the feeler gauge measurement. If the drive pinion is marked with a minus (–) reading, the amount marked should be added to the feeler gauge measurement.
205–456
Rear Bearing Cone Assembly Note Assemble the selected spacer on the drive pinion and press the rear bearing inner race until it is firmly seated on the shaft.
205–110, T76P–4020–A10 205–457
205–105, T76P–4020–A3
205–090 T75L–1165–B
205–109, T76P–4020–A9
Drive Pinion Assembly Note Drive pinion preload adjustment
205–111, T76P–4020–A11
3. Roll the SST component back and forth a few times to seat the bearings while tightening the SST by hand. Tightening torque 27 N·m {2.8 kgf·m, 20 ft·lbf}
Caution Never loosen pinion nut to decrease drive pinion preload torque, and never exceed specified preload torque. If preload torque is exceeded, a new collapsible spacer must be installed and the torque sequence repeated. 1. Install the drive pinion, collapsible spacer and companion flange to the carrier, and tighten the pinion nut until all end play is removed. 2. Continue to tighten in small increments until the specified preload can be obtained.
4. Center the SST (205–456) into the side bearing bore. Install the bearing caps and tighten the bolt. Tightening torque 75—95 N·m {7.6—9.7 kgf·m, 55—70 ft·lbf} Note There should be drag on the feeler gauge when it is inserted between the SSTs (205–110, T76P–4020–A10 and 205–456). 5. Insert the thickest feeler gauge possible between the SSTs (205–110, T76P–4020–A10 and 205–456).
Drive pinion preload 1.2—1.5 N·m {12.2—15.3 kgf·cm, 10.6—13.2 in·lbf} 3. If the specified preload can’t be obtained within the specified tightening torque range, replace the collapsible spacer and inspect again.
205–110 T76P–4020–A10 FEELER GAUGE
205–456
CONTINUED
M–25
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REAR DIFFERENTIAL Case Assembly Note Assemble the side gears, thrust washer, thrust block, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.
Front Bearing Cup, Rear Bearing Cup Assembly Note 1. Install the oil baffle in the outer bearing cup bore of the carrier. 2. Install the outer bearing cup and inner bearing cup using the SST. 205–024 T76P–4616–A
Side Gear Thrust Washer Assembly Note Adjust the backlash of the side gears and pinon gear as follows. (1) Set a dial gauge to the pinion gear as shown in the figure. (2) Secure one of the side gears. (3) Move the pinion gear and measure the backlash at the end of the pinion gear.
Oil Seal Assembly Note 1. Apply a light coat of oil to the lip of a new oil seal. 2. Assemble the new oil seal using the SST.
205–007 T56T–4676–B
Standard backlash 0—0.1 mm {0—0.004 in} (4) If the backlash exceeds the standard, use the thrust washers to adjust. Side Bearing Cone Assembly Note Caution Bearings should be assembled to the original positions. Press the side bearings into the gear case using
the SST.
205–092 T75L–1165–DA
Side Bearing Cup, Adjusting Shim, Bearing Cap Assembly Note Ring gear backlash adjustment 1. Install the gear case component on the carrier. 2. Push the gear case component to the left side of the carrier and measure the clearance between the side bearing and carrier. This measurement is the left and right total shim thickness. 3. Divide the amount of shim in step 2 appropriately between the right and left side, then install the bearing cap. 4. Adjust the drive pinion, ring gear backlash and the side bearing preload as follows. (1) Mark the ring gear at four points at approx. 90° intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90° angle with one of the ring gear teeth.
CONTINUED
M–26
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REAR DIFFERENTIAL DIAL INDICATOR WITH BRACKETRY RING GEAR
5. Inspect the backlash at the three other marked points and make sure that the minimum backlash is more than 0.12 mm {0.005 in} and difference of the maximum and minimum backlash value is less than 0.08 mm {0.003 in}.
6. If backlash is not as specified, correct the backlash by switching shims from one side of the differential case to the other. 7. Using a torque wrench, inspect the total rotating torque of the pinion and differential component by rotating the pinion three complete revolutions, and then reading the rotating torque. The readings should not exceed 2.4 N·m {24.0 kgf·cm, 20.8 in·lbf}. If the backlash is within specification but the rotating torque is to high, the preload may be adjusted by removing an equal amount of shims from both sides of the differential. 8. Inspect the drive pinion and ring gear tooth contact. (1) Coat both surfaces of 6—8 teeth of the ring gear uniformly with a thin red lead coating. (2) While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact. (3) If the tooth contact is good, wipe off the red lead coating. (4) If it is not good, adjust the pinion height, then adjust the backlash.
M–27
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MANUAL FREEWHEEL (MFW) MECHANISM REMOTE FREEWHEEL (RFW) MECHANISM
MANUAL FREEWHEEL (MFW) MECHANISM
REMOTE FREEWHEEL (RFW) MECHANISM
ON-VEHICLE INSPECTION 1. Jack up the front of the vehicle and support it on safety stands. 2. Set the select lever in “2H” position. 3. Set the freewheel hub control handle to the “FREE” position, then turn the handle clockwise and counterclockwise by hand, and inspect that it turns smoothly. 4. Set the freewheel hub control handle to “LOCK” position and inspect that the wheel turns with considerable force applied to make it turn. 5. If not as specified, replace the freewheel hub component as necessary.
44 INDICATOR SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Remove the transfer case switch (44 indicator switch).
3. Inspect for continuity between the terminals as shown using an ohmmeter. Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
4. If not correct, replace the switch. TRANSFER NEUTRAL SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Remove the transfer case switch (neutral switch).
CONTINUED
M–32
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REMOTE FREEWHEEL (RFW) MECHANISM 1. Inspect for continuity at the switch using an ohmmeter. Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
OFF
RFW MAIN SWITCH REMOVAL/INSTALLATION 1. Remove the meter hood. (Refer to Section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
ON
12 mm {0.472 in} 13 mm {0.512 in}
À
2. If not correct, replace the switch.
1
RFW SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Disconnect the RFW switch connector and remove the switch.
RFW main switch
RFW MAIN SWITCH INSPECTION 1. Remove the RFW main switch. 2. Inspect for continuity between the terminals as shown using an ohmmeter. : Continuity Switch
Terminal A
B
D
F
OFF ON
3. Inspect for continuity at the switch using an ohmmeter. Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
123456567
3. If not correct, replace the switch.
4. If not correct, replace the switch.
CONTINUED
M–33
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REMOTE FREEWHEEL (RFW) MECHANISM ONE–WAY CHECK VALVE INSPECTION 1. Remove the one–way check valve. 2. Blow through A and inspect that air flows from B. 3. Blow through B and inspect that air does not flow from A. B
RFW ACTUATOR INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Disconnect the vacuum hoses from the actuator. 3. Connect a vacuum pump tester to the actuator (free side) as shown. 4. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum, and verify that the rod moves toward the left (driver’s side).
A
4. If not correct, replace the one–way check valve. LOCK AND FREE SOLENOID VALVES INSPECTION 1. Disconnect the vacuum hoses and the connector from each solenoid valve. 2. Blow through each valve from port B. 3. Inspect that air flows from the air filter. BLOW B
5. Disconnect the vacuum pump tester. 6. Connect the vacuum pump tester to the actuator (lock side) as shown. 7. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum, and inspect that the rod moves toward the right (passenger side).
A
AIR FILTER
4. Connect 12V and a ground to the terminals of each valve. 5. Blow through each valve from port B. 6. Inspect that air flows from port A. B
8. If not correct, replace the actuator.
A
7. If not correct, replace the solenoid valve(s).
CONTINUED
M–34
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REMOTE FREEWHEEL (RFW) MECHANISM RFW CONTROL MODULE INSPECTION 1. Remove the scuff plate. (Refer to section S, TRIM, SCUFF PLATE REMOVAL/INSTALLATION.) 2. Remove the front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Turn the ignition switch on and inspect the RFW control module terminal voltages, referring to the Terminal Voltage Chart. RFW CONTROL MODULE
4. If not correct, replace the component(s), wiring, and/or RFW control module. REW CONTROL MODULE REMOVAL/INSPECTION 1. Remove the scuff plate. (Refer to section S, TRIM, SCUFF PLATE REMOVAL/INSTALLATION.) 2. Remove the front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Connector
2
Nut
3
Bolt
4
RFW control module
CONTINUED
M–35
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REMOTE FREEWHEEL (RFW) MECHANISM Terminal Voltage Chart
RFW CONTROL MODULE TERMINAL
B+: Battery positive voltage Terminal
Signal name
Connected to
A
Lock solenoid
Lock solenoid
B
Ground
Body
C
Free solenoid
Free solenoid
D
–
Condition
Inspection point
Solenoid OFF
B+
Harness (Lock solenoid—RFW
Solenoid ON
Below 0.5 V
Lock solenoid
CM) –
–
Voltage
Below 0.5 V
Harness to ground point
Solenoid OFF
B+
Harness (Free solenoid—RFW
Solenoid ON
Below 0.5 V
Free solenoid
CM) –
–
–
44 indicator light
44 indicator light
44 indicator light OFF
B+
Harness (44 indicator
44 indicator light ON
Below 0.5 V
44 indicator light
Lock indicator light
LOCK indicator light
Lock indicator light OFF
B+
Harness (Lock indicator
Lock indicator light ON
Below 0.5 V
Lock indicator light
H
Battery
Battery
Ignition swtich ON
B+
Ignition swtich OFF
Below 0.5 V
RFW main switch
RFW main switch released (OFF)
B+
Harness (RFW main
I
RFW main switch
RFW main switch depreased (ON)
Below 0.5 V
RFW main switch
RFW switch
RFW switch
RFW switch OFF
B+
RFW switch ON
Below 0.5 V
Harness ((RFW switch—RFW CM)) RFW switch
44 indicator switch OFF
B+
Harness (44 indicator
44 indicator switch ON
Below 0.5 V
44 indicator switch
Transfer neutral switch OFF
B+
Harness (Transfer neutral
Transfer neutral switch ON
Below 0.5 V
Transfer neutral switch
E
F
J
K
L
44 indicator switch
44 indicator switch
Transfer neutral switch
Transfer neutral switch
light RFW CM) light—RFW
light RFW CM) light—RFW Harness,, Fuse ((Battery-Ignition y g switch—RFW CM)
switch—RFW switch RFW CM)
switch—RFW switch RFW CM)
switch—RFW switch RFW CM)
CONTINUED
M–36
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REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT REMOVAL/INSTALLATION 1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, DIFFERENTIAL OIL REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
23—26 {2.3—2.7, 17—19}
R
SST
37—53 {3.7—5.5, 27—39} 37—53 {3.7—5.5, 27—39}
N·m {kgf·m, ft·lbf}
1
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION
2
Vacuum hose
3
RFW switch connector
4
Snap pin
5
Joint shaft component, control box component
6
Gear sleeve
7
Output shaft + Removal Note
Output Shaft Removal Note Remove the output shaft using the SST.
49 0813 215A
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT DISASSEMBLY Disassemble in the order indicated in the table.
SST
SST
SST
1
Control box
2
Clip
9
Bearing + Disassembly Note
3
Remote freewheel hub + Disassembly Note
10
Oil seal + Disassembly Note
4
Spacer
11
Joint shaft
5
Retaining ring
12
Needle bearing
Ball bearing + Disassembly Note
13
Clip
14
Casing
7
Adjustment shim (s)
15
Output shaft and gear sleeve
8
Dust seal
6
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM Remote Free Wheel Hub Disassembly Note Remove the remote free wheel hub using the SST.
Oil Seal Disassembly Note Remove the oil seal using the SST.
49 U027 004
49 0710 520
Ball Bearing Disassembly Note 1. Remove the ball bearing and the joint shaft using a press.
JOINT SHAFT INSPECTION 1. Measure the joint shaft runout. Maximum runout 0.03 mm {0.0012 in}
2. Remove the ball bearing using a press. 2. If not correct, replace the joint shaft.
Bearing Disassembly Note Remove the dust seal and bearing using the SST and a suitable bar.
49 W027 001
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT ASSEMBLY Assemble in the order indicated in the table.
16—22 {1.6—2.3, 12—16}
SST SST
R
SST R R SELECTIVE
R
SST SELECTIVE SST
R
SST
R
SST N·m {kgf·m , ft·lbf}
1
Output shaft and gear sleeve
2
Casing
9
Spacer + Assembly Note
3
Oil seal + Assembly Note
10
Remote freewheel hub + Assembly Note
4
Adjustment shim(s) + Assembly Note
11
Clip
12
5
Ball bearing + Assembly Note
Dust seal + Assembly Note
13
Needle bearing
14
Clip
15
Control box
6
Joint shaft + Assembly Note
7
Bearing + Assembly Note
8
Retaining ring
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM Oil Seal Assembly Note 1. Apply differential oil to a new oil seal. 2. Install the new oil seal using the SST and a press.
Joint Shaft Assembly Note Install the joint shaft using the SST and a press.
49 U027 006 49 U027 006
Bearing Assembly Note Install the bearing using the SSTs and a press.
Ajustment Shim(s), Ball Bearing Assembly Note 1. Install the removed shim(s) and the ball bearing using the SST and a press.
49 U027 005
49 U027 006
49 U027 006
Spacer, Remote FreeWheel Hub Assembly Note 1. Install the removed spacer and the remote freewheel hub using a suitable pipe and the SST and a press.
2. Install a new retaining ring. 3. Measure the clearance between the ball bearing and the retaining ring.
49 U027 005
4. If not as specified, adjust by adding or removing shims. Use no more than two shims on either side.
2. Install a new clip. 3. Measure the clearance between the remote freewheel hub and the clip.
Maximum clearance 0.15 mm {0.0059 in} Available shim thickness 0.15 mm {0.0059 in}, 0.30 mm {0.0118 in}, 0.35 mm {0.0138 in}, 0.40 mm {0.0157 in}, 0.50 mm {0.0197 in} 5. Remove the retaining ring.
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM 4. If not as specified, adjust by adding or removing spacers. Use no more than two spacers on either side. Maximum clearance 0.15 mm {0.0059 in} Available shim thickness 0.15 mm {0.0059 in}, 0.30 mm {0.0118 in}, 0.35 mm {0.0138 in}, 0.40 mm {0.0157 in}, 0.50 mm {0.0197 in} Dust Seal Assembly Note 1. Install the new dust seal using the SST and a press.
49 M005 796
CONTROL BOX REMOVAL/INSTALLATION 1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 23—26 {2.3—2.7, 17—19}
Á À
16—22 {1.6—2.3, 12—16}
1
Vacuum hose
2
RFW switch connector
3
Control box
Â
N·m {kgf·m , ft·lbf}
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM CONTROL BOX DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. R
R
R
R SST
R
R
N·m {kgf·m , ft·lbf}
1
Snap pin
9
Change rod
2
Washer
10
Shift fork
3
RFW actuator
11
4
RFW switch and washer
Boot + Assembly Note
5
Spring cap
12
6
Spring and ball
Oil seal + Assembly Note
7
Washer
13
Control box
8
Roll pin + Disassembly Note + Assembly Note
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM Roll Pin Disassembly Note Remove the roll pin as shown in the figure.
SHIFT FORK INSPECTION 1. Measure the clearance between the gear sleeve and the shift fork. Standard clearance 0.1—0.40 mm {0.0040—0.0157 in} Maximum clearance 0.50 mm {0.0197 in}
Oil Seal Assembly Note Install a new oil seal using the SST and a press.
49 U027 007
2. Inspect the output shaft and gear sleeve of the splines for damage and wear. 3. If not correct, replace the output shaft and gear sleeve as necessary.
Boot Assembly Note Install the boot as shown in the figure.
Roll Pin Assembly Note Install a new roll pin as shown in the figure.
CONTINUED
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FRONT DIFFERENTIAL
FRONT DIFFERENTIAL FRONT DIFFERENTIAL OIL INSPECTION (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL INSPECTION.) Specified oil Type Above –18 °C {0 °F}: API GL–5, SAE 90 Below –18 °C {0 °F}: API GL–5, SAE 80 Capacity MFW: 1.2 L {1.3 US qt, 1.1 lmp qt} RFW: 1.5 L {1.6 US qt, 1.3 lmp qt} FRONT DIFFERENTIAL OIL REPLACEMENT (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) Specified oil Type Above –18 °C {0 °F}: API GL–5, SAE 90 Below –18 °C {0 °F}: API GL–5, SAE 80 Capacity MFW: 1.2 L {1.3 US qt, 1.1 lmp qt} RFW: 1.5 L {1.6 US qt, 1.3 lmp qt} FRONT DIFFERENTIAL OIL SEAL REPLACEMENT 1. Remove the drive shaft. (Refer to DRIVE SHAFT, DRIVE SHAFT REMOVAL/INSTALLATION, Drive shaft removal Note.) 2. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) 3. Remove the oil seal using a screwdriver. 4. Tap in the new oil seal to the differential using the SST. 49 G030 795
5. Install the drive shaft. (Refer to DRIVE SHAFT, DRIVE SHAFT REMOVAL/INSTALLATION, Drive Shaft Installation Note.) 6. Add the differential oil to the specified level. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)
CONTINUED
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FRONT DIFFERENTIAL FRONT DIFFERENTIAL REMOVAL/INSTALLATION 1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.) 2. Remove the propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. MFW
APPLY SCREW LOCK AGENT 95—115 {9.5—11.8, 69—85}
37—53 {3.7—5.5, 27—39}
63—93 {6.4—9.5, 47—68}
55—80 {5.6—8.2, 41—59} N·m {kgf·m, ft·lbf}
1
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Drive Shaft Removal Note
2
Front differential component + Removal Note
3
Differential bracket
CONTINUED
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FRONT DIFFERENTIAL
RFW
APPLY LOCKING COMPOUND 94.2—115.7 {9.5—11.8, 68.8—85.3}
28—30 {2.8—3.1, 21—22}
23—26 {2.3—2.7, 17—19}
94.2—115.7 {9.5—11.8, 68.8—85.3}
62.8—93.1 {6.4—9.5, 46.3—68.7} 37—53 {3.7—5.5, 27—39}
APPLY SCREW LOCK AGENT
N·m {kgf·m, ft·lbf}
1
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Drive Shaft Removal Note
4
Front differential, joint shaft component + Removal Note
5
Joint shaft, crossmember
2
Vacuum hose
6
Front differential
3
RFW switch component
Front Differential, Joint Shaft Component Removal Note 1. Set the transmission jack on the differential. 2. Remove the bolts and nuts indicated by arrows.
3. Remove the front differential and joint shaft component from the vehicle using the transmission jack.
CONTINUED
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FRONT DIFFERENTIAL FRONT DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table. SST
À
SST
É
Å
È
Ä
Ã
SST
SST
Ç
Æ
SST
Â
Á
SST
1
Bolt
7
Adjusting screw
2
Differential casing
8
Side bearing outer race
3
Oil baffle
9
4
Differential component + Disassembly Note
Locknut + Disassembly Note
10
Washer
5
Lock plate
11
6
Bearing cap + Disassembly Note
Companion flange + Disassembly Note
CONTINUED
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FRONT DIFFERENTIAL Locknut Disassembly Note Hold the companion flange using the SST and remove the locknut.
12
Oil seal + Disassembly Note
13
Drive pinion + Disassembly Note
14
Front bearing inner race
15
Collapsible spacer
16
Rear bearing inner race + Disassembly Note
17
Spacer
18
Front bearing outer race + Disassembly Note
19
Rear Bearing outer race + Disassembly Note
20
Carrier
21
Bolt
22
Ring gear
23
Knock pin + Disassembly Note
24
Pinion shaft
25
Pinion gear
26
Thrust washer
27
Side gear
28
Thrust washer
29
Side bearing inner race + Disassembly Note
30
Gear case
49 S120 710
Companion Frange Disassembly Note Pull the companion flange out using the SST.
49 0839 425C
Oil Seal Disassembly Note Remove the oil seal using a screw driver.
Differential Component Disassembly Note Install the differential component on the SSTs. 49 M005 561
49 0107 680A
Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that the left and right bearing caps won’t get mixed up. Use the mark for matching at the time of assembly.
Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic hammer.
MARK
CONTINUED
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FRONT DIFFERENTIAL Rear Bearing Inner Race Disassembly Note Note Mark or otherwise distinguish between the front and rear inner races so that they are not mixed up at the time of reassembly. Remove the rear bearing inner race using the SST.
Side Bearing Inner Race Disassembly Note Caution Mark the left bearing in order to install in the same position.
49 H027 002
Remove the side bearing inner race from the gear
case using the SST. Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note
49 0839 425C
Note Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the time of reassembly. Remove the bearing outer races using the two
grooves on the carrier and tapping the outer races alternately.
Knock Pin Disassembly Note Caution Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. Secure the gear case in a vise and remove the
knock pin using a 4 mm {0.16 in} diameter bar.
CONTINUED
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FRONT DIFFERENTIAL FRONT DIFFERENTIAL ASSEMBLY Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oll. Assemble in the order indicated in the table. 184—284 {13—29, 95—209} 23—27 {2.3—2.7, 17—19}
R SST
14—51 {3.8—5.3, 28—38}
R R
18—25 {1.8—2.6, 14—18}
R
SST
SST R SST 69—83 {7.0—8.5, 51—61}
SST
R
R
SST
SST
R SST SST R
N·m {kgf·m, ft·lbf}
1
Gear case + Assembly Note
9
Side bearing inner race + Assembly Note
2
Thrust washer + Assembly Note
10
Bolt
11
Carrier
3
Side gear
12
4
Thrust washer
Front Bearing outer Race + Assembly Note
5
Pinion gear
13
6
Pinion shaft
Rear bearing outer race + Assembly Note
7
Knock pin
14
8
Ring gear + Assembly Note
Spacer + Assembly Note
15
Rear bearing inner race + Assembly Note
CONTINUED
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FRONT DIFFERENTIAL
16
Drive pinion + Assembly Note
17
Collapsible spacer
18
Front bearing inner race
19
Oil seal + Assembly Note
20
Companion flange
21
Washer
22
Locknut + Assembly Note
23
Side bearing outer race + Assembly Note
24
Adjusting screw + Assembly Note
25
Bearing cap + Assembly Note
26
Lock plate
27
Baffle plate
28
Differential casing
29
Bolt
Standard backlash 0—0.1 mm {0—0.004 in} 4. If the backlash exceeds the standard, use the thrust washers to adjust. Ring Gear Assembly Note 1. Coat the ring gear and gear case facing surfaces with locking agent. 2. Install the ring gear and tighten the bolt to the specified torque. Side Bearing Inner Race Assembly Note Caution Bearings should be assembled to the original positions. Press the side bearings into the gear case using
the SST.
49 G030 338
Gear Case Assembly Note Assemble the side gears, thrust washer, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case. Front Bearing Outer Race Assembly Note Press the front bearing outer race into the carrier using the SST and a press.
49 F027 005
Thrust Washer Assembly Note 1. Set a dial gauge to the pinion gear as shown in the figure. 2. Secure one of the side gears. 3. Move the pinion gear and measure the backlash at the end of the pinion gear.
Rear Bearing Outer Race Assembly Note Press the rear bearing outer race into the carrier using the SST and a press.
49 F027 004
CONTINUED
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FRONT DIFFERENTIAL Spacer Assembly Note Pinion height adjustment
49 0727 570
Notes Use the same spacer and nut. Be careful to install collars A and B in the correct position and facing in the correct direction. 1. Assemble the spacer, rear bearing inner race and SST (49 8531 568) on to the SST (49 8531 565). Secure the collar with the O-ring. Then install this to the carrier. 2. Assemble the front bearing inner race, SST (49 8531 567), companion flange, washer and nut to the SST (49 8531 565). 3. Tighten the nut to the extent that the SST (49 8531 565) can be turned by hand.
49 0350 555
7. Add the two (left and right) values obtained by the measurements taken in Step 6 and then divide the total by 2. From this result, subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value. Note For example, the measured results obtained at Step 6 are 0.06 mm and 0.04 mm, and the figure inscribed on the end of the drive pinion is –2:
49 0350 555 49 8531 565
pinion height 0.06+0.04 – –2 = 0.07 = adjustment value 2 100
SPACER REAR BEARING
Therefore, replace it with a spacer 0.07 mm {0.003 in} thicker than the currently used one.
49 8531 568 O RING
49 8531 567 FRONT BEARING
4. Place the SST on the surface plate and set the dial indicator to zero.
Rear Bearing Inner Race Assembly Note Caution Press in until the force required suddenly increases. Install the spacer selected for the pinion height adjustment, confirm that the installation direction is correct. Press the rear bearing inner race in using the
49 0727 570
SSTs. SPACER
5. Place the SST (49 0350 555) on top of the SST (49 8531 565), and then set the SST (49 0727 570) on top of the SST (49 0350 555). 6. Place the measuring probe of the dial indicator so that it contacts the place where the side bearing is installed in the carrier. Then measure left and right side of the lower position.
49 F401 331 49 G030 338
CONTINUED
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FRONT DIFFERENTIAL Drive Pinion Assembly Note Drive pinion preload adjustment
Locknut Assembly Note 1. Assemble the companion flange and washer. 2. Tighten the new locknut using the SST with the determined torque while performing drive pinion preload adjustment. 3. Verify that the preload is within the specification.
Caution Do not install the oil seal. 1. Install the drive pinion, spacer, front bearing, collapsible spacer and companion flange to the carrier, and temporarily tighten the locknut. 2. Adjust the preload of the drive pinon bearing as follows. (1) Turn the companion flange by hand to seat the bearing. (2) Use a torque wrench to tighten the locknut temporarily tightened in Step 1, and confirm that the specified preload can be obtained within the specified tightening torque range. The torque applied at this time will be used after the oil seal is installed. Locknut tightening torque 128—284 N·m {13—29 kgf·m, 95—209 ff·lbf} Drive pinion preload 0.9—13.4 N·m {9—14 kgf·cm, 7.9—12.1 in·lbf} 49 S120 710
Preload 0.9—1.3 N·m {9—14 kgf·cm, 7.9—12.1 in·lbf}
49 S120 710
Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note Ring gear backlash adjustment 1. Install the differential gear component to the carrier. After loosely tightening the bearing outer race and bearing cap mounting bolts, completely tighten the adjustment screw by hand. Then, while turning the ring gear, alternately tighten the left and right adjustment screws using the SST.
49 0259 720
(3) If the specified preload can’t be obtained within the specified tightening torque range, replace the collapsible spacer and inspect again. (4) Remove the locknut, washer and companion flange. Oil Seal Assembly Note Apply differential oil to the oil seal lip and press the oil seal in until it touches the end of the differential carrier using the SST.
2. Adjust the drive pinion, ring gear backlash and the side bearing preload as follows. (1) Mark the ring gear at four points at approx. 90° intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90° angle with one of the ring gear teeth. (2) Turn both bearing adjusters equally until the backlash becomes 0.09—0.11 mm {0.0035—0.0043 in} using the SST.
49 0259 720 49 U027 003
CONTINUED
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FRONT DIFFERENTIAL (3) Inspect for the backlash at the three other marked points and make sure that the minimum backlash is more than 0.05 mm {0.002 in} and difference of the maximum and minimum backlash value is less than 0.07 mm {0.0028 in}.
Toe and flank contact Replace the spacer with a thinner one, and move the drive pinion outward. TOE CONTACT
FLANK CONTACT
Heel and face contact Replace the spacer with a thicker one. Bring the drive pinion inward. (4) After adjusting the backlash, tighten the adjustment screws equally until the distance between both pilot sections on the bearing caps (L) become as specified.
HEEL CONTACT
FACE CONTACT
Bearing cap bolt tightening torque 38—51 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
Standard distance 185.43—185.50 mm {7.300—7.303 in} 3. The inspection and adjustment procedure is as follows: (1) Coat both surfaces of 6—8 teeth of the ring gear uniformly with a thin red lead coating. (2) While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact. (3) If the tooth contact is good, wipe off the red lead coating. (4) If it is not good, adjust the pinion height, then adjust the backlash. RED LEAD
CONTINUED
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TROUBLESHOOTING
TROUBLESHOOTING REMOTE FREEWHEEL (RFW) Foreword Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read and understand the basic flow of troubleshooting in order to properly perform the basic procedures. Precaution This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary for trouble caused by other sources. Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.) Diagnostic Index No
TROUBLESHOOTING ITEM
DESCRIPTION
1
No RFW operation from free to lock (RFW indicator light does not illuminate)
Free solenoid valve malfunction RFW indicator light bulb malfunction RFW actuator malfunction RFW switch malfunction Print plate in instrument cluster malfunction METER 15 A fuse malfunction ENGINE 15 A fuse malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction
2
No RFW operation from lock to free (RFW indicator light does not go off)
Lock solenoid valve malfunction RFW switch malfunction RFW actuator malfunction Print plate in instrument cluster malfunction Engine 15 A fuse malfunction RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction
3
Noise
Joint shaft bearing abrasion or damage RFW hub abrasion Joint shaft abrasion
4
Oil leakage
RFW control box is poorly installed.
CONTINUED
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TROUBLESHOOTING Quick Diagnosis Chart Possible factor
Troubleshooting item No RFW operation from free to lock
R R R Pr M EN Tr 4 Ę Ę Ę Ę Ę Ę Ę Ę
No RFW operation from lock to free
Ę Ę Ę
R
R Lo Fr R O Ę Ę Ę Ę Ę
Jo R
Jo Con Va R Ę Ę
Ę Ę Ę Ę Ę Ę Ę Ę Ę
Ę Ę Ę Ę Ę
Noise Ę
Oil leakage
Ę Ę
Symptom Troubleshooting 1
NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)
DESCRIPTION
RFW does not change from free to lock.
[TROUBLESHOOTING HINTS]
Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction Free solenoid valve malfunction RFW indicator light bulb malfunction RFW control box malfunction
STEP 1
2
3
4
5
6
METER 15 A fuse and/of ENGINE 15 A fuse malfunction Print plate in instrument cluster malfunction RFW switch malfunction RFW actuator malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harnesses malfunction
INSPECTION
ACTION
Disconnect RFW control module connector. Turn ignition (engine) g ( g ) switch on. Measure voltage between RFW control module connector terminal F and ground. Is the voltage greater than 10 V?
Yes
Go to Step 6.
No
Turn ignition (engine) switch off. Then go to next step.
Is the METER 15 A fuse okay?
Yes
Go to next step.
No
Replace 15 A METER fuse. Then go to Step 31.
Inspect RFW indicator light bulb. Is it okay?
Yes
Go to next step.
No
Replace RFW indicator light bulb. Then go to Step 31.
Measure voltage between instrument cluster connector terminal 1J and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between METER 15 A fuse and instrument cluster. Then go to Step 31.
Measure voltage between instrument cluster connector terminal 2H and ground. Is the voltage greater than 10 V?
Yes
Repair wiring harness between instrument cluster and RFW control module. Then go to Step 31.
No
Replace print plate in instrument cluster. Then go to Step 31.
Yes
Go to Step 8.
No
Turn ignition (engine) switch off. Then go to next step.
Measure voltage between RFW control module connector terminal H and ground. Is the voltage greater than 10 V?
CONTINUED
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TROUBLESHOOTING
STEP 7
INSPECTION
ACTION Yes
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31.
No
Replace the ENG 15 A fuse. Then go to Step 31.
Disconnect free solenoid valve connector. Measure voltage between free solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect free solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31.
Measure voltage between free solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Inspect free solenoid valve. Then go to Step 31.
Measure voltage between RFW control module connector terminal C and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between free solenoid valve and RFW control module. Then go to Step 31.
Disconnect lock solenoid valve connector. Measure voltage between lock solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect lock solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31.
Measure voltage between lock solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Inspect lock solenoid valve. Then go to Step 31.
Measure voltage between RFW control module connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between lock solenoid valve and RFW control module. Then go to Step 31.
Turn ignition (engine) switch off. Is there continuity between RFW control module connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW control module and ground. Then go to Step 31.
Shift select lever to N position. Is there continuity between RFW control module connector terminal L and ground?
Yes
Go to Step 19.
No
Go to next step.
16
Is there continuity between transfer neutral switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and transfer neutral switch. Then go to Step 31.
No
Go to next step.
17
Inspect transfer neutral switch. Is it okay?
Yes
Go to next step.
No
Replace transfer neutral switch. Then go to Step 31.
Is there continuity between transfer neutral switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between transfer neutral switch and ground. Then go to Step 31.
Shift select lever to 44 indicator position. Is there continuity between RFW control module connector terminal K and ground?
Yes
Go to Step 23.
No
Go to next step.
Is there continuity between 44 indicator switch connector terminal A and ground?
Yes
Repair wiring harness between 44 indicator switch and RFW control module. Then go to Step 31.
No
Go to next step.
8
9
10
11
12
13
14
15
18
19
20
Is the ENG 15 A fuse okay?
CONTINUED
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TROUBLESHOOTING
STEP 21
22
23
24
25
26
27
28
29
30
31
2
INSPECTION
ACTION
Inspect 44 indicator switch. Is it okay?
Yes
Go to next step.
No
Replace 44 indicator switch. Then go to Step 31.
Is there continuity between 44 indicator switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between 44 indicator switch and ground. Then go to Step 31.
Shift select lever to 4H position. Is there continuity between RFW control module connector terminal J and ground?
Yes
Go to Step 27
No
Go to next step.
Is there continuity between RFW switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and RFW switch. Then go to Step 31.
No
Go to next step.
Inspect RFW switch. Is it okay?
Yes
Go to next step.
No
Replace RFW switch. Then go to Step 31.
Is there continuity between RFW switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW switch and ground. Then go to Step 31.
Inspect one-way check valve. Is it okay?
Yes
Go to next step.
No
Replace one-way check valve. Then go to Step 31.
Inspect RFW control box. Is it okay?
Yes
Go to next step.
No
Replace RFW control box. Then go to Step 31.
Inspect vacuum in vacuum hoses. Is it okay?
Yes
Go to next step.
No
Repair vacuum in vacuum hoses. Then go to Step 31.
Inspect RFW control module. Is it okay?
Yes
Go to next step.
No
Repair or replace RFW control module. Then go to next step.
Turn ignition (engine) switch on. Shift select lever from 2H to 4H position. Does RFW operate from free to lock?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)
DESCRIPTION
RFW does not change from lock to free.
[TROUBLESHOOTING HINTS]
RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction Lock solenoid valve malfunction RFW control box malfunction
STEP 1
ENGINE 15 A fuse malfunction RFW main switch malfunction RFW actuator malfunction RFW switch malfunction Air leakage from vacuum reservoir or actuator system One-way check valve Print plate in instrument cluster malfunction Related fuses and/or harnesses malfunction
INSPECTION
ACTION
Disconnect RFW control module connector. Is there continuity between RFW control module connector terminal F and ground?
Yes
Go to next step.
No
Go to Step 3.
CONTINUED
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TROUBLESHOOTING
STEP 2
INSPECTION
ACTION Yes
Repair wiring harness between RFW control module and instrument cluster. Then go to Step 32.
No
Inspect for no continuity between Instrument cluster terminal 2H and ground.
Turn ignition (engine) switch off. Disconnect RFW control module connector. Turn ignition (engine) switch on on. Measure voltage between RFW control module connector terminal H and ground. Is the voltage greater than 10 V?
Yes
Go to Step 5.
No
Turn ignition (engine) switch off. Then go to next step.
Is the ENG 15 A fuse okay?
Yes
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32.
No
Replace the ENG 15 A fuse. Then go to Step 32.
Disconnect free solenoid valve connector. Measure voltage between free solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect free solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32.
Measure voltage between free solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Inspect free solenoid valve. Then go to Step 32.
Measure voltage between RFW control module connector terminal C and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between free solenoid valve and RFW control module. Then go to Step 32.
Disconnect lock solenoid valve connector. Measure voltage between lock solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect lock solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32.
Measure voltage between lock solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go next step.
No
Inspect lock solenoid valve. Then go to Step 32.
Measure voltage between RFW control module connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Go next step.
No
Repair wiring harness between lock solenoid valve and RFW control module. Then go to Step 32.
Turn ignition (engine) switch off. Is there continuity between RFW control module connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW control module and ground. Then go to Step 32.
Shift select lever to N position. Is there continuity between RFW control module connector terminal L and ground?
Yes
Go to Step 16.
No
Go to next step.
13
Is there continuity between transfer neutral switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and transfer neutral switch. Then go to Step 32.
No
Go to next step.
14
Inspect transfer neutral switch. Is it okay?
Yes
Go to next step.
No
Replace transfer neutral switch. Then go to Step 32.
3
4
5
6
7
8
9
10
11
12
Disconnect instrument cluster connector No.2. Is there continuity between instrument cluster terminal 2H and ground?
CONTINUED
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TROUBLESHOOTING
STEP 15
16
17
18
19
20
21
22
23
24
25
INSPECTION
ACTION
Is there continuity between transfer neutral switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between transfer neutral switch and ground. Then go to Step 32.
Shift select lever to 2H position. Is there continuity between RFW control module connector terminal K and ground?
Yes
Go to Step 20.
No
Go to next step.
Is there continuity between 44 indicator switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and 44 indicator switch. Then go to Step 32.
No
Go to next step.
Inspect 44 indicator switch. Is it okay?
Yes
Go to next step.
No
Replace 44 indicator switch. Then go to Step 32.
Is there continuity between 44 indicator switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between 44 indicator switch and ground. Then go to Step 32.
Shift select lever to 4H position. Is there continuity between RFW control module connector terminal J and ground?
Yes
Go to Step 28.
No
Go to next step.
Is there continuity between RFW switch connector terminal A and ground?
Yes
Repair wiring harness between RFW switch. Then go to Step 32.
No
Go to next step.
Inspect RFW switch. Is it okay?
Yes
Go to next step.
No
Replace RFW switch. Then go to Step 32.
Is there continuity between RFW switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW switch and ground. Then go to Step 32.
Push RFW main switch on. Is there continuity between RFW main switch connector terminal I and ground?
Yes
Go to Step 28.
No
Go to next step.
Is there continuity between RFW main switch connector terminal F and ground?
Yes
Repair wiring harness between RFW main switch and RFW control module. Then go to Step 32.
No
Go to next step.
26
Inspect RFW main switch. Is it okay?
Yes
Go to next step.
No
Replace RFW main switch.
27
Is there continuity between RFW main switch connector terminal D and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW main switch and ground. Then go to Step 32.
Inspect one-way check valve. Is it okay?
Yes
Go to next step.
No
Replace one-way check valve. Then go to Step 32.
Inspect RFW actuator. Is it okay?
Yes
Go to next step.
No
Replace RFW actuator. Then go to Step 32.
Inspect vacuum in vacuum hoses. Is it okay?
Yes
Go to next step.
No
Repair vacuum in vacuum hoses. Then go to Step 32.
28
29
30
CONTINUED
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TROUBLESHOOTING
STEP 31
32
3
INSPECTION
ACTION
Inspect RFW control module. Is it okay?
Yes
Go to next step.
No
Repair or replace RFW control module. Then go to next step.
Turn ignition (engine) switch on. Move selector lever from 2H to 4H position. Does RFW operate from free to lock?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
NOISE
DESCRIPTION
Noise is heard from front differential.
[TROUBLESHOOTING HINTS] Joint shaft bearing abrasion or damage RFW hub abrasion
STEP 1 2 3 4
5
4
Joint shaft abrasion Conventional front differential parts malfunction
INSPECTION
ACTION
Inspect joint shaft bearing. Is it okay?
Yes
Go to next step.
No
Replace joint shaft bearing.
Inspect RFW hub. Is it okay?
Yes
Go to next step.
No
Replace RFW hub.
Inspect joint shaft. Is it okay?
Yes
Go to next step.
No
Replace joint shaft.
Malfunction is caused by other than RFW. Inspect conventional front differential parts. parts Are they okay?
Yes
Go to next step.
No
Replace defective part(s).
Has front differential noise stopped?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
OIL LEAKAGE
DESCRIPTION
The oil leaks from front differential.
[TROUBLESHOOTING HINTS] Poor installation of the RFW control box
STEP 1
2
3
Malfunction of conventional front differential parts
INSPECTION Is RFW control box installed completely?
ACTION Yes
Go to next step.
No
Install RFW control box securely. Then go to Step 3.
Malfunction is caused by something other than RFW. Inspect conventional front differential parts. Are they okay?
Yes
Go to next step.
No
Replace defective part(s).
Is there any oil leakage from front differential?
Yes
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction still occurs.
No
Troubleshooting completed. Explain repairs to customer.
CONTINUED
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STEERING SYSTEM GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N–1 MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N–1 STEERING WHEEL AND COLUMN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1/2 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N–3/4 STEERING SHAFT INSPECTION . . . . . . . . . . . N–4 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–5/6 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–7/9 STEERING GEAR AND LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–9 POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . N–10 AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N–10 POWER STEERING FLUID INSPECTION . . . N–10/12
GENERAL PROCEDURES
STEERING WHEEL AND COLUMN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–12 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–12 STEERING SHAFT INSPECTION . . . . . . . . . . . N–12 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–13 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–14/15 STEERING GEAR AND LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–15 POWER STEERING OIL PUMP REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–16/18 POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N–19/20 POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–21
MANUAL STEERING
Wheels and tires removal/installation STEERING WHEEL AND COLUMN INSPECTION The removal and installation procedures for the Steering Wheel Play Inspection wheels and tires are not mentioned in this section. If the play exceeds specification, either the steering When a wheel is removed, retighten it to the joints are worn or the backlash of the steering gear specified torque. is excessive. With the wheels in the straight-ahead (Refer to section TD,SUSPENSION, Wheels and Tires.) position, gently turn the steering wheel to the left and right and verify that the play is within Power steering components removal/installation specification. If any power steering fluid line has been disconnected anytime during the procedure, add Steering wheel play ATF M–III or equivalent (e.g. Dexron II), bleed 0—30 mm {0—1.18 in} the fluid lines, and inspect for leakage after the procedure has been completed. Steering Wheel Looseness Inspection Move the steering wheel as shown in the figure to Connectors disconnection/connection inspect for column bearing wear, steering shaft Disconnect the negative battery cable before doing joint play, steering wheel looseness, and column any work that requires handling of connectors. looseness. Reconnect the negative battery cable only after the work is completed.
CONTINUED
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MANUAL STEERING Steering Wheel Effort Inspection 1. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 2. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Measure the steering wheel effort using a torque wrench.
Steering wheel effort 4.5 N·m {460 kgf·cm, 399 in·lbf} max. 4. If not as specified, inspect the following: rotation starting torque of pinion, rotation torque of each ball joint, and steering joints.
CONTINUED
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MANUAL STEERING STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 40—50 {4.0—5.0, 29—36}
40—50 {4.0—5.0, 29—36}
AIR BAG MODEL
R
16—22 {1.6—2.3, 12—16} 16—22 {1.6—2.3, 12—16} 20—26 {2.0—2.7, 15—19} 18—24 {1.8—2.5, 14—18}
20—26 {2.0—2.7, 15—19}
N·m {kgf·m, ft·lbf}
1
Horn cap
6
Combination switch
2
Air bag module (with air bag) + section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION
7
Steering shaft + Installation Note
8
Universal joint
3
Locknut
9
Boot
4
Steering wheel + Removal Note + Installation Note
10
Intermediate shaft
11
Steering lock component + Removal Note + Installation Note
5
Column cover
CONTINUED
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MANUAL STEERING Steering Wheel Removal Note Caution Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse. Set the wheels in the straight-ahead position,
remove the steering wheel using a suitable puller. Steering Lock Component Removal Note Use a chisel to make a groove in the heads of the steering lock mounting bolts. Remove the bolts using a screwdriver. Remove the steering lock component.
Steering Lock Component Installation Note Install the new steering lock mounting bolts. Tighten the bolts until the heads break off.
A
B
Steering Wheel Installation Note 1. For vehicles with air bags, adjust the clock spring. (Refer to section T, CLOCK SPRING, CLOCK SPRING ADJUSTMENT.) 2. Install the steering wheel with the vehicle in the straight-ahead position. STEERING SHAFT INSPECTION Inspect the following, and replace the column component as necessary. 1. Needle and ball bearing damage. 2. Steering shaft length. Length 816.9—819.9 mm {32.17—32.27 in}
Steering Shaft Installation Note 1. Temporarily tighten the bolt A. 2. Tighten the nut B to the specified torque. 3. Tighten the bolt A to the specified torque. Tightening torque 16—22 N·m {1.6—2.3 kgf·m, 12—16 ft·lbf} 3. Dust boot damage.
CONTINUED
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MANUAL STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1. With the wheels in the straight-ahead position, remove in the order indicated in the table. 2. Install in the reverse order of removal.
37—54 {3.7—5.5, 27—39} 20—26 {2.0—2.7, 15—19}
45—58 {4.5—6.0, 33—43}
SST 69—78 {7.0—8.0, 51—57}
R
R
45—58 {4.5—6.0, 33—43}
SST
79—157 {8.0—16.0, 58—115}
R
45—58 {4.5—6.0, 33—43}
R
SST
37—54 {3.7—5.5, 27—39} 45—58 {4.5—6.0, 33—43}
R
SST
SST N·m {kgf·m, ft·lbf}
1
Cotter pin
9
Washer
2
Nut
10
Bolt, nut, washer
3
Ball joint + Removal Note
11
Idler arm bracket
12
Bolt, nut, washer
4
Locknut
13
Bolt
5
Tie rod
14
6
Center link
Steering gear and pitman arm + Removal Note
7
Idler arm + Removal Note
15
8
Bushing
Dust boot + Removal Note + Installation Note
CONTINUED
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MANUAL STEERING Ball Joint, Idler Arm, Steering Gear and Pitman Arm Removal Note Remove the ball joint from the knuckle and center link, the idler arm from the center link, and steering gear and pitman arm from the center link using the SST. 49 T028 3A0
Dust Boot Removal Note 1. Place the chisel against the boot and hold it at the angle shown. 2. Remove the dust boot by tapping it with a hammer.
Dust Boot Installion Note 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot using the SST and a press.
49 1243 785A
CONTINUED
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MANUAL STEERING STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 25—34 {2.5—3.5, 25—34} 15—21 {1.5—2.2, 11—15}
15—24 {1.5—2.5, 11—18}
R
128—166 {13.0—17.0, 95—122}
R SST
R
R R
197—235 {20.0—24.0, 145—173}
SST
R
1
Nut
9
Adjusting screw
2
Pitman arm + Disassembly Note
10
Oil seal
11
Retaining ring
3
Clip
12
4
Dust boot + Assembly Note
Locknut + Disassembly Note
13
Oil seal
5
Locknut (side cover) + Disassembly Note
14
Adjusting nut + Disassembly Note
6
Sector shaft + Disassembly Note + Assembly Note
15
Bearing
16
Worm ball nut + Assembly Note
17
Bearing
7
Side cover
8
Adjusting shim
N·m {kgf·m, ft·lbf}
CONTINUED
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MANUAL STEERING Pitman Arm Disassembly Note Separate the pitman arm from the steering gear using the SST.
Adjusting Nut Disassembly Note Remove the adjusting nut using the SST.
49 UB39 585A
49 U032 3A0
Locknut (Side Cover), Sector Shaft Disassembly Note 1. Loosen the locknut. 2. Remove the side cover attaching bolts. 3. Set the sector shaft in the middle position. 4. Tap the sector shaft lower end using a plastic hammer to loosen the sector shaft. 5. Lift and remove the sector shaft with the locknut and the side cover from the gear housing.
Worm Ball Nut Assembly Note 1. Inspect the worm ball nut preload using the SST.
49 0180 510B
Worm ball nut preload 1.0—1.3 N·m {10—14 kgf·cm, 8.7—12.1 in·lbf} [Without the sector shaft] 2. If not as specified, adjust the preload. (1) Loosen the locknut and turn the adjusting screw using the SST. Locknut Disassembly Note Remove the locknut using the SST.
49 U032 201 49 U032 201
CONTINUED
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MANUAL STEERING (2) Tighten the locknut to the specified torque using the SST. Tightening torque 128—166 N·m {13—17 kgf·m, 95—122 ft·lbf} 49 U032 201 49 U034 209
5. Wipe away excessive grease. STEERING GEAR AND LINKAGE INSPECTION Steering Gear Backlash Adjustment Caution Adjust the backlash while keeping the steering gear in the center position. Otherwise, the backlash becomes excessively small and gears may be damaged.
(3) Inspect the worm ball nut preload again. Sector Shaft Assembly Note 1. Set the adjusting screw and shim, in the “T” groove. 2. Measure the clearance in the axial direction.
Turn the adjusting screw to adjust steering gear
backlash. Backlash 0 mm ADJUSTING SHIM
3. Adjust the clearance to the specified value if the clearance is more than the specified value. Clearance 0—0.1 mm (0—0.004 in) Adjusting shim thickness 1.97 mm {0.077 in} 2.00 mm {0.079 in} 2.03 mm {0.079 in} 2.06 mm {0.081 in} 2.09 mm {0.082 in} Caution Be careful not to damage the oil seal and bearing. 4. Assemble the sector shaft in such a way that the teeth of the sector shaft mesh with the center part of the teeth of the worm ball nut. Dust Boot Assembly Note 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot onto the ball joint. 4. Set the SST over the boot and install a new clip.
CONTINUED
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POWER STEERING
POWER STEERING AIR BLEEDING 1. Inspect the fluid level. (Refer to POWER STEERING, POWER STEERING FLUID INSPECTION, Fluid Level Inspection.) 2. Jack up the front of the vehicle and support it on safety stands. 3. Turn the steering wheel fully to the left and right several times with the engine not running. 4. Reinspect the fluid level. If it has dropped, add fluid. 5. Repeat Steps 3 and 4 until the fluid level stabilizes. 6. Lower the vehicle. 7. Start the engine and let it idle. 8. Turn the steering wheel fully to the left and right several times. 9. Verify that the fluid is not foamy and that the fluid level has not dropped. 10. Add fluid as necessary and repeat Steps 8 and 9.
POWER STEERING FLUID INSPECTION Fluid Level Inspection Inspect the power steering fluid level. Add fluid to the specified level as necessary. Fluid specification ATF M–III or equivalent (e.g. Dexron II) Fluid Leakage Inspection Caution To prevent damage to the steering system, do not keep the steering wheel in the fully turned position for more than 5 seconds. 1. Start the engine and let it idle. Turn the steering wheel fully to the left and right to apply fluid pressure. Note The points where fluid leakage may occur are indicated in the figure. 2. Inspect for fluid leakage.
R.H.D.
L.H.D.
F2 CIS F2 CARB
F2 CIS F2 CARB
WL WL TURBO
WL WL TURBO
G6
G6
CONTINUED
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POWER STEERING Fluid Pressure Inspection 1. Assemble the SSTs as shown in the figure.
7. Close the gauge valve completely. Increase the engine speed to 1,000—1,500 rpm and measure the fluid pressure generated by the oil pump. If the pressure is not within the specification, replace the oil pump component.
49 1232 670A
Oil pump fluid pressure 8.9—9.3 MPa {90—95 kgf/cm2, 1280—1350 psi} THERMOMETER 50—60 °C {122—140 °F}
49 H002 671
GAUGE CLOSE VALVE COMPLETELY
2. Mark both hose connections to ensure that the hose is reinstalled in its original position. 3. Disconnect the pressure hose from the oil pump. Attach the SST (49 G032 304). Tightening torque G6: 32—47 N·m {3.2—4.8 kgf·m, 24—34 ft·lbf} F2 CIS, F2 CARB, WL, WL Turbo: 30—44 N·m {3.0—4.5 kgf·m, 22—32 ft·lbf}
Caution If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid temperature will rise excessively and adversely affect the oil pump.
4. Connect the SSTs (49 1232 670A and 49 H002 671) to the SST (49 G032 304). G6
8. Open the gauge valve fully and increase the engine speed to 1,000—1,500 rpm. 9. Turn the steering wheel fully to left and right and measure the fluid pressure generated at the gear housing. If the pressure is not within the specification, repair or replace the steering gear component.
49 B032 304
Gear housing fluid pressure 8.9—9.3 MPa {90—95 kgf/cm2, 1280—1350 psi} F2 CIS, F2 CARB, WL, WL TURBO
THERMOMETER 50—60 °C {122—140 °F}
49 G032 3A4
GAUGE OPEN VALVE COMPLETELY
49 H002 671
5. Bleed the air from the system. 6. Open the gauge valve fully. Start the engine and turn the steering wheel fully left and right to raise the fluid temperature to 50—60 °C {122—140 °F}. Caution If the valve is left closed for more than 5 seconds, the fluid temperature will increase excessively and adversely affect the oil pump.
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque. Tightening torque 30—44 N·m {3.0—4.5 kgf·m, 22—32 ft·lbf} 11. Bleed the air from the system.
CONTINUED
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POWER STEERING Note To determine whether the steering effort is satisfactory or not, perform the inspection on another vehicle of the same model and under the same conditions, and compare the results. The steering wheel effort varies with conditions as shown below. 1. Road conditions, such as dry or wet, and asphalt or concrete. 2. Tire conditions, such as brand, wear, and tire pressure. 12. If not as specified, inspect the following points: Air in system Fluid leakage at hose or connectors Function of oil pump and steering gear STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) STEERING SHAFT INSPECTION (Refer to MANUAL STEERING, STEERING SHAFT INSPECTION.) STEERING WHEEL AND COLUMN INSPECTION Steering Wheel Play Inspection (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN INSPECTION, Steering Wheel Play Inspection.) Steering Wheel Looseness Inspection (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN INSPECTION, Steering Wheel Looseness Inspection.) Steering Wheel Effort Inspection 1. Inspect the following points: Tire size and tire pressure Fluid level 2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 3. Start the engine and warm the power steering fluid to 50—60 °C {122—140 °F}. 4. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 5. Measure the steering wheel effort using a torque wrench.
Steering wheel effort 7.8 N·m {80 kgf·cm, 69 in·lbf} max.
CONTINUED
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POWER STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 32—47 {3.2—4.8, 24—34} 24—35 {2.4—3.6, 18—26} 37—54 {3.7—5.5, 27—39}
20—26 {2.0—2.7, 15—19}
SST 69—78 {7.0—8.0, 51—57}
SST
R
79—157 {7.0—16.0, 58—115}
R
R 37—54 {3.7—5.5, 27—39}
45—58 {4.5—6.0, 33—43}
SST
R 45—58 {4.5—6.0, 33—43}
SST
SST N·m {kgf·m, ft·lbf}
1
Cotter pin
11
Idler arm bracket
2
Locknut
12
Pressure pipe
3
Ball joint + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Ball Joint Removal Note
13
Return pipe
14
Bolt
15
Bolt, nut, washer
4
Locknut
16
5
Tie rod
6
Center link
Steering gear and pitman arm + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Steering Gear and Pitman Arm Removal Note
7
Idler arm + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Idler Arm Removal Note
17
8
Bushing
9
Washer
Dust boot + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Dust Boot Disassembly Note + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Dust Boot Assembly Note
10
Bolt, nut, washer
CONTINUED
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POWER STEERING STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 57—64 {5.7—6.5, 42—47} 30—44 {3.0—4.5, 22—32}
R R
R R
R
R R
R
R R 56—63 {5.7—6.5, 42—47}
SST R
R
R
197—235 {20.0—24.0, 145—173}
SST
1
Nut
8
O-ring
2
Pitman arm + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Pitman Arm Disassembly Note
9
Y packing
10
Back up ring
11
Oil seal
3
Clip
12
Back up ring
4
Dust boot + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Dust Boot Assembly Note
13
Y packing
14
Dust cover
15
Snap ring
16
Washer
17
Oil seal
18
Valve and piston component + Assembly Note
19
O-ring
20
Seal ring
21
Gear housing
5
6
7
Locknut + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Locknut (Side Cover), Sector Shaft Disassembly Note Sector shaft + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Locknut (Side Cover) Sector Shaft Disassembly Note Side cover
N·m {kgf·m, ft·lbf}
CONTINUED
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POWER STEERING Valve and Piston Component Assembly Note Caution Do not scratch the seal ring and O-ring on the piston against the entrance to the housing. Insert the piston by slightly turning to the left and right so as not to create flection at the O-ring and seal ring. Insert the valve and piston component to the gear
housing.
STEERING GEAR AND LINKAGE INSPECTION (Refer to MANUAL STEERING, STEERING GEAR AND LINKAGE INSPECTION, Steering Gear Backlash Adjustment.)
N–15
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POWER STEERING POWER STEERING OIL PUMP REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. For F2 CIS, F2 Carb and G6 engine model, adjust the drive belt. (Refer to Section B2, DRIVE BELT,DRIVE BELT ADJUSTMENT.) F2 CIS, F2 CARB
30—44 {3.0—4.5, 22—32}
R
30—39 {3.0—4.0, 22—28}
SST 50—59 {5.0—6.0, 37—43} N·m {kgf·m, ft·lbf}
CONTINUED
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POWER STEERING
G6
19—25 {1.9—2.6, 14—18}
32—46 {3.2—4.7, 24—33}
32—47 {3.2—4.8, 24—34}
50—59 {5.0—6.0, 37—43}
SST
CLAMP POSITION
30 mm {1.2 in}
N·m {kgf·m, ft·lbf}
1
Drive belt
5
Return hose
2
Locknut + Removal Note
6
Power steering fluid pressure switch connector (except F2 Carb)
3
Oil pump pulley
7
Power steering oil pump component
4
Pressure pipe (F2 CIS, F2 Carb), pressure hose (G6)
Locknut Removal Note Secure the pulley using the SST and remove the locknut.
49 G032 354
CONTINUED
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POWER STEERING
WL, WL TURBO
30—44 {3.0—4.5, 22—32}
R
19—25 {1.9—2.6, 14—18}
19—25 {1.9—2.6, 14—18}
R
N·m {kgf·m, ft·lbf}
1
Pressure pipe
4
Power steering oil pump
2
Return hose
5
O-ring
3
Bolt and nut
CONTINUED
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POWER STEERING POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY 1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs are necessary. 2. Disassemble in the order indicated in the table. 3. Assemble in the reverse order of disassembly.
R
9.9—13.7 N·m {100—140 kgf·cm, 87—121 in·lbf}
15—19 {1.5—2.0, 11—14}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
G6
R
22—25 {2.2—2.6, 16—18}
R
R
R F2 CIS 50—68 {5.0—7.0, 37—50}
R
R
F2 CARB
18—21 {1.8—2.2, 14—16}
16—23 {1.6—2.4, 12—17}
22—25 {2.2—2.6, 16—18}
À N·m {kgf·m, ft·lbf}
SST
1
Power steering oil pump component + Disassembly Note
13
Rear body + Assembly Note
2
Pressure switch component
14
O-ring
3
O-ring
15
4
Nut (G6)
Cam ring + Assembly Note
5
Connector (G6)
16
Rotor
6
Connector bolt
17
7
O-ring
Vane + Assembly Note
8
Control valve component
18
Pin
9
Spring
19
Side plate + Assembly Note
10
Suction pipe
20
O-ring
11
O-ring
21
Oil seal
12
Shaft component
22
Front body
CONTINUED
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POWER STEERING Power Steering Oil Pump Disassembly Note
3. Install the vanes in the rotor with the rounded edges outward.
Caution To secure the oil pump in a vise, use the SST as shown to prevent damage to the pump.
ROUND EDGE
49 F032 301
Rear Body Assembly Note After installing the rear body, manually turn the shaft to verify that it rotates smoothly. Side Plate Assembly Note 1. Install a new O-ring and the side plate to the front body. 2. Position the side plate using the rear body.
Vane, Cam Ring Assembly Note 1. Install the cam ring with the marks facing the front body.
2. Install the rotor with the mark facing the rear body. MARK
CONTINUED
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POWER STEERING POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY 1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs are necessary. 2. Disassemble in the order indicated in the table. 3. Assemble in the reverse order of disassembly. R
7.9—11.7 N·m {80—120 kgf·cm, 69.5—104.1 in·lbf}
22—25 {2.2—2.6, 16—18}
R SST
R R
50—68 {5.0—7.0, 37—50} N·m {kgf·m, ft·lbf}
1
Power steering oil pump component + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Power Steering Oil Pump Component Disassembly Note
10
Cam ring + POWER STEERING POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Cam Ring Assembly Note
2 3
Suction pipe
11
Rotor
O-ring
12
Vane + POWERSTEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Vane Assembly Note
4
Connector
5
O-ring
6
Control valve
7 8
Spring
13
Rear body + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Rear Body Assembly Note
Side plate + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Side Plate Assembly Note
9
14
O-ring
O-ring
15
Front body
CONTINUED
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BRAKING SYSTEM GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . CONVENTIONAL BRAKE SYSTEM . . . . . . . . . . . AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM LINE INSPECTION . . . . . . . . . . . . . . BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . BRAKE PEDAL REMOVAL/INSTALLATION . . BRAKE SWITCH INSPECTION . . . . . . . . . . . . . MASTER CYLINDER REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FLUID LEVEL SENSOR INSPECTION . . . . . . MASTER CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER BRAKE UNIT INSPECTION . . . . . . . . POWER BRAKE UNIT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM SWITCH INSPECTION . . . . . . . . . . . VACUUM SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . VACUUM PUMP INSPECTION . . . . . . . . . . . . . VACUUM PUMP REMOVAL/INSTALLATION . LOAD SENSING PROPORTIONING VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . LOAD SENSING PROPORTIONING VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . .
P– 1 P– 2 P– 2 P– 2 P– 2 P– 3 P– 4 P– 4/6 P– 6 P– 7/8 P– 8 P– 9 P– 9 P–10 P–10 P–10 P–11
LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION . . . . . . . . . FRONT BRAKE (DISC) INSPECTION . . . . . . . FRONT BRAKE (DISC) REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . DISC PAD (FRONT) REPLACEMENT . . . . . . . CALIPER (FRONT) DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE (DRUM) INSPECTION . . . . . . . REAR BRAKE (DRUM) REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DRUM INSPECTION . . . . . . . . . . . . . . . WHEEL CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . PARKING BRAKE (STICK TYPE) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE (STICK TYPE) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
P–11 P–12 P–13/14 P–14 P–14 P–15 P–15 P–16 P–16 P–16 P–16 P–16 P–17 P–18/19
P–11
GENERAL PROCEDURES Wheel and tires removal/installation The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, retighten it to the specified tightening torque, referring to section TD. Brake lines disconnection/connection Caution Brake fluid will damage painted surfaces. If brake fluid get on a painted surface, wipe it off immediately.
Brake pipe flare nut tightening Tighten the brake pipe flare nut by using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.) Connectors disconnection Disconnect the negative battery cable before doing any work that requires handling of connectors. Reconnect the negative battery cable only after the work is completed.
If any brake line has been disconnected anytime
during the procedure, add brake fluid, bleed the brakes, and inspect leakage after the procedure has been completed. Fluid specification SAE J1703 or FMVSS116 DOT–3 or DOT–4
CONTINUED
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CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM AIR BLEEDING Note The reservoir should be kept 3/4 full during bleeding. The brakes should be bled whenever a brake line is disconnected. If a hydraulic line is disconnected at the master cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the next farthest slave cylinder until all four cylinders have been bled. If the disconnection point is anywhere except the master cylinder, start at the point closest to the disconnection, and move to the next closest slave cylinder until all four cylinders have been bled. 1. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. 2. Place the other end of the vinyl tube in a clear fluid-filled container. 3. One person should depress the brake pedal a few times, and then hold it in the depressed position. 4. A second person should loosen the bleeder screw, drain out the fluid and retighten the screw using the SST.
VACUUM LINE INSPECTION 1. Remove the clamps and the vacuum hose. 2. Apply both suction and pressure to the engine-side hose (Gasoline) or vacuum pump side of the hose (Diesel), and verify that air blows only toward that side. If air flows in both directions or not at all, replace the vacuum hose.
CHECK VALVE
ENG
BRAKE PEDAL INSPECTION Brake Pedal Height Inspection Verify that the distance from the center of the upper surface of the pedal pad to the floor pannel is as specified.
Tightening torque Front: 9—14 N·m {92—142 kgf·cm, 80—123 in·lbf} Rear: 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
Pedal height L.H.D.: 214—219 mm {8.43—8.81 in} R.H.D.:219—224 mm {8.63—8.81 in}
PEDAL HEIGHT
49 0259 770B
5. Repeat steps 3 and 4 until no air bubbles are seen. 6. After air bleeding, inspect the following: (1) brake operation (2) fluid leakage (3) fluid level
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Brake Pedal Height Adjustment 1. Disconnect the brake switch connector. 2. Loosen locknut B and turn switch A until it does not contact the pedal. 3. Loosen locknut D and turn rod C to adjust the height. 4. Tighten the bolt with locknut B so that clearance between the bolt for brake light switch A and pedal stopper is within the specification.
D
C
Specification 0.1—1.0 mm {0.004—0.039 in} Tightening torque 14—17 N·m {140—180 kgf·cm, 122—156 in·lbf} 5. Connect the brake switch connector. 6. After adjustment, inspect the pedal play and the brake light operation.
D
5. After adjustment, inspect the pedal height and the brake light operation. Pedal-to-floor Clearance Inspection 1. Start the engine and verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is depressed with a force of 589 N {60 kgf, 132 lbf}.
A
Clearance 105 mm {4.2 in} min. C
B
Brake Pedal Play Inspection 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Remove the snap pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin. 3. Gently depress the pedal by hand until resistance is felt (approx. 20N {2 kgf, 4.4 lbf}) and inspect the free play.
PEDAL-TO-FLOOR CLEARANCE
2. If the distance is less than specified, inspect the following: (1) Air in brake system (2) Malfunction of the automatic adjuster (3) Excessive shoe clearance
Pedal play 3—8 mm {0.12—0.31 in}
Brake Pedal Play Adjustment 1. Remove the snap pin and clevis pin. 2. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal. 3. Install the clevis pin and the snap pin. 4. Tighten locknut D.
BRAKE PEDAL REMOVAL/INSTALLATION R.H.D. The brake pedal is mounted on the bracket integrated with the clutch pedal and accelerator pedal. Refer to section F2, INTAKE AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION for the brake pedal removal/installation. L.H.D. The brake pedal is mounted on the bracket integrated with the clutch Pedal. Refer to section H, CLUTCH PEDAL REMOVAL/ INSTALLATION for the brake pedal removal/installation.
Tightening torque 24—34 N·m {2.4—3.5 kgf·m, 18—25 ft·lbf}
CONTINUED
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CONVENTIONAL BRAKE SYSTEM BRAKE SWITCH INSPECTION 1. Disconnect the brake switch connector. 2. Inspect for continuity between the terminals of the brake switch connector using the circuit tester. : Continuity
R.H.D.
Terminal
Condition
A
SST
B
R
When the brake pedal is depressed. When the brake pedal is not depressed.
SST * 12.9—21.5 {130—220, 113—190}
A
9.81—15.6 {100—160, 87—138}
B * 49 0259 770B
3. If not as specified, replace the brake switch. MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. L.H.D.
N·m {kgf·cm, in·lbf}
1
Brake fluid level sensor connector
2
Brake pipe
3
Bracket (R.H.D.)
4
Master cylinder + Installation Note
5
O-ring
Master Cylinder Installation Note 1. Loosen the adjusting nut of the SST. 2. Place the SST on the power brake unit and tighten the nut and washer. Tightening torque 9.81—15.6 N·m {100—160 kgf·cm, 87—138 in·lbf}
SST
R
3. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum to the power brake unit using a vacuum pump.
9.81—15.6 {100—160, 87—138}
SST * 12.9—21.5 {130—220, 113—190}
* 49 0259 770B
N·m {kgf·cm, in·lbf}
49 B043 001
CONTINUED
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CONVENTIONAL BRAKE SYSTEM 4. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and SST body. 5. Remove the SST from the power brake unit.
Clearance at B 1. Measure and record the height D1 of the gauge rod.
(D1)
TOUCHING
49 B043 001
49 B043 001
2. Turn the adjusting nut until the SST body sets closely on the master cylinder. Turn only enough for the body to touch. 3. Measure and record height D2 of the gauge rod.
TOUCHING ADJUSTING NUT
6. Remove the SST from the power brake unit without disturbing the adjusting nut. Set the SST onto the master cylinder as shown in the figure. 7. Push lightly on the end of the SST gauge rod to be sure that it is contacting the bottom of the master cylinder piston, but do not push so hard that the piston moves. Note any clearance between the SST body and the adjusting nut: clearance B, or between the body and the master cylinder: clearance C. Adjust the push rod as necessary as outlined in “Adjustment” below. Adjustment Measurement
Push rod
Clearance at B
Too long
Clearance at C
Too short
No clearance at B or C
Okay
ADJUSTING NUT (D2)
CLEARANCE (B)
49 B043 001
4. Subtract D1 from D2. Using the SST, turn the nut to shorten the power brake unit push rod an amount equal to the difference. 49 B043 004
CLEARANCE (C)
49 B043 001 49 E043 003A
CLEARANCE (B)
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Clearance at C 1. Push lightly on the end of the SST gauge rod, and measure the clearance between the adjusting nut and the SST body.
CLEARANCE (C)
49 B043 001
2. Using the SSTs, turn the nut to lengthen the power brake unit push rod an amount equal to the clearance measured at B. 49 B043 004
49 E043 003A
FLUID LEVEL SENSOR INSPECTION 1. Disconnect the sensor connector. 2. Connect an ohmmeter to the connector. 3. Starting with the fluid level above MIN, verify that there is no continuity. 4. Remove the brake fluid and verify that there is continuity when the level is below MIN. : Continuity Terminal
Fl id level Fluid
A
B
Below MIN. Above MIN.
5. If not as specified, replace the sensor.
A B
CONTINUED
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CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER DISASSEMBLY/ASSEMBLY Caution If the master cylinder body is damaged, replace the unit as a component. When securing the master cylinder in a vise, tighten only the flange of the master cylinder. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R
À
R
R
R
R
1.0—1.5 {10—15, 8.7—13}
R 2.0—2.4 {20—25, 18—21}
N·m {kgf·cm , in·lbf}
1
Cap set
10
Cup
2 3
Screw
11
Primary piston stopper
Reservoir
12
Primary piston
4
Joint bushing
13
5
Fluid level sensor
Stop screw + Assembly Note
6
Snap ring
14
O-ring
7
Spacer
15
Secondary piston
8
Piston guide
16
Master cylinder body
9
O-ring
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Stop Screw and O-ring Assembly Note 1. Install a new O-ring onto the stop screw. 2. Push the primary piston component in full. 3. Install and tighten the stop screw.
(Inspection using the testers) 1. Connect the SSTs, vacuum gauge, and pedal depression force gauge as shown in the figure. Note Use commercially available gauges and pedal depression force gauge. Bleed the air from the SST at gauge A.
Tightening torque 2.0—2.4 N·m {20—25 kgf·cm, 18—21 in·lbf}
49 U043 004
A A
49 U043 006
POWER BRAKE UNIT INSPECTION Power Brake Unit Function Inspection (Simple method)
PEDAL DEPRESSION FORCE GAUGE VACUUM GAUGE
2. After bleeding the air from the SST, conduct the test as described in the following steps. a) Inspection for vacuum loss Unloaded condition 1. Start the engine. 2. Stop the engine when the vacuum gauge reading reaches 66.7 kPa {500 mmHg, 19.7 inHg}. 3. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3—66.7 kPa {475—500 mmHg, 18.7—19.7 inHg}, the unit is operating.
Note Replace power brake unit component as necessary. Step 1 1. With the engine stopped, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. If the pedal moves down slightly, immediately after the engine starts, the unit is operating. Step 2 1. Start the engine. 2. Stop the engine after it has run for 1 or 2 minutes. 3. Depress the pedal with the usual force. 4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating. Note If a problem is found, inspect for damage on the check valve or vacuum hose, and examine the installation. Repair as necessary, and inspect it again.
49 U043 005
Loaded condition 1. Start the engine. 2. Depress the brake pedal with a force of 196 N {20 kgf, 44 lbf}. 3. With the brake pedal depressed, stop the engine when the vacuum gauge reading reaches 66.7 kPa {500 mmHg, 19.7 inHg}. 4. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3—66.7 kPa {475—500 mmHg, 18.7—19.7 inHg}, the unit is operating. b) Inspection for hydraulic pressure 1. When the engine is stopped (vacuum 0 kPa {0 mmHg, 0 inHg}) and the fluid pressure is within the specification, the unit is operating.
Step 3 1. Start the engine. 2. Depress the pedal with the usual force. 3. Stop the engine with the pedal held depressed. 4. Hold the pedal down for about 30 seconds. 5. If the pedal height does not change, the unit is operating.
Pedal force
Fluid pressure
196 N {20 kgf, 44 lbf}
790 kPa {8 kgf/cm2, 114 psi} min
2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg}. If the fluid pressure is within the specification, the unit is operating. Pedal force
Fluid pressure
196 N {20 kgf, 44 lbf}
8,240 kPa {84 kgf/cm2, 1,200 psi} min
CONTINUED
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CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT REMOVAL/INSTALLATION 1. Remove the master cylinder. (Refer to CONVENTIONAL BRAKE SYSTEM, MASTER CYLINDER REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. L.H.D.
R
19—25 {1.9—2.6, 14—18}
1
Vacuum switch connector (Diesel)
2
Vacuum hose
3
Snap pin
4
Clevis pin
5
Nut
6
Power brake unit
7
Gasket
8
Fork
9
Nut
VACUUM SWITCH INSPECTION (DIESEL) 1. Remove the vacuum hose from the power brake unit. 2. Set the vacuum pump hose (commercially available on the market) onto the power brake unit as shown.
24—34 {2.4—3.5, 18—25}
N·m {kgf·m, ft·lbf}
3. Turn the engine switch on. 4. Release the parking brake. 5. Apply vacuum to the power brake unit using the vacuum pump (commercially available on the market) and verify the operating condition of the brake light warning light.
R.H.D.
Vacuum kPa {mmHg, inHg}
R
19—25 {1.9—2.6, 14—18}
Brake warning light
Below 10.71.3 {8010, 3.20.4}
ON
Above 10.71.3 {8010, 3.20.4}
OFF
6. The vacuum switch is functioning normally if it corresponds to the above specifications. Replace the vacuum switch as necessary.
24—34 {2.4—3.5, 18—25}
N·m {kgf·m, ft·lbf}
CONTINUED
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CONVENTIONAL BRAKE SYSTEM VACUUM SWITCH REMOVAL/INSTALLATION (DIESEL) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
VACUUM PUMP INSPECTION (DIESEL) 1. Warm up the engine. 2. Disconnect the vacuum hose from the vacuum pump and connect a vacuum gauge as shown in the figure, then inspect the vacuum.
L.H.D.
Vacuum specification (In 20 seconds) Engine speed 1,500 rpm 73.3 kPa {550 mmHg, 21.7 inHg} Maximum vacuum Engine speed 3,000 rpm 93.3 kPa {700 mmHg, 27.6 inHg}
20—24 {2.0—2.5, 15—18}
N·m {kgf·m, ft·lbf}
R.H.D.
3. If the pressure is less than the specification, inspect for the following. (1) Malfunction of the vacuum pump (2) Shortage of the lubrication oil pressure
20—24 {2.0—2.5, 15—18} N·m {kgf·m, ft·lbf}
1
Vacuum switch connector
2
Vacuum switch + Installation Note
VACUUM PUMP REMOVAL/INSTALLATION (DIESEL) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
Vacuum Switch Installation Note 1. Remove the old sealant. Caution Do not apply sealant to the tip of the vacuum switch as a malfunction may occur. 2. Apply sealant to the area shown before installation of the vacuum switch onto the power brake unit, and then tighten it to the specified torque. Tightening torque 20—24 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
R DO NOT APPLY SEALANT ON THIS AREA
19—25 {1.9—2.6, 14—18} N·m {kgf·m, ft·lbf}
1
Vacuum hose
2
Bolt
3
Vacuum pump
4
O-ring
CONTINUED
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CONVENTIONAL BRAKE SYSTEM LOAD SENSING PROPORTIONING VALVE INSPECTION 1. Place the vehicle on level ground. 2. Inspect the tire inflations and set them to the recommended pressure as necessary. 3. Prepare the vehicle with a person in the driver’s seat; include the standard vehicle tools, the spare wheel and tire, and a full tank of fuel. 4. Connect pressure gauges (commercially available) to the front and rear calipers.
LOAD SENSING PROPORTIONING VALVE ADJUSTMENT 1. Place the unloaded vehicle on level ground. Unloaded condition: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated position. Note A change of 5 mm {0.197 in} dimension L results in a change of 853 kPa {8.7 kgf/cm2, 124 psi} for 42 and 1020 kPa {10.4 kgf/cm2, 148 psi} for 44. 2. Adjust main spring dimension L between the LSPV and the adjustment link by loosening and repositioning the LSPV. (1) Decrease dimension L if the fluid pressure is low. (2) Increase dimension L if the fluid pressure is high. Reference value Dimension L 42: 147.5—154.5 mm {5.808—6.082 in} 44: 175.5—182.5 mm {6.910—7.185 in}
Note When applying the specified pressure, the brake pedal must not be “double pumped” or released. Approximately two seconds after setting the front wheel cylinder fluid pressure, read the rear pressure. 5. Bleed the air from the brake system. 6. Slowly depress the brake pedal until the front pressure gauge indicates the specified pressure shown in the table, then note the reading on the rear pressure gauge. kPa {kgf/cm2, psi} Front pressure
Rear pressure
4,900 {50, 711}
2,550 {26, 370}
9,810 {100, 1,422}
3,530 {36, 512}
MAIN SPRING
ADJUSTMENT LINK
AXLE CASING
LOADED A PERSON IN DRIVER’S SEAT BOLT 4,900 {50, 711} 9,810 {100, 1,422} REAR PRESSURE FRONT PRESSURE
3. After adjustment, recheck the fluid pressure. If not as specified, replace the LSPV as a component.
kPa {kgf/cm2, psi}
7. If not as specified, replace and adjust the LSPV.
LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION Caution Do not disassemble the LSPV. Do not move the nut A. 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
CONTINUED
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CONVENTIONAL BRAKE SYSTEM 3. After installation, adjust the main spring dimension. (Refer to CONVENTIONAL BRAKE SYSTEM, LOAD SENSING PROPORTIONING VALVE ADJUSTMENT.)
Disc Plate Thickness Inspection 1. Measure the thickness of the disc plate. Caution When it is necessary to machine the disc plate, if the disc plate is removed from the vehicle then machined, excessive runout may result. Machine the disc plate with it installed on the vehicle.
12.8—21.5 N·m {130—220 kgf·cm, 113—190 in·lbf}
SST * 12.8—21.5 N·m
SST *
{130—220 kgf·cm, 113—190 in·lbf}
A
Standard 24 mm {0.94 in} Minimum 22 mm {0.87 in} Minimum thickness after machining by using a brake lathe on-vehicle 22.8 mm {0.90 in}
19—25 {1.9—2.6, 14—18}
2. If the thickness is not within the specification, replace the disc plate. 19—25 {1.9—2.6, 14—18}
* 49 0259 770B
1
Brake pipe
2
Nut
3
Bolt
4
Load sensing proportioning valve
N·m {kgf·m, ft·lbf}
FRONT BRAKE (DISC) INSPECTION Disc Pad Thickness Inspection 1. Jack up the front of the vehicle and support it on safety stands. 2. Remove the wheel and tires. 3. Look through the caliper inspection hole and inspect the remaining thickness of the pads.
Disc Plate Runout Inspection 1. Verify that there is no wheel bearing looseness. 2. Measure the runout at the outer edge of the contact surface of the disc pad.
Thickness 2.0 mm {0.08 in} min.
Runout 0.05 mm {0.002 in} max. 3. If the runout is not within the specification, repair or replace the disc plate.
4. Replace the pads as a set (right and left wheels) if either is at or less than the minimum thickness.
CONTINUED
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CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
22—29 {2.2—3.0, 16—29}
R 29—34 {2.9—3.5, 21—25}
R
108—127 {10.4—14.0, 80—94}
SST
N·m {kgf·m, ft·lbf}
1
Brake hose
6
Disc pad + Installation Note
2
Bolt
3
Guide pin
7
Plate
4
Dust boot
8
Guide plate
5
Caliper
9
Mounting support
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Disc Pad Installation Note 1. Push the piston fully inward using the SST. 2. Install the disc pad.
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
* SST 9—14 {92—143, 80–123}
49 0221 600C SST
DISC PAD (FRONT) REPLACEMENT 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. R 29—34 {2.9—3.5, 21—25}
*49 0259 770B
N·m {kgf·cm, in·lbf}
R
1
Piston + Disassembly Note
2
Dust seal
3
Piston seal + Disassembly Note
4
Bleeder cap, screw
5
Caliper body
Piston Disassembly Note SST
Caution Blow the compressed air slowly to prevent the piston from suddenly popping out.
N·m {kgf·m, ft·lbf}
1
Bolt
2
Caliper
3
Disc pad + CONVENTIONAL BRAKE SYSTEM, FRONT BRAKE (DISC) REMOVAL/INSTALLATION, Disc Pad Installation Note
4
Plate
5
Guide plate
Place a piece of wood in the caliper, then blow
compressed air through the hole to force the piston out of the caliper. WOOD
Piston Seal Disassembly Note Remove the piston seal from the brake caliper using the SST.
CONTINUED
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CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DRUM) INSPECTION Brake Lining Thickness Inspection 1. Remove the brake drum. 2. Inspect the remaining thickness of the lining. Thickness 1.0 mm {0.04 in} min. 3. Replace both left and right brake shoes if either is at or less than the minimum thickness.
REAR BRAKE (DRUM) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation. (1) Depress the brake pedal a few times, then verify that the brakes do not drag. (2) Inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION, Parking Brake Lever Stroke Inspection.) 9.8—12.7 {100—130, 87—112}
* SST 12.8—21.5 {130—220, 113—190}
APPLY
*49 0259 770B
1
Brake drum
2 3 4 5
TO SHADED EREA
N·m {kgf·cm, in·lbf}
8
Adjust strut
Hold spring, washer
9
Brake shoe
Hold pin
10
Parking brake cable
Lower return spring
11
Operating lever
Upper return spring
12
Brake pipe
6
Pawl lever spring
13
Wheel cylinder
7
Pawl lever
14
Gasket
CONTINUED
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CONVENTIONAL BRAKE SYSTEM, PARKING BRAKE SYSTEM BRAKE DRUM INSPECTION 1. Measure the inner diameter of the drum.
PARKING BRAKE SYSTEM PARKING BRAKE (STICK TYPE) INSPECTION Parking Brake Lever Stroke Inspection 1. Pull the parking brake lever a few times. 2. Verify that the stroke is within the specification when the parking brake lever is pulled with a force of 98 N {10 kgf, 22 ibf}.
Maximum diameter 42: 271.5 mm {10.68 in} 44: 296.5 mm {11.67 in} 2. Apply chalk to the inside of the brake drum. 3. Inspect for scratches and uneven or abnormal wear inside the drum as shown in the figure.
Stroke 1—7 notches 3. If not as specified, adjust the parking brake lever stroke. PARKING BRAKE (STICK TYPE) ADJUSTMENT Parking Brake Lever Stroke Adjustment 1. Before adjustment, depress the brake pedal several times while the vehicle is moving in reverse. 2. Loosen the locknut A and turn the adjustment nut B so that the stroke is within the above range. 3. After adjustment, tighten the locknut A.
4. Repair or replace the drum as necessary. Repair if the problem is minor. 5. When repairing or replacing the drum, check the contact with the shoes. 6. Wipe the chalk off after inspection. WHEEL CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Tightening torque 6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
B A
R SST *
R
4. After adjustment, inspect the following points. (1) Turn the ignition (engine) switch on, pull the parking brake lever one notch, and verify that the brake warning light illuminates. (2) Verify that the rear brakes do not drag when the wheels are turned by hand.
5.9—8.8 { 60—90 , 53—78 }
R
R
* 49 0259 770B
1
Dust boot
2
Piston
3
Piston cap
4
Spring
5
Bleeder cap, screw
6
Cylinder body
N·m { kgf·cm , in·lbf }
CONTINUED
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PARKING BRAKE SYSTEM PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
12.8—18.6 {130—190, 113—164}
6.9—9.8 {70—100, 43—86}
N·m {kgf·cm, in·lbf}
1
Clip
9
Pin and clip
2
Joint pin
10
Spring
3
Cable connector
11
Rachet pawl
4
Parking brake switch
12
Stopper
5
Clip
13
Fork joint
6
Pin
14
Spring
7
Clip and joint pin
15
Guide
8
Lever
16
Rod
CONTINUED
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PARKING BRAKE SYSTEM PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION 1. Remove the under guard. (Refer to section F1–F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.) 4x2
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
4x4
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
N·m {kgf·m, ft·lbf}
CONTINUED
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PARKING BRAKE SYSTEM LHD model with F2 and G6 engine
1
Nut
7
Grommet
2
Bolt
8
Bolt
3
Spring
9
Spring (44)
4
Front brake cable
10
Clip
5
Bolt (44)
11
Rear cable (left)
6
Bracket (44)
12
Rear cable (right)
CONTINUED
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SUSPENSION GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT PREINSPECTION . . . . . FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . VEHICLE HEIGHT ADJUSTMENT . . . . . . . . . . FRONT SHOCK ABSORBER REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBER INSPECTION . . TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2) . . . . . . . . .
R–1 R–1 R–1 R– 2/3 R–3 R–3 R–5 R–5 R– 6/8
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4) . . . . . . . . . R– 9/11 LOWER ARM INSPECTION . . . . . . . . . . . . . . . . R–11 UPPER ARM REMOVAL/INSTALLATION . . . . R–12 UPPER ARM INSPECTION . . . . . . . . . . . . . . . . R–13 STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2) . . . . . . . . . R–13/14 STABILIZER REMOVAL/INSTALLATION (4 4) . R–14 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . R–15 REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION . . . . . . . R–15
GENERAL PROCEDURES
WHEEL ALIGNMENT
Wheels and tires removal/installation D The removal and installation procedures for the wheels and tires are not mentioned in this section. If a wheel is removed, retighten it to the specified tightening torque, referring to section TD.
WHEEL ALIGNMENT PREINSPECTION 1. Inspect the inflation of each tire, and set to the recommended pressure, as necessary. 2. Inspect the front wheel bearing play. Adjust the bearing preload or replace bearing(s) as necessary. (Refer to section M, FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE INSPECTION or FRONT AXLE (4 4), WHEEL HUB, STEERING KNUCKLE INSPECTION.) 3. Inspect the wheel and tire runout at all wheels. (Refer to section TD, SUSPENSION, Wheels and Tires.) 4. Inspect the ball joints and steering linkage for excessive looseness. 5. Place the vehicle on level ground with no luggage and passenger load. 6. The difference in height between the left and right sides from the center of the wheel to the fender brim must not exceed 10 mm {0.39 in}. If not within the specification, adjust the vehicle height. (Refer to FRONT SUSPENSION, VEHICLE HEIGHT ADJUSTMENT.)
Suspension arms removal/installation D Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded*. * Unloaded condition: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated position.
7. Shake the vehicle to settle the suspension.
CONTINUED
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WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Specifications Specification
Item
4 2 (mm {in})
Total toe toe-in in
Front wheel heel alignment (*1Unloaded condition)
Maximum steering g angle
3"3 {0.12"0.12} 0° 16’ "16’
(degree) Inner
35° 00’
+2° –3°
Outer
33° 00’
+2° –3°
*2 *3
0° 14’ "14’ 33° 30’
+2° –3°
30° 00’
+2° –3°
Camber angle*2
0° 56’ "30’
1° 06’ "30’
Caster angle*3
1° 37’ "45’
2° 02’ "45’
8° 04’
10° 15’
Steering axis inclination (reference value) *1
4 4
Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Difference between left and right must not exceed 30’. Difference between left and right must not exceed 45’.
Maximum Steering Angle Adjustment 1. Loosen the adjusting bolt locknut. 2. Turn the adjusting bolt to provide the correct turning angle. 3. After adjustment, tighten the locknut to the specified torque.
Total Toe-in Adjustment 1. Loosen the tie-rod end locknuts. 2. Turn the tie rods by the same amount in the opposite direction. Note D One turn of the tie rod (both sides) changes the toe-in by about 30 mm {1.18 in}. D The left and right tie rods are both right threaded. To increase the toe-in, turn the right tie rod toward the front of the vehicle and the left tie rod equally toward the rear.
Tightening torque 40—58 N·m {4.0—6.0 kgf·m, 29—43 ft·lbf} 4 2
3. Tighten the tie-rod end locknuts. Tightening torque 69—78 N·m {7.0—8.0 kgf·m, 51—57 ft·lbf} TIE ROD
ADJUSTING BOLT 4 4
ADJUSTING BOLT
CONTINUED
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WHEEL ALIGNMENT, FRONT SUSPENSION Caster and Camber Adjustment 1. Loosen the upper arm shaft bolt and insert or remove adjustment shims to provide the correct angle. No.1—5 No.6—11
FRONT SUSPENSION VEHICLE HEIGHT ADJUSTMENT 1. Place the vehicle on level ground. 2. Inspect the front and rear tire pressure and adjust it as necessary. 3. Measure the distance from the center of each front wheel to the fender brim.
FRONT
Left/right difference 10 mm {0.39 in} max. Standard vehicle height (reference value) 4 2 Adjustment shim No.
Thickness (mm {in})
No.
Thickness (mm {in})
1
1.0 {0.039}
7
1.0 {0.039}
2
1.6 {0.063}
8
1.6 {0.063}
3
2.0 {0.079}
9
2.0 {0.079}
4
3.2 {0.126}
10
3.2 {0.126}
5
4.0 {0.157}
11
4.0 {0.157}
6
0.6 {0.024}
mm {in}
Cab type
Vehicle height
Regular Cab, Stretch Cab
427 {16.8}
Double Cab
422 {16.6}
4 4 Cab type
Tire size
Vehicle height
Regular g Cab,, Stretch Cab
205R16
519 {20.4}
235/75R15
515 {20.3}
205R16
510 {20.1}
235/75R15
506 {19.9}
Double Cab
Note D Shims No.1—5 are used on either side. Do not use more than two. D Shims No.6—11 are used at the front and rear of either sides. Do not use more than one. D Camber: A change of shim thickness (at front and rear) of 1 mm {0.039 in} results in a change of about 15’. D Caster: A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results in a change of about 30’. 2. After adjustment, tighten the upper arm shaft bolt to the specified torque. Tightening torque 94—116 N·m {9.5—11.9 kgf·m, 69—86 ft·lbf}
CONTINUED
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FRONT SUSPENSION 1. If the difference between left and right is not within the specification, adjust the vehicle height by turning the torsion bar spring anchor bolt. 4 2
4 4
ANCHOR BOLT
ANCHOR BOLT
CONTINUED
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FRONT SUSPENSION FRONT SHOCK ABSORBER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
6—8 mm {0.24—0.31 in}
55—80 {5.6—8.2, 41—59}
N·m {kgf·m, ft·lbf}
1
Nut + Installation Note
3
Bolt
4
Washer and nut
2
Retainer, bushing
5
Shock absorber
Nut Installation Note Tighten the nut so that the exposed thread of the shock absorber piston is 6—8 mm {0.24—0.31 in}.
FRONT SHOCK ABSORBER INSPECTION 1. Remove the front shock absorber from the vehicle. 2. Inspect for damage and oil leakage. 3. Inspect the rubber bushing for deterioration and wear. 4. Compress and extend the shock absorber piston at least three (3) times. Verify that the operational force does not change and that there is no unusual noise. 5. Compress the shock absorber piston and release it. Verify that the piston extends fully at a normal speed.
CONTINUED
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FRONT SUSPENSION TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Inspect the vehicle height and adjust it as necessary.
APPLY THREAD LOCKING COMPOUND
APPLY THREAD LOCKING COMPOUND
118—156 {12.0—16.0, 87—115} 118—156 {12.0—16.0, 87—115}
SST R
N·m {kgf·m, ft·lbf}
1
Cotter pin
11
Torque plate
2
Nut
12
Lower arm spindle, washer, and nut
3
Lower arm ball joint/Knuckle arm + Removal Note
13
4
Bolt, washer, and nut (shock absorber)
Rubber bushing + Removal Note + Installation Note
5
Anchor bolt + Removal Note + Installation Note
14
Tension rod bolt
15
Stabilizer bolt, bushing, retainer, spacer, and nut + Installation Note
6
Anchor swivel
16
Lower arm
7
Bolt and washer
17
Bound bumper, washer, and nut
8
Torsion bar component
18
Bolts and washer (ball joint)
9
Anchor arm
19
Lower arm ball joint
10
Torsion bar spring + Removal Note + Installation Note
20
Clip + Installation Note
21
Lower arm ball joint boot
CONTINUED
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FRONT SUSPENSION Lower Arm Ball Joint/Knuckle Arm Removal Note Separate the ball joint from the knuckle arm using the SST.
Clip Installation Note 1. Install the SST to the ball joint stud with the stud stands straight up. 2. Install the clip in the dust boot groove.
KNUCKLE
49 T028 3A0
Anchor Bolt Removal Note Mark the anchor bolt and swivel for reference during installation.
49 U034 208
Stabilizer Bolt, Bushing, Retainer, Spacer And Nut Installation Note Tighten the nuts so that 18—21 mm {0.71—0.82 in} of thread is exposed at the end of the bolt.
MATCHING MARK
18—21 mm {0.71—0.82 in}
Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation.
MATCHING MARK
Rubber Bushing Installation Note Install a new bushing using the SST.
MATCHING MARK
49 UB39 615
Rubber Bushing Removal Note Remove the rubber bushing from the body using the SST.
49 UB39 615
CONTINUED
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FRONT SUSPENSION Torsion Bar Spring Installation Note 1. Before installation, check the identification mark on the end of the torsion bar spring. L: Left bar, R: Right bar 2. Align the marks made during removal, and connect the torsion bar spring to the torque plate.
MATCHING MARK
MATCHING MARK
Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks made during removal are aligned.
MATCHING MARK
Note If the anchor bolt was not marked during removal, install it as follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper. (2) Install the anchor arm so that the angle A is 34° "4.5°. (3) Install the anchor bolt and tighten it 27.3 turns.
A
CONTINUED
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FRONT SUSPENSION TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (44) 1. Remove the driveshaft snap ring. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Inspect the vehicle height and adjust it as necessary.
118—156 {12.0—16.0, 87—115}
118—156 {12.0—16.0, 87—115}
SST
APPLY THREAD LOCKING COMPOUND
R
R
1
Cotter pin
13
Lower arm spindle (front), washer and nut
2
Nut
14
3
Lower arm ball joint/Knuckle arm + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Lower Arm Ball Joint/Knuckle Arm Removal Note
Stabilizer bolt, bushing, retainer, spacer and nut + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note
4
Bolt, washer and nut (shock absorber)
15
Lower arm
Anchor bolt and washer + Installation Note
16
Bound bumper, washer, and nut
17
Bolt, washer and nut
6
Anchor swivel
18
Lower arm ball joint
7
Bolt and washer
19
8
Torsion bar spring component
9
Anchor arm + Removal Note + Installation Note
Clip + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Clip Installation Note
10
Torsion bar spring + Removal Note + Installation Note
20
Lower arm ball joint boot
21
11
Torque plate
Lower arm bushing + Removal Note + Installation Note
12
Lower arm spindle (rear), washer and nut
5
CONTINUED
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FRONT SUSPENSION Anchor Arm Removal Note Mark the anchor arm and body for reference during installation.
Lower Arm Bushing Installation Note 1. Apply soapy water to the new bushing. 2. Install the bushing using the SST. 49 U034 2A0
Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation.
Torsion Bar Spring Installation Note 1. Before installation, inspect the identification mark on the end of the torsion bar spring. L: Left bar, R: Right bar 2. Align the marks made during removal, and connect the torsion bar spring to the torque plate.
Anchor Arm Installation Note Align the marks made during removal, and install the anchor arm onto the torsion bar spring.
Lower Arm Bushing Removal Note Remove the lower arm bushing using the SST. 49 U034 2A0
CONTINUED
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FRONT SUSPENSION Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks made during removal are aligned.
Note If the anchor bolt was not marked during removal, install it at follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper. (2) Install the anchor arm so that the angle A is 60°"4.5°. (3) Install the anchor bolt and tighten it 26.9 turns.
A
LOWER ARM INSPECTION 1. Remove the lower arm from the vehicle. 2. Inspect for damage, cracks, and bending. 3. Check the ball joint rotation torque. (1) Rotate the ball joint five times. (2) Connect the SST to the ball stud, and measure the rotation torque using a pull scale. (3) Replace it if not within the specification. Pull scale reading 20—34 N {2.0—3.5 kgf, 4.4—7.7 lbf} 49 0180 510B
CONTINUED
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FRONT SUSPENSION UPPER ARM REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Inspect the wheel alignment and adjust it as necessary.
R SST
1
Clip
6
Upper arm component
2
Cotter pin and nut
7
Bolt and washer
3
Upper arm ball joint/Knuckle arm + Removal Note
8
Upper arm ball joint
9
4
Bolt and washer
Clip + Installation Note
5
Adjustment shim + Removal Note
10
Upper arm ball joint boot
Upper Arm Ball Joint/Knuckle Arm Removal Note Separate the upper arm ball joint from the knuckle arm using the SST.
Clip Installation Note 1. Install the SST to the ball joint stud with the stud stands straight up. 2. Install the clip in the dust boot groove.
49 T028 3A0
49 U034 209
KNUCKLE
Adjustment Shim Removal Note Note the number, amount and position of the shims so that they are reinstalled in the correct positions.
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FRONT SUSPENSION UPPER ARM INSPECTION 1. Remove the upper arm from the vehicle. 2. Inspect for damage, cracks, and bending. 3. Check the ball joint rotation torque. (1) Rotate the ball joint five times. (2) Connect the SST to the ball stud, and measure the rotation torque using a pull scale. (3) Replace it if not within the specification.
49 0180 510B
Pull scale reading 5.0—24 N {0.5—2.5 kgf, 1.2—5.5 lbf} STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (42) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
22—26 {2.2—2.7, 16—19}
APPLY THREAD LOCKING COMPOUND
94—116 {9.5—11.9, 69—86}
94—127 {9.5—13.0, 69—94} N·m {kgf·m, ft·lbf}
1
Nut + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note
6
Stabilizer bracket
7
Bushing
8
Stabilizer bar
9
Tension rod nut + Installation Note
2
Retainer
10
Bushing and retainer
3
Bolt
11
Bolt
4
Bushing, retainer and spacer
12
Tension rod
5
Bolt
CONTINUED
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FRONT SUSPENSION Tension Rod Nut Installation Note Tighten the tension rod nuts so that length L is 98.5 mm {3.88 in}.
L
STABILIZER REMOVAL/INSTALLATION (44) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
22—26 {2.2—2.7, 16—19}
N·m {kgf·m, ft·lbf}
1
Nut + FRONT SUSPENSION, STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (42), Nut Installation Note
5
Retainer, bushing, and spacer
6
Bolt
7
Stabilizer bracket
2
Retainer and bushing
8
Bushing
3
Bolt
9
Stabilizer bar
4
Retainer and bushing
CONTINUED
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REAR SUSPENSION
REAR SUSPENSION REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION 1. Support the frame with safety stands and place a jack under the differential casing. Remove in the order indicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary. 2. Install in the reverse order of removal. 42
R
64—78 {6.5—8.0, 48—57}
59—78 {6.0—8.0, 44—57}
APPLY THREAD LOCKING COMPOUND
R
78—98 {8.0—10.0, 58—72}
R 20—26 {2.0—2.7, 15—19.5}
54—73 {5.5—7.5, 40—54}
N·m {kgf·m, ft·lbf}
1
Nut, washer, retainer, and bushing
10
Spring pin
2
Nut, washer, retainer, and bushing
11
Nut and washer
3
Shock absorber
12
Shackle pin
4
Nut and washer
13
Shackle plate
5
Nut and washer
14
Leaf spring component
6
U-bolt
15
7
Spring clamp
8
Stopper rubber
Leaf spring bushing + Removal Note + Installation Note
9
Bolt and washer
CONTINUED
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REAR SUSPENSION
44
99.1—112 {10.1—11.5, 73.1—83.1}
APPLY THREAD LOCKING COMPOUND
R
64—78 {6.5—8.0, 48—57}
59—78 {6.0—8.0, 44—57}
R 78—98 {8.0—10.0, 58—72}
20—26 {2.0—2.7, 15—19.5}
N·m {kgf·m, ft·lbf}
1
Bolt and nut
11
Bolt and washer
2
Washer, retainer, and bushing
12
Spring pin
3
Nut, washer, retainer, and bushing
13
Nut and washer
4
Shock absorber
14
Shackle pin
5
Nut and washer
15
Shackle plate
6
Nut and washer
16
Leaf spring component
7
U-bolt
17
8
Set plate
9
Spring clamp
Leaf spring bushing + Removal Note + Installation Note
10
Stopper rubber
CONTINUED
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REAR SUSPENSION Leaf Spring Bushing Removal Note Secure the leaf spring in a vise and remove the bushing using a chisel.
Leaf Spring Bushing Installation Note Press in the bushing using a suitable pipe.
CONTINUED
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PAGE 1 OF 2 BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BONNET REMOVAL/INSTALLATION . . . . . . . . BONNET ADJUSTMENT . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL . . . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DOOR REMOVAL/INSTALLATION . . . FRONT DOOR DISASSEMBLY/ASSEMBLY . . FRONT DOOR ADJUSTMENT . . . . . . . . . . . . . REAR DOOR REMOVAL/INSTALLATION . . . . REAR DOOR DISASSEMBLY/ASSEMBLY . . . REAR DOOR ADJUSTMENT . . . . . . . . . . . . . . . DOOR LOCK STRIKER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REGULATOR HANDLE REMOVAL . . . . . . . . . . REGULATOR HANDLE INSTALLATION . . . . . POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . POWER WINDOW MOTOR INSPECTION . . . POWER DOOR LOCK SYSTEM . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH INSPECTION . . . DOOR LOCK ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK ACTUATOR INSPECTION . . . . . DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK TIMER UNIT INSPECTION . . . . FUEL-FILLER LID AND OPENER . . . . . . . . . . . . FUEL-FILLER LID REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FUEL-FILLER LID ADJUSTMENT . . . . . . . . . . BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BUMPER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT BUMPER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . REAR BUMPER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR BUMPER DISASSEMBLY/ASSEMBLY . .
TO. MODEL .INDEX
BODY S– 2 S– 2/3 S– 3 S– 4 S– 4 S– 5 S– 5 S– 6 S– 7 S– 7 S– 8/9 S– 9 S– 9 S– 9 S– 9 S–10 S–10 S–10/12 S–12 S–12/13 S–13 S–13 S–13/14 S–14 S–14 S–15 S–15 S–15 S–15 S–15 S–15 S–16 S–16 S–17 S–19 S–19 S–19 S–19 S–19 S–19 S–20 S–20/21
EXTERIOR ATTACHMENT . . . . . . . . . . . . . . . . . . . RADIATOR GRILLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COWL GRILLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD GARNISH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . SIDE PROTECTOR REMOVAL . . . . . . . . . . . . . SIDE PROTECTOR INSTALLATION . . . . . . . . OVER FENDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . TAILGATE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . TAILGATE ADJUSTMENT . . . . . . . . . . . . . . . . . ROPE HOOK REMOVAL/INSTALLATION . . . . MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD SIDE MOLDING REMOVAL . . . WINDSHIELD SIDE MOLDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BELTLINE MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR BELTLINE MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . ROOF MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . OUTSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR INSPECTION . . POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . FILAMENT INSPECTION . . . . . . . . . . . . . . . . . . FILAMENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD REMOVAL . . . . . . . . . . . . . . . . . . WINDSHIELD INSTALLATION . . . . . . . . . . . . . . QUARTER WINDOW GLASS REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW GLASS REMOVAL . . . . . . . . REAR WINDOW GLASS INSTALLATION . . . . DASHBOARD AND CONSOLE . . . . . . . . . . . . . . .
S–1
S–21 S–21 S–21 S–21/22 S–22 S–22/23 S–23 S–23 S–23 S–24 S–24 S–24 S–24 S–24 S–24 S–24 S–25 S–25 S–25 S–25 S–25 S–25/26 S–26 S–26 S–27 S–27 S–27 S–27 S–27 S–27/28 S–28 S–28 S–28 S–29 S–29/30 S–30/31 S–32 S–33 S–33 S–34
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BONNET
BODY
PAGE 2 OF 2 DASHBOARD REMOVAL/INSTALLATION . . . DASHBOARD DISASSEMBLY/ASSEMBLY . . DASHBOARD MEMBER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COLUMN COVER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT CONSOLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . REAR CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR CONSOLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . GLOVE COMPARTMENT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . METER HOOD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-PILLAR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SIDE TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SCUFF PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR SCUFF PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
S–34 S–35 S–36 S–36 S–36 S–36 S–36 S–37 S–37 S–37 S–38 S–38 S–38 S–38 S–38 S–39 S–39 S–39
C-PILLAR TRIM REMOVAL/INSTALLATION . . S–39 QUARTER UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–39/40 QUARTER LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40 BACK UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40 BACK LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40 FRONT DOOR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–41 REAR DOOR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–41 HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–42 HEADLINER REMOVAL/INSTALLATION . . . . . S–42 FLOOR COVERING . . . . . . . . . . . . . . . . . . . . . . . . . S–42 FLOOR COVERING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–42/43 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–44 SEAT BELT REMOVAL/INSTALLATION . . . . . . S–44/45 SEAT BELT INSPECTION . . . . . . . . . . . . . . . . . S–45/46 BUCKLE REMOVAL/INSTALLATION . . . . . . . . . S–46 BUCKLE SWITCH INSPECTION . . . . . . . . . . . . S–47 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–48 FRONT SEAT REMOVAL/INSTALLATION . . . . S–48 FRONT SEAT DISASSEMBLY/ASSEMBLY . . . S–49/50 CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . S–51 REAR SEAT REMOVAL/INSTALLATION . . . . . S–51/52 REAR SEAT DISASSEMBLY/ASSEMBLY . . . . S–52/53 SEAT WARMER SWITCH REMOVAL . . . . . . . S–54 SEAT WARMER SWITCH INSTALLATION . . . S–54 SEAT WARMER SWITCH INSPECTION . . . . . S–54 SEAT WARMER UNIT INSPECTION . . . . . . . . S–54
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BONNET 3.0—3.9 {30—40, 27—34}
Warning D Removing the bonnet without supporting it can be dangerous. The bonnet may fall and injure you. Always perform these procedures together with at least another person.
Á
À
Â
A A
BONNET REMOVAL/INSTALLATION 1. Pull out the windshield washer pipe. 2. To remove the bonnet hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 3. To remove the bonnet lock, remove the radiator grille. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the bonnet. (Refer to BONNET ADJUSTMENT.)
Å
Ã
Ä
Æ 7.9—10.7 {80—110, 69.5—95.4}
N·m {kgf·cm, in·lbf}
S–2
1
Shroud seal weatherstrip
2
Bonnet
3
Bonnet hinge
4
Bonnet stay
CONTINUED
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BONNET
5
Bonnet lock
6
Bonnet release lever
7
Bonnet release cable
Height Adjustment 1. Loosen the bonnet lock installation bolts and move the bonnet lock to reposition the bonnet. BOLT
BONNET ADJUSTMENT 1. Measure the gap and height between the bonnet and the body. Clearance a: 2.7—5.3 mm {0.11—0.20 in} b: –1.8—0.8 mm {–0.07—0.03 in} (sec. A—A) c: –2.3—0.8 mm {–0.09—0.03 in} (sec. B—B) d: –2.3—0.3 mm {–0.09—0.01 in} (sec. C—C) e: 6.0—10.0 mm {0.24—0.39 in} f: 7.0—13.0 mm {0.28—0.51 in}
50 {2.0}
A A
30 {1.2} E
D D
2. Tighten the bonnet lock installation bolts.
B B C C
E
a e b , c, d
SEC. A—A SEC. B—B SEC. C—C
f SEC. D—D
SEC. E—E mm {in}
2. If not as specified, adjust the gap and height. (Refer to Gap Adjustment.) (Refer to Height Adjustment.) Gap Adjustment 1. Loosen the bonnet installation bolts and reposition the bonnet.
BOLT
2. Tighten the bonnet installation bolts.
CONTINUED
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FRONT FENDER PANEL
FRONT FENDER PANEL FRONT FENDER PANEL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front side turn light. 3. Remove the front bumper. 4. Remove the front turn light. 5. Remove the front flap. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
B B
A
A
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
1
Mud guard
2
Front fender panel
CONTINUED
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DOOR DOOR FRONT DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. To remove the front door hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 4. To remove the checker, remove the speaker. (Refer to section T, AUDIO, SPEAKER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Adjust the front door. (Refer to FRONT DOOR ADJUSTMENT.)
Front Door Harness Removal Note 1. Disconnect the connectors indicated in the table, if equipped. Symbol A B C D E
Connector name Passenger's side Driver's side Door lock-link switch Door lock actuator Power window main Power window switch subswitch Power outside mirror Front power window regulator Speaker
← ← ←
2. Disengage the clips.
3. Remove the rubber boot and pull out the door harness. 1 2 3 4 5
Front door harness ☞ Removal Note Checker pin Front door hinge Front door Checker
CONTINUED
S-5
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DOOR FRONT DOOR DISASSEMBLY/ASSEMBLY 1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position. 2. Disconnect the negative battery cable. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. To remove the inner handle, peel off the door screen partially. 5. Disassemble in the order indicated in the table. 6. Assemble in the reverse order of disassembly. WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
B B A D
E
6.87–9.80 {70–100, 60.8–86.7}
H
4.3–6.1 {43–63, 38–54}
C
C 6.87–9.80 {70–100, 60.8–86.7}
D H
WITH POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
A
F
J
8.9–12.7 {90–130, 79–112}
G I
F
G
E
4.3–6.1 {43–63, 38–54}
2.0–2.9 {20–30, 18–26}
6.87–9.80 {70–100, 60.8–86.7}
J I
N·m {kgf·cm, in·lbf}
1
Inner handle
8
Front power window regulator
2 3
Door screen
9
Outer handle
Front door glass
10
Retainer
4 5
Glass run channel
11
Door key cylinder
Front glass guide
12
Front door lock (manual)
6
Rear glass guide
13
Front door lock (power)
7
Front manual window regulator
14
Door lock knob
CONTINUED
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DOOR FRONT DOOR ADJUSTMENT 1. Measure the clearance between the door and the body.
22—30 {2.2—3.1, 16—22}
Clearance a: 4.0—6.0 mm {0.16—0.23 in} b: –1.5—1.0 mm {–0.059—0.039 in} c: –2.0—0.5 mm {–0.078—0.019 in} d: 4.5—8.5 mm {0.18—0.33 in} e: 1.2 mm {0.047 in} f: 3.5—6.5 mm {0.14—0.25 in} g: 2.7 mm {0.11 in} h: 5.5 mm {0.22 in}
D
D
C
C
E E
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
A A B B
a
(+)
N·m {kgf·m, ft·lbf}
d
F F
e (+)
a b
c
(–) SEC. B—B
SEC. A—A
(+) b
f
(–)
SEC. C—C
f
1
Connector
2
Checker pin
3
Rear door hinge
4
Rear door
5
Checker
g (–) SEC. D—D
h SEC. E—E
SEC. F—F
2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation screws, and move them to reposition the door. (Refer to FRONT DOOR REMOVAL/INSTALLATION.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.) 3. Tighten the bolts or the screws. REAR DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. To remove the checker, remove the ashtray bracket. (Refer to REAR DOOR DISASSEMBY/ASSEMBLY.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the rear door. (Refer to REAR DOOR ADJUSTMENT.)
S–7
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DOOR REAR DOOR DISASSEMBLY/ASSEMBLY 1. Close the rear door glass completely. 2. Disconnect the negative battery cable. 3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.) 4. Disassemble in the order indicated in the table. 5. Assemble in the reverse order of disassembly. WITH POWER WINDOW SYSTEM
6.87—9.80 {70—100, 60.8—86.7}
E WITHOUT POWER WINDOW SYSTEM
E
6.87—9.80 {70—100, 60.8—86.7}
B
2.5—3.5 {25—36, 22—31}
B
4.3—6.1 {43—63, 38—54}
D A C
D
6.87—9.80 {70—100, 60.8—86.7}
C
A
N·m {kgf·cm, in·lbf}
1
Inner handle
7
Rear door glass + Removal Note
2
Door screen
3
Ashtray bracket
8
Glass run channel
4
Glass hole lid
9
Glass guide
5
Rear manual window regulator
10
Door lock knob
6
Rear power window regulator
11
Rear door lock
12
Outer handle
CONTINUED
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DOOR Rear Door Glass Removal Note D Draw out the rear door glass through the glass hole.
DOOR LOCK STRIKER REMOVAL/INSTALLATION 1. Remove the screws. 2. Remove the door lock striker. DOOR LOCK STRIKER
SCREW
18–26 {1.8–2.7, 14–19}
REAR DOOR
REAR DOOR GLASS N·m {kgf·m, ft·lbf}
REAR DOOR ADJUSTMENT 1. Measure the clearance between the door and the body. Clearance a: 3.5—6.5 mm {0.14—0.25 in} b: –1.5—1.0 mm {–0.059—0.039 in} c: 5.5 mm {0.22 in}
3. Install in the reverse order of removal. REGULATOR HANDLE REMOVAL 1. Remove the regulator handle clip using a rag as shown.
DD A A E E B B RAG
a
C C
2. Remove the regulator handle. a
(+)
(+)
b (–)
b (–)
SEC. A–A
SEC. B–B a
(+) b
CLIP
(+)
c SEC. C–C
REGULATOR HANDLE INSTALLATION 1. Install the clip in the regulator handle. 2. Set the door glass at the fully raised position and push the regulator handle on as shown.
a
b (–)
(–)
SEC. D–D
SEC. E–E
2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation CLIP screws, and move them to reposition the door. (Refer to REAR DOOR REMOVAL/INSTALLATION.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.)
FRONT
3. Tighten the bolts or screws.
CONTINUED
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POWER WINDOW SYSTEM
POWER WINDOW SYSTEM POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disengage the clip using a tape-wrapped flathead screwdriver. 3. Pull the switch panel forward, and disengage the hook.
POWER WINDOW MAIN SWITCH INSPECTION Regular Cab, Stretch Cab 1. Remove the switch panel. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. 3. When inspecting the driver’s side, connect the battery positive voltage to terminal F and connect the ground to terminal D. 4. When inspecting the passenger’s side, turn the power-cut switch to ON. Power window switch Driver’s side : Continuity
BODY
SWITCH PANEL
Switch position
Terminal F
D
A (H)
B (I)
BODY CLIP
Manual close
HOOK
Off Auto open Manual open
( ): R.H.D. Passenger’s side : Continuity Switch position
Terminal F
D
H (A)
I (B)
Close
4. Disconnect the power window main switch connector. 5. Remove the screws to remove the power window main switch from the switch panel.
Off Open
SWITCH PANEL
( ): R.H.D. Power-cut switch : Continuity
POWER WINDOW MAIN SWITCH
Switch position
Terminal D
A (H)
B (I)
H (A)
I (B)
ON OFF
( ): R.H.D.
SCREW
6. Install in the reverse order of removal.
CONTINUED
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POWER WINDOW SYSTEM Rear left : Continuity
F
POWER-CUT SWITCH
D
MANUAL OPEN
MANUAL CLOSE
A
H
K
I
Close
OPEN
CLOSE AUTO OPEN
AUTO CIRCUIT
Terminal
Switch position
Off O en Open
( ): R.H.D.
I (B) H (A) PASSENGER’S SIDE
Rear right : Continuity
OPEN
CLOSE A (H) B (I) DRIVER’S SIDE H I
Terminal
Switch position
∗ D
H
E
C
Close
∗ A
F
A
B
Off
( ) : R.H.D.
O en Open
5. If not as specified, replace the power window main switch.
( ): R.H.D. Power-cut switch
Double Cab 1. Remove the switch panel. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. 3. When inspecting the driver’s side, connect the battery positive voltage to terminal A (L.H.D.) or F (R.H.D.) and connect the ground to terminal H. 4. When inspecting the passenger’s side and rear, turn the power-cut switch to ON.
: Continuity Terminal Switch position
L (D )
H
J (B )
D (L )
B (J)
E
C
K
I
K
I
ON OFF
( ): R.H.D. L.H.D.
Power window switch Driver’s side : Continuity Switch position
Terminal A (F)
H
L (D)
J (B)
Manual close
A H
Off Auto open Manual open
( ): R.H.D. D B PASSENGER’S
Passenger’s side : Continuity Switch position
Terminal A (F)
H
D (L)
B (J)
E
C RIGH T
J
Close Off Open O en
( ): R.H.D.
CONTINUED
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POWER WINDOW SYSTEM R.H.D.
Rear 1. Disconnect the negative battery cable. 2. Remove the hook by inserting a tape-wrapped, flathead screwdriver between the switch and the rear door trim. A
F H
HOOK
J PASSENGER’S B
D
K
I
L
J
E
H
C
K
I
E
C
A
F
D
B
POWER WINDOW SUBSWITCH
3. Disconnect the connector, and remove the power window subswitch. 4. Install in the reverse order of removal.
5. If not as specified, replace the power window main switch. POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION Passenger’s side 1. Disconnect the negative battery cable. 2. Disengage the clip using a tape-wrapped flathead screwdriver. 3. Pull the power window subswitch forward, and disengage the hook.
POWER WINDOW SUBSWITCH INSPECTION 1. Remove the power window subswitch. (Refer to POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window subswitch terminals using an ohmmeter. Passenger’s side : Continuity Switch position
Terminal A
B
D
E
F
Off Close Open O en
BODY CLIP
BODY
POWER WINDOW SUBSWITCH
E
A
F
CLOSE OPEN
D
B
HOOK
Rear : Continuity Switch position
Terminal A
B
D
E
F
Close Off
4. Disconnect the power window subswitch connector. 5. Install in the reverse order of removal.
Open
CONTINUED
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POWER WINDOW SYSTEM
F
B
D F
E
D
B
A
CLOSE OPEN E
A
3. If not as specified, replace the power window subswitch. FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position. 2. Disconnect the negative battery cable. 3. Remove the front glass guide and the rear glass guide. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 4. Remove in the order indicated in the table. 1 Bolt 5. Install in the reverse order of removal.
B
2
Power window motor + Disassembly Note + Assembly Note
3
Frame
3.0—4.9 N·m {30—50 kgf·cm, 27—43 in·lbf}
A 8.9—12.7 {90—130, 79—112}
D C
Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor.
A B
BASE MARK
D C 6.87—9.80 {70—100, 60.8—86.7}
GEAR
N·m {kgf·cm, in·lbf}
1
Front power window regulator connector
2
Bolt
3
Nut
4
Front power window regulator
FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Power Window Motor Assembly Note D Align the marks of the gear and the frame to install the power window motor. REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. Raise the rear door glass completely. 2. Disconnect the negative battery cable. 3. Remove the door screen. (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
CONTINUED
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POWER WINDOW SYSTEM Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor. MARK A
A
BASE
GEAR
D C
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
1
Rear power window regulator connector
2
Bolt
3
Rear power window regulator
REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Power Window Motor Assembly Note D Align the marks of the gear and base of the frame to install the power window motor. POWER WINDOW MOTOR INSPECTION 1. Remove the power window motor. (Refer to FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY.) (Refer to REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY.) 2. Apply battery positive voltage to the power window motor terminals and inspect the operation of the power window motor. B+: Battery positive voltage Connection
3.1—4.8 N·m {31—49 kgf·cm, 27—42 in·lbf}
Motor operation
B+
GND
A
B
Up
B
A
Down
UP
DOWN
A B
A
B
3. If not as specified, replace the power window motor.
1
Bolt
2
Power window motor + Disassembly Note + Assembly Note
3
Frame
CONTINUED
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POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION Note • The door lock-link switch is mounted to the driver-side door lock. 1. Disconnect the negative battery cable. 2. Remove the driver-side door lock. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Remove the door lock-link switch from the front door lock.
5. If not as specified, replace the door lock-link switch. DOOR LOCK ACTUATOR REMOVAL/INSTALLATION Front Note • The front door lock actuator is mounted to the passenger-side door lock. 1. Disconnect the negative battery cable. 2. Remove the passenger-side door lock. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Remove the front door lock actuator from the front door lock.
5. Install in the reverse order of removal. DOOR LOCK-LINK SWITCH INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side door screen. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Disconnect the door lock-link switch connector. 4. Inspect for continuity between the door lock-link switch terminals using an ohmmeter. 5. Install in the reverse order of removal.
CONTINUED S-15
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POWER DOOR LOCK SYSTEM Rear Note • The rear door lock actuator is mounted to the rear door lock. 1. Disconnect the negative battery cable. 2. Remove the rear door lock. (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Disconnect the rod. 5. Remove the rear door lock actuator from the rear door lock.
5. If not as specified, replace the door lock actuator. DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the flasher unit. (Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
6. Install in the reverse order of removal. DOOR LOCK ACTUATOR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. Disconnect the door lock actuator connector. 4. Apply battery positive voltage to the door lock actuator terminals and inspect the operation of the door lock actuator.
1 2 3
Door lock timer unit connector Nut Bracket
4
Door lock timer unit
B+: Battery positive voltage Terminal A GND B+
B B+ GND
Actuator operation Lock Unlock
CONTINUED S-16
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POWER DOOR LOCK SYSTEM DOOR LOCK TIMER UNIT INSPECTION 1. Remove the flasher unit. (Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 2. Measure the voltage at the door lock timer unit terminals as indicated below. 3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals A, C, D, and H. 4. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock timer unit. Terminal Voltage List (Reference) B+: Battery positive voltage
Terminal
Signal
Connection
Test condition
Voltage (V) /Continuity
Inspection area
A
GND
Body ground
Constant: inspect for continuity to ground
Yes
-
B
Power supply
D/L 30 A fuse
B+
D/L 30 A fuse
C
Unlock input
Door lock-link switch
Constant Door lock-link switch is at lock: inspect for continuity to terminal H Door lock-link switch is at unlock: inspect for continuity to terminal H Door lock-link switch is at lock: inspect for continuity to terminal H Door lock-link switch is at unlock: inspect for continuity to terminal H Door lock actuators are locked
0 → B+ → 0
Other Door lock actuators are unlocked Other
0 0 → B+ → 0 0
D
Lock input
Door lock-link switch
E
Lock output
Door lock actuator
F
Unlock output
Door lock actuator
G H
GND
Not used Terminal A of door lock timer unit
Constant: inspect for continuity to terminal A
No Yes Yes No
Door lock-link switch
Door lock-link switch Door lock actuator Door lock actuator
-
-
Yes
-
CONTINUED
S-17
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FUEL-FILLER LID AND OPENER, BUMPER
FUEL-FILLER LID AND OPENER
BUMPER
FUEL-FILLER LID REMOVAL/INSTALLATION 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
FRONT BUMPER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
63—93 {6.4—9.5, 47—68} 6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
1
Fuel-filler lid
FUEL-FILLER LID ADJUSTMENT 1. Measure the gap and height between the fuel-filler lid and the body.
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
Clearance a: 3.5—5.5 mm {0.14—0.21 in} b: –0.5—2.0 mm {–0.01—0.07 in}
63—93 {6.4—9.5, 47—68} N·m {kgf·m, ft·lbf}
A a
b A
1
Front bumper
2
Front bumper stay
FRONT BUMPER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 0.2—0.8 {2—9, 2—7}
SEC.A–A
2. If not as specified, loosen the fuel-filler lid installation bolts and reposition the fuel-filler lid. 3. Tighten the fuel-filler lid installation bolts.
6.87—9.80 {70—100, 60.8—86.7}
0.2—0.3 {2—4, 2—3}
12345678
N·m {kgf·cm, in·lbf}
1
Front bumper side fascia
2
Front bumper upper fascia
3
Front bumper lower fascia
CONTINUED
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BUMPER REAR BUMPER REMOVAL/INSTALLATION With Step 1. Remove the bolts, then remove the rear bumper.
REAR BUMPER DISASSEMBLY/ASSEMBLY With Step 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf} 32—46 {3.2—4.7, 24—33} A A
B
A B
BOLT 79—116 {8.0—11.9, 58.0—86.0}
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
REAR BUMPER
A B
0.30—0.78 N·m {3.0—8.0 kgf·cm, 2.7—6.9 in·lbf}
N·m {kgf·m, ft·lbf}
B
N·m {kgf·m, ft·lbf}
2. Install in the reverse order of removal. Without Step 1. Disconnect the negative battery cable. 2. Disconnect the rear fog light connector. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Side bumper step + Removal Note
2
Center bumper step + Removal Note
3
Rear bumper fascia
4
Rear bumper stay
5
Rear bracket
6
Set plate
Side Bumper Step Removal Note 1. Disengage clips A using pliers. 2. Pull the side bumper step upward, then remove it.
A
A
A
A
A
A SIDE BUMPER STEP
79—116 {8.0—11.9, 58.0—86.0}
16—22 {1.6—2.3, 12—16} N·m {kgf·m, ft·lbf}
1
Rear bumper stay
3
Rear bumper fascia
CLIP A
Center Bumper Step Removal Note 1. Remove the screws. 2. Disengage clips A using pliers. 3. Disengage clips B, then remove the center bumper step. 12345678
CONTINUED
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BUMPER, EXTERIOR ATTACHMENT B
SCREW
B A
A
A
B
A
SCREW A
A
CENTER BUMPER STEP
SCREW
CLIP B
B
EXTERIOR ATTACHMENT RADIATOR GRILLE REMOVAL/INSTALLATION 1. Pull the radiator grille toward you, then disengage clips A to remove the radiator grille.
A
A
A
A
A
SCREW
A
CLIP A
A
A CLIP
RADIATOR GRILLE
A
2. Install in the reverse order of removal. COWL GRILLE REMOVAL/INSTALLATION 1. Remove the windshield wiper arm and blade. (Refer to section T, WIPER AND WASHER, WIPER ARM AND BLADE REMOVAL/INSTALLATION.) 2. Remove the weatherstrip. 3. Remove the screws, then remove the cowl grille.
SCREW
COWL GRILLE
WEATHERSTRIP
4. Install in the reverse order of removal. WINDSHIELD GARNISH REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the windshield garnish upward, then disengage hook A from the cowl grille.
CONTINUED
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EXTERIOR ATTACHMENT CENTER SIDE PROTECTOR (REGULAR CAB)
FRONT SIDE PROTECTOR d
b c
d
d ca
a e
SCREW
a
a
c
c
a
c DOUBLE-SIDED ADHESIVE TAPE CENTER SIDE REAR SIDE PROTECTOR PROTECTOR (STRETCH CAB) d d d b c c a a
WINDSHIELD GARNISH COWL GRILLE
e e
e
A
a
c
A
a c c
c
HOOK
1. Install in the reverse order of removal.
a
c
4. Peel off the backing paper from the double-sided adhesive tape and attach the side protector onto the body as shown.
SIDE PROTECTOR REMOVAL Warning D Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife.
Clearance a : 4.8—5.8 mm {0.19—0.22 in} b : 5.0—6.0 mm {0.20—0.23 in} c : 13.0—14.0 mm {0.51—0.55 in} d : 16.5—17.0 mm {0.65—0.66 in} e : 12.3—13.3 mm {0.49—0.52 in} f : 6.0—8.0 mm {0.24—0.31 in}
1. Pry the side protector end 20—30 mm {0.8—1.1 in} using a flathead screwdriver or a razor knife. 2. Pull the side protector, then remove it.
Regular Cab Note D The side protector is installed with double-sided adhesive tape. If the side protector is difficult to remove, soften the double-sided adhesive tape using a hot air blower.
CENTER SIDE PROTECTOR
Clearance a : 0—3.0 mm {0—0.11 in} b : 37.5 mm {1.48 in} c : 10.0 mm {0.39 in} d : 2.0—5.0 mm {0.08—0.19 in} e : 25.0 mm {0.98 in}
f
a
A A
SIDE PROTECTOR INSTALLATION 1. Remove the adhesive remaining on the side protector (if it will be reused) and the body using a razor knife. 2. Remove any grease or dirt from the adhesion surface of the side protector (if it will be reused) and the body. 3. Attach double-sided adhesive tape to the side protector as shown (if it will be reused).
REAR SIDE PROTECTOR
FRONT SIDE PROTECTOR
b
c
SEC. A—A
Stretch Cab CENTER SIDE PROTECTOR REAR SIDE PROTECTOR
FRONT SIDE PROTECTOR a
A A
f
b
d
SEC. A—A
CONTINUED
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EXTERIOR ATTACHMENT Double Cab NUT REAR SIDE PROTECTOR f
FRONT SIDE PROTECTOR
e
A A
b TAILGATE LOCK
SEC. A—A
ROD
5. Remove the bolts, then remove the latch guide, latch and rod.
5. After installing the side protector to the body, apply pressure of 50 N·m {5.0 kgf·m, 37 ft·lbf} or more with a roller, etc.
BOLT
OVER FENDER REMOVAL/INSTALLATION 1. Remove the screws. 2. Remove the fasteners. 3. Disengage clips A of the over fender using a fastener remover, then remove the over fender.
ROD
LATCH GUIDE
LATCH
FRONT CLIP A
A
A A
TAILGATE ADJUSTMENT 1. Loosen the bolts. 2. Move the striker forward and rearward until the tailgate will lock properly. 3. After the correct adjustment is made, tighten the bolts securely.
OVER FENDER FASTENER REAR A A
SCREW A
6. Remove the handle. 7. Assemble in the reverse order of disassembly.
A
A
CLIP A
A
BOLT
A
A
OVER FENDER
STRIKER
SCREW FASTENER
4. Install in the reverse order of removal. TAILGATE DISASSEMBLY/ASSEMBLY 1. Remove the cover. 2. Remove the nuts attaching the tailgate lock. 3. Disconnect the rods from the tailgate lock. 4. Remove the tailgate lock.
CONTINUED
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EXTERIOR ATTACHMENT, MOLDING ROPE HOOK REMOVAL/INSTALLATION 1. Remove the screws and bolts, then remove the rope hook.
ROPE HOOK SCREW
MOLDING WINDSHIELD UPPER MOLDING REMOVAL D Remove the windshield upper molding from the windshield. (Refer to WINDOW GLASS, WINDSHIELD REMOVAL.) WINDSHIELD UPPER MOLDING INSTALLATION D Install the windshield upper molding to the windshield. (Refer to WINDOW GLASS, WINDSHIELD INSTALLATION.) WINDSHIELD SIDE MOLDING REMOVAL D Remove the windshield side molding from the windshield. (Refer to WINDOW GLASS, WINDSHIELD REMOVAL.)
ROPE HOOK
WINDSHIELD SIDE MOLDING INSTALLATION D Install the windshield side molding to the windshield. (Refer to WINDOW GLASS, WINDSHIELD INSTALLATION.)
BOLT
2. Install in the reverse order of removal.
FRONT BELTLINE MOLDING REMOVAL/INSTALLATION 1. Lower the front door glass fully. 2. Remove the manual outside mirror or the power outside mirror. (Refer to OUTSIDE MIRROR, MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION.) (Refer to OUTSIDE MIRROR, POWER OUTSIDE MIRROR REMOVAL/INSTALLATION.) 3. Pull the rear end of the front beltline molding to disengage the hook. FRONT BELTLINE MOLDING
HOOK
4. Pull the front beltline molding upward, then remove clips A. A
BELTLINE MOLDING
CLIP A
A
A
5. Install in the reverse order of removal.
CONTINUED
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MOLDING, OUTSIDE MIRROR REAR BELTLINE MOLDING REMOVAL/INSTALLATION 1. Lower the rear door glass fully. 2. Pull the rear end of the rear beltline molding to disengage the hook.
OUTSIDE MIRROR MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION 1. Remove the inner garnish. 2. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 3. Remove the screws. 4. Remove the manual outside mirror.
REAR BELTLINE MOLDING
MANUAL OUTSIDE MIRROR SCREW
HOOK
3. Pull the rear beltline molding upward, then remove clips A. 5. Install in the reverse order of removal.
A
BELTLINE MOLDING CLIP A
A
A
4. Install in the reverse order of removal.
POWER OUTSIDE MIRROR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the inner garnish. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. Partially peel off the door screen. 5. Disconnect the power outside mirror connector. 6. Remove the screws. 7. Remove the power outside mirror.
ROOF MOLDING REMOVAL/INSTALLATION 1. Pull the rear edge of roof molding upward, then disengage clips A.
SCREW
A
A
A
POWER OUTSIDE MIRROR
ROOF MOLDING ROOF MOLDING
POWER OUTSIDE MIRROR CONNECTOR
CLIP BODY A
2. Install in the reverse order of removal.
8. Install in the reverse order of removal. POWER OUTSIDE MIRROR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the inner garnish. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. Partially peel off the door screen. 5. Disconnect the power outside mirror connector. 6. Apply battery positive voltage to the power outside mirror and inspect the operation of the power outside mirror.
CONTINUED
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OUTSIDE MIRROR B+: Battery positive voltage Connection B+
GND
Mirror operation
A
C
Up
C
A
Down
C
D
Left
D
C
Right
: Continuity Switch position
Terminal I
L
A
D
C
B
K
Up Down LH Left
C
A
D
Right Up
DOWN UP
M LEFT
Down *
123456567
RH
RIGHT
Left
M
Right
1. If not as specified, replace the power outside mirror. POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the fuse block cover. 3. Remove the fuse block installation screws, and push the fuse block into the dashboard. 4. Insert your hand into the hole for the fuse block, and press the hooks of the power outside mirror switch. 5. Push the power outside mirror switch out, then remove it. 6. Disconnect the power outside mirror switch connector. POWER OUTSIDE MIRROR SWITCH POWER OUTSIDE MIRROR SWITCH CONNECTOR
3. If not as specified, replace the power outside mirror switch.
7. Install in the reverse order of removal. POWER OUTSIDE MIRROR SWITCH INSPECTION 1. Remove the power outside mirror switch. (Refer to POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power outside mirror switch terminals using an ohmmeter.
CONTINUED
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REARVIEW MIRROR, REAR WINDOW DEFROSTER
REARVIEW MIRROR
REAR WINDOW DEFROSTER
REARVIEW MIRROR REMOVAL/INSTALLATION Regular Cab
REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. 3. Press the hooks of the rear window defroster switch and push the switch out.
Note D The rearview mirror is attached to the interior light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION, Regular Cab.) Stretch Cab, Double Cab 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
HOOK
REAR WINDOW DEFROSTER SWITCH
2.0—3.9 {20—40, 18—34}
N·m {kgf·cm, in·lbf}
1
Cover
2
Screw
3
Rearview mirror
METER HOOD
4. Install in the reverse order of removal. REAR WINDOW DEFROSTER SWITCH INSPECTION 1. Remove the rear window defroster switch. 2. Inspect for continuity between the rear window defroster switch terminals using an ohmmeter. : Continuity : Bulb Switch position
Terminal A
B
C
D
ON OFF
D
C
A
:
C
A
:
D
B
B
3. If not as specified, replace the rear window defroster switch. FILAMENT INSPECTION 1. Turn the ignition switch to ON position. 2. Turn the rear window defroster switch on. Caution D Directly touching the rear window defroster filament with the lead of the circuit tester will damage it. Wrap aluminum foil around the end of the lead and test the filament by touching it with the foil.
CONTINUED
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REAR WINDOW DEFROSTER Caution D Do not use the rear window defroster until the paint is completely dry. It may cause other malfunctions if it is used before the paint is dry.
LEAD OF THE CIRCUIT TESTER PUSH
5. Use a hot air blower heated to 150°C {302°F} for 30 minutes or let the paint set for 24 hours at 25°C {77°F} to allow it to dry completely.
FILAMENT
ALUMINUM FOIL
1. Connect the positive ()) lead of the voltmeter to the positive side of each filament and the negative (*) lead to ground. 2. Gradually, slide the positive ()) lead from the positive side to the negative side and measure the voltage. Verify that the voltage decreases accordingly. Measurement place
Voltage (Reference value)
(1) (2)
Approx. 12 V Approx. 0 V
(2) NEGATIVE SIDE
REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the rear window defroster relay connector. 3. Slide the rear window defroster relay upward, then remove it.
REAR WINDOW DEFROSTER RELAY
REAR WINDOW DEFROSTER RELAY CONNECTOR
(1) POSITIVE SIDE
4. Install in the reverse order of removal. REAR WINDOW DEFROSTER RELAY INSPECTION 1. Remove the rear window defroster relay. (Refer to REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the rear window defroster relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage
3. If the voltage is not as specified or it changes rapidly, the filament is faulty. Repair the filament. FILAMENT REPAIR 1. Use white gasoline to clean around the damaged section of the filament. 2. Attach tape above and below the damaged section of the filament. BROKEN FILAMENT
Terminal
Step
A
B
C
B)
GND
D
1 2
TAPE
C
A
D
B
D
A
C
B
SECTION TO BE REPAIRED
3. Using a small brush or marking pen, repair the filament with silver paint or equivalent. 4. After approximately 2—3 minutes, carefully remove the tape without disturbing the repaired area.
3. If not as specified, replace the rear window defroster relay.
CONTINUED
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WINDOW GLASS Reusing Windshield 1. Make a hole through the sealant from the inside of the vehicle using an awl. 2. Pass the SST (piano wire) through the hole.
WINDOW GLASS WINDSHIELD REMOVAL 1. Remove the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.) 2. Apply protective tape to the headliner, the body and the dashboard.
PROTECTIVE TAPE
WINDSHIELD UPPER MOLDING R
Warning D Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife.
SEALANT
HEADLINER PROTECTIVE TAPE
3. Wind each end of the wire around a bar.
3. Cut the lip of the windshield upper molding using a razor knife. R
WINDSHIELD DAM
Note D The windshield upper molding and windshield side molding are replacement parts.
PROTECTIVE TAPE
49 0305 870A
WINDSHIELD UPPER MOLDING
Note D Use the entire length of piano wire to prevent it from breaking when cutting through the sealant. 4. Working with another person, saw through the sealant around the edge of the glass, being careful not to damage the body.
LIP
Not Reusing Windshield Warning D Using a piano wire with bare hands can cause injury. Always wear gloves when using a piano wire.
49 0305 870A
Note D For the areas of the sealant that are difficult to cut, use a piano wire and follow the procedures under “Reusing Windshield”.
5. Remove the windshield. 6. Remove the spacers from the body. 7. Remove the spacer and the dam from the glass. CENTER
1. Use a tool like that shown in the figure, and insert the blade into the sealant. 2. Pull through the sealant around the edge of the glass.
DAM
SPACER
R
R
8. Remove the windshield upper molding and the windshield side molding from the windshield.
3. Remove the windshield. 4. Remove the spacers from the body.
CONTINUED
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WINDOW GLASS
WINDSHIELD UPPER MOLDING
GLASS MARK
R
WINDSHIELD
WINDSHIELD SIDE MOLDING
R
WINDSHIELD SIDE MOLDING
WINDSHIELD
WINDSHIELD INSTALLATION
7. Securely bond a dam along the circumference of the glass 8.5 mm {0.33 in} from the upper edge and 14.5 mm {0.57 in} from the lower and side edge. 8. Install the spacer to the glass.
Warning Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife.
CENTER 8.5 {0.33}
Caution To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened. 1. Cut away the old sealant using a razor knife so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around the circumference of the frame. If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer. 2. Clean and degrease an approximately 50 mm {1.97 in} wide strip around the circumference of the glass and the bonding area on the body. 3. Align the center mark on the windshield upper molding with the glass mark. 4. Install the windshield upper molding from the center toward both sides.
14.5 {0.57} 6.0 {0.24}
DAM
SPACER
CERAMIC PARTING LINE
14.5 {0.57}
14.5 {0.57}
mm {in}
9. Install spacers into the hole of the body. 10. Temporarily install the glass onto the body and adjust the glass to body clearance. 11. Make a mark on the glass directly above the V-notch of spacers. 12. Verify that the gap along the upper edge is 7.5 mm {0.30 in}. 7.5 {0.30}
CENTER
MARKING
BODY
WINDSHIELD UPPER MOLDING MARK
SPACER
GLASS MARK
mm {in}
13. Remove the windshield. WINDSHIELD
Caution Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
5. Align the upper edge of the windshield side molding with the glass mark. 6. Install the windshield side molding from the upper part towards the lower part.
14. Use a brush to apply primer to the bonding area of the glass and body within the region shown. Use only glass primer on the glass and body primer on the body and molding. Allow it to dry for approximately 30 minutes.
CONTINUED
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WINDOW GLASS
8.5 {0.33}
UPPER
GLASS PRIMER
14.5 {0.57}
BODY
WINDSHIELD
GLASS PRIMER BODY PRIMER
BODY PRIMER
13.0 {0.51}
UPPER
SEALANT
SIDE
14.5 {0.57}
ADJUST SEALANT IN THIS AREA
SIDE
GLASS PRIMER BODY PRIMER
DAM
19.0 {0.75}
BODY PRIMER 19.0 {0.75}
WINDSHIELD
BODY
16.0 {0.63}
LOWER
DAM
WINDSHIELD SIDE MOLDING WINDSHIELD UPPER MOLDING
BODY PRIMER
ADJUST SEALANT IN THIS AREA mm {in}
15. Once the primer is dry, apply a 11.0 mm {0.43 in} high, 5.0 mm {0.20 in} wide bead of sealant along the dam around the entire circumference to fill the gap between the dam and the edge of the windshield.
Hardening time of sealant
5.0 {0.20}
11.0 {0.43}
Temperature
Surface hardening time
Time required until car can be put into service
5 °C {41 °F}
Approx. 1.5 h
Approx. 12 h
20 °C {68 °F}
Approx. 1 h
Approx. 4 h
35 °C {95 °F}
Approx. 10 min
Approx. 2 h
20. Use white gasoline to remove any sealant that oozes out. 21. Install the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.)
DAM
mm {in}
16. Align the glass marks with the V-notches in spacers and install the glass onto the body. 17. Press firmly inward on the glass to compress the sealant. 18. Verify that the gap along the upper and side edge is 7.5 mm {0.30 in}. 19. Adjust the sealant as indicated in the figure.
CONTINUED
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WINDOW GLASS QUARTER WINDOW GLASS REMOVAL/INSTALLATION Stretch Cab 1. To remove the quarter window hinge, remove the quarter upper trim. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Hinge cover
4
Quarter window glass
2
Quarter window hinge
5
Quarter window glass weatherstrip
3
Quarter window lock
CONTINUED
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WINDOW GLASS REAR WINDOW GLASS REMOVAL 1. Remove the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.) 2. Remove the rear window defroster connector if equipped. 3. While another person presses the rear window glass, use the SST to push the lip of the rear window weatherstrip from the inside.
REAR WINDOW WEATHERSTRIP BODY
REAR WINDOW WEATHERSTRIP SOAPY WATER
5. Align the rear window glass with the rear window weatherstrip and body. 6. While another person lightly taps the outside of the rear window glass near the rear window weatherstrip all around its circumference, pull one end of the SST and install the rear window glass.
LIP
49 0259 866A
4. After the top of the rear window weatherstrip is removed, push the rear window glass outside and remove it with the rear window weatherstrip attached. 5. Remove the rear window weatherstrip from the rear window glass. 49 0259 866A
REAR WINDOW GLASS INSTALLATION 1. Clean and degrease the body and the rear window glass. 2. Install the rear window weatherstrip to the rear window glass. REAR WINDOW WEATHERSTRIP
7. Install the rear window defroster connector if equipped. 8. Install the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.)
3. Fit the SST into the rear window weatherstrip and cross the ends as shown, leave 200 mm {7.87 in}. REAR WINDOW WEATHERSTRIP
49 0259 866A 200 {7.87}
mm {in}
4. Apply soapy water as shown.
CONTINUED
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DASHBOARD AND CONSOLE
DASHBOARD AND CONSOLE DASHBOARD REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Remove the passenger-side air bag module. (Refer to section T, AIR BAG SYSTEM, PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 4. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 5. Remove the installation bolts then lower the assembled steering shaft from the dashboard. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 6. Remove the meter hood. 7. Remove the instrument cluster. 8. Remove the front console. (Refer to FRONT CONSOLE REMOVAL/INSTALLATION.) 9. Remove the glove compartment. 10. Remove the bonnet release cable installation nut. 11. Remove the A-pillar trims. (Refer to TRIM, A-PILLAR TRIM REMOVAL/INSTALLATION.) 12. Disconnect the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT REMOVAL.) (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT INSTALLATION.) 13. Remove the fuse block. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Adjust the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT ADJUSTMENT.)
7.9—11.7 {80—120, 70—104}
7.9—11.7 {80—120, 70—104}
7.9—11.7 {80—120, 70—104}
N·m {kgf·cm, in·lbf}
1
Bolt
2
Dashboard
CONTINUED
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DASHBOARD AND CONSOLE DASHBOARD DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Defroster nozzle
4
Duct
2
Side demister nozzle
5
Dashboard crash pad
3
Center duct
CONTINUED
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DASHBOARD AND CONSOLE DASHBOARD MEMBER REMOVAL/INSTALLATION 1. Remove the dashboard. (Refer to DASHBOARD REMOVAL/INSTALLATION.) 2. Remove the bolts, then remove the dashboard member.
FRONT CONSOLE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
DASHBOARD MEMBER 16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
BOLT
16—22 {1.6—2.3, 12—16} N·m {kgf·m, ft·lbf}
3. Install in the reverse order of removal. COLUMN COVER REMOVAL/INSTALLATION 1. Remove the screws, then remove the column cover.
COLUMN COVER
1
Screw
2
Front console
3
Boot
4
Set plate
REAR CONSOLE REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the rear console upward, then remove it.
SCREW
2. Install in the reverse order of removal. FRONT CONSOLE REMOVAL/INSTALLATION 1. Remove the rear console. 2. For manual transaxle vehicle, remove the shift lever knob. 3. Remove the screws, then remove the front console.
REAR CONSOLE
Caution In order to prevent noise caused by interference with the dashboard, install the screws to the rear of the front console before installing the front of the front console. FRONT CONSOLE SCREW
SCREW
3. Install in the reverse order of removal. 4. Install in the reverse order of removal.
CONTINUED
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DASHBOARD AND CONSOLE METER HOOD REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the meter hood toward you, then disengage clips A and pins B.
REAR CONSOLE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
SCREW
A B
A B A
A
B A
A
A
CLIP B PIN A
3. Disconnect the connectors, then remove the meter hood. 4. Install in the reverse order of removal.
1
Screw
2
Console lid outer
3
Console lid inner
4
Rear console
5
Console lid lock
6
Console lid hinge
7
Console lid bracket
GLOVE COMPARTMENT REMOVAL/INSTALLATION 1. Open the glove compartment and bend the sides inward to disengage the pins. 2. Pull the glove compartment downward, then disengage clips A. PIN PIN
A
A CLIP A
GLOVE COMPARTMENT
3. Install in the reverse order of removal.
CONTINUED
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TRIM
TRIM A-PILLAR TRIM REMOVAL/INSTALLATION 1. Remove the quarter upper trim. (Regular cab, stretch cab) (Refer to QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove the B-pillar upper trim. (Double cab) (Refer to B-PILLAR UPPER TRIM REMOVAL/INSTALLATION.) 3. Pull the A-pillar trim toward you, then disengage clips A and pin B. 4. Pull the A-pillar trim upward, then disengage the hook. A
B-PILLAR LOWER TRIM REMOVAL/INSTALLATION Double Cab 1. Remove the front scuff plate. 2. Remove the rear scuff plate. 3. Turn over the seaming welt. 4. Pull the B-pillar lower trim indicated by the arrow, then disengage clips A and pin B. 5. Remove the seat belt from B-pillar trim. 6. Pull the B-pillar lower trim upward, then disengage hooks C from the body.
CLIP
A
A A-PILLAR TRIM
B
A
A CLIP
PIN
A
B PIN A
A B A
A
B-PILLAR LOWER TRIM
HOOK B
A
HOOK
5. Install in the reverse order of removal. B-PILLAR TRIM REMOVAL/INSTALLATION Regular Cab 1. Turn over the seaming welt. 2. Remove the seat belt upper anchor installation bolt. 3. Remove the back upper trim. 4. Pull the B-pillar trim toward you, then disengage clips A and pins B. 5. Remove clip C. 6. Remove the seat belt from the B-pillar trim.
B A A CLIP A A
C C
C
7. Install in the reverse order of removal. B-PILLAR UPPER TRIM REMOVAL/INSTALLATION Double Cab 1. Remove the B-pillar lower trim.(Refer to B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove the front seat belt upper anchor installation bolt. 3. Remove the C-pillar trim. (Refer to C-PILLAR TRIM REMOVAL/INSTALLATION.) 4. Remove the fastener. 5. Pull the B-pillar upper trim toward you, then disengage clips A and pins B from the body. A
A
A
A PIN
B
CLIP C A
CLIP A
B-PILLAR TRIM
HOOK B
A B
A
A B
A
B-PILLAR UPPER TRIM
A
FASTENER
B
6. Install in the reverse order of removal. 7. Install in the reverse order of removal.
CONTINUED
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TRIM FRONT SIDE TRIM REMOVAL/INSTALLATION 1. Remove the scuff plate. 2. Loosen the nut. 3. Pull the front side trim in the direction indicated by the arrow, then remove it.
SCREW REAR SCUFF PLATE B
A A
NUT
B
A CLIP
PIN
3. Install in the reverse order of removal.
FRONT SIDE TRIM
4. Install in the reverse order of removal. FRONT SCUFF PLATE REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the front scuff plate upward, then disengage pin A.
C-PILLAR TRIM REMOVAL/INSTALLATION Double Cab 1. Turn over the seaming welt. 2. Remove the rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Double Cab, Rear.) 3. Remove the rear seat belt upper anchor installation bolt. 4. Remove the fasteners. 5. Pull the C-pillar trim toward you, then disengage clips A and pin B. 6. Remove the seat belt from C-pillar trim. A A
SCREW
A B
CLIP A
A
PIN
A
B
PIN C-PILLAR TRIM A A FRONT SCUFF PLATE
FASTENER
3. Install in the reverse order of removal. REAR SCUFF PLATE REMOVAL/INSTALLATION Double Cab 1. Remove the screw. 2. Pull the rear scuff plate upward, then disengage clips A and pin B.
7. Pull the C-pillar trim upward, then remove it from the body. 8. Install in the reverse order of removal. QUARTER UPPER TRIM REMOVAL/INSTALLATION Stretch Cab 1. Remove the back upper trim. 2. Remove the upper anchor of the seat belt. 3. Remove the quarter window lock. (Refer to WINDOW GLASS, QUARTER WINDOW GLASS REMOVAL/INSTALLATION.) 4. Remove the hook. 5. Remove the fasteners. 6. Pull the quarter upper trim toward you, then disengage clips A and pins B.
CONTINUED
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TRIM BACK UPPER TRIM REMOVAL/INSTALLATION 1. Pull the back upper trim toward you, then disengage clips A and pins B.
A
A
A B
A
A
HOOK A
B A
A
A
PIN
A
A A
A
B
A
A
B
A
A
BACK UPPER TRIM
CLIP
A
B
PIN
FASTENER
A A
CLIP
A A B
A
QUARTER UPPER TRIM
A
A
7. Install in the reverse order of removal.
B
QUARTER LOWER TRIM REMOVAL/INSTALLATION Stretch Cab 1. Remove the quarter upper trim. (Refer to QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove the back lower trim. 3. Remove the fasteners. 4. Pull the quarter lower trim toward you, then disengage clips A and pins B.
2. Install in the reverse order of removal. BACK LOWER TRIM REMOVAL/INSTALLATION 1. Remove the fasteners, then remove the back lower trim.
QUARTER LOWER TRIM FASTENER
B A
B
A A A
CLIP PIN
A FASTENER
BACK LOWER TRIM A
B
2. Install in the reverse order of removal. 5. Install in the reverse order of removal.
CONTINUED
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TRIM FRONT DOOR TRIM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable if equipped with a power window system. 2. Remove the regulator handle if equipped. 3. Remove the inner garnish. 4. Remove the power window switch if equipped. 5. Remove the screws and the fastener. 6. Pull the front door trim toward you, then disengage clips A. 7. Pull the front door trim upward, then disengage hook B. FASTENER
7. Extract the inner handle from the rear door trim. 8. Pull the rear door trim upward, then disengage hooks B. 9. Install in the reverse order of removal.
FRONT DOOR TRIM
B A
A
CLIP
A A
A
A
A SCREW
B
A
A A
FASTENER
HOOK
FRONT DOOR TRIM
B A
A A
SCREW
CLIP A
A B
A A
A
A A
HOOK
8. Install in the reverse order of removal. REAR DOOR TRIM REMOVAL/INSTALLATION Double cab 1. Disconnect the negative battery cable if equipped with power window. 2. Remove the regulator handle if equipped. 3. Remove the power window switch if equipped. 4. Remove the screws. 5. Remove the ashtray. 6. Pull the door trim toward you, then disengage clips A. INNER HANDLE B
SCREW A
A
CLIP A
A A ASHTRAY
A A A
A A
B HOOK
A
REAR DOOR TRIM
CONTINUED
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HEADLINER, FLOOR COVERING
HEADLINER
FLOOR COVERING
HEADLINER REMOVAL/INSTALLATION 1. Remove the A-pillar trims. 2. Remove the B-pillar upper trims. (Refer to TRIM, B-PILLAR UPPER TRIM REMOVAL/INSTALLATION, Double Cab.) 3. Remove the quarter upper trims. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION, Stretch Cab.) 4. Remove the C-pillar trims. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION, Double Cab.) 5. Remove the assist handle. 6. Remove the rearview mirror. 7. Remove the sunvisors and adapters. 8. Remove the interior light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION.) 9. Remove the fasteners, then remove the headliner.
FLOOR COVERING REMOVAL/INSTALLATION Regular Cab, Stretch Cab 1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.) 2. Remove the quarter lower trims. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION, Stretch Cab.) 3. Remove the back lower trim. 4. Remove the front seats. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Regular Cab.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.) 5. Remove the rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.) 6. Remove the rear console bracket. 7. Remove the lower anchor installation bolts of front seat belts. 8. Remove the front side trims. 9. Remove the air outlet ducts. (Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.) 10. Remove the footrest. 11. Remove the fasteners, then remove the floor covering.
HEADLINER
FASTENER
ASSIST HANDLE FASTENER
ADAPTER SUNVISOR
10. Remove the headliner from the vehicle through the passenger-side door.
FLOOR COVERING
12. Install in the reverse order of removal.
HEADLINER
11. Install in the reverse order of removal.
Double cab 1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.) 2. Remove the B-pillar lower trims. (Refer to TRIM, B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.) 3. Remove the C-pillar trims. (Refer to TRIM,C-PILLAR TRIM REMOVAL/INSTALLATION)
CONTINUED
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FLOOR COVERING 4. Remove the front seats and rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.) 5. Remove the rear console bracket. 6. Remove the lower anchor installation bolts of front seat belts and rear seat belts. 7. Remove the front side trim. 8. Remove the air outlet duct. (Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.) 9. Remove the footrest. 10. Remove the fasteners, then remove the floor covering. Type 1
FASTENER
FLOOR COVERING Type 2 FLOOR COVERING FASTENER
11. Install in the reverse order of removal.
CONTINUED
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SEAT BELT
SEAT BELT SEAT BELT REMOVAL/INSTALLATION Caution The ELR has a spring that will unwind if the retractor’s cover is removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the retractor.
Stretch Cab Front 1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
Regular Cab Driver’s side and passenger’s side 1. Remove the B-pillar trim if equipped with a B-pillar trim. (Refer to TRIM, B-PILLAR TRIM REMOVAL/INSTALLATION, Regular Cab.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Anchor cover
2
Retractor cover (if equipped)
3
Seat belt
1
Anchor cover
2
Seat belt
N·m {kgf·m, ft·lbf}
Rear 1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Except driver’s side and passenger’s side Except Europe and UK 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Seat belt
CONTINUED
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SEAT BELT Rear 1. Remove the C-pillar trim. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Anchor cover
2
Seat belt
Double Cab Front 1. Remove the B-pillar lower trim. (Refer to TRIM, B-PILLAR LOWER TRIM REMOVAL/INSTALLATION, Double Cab.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Anchor cover
2
Seat belt
SEAT BELT INSPECTION Belt 1. Inspect the webbing for scars, tears, and wear. 2. Inspect the fitting for deformation or damage. 3. If a problem is found, replace the seat belt. ELR 1. Verify that the belt can be pulled out smoothly, and that it moves smoothly when worn. 2. Verify that the retractor locks when the belt is quickly pulled.
39—78 {3.9—8.0, 29—57}
1
Anchor cover
2
Seat belt
3. Remove the retractor. 4. Make sure that the seat belt does not lock when the retractor is tilted slowly up to 15° from the mounted position. Make sure that the seat belt locks when the retractor is tilted 40° or more.
N·m {kgf·m, ft·lbf}
CONTINUED
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SEAT BELT
RETRACTOR
39—78 {3.9—8.0, 29—57} N·m {kgf·m, ft·lbf}
5. If any of the above-mentioned steps are not as specified, replace the seat belt. BUCKLE REMOVAL/INSTALLATION Bench Seat Driver’s side and passenger’s side 1. Disconnect the negative battery cable. 2. Remove as indicated in the table. 3. Install in the reverse order of removal.
1
Front buckle
Stretch Cab Rear 1. Remove as indicated in the table. 2. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
N·m {kgf·m, ft·lbf}
1
Buckle
Except driver’s side and passenger’s side Except Europe and UK 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
Rear buckle
Double Cab Rear 1. Remove the seat cushion. (Refer to SEAT, REAR SEAT REMOVAL/INSTALLATION, Double Cab.) 2. Remove as indicated in the table. 3. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
1
1
Buckle
Bucket Seat Front 1. Disconnect the negative battery cable. 2. Remove the side cover. (Refer to SEAT, FRONT SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
Rear buckle
CONTINUED
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SEAT BELT BUCKLE SWITCH INSPECTION
1. Disconnect the negative battery cable. 2. Disconnect the buckle switch connector. 3. Inspect for continuity between the buckle switch terminals using an ohmmeter.
4. If not as specified, replace the buckle.
CONTINUED
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SEAT Bucket Seat 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
SEAT FRONT SEAT REMOVAL/INSTALLATION Bench Seat 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
35—63 {3.5—6.5, 26—47} 35—63 {3.5—6.5, 26—47}
35—63 {3.5—6.5, 26—47} 35—63 {3.5—6.5, 26—47}
N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
1
Front seat + Installation note
Front seat installation note 1. To install the seat, tighten the bolts in the order indicated in the figure. FRONT
LEFT SIDE
1
Connector
2
Cover
3
Front seat + Installation note
Front seat installation note 1. To install the seat, tighten the bolts in the order indicated in the figure. FRONT
RIGHT SIDE
DOOR SIDE
2. Verify that the seat slider is securely locked in position before fully tightening the bolts. 3. After installing the seat, slide it forward and backward and verify that the seat slider securely locks in position.
TUNNEL SIDE
2. Verify that the seat slider is securely locked in position before fully tightening the bolts. 3. After installing the seat, slide it forward and backward and verify that the seat slider securely locks in position.
CONTINUED
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SEAT FRONT SEAT DISASSEMBLY/ASSEMBLY Bench Seat 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
A 32—46 {3.2—4.7, 24—33}
A
N·m {kgf·m, ft·lbf}
1
Headrest
8
Seat back frame
2
Pole guide
9
Seat cushion trim
3
Recliner lever
10
Seat cushion pad
4
Side cover
11
Seat cushion frame
5
Lower cover
12
Cable
6
Seat back trim
13
Slide adjuster
7
Seat back pad
14
Connecting rod
CONTINUED
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SEAT Bucket Seat 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 3. When removing the cable (passenger’s seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)
39—78 {3.9—8.0, 29—57}
PASSENGER’S SEAT
A
37—53 {3.7—5.5, 27—39}
B A
C B 39—78 {3.9—8.0, 29—57}
C
N·m {kgf·m, ft·lbf}
1
Headrest
11
Slide adjuster No.3
2
Recliner lever
12
Pole guide
3
Side cover
13
Seat back trim
4
Front buckle
14
Seat back warmer unit (Europe only)
5
Spring (stretch cab)
15
Seat back pad
6
Cable (stretch cab)
16
Seat cushion trim
7
Wire
17
Seat cushion warmer unit (Europe only)
8
Connecting rod
18
Seat cushion pad
9
Slide adjuster No.1
19
Seat cushion frame
10
Slide adjuster No.2
CONTINUED
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SEAT CABLE ADJUSTMENT Verify the slide adjuster slides and locks smoothly when the slide adjuster lever is operated.
SEAT BACK
LEVER
BOLT 16—22 {1.6—2.3, 12—16}
SLIDE LOCK
SCREW 2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}
LEVER
N·m {kgf·m, ft·lbf}
REAR SEAT REMOVAL/INSTALLATION Stretch Cab Seat back 1. Remove the back upper trim. 2. Remove the bolts. 3. Lift the seat back up in the direction of the arrow, then unhook it from the body.
Hinge 1. Remove the back lower trim. (Refer to TRIM, BACK LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove the fasteners, and then turn over the floor covering. 3. Remove the bolts, and then remove the hinge. BOLT 16—22 {1.6—2.3, 12—16}
SEAT BACK
HOOK
HOOK
HOOK HINGE
BOLT 6.87—9.80 {70—100, 60.8—86.7}
N·m {kgf·m, ft·lbf}
N·m {kgf·cm, in·lbf}
Seat cushion 1. Lift up the rear seat cushion. 2. Remove the screws. 3. Remove the bolts, and then remove the seat cushion.
CONTINUED
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SEAT Double Cab 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 35—63 {3.5—6.5, 26—47}
1
Seat cushion trim
2
Seat cushion pad
16—22 {1.6—2.3, 12—16}
PULL
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
35—63 {3.5—6.5, 26—47} N·m {kgf·m, ft·lbf}
1
Seat cushion
2
Seat back + Installation note
3
Hinge
4
Striker
Seat back installation note After installing the seat back, verify that it securely locks to the striker. REAR SEAT DISASSEMBLY/ASSEMBLY Stretch Cab 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
CONTINUED
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SEAT Double Cab 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Headrest
6
Side cover
2
Pole guide
7
Stopper
3
Seat back trim
8
Seat back frame
4
Seat back pad
9
Seat cushion trim
5
Rear back catch
10
Seat cushion pad
CONTINUED
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SEAT SEAT WARMER SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the seat warmer switch and pull it forward to remove it. 3. Disconnect the seat warmer switch connector, and then remove the seat warmer switch.
SEAT WARMER UNIT INSPECTION 1. Remove the front seat. (Refer to FRONT SEAT REMOVAL/INSTALLATION, Bucket Seat.) 2. Inspect seat warmer unit at roor temperature of 20 °C {68 °F}. 3. Apply battery positive voltage to the seat warmer unit terminal A, connect the ground to terminal B, and measure the temperature of the thermometal switch with a thermometer. A
HOOK
A B SEAT WARMER SWITCH
CONNECTOR
SEAT WARMER SWITCH INSTALLATION 1. Connect the seat warmer switch connector. 2. Insert the seat warmer switch in the hole to install it. 3. Connect the negative battery cable.
B
THERMOMETER
SEAT WARMER SWITCH INSPECTION 1. Remove the seat warmer switch. (Refer to SEAT WARMER SWITCH REMOVAL.) 2. Inspect for continuity between the seat warmer switch terminals using an ohmmeter. : Continuity
: Bulb
Terminal
Switch position
D
C
F
On Off
D
C
:
:
F
:
F
3. If not as specified, replace the seat warmer switch.
THERMOMETAL SWITCH
4. When the temperature of the thermometal switch is approximately 40 °C {104 °F}, inspect the resistance between the seat warmer unit terminals using an ohmmeter. Verify that the resistance changes from approximately 4.8 Ω to approximately 13.0 Ω. 5. Remove battery positive voltage from seat warmer unit terminals. 6. When the temperature of the thermometal switch is approximately 30 °C {86 °F}, inspect the resistance between the seat warmer unit terminals using an ohmmeter. Verify that the resistance changes from approximately 13.0 Ω to approximately 4.8 Ω. 7. If any of the above-mentioned steps are not as specified, replace the seat back pad (with seat warmer unit) and seat cushion pad (with seat warmer unit).
CONTINUED
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BODY ELECTRICAL SYSTEM PAGE 1 OF 2 POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE SERVICE CAUTION . . . . . . . . . . . . . . . . . MAIN FUSE REMOVAL/INSTALLATION . . . . . IGNITION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . IGNITION SWITCH INSPECTION . . . . . . . . . . . KEY REMINDER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . KEY REMINDER SWITCH INSPECTION . . . . CIGARETTE LIGHTER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . CIGARETTE LIGHTER INSPECTION . . . . . . . EXTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . FRONT COMBINATION LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HEADLIGHT AIMING . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PARKING LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT TURN LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT TURN LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SIDE TURN LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR COMBINATION LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR COMBINATION LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . LICENSE PLATE LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COMBINATION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COMBINATION SWITCH DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . LIGHT SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . HAZARD WARNING SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HAZARD WARNING SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH REMOVAL . . . . . REAR FOG LIGHT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH INSPECTION . . . .
T– 3 T– 3 T– 3 T– 3 T– 3 T– 3 T– 4 T– 4 T– 4 T– 5 T– 5 T– 5 T– 5/6 T– 6 T– 6 T– 6 T– 6 T– 7 T– 7 T– 7 T– 7 T– 8 T– 8 T– 8 T– 8 T– 8/9 T– 9 T– 9 T–10 T–10 T–10 T–10 T–10 T–10 T–11 T–11
FLASHER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FLASHER UNIT INSPECTION . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY INSPECTION . . . . RUNNING LIGHT RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . RUNNING LIGHT RELAY INSPECTION . . . . . INTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . . INTERIOR LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . INTERIOR LIGHT INSPECTION . . . . . . . . . . . . DOOR SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR SWITCH INSPECTION . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WIPER AND WASHER . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER LINK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER TANK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION . . . . . . . WINDSHIELD WIPER AND WASHER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . WARNING AND INDICATOR SYSTEM . . . . . . . . INSTRUMENT CLUSTER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . INSTRUMENT CLUSTER INSPECTION . . . . . INSTRUMENT CLUSTER REPAIR . . . . . . . . . .
T–11 T–12 T–12 T–13 T–14 T–14 T–14 T–14/15 T–16 T–16 T–16 T–17 T–17 T–17 T–18 T–19 T–19 T–19 T–19 T–19 T–20 T–20 T–20 T–20 T–20 T–20 T–21 T–21 T–21 T–21 T–22 T–22 T–22 T–22/24 T–24
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POWER SYSTEM
BODY ELECTRICAL SYSTEM PAGE 2 OF 2 WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . FUEL GAUGE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH INSPECTION . . . . . HORN REMOVAL/INSTALLATION . . . . . . . . . . HORN RELAY REMOVAL/INSTALLATION . . . HORN RELAY INSPECTION . . . . . . . . . . . . . . . CLOCK REMOVAL/INSTALLATION . . . . . . . . . AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUDIO UNIT REMOVAL . . . . . . . . . . . . . . . . . . . AUDIO UNIT INSTALLATION . . . . . . . . . . . . . . . SPEAKER REMOVAL/INSTALLATION . . . . . . . SPEAKER INSPECTION . . . . . . . . . . . . . . . . . . . ROOF ANTENNA REMOVAL . . . . . . . . . . . . . . . ROOF ANTENNA INSTALLATION . . . . . . . . . . ROOF ANTENNA INSPECTION . . . . . . . . . . . . ANTENNA FEEDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . ANTENNA FEEDER INSPECTION . . . . . . . . . . CONDENSER REMOVAL/INSTALLATION . . .
T–24 T–24/25 T–25 T–25 T–25 T–25 T–25 T–25/26 T–26 T–26 T–26 T–26 T–26 T–26/27 T–27 T–27 T–27 T–27/28 T–28 T–28 T–28
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POWER SYSTEM
POWER SYSTEM FUSE SERVICE CAUTION Caution Determine and correct the cause of the burnt fuse before replacing it with the specified type. If the fuse is replaced before doing this, it may burn again.
IGNITION SWITCH INSPECTION 1. Remove the column cover. 2. Disconnect the ignition switch connectors. 3. Inspect for continuity between the ignition switch terminals using an ohmmeter. : Continuity Ignition g key y position
Terminal 2A
2B
1D
1C
1B
1A
LOCK
MAIN FUSE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
ACC ON START
G6, WL, WL TURBO, F2 CIS
2A
2B
2B
2A
123456567
START START LOCK LOCK ON ON ACC ACC 1A 1B 1C 1D
1C
1A
1D
1B
F2 CARB
4. If not as specified, replace the ignition switch. KEY REMINDER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key reminder switch connector. 4. Remove the key reminder switch. KEY REMINDER SWITCH
1
Nut
2
Bolt
3
Main fuse
IGNITION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the ignition switch connectors. 4. Remove the screw to remove the ignition switch.
STEERING LOCK
5. Install in the reverse order of removal.
IGNITION SCREW SWITCH CONNECTOR
IGNITION SWITCH
5. Install in the reverse order of removal.
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POWER SYSTEM KEY REMINDER SWITCH INSPECTION 1. Remove the column cover. 2. Disconnect the key reminder switch connector. 3. Inspect for continuity between the key reminder switch terminals using an ohmmeter. : Continuity Key position
Socket Removal Note 1. Pry up the stopper with a tape-wrapped screwdriver. 2. Pull the socket by prying up the stopper.
Terminal A
B
Inserted Removed A
B
CIGARETTE LIGHTER INSPECTION Verify that the cigarette lighter plug will move normally within 10—20 seconds, after pressing the plug into the socket. If the plug does not move, replace the cigarette lighter.
A
B
4. If not as specified, replace the key reminder switch. CIGARETTE LIGHTER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the center panel. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Cigarette lighter plug
2
Connector
3
Socket + Removal Note
4
Ring
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EXTERIOR LIGHTING SYSTEM If it is difficult to remove front combination light with pliers Remove the adjusting screws and the screw by loosening them.
EXTERIOR LIGHTING SYSTEM FRONT COMBINATION LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the radiator grille. (Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.) 3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the headlight aiming. (Refer to HEADLIGHT AIMING.)
ADJUSTING SCREW SCREW
ADJUSTING SCREW
HEADLIGHT AIMING 1. Adjust the tire air pressure to the specification. 2. Position the unloaded vehicle on a level surface. 3. Seat one person in the driver’s seat. 4. Start the engine and charge the battery fully. 5. Position the vehicle straight ahead and perpendicularly to a wall. 6. Set the headlights 7.6 m {25 ft} from the wall. 7. While adjusting one headlight, disconnect the connector of the other. 1
Front combination light connector
2
Front combination light + Removal Note
3
Spring
Caution Always tighten the adjusting screws last. When loosening the adjusting screws, loosen the screws first and then tighten them. If the adjusting screws are tightened first, then loosened, they will continue to loosen when the vehicle is in motion and may cause the headlights to become misaligned.
Front Combination Light Removal Note Removal with pliers Caution When pressing the hook of the adjusting screws and the screw with the pliers, do not damage the front combination light mounting.
8. Adjust the headlights by turning the adjusting screws as shown in the figure. Loosen the screws first, then tighten them.
1. Press the hook of the adjusting screws and the screw with the pliers. 2. Pull the front combination light out of the adjusting screws and the screw.
ADJUSTING SCREW
OUTWARD
INWARD
UP
HOOK
DOWN SCREW
HEADLIGHT BULB REMOVAL/INSTALLATION Caution A halogen bulb generates extremely high heat when it is used. If the surface of the bulb is soiled, excessive heat will build up and the light’s life will be shortened. When replacing the bulb, hold the metal flange, not the glass.
FRONT COMBINATION LIGHT MOUNTING
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EXTERIOR LIGHTING SYSTEM 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Headlight bulb connector
2
Cover + Installation Note
3
Headlight bulb
Cover Installation Note Align the TOP mark with top side.
1
Screw
2
Front turn light
3
Front turn light connector
FRONT TURN LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
TOP MARK
PARKING LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Socket
2
Front turn light bulb
FRONT SIDE TURN LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
FRONT
1
Socket
2
Parking light bulb
REAR
FRONT TURN LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Front side turn light
2
Front side turn light connector
3
Socket
4
Front side turn light bulb
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EXTERIOR LIGHTING SYSTEM REAR COMBINATION LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
REAR FOG LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. WITHOUT REAR BUMPER
Screw
2
Rear combination light
3
Rear combination light connector
REAR COMBINATION LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the rear combination light. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Screw
2
Lens + Removal Note
3
Rear turn light bulb
4
Back-up light bulb
5
Brake light/taillight bulb
1
Rear fog light connector
2
Nut
3
Spring washer
4
Rear fog light
WITH REAR BUMPER
1
Rear fog light connector
2
Screw
3
Rear fog light
REAR FOG LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Lens Removal Note Push the hook upward with your finger. HOOK
1
Screw
2
Lens
3
Rear fog light bulb
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EXTERIOR LIGHTING SYSTEM LICENSE PLATE LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
COMBINATION SWITCH DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Screw
1
Screw
2
License plate light
2
Windshield wiper and washer switch
3
License plate light bulb
3
Light switch
4
Socket
4
Body
5
License plate light connector
COMBINATION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. For vehicles without air bag system, remove the horn cap. For vehicles with air bag system, remove the driver-side air bag module. (Refer to AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 4. For vehicles with air bag system, remove the clock spring. (Refer to AIR BAG SYSTEM, CLOCK SPRING REMOVAL/INSTALLATION.) 5. Remove the column cover. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
LIGHT SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Light switch connector
2
Screw
3
Light switch
LIGHT SWITCH INSPECTION Headlight Switch 1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)
1
Screw
2
Combination switch
3
Combination switch connector
Note When the flash-to-pass switch is on, the contact of the low-high switch is at neutral. 2. Inspect for continuity between the light switch terminals using an ohmmeter.
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EXTERIOR LIGHTING SYSTEM : Continuity Switch position Light
Dimmer
OFF
–
TNS
–
HeadHead light
Low
Terminal
Flashto-pass
P (B)
D (N)
L (H)
F (J)
3. If not as specified, replace the light switch. HAZARD WARNING SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
H (L)
Off On Off On Off On
High
–
( ): Light switch right side lever (J)
(N)
F
D
OFF OFF TNS FLASH -TO -PASS
HIGH
HOOK
HEADLIGHT
HEADLIGHT TNS
1
H
L
P
(L)
(H)
(B)
* (O)
* (M)
* (K)
N
L
P (*)
Hazard warning switch
LOW
E
(*)
* (J)
H
F (*)
HAZARD WARNING SWITCH INSPECTION 1. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Inspect for continuity between the hazard warning switch terminals using an ohmmeter. : Continuity : Bulb
C
(*)
D
* (B)
Terminal
Switch position
A
(*)
F
D
B
A
C
I
K
H
J
Off On
( ): LIGHT SWITCH RIGHT SIDE LEVER
3. If not as specified, replace the light switch. Turn Switch 1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the light switch terminals using an ohmmeter. : Continuity Switch position
H
K
F
D
Terminal C (M)
A (K)
E (O)
Right Off
J
A
K
I
*
J
C
I
B
Left
( ): Light switch right side lever (M) C
* * * (M) (O) (K) * H P N L (J) (*) A
E
(*)
F (*)
C
(*)
D
H
F
C
A
D
B
A
(*)
* (B)
3. If not as specified, replace the hazard warning switch.
E
(K) (O) ( ): LIGHT SWITCH RIGHT SIDE LEVER
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EXTERIOR LIGHTING SYSTEM REAR FOG LIGHT SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the rear fog light switch and pull it forward to remove it. 3. Disconnect the connector to remove the rear fog light switch.
HEADLIGHT LEVELING SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the headlight leveling switch and pull it forward to remove it. 3. Disconnect the connector to remove the headlight leveling switch.
HOOK
HOOK CONNECTOR
CONNECTOR REAR FOG LIGHT SWITCH
HEADLIGHT LEVELING SWITCH
REAR FOG LIGHT SWITCH INSTALLATION 1. Connect the rear fog light switch connector. 2. Insert the rear fog light switch in the hole to install it. 3. Connect the negative battery cable.
HEADLIGHT LEVELING SWITCH INSTALLATION 1. Connect the headlight leveling switch connector. 2. Insert the headlight leveling switch in the hole to install it. 3. Connect the negative battery cable.
REAR FOG LIGHT SWITCH INSPECTION 1. Remove the rear fog light switch. (Refer to REAR FOG LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the rear fog light switch terminals using an ohmmeter. : Continuity
HEADLIGHT LEVELING SWITCH INSPECTION 1. Remove the headlight leveling switch. (Refer to HEADLIGHT LEVELING SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the headlight leveling switch terminals using an ohmmeter. : Continuity : Resistance : Bulb
Switch position
Terminal A
D
F
Terminal
Switch position
C
Off Neutral
0 1 2
R3
3
D
R1:1600 Ω
A
B
R2+R3
F
F
A
R1+ R2+ R3
On
A
D
3. If not as specified, replace the rear fog light switch.
0
1
2
3:300
Ω
3 *
R1 R2 R3
D
560 Ω
A
C
D
2:
*
*
*
C
A
D
B
B
3. If not as specified, replace the headlight leveling switch.
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EXTERIOR LIGHTING SYSTEM BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
FLASHER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
25—34 {2.5—3.4, 19—24}
R
DRIVER-SIDE FRONT SIDE TRIM
N·m {kgf·m, ft·lbf}
1
Back-up light switch connector
2
Back-up light switch
3
Gasket
BACK-UP LIGHT SWITCH INSPECTION 1. Disconnect the back-up light switch connector. 2. Inspect for continuity between the back-up light switch terminals using an ohmmeter. : Continuity Terminal
Shift lever position
A
B
Reverse
1
Nut
2
Flasher unit
3
Flasher unit connector
Other
A
A
B
B
3. If not as specified, replace the back-up light switch.
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EXTERIOR LIGHTING SYSTEM FLASHER UNIT INSPECTION 1. Measure the voltage at the flasher unit terminals as indicated below. 2. Disconnect the flasher unit connector before inspecting for continuity at terminal C. 3. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses. 4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the flasher unit. Terminal Voltage List (Reference) B+: Battery positive voltage A C
Terminal
Signal
Connection
B
Test condition Hazard warning switch on
A
Flasher unit out ut output
Hazard warning switch
Hazard warning switch off
B
C
Power supply su ly
Flasher unit ground
Hazard warning switch off
B+
Ignition switch at LOCK or ACC position
0
Inspection area
Hazard
warning switch Turn signal
light
B+
Ignition switch at ON position
B+
Ignition switch at LOCK or ACC position
0
Constant: inspect for continuity to ground
GND
Alternates B+ and 0
Ignition switch at ON position
Hazard warning switch on Hazard warning switch
Voltage (V) /Continuity
HAZARD 10 A
fuse METER 15 A
fuse
Yes
Hazard
warning switch GND
HEADLIGHT LEVELING ACTUATOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the radiator grille. (Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.) 3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.) 4. Remove the front combination light. (Refer to FRONT COMBINATION LIGHT REMOVAL/INSTALLATION.) 5. Remove the headlight leveling actuator connector from the bracket. 6. Disconnect the headlight leveling actuator connector. 7. Remove the nuts. 8. Remove the headlight leveling actuator. HEADLIGHT LEVELING ACTUATOR
HEADLIGHT LEVELING ACTUATOR CONNECTOR
9. Install in the reverse order of removal.
CONTINUED
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EXTERIOR LIGHTING SYSTEM HEADLIGHT LEVELING ACTUATOR INSPECTION 1. Measure the voltage at the headlight leveling actuator terminals as indicated below. Note Because the headlight leveling actuator connector is waterproof, it is impossible to measure the voltage at the headlight leveling actuator terminals. When inspecting, measure the voltage at the terminal of the part which is connected to the headlight leveling actuator. (1) To measure the voltage at the terminal A of the headlight leveling actuator, remove the column cover and measure the voltage at the terminal N of the light switch connector. (Refer to LIGHT SWITCH INSPECTION.) (2) To measure the voltage at the terminal B of the headlight leveling actuator, remove the headlight leveling switch with the connector connected and measure the voltage at the terminal C of the headlight leveling switch connector. (Refer to HEADLIGHT LEVELING SWITCH INSPECTION.) (3) Disconnect the headlight leveling actuator connector before inspecting for continuity at terminal C. 2. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses. 3. If the parts and wiring harnesses are okay but the system still does not work properly, replace the headlight leveling actuator. Terminal Voltage List (Reference) B+: Battery positive voltage
A
Terminal
Signal
A
Headlight leveling g actuator power supply
B
C
Headlight leveling switch position
Headlight leveling actuator ground
Connection
Combination switch
g Headlight leveling switch
GND
B
C
Test condition Headlight illuminated
Voltage ( V ) /Continuity
Inspection area
B+ Combination switch
Headlight unilluminated
g Headlight switch on
0
Headlight leveling switch at 0
6.2
Headlight leveling switch at 1
4.2
Headlight leveling switch at 2
2.1
Headlight leveling switch at 3
0
Constant : inspect for continuity to ground
Headlight leveling switch
Yes
GND
CONTINUED
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EXTERIOR LIGHTING SYSTEM REAR FOG LIGHT RELAY REMOVAL/INSTALLATION
RUNNING LIGHT RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the washer tank from the bracket. 3. Remove the running light relay with the cover attached.
Note Because the lock section of the relay is damaged easily, do not remove the relay from the bracket unless replacement is necessary. Always perform an inspection of the rear fog light relay before removal.
NUT
1. Disconnect the negative battery cable. 2. Disconnect the rear fog light relay connector. 3. Remove the rear fog light relay by prying the lock section of the upper part with a flathead screwdriver.
RUNNING LIGHT RELAY WITH COVER
4. Remove the cover. 5. Disconnect the running light relay connector.
REAR FOG LIGHT RELAY
COVER
BRACKET
REAR FOG LIGHT RELAY CONNECTOR
RUNNING LIGHT RELAY
4. Install in the reverse order of removal. REAR FOG LIGHT RELAY INSPECTION 1. Remove the bracket and pull it toward you. 2. Inspect for continuity between the rear fog light relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage Terminal
Step
A
B
B+
GND
C
D
1 2
C
D
RUNNING LIGHT RELAY CONNECTOR
6. Install in the reverse order of removal. RUNNING LIGHT RELAY INSPECTION 1. Remove the running light relay. (Refer to RUNNING LIGHT RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the running light relay terminals using an ohmmeter. : Continuity : Diode
C
A
Test cond condi tion
D
B
Constant
A
Terminal A
B
C
D
E
F
B B
A
C
3. If not as specified, replace the rear fog light relay.
F
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E
D
E
C
A
F
D
B
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EXTERIOR LIGHTING SYSTEM 3. Connect the terminal A to the positive battery terminal and the terminal D to the negative battery terminal. 4. Verify that there is continuity between terminals A and E, and that there is no continuity between terminals B and F. B
A
C
F
E
E
C
A
F
D
B
D
5. Connect the terminal C to the positive battery terminal and the terminal D to the negative battery terminal. 6. Verify that there is no continuity between terminals B and F, and between terminals A and E. B
F
A
C
E
E
C
A
F
D
B
D
7. If not as specified, replace the running light relay.
CONTINUED
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INTERIOR LIGHTING SYSTEM
INTERIOR LIGHTING SYSTEM INTERIOR LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. ALL VEHICLES EXCEPT REGULAR CAB
Interior Light Installation Note Regular cab Note The spacer acts as a ground. If the spacer is not installed in the position shown in the figure, the interior light may not illuminate. REGULAR CAB
1. Tighten the screw fully. (More than 4 mm {0.2 in} of thread should be exposed.) 2. Install the interior light. SCREW
4.0 mm {0.2 in}
1
Lens + Removal Note
2
Interior light bulb
3
Screw
4
Spacer
5
Interior light + Installation Note
6
Interior light connector
SPACER INTERIOR LIGHT
INTERIOR LIGHT INSPECTION 1. Remove the interior light. (Refer to INTERIOR LIGHT REMOVAL/INSTALLATION.) 2. Inspect for continuity between the interior light terminals using an ohmmeter. : Bulb
Lens Removal Note All vehicles except regular cab 1. Insert a tape-wrapped flathead screwdriver into the lens. 2. Twist the screwdriver to remove the lens.
Terminal
Step
A
B
Body GND
ON DOOR OFF B
A OFF
B
ON
DOOR A
Regular cab Push the areas indicated by the arrows to pull out the lens.
3. If not as specified, replace the interior light.
CONTINUED
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INTERIOR LIGHTING SYSTEM DOOR SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Screw
2
Door switch
3
Door switch connector
1
Panel light control switch
DOOR SWITCH INSPECTION 1. Remove the door switch. 2. Inspect for continuity between the door switch terminals using an ohmmeter. : Continuity Terminal
Switch condition
A
Body GND
Pressed Released
A
A
BODY GND
3. If not as specified, replace the door switch. PANEL LIGHT CONTROL SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
HOOK
CONTINUED
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INTERIOR LIGHTING SYSTEM PANEL LIGHT CONTROL SWITCH INSPECTION 1. Remove the meter hood without disconnecting the panel light control switch connector. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Measure the voltage at the panel light control switch as indicated below. 3. Disconnect the panel light control switch connector before inspecting for continuity at terminal G. 4. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the panel light control switch. Terminal Voltage List (Reference) B+: Battery positive voltage G H
Terminal A B D F G H
Signal Panel light control output
Connection Each illumination
— Power supply
F
g switch Light
D
B
Voltage (V)/ Continuity
Test condition Inspect using an oscilloscope + A terminal inspection
Not used
—
— Headlight switch at TNS or headlight position
Not used
—
—
Not used
—
0
Light switch TAIL 10 A fuse
—
—
A Terminal Inspection 1. Measure the wave pattern of the A terminal on the panel light control switch using an oscilloscope.
Each illumination
B+
Constant: Inspect for continuity to ground
GND
Inspection area
—
Headlight switch at OFF position
— Panel light control switch ground
A
—
Yes
GND
—
—
V
0
PANEL LIGHT CONTROL SWITCH
5. Verify that the pattern on the screen matches the pattern shown in the figure as the panel light control switch is gradually turned to the darkest position.
OSCILLOSCOPE
2. Set the headlight switch to either the TNS or headlight position. 3. Set the panel light control switch to the brightest position. 4. Verify that the pattern of the screen is as shown in the figure.
V B+ 0
1—3.2 ms 5—15.4 ms
CONTINUED
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WIPER AND WASHER WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Adjust the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.)
WIPER AND WASHER WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Loosen the bolts. 4. Pull the windshield wiper motor forward until the connection between the windshield wiper motor and windshield wiper link is in the engine room. 5. Pry off the connection between the windshield wiper motor and windshield wiper link. 6. Remove the windshield wiper motor.
16—19 {1.6—2.0, 12—14}
WINDSHIELD WIPER MOTOR
N·m {kgf·m, ft·lbf}
CONNECTOR
WINDSHIELD WIPER LINK
BOLT 4.0—6.8 {40—70, 35—60}
1
Cap
2
Nut
3
Windshield wiper arm + Installation Note
4
Windshield wiper blade
5
Rubber brush
N·m {kgf·cm, in·lbf}
7. Install in the reverse order of removal. WINDSHIELD WIPER MOTOR INSPECTION 1. Disconnect the windshield wiper motor connector. 2. Connect battery positive voltage and inspect the operation of the windshield wiper motor as indicated below. Terminal
Operation
A
High
C
Low
A B
Windshield Wiper Arm Installation Note Clean the windshield wiper arm connector shafts with a wire brush before installing the windshield wiper arms.
WINDSHIELD WIPER ARM CONNECTOR SHAFT
C D
3. Connect battery positive voltage to terminal C of the windshield wiper motor to operate the windshield wipers at low speed. 4. Disconnect battery positive voltage from terminal C of the motor while the wipers are operating. 5. Verify that the wipers do not stop in the park position. 6. Short between terminal C and B of the motor, and connect battery positive voltage to terminal D of the motor. 7. Verify that the wipers operate at low speed again, then stop in the park position. 8. If not as specified, replace the windshield wiper motor.
WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT 1. Operate the windshield wiper motor to set the windshield wipers in the park position. 2. Align both ends of the wiper blades to the marks on the ceramic section.
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CERAMIC SECTION
MARK
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WIPER AND WASHER WINDSHIELD WIPER LINK REMOVAL/INSTALLATION 1. Remove the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.) 2. Remove the cowl grille. 3. Remove the windshield wiper motor. (Refer to WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.) 6.87—9.80 {70—100, 60.8—86.7}
1
Windshield washer motor
2
Grommet
WINDSHIELD WASHER MOTOR INSPECTION 1. Disconnect the windshield washer motor connector. 2. Connect battery positive voltage to terminal B and ground to terminal A of the motor. 3. Verify that the windshield washer motor operates. B N·m {kgf·cm, in·lbf}
1
Bolt
2
Windshield wiper link
M A
WINDSHIELD WASHER TANK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Disconnect the windshield washer pipe from the windshield washer motor. 4. Pull the windshield washer tank up and slide it off the bracket.
WINDSHIELD WASHER TANK
CONNECTOR WINDSHIELD WASHER PIPE
B A
4. If the motor does not operate, replace the windshield washer motor. WINDSHIELD WASHER NOZZLE REMOVAL 1. Disconnect the windshield washer pipe from the windshield washer nozzle. 2. Remove the windshield washer nozzle using a 10 mm {0.4 in} deep socket wrench from underneath the bonnet. DEEP SOCKET WRENCH
WINDSHIELD WASHER NOZZLE
BRACKET
5. Install in the reverse order of removal. WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the windshield washer tank. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
WINDSHIELD WASHER NOZZLE INSTALLATION 1. Connect the windshield washer pipe to the windshield washer nozzle. 2. Push the windshield washer nozzle into the installation hole. 3. Adjust the windshield washer nozzle. (Refer to WINDSHIELD WASHER NOZZLE ADJUSTMENT.)
CONTINUED
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WIPER AND WASHER WINDSHIELD WASHER NOZZLE ADJUSTMENT Insert a needle or equivalent tool into the spray holes of the windshield washer nozzle and adjust the nozzle direction as shown.
SCREW
WINDSHIELD WIPER AND WASHER SWITCH
CENTER
320 {12.6}
CONNECTOR
390 {15.4}
6. Install in the reverse order of removal.
100 100 {3.9} {3.9}
290 {11.4} 290 {11.4}
270 {10.6}
180 {7.1}
WINDSHIELD WIPER AND WASHER SWITCH INSPECTION 1. Remove the column cover. 2. Remove the windshield wiper and washer switch. 3. Inspect for continuity between the windshield wiper and washer switch terminals using an ohmmeter. : Continuity
WINDSHIELD GLASS END LINE
MOLDING END LINE
Switch position
WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION 1. Disconnect the windshield washer pipe from the windshield washer nozzle and the windshield washer motor. 2. Remove the clips. 3. Remove the windshield washer pipe.
Wiper switch
L(F)
G(E )
M(C )
N(D )
C(M )
123
Off
OFF
mm {in}
Terminal
Onetouch
On
INT LO HI
Washer switch
On
( ): Wiper and washer switch left side lever (D) N ONE-TOUCH WIPER SWITCH HI OFF
OFF
HI LO
INT INT
LO CLIP
INT RELAY
WINDSHIELD WASHER PIPE
L (F)
H (J)
4. Install in the reverse order of removal.
M (C)
G (E)
C (M) WASHER SWITCH
WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the connector. 4. Remove the screws. 5. Remove the windshield wiper and washer switch.
0 (*) *
G (*)
M N (*)
L (*)
* (J)
H (*)
* (E) * (F)
C
* (A)
* (D)
*
( ): WIPER AND WASHER SWITCH LEFT SIDE LEVER
4. If not as specified, replace the windshield wiper and washer switch.
CONTINUED
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WARNING AND INDICATOR SYSTEM
WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Screw
2
Instrument cluster connector
3
Instrument cluster
INSTRUMENT CLUSTER INSPECTION Speedometer 1. Adjust the tire air pressure to the specification. 2. Using a speedometer tester, verify that the speedometer indication is within the allowable range indicated in the table. Allowable range (km/h)
20
18—22
40
36—44
60
54—66
80
72—88
100
90—110
120
108—132
140
126—154
160
144—176
180
162—198
3. Verify that fluctuation of the speedometer needle is within the allowable range. Needle fluctuation allowable range Within 0.5 km/h
INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY
4. If the speedometer needle does not move or if the indication is outside of the allowable range, inspect the vehicle speedometer sensor and related wiring harness. 5. If the vehicle speedometer sensor and related wiring harness are normal, replace the instrument cluster.
Caution If the print plate on the back of the instrument cluster is damaged, the system will not operate properly and it may become the cause of trouble or malfunction. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Speedometer tester p indication (km/h)
Tachometer Using the SSTs (NGS kit) or a dwell tacho tester Caution If the engine speed exceeds the allowable range, the engine could be damaged. Therefore, when inspecting the tachometer, do not allow the engine speed to exceed the allowable range indication on the tachometer. 1. Follow the appropriate procedure for using the SSTs (NGS kit) or dwell tacho tester.
1
Screw
2
Bulb
3
Alarm
4
Front lens
5
Instrument cluster
Using the SSTs (NGS kit) (1) Connect the SSTs (NGS kit) to the data link connector and battery.
DIAGNOSTIC PROGRAM CARD
NGS KIT
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WARNING AND INDICATOR SYSTEM (2) Select “VEHICLE & ENGINE SELECTION” and press TRIGGER. (Select the model and specifications of the vehicle you are testing.) (3) Select “PCM-POWERTRAIN CTRL MODULE” and press TRIGGER. (4) Select “PID/DATA MONITOR AND RECORD” and press TRIGGER. (5) Select “RPM” and press TRIGGER. (6) Press START.
: Resistance Step 1
FUEL –
GND
COM
R1 R2
2
R1, R2: 140—200 Ω
Using a dwell tacho tester Connect a dwell tacho tester to the terminals K and B of the PCM connector.
GND FUEL+ COM
2. Verify that the tachometer indication is within the allowable range indicated in the table. Dwell tacho tester indication (rpm)
Terminal FUEL +
FUEL–
Allowable range (rpm)
650
583—705
1000
926—1060
2000
1954—2120
3000
2980—3180
4000
4008—4240
12. Verify that the difference in resistance between R1 and R2 is less than 6 Ω. 13. If not as specified, replace the instrument cluster.
3. If the tachometer needle does not move or if the indication is outside of the allowable range, inspect the PCM and related wiring harness. 4. If the PCM and related wiring harness are normal, replace the instrument cluster.
Water Temperature Gauge 1. Disconnect the water temperature sender unit connector. 2. Turn the ignition switch to ON position. 3. Verify that the needle is below C. 4. Ground terminal A of the water temperature sender unit’s vehicle side connector.
Fuel Gauge 1. Disconnect the fuel gauge sender unit connector. 2. Connect the red lead of SST (Fuel And Thermometer checker) to terminal B of the fuel gauge sender unit connector and black lead to ground. 3. Set the resistance of SST (Fuel And Thermometer checker) to 180 Ω.
A
49 N088 0A0 49 0839 285
5. Verify that the needle is above H. 6. If the needle does not move or moves irregularly, remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 7. Measure the resistance between the water temperature gauge terminals using an ohmmeter. : Resistance
*
C
B
4. Turn the ignition switch to ON position. 5. Verify that the needle is below E. 6. Turn the ignition switch to LOCK position. 7. Set the resistance of SST (Fuel And Thermometer checker) to 10 Ω. 8. Turn the ignition switch to ON position. 9. Verify that the needle is above F. 10. If the needle does not move or moves irregularly, remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 11. Measure the resistance between the fuel gauge terminals using an ohmmeter.
T–23
Step 1 2
Terminal TEMP +
TEMP –
V+
COM
R1 R2
R1, R2: 140—200 Ω
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WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 3. Turn the socket counterclockwise to remove the bulb as shown in the figure.
TEMP+ COM
V+
TEMP–
8. Verify that the difference in resistance between R1 and R2 is less than 6 Ω. 9. If not as specified, replace the instrument cluster.
BULB
INSTRUMENT CLUSTER REPAIR Note The needle of speedometer or tachometer may continue to rotate clockwise until it rests on the mask plate. If a customer complains of this concern, repair the needle position according to the following steps. 1. Verify the concern. TACHOMETER
SPEEDOMETER
4. Install in the reverse order of removal. FUEL GAUGE SENDER UNIT INSPECTION 1. For G6, F2 CIS, or F2 Carb engine vehicles, remove the fuel pump unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) For WL or WL Turbo engine vehicles, remove the fuel gauge sender unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Using an ohmmeter, measure and verify that the resistance between terminals B and C (WL, WL Turbo) or A and B (G6, F2 CIS, F2 Carb) of the fuel gauge sender unit is as shown in the following chart while slowly moving the unit arm from empty to full.
2. Turn the ignition switch to LOCK position. 3. Remove the ROOM fuse, then wait for 10 minutes or more until the power supply in the instrument cluster is spent. 4. Turn the ignition switch to ON position. 5. Verify that the needle returns to zero. TACHOMETER
Measuring point
Resistance (Ω)
Full
18.4—26.4
1/2
81.5—93.5
Empty
136—154
WL, WL TURBO 87.0 {3.43} * 65.5 {2.58}
SPEEDOMETER
* DOUBLE CAB 2WD, STRETCH CAB 2WD
FULL
169.7 {6.681} * 158.1 {6.224}
1/2 253.7 {9.988}
EMPTY
6. After the needle returns to zero, install the ROOM fuse with the ignition switch at ON position. If the needle does not return to zero, remove the front lens and carefully move the needle to zero by hand. (Refer to INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY.)
* B C mm {in}
CONTINUED
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WARNING AND INDICATOR SYSTEM WATER TEMPERATURE SENDER UNIT INSPECTION 1. Remove the water temperature sender unit. 2. Place the sender unit in a container of water. 3. Heat the water gradually. 4. Using an ohmmeter, measure and verify that the resistance between terminal of the sender unit and the sender unit body is as shown below.
G6, F2 CIS, F2 CARB 67.5 {2.66}
FULL
160.1 {6.303}
1/2 A B
255.7 {10.067}
EMPTY
Water temperature (°C {°F })
Resistance (Ω)
49.8—50.2 {121.7—122.3}
189.4—259.6
mm {in}
3. If not as specified, replace the fuel gauge sender unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) (Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY.) (Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/INSTALLATION.) WATER TEMPERATURE SENDER UNIT REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Remove the water temperature sender unit. CONNECTOR
WATER TEMPERATURE SENDER UNIT
WATER TEMPERATURE SENDER UNIT INSTALLATION 1. Apply sealant from the third thread to the top thread.
5. If not as specified, replace the water temperature sender unit. OIL PRESSURE SWITCH INSPECTION 1. Verify that the oil pressure warning light illuminates when the ignition switch is turned to ON position. 2. Verify that the oil pressure warning light goes off when the engine is started. 3. If the oil pressure warning light does not illuminate or remains illuminated, inspect the oil pressure warning light bulb and related wiring harness. 4. If the oil pressure warning light bulb and related wiring harness are normal, inspect the oil pressure. (Refer to section D, LUBRICATION SYSTEM, OIL PRESSURE INSPECTION.) 5. If the oil pressure is normal, replace the oil pressure switch. HORN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the horn connector. 3. Remove the bolt. 4. Remove the horn.
BOLT THIRD THREAD
6—8 {0.24—0.31}
mm { in }
HORN
2. Install the water temperature sender unit. Tightening torque 11.8—17.6 N·m {120—180 kgf·cm, 105—156 in·lbf} 3. Connect the water temperature sender unit connector. 4. Connect the negative battery cable.
HORN CONNECTOR
5. Install in the reverse order of removal. HORN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
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WARNING AND INDICATOR SYSTEM, AUDIO 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
AUDIO AUDIO UNIT REMOVAL 1. Disconnect the negative battery cable. 2. With the beveled parts of the SST (Removing tool) facing inward, insert them into the unit. 3. Pull the SST (Removing tool) outward and rearward to slide out the unit. 49 D066 801A
1
Nut
2
Horn relay connector
3
Horn relay
HORN RELAY INSPECTION 1. Remove the horn relay. (Refer to HORN RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the horn relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage
4. Disconnect the connectors and antenna jack. AUDIO UNIT INSTALLATION Caution If the harness or the antenna feeder is caught between the unit and dashboard, it may become the cause of trouble or malfunctions. Make certain that the wiring harness and antenna feeder are not caught between the unit and dashboard.
Terminal
Step
A
B
B+
GND
C
D
1 2
D
C
1. Connect the connectors and antenna jack. 2. Insert the unit until each clip clicks. 3. Connect the negative battery cable.
A C
A
D
B
SPEAKER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front door trim. (Refer to section S, TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.)
B
3. If not as specified, replace the horn relay. CLOCK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove the screws and remove the clock. SCREW
CLOCK
Caution When removing or installing a speaker, touching the radio cone paper could cause poor sound quality. When removing or installing a speaker, hold the speaker’s bracket and handle with care. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
SCREW
4. Install in the reverse order of removal.
CONTINUED
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AUDIO
1
Screw
2
Speaker + Installation Note
3
Connector
SCREW
Speaker Installation Note When installing the speakers, position the speakers so that the terminals face downward. ROOF ANTENNA
SPEAKER INSPECTION 1. Remove the speaker. (Refer to SPEAKER REMOVAL/INSTALLATION.) 2. Inspect for resistance between the speaker terminals using an ohmmeter.
ROOF ANTENNA INSTALLATION 1. Tape the antenna jack to the antenna drain hose.
: Resistance Test condition
Terminal A
B R
Constant
R: 4 Ω
2. Pass the roof antenna and antenna drain hose through the A-pillar from the hole in the roof. 3. Connect the antenna feeder. 4. Install the screws. 5. Install the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 6. Connect the negative battery cable.
123456567
3. Touch the leads of an ohmmeter to the speaker terminals and verify that the speaker clicks. Range 1 Ω 4. If not as specified, replace the speaker. ROOF ANTENNA REMOVAL 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the roof antenna and the antenna feeder.
ROOF ANTENNA INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the roof antenna and the antenna feeeder. 4. Verify that there is no continuity between roof antenna terminals A and B using an ohmmeter. 5. Inspect for continuity between the roof antenna terminals using an ohmmeter. : Continuity Terminal
Step
A
B
C
D
1 2 C
ANTENNA FEEDER
D
ROOF ANTENNA B A
4. Remove the screws and pull out the roof antenna.
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AUDIO 6. If not as specified, replace the roof antenna.
CONDENSER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
ANTENNA FEEDER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the antenna feeder and the roof antenna. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
1
Clip
2
Antenna feeder
IGNITION COIL
1
Screw
2
Clip
3
Nut
4
Condenser
ANTENNA FEEDER INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the antenna feeder and the roof antenna. 4. Verify that there is no continuity between the antenna feeder terminals A and B using an ohmmeter. 5. Inspect for continuity between the antenna feeder terminals using an ohmmeter. : Continuity Terminal
Step
A
B
C
D
1 2
B D A
C
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6. If not as specified, replace the antenna feeder.
CONTINUED
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HEATER AND AIR CONDITIONER SYSTEMS SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . U– 2 STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U–19 HANDLING REFRIGERANT . . . . . . . . . . . . . . . . U– 2 MAGNETIC CLUTCH STORING REFRIGERANT . . . . . . . . . . . . . . . . . U– 2 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U–20 SERVICE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . U– 2 MAGNETIC CLUTCH CLEARANCE HANDLING COMPRESSOR OIL . . . . . . . . . . . . U– 2 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U–20/21 REFRIGERANT SYSTEM SERVICE MAGNETIC CLUTCH INSPECTION . . . . . . . . . U–21 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3 A/C RELAY No.1 MANIFOLD GAUGE SET INSTALLATION . . . . U– 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–21 RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3 A/C RELAY No.1 INSPECTION . . . . . . . . . . . . . U–22 CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3/5 A/C RELAY No.2 REFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 5/6 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–22 REFRIGERANT CHARGE CHECK . . . . . . . . . . U– 6/7 A/C RELAY No.2 INSPECTION . . . . . . . . . . . . . U–22 REFRIGERANT PRESSURE CHECK . . . . . . . U– 7 REFRIGERANT PRESSURE SWITCH PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . U– 7 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–22 BASIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 8 REFRIGERANT PRESSURE SWITCH STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U– 8/9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . U–23 BLOWER UNIT REMOVAL/INSTALLATION . . U–10 THERMOSWITCH INSPECTION . . . . . . . . . . . U–23/24 BLOWER UNIT DISASSEMBLY/ASSEMBLY . U–10 BLOWER MOTOR COOLING UNIT REMOVAL/INSTALLATION . . U–10/11 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–24 COOLING UNIT DISASSEMBLY/ASSEMBLY . U–12 BLOWER MOTOR INSPECTION . . . . . . . . . . . U–24 EVAPORATOR INSPECTION . . . . . . . . . . . . . . U–13 RESISTOR REMOVAL/INSTALLATION . . . . . . U–24 HEATER UNIT REMOVAL/INSTALLATION . . . U–13 RESISTOR INSPECTION . . . . . . . . . . . . . . . . . . U–25 HEATER UNIT DISASSEMBLY/ASSEMBLY . . U–14 CLIMATE CONTROL UNIT REMOVAL . . . . . . U–25 HEATER CORE INSPECTION . . . . . . . . . . . . . . U–15 CLIMATE CONTROL UNIT INSTALLATION . . U–25 A/C COMPRESSOR CLIMATE CONTROL UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–15 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U–25/26 CONDENSER REMOVAL/INSTALLATION . . . U–16 CLIMATE CONTROL UNIT WIRE CONDENSER INSPECTION . . . . . . . . . . . . . . . U–16 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U–26/27 RECEIVER/DRIER CLIMATE CONTROL UNIT INSPECTION . . . . U–27 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–16/17 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . U–28 REFRIGERANT LINES FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U–28 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–17/18 TROUBLESHOOTING INDEX . . . . . . . . . . . . . . U–28 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . U–19 SYMPTOM TROUBLESHOOTING . . . . . . . . . . U–28/39
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SERVICE WARNINGS, SERVICE CAUTIONS
SERVICE WARNINGS
SERVICE CAUTIONS
HANDLING REFRIGERANT D Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. If accidental system discharge occurs, ventilate work area before resuming service. D Do not pressure test or leak test R-134a service equipment and/or vehicle air conditioning system with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. D Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources and maintain adequate ventilation. D Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor.
HANDLING COMPRESSOR OIL D Use FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil for this vehicle. Using a PAG oil other than FD46XG (G6, WL, WL turbo) or ZXL 100PG compressor oil can damage the A/C compressor. D Do not spill compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately. D FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil (PAG oil) has a higher moisture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. Therefore, install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption.
STORING REFRIGERANT D The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at temperatures below 40 °C {104 °F}.
FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) COMPRESSOR OIL
MINERAL OIL
TIME MOISTURE ABSORPTION
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES
REFRIGERANT SYSTEM SERVICE PROCEDURES
TAP PIN SIDE
49 C061 001 49 C061 005
MANIFOLD GAUGE SET INSTALLATION 1. Fully close the valves of the SST (49 C061 001). 2. Connect the SSTs (49 C061 002, 49 C061 003) to the high- and low-pressure side joints of the SST (49 C061 001). 3. Connect the SSTs (49 C061 006A, 49 C061 007) to the ends of the SSTs (49 C061 002, 49 C061 003). 4. Connect the SSTs (49 C061 006A, 49 C061 007) to the charging valves.
49 C061 004 REFRIGERANT TANK SCALE VACUUM PUMP
7. Open all the valves of the SST (49 C061 001).
49 C061 001
Caution Close the SST (49 C061 001) valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner.
49 C061 002 49 C061 003
49 C061 006A CAP
49 C061 007 CAP CHARGING VALVE OF LOW-PRESSURE SIDE
AIR PURGE VALVE
CHARGING VALVE OF HIGH-PRESSURE SIDE
8. Start the vacuum pump and let it operate for 15 minutes. 49 C061 001
RECOVERY Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer’s instructions.
CLOSE
CHARGING Charging Recycled R-134a Refrigerant Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer’s instructions. Charging New R-134a Refrigerant
9. Verify that high- and low-pressure side readings of the SST (49 C061 001) are at –101 kPa {–760 mmHg, –29.9 inHg}. Close each valve of the SST (49 C061 001).
Caution Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts.
49 C061 001
1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49 C061 001). 3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001). 4. Connect the SST (49 C061 005) to the vacuum pump. 5. Connect the SST (49 C061 004) to the refrigerant tank. 6. Place the refrigerant tank on the scale. Regular amount of refrigerant 550 g {19.4 oz}
10. Stop the vacuum pump and wait for 5 minutes. 11. Check the high- and low-pressure side readings of the SST (49 C061 001). If the reading has changed, inspect for leakage and then repeat from step 7. If the reading has not changed, go to step 12. 12. Open the valve of the refrigerant tank. 13. Weigh the refrigerant tank.
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES Warning If the refrigerant system is charged with a large amount of refrigerant when checking for gas leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In order to prevent the accidental release of refrigerant which can destroy the ozone layer in the stratosphere, follow the proper procedures and charge with only a small amount of refrigerant when checking for gas leakage. If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
Warning If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. 17. Open the high-pressure side valve of the SST (49 C061 001) and charge with refrigerant until the weight of refrigerant tank has decreased 300 g {10.6 oz} from the amount in step 13. 49 C061 001 OPEN
14. Open the high-pressure side valve of the SST (49 C061 001). 49 C061 001 OPEN
18. Close the high-pressure side valve of the SST (49 C061 001). 49 C061 001
15. When the low-pressure side reading increases to 0.098 MPa {1.0 kgf/cm2, 14 psi}, close the high-pressure side valve of the SST (49 C061 001). 49 C061 001
16. Inspect for leakage from the cooler pipe/hose connections using the SST (Gas leak tester). If there is no leakage, go to step 17. If a leakage is found at a loose joint, tighten the joint and inspect for leakage again. If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 7. If there is no leakage after tightening the joint, go to step 17.
Warning If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. 19. Start the engine and actuate the A/C compressor. 20. Open the low-pressure side valve of the SST (49 C061 001) and charge with refrigerant until the refrigerant tank is empty.
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES
49 C061 001
TAP PIN SIDE
AIR PURGE VALVE
49 C061 001
OPEN
49 C061 005 49 C061 004 REFRIGERANT TANK
VACUUM PUMP
21. Close the low-pressure side valve of the 6. Open only the center valve of the SST (49 C061 SST (49 C061 001) and the valve of the refrigerant tank. (49 C061 001). 22. Stop the engine and A/C compressor. 23. Inspect for leakage using the SST (Gas leak Caution tester). If there is no leakage, go to step 24. If Close the SST (49 C061 001) valve leakage is found at a loose joint, tighten the joint immediately after stopping the vacuum and inspect for leakage again. If there is still a leak pump. If the valve is left open, the vacuum at the same joint, discharge the refrigerant and pump oil will flow back into the refrigeration then repair the joint. Repeat the charging cycle and cause a decrease in the efficiency procedure from step 7. If there is no leakage after of the air conditioner. tightening the joint, go to step 24. 24. Disconnect the SSTs (49 C061 006A, 7. Start the vacuum pump and let it run for 1 minute. 49 C061 007) from the charging valves. 49 C061 001 25. Install the caps to the charging valves. CLOSE
49 C061 006A 49 0061 007 CAP
CAP
8. Close the center valve of the SST (49 C061 001). REFILLING
49 C061 001
Caution Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts. 1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49 C061 001). 3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001). 4. Connect the SST (49 C061 005) to the vacuum pump. 5. Connect the SST (49 C061 004) to the refrigerant tank.
9. Stop the vacuum pump. 10. Open the valve of the refrigerant tank. Warning If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
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REFRIGERANT SYSTEM SERVICE PROCEDURES 11. Start the engine and actuate the A/C compressor. 12. Open the low-pressure side valve of the SST (49 C061 001).
49 C061 007
49 C061 006A
CAP
49 C061 001 OPEN CAP
REFRIGERANT CHARGE CHECK Caution The FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil will separate from refrigerant at high temperatures of 50 °C {122 °F} or more. If this happens, the sight glass will change to a milky-white color, and there is a possibility that you might mistakenly believe the refrigerant amount to be insufficient and recharge with additional refrigerant. If the system is overcharged with refrigerant, the sight glass will become clear and give a false indication. You will mistakenly believe that the refrigerant amount is correct. Therefore, when checking the refrigerant amount, verify the refrigerant pressure and cooler pipe temperature in addition to the sight glass condition.
13. Refer to refrigerant charge check and refill with refrigerant. L.H.D.
SIGHT GLASS
R.H.D. (WL, G6, F2 Cab)
1. Warm up the engine and run it at a constant 1,500 rpm. 2. Set the fan switch at 4th. 3. Set the temperature control dial to MAX COLD. 4. Close all the doors and windows. 5. Check the refrigerant amount condition according to the following table.
SIGHT GLASS
R.H.D. (WL turbo)
SIGHT GLASS
14. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank. 15. Stop the engine and the A/C compressor. 16. Disconnect the SSTs (49 C061 006A, 49 C061 007) from the charging valves. 17. Install the caps to the charging valves.
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REFRIGERANT SYSTEM SERVICE PROCEDURES
Amount
Condition of sight glass
Mpa {kgf/cm2, psi}
Other conditions
Insufficient Bubbles
pipe is warm; low-pressure side cooler pipe is cool. High- and low-pressure side readings are lower than normal. Air cooling ability is low.
1.5 {15, 213} 1.0 {10, 142}
0.2 {2.0, 28}
High-pressure side cooler
Clear Correct
Milky white
pipe is hot; low-pressure side cooler pipe is cold. High- and low-pressure side readings are normal. * If sight glass is milky-white, pour water into condenser for approximately 20 seconds to cool it off, then the sight glass will clear.
Clear
LOW-PRESSURE SIDE
0.1 {1.0, 14}
PRESSURE READING OF MANIFOLD GAUGE 20 {68}
25 {77}
30 {86}
35 {95}
40 °C {104} {°F}
AMBIENT TEMPERATURE
High-pressure side cooler
Over
HIGH-PRESSURE SIDE
2.0 {21, 299}
High-pressure side cooler
9. If not as specified, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
pipe is hot; low-pressure side cooler pipe is cold. High- and low-pressure side reading are higher than normal. Air cooling ability is low.
PERFORMANCE TEST Note After servicing the refrigerant system, the test is performed.
6. If not as specified, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
1. Install the SSTs (manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Open the bonnet. 3. Close all the doors and windows. 4. Warm up the engine and run it at a constant 1,500 rpm. 5. Set the fan switch at 4th. 6. Set the temperature control dial to MAX COLD. 7. Record center ventilator right side temperature. 8. Determine and record ambient temperature. 9. Verify that the temperature reading is in the shaded zone.
REFRIGERANT PRESSURE CHECK 1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Open the bonnet. 3. Close all the doors and windows. 4. Warm up the engine and run it at a constant 1,500 rpm. 5. Set the fan switch at 4th. 6. Set the temperature control dial to MAX COLD. 7. Measure the ambient temperature and the highand low-pressure side reading of the SST (49 C061 001). 8. Verify that the intersection of the pressure reading of the SST (49 C061 001) and ambient temperature is in the shaded zone.
°C {°F} 6 {43} 5 {41} 4 {39} 3 {37} 2 {36} 1 {34} 0 {32} 20 {68}
CENTER VENTILATOR TEMPERATURE
25 {77}
30 {86}
35 {95}
40 °C {104} {°F}
AMBIENT TEMPERATURE
10. If the performance is not within the shaded zone, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
CONTINUED
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BASIC SYSTEM
BASIC SYSTEM STRUCTURAL VIEW BLOWER UNIT
L.H.D. (G6)
COOLING UNIT HEATER UNIT
COOLER PIPE (LOW) COOLER PIPE (HIGH)
HEATER HOSE A/C COMPRESSOR
L.H.D. (WL, WL turbo)
COOLER HOSE (LOW)
BLOWER UNIT COOLING UNIT
CONDENSER
HEATER UNIT
RECEIVER/DRIER
COOLER PIPE (LOW)
HEATER HOSE COOLER PIPE (HIGH)
A/C COMPRESSOR
COOLER HOSE (HIGH) CONDENSER
RECEIVER/DRIER
L.H.D. (F2, F2 Cab) BLOWER UNIT COOLING UNIT HEATER UNIT
COOLER PIPE (LOW)
HEATER COOLER HOSE PIPE A/C (HIGH) COMPRESSOR COOLER HOSE (HIGH)
CONDENSER
RECEIVER/DRIER
CONTINUED
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BASIC SYSTEM
R.H.D. (G6) HEATER UNIT COOLING UNIT
HEATER HOSE A/C COMPRESSOR
BLOWER UNIT COOLER HOSE (LOW)
COOLER PIPE (HIGH)
CONDENSER COOLER HOSE (HIGH)
RECEIVER/DRIER
R.H.D. (WL, WL turbo) HEATER UNIT HEATER HOSE
COOLING UNIT
A/C COMPRESSOR
BLOWER UNIT COOLER HOSE (LOW)
COOLER PIPE (HIGH)
SIGHT GLASS
CONDENSER
R.H.D. (F2 Cab)
RECEIVER/DRIER
COOLER HOSE (HIGH)
WL turbo
HEATER UNIT HEATER HOSE
COOLING UNIT
A/C COMPRESSOR
BLOWER UNIT COOLER HOSE (LOW)
COOLER PIPE (HIGH) CONDENSER
CONTINUED
RECEIVER/DRIER
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BASIC SYSTEM BLOWER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove the cooling unit. (Refer to COOLING UNIT REMOVAL/INSTALLATION.) 4. Remove the passenger’s side front side trim (L.H.D. only.) 5. Remove as indicated in the table. 6. Install in the reverse order of removal.
R.H.D.
B C A
A B C
1
Connector
2
Blower unit
BLOWER UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. L.H.D.
Blower motor
2
Resistor
3
Blower harness
4
Polyurethane protector
5
Inlet duct case (front)
6
Inlet duct case (rear)
7
Blower case (upper)
8
Blower case (lower)
9
Air intake door
10
Air intake link
11
Air intake crank
COOLING UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the glove compartment. 4. Disconnect the air intake wire from the cooling unit. (Refer to CONTROL SYSTEM, CLIMATE CONTROL UNIT WIRE ADJUSTMENT.) Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
B C A
1
A
CONTINUED
B C
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BASIC SYSTEM 5. Remove in the order indicated in the table. Do not allow compressor oil to spill. 6. Install in the reverse order of removal. 7. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
1
Cooler hose (low) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Removal Note + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
2
Cooler pipe (high) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Removal Note + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
3
Connector
4
Cooling unit + Removal Note + Installation Note
L.H.D.
R
15—21 N·m {1.5—2.2 kgf·m, 130.2—190.9 in·lbf}
R
6.9—9.8 N·m {0.7—1.0 kgf·m, 60.8—86.7 in·lbf}
R.H.D. 20—29 N·m {2.0—3.0 kgf·m, 15—21 ft·lbf}
Cooling Unit Removal Note (R.H.D. only) Turn the cooling unit 90 degrees to the right, and remove the cooling unit.
R
R 9.81—19.61 N·m {100—200 kgf·cm, 86.8—173.5 in·lbf}
Cooling Unit Installation Note When installing a new cooling unit (evaporator), add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplement amount 40 ml {40 cc, 1.4 fl oz}
CONTINUED
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BASIC SYSTEM COOLING UNIT DISASSEMBLY/ASSEMBLY Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. L.H.D.
1
Cooler case (upper)
2
Cooler case (lower)
3
Thermoswitch clip
4
Thermoswitch + Assembly Note
5
Evaporator
6
Expansion valve + Assembly Note
7
High pressure pipe
Expansion Valve Assembly Note Replace the O-rings at the expansion valve joints and apply compressor oil to the O-rings and connect the joints. Tighten the joint to the specified torque using two open-end wrenches. Assemble the heat-sensing tube as shown in the figure. 20—24 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
11.8—14.7 N·m {120—150 kgf·cm, 105—130 in·lbf}
R.H.D.
HEAT-SENSING TUBE
Thermoswitch Assembly Note 1. Insert the thermoswitch probe in location as shown in the figure. EVAPORATOR
40 mm {1.6 in}
CONTINUED
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BASIC SYSTEM EVAPORATOR INSPECTION 1. Remove the cooling unit. (Refer to COOLING UNIT REMOVAL/INSTALLATION.) 2. Remove the evaporator from the cooling unit. 3. Inspect for cracks, damage, and oil leakage. If any problems are found, replace the evaporator. 4. Inspect for bent fins. If they are bent, use a flat-head screwdriver to straighten them. HEATER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) (With heater core only) 3. Remove the dashboard. (Refer to section S, DASHBOARD AND CONSOLE, DASH BOARD REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
*
*
WITH HEATER CORE ONLY
1
Heater hose
2
Heater unit
CONTINUED
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BASIC SYSTEM HEATER UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
*
*
*
*
* * *
WITH HEATER CORE ONLY
1
Heater core
9
Airflow mode crank (2)
2
Air mix rod
10
Airflow mode crank (3)
3
Air mix link
11
Airflow mode crank (4)
4
Air mix crank (1)
12
Airflow mode sub link (1)
5
Air mix crank (2)
13
Airflow mode sub link (2)
6
Air mix shaft
14
Heater case (1)
7
Airflow mode main link
15
Heater case (2)
8
Airflow mode crank (1)
16
Heater case (3)
CONTINUED
U–14
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BASIC SYSTEM HEATER CORE INSPECTION 1. Remove the heater unit. (Refer to HEATER UNIT REMOVAL/INSTALLATION.) 2. Remove the heater core from the heater unit. 3. Inspect for cracks, damage, and coolant leakage. If any are found, replace the heater core. 4. Inspect for bent fins. If any are bent, use a flathead screwdriver to straighten them. 5. Verify that the heater core inlet and outlet are not distorted or damaged. Repair with pliers if necessary.
G6, WL, WL turbo 15—21 {1.5—2.2, 11—15}
R
A/C COMPRESSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the drive belt (P/S + A/C). 4. Remove the air cleaner and air hose. (WL turbo only) (Refer to section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Loosen the A/C compressor bolts, then slide the A/C compressor. (WL turbo only) Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
R
24—35 {2.4—3.6, 18—26}
N·m {kgf·m, ft·lbf}
F2, F2 Cab
R 30—39 {3.0—4.0, 22—28}
6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Adjust the drive belt (P/S + A/C). (Refer to section B2, DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
N·m {kgf·m, ft·lbf}
1
Connector
2
Cooler hose (high) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
3
Cooler hose (low) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
4
A/C compressor + Installation Note
A/C Compressor Installation Note Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C compressor. Compressor oil to be removed = 180 ml {180 cc, 6.08 fl oz} – [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz} ]
CONTINUED
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BASIC SYSTEM CONDENSER REMOVAL/INSTALLATION Condenser Installation Note When installing a new condenser, add FD46XG 1. Disconnect the negative battery cable. (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) 2. Discharge the refrigerant from the system. compressor oil into the refrigeration cycle. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE Supplemental amount PROCEDURES, CHARGING.) 30 ml {30 cc, 1.0 fl oz} 3. Remove the radiator grille. 4. Remove the charge air cooler and air hose. (WL CONDENSER INSPECTION turbo only) 1. Inspect for cracks, damage, and oil leakage. If any (Refer to section F2, INTAKE-AIR SYSTEM, problems are found, replace the condenser. INTAKE-AIR SYSTEM 2. Inspect for fins clogged by dust. If any are clogged, REMOVAL/INSTALLATION.) remove the dust from the fins. 5. Remove the receiver/drier. 3. Inspect for bent fins. If any are bent, use a flathead (Refer to RECEIVER/DRIER REMOVAL/INSTALLATION.) screwdriver to straighten them. Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
RECEIVER/DRIER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the radiator grille.
6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
4. Remove in the order indicated in the table. Do not allow compressor oil to spill. 5. Install in the reverse order of removal. 6. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
15—21 N·m {1.5—2.2 kgf·m, 11—15 ft·lbf}
B
Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
6.85—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
A
B C C
A
D R
D
1
Cooler pipe + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
2
Bonnet lock stay
3
Condenser + Installation Note
R
R
CONTINUED
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BASIC SYSTEM
1
Connector
2
Cooler pipe + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
3
Condenser + CONDENSER REMOVAL/INSTALLATION, Condenser Installation Note
4
Receiver/drier + Installation Note
Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 3. Remove the radiator grille. 4. Remove the front bumper. (Refer to section S, BUMPER, FRONT BUMPER REMOVAL/INSTALLATION.) 5. Remove the radiator. (WL turbo only) 6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
Receiver/drier Installation Note When installing a new receiver/drier, add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplemental amount 35 ml {35 cc, 1.2 fl oz} REFRIGERANT LINES REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) L.H.D.
R
R
B
R
A
B C
R
E
D F
B
R R
R
D
A
C
D F
A C
B A R
R R
B A
E
E
C
CONTINUED
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BASIC SYSTEM
R.H.D.
B R
R
R D
E B R B
C
C A R A
D B A
R
D C
A: 6.85—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf} B: 15—21 N·m {1.5—2.2 kgf·m, 11—15 ft·lbf} C: 20—29 N·m {2.0—3.0 kgf·m, 15—21 ft·lbf} D: 9.81—19.61 N·m {100—200 kgf·cm, 86.8—173.5 in·lbf} E: 24—35 N·m {2.4—3.6 kgf·m, 18—26 ft·lbf}
1
Cooler hose (low) + Removal Note + Refrigerant Lines Removal Note + Refrigerant Lines Installation Note
2
Cooler hose (high) + Removal Note + Refrigerant Lines Installation Note
3
Cooler pipe (high) + Refrigerant Lines Removal Note + Refrigerant Lines Installation Note
Refrigerant Lines Installation Note 1. When installing a new cooler pipe or hose, add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplemental amount Cooler hose (low): 8 ml {8 cc, 0.3 fl oz} Cooler hose (high): 5 ml {5 cc, 0.2 fl oz} Cooler pipe: 3 ml {3 cc, 0.1 fl oz} 2. Apply compressor oil to the O-rings and connect the joints. 3. Tighten the joints. (1) Tighten the nut or bolt of the joint by hand. (2) Tighten the joint to the specified torque. If it is a nut joint, tighten the nut using a spanner and torque wrench.
Cooler Hose Removal Note WL turbo only Loosen the A/C compressor bolts, then slide the A/C compressor, and remove the cooler hose bolt from the A/C compressor. Refrigerant Lines Removal Note Loosen the nut using two spanners, then remove the cooler pipe or hose.
CONTINUED
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CONTROL SYSTEM
CONTROL SYSTEM STRUCTURAL VIEW L.H.D. A/C RELAY No.2*
A/C RELAY No.1
REFRIGERANT PRESSURE SWITCH
MAGNETIC CLUTCH
CLIMATE CONTROL UNIT
THERMOSWITCH RESISTOR
BLOWER MOTOR
R.H.D.
REFRIGERANT PRESSURE SWITCH MAGNETIC CLUTCH A/C RELAY No.2*
A/C RELAY No.1
CLIMATE CONTROL UNIT
THERMOSWITCH
RESISTOR BLOWER MOTOR
CONTINUED * F2 Cab only
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CONTROL SYSTEM MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 3. Adjust the magnetic clutch clearance. (Refer to MAGNETIC CLUTCH CLEARANCE ADJUSTMENT.)
Stator Removal Note Set a straight-socket (17 mm {0.67 in}) on the shaft of the A/C compressor to protect it. Remove the stator using a pulley puller as shown in the table. STRAIGHT-SOCKET (17 mm {0.67 in})
10.1—15.0 N {102—153 89—132 kgf in·lbf}
Stator Installation Note Install the stator perpendicularly using the SST and a pulley puller as shown in the table.
49 H061 005
1
Bolt + Removal/Installation Note
2
Pressure plate + Installation Note
3
Shim
4
Snap ring
5
A/C compressor pulley
6
Stator + Removal Note + Installation Note
Pressure Plate Installation Note When installing the pressure plate, carry out magnetic clutch clearance adjustment.
Bolt Removal/Installation Note When removing or installing the bolt, hold the pressure plate in place as shown in the table. BOLT
A/C COMPRESSOR
MAGNETIC CLUTCH CLEARANCE ADJUSTMENT G6, WL, WL turbo Only 1. Set the A/C compressor on a level block. 2. Turn on the magnetic clutch by connecting the battery positive voltage to the magnetic clutch connector terminal and the ground to the A/C compressor body. 3. Fix a dial gauge on a magnetic base and set the measuring probe onto point A on the pressure plate surface.
CONTINUED
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CONTROL SYSTEM 3. If not within the specification, remove the pressure plate and adjust the clearance by changing the shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5 mm {0.020 in}) or the number of shims.
4. Turn off the magnetic clutch by disconnecting the ground from the A/C compressor body, then measure the dial gauge readings. 5. Measure the clearance for point B and C on the pressure plate surface by repeating the above steps 2 through 4.
MAGNETIC CLUTCH INSPECTION 1. Disconnect the magnetic clutch connector. 2. Connect battery positive voltage to terminal A of magnetic clutch and ground to the A/C compressor body.
Clearance 0.35—0.75 mm {0.014—0.029 in} MEASURING POINT A
B
C
6. If the clearance is not as specified, adjust it by changing the shim.
A
Note The seven shim sizes from 0.7 mm {0.028 in} to 1.3 mm {0.051 in} differ in 0.1 mm {0.004 in} increments.
A
3. Verify that the magnetic clutch operates. 4. If not as specified, replace the stator. A/C RELAY No.1 REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. F2, F2 Cab Only 1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a thickness gauge.
1
Connector
2
A/C relay No.1
2. Verify that the clearance is within the specification. Clearance 0.3—0.6 mm {0.01—0.02 in}
CONTINUED
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CONTROL SYSTEM A/C RELAY No.1 INSPECTION 1. Remove the A/C relay No.1. 2. Inspect for continuity between the A/C relay No.1 terminals using an ohmmeter. : Continuity B+: Battery positive voltage
A
B C
A
D
B
Terminal
Step
A
B
B+
GND
C
D
1
C
2
3. If not as specified, replace the A/C relay No.2.
A
C
D
D
C
A
D
B
REFRIGERANT PRESSURE SWITCH REMOVAL/ INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the radiator grille.
B 123456567
3. If not as specified, replace the A/C relay No.1.
Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
A/C RELAY NO.2 REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
4. Remove as indicated in the table. 5. Install in the reverse order of removal. 6. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
À 5.9—7.8 N·m {60—80 kgf·cm, 53—69 in·lbf}
1
Connector
2
A/C relay No.2
A/C RELAY NO.2 INSPECTION 1. Remove the A/C relay No.2. 2. Inspect for continuity between the A/C relay No.2 terminals using an ohmmeter. : Continuity B+: Battery positive voltage Step
R
Terminal B
D
A
C
1 2
B+
GND
1
Connector
2
Refrigerant pressure switch + Installation Note
Refrigerant Pressure Switch Installation Note Apply compressor oil to the O-ring and connect the joint.
CONTINUED
123456567
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CONTROL SYSTEM REFRIGERANT PRESSURE SWITCH INSPECTION 1. Install the SSTs (manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Disconnect the refrigerant pressure switch connector. 3. Verify the high-pressure side reading of the SST (Manifold gauge). 4. Inspect for continuity between the terminals of the refrigerant pressure switch using an ohmmeter. 0.18—0.21 {1.8—2.2, 26—31}
WITH HEATER CORE A
B
C
WITHOUT HEATER CORE A
3.0—3.3 {30—34, 427—483}
CONTINUITY
B
7. If not as specified, inspect on/off points of the thermoswitch.
NO CONTINUITY 0.02 {0.25, 3.56} OR LESS
0.4—0.7 {4.0—8.0, 57—113} MPa { kgf/cm2 , psi }
B
A
B
A
5. If not as specified, replace the refrigerant pressure switch. THERMOSWITCH INSPECTION To Determine if the Switch is Functioning 1. Remove the glove compartment. 2. Start the engine. 3. Turn the fan switch on. 4. Turn the A/C switch on. 5. Connect the positive (+) and negative (–) probes of the voltmeter to terminal A and terminal B of the thermoswitch respectively. (The wiring harness connector must be connected to the thermoswitch connector.) 6. Inspect the voltage as shown below.
To Inspect On/Off Points of the Thermoswitch 1. Disconnect the negative battery cable. 2. Remove the cooling unit (Refer to BASIC SYSTEM, COOLING UNIT REMOVAL/INSTALLATION.) 3. Remove the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNIT DISASSEMBLY/ASSEMBLY.) 4. Connect the negative battery cable. 5. Connect the thermoswitch connector to the wiring harness connector. 6. Turn the ignition switch to ON position. 7. Turn the A/C switch on. 8. Turn the fan switch on. 9. Immerse the sensor part of thermoswitch in a container of ice water. 10. Connect the positive (+) and negative (–) probes of the voltmeter to terminal A and terminal B of the thermoswitch respectively. 11. Inspect the voltage as shown below. WITH HEATER CORE
: Continuity Water temperature temperat re
C
1°C {34°F} or less WITHOUT HEATER CORE
: Continuity
: Continuity Temperature control dial position MAX COLD
Terminal A
A
3°C {37°F} or more
WITH HEATER CORE
Magnetic clutch cl tch
Terminal
C
1/2
On Off
MAX WARM
Water temperature temperat re
Terminal A
B
0—3°C {32—37°F} 3°C {37°F} or more 7—11°C {45—52°F}
123456567
11°C {52°F} or more 14—18°C {57—64°F} 18°C {64°F} or more
WITHOUT HEATER CORE
: Continuity Magnetic clutch cl tch
Terminal A
B 123456567
On Off
CONTINUED 123456567
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CONTROL SYSTEM
WITH HEATER CORE A
B
C
BLOWER MOTOR INSPECTION 1. Remove the glove compartment. 2. Disconnect the blower motor connector. 3. Connect battery positive voltage to terminal B and ground to terminal A of the blower motor, and verify its operation.
WITHOUT HEATER CORE A
B
12. If not as specified, replace the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNIT DISASSEMBLY/ASSEMBLY.) BLOWER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
1
Connector
2
Blower motor
4. If not as specified, replace the blower motor. RESISTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
1
Connector
2
Resistor
CONTINUED
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CONTROL SYSTEM RESISTOR INSPECTION 1. Remove the glove compartment. 2. Disconnect the resistor connector. 3. Verify that the resistance between the terminals of the resistor is as shown in the table. Terminal
Resistance (Ω)
1A–1B (2A)
R1: 0.43—0.47
1A–1C
R2: 1.04—1.16
1C–1D
R3: 1.47—1.63
R3
1D
R2
1C
R1
1A
1B
2A
1C
1A
1D
1B
CLIMATE CONTROL UNIT INSTALLATION 1. Connect the climate control unit connectors. 2. Insert the climate control unit until each clip clicks.
3. Adjust the wire of the climate control unit. (Refer to CLIMATE CONTROL UNIT WIRE ADJUSTMENT.) 4. Install the glove compartment. 5. Connect the negative battery cable.
2A
Climate Control Unit Removal/Installation Note With heater core Set the temperature control dial at MAX COLD, the airflow mode control dial at DEF.
4. If not as specified, replace the resistor. CLIMATE CONTROL UNIT REMOVAL 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Disconnect the air intake wire from the blower unit. 4. Disconnect the air mix wire and airflow mode wire from the heater unit. 5. With the beveled parts of the SST facing inward, insert them into the climate control unit. 6. Pull the SST outward and rearward to slide out the climate control unit.
CLIMATE CONTROL UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. WITH HEATER CORE
49 D066 801A
7. Disconnect the climate control unit connectors.
CONTINUED
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CONTROL SYSTEM WITHOUT HEATER CORE
CLIMATE CONTROL UNIT WIRE ADJUSTMENT Air Intake Wire 1. Set the air intake lever at FRESH. 2. Set the air intake link to FRESH in the direction of the arrow and insert a screwdriver into the set hole. L.H.D.
AIR INTAKE WIRE
SET HOLE
R.H.D. AIR INTAKE WIRE
1
Dial
2
Knob + Removal Note
3
A/C switch
4
Panel
5
Fan switch
6
Climate control unit harness
7
Illumination bulb
8
A/C amplifer
9
Air mix wire
10
Airflow mode wire
11
Air intake wire
11
Cap
13
Body
SET HOLE
3. Connect the air intake wire to the air intake link. 4. Clamp the air intake wire to wire clamp. 5. Verify that the air intake lever moves its full stroke. Air Mix Wire (With heater core only) 1. Set the temperature control dial at MAX COLD. 2. Set the air mix link to MAX COLD in the direction of the arrow and insert a screwdriver into the set hole.
SET HOLE
Knob Removal Note Use a wire to push the knob from the reverse side and remove it as shown in the figure.
AIR MIX WIRE
WIRE
3. Connect the air mix wire to the air mix link. 4. Clamp the air mix wire to wire clamp. 5. Verify that the temperature control dial moves its full stroke.
KNOB
CONTINUED
U–26
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CONTROL SYSTEM Airflow Mode Wire 1. Set the airflow mode control dial at DEF. 2. Set the airflow mode link to DEF in the direction of the arrow and insert a screwdriver into the set hole. SET HOLE
Fan Switch 1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.) 2. Inspect for continuity between the fan switch terminals using an ohmmeter. : Continuity Terminal
Switch position
A
B
C
D
E
F
0 1 2 3
AIRFLOW MODE WIRE
4
3. Connect the airflow mode wire to the airflow mode link. 4. Clamp the airflow mode wire to wire clamp. 5. Verify that the airflow mode control dial moves its full stroke. CLIMATE CONTROL UNIT INSPECTION A/C Switch 1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.) 2. Inspect for continuity between the A/C switch terminals using an ohmmeter. : Continuity
F
E
B C
4
D
3
A
2
1
123456567 E C A
F
D
B
0
3. If not as specified, replace the fan switch.
Terminal
Switch position
A
B
OFF ON
A
C
B
C
B
A
3. Connect battery positive voltage to terminal C and 123456567 ground to the terminal A. 4. Turn the A/C switch on. 5. Verify that the LED illuminaltes. 6. If not as specified, replace the A/C switch.
CONTINUED
U–27
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BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
TROUBLESHOOTING
TROUBLESHOOTING FOREWORD Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly perform the procedures. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged. The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area. TROUBLESHOOTING INDEX No.
Malfunction symptom
1
Insufficient blown air volume and/or no blown air depending on airflow mode.
2
No blown air in any airflow mode. Blown air volume does not change at any fan speed.
3
Airflow mode does not change.
4
Improper air circulation and/or no air circulation.
5
No temperature control.(For climate control unit without variable thermistor only)
6
Air from vent not cold enough.
7
No cool air.
8
Noise while operating A/C system.
SYMPTOM TROUBLESHOOTING 1
Insufficient blown air volume and/or no blown air depending on airflow mode.
TROUBLESHOOTING HINTS 1 Malfunction in VENT mode system Steps 1—4 2 Malfunction in HEAT mode system Step 5 3 Malfunction in DEFROSTER mode system Steps 6—8 STEP 1
2 3 4
INSPECTION
ACTION
When airflow mode control dial is operated, is appropriate resistance felt and can it be moved throughout its full range?
Yes
Go to next step.
No
Go to Step 1 of troubleshooting index No. 3.
Does air blow out when in VENT mode?
Yes
Go to Step 5.
No
Go to next step.
Yes
Remove obstruction, then go to Step 9.
No
Go to next step.
Yes
Inspect duct for clogging, deformity and air leakage, then go to Step 9.
No
Install duct securely in the proper position, then go to Step 9.
Is vent clogged? Is duct in dashboard properly installed?
5
Does air blow out when in HEAT mode?
Yes
Go to next step.
No
Inspect vent for clogging, then go to Step 9.
6
Does air blow out when in DEFROSTER mode?
Yes
Operation is okay. Recheck malfunction symptoms.
No
Go to next step.
7
Is vent clogged?
Yes
Remove obstruction, then go to Step 9.
No
Go to next step.
8
Is defroster duct properly installed?
Yes
Inspect duct for clogging, deformity, and air leakage, then go to next step.
No
Install duct securely in the proper position, then go to next step.
CONTINUED
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TO. MODEL .INDEX
CONTROL SYSTEM
STEP 9
2
INSPECTION
ACTION
Does air blow out?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
No blown air in any airflow mode. Blown air volume does not change at any fan speed.
TROUBLESHOOTING HINTS 1 Blower motor, resistor, fan switch malfunction Step 1 2 Blower unit malfunction Steps 2—4 STEP 1
2
3
4
5
3
INSPECTION
ACTION
Inspect the following systems and electrical parts: Blower motor, resistor, fan switch. Are they okay?
Yes
Go to next step.
No
Repair or replace malfunctioning part, then go to Step 5.
Turn ignition switch to ON position. Turn fan switch on. on Is noise coming from blower unit?
Yes
Go to next step.
No
Go to Step 4.
Inspect fan in blower unit. Is fan free of interference from blower unit case? Is fan free of foreign material and obstructions? Is fan okay?
Yes
Go to next step.
No
Remove obstruction, repair or replace fan and blower unit case, then go to Step 5.
Is blower unit intake vent clogged?
Yes
Remove obstruction, then go to next step.
No
Inspect if there are any obstructions in passage between blower unit and heater unit, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
Does air blow out?
Airflow mode does not change.
TROUBLESHOOTING HINTS 1 Malfunction in heater unit’s airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow mode wire or wire clamp Steps 1, 2 2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunction Step 3 3 Malfunction in one or more heater unit doors Steps 4, 5 STEP 1
INSPECTION
ACTION
Inspect heater unit’s airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub links, airflow mode wire and wire clamp. Is there g grease on airflow mode main link,, airflow mode cranks and airflow mode sub links? Are airflow mode main link, airflow mode rod, airflow mode cranks, and airflow mode sub links installed securely and in the proper position? Is wire clamp free of deformation? Are above items all okay?
Yes
Go to next step.
No
Apply grease or install airflow mode main link, airflow mode rod, airflow mode cranks and airflow mode sub links securely in their proper positions, repair wire clamp, then go to Step 6.
CONTINUED
U–29
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TO. MODEL .INDEX
TROUBLESHOOTING
STEP 2
3
4 5
6
4
INSPECTION
ACTION
Is airflow mode wire positioned securely and correctly in relation to the heater unit’s airflow mode main link?
Yes
Go to next step.
No
Adjust airflow mode wire or install it correctly, then go to Step 6.
Inspect climate control unit. Is bevel g gear set properly y engaged? g g Is airflow mode wire properly installed in correct direction on bevel gear? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Properly engage bevel gear set or install airflow mode wire in correct direction, repair or replace wire clamp, then go to Step 6.
Is there any foreign material or obstruction in any of heater unit’s doors?
Yes
Remove obstruction, then go to Step 6.
No
Go to next step.
Are all doors within heater unit securely and properly positioned?
Yes
Inspect each door for cracks or damage, then go to next step.
No
Install malfunction doors securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
Does airflow mode change?
Improper air circulation and/or no air circulation.
TROUBLESHOOTING HINTS 1 Malfunction in blower unit’s air intake crank, air intake link, air intake wire or wire clamp Steps 1, 2 2 Climate control unit air intake wire or wire clamp malfunction Step 3 3 Blower unit air intake door malfunction Steps 4, 5 STEP 1
INSPECTION
ACTION
Inspect blower unit’s air intake crank, air intake link and wire clamp. Is there grease g on air intake crank and air intake link? Are air intake crank and air intake link securely and properly positioned? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Apply grease or install air intake crank and air intake link properly and securely, repair wire clamp, then go to Step 6.
Is air intake wire positioned securely and correctly in relation to the blower unit’s air intake link?
Yes
Go to next step.
No
Adjust air intake wire or install securely in correct position, then go to Step 6.
Inspect climate control unit. Is air intake wire properly installed in correct direction in relation to the air intake lever of climate control unit? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Install air intake wire securely in correct position, repair or replace wire clamp, then go to Step 6.
4
Is there any foreign material or obstruction in blower unit’s air intake door?
Yes
Remove obstruction, then go to Step 6.
No
Go to next step.
5
Is blower unit’s air intake door securely and properly positioned?
Yes
Inspect air intake door for cracks or damage, then go to next step.
No
Install air intake door securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
2
3
6
Does air circulate?
CONTINUED
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CONTROL SYSTEM
5
No temperature control.(Without variable thermistor in climate control unit only)
TROUBLESHOOTING HINTS 1 Malfunction in heater unit’s air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp Steps 2, 3 2 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction Step 4 3 Heater unit air mix door malfunction Steps 5, 6 STEP
INSPECTION
ACTION
1
Is coolant sufficiently warmed up?
Yes
Go to next step.
No
Warm engine up, then go to Step 7.
2
Inspect heater unit’s air mix rod, air mix link, air mix cranks, air mix shaft and wire clamp. Is there grease g on air mix rod,, air mix link and air mix cranks? Are air mix rod, air mix link, air mix cranks, and air mix shaft securely installed in their proper positions? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Apply grease or install air mix rod, air mix link, air mix cranks, and air mix shaft securely in their proper positions, repair wire clamp, then go to Step 7.
Is air mix wire securely installed in the correct position in relation to heater unit’s air mix link?
Yes
Go to next step.
No
Adjust air mix wire or install securely in correct position, then go to Step 7.
Inspect climate control unit. Is bevel g gear set properly y engaged? g g Is air mix wire properly installed in correct position in relation to bevel gear? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Properly engage bevel gear set or install air mix wire in correct position, repair or replace wire clamp, then go to Step 7.
5
Is there any foreign material or obstruction in heater unit’s air mix door?
Yes
Remove obstruction, then go to Step 7.
No
Go to next step.
6
Is heater unit’s air mix door securely and properly installed?
Yes
Inspect door for cracks or damage, then go to next step.
No
Install door securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
3
4
7
6
Does unit operate in every temperature setting?
Air from vent not cold enough.
TROUBLESHOOTING HINTS 1 Drive belt malfunction Step 1 2 Malfunction in blower unit or condenser Steps 4, 5 3 Malfunction in receiver/drier or expansion valve (valve closes too much) Steps 8, 9 4 Malfunction in refrigerant lines Steps 10, 11 5 Malfunction in piping connections Steps 1, 2, 13 6 A/C compressor system malfunction, insufficient compressor oil Steps 15, 16 7 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system Steps 17—20
CONTINUED
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TO. MODEL .INDEX
TROUBLESHOOTING
STEP
INSPECTION
ACTION Yes
Go to next step.
No
Adjust or replace drive belt, then go to Step 21. + Section B2, DRIVE BELT, DRIVE BELT ADJUSTMENT
Carry out refrigerant system performance test. + REFRIGERANT SYSTEM SERVICE PROCEDURES PERFORMANCE TEST PROCEDURES, Is operation normal?
Yes
Operation is normal. (Recheck malfunction symptoms.)
No
Go to next step.
Are refrigerant’s high-pressure and low-pressure values both high?
Yes
Go to next step.
No
Go to Step 6.
4
Is blower unit intake clogged?
Yes
Remove obstruction, then go to Step 21. (If air does not reach evaporator within cooling unit, heat exchange does not occur and refrigerant pressure rises. Therefore, removal of obstruction is necessary.)
No
Go to next step.
5
Inspect condenser. + BASIC SYSTEM, CONDENSER INSPECTION Is it okay?
Yes
Add or subtract refrigerant to make specified amount, then go to Step 21. (Excessive amount of refrigerant.)
No
Replace condenser, or repair and clean condenser fins, then go to Step 21.
Are refrigerant’s high-pressure and low-pressure values both low?
Yes
Go to next step.
No
Go to Step 14.
Immediately after A/C compressor operates, does refrigerant’s high-pressure value momentarily g g y rise to correct value, then fall and stay below it? (Is there negative pressure on low-pressure side?)
Yes
Go to next step.
No
Go to Step 10.
Turn A/C switch off and let air conditioner stop for 10 minutes. min tes Start engine. Turn both A/C switch and fan switch on. Does malfunction occur after A/C compressor turns on?
Yes
Go to next step.
No
Start vacuum pump for 30 minutes and replace receiver/drier, then go to Step 21. (Since receiver/drier has become saturated with water, replacement is necessary.)
Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?
Yes
Replace expansion valve, then go to Step 21. (Since valve closes too much, replacement is necessary.)
No
Install heat-sensing tube securely in proper position, then go to Step 21.
Yes
Go to next step.
No
If piping or an A/C component is damaged or cracked, replace it. Then go to Step 21. If there is no damage, go to Step 13.
1
Inspect drive belt. + Section B2, DRIVE BELT, DRIVE BELT INSPECTION
Is it okay? 2
3
6 7
8
9
10
Inspect refrigerant lines. Is piping free of damage and cracks? Are piping connections free of oil grime? (Visual inspection) Are piping connections free of gas leakage? Are piping installation points on condenser free of gas g leakage? g Are piping installation points on receiver/drier free of gas leakage? Are piping installation points on A/C compressor free of gas leakage? Are piping installation points on cooling unit free of gas leakage? *Perform gas leak inspection using gas leak tester. Are above items okay?
CONTINUED
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CONTROL SYSTEM
STEP 11
12
13
14 15 16
17 18
INSPECTION
ACTION
Are piping connections for evaporator in cooling unit free of gas leakage?
Yes
If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Add or subtract refrigerant to make specified amount, then go to Step 21.
No
If piping is damaged or cracked, replace it. Then go to Step 21. If there is no damage, go to next step.
Yes
Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.
No
If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.
Yes
Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.
No
If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.
Does refrigerant’s high-pressure value hardly increase?
Yes
Go to next step. (Pressure hardly increases.)
No
Go to Step 17.
When engine is racing, does high-pressure value increase?
Yes
Return to Step 3.
No
Go to next step.
After compressor oil is replenished each 10 ml {10 cc, 0.34 fl oz}, does high-pressure value increase?
Yes
Troubleshooting completed. (Explain to customer that cause was insufficient compressor oil.)
No
Replace A/C compressor, then go to Step 21. (Cause is defective A/C compressor.)
Is only refrigerant low-pressure value high?
Yes
Go to Step 20.
No
Go to next step.
Yes
Go to next step.
No
Repair or install air mix rod, air mix link, air mix cranks and air mix shaft securely in proper position, then go to Step 21.
Are piping connections for evaporator in cooling unit loose?
Are piping connections loose?
Are heater unit’s air mix rod, air mix link, air mix cranks and air mix shaft securely and properly installed?
CONTINUED
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TO. MODEL .INDEX
TROUBLESHOOTING
STEP 19
20
21
7
INSPECTION
ACTION
1. 2. 3. 4. 5. 6.
Set the fan switch at 4th position. Turn the A/C switch on. Set to FRESH mode. Set the temperature control to MAX COLD. Set to VENT mode. Run engine at a constant 1,500 rpm for 10 minutes. 7. Run engine at idle speed for 1 minute. 8. 1 engine speed cycle is defined as going from idle speed to 4,000 rpm and back to idle speed over a period of 12 seconds. Perform 5 cycles cycles. 9. Run engine at idle speed for 30 seconds. 10. Remove all compressor oil from A/C compressor and verify that it is 105 ml {105 cc, 3.55 fl oz}. 11. If it is more than 105 ml {105 cc, 3.55 fl oz}, put only 105 ml {105 cc, 3.55 fl oz} back into A/C compressor. 12. Carry out above steps 1 to 10 again and verify that compressor oil is 105 ml {105cc, 3.55 fl oz}. Is there 105 ml {105 cc, 3.55 fl oz} of compressor oil in A/C compressor?
Yes
Go to Step 21.
No
Carry out 1 to 10 of step 19 again until compressor oil is 105 ml {105 cc, 3.55 fl oz}.
Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?
Yes
Replace expansion valve, then go to next step. (Since valve opens too much, replacement is necessary.)
No
Install heat-sensing tube securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
Does cool air blow out? (Are results of refrigerant system performance test okay?)
No cool air.
TROUBLESHOOTING HINTS 1 A/C compressor system malfunction Step 2 2 Incorrect amount of refrigerant Step 3 3 A/C switch indicator light malfunction Steps 4—6 4 A/C relay system malfunction (WL, WL turbo, F2 Cab) Steps 7, 11—13 (G6, F2) Steps 7, 11, 12 5 Refrigerant pressure switch malfunction Step 8 6 PCM A/C cut-off control system (WL, WL turbo) Steps 9, 26 (G6, F2) Step 9 7 PCM (IG1 signal) system malfunction Steps 10, 25 8 Magnetic clutch system malfunction Step 14 9 PCM (A/C signal) system malfunction (WL, WL turbo) Steps 15, 20 (G6, F2) Steps 15, 19, 20 (F2 Cab) Step 15 10 Thermoswitch, A/C switch malfunction (WL, WL turbo, G6, F2) Steps 21—24 (F2 Cab) Steps 16—18
CONTINUED
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CONTROL SYSTEM
STEP 1 2
3
4 *5
*6
7
*8
*9
INSPECTION
ACTION
Does air blow out?
Yes
Go to next step.
No
Go to Step 1 of troubleshooting indexes 1, 2.
Start engine. Turn both A/C switch and fan switch on on. Does A/C compressor operate?
Yes
Go to Step 1 of troubleshooting index 6.
No
Go to next step.
Inspect refrigerant amount. + REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST Is it okay?
Yes
Go to next step.
No
Add or subtract refrigerant to specified level, then go to Step 27.
Does A/C switch indicator light illuminate?
Yes
Go to Step 7.
No
Go to next step
Turn ignition switch to ON position. (With air mix wire) Remove airflow mode wire, air intake wire and air mix wire. Remove climate control unit. (Without air mix wire) Remove airflow mode wire and air intake wire. Remove climate control unit. Remove A/C switch from climate control unit and connect A/C switch connector. Test voltage at A/C switch terminal C (IG2 signal). Is voltage approximately 12 V?
Yes
Go to next step.
No
Repair wiring harness between fuse block and A/C switch, then go to Step 27.
Inspect A/C switch. + CONTROL SYSTEM, CLIMATE CONTROL UNIT INSPECTION Is it okay?
Yes
Inspect wiring harness between A/C switch and resistor, then go to Step 27.
No
Replace A/C switch, then go to Step 27.
Are A/C relay power supply fuses okay?
Yes
Go to next step.
No
Check for a short to ground on blown fuse’s circuit. Repair or replace as necessary. Install appropriate amperage fuse.
Remove radiator grille. Disconnect refrigerant pressure switch connector. When refrigerant pressure switch connector terminals A and B (on wiring harness side) are shorted, does cool air blow out?
Yes
Inspect refrigerant pressure switch, then go to Step 27.
No
WL for ISRAEL: Undo short, reconnect refrigerant pressure switch connector, then go to Step 10. Other models: Undo short, reconnect refrigerant pressure switch connector, then go to next step.
Check the DTC for the PCM ON-BOARD DIAGNOSTIC SYSTEM. Are the following DTCs displayed? DTC 09 (WL or WL turbo) DTC 0120 (F2 or G6)
Yes
Go to appropriate inspection procedure. (The engine coolant temperature sensor (DTC 09) or throttle position sensor (DTC 0120), which sends the PCM’s A/C cut off control input signal, may be the cause of the trouble.)
No
Go to next step.
Yes
Go to Step 15.
No
Go to next step.
+ Section F2, ON-BOARD DIAGNOSTIC SYSTEM, DIAGNOSTIC TROUBLE CODE INSPECTION
*10
Turn ignition switch to ON position. Does magnetic clutch operate when A/C relay connector terminal B (IG2 signal) is grounded?
CONTINUED
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TROUBLESHOOTING
STEP *11
*12
*13
*14
*15
*16
*17
*18
*19
INSPECTION
ACTION
Turn ignition switch to ON position. Test voltage at the following A/C relay connector terminals: Terminal A (IG2 signal) Terminal C (A/C control signal) Is voltage approximately 12 V?
Yes
Go to next step.
No
Repair wiring harness between fuse block and A/C relay, then go to Step 27.
Test voltage at A/C relay terminal D (A/C control signal). Is voltage approximately 12 V?
Yes
G6 or F2: Go to Step 14. Other models: Go to next step.
No
Inspect A/C relay, then go to Step 27.
Disconnect refrigerant pressure switch connector. Test voltage at refrigerant pressure switch connector (on wiring harness side) terminal A (A/C control signal). Is voltage approximately 12 V?
Yes
Reconnect refrigerant pressure switch connector, then go to next step.
No
Repair wiring harness between A/C relay and refrigerant pressure switch, then go to Step 27.
Test voltage at magnetic clutch connector terminal A (A/C control signal). Is voltage approximately 12 V?
Yes
Inspect magnetic clutch, then go to Step 27.
No
G6 or F2: Repair wiring harness between A/C relay and magnetic clutch, then go to Step 27. Other models: Repair wiring harness between refrigerant pressure switch and magnetic clutch, then go to Step 27.
Turn A/C switch off. Remove glove compartment. Turn ignition switch to ON position. Test voltage at the following thermoswitch connector terminal (A/C signal): Terminal B (with variable thermistor in climate control unit) Terminal A (without variable thermistor in climate control unit) Is voltage approximately 12 V?
Yes
F2 Cab: Go to next step. Other models: Go to Step 21.
No
F2 Cab: Repair wiring harness between A/C relay and thermoswitch, then go to Step 27. G6 or F2: Go to Step 19. Other models: Go to Step 20.
Turn ignition switch to LOCK position. Disconnect thermoswitch connector. Start engine. Turn both A/C switch and fan switch on. When following thermoswitch connector terminals shorted does cool (on wiring harness side) are shorted, air blow out? Terminal A—C (with variable thermistor in climate control unit) Terminal B—C (without variable thermistor in climate control unit)
Yes
Undo short, then go to next step.
No
Undo short, then go to Step 18.
Turn ignition switch to ON position. Test voltage at the following thermoswitch connector terminals (IG2 signal): Terminal B (with variable thermistor in climate control unit) Terminal A (without variable thermistor in climate control unit) Is voltage approximately 12 V?
Yes
Inspect thermoswitch, then go to Step 27.
No
Repair wiring harness between fuse block and thermoswitch, then go to Step 27.
Turn ignition switch to ON position. Turn A/C switch on. Turn fan switch off. Test voltage at A/C switch connector terminal A (A/C signal). Is voltage approximately 12 V?
Yes
Inspect wiring harness between thermoswitch and A/C switch, then go to Step 27.
No
Inspect A/C switch, then go to Step 27.
Disconnect refrigerant pressure switch connector. Test voltage at refrigerant pressure switch connector ((on wiring g harness side)) terminal A (A/C control signal). Is voltage approximately 12 V?
Yes
Repair wiring harness between thermoswitch and refrigerant pressure switch, then go to Step 27.
No
Go to next step.
CONTINUED
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TO. MODEL .INDEX
CONTROL SYSTEM
STEP *20
*21
22
*23
*24
*25
*26
27
INSPECTION
ACTION
Turn ignition switch to ON position. Test voltage at the following PCM connector terminals (A/C signal): Terminal G (WL or WL turbo) Terminal Q (G6 or F2) Is voltage approximately 12 V?
Yes
G6 or F2: Repair wiring harness between PCM and refrigerant pressure switch, then go to Step 27. Other models: Repair wiring harness between PCM and thermoswitch, then go to Step 27.
No
Inspect PCM, then go to Step 27.
Turn ignition switch to LOCK position. Disconnect thermoswitch connector. Start engine. Turn both A/C switch and fan switch on. When following thermoswitch connector terminals (on wiring harness side) are shorted, shorted does cool air blow out? Terminal B—C (without variable thermistor in climate control unit) Terminal A—C (with variable thermistor in climate control unit)
Yes
Undo short, then go to next step.
No
Go to Step 23.
Turn ignition switch to ON position. Test voltage at the following thermoswitch ( g ) connector terminals (IG2 signal): Terminal A (without variable thermistor in climate control unit) Terminal B (with variable thermistor in climate control unit) Is voltage approximately 12 V?
Yes
Inspect thermoswitch, then go to Step 27.
No
Repair wiring harness between fuse block and thermoswitch, then go to Step 27.
Turn ignition switch to ON position. Turn A/C switch on. Turn fan switch off. Test voltage at A/C switch connector terminal A (A/C signal). Is voltage approximately 12 V?
Yes
Go to next step.
No
Inspect A/C switch, then go to Step 27.
Test voltage at thermoswitch connector terminal C (A/C signal). Is voltage approximately 12 V?
Yes
Go to next step.
No
Repair wiring harness between thermoswitch and A/C switch, go to Step 27.
Test voltage at the following PCM connector terminals (A/C signal): Terminal L (WL or WL turbo) Terminal J (G6 or F2) Is voltage approximately 12 V?
Yes
WL or WL turbo: Go to next step. Other models: Recheck malfunction symptoms.
No
Repair wiring harness between A/C relay and PCM, then go to Step 27.
Inspect the following input signal components: Engine coolant temperature sensor and PCM wiring harness (A/C cut-off control). Are they okay?
Yes
Recheck malfunction symptoms.
No
Replace input signal components, then go to next step.
Does cool air blow out? (Is refrigerant system performance test result correct?)
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
CONTINUED
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TO. MODEL .INDEX
TROUBLESHOOTING
8
Noise while operating A/C system.
TROUBLESHOOTING HINTS 1 Magnetic clutch operation noise Step 3 2 A/C compressor operation noise Steps 4—8 3 A/C compressor slippage noise Steps 9—11 4 Hose or refrigerant line interference noise Step 12 STEP 1
INSPECTION
ACTION
Is there a squeaking or whirling sound (A/C compressor slippage noise)?
Yes
Go to Step 9.
No
Go to next step.
Is there a rattling or vibrating sound (interference noise)?
Yes
Go to Step 12.
No
Go to next step.
3
Is there a clicking sound (magnetic clutch operation noise)?
Yes
Adjust clearance between magnetic clutch pressure plate and A/C compressor pulley, then go to Step 13. + CONTROL SYSTEM, MAGNETIC CLUTCH CLEARANCE ADJUSTMENT
No
Go to next step.
4
Is noise heard continuously for more than 3 seconds after A/C compressor comes on?
Yes
Go to next step.
No
Condition is normal. (Noise normally occurs for 2—3 seconds immediately after A/C compressor turns on.)
Inspect idle speed. + Section F2, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
Yes
Go to next step.
No
Adjust idle speed, then go to Step 13.
2
5
Is it okay? 6
Drain compressor oil. Is it contaminated with metal particles?
Yes
Go to next step.
No
Replace A/C compressor, then go to Step 13.
7
Is compressor oil whitish and mixed with water?
Yes
Replace entire A/C system (excluding heater), then go to Step 13.
No
Go to next step.
8
Is compressor oil darker than normal and contaminated with aluminum chips?
Yes
Replace A/C compressor and receiver/drier, then go to Step 13. (Since A/C compressor may be worn and receiver/drier may be clogged, replacement of receiver/drier is necessary.)
No
Condition is normal. Recheck malfunction symptoms.
Yes
Go to next step.
No
Adjust or replace drive belt, then go to Step 13.
Yes
Remove obstruction, remove oil, or replace drive belt, then go to Step 13.
No
Go to next step.
9
Inspect drive belt. + Section B2, DRIVE BELT, DRIVE BELT INSPECTION
Is it okay? 10
Is drive belt worn? Does it have foreign material imbedded in it, or have oil on it?
CONTINUED
U–38
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CONTROL SYSTEM
STEP
INSPECTION
ACTION
11
Inspect magnetic clutch. + CONTROL SYSTEM, MAGNETIC CLUTCH INSPECTION Is it okay?
Yes
Replace A/C compressor (excluding pressure plate, A/C compressor pulley, and stator), then go to Step 13.
No
Replace magnetic clutch, then go to Step 13.
12
Is noise coming from A/C compressor?
Yes
Visually inspect A/C compressor, replace appropriate parts if necessary, then go to next step.
No
If noise is coming from refrigerant lines, repair any detached or missing clips, tighten loose bolts, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
13
Has A/C compressor noise stopped?
CONTINUED
U–39
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TECHNICAL DATA TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . TD– 1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD– 1/3 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . TD– 4 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD– 4 FUEL AND EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD– 5/6 ENGINE ELECTRICAL SYSTEM . . . . . . . . . TD– 6/10 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD–10 MANUAL TRANSMISSION . . . . . . . . . . . . . . . TD–10/11
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . TD–11 FRONT AND REAR AXLES . . . . . . . . . . . . . . TD–11 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . TD–12 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD–12 SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . TD–13/14 BODY ELECTRICAL SYSTEM . . . . . . . . . . . TD–14/15 HEATER AND AIR CONDITIONER SYSTEMS . . . . . . . . . . . . . TD–15
TECHNICAL DATA ENGINE Engine
Item Generator Drive belt deflection [[Applied pressure 98 N {10 kgf, 22 lbf}] ( (mm {i {in}) })
P/S A/C Generator
Drive belt tension (N {kgf, lbf})
P/S A/C
Compression
(kPa {kgf/cm2, psi} [rpm])
Pushing distance of the front oil seal (from the edge of the chain cover) Pushing distance of the rear oil seal (from the edge of the rear cover)
G6 New
10.0—12.0 {0.40—0.47}
Used
12.0—14.0 {0.48—0.55}
New
6.6—7.2 {0.26—0.28}
Used
7.2—8.0 {0.29—0.31}
New
8.5—10.0 {0.34—0.39}
Used
10.0—11.5 {0.40—0.45}
New
491—588 {50—60, 110—132}
Used
393—490 {40—50, 88—110}
New
412—470 {42—48, 93—105}
Used
354—402 {36—41, 80—90}
New
557—641 {56.7—65.4, 125—143}
Used
471—556 {48.0—56.7, 106—124}
Standard
1255 {12.8, 182} [270]
Minimum
882.6 {9.0, 128} [270]
(mm {in}) (mm {in})
0—0.7 {0—0.027} 0—0.5 {0—0.019}
CONTINUED
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TECHNICAL DATA
Engine
Item
WL, WL Turbo
Generator Drive belt deflection [A li d pressure 98 [Applied kgf 22 lbf}] N {10 kgf, ((mm {{in}) })
A/C (meas (measuring ring point oint a)
A/C (meas (measuring ring point oint b)
Generator Drive belt tension (N {kgf, lbf}) A/C
New
7.0—9.0 {0.28—0.35}
Used
8.0—10.0 {0.32—0.39}
Limit
16.0 {0.63}
New
5.0—6.2 {0.20—0.24}
Used
6.0—6.5 {0.24—0.25}
Limit
11.3 {0.44}
New
9.5—11.8 {0.38—0.46}
Used
11.0—12.5 {0.44—0.49}
Limit
18.0 {0.71}
New
442—637 {45—65, 99—143}
Used
383—539 {39—55, 86—121}
Limit
177 {18, 40}
New
403—519 {41—53, 91—116}
Used
354—431 {36—44, 80—96}
Limit Valve clearance [Engine cold]
Compression
Timing belt deflection [Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in}) Bolt head mark W Cylinder y head bolt length (mm {in})
IN EX
0.15—0.25 {0.0060—0.0098} (0.20"0.05 {0.0079"0.0020}) 0.25 {0.0098} [Engine hot (Reference)]
(mm {in})
(kPa {kgf/cm2, psi} [rpm])
Bolt head mark N
181 {18.5, 41} 0.05—0.15 {0.0020—0.0059} (0.10"0.05 {0.0039"0.0020}) 0.15 {0.0059} [Engine hot (Reference)]
Standard
2,942 {30, 427} [200]
Minimum
2,648 {27, 384} [200]
Standard
9.0—10.0 {0.36—0.39}
Standard
101.2—101.8 {3.985—4.007}
Minimum
102.5 {4.035}
Standard
113.2—113.8 {4.457—4.480}
Minimum
114.5 {4.508}
Camshaft oil seal tapping amount
(mm {in})
0.5—1.0 {0.02—0.03}
Front oil seal tapping amount
(mm {in})
0—0.4 {0—0.01}
Rear oil seal tapping amount
(mm {in})
0—0.5 {0—0.01}
CONTINUED
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TECHNICAL DATA
Engine
Item Generator Drive belt deflection [[Applied pressure 98 N {10 kgf, 22 lbf}] ( (mm {i {in}) })
P/S A/C Generator
Drive belt tension (N {kgf, lbf})
P/S A/C
Compression
(kPa {kgf/cm2, psi} [rpm])
Timing g belt deflection [Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in}) Pushing distance of the front oil seal (from the edge of the chain cover) Pushing distance of the rear oil seal (from the edge of the rear cover)
F2 CARB
F2 CIS
New
7.0—8.0 {0.28—0.31}
Used
8.0—9.0 {0.32—0.35}
New
5.0—6.0 {0.20—0.23}
Used
5.5—6.5 {0.22—0.25}
New
10.0—12.0 {0.40—0.47}
Used
12.0—14.0 {0.48—0.55}
New
510—588 {52—60, 115—132}
Used
432—509 {44—52, 97—114}
New
393—490 {40—50, 88—110}
Used
344—441 {35—45, 77—99}
New
373—490 {38—50, 84—110}
Used
275—372 {28—38, 62—83}
Standard
1196 {12.2, 173} [300]
1226 {12.5, 178} [300]
Minimum
837 {8.54, 121} [300]
858 {8.75, 124} [300]
New
8.0—9.0 {0.32—0.35}
Used
9.0—10.0 {0.36—0.39}
(mm {in}) (mm {in})
0 {0} 0—0.5 {0—0.019}
CONTINUED
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TECHNICAL DATA LUBRICATION SYSTEM Engine
Item
Oil pressure
F2
G6
WL
WL Turbo
295—392 {3.0—4.0, 43—56} [3000]
305—402 {3.1—4.1, 45—58} [3000]
452—529 {4.6—5.4, 66—76} [3000]
402—480 {4.1—4.9, 59—69} [3000]
Oil replacement
3.9 {4.1, 3.4}
4.5 {4.8, 4.0}
5.6 {5.9, 4.9}
Oil and oil filter replacement
4.2 {4.4, 3.7}
4.7 {5.0, 4.4}
6.3 {6.7, 5.5}
Total (dry engine)
4.6 {4.9, 4.0}
5.5 {5.8, 4.8}
6.7 {7.1, 5.9}
(kPa
Oil capacit capacity (L {US qt, qt lmp lm qt})
{kgf/cm2,
psi} [rpm])
Engine oil
API service SG
API service CD
SAE 40
—
0°C—40_C {32_F—104°F}
SAE 30
—
–10°C—20_C {14_F—68°F}
SAE 20W-20
—
Above 30_C {86_F}
Above –25_C {–13_F} Viscosity
SAE
10W-30*,
10W-40, 10W-50
—
Above –10_C {14_F}
SAE 20W-40, 20W-50
—
Below –20_C {–4_F}
SAE 5W-20
—
Below 0_C {32_F}
SAE
–15°C—40_C {5_F—104°F}
5W-30*
—
— —
SAE 10W-30
Below 10_C {50_F} — — D European specification vehicles use only those oils marked with an asterisk
SAE 5W-30
COOLING SYSTEM Engine
Item Coolant capacity ca acity
(L {US qt, qt lmp lm qt})
F2
G6
9.4 {9.9, 8.3}
Without heater
6.9 {7.3, 6.1}
8.8 {9.3, 7.7}
(_C {_F})
Full-open temperature
(_C {_F})
83.5—89.5 {183—193}
Thermostat
Radiator cap
WL Turbo
7.5 {7.9, 6.6}
Opening temperature
Full-open lift
WL
With heater
100 {212} 8.5 {0.33} min.
(mm {in})
Cap valve opening pressure (kPa {kgf/cm2, psi})
Sub: 83.5—86.5 {183—187} Main: 86.5—89.5 {188—193}
74—102 {0.75—1.05, 10.7—14.9}
80—84 {176—183}
95 {203}
Sub: 1.5 {0.06} min. Main: 8.0 {0.31} min.
8.5 {0.33} min.
94—122 {0.95—1.25, 13.5—17.7}
CONTINUED
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TECHNICAL DATA FUEL AND EMISSION CONTROL SYSTEMS CIS vehicles Engine
Item Idle speed
(rpm)
F2
730—770 (750"20)
730—770 (750"20)
4—6/750
5—7/750
700—800 (750"50)
780—880 (830"50)
(BTDC °/rpm)
Injection timing Idle speed*11
G6
(rpm)
A/C
ON*2
P/S
ON*3
700—800 (750"50)
CO concentration
Within the regulation
HC concentration
Within the regulation
Fuel pressure (kPa {kgf/cm2, psi})
Hold pressure
More than 340 {3.5, 50}
Fuel pump maximum pressure
500—630 {5.0—6.5, 72—92}
Fuel leakage
Less than 1
(drop/2 minutes) Injection volume (ml {cc, fl oz}/15 sec.)
Fuel injector
55—71 {55—71, 1.9—2.3}
Resistance
12—16
(Ω) [20°C {68°F}]
Pressure regulator *1: *2: *3: *4:
46—60 {46—60, 1.6—2.0}
Fuel pressure (at vacuum ON) (kPa {kgf/cm2, psi})
210—250 {2.1—2.6, 30—36}
Fuel pressure (at vacuum OFF*4) (kPa {kgf/cm2, psi})
270—310 {2.7—3.2, 39—45}
Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on. A/C switch and fan switch are turned on. Steering wheel is fully turned. Hot condition at start.
DIESEL vehicles Engine
Item
WL Turbo
Idle speed
(rpm)
WL
(780"20)*1
760—800 700—740 (720"20)*2
Injection timing
ATDC 10° 107—115 {1.09—1.18, 15.5—16.8}
—
When A/C is operated
825—875 (850"25)
805—855 (830"25) 825—875 (850"25)*3
When P/S is operated
—
—
(kPa {kgf/cm2, psi})
Boost relief pressure
Idle-up Idle u sspeed eed (rpm)
When engine is cold Injection pump
Injection nozzle
Cam lift
1200—1500 (1350"150) (mm {in})
Diesel smoke
2.48 {0.098}
Injection starting pressure (MPa {kgf/cm2, psi})
New: 11.4—12.2 {116—124, 1650—1760} Inspection: More than 10.0 {102, 1450} No leakage when pressure of 8.8 MPa {90 kgf/cm2, 1280 psi}) is applied.
Nozzle leakage *1: *2: *3:
700—740 (720"20)
(%)
Within the regulation
General (L.H.D.) Europe and UK Europe
CONTINUED
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TECHNICAL DATA CARB vehicles Engine
Item
F2 CARB
Idle speed
800—850 (800 +50 –0 )
(rpm)
Injection timing
(BTDC°)
Idle up speed Idle-up
(rpm)
5—7 (6"1)
A/C Operated
1400—1600 (1500"100)
P/S Operated
—
D/P Operated
1900—2100 (2000"100)
T/P Operated CO concentration HC concentration Fuel pump um
Carburetor
(ppm) Discharge pressure
(kPa
Discharge amount Float level
(mm {in})
{kgf/cm2,
—
psi})
20—25 {0.2—0.25, 2.8—3.6}
cc {cu in} min.
1150 {70.2}
H
8—9 {0.315—0.354}
L
Primary throttle opening angle *1: *2:
1050—1250 (1150"100) 1 2 2.0—2.5 (2.0 +0.5 –0 )* , 2.0—3.0 (2.5"0.5)*
(%)
44—45 {1.732—1.772} (°)
48—52 {50"2}
GULF General
ENGINE ELECTRICAL SYSTEM Engine
Item
G6
Electrolyte gravity
1.27—1.29
Back-up current *1 Test load chart
(mA)
Max. 20
Battery type
80D26R
(A)
Battery type (5-hour rate)
80D26R (55)
5.5—6.5
Quick charge (A/30 min.)
Battery type (5-hour rate)
80D26R (55)
35
(A)
Battery Slow charge
195
Rotor resistance (Between slip rings)
(Ω)
Standard
Brush length Brush sspring ring force
(mm {in})
Standard
(N {kgf, lbf})
4.8—6.0 {0.48—0.62, 1.06—1.36}
Minimum
(N {kgf, lbf})
2.2 {0.22, 0.48}
Terminal
Standard voltage g (V) Idle [20C [20 C {68F}] {68 F}] Generated current*2 (Reference) (A)
18.5 {0.73}
Minimum
Ignition switch ON
Generator
(mm {in})
3.7—4.4
Engine speed s eed
Terminal
5.0 {0.20}
B
B+
L
Approx. 1
S
B+
B
14.1—14.7
L
13.0—14.0
S
14.1—14.7
1000
Approx. 0—43
2000
Approx. 0—62
(r (rpm) m)
*1:
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is at OFF position and the ignition key is removed. *2: Must not be 0 A. CONTINUED
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TECHNICAL DATA
Engine
Item Ignition g coil
G6
Primary coil
Resistance [20C {68F}]
(Ω)
Secondary coil
(kΩ) NGK DENSO
KJ16CR11*3, *5, KJ20CR11*4, *5 K16PR–U*3, K20PR–U*4
Plug gap
(mm {in})
Resistance
(kΩ)
Tightening torque
High Hightension l d lead
(kΩ ) [20 C C {68 F}] F}]
Commutator diameter Brush length Starter
Brush sspring ring force
1.0—1.1 {0.040—0.043}*5, 0.7—0.8 {0.028—0.031} 3 0—7 5 3.0—7.5
DENSO
15—22 {1.5—2.3, 11—16}
No.1 lead
2.9—7.7
No.2 lead
4.3—10.8
No.3 lead
5.4—13.5
No.4 lead
6.6—16.2
Center lead
4.5—11.2
Standard
(mm {in})
29.4 {1.16}
Minimum
(mm {in})
28.8 {1.14}
Standard
(mm {in})
12.3 {0.48}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
180—243 {18.3—24.8, 40.3—54.5}
Minimum
(N {kgf, lbf})
57.7 {5.88, 12.9}
Pinion gap No load test
NGK (N·m {kgf·m, ft·lbf})
Resistance
10—16 ZFR5F–11*3, *5, ZFR6F–11*4, *5, BKR5E*3, BKR6E*4
Type Ty e Spark S plug
0.81—0.99
(mm {in})
7.0 {0.28}
3.0 {1.118}
Voltage
(V)
11.5
Current
(A)
Below 100
*3:
Standard plug *4: Cold type plug *5: Europe
CONTINUED
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TECHNICAL DATA
Engine
Item
F2 CARB
F2 CIS
Electrolyte gravity Back-up current Test load chart (A)
Battery
1.27—1.29
*1
(mA) Battery ty type e
34B19R
180
(A)
Battery y type y (5-hour rate)
Quick charge g (A/30 min.)
Battery y type y (5-hour rate)
34B19R (27)
3.0—4.0
Brush sspring ring force
4.5—5.5 20 30 (Ω)
18.5 {0.73}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
4.8—6.0 {0.48—0.62, 1.06—1.36}
Minimum
(N {kgf, lbf})
2.2 {0.22, 0.48}
B
B+
L
Approx. 1
S
B+
B
14.1—14.7
L
13.0—14.0
S
14.1—14.7
Terminal
(V) Idle [20C [20 C {68F}] {68 F}]
Ignition g coil
Engine speed s eed
Terminal
1000
Approx. 0—43
2000
Approx. 0—62
(r m) (rpm)
Primary coil
Resistance [20C {68F}]
(Ω)
Secondary coil
0—2/1200, 9—13/2200, 19—23/6000
—
°/kPa {mmHg, inHg}
0—2/20 {150, 5.9}, 11—15/53.3 {400, 15.7}
—
BKR5E*5 BKR6E*3 BKR7E*4
BPR5ES–11*3 BPR6ES–11*4
K16PR–U*5 K20PR–U*3 K22PR–U*4
W16EXR–U11*3 W20EXR–U11*4
0.7—0.8 {0.028—0.031}
1.0—1.1 {0.040—0.043}
NGK Type Ty e DENSO
Spark plug lug Plug gap
(mm {in}) (kΩ)
Tightening torque
High Hightension l d lead
Resistance (kΩ ) [20 C C {68 F}] F}]
NGK
*2: *3: *4: *5:
30 75 3.0—7.5
DENSO (N·m {kgf·m, ft·lbf})
15—22 {1.5—2.3, 11—16}
No.1 lead
2.75—7.07
No.2 lead
4.19—10.43
No.3 lead
4.38—10.88
No.4 lead Center lead
*1:
0.81—0.99 10—16
°/rpm
Distributor Vacuum spark advance
1.035—1.265
(kΩ)
Centrifugal spark advance
Resistance
3.7—4.4
(mm {in})
Standard voltage g
Generated current*2 (Reference) (A)
—
55D23R (48)
Standard
Ignition switch ON
Generator
—
55D23R (48)
Rotor resistance (Between slip rings) Brush length
—
55D23R 34B19R (27)
Slow charge g
Max. 20 110
5.73—14.08 2.00—5.33
3.9—9.9
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is at OFF position and the ignition key is removed. Must not be 0 A. Standard plug Cold type plug Hot type plug
CONTINUED
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TECHNICAL DATA
Engine
Item Commutator diameter Brush length Starter
Brush sspring ring force
F2 CARB
Standard
(mm {in})
32.0 {1.26}
Minimum
(mm {in})
31.4 {1.24}
Standard
(mm {in})
17.0 {0.67}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
19.2 {1.95, 4.25}
Minimum
(N {kgf, lbf})
8.83 {0.90, 1.98}
Pinion gap
11.5 {0.46}
(mm {in})
No load test
0.5—2.0 {0.020—0.078}
Voltage
(V)
11.5
Current
(A)
Below 60 Engine
Item
WL, WL Turbo
Electrolyte gravity
1.27—1.29
Back-up current *1 Test load chart (A)
(mA) Battery type
Battery Slow charge (A)
Quick charge (A/30 min.) min )
Battery type (5-hour rate)
Battery type (5-hour rate)
195
75D26R
195
95D31R
250
75D26L (52)
5.5—6.5
75D26R (52)
5.5—6.5
95D31R (64)
6.5—8.0
75D26L (52)
35
75D26R (52)
35
95D31R (64)
Brush sspring ring force
40 (Ω) (mm {in})
17.9 {0.70}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
2.65 {0.27, 0.59}
(N {kgf, lbf})
1.18 {0.12, 0.26}
Minimum
B
B+
A
B+
S
0
I
2.0—4.0
B
14.05—14.85
A
14.05—14.85
S
7.025—7.425
I
13.00—14.85
1000
Terminal B current
Approx. 0—58
2000
Terminal B current
Approx. 0—74
Terminal
Standard voltage g (V) Idle [20C {68F}]
Generated current*2 (Reference) (A)
2.50
Standard
Engine g switch ON G Generator
20 max.
75D26L
Rotor resistance (Between slip rings) Brush length
F2 CIS
Engine g speed (rpm)
Terminal
*1: Back-up
current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine switch is at OFF position and the engine key is removed. *2: Must not be 0 A.
CONTINUED
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TECHNICAL DATA
Engine
Item Commutator diameter Brush length Starter
Brush sspring ring force
WL, WL Turbo
Standard
(mm {in})
29.5 {1.16}
Minimum
(mm {in})
27.3 {1.07}
Standard
(mm {in})
17.7 {0.70}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
27.0—33.0 {2.75—3.37, 6.05—7.41}
Minimum
(N {kgf, lbf})
—
Pinion gap
(mm {in})
No load test
8.7 {0.34}
3.0 {0.12}
Voltage
(V)
11
Current
(A)
Below 130
CLUTCH Item
Specification
Clutch pedal Height
(mm {in})
241.6—246.6 {9.52—9.70}
Pedal free play
(mm {in})
3.0—8.0 {0.12—0.31}
(mm {in})
0.7 {0.027} max.
Clutch disc Runout limit Clutch fluid Type
SAE J1703 or FMVSS116 DOT-3 or DOT-4
MANUAL TRANSMISSION M15M-D Item
Specification
Type Transmission oil
Viscosity Capacity
API service GL-4 or GL-5 All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
M15MX-D Item
Specification
Type Transmission oil
Viscosity Capacity
API service GL-4 or GL-5 All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
Type Transfer oil
Viscosity Capacity
2.5 {2.6, 2.2} API service GL-4 or GL-5
All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
R15M-D Item
Specification
Type Transmission oil
Viscosity Capacity
API service GL-4 or GL-5 All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
2.8 {3.0, 2.5}
CONTINUED
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TECHNICAL DATA R15MX-D Item
Specification
Type Transmission oil
API service GL-4 or GL-5
Viscosity
All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
Capacity
(L {US qt, lmp qt})
3.2 {3.4, 2.8}
Type Transfer oil
API service GL-4 or GL-5
Viscosity
All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
Capacity
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
PROPELLER SHAFT Item Runout limit
Propeller shaft (42)
Front propeller shaft (44)
Rear propeller shaft (44)
0.4 {0.016}
0.4 {0.016}
0.4 {0.016}
0.3—1.1 {3.0—12.0, 2.7—10.4}
0.3—0.7 {3.0—8.0, 2.7—6.9}
0.3—1.1 {3.0—12.0, 2.7—10.4}
(mm {in})
Starting torque of universal (N·m {kgf·cm, in·lbf})
FRONT AND REAR AXLES Item
42 Play Preload
Front axle
Wheel bearing
(N·m {kgf·cm, in·lbf}) Pull scale reading (N {kgf, lbf})
Rear axle
Wheel bearing play
Drive shaft
Shaft length g (mm {in})
(mm {in})
0.4—0.7 {4.0—8.0, 3.5—6.9} 5.9—10.7 {0.6—1.1, 1.4—2.4} 0.05—0.25 {0.002—0.010} 551.0—561.0 {21.7—22.0}
Right side
619.0—629.0 {24.4—24.7} (mm {in})
Backlash of side gear g and differential pinion (mm {in}) Drive pinion inion preload reload (N·m {kgf·cm, {kgf·cm in·lbf})
Differential
0 {0}
Left side
Pinion height
Backlash of drive pinion inion and ring gear (mm {in})
Front
–0.032—0.032 {–0.001—0.001}
Rear
–0.254—0.254 {–0.010—0.010}
Front
0—0.1 {0—0.003}
Rear
—
Front
0.9—1.3 {9.0—14.0, 7.9—12.1}
Rear
1.8—2.6 {18.0—27.0, 15.7—23.4}
Standard
0.09—0.11 {0.0036—0.0043} [Front] 0.12—0.20 {0.005—0.008} [Rear]
Minimum
0.05 {0.002} [Front], 0.12 {0.008} [Rear]
Allowance variation
0.07 {0.003} [Front], 0.08 {0.005} [Rear]
Grade
API service GL-5 Front
Viscosity y Standard
SAE 90 1.20 {1.27, 1.06} [MFW] 1.50 {1.59, 1.32} [RFW]
Front
—
Rear
1.40 {1.48, 1.23}
Grade LSD
Above-18C {0F}: SAE 90 Below-18C {0F}: SAE 80
—
Rear Capacity (L {US qt qt, lmp qt})
Oil
44
(mm {in})
Viscosity Capacity
1.85 {1.96, 1.63}
API service GL-6 SAE 90 (L {US qt, lmp qt})
1.40 {1.48, 1.23}
1.85 {1.96, 1.63}
CONTINUED
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TECHNICAL DATA STEERING SYSTEM Item Play
Steering wheel
(mm {in})
Effort
0—30 {0—1.18}
(N·m {kgf·cm, in·lbf})
Backlash
45 {460, 399} max.
(mm {in})
Worm shaft preload
Steering gear
(N·m {kgf·cm, in·lbf})
Grade Capacity
Power steering oil pump
7.8 {80, 69} max. 0 {0}
1.0—1.3 {10—14, 8.7—12.1}
0.7—1.2 {6.5—12.5, 5.7—10.8}
—
8.9—9.3 {90—95, 1280—1350}
API service GL-4, SAE 90
ATF M-III or equivalent (e.g. DexronRII)
0.34 {0.36, 0.30}
1.1 {1.2, 1.0}
—
8.9—9.3 {90—95, 1280—1350}
Gear housing pressure (MPa {kgf/cm2, psi}) Oil
Engine speed sensing power steering
Manual steering
(L {US qt, lmp qt})
Oil pump fluid pressure (MPa {kgf/cm2, psi})
BRAKING SYSTEM 42
Item
F2, G6
44
WL, WL Turbo
Brake pedal Brake pedal height
(mm {in})
L.H.D.: 214—219 {8.43—8.81} R.H.D.: 219—224 {8.63—8.81}
Brake pedal play
(mm {in})
3—8 {0.12—0.31}
Brake pedal-to-floor clearance
(mm {in})
105 {4.2} min.
Power brake unit Fluid pressure when pedal depressed at 196 N {20 kgf ,44 lbf}) (kPa {kgf/cm2, psi})
Power brake unit at 0 kPa {0 mmHg, 0 in Hg}
790 {8, 114} min.
Power brake unit at 66.7 kPa {500 mmHg, 19.7 in Hg}
8,240 {84, 1,200} min.
Vacuum pump Vacuum specification [In 20 seconds] [When engine speed 1,500 rpm] (kPa {mmHg, in Hg})
73.3 {550, 21.7}
Maximum vacuum [When engine speed 3,000 rpm] (kPa {mmHg, in Hg})
93.3 {700, 27.6}
Braking force control device Type
LSPV
Rear fluid pressure when front pressure is 4,900 kPa {50 kgf/cm2, 711 psi} (kPa {kgf/cm2, psi})
2,550 {26, 370}
Front disc brake Disc pad thickness limit
(mm {in})
2.0 {0.08}
Thickness limit
(mm {in})
22 {0.87}
Runout limit
(mm {in})
0.05 {0.002}
Brake lining thickness limit
(mm {in})
1.0 {0.04}
Drum maximum diameter
(mm {in})
Disc plate late
Rear drum brake 271.5 {10.68}
296.5 {11.67}
Parking brake Parking brake lever stroke [When pulled at 98 N {10 kgf, 22 lbf}] (notches)
1—7
Brake fluid Type
SAE J1703 or FMVSS116 DOT-3 or DOT-4
TD–12
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TECHNICAL DATA SUSPENSION Suspension Item
4 2 (mm {in})
Total toe-in Front wheel alignment li [unloaded*1]
4 4 3"3 {0.12"0.12}
0_16’ "16’
(Degree)
0_14’ "14’
Camber angle
+2_ 35_00’ –3_ 33_00’ +2_ –3_ 0_56’"30’
33_30’ +2_ –3_ 30_00’ +2_ –3_ 1_ 06’"30’
Caster angle*2
1_37’"45’
2_02’"45’
Inner
Maximum steering angle
Outer
Exposed thread of shock absorber piston
(mm {in})
Lower arm ball joint rotation torque (Pull scale reading)
(N {kgf, lbf})
Upper arm ball joint rotation torque (Pull scale reading)
(N {kgf, lbf})
Exposed thread of stabilizer control link bolt
6—8 {0.24—0.31} 14—44 {0.7—4.5, 1.6—9.9} 3.4—32.5 {0.4—3.2, 0.9—7.0}
(mm {in})
18—21 {0.71—0.82}
*1:
Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated positions. Adjust to the median when carrying out wheel alignment. *2: Difference between left and right must not exceed 45’.
Wheels and Tires Europe Item
4 2 Front
Size
Front Tire
195R14C-8PR
Rear
Air pressure ressure (kPa {kgf/cm2, psi}) Rear Wear limit
Up to full passenger Full loaded Up to full passenger Full loaded
Offset
(mm {in})
Pitch circle diameter
(mm {in})
(N·m {kgf·cm, in·lbf}) Runout limit (mm {in}) Imbalance limit
235/75R15 105S
200 {2.0, 28} 8 26} 180 {1 {1.8,
180 {1.8, 26}
205R16C-8PR 180 {1.8, 26}
8 26} 180 {1 {1.8, 220 {2.2, 31} 200 {2.0, 28}
450 {4.5, 63}
200 {2.0, 28} 180 {1.8, 26}
180 {1.8, 26}
250 {2.5, 35}
450 {4.5, 63}
1.6 {0.06} 14 5J 14 5 1/2J
Tightening torque Wheel and tire
205/75R14C
(mm {in})
Size Wh l Wheel
4 4
14 5 1/2J
15 6 1/2JJ
16 6JJ
25 {0.98}
35 {1.38}
40 {1.57}
139.7 {5.45} Standard wheel: 89—117 {9—12, 65—86} Styled wheel (16 6JJ): 118—147 {12—15, 87—108}
Horizontal
2.0 {0.078}
Vertical
1.5 {0.059} (g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}. D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim. D Do not use more than two balance weights on either side of the wheel.
CONTINUED
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TECHNICAL DATA General Item Size
42 Front
185R14C 185R14C8PR
Rear Unloade d (Up to full Front passenger )
Tire
Air pressure ressure (kPa {kgf/cm2, psi})
Loaded (Full loaded)
44
195R14C 195R14C8PR
180 {1.8, 26} 200 {2.0, 28}
205R16C 235/75R15 P235/75R1 P235/75R1 205R16C8PR 105S 5 105S 5 106S
180 {1.8, 26} 180 {1.8, 26} 200 {2.0, 28}
Unloade d (Up to full Rear passenger )
180 {1.8, 26}
Loaded (Full loaded) Wear limit
(mm {in})
Size Wheel (mm {in})
Pitch circle diameter
(mm {in})
Tightening torque (N·m {kgf·cm, in·lbf}) Wheel Horizontal and tire Runout limit (mm {in}) Vertical Imbalance limit
240 {2.4, 34}
260 {2.6, 36}
1.6 {0.06} 145J
Offset
250 {2.5, 35}
450 {4.5, 63}
145J 145 1/2J
40 {1.57}
166JJ
156 1/2JJ
35 {1.38}
25 {0.98}
139.7 {5.45} Standard wheel: 89—117 {9—12, 65—86} Styled wheel (166JJ): 118—147 {12—15, 87—108} 2.0 {0.078} 1.5 {0.059}
(g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}. D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim. D Do not use more than two balance weights on the inner or outer side of the wheel.
BODY ELECTRICAL SYSTEM Item Headlight
Exterior light bulb capacity ca acity
Interior light bulb capacity
(W)
(W)
Specification High beam/Low beam*
60/552
Parking light
52
Front turn light
212
Brake light/taillight
21/52
Rear turn light
212
Back-up light
212
Rear fog light
211
License plate light
52
Interior light
Stretch cab, Double cab
101
Regular cab
81
Instrument cluster illumination
3.44
CONTINUED
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TECHNICAL DATA
Warning and indicator light bulb capacity
(W)
Oil pressure warning light
1.41
Generator warning light
1.41
Sedimentor warning light
1.41
Brake system warning light
1.41
Rear window defroster indicator light
1.41
Glow indicator light
1.41
High beam indicator light
1.41
Turn indicator light
1.42
Air bag system warning light
1.41
44 indicator light
1.41
LOCK indicator light
1.41
*: Also remains illuminated when high beam turned on. HEATER AND AIR CONDITIONER SYSTEMS Specification
Item Refrigerant
Regular amount Lubricating oil
A/C compressor com ressor
G6, WL (g {oz}) Sealed volume (ml {cc, fl oz})
Magnetic clutch clearance (mm {in})
F2 550 {19.4} 180 {180, 6.08}
0.35—0.75 {0.014—0.029}
0.3—0.6 {0.012—0.023}
CONTINUED
TD–15
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SPECIAL TOOLS SPECIAL TOOLS.............................................. ST-1 ENGINE ........................................................ ST-1 LUBRICATION SYSTEM ............................... ST-1 COOLING SYSTEM ...................................... ST-2 FUELAND EMISSION CONTROL SYSTEMS ................................. ST-2 CLUTCH ....................................................... ST-2 PROPELLER SHAFT .................................... ST-3
FRONT AND REAR AXLES ......................... ST-3/5 STEERING SYSTEM ...................................ST-6 BRAKING SYSTEM ......................................ST-7 SUSPENSION ..............................................ST-7 BODY ...........................................................ST-7 BODY ELECTRICAL SYSTEM .....................ST-8 HEATER AND AIR CONDITIONER SYSTEMS ......................ST-8
SPECIAL TOOLS
CONTINUED
ENGINE 49 S013 1A1
49 9200 020A
49 S011 103
Compression gauge set
Belt tension gauge
Oil seal installer
49 8010301
49 S010 001
49 S011 102A
Oil seal installer
Oil seal installer
Crankshaft lock tool
49 B025 001
49 G033 107A
49 S120 710
Body
Dust cover installer
Coupling flange holder
49 P005 204
49 H011 101A
Oil seal installer
Crankshaft lock tool
—
LUBRICATION SYSTEM 490187280
49 G014 001 Oil filter wrench
Oil pressure gauge
—
CONTINUED
ST-1
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SPECIAL TOOLS COOLING SYSTEM 49 9200 145 —
Radiator cap tester adapter set
—
FUEL AND EMISSION CONTROL SYSTEMS 49 8120 215B
49L018901
Pulley puller
Injector checker
49H01S9A1A
Self-diagnosis checker 49 B019 9A0
499140074
System selector
Cam lift measuring device
Program card
1
49 T088 0A3* 2 49 T088 0A5* NGS set
SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031 E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)
• • • • • • •
49 T088 037B (English & Danish) 49 T088 038B (English & Norwegian) 49 T088 039B (English & Czech) 49 T088 041 B (English & Greek) 49 T088 042B (English & Hungarian) 49 T088 043B (English & Polish) 49 T088 044B (English & Spanish) 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only CLUTCH 49 0259 770B
49 E011 1A0
Flare nut wrench
Ring gear brake set
49 SE01 310A Clutch disc centering tool
49 1285 071 Needle bearing puller
—
—
CONTINUED
ST-2
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SPECIAL TOOLS PROPELLER SHAFT 49 0259 440
49 S 120 440
Mainshaft holder
Mainshaft holder
—
FRONT AND REAR AXLES 49 T028 3A0
49 T028 303
49 T028 304
Ball joint puller set
Body (Part of 49 T028 3A0)
Attachment (Part of 49 T028 3A0)
49 H033 101
49 B025 001
49 F019 001
Bearing remover
Body
Oil seal installer
49 S231 635
49 S231 660
49 S033 108
Front hub locknut wrench
Needle bearing puller
Bearing installer
49 S033 107
49 S033 106
49 F027 007
Oil seal installer
Oil seal installer
Attachment ∅72
49 F027 005
49 S120 645A
49 0603 635A
Attachment ∅62
Rear shaft holder
Rear shaft nut wrench
49 S 120 748
49 F027 004
49 U027 003
Attachment
Attachment ∅80
Oil seal installer
CONTINUED
ST-3
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SPECIAL TOOLS 49 H025 001
49 M005 561
49 0727 570
Bearing installer
Differential hanger carrier
Pinion height gauge body
49 8531 565
49 0305 555
49 0259 720
Drive model pinion
Gauge block
Differential side bearing adjust nut wrench
49 0839 425C
49 F027 005
49 S120 710
Bearing puller set
Attachment ∅62 (Part of 49 F027 0A1)
Coupling flange holder
49 H027 002
49 G030 795
49 G030 338
Bearing remover
Oil seal installer
Attachment E
49 F401 331
49 S026 2A1
49 S026 204
Body (Part of 49 F401 330B)
Rear shaft bearing puller
Plate (Part of 49 S026 2A1)
49 S026 205
49 S026 208
Rod (Part of 49 S026 2A1)
Attachment (Part of 49 S026 2A1)
49 W027 0A0
49 W027 001
49 U027 004
Oil seal installer set
Body (Part of 49 W027 0A0)
Oil seal remover
49 M005 795
49 U027 005
49 U027 006
Oil seal installer
Bearing installer
Bearing installer
49 0710 520 Bearing puller
CONTINUED ST-4
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SPECIAL TOOLS 49 U027 007
49 F028 204
Oil seal installer
49 0813 215A Tubular dowel puller
49 M005 796
49 U027 0A0
49 UN27 003
Body (Part of 49 M005 795)
L.S.D. replacer set
Bushing installer
Collar A
49 UN27 004
49 U027 008
49 F027 009
Collar B
Gauge block
Attachment ∅68 & ∅77
49 U027 009
49 UB71525
49 U027 010
Oil seal installer
Bearing installer
Bearing installer
49 0107 680A
49 U027 011
49 U027 012
Engine stand
Shaft (Part of 49 U027 0A0)
Attachment A (Part of 49 U027 0A0)
49 U027 013
49 U027 014
Attachment B (Part of 49 U027 0A0)
Bolt (Part of 49 U027 0A0)
—
CONTINUED
ST-5
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SPECIAL TOOLS STEERING SYSTEM 49 T028 3A0
49 T028 303
49 T028 304
Ball joint puller set
Body (Part of 49 T028 3A0)
Attachment (Part of 49 T028 3A0)
491232670A
49 1232 672
49 1232 673
Power steering gauge set
Gauge (Part of 49 1232 670A)
Valve body (Part of 49 1232 670A)
49 H002 671
49 0180 510B
49 U032 3A0
Adapter
Preload measuring attachment
Pitman arm puller
49 B032 304
491243785A
49 U034 209
Adapter
Dust boot installer
Clip guide
49 U032 201
49 G032 354
49 G032 3A4
Locknut wrench
Adjust wrench
Power steering gauge adapter set
CONTINUED
ST-6
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SPECIAL TOOLS BRAKING SYSTEM 49 U043 0A0
49 U043 004
49 U043 005
Oil pressure gauge set
Oil pressure gauge (Part of 49 U043 0A0)
Joint (Part of 49 U043 0A0)
49 U043 006
49 0259 770B
49 B043 001
Hose (Part of 49 U043 0A0)
Flare nut wrench
Adjust gauge
49 0221 600C
49 E043 003A
49 0208 701 A
Disc brake expand tool
Turning lock tool
Boot air out tool
49 B043 004 Socket wrench
—
—
SUSPENSION 49 T028 3A0
49 0180 510B
49 U034 208
Ball joint puller set
Preload measuring attachment
Clip guide
49 UB39 615
49 U034 2A0
49 U034 209
Bushing puller & installer set
Lower arm bushing puller & installer set
Clip guide
BODY 49 0305 870A
49 0259 866A
Window tool set
Window inserting tool
—
CONTINUED
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SPECIAL TOOLS BODY ELECTRICAL SYSTEM 49 H066 002
49 D066 002
49 0839 285
Deployment tool
Adapter harness
Fuel And Thermometer checker (OLD)
49 N088 0A0
49 D066 801 A
49 T088 0A3* 49 T088 0A5*2
Fuel And Thermometer checker (NEW)
Removing tool
Program card
1
NGS set
SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)
• • • • • • • •
49 T088 037B (English & Danish) 49 T088 038B (English & Norwegian) 49 T088 039B (English & Czech) 49 T088 041 B (English & Greek) 49 T088 042B (English & Hungarian) 49 T088 043B (English & Polish) 49 T088 044B (English & Spanish) 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only HEATER AND AIR CONDITIONER SYSTEMS 49 C061 0A0A
49 C061 012
49 C061 013
Manifold gauge set (R-134a)
Anti-back flow valve (R-134a)
Gas leak tester (R-134a)
49 D066 801A
49 H061 005
Removing tool
Attachment
—
ST-8
RANG.DRFT.REPAIR MANUAL
VIEW MAIN INDEX TO MODEL INDEX
Ranger / Drifter Repair Manual FOREWORD This Manual has been prepared to provide information covering normal service repairs and maintenance for the RANGER / DRIFTER SERIES. As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information.
Ford/Mazda Motor Company
WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford/Mazda-trained technicians in mind. This manual may be useful to non-Ford/Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are excepted at least to know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools, which are not recommended by Ford/Mazda Motor Corporation, must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford/Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation. Parts should be replaced with genuine Ford/Mazda replacement parts or with parts, which match the quality of genuine Ford/Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. Ford/Mazda Motor Corporation is not responsible for any problems, which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts, or not being aware of any revision of this manual.
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CONTENTS Title
Section
General Information
Ranger / Drifter Repair Manual
G6 Engine
B1
F8/FE WL, WL Turbo
B2
F2
B3
Lubrication System
D
Cooling System
E
Fuel and Emission Control Systems
APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page.
GI GI
G6
F1
WL, WL Turbo
F2
F2 CIS
F3
F2 CARB
F4
Engine Electrical System
G
Clutch
H
Manual Transmission
M15M–D M15MX–D R15M–D R15MX–D
J2
Transfer
J3
J1
Propeller Shaft
L
Front and Rear Axles
M
Steering System
N
Braking System
P
Suspension
R
Body
S
Body Electrical System
T
Heater and Air Conditioner Systems
U
Technical Data
TD
Special Tools
ST ST
1999 Ford/Mazda Motor Company All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford/Mazda Motor Company. PRINTED IN JAPAN, JAN.1999 F161–10–99A
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VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs. JMZ JMZ JMZ
UN1B320W UN8B320W UN8F420W
100001– 100001– 100001–
European specs. JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ
UN1*620W UN1*62WW UN1*320W UN1*32WW UN8*720W UN8*72WW UN8*320W UN8*32WW
100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001–
General specs. (L.H.D.) MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7
UNY02100 UNY021WW UNYOW100 UNYOW1 WW UN2*6*00 UN2*6*WW UN3*6*00 UN3*6*WW UN2*2*00 UN2*2*WW
100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001– 100001–
General specs. (R.H.D.) MM6 UNY02100 MM6 UNYOW100
100001– 100001–
RELATED MATERIALS B Series Training Manual .......................................... 3333-10-99A Engine Workshop Manual WL, WL Turbo ................ 1532-10-96C Engine Workshop Manual G6 .................................... 1640-10-99A Engine Workshop Manual F2 .................................... 1641-10-99A Manual Transmission Workshop Manual M15M-D M15MX-D .............................................................. 1645-10-99A
Manual Transmission Workshop Manual R15M-D R15MX-D.................................................... 1642-10-99A B Series Wiring Diagrams (European, General specs. (L.H.D.)) ..................... 5449-10-99A B Series Wiring Diagrams (European, General specs. (R.H.D.)) .................... 5450-10-99A
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GENERAL INFORMATION HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . . SERVICING PROCEDURE . . . . . . . . . . . . . . . SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADVISORY MESSAGES . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES . . . . . . . . . . . . PROTECTION OF THE VEHICLE . . . . . . . . . . PREPARATION OF TOOLS AND MEASURING EQUIPMENT . . . . . . . . . . . . . . SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . DISCONNECTION OF THE NEGATIVE BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION DURING REMOVAL, DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF PARTS . . . . . . . . . . . . . . CLEANING OF PARTS . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER PARTS AND TUBING . . . . . . . . . . . HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . . VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GI-1 GI-1 GI-1/2 GI-3 GI-3 GI-3/6 GI-6 GI-7 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8/9 GI-9 GI-9 GI-9 GI–19 GI–19 GI–10 GI–10
HOW TO USE THIS MANUAL RANGE OF TOPICS This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment Simple operations which can be performed easily just by looking at the vehicle, such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.
DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . GI–10 INSTALLATION OF RADIO SYSTEM . . . . . . . . GI–10 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . GI–11 ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . GI–11 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–11/13 ELECTRICAL TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–13 JACKING POSITIONS . . . . . . . . . . . . . . . . . . . . . . GI–14 VEHICLE LIFT (2 SUPPORTS) POSITIONS . . . GI–14 SAFETY STAND POSITIONS . . . . . . . . . . . . . . . GI–14 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–15 TOWING HOOKS . . . . . . . . . . . . . . . . . . . . . . . . GI–16 TIEDOWN HOOKS . . . . . . . . . . . . . . . . . . . . . . . GI–16 IDENTIFICATION NUMBER LOCATIONS . . . . . GI–16 VEHICLE IDENTIFICATION NUMBER . . . . . . GI–16 ENGINE IDENTIFICATION NUMBER . . . . . . . GI–16 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI–17/19 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–19 PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI-20 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20
SERVICING PROCEDURE Inspection, Adjustment The procedures for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.
SHOWS PROCEDURE ORDER FOR SERVICE
SHOWS TIGHTENING TORQUE SPECIFICATIONS
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HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part. SHOWS SERVICE ITEM (S)
Procedure
Indicates any relevant references which need to be followed during installation.
“Removal/Installation” Portion “Inspection After Installation” Portion
SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION
SHOWS PROCEDURE ORDER FOR SERVICE Install the parts by performing Steps 1—3 in reverse order
SHOWS APPLICATION POINTS OF GREASE, ETC. SHOWS TIGHTENING TORQUE SPECIFICATIONS
SHOWS EXPENDABLE PARTS
SHOWS DETAILS SHOWS TIGHTENING TORQUE UNITS
SHOWS THERE ARE REFERRAL NOTES FOR SERVICE
SHOWS SPECIAL SERVICE TOOL (SST) NO.
SHOWS REFERRAL NOTES FOR SERVICE
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HOW TO USE THIS MANUAL SYMBOLS There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such materials during service. Symbol
Meaning
TROUBLESHOOTING PROCEDURE Basic Flow of Troubleshooting
Kind SECTION F ONLY
Apply oil
R
SST
Appropriate new engine oil or gear oil
Apply brake fluid
Appropriate new brake fluid
Apply automatic transaxle/ transmission fluid
Appropriate new automatic transaxle/ transmission fluid
Apply grease
Appropriate grease
Apply sealant
Appropriate sealant
Apply petroleum jelly
Appropriate petroleum jelly
Replace part
O-ring, gasket, etc.
Use SST
Appropriate SST
ADVISORY MESSAGES You’ll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual.
ACTUAL TROUBLESHOOTING PROCEDURES SECTION K ONLY
IF MENTIONED
SECTION F ONLY
On-board diagnosis The service codes are important hints for repairing malfunctions that are difficult to simulate. By following the service code, perform the inspection to quickly and accurately diagnose the malfunction. The self-diagnostic function is used during inspection. When a service code is shown, specifying the cause of a malfunction, continue the inspection according to the items indicated by the self-diagnostic function. Engine tune-up (Section F) Any necessary adjustments are made after starting the engine.
Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored.
Basic inspection (Section K) The basic inspection is performed to quickly narrow down the possible causes after a malfunction occurs regardless of the symptoms. ST The basic inspection is performed to also locate the region of many malfunction symptoms.
Caution A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored.
Diagnostic index The diagnostic index lists the symptoms of the malfunctions. Select the symptoms pertaining or most closely pertaining to the actual malfunction.
Note A Note provides added information that will help you to complete a particular procedure.
Quick diagnosis chart (If mentioned) The quick diagnosis chart lists the diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction.
Specification The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
Symptom troubleshooting Symptom troubleshooting quickly determines the location of the malfunction according to the type of symptoms.
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HOW TO USE THIS MANUAL Procedures For Use Using the basic inspection
Perform the basic inspection before the symptom troubleshooting. Perform each step in the order shown. The reference column lists the location of the detailed procedure for each basic inspection. Although inspection and adjustment are performed as according to the procedures referred to in the reference column, if the cause of the malfunction is discovered during the basic inspection, continue the procedures as indicated in the remarks column. SHOWS INSPECTION ORDER
SHOWS ITEM NAMES FOR THE DETAILED PROCEDURES
SHOW POINTS REQUIRING ATTENTION IN REGARD TO INSPECTION RESULTS
Perform malfunction diagnosis according to No. 26 “HOLD INDICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON” or No. 27 “HOLD INDICATOR LIGHT ILLUMINATES WHEN HOLD SWITCH IS NOT TURNED ON”
Using the diagnostic index The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting. The exact malfunction symptoms can be selected using the details.
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HOW TO USE THIS MANUAL Using the quick diagnosis chart The chart lists the relation between the symptoms and cause of the malfunction. The chart is effective in quickly narrowing down the relation between the symptoms and cause of the malfunction and specifying the region of the common cause when multiple malfunction symptoms occur. The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart.
PARTS WHICH MAY BE THE CAUSE OF PROBLEMS ENGINE QUICK DIAGNOSTIC CHART
PART WHICH MAY BE THE SYMPTOM
CHOOSE THE ACTUAL SYMPTOM
ST
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HOW TO USE THIS MANUAL Using the symptom troubleshooting Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for each
trouble symptom.
TROUBLESHOOTING HINTS describes possible point of malfunction.
TROUBLE SYMPTOM
STEP shows the order of troubleshooting.
ACTION describes the appropriate action to take as a result (Yes/No) of INSPECTION.
INSPECTION describes an inspection (method) to quickly determine the failed part.
Reference page(s) for the detailed procedure to perform INSPECTION is shown. How to perform ACTION is described in the relative material shown.
TEXT SEQUENCE The text sequence is as indicated by the arrows shown below. Example:
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UNITS
UNITS
The actual converted values for 2.7 kgf/cm2 are
Electric current
A (ampere)
Electric power
W (watt)
Electric resistance
(ohm)
Electric voltage
V (volt)
Length
264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2.7 is used as a lower limit, so its converted values are rounded up to 270 and 39.
mm (millimeter) in (inch) kPa (kilo pascal)
Negative pressure
mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal)
Positive pressure
kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch)
Number of revolutions
rpm (revolutions per minute) N·m (Newton meter) kgf·m (kilogram force per meter)
Torque
kgf·cm (kilogram force per centimeter) ft·lbf (foot pound) force in·lbf (inch pound) force L (liter) US qt (U.S. quart) Imp qt (Imperial quart)
Volume
ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce)
Weight
g (gram) oz (ounce)
Conversion to SI Units (Système International d’Unités) All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values.
ST
Rounding off Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and lower limits When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications: 210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi} 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
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FUNDAMENTAL PROCEDURES REMOVAL OF PARTS While correcting a problem, try also to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering.
FUNDAMENTAL PROCEDURES PROTECTION OF THE VEHICLE Always be sure to cover fenders, seats, and floor areas before starting work.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT Be sure that all necessary tools and measuring equipment are available before starting any work.
DISASSEMBLY If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
SPECIAL SERVICE TOOLS Use special tools when they are required.
INSPECTION DURING REMOVAL, DISASSEMBLY When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.
DISCONNECTION OF THE NEGATIVE BATTERY CABLE Before beginning any work, turn the ignition switch to LOCK, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS unit to deplete its stored power. Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is neccessary to verify those memories before disconnecting the cable.
ARRANGEMENT OF PARTS All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
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FUNDAMENTAL PROCEDURES Oil should be applied to the moving components of
parts. Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before reassembly.
CLEANING OF PARTS All parts to be reused should be carefully and thoroughly cleaned using the appropriate method. SXU00012
Warning Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
ADJUSTMENT Use suitable gauges and/or testers when making adjustments.
SXU00013
RUBBER PARTS AND TUBING Prevent gasoline or oil from spilling on rubber parts or tubing.
REASSEMBLY Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones: 1
Oil seals
2
Gaskets
3
O-rings
4
Lockwashers
5
Cotter pins
6
Nylon nuts
ST SXU00014
HOSE CLAMPS When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.
SXU00011
Sealant, a gasket, or both should be applied to the
specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks.
SXU00015
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FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM TORQUE FORMULAS When using a torque wrench-SST combination, the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque using the following formulas. Choose the formula that applies to you. Torque Unit
Formula
kgf·m
kgf·m [L/(L+A) ]
kgf·cm
kgf·cm [L/(L+A) ]
ft·lbf
ft·lbf [L/(L+A) ]
in·lbf
in·lbf [L/(L+A) ]
A: The length of the SST past the torque wrench drive. L: The length of the torque wrench.
INSTALLATION OF RADIO SYSTEM If a radio system is installed improprerly or if a highpowered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions. 1. Install the antenna at the farthest point from control modules. 2. Install the antenna feeder as far as possible from the control modules harness, and perpendicular to wiring harnesses. 3. Do not install a high-powered radio system. 4. After installing the radio system, start and idle the engine, then confirm that the engine is not influenced by output waves from the system.
SXU00016
VISE When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
SXU00017
DYNAMOMETER When test-running a vehicle on dynamometer : Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle uncluttered. Watch the water temperature gauge.
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ELECTRICAL SYSTEM Disconnecting Connectors When disconnecting two connectors, grasp the connectors, not the wires.
ELECTRICAL SYSTEM ELECTRICAL PARTS Battery Cable Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable.
SXU00020
Connectors can be disconnected by pressing or
pulling the lock lever as shown. SXU00018
Wiring Harness To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
SXU00021
Locking Connector When locking connectors, listen for a click that will indicate they are securely locked.
CONNECTORS Data Link Connector Insert the probe into the service hole when connecting a jumper wire to the data link connector. Caution Inserting a jumper wire probe into the data link connector terminal may damage the terminal.
SXU00022
Inspection 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring harness side.
SXU00019
SXU00023
2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.
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ELECTRICAL SYSTEM Caution To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal.
SXU00027
SXU00024
Terminals Inspection Pull lightly on individual wires to check that they are secured in the terminal.
Wiring Harness Wiring color codes Two-color wires are indicated by a two-color code symbol. The first letter indicates the base color of the wire and the second the color of the stripe. CODE
COLOR
CODE
COLOR
B
Black
O
Orange
BR
Brown
P
Pink
G
Green
R
Red
GY
Gray
V
Violet
L
Blue
W
White
LB
Light Blue
Y
Yellow
LG
Light Green
B/R
BR/Y BLACK
SXU00025
Replacement Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. Insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down, pull the terminal out from the connector.
RED
BROWN
YELLOW
SXU00028
Fuse Replacement 1. When replacing a fuse, be sure to replace it with one of the specified capacity. If a fuse again fails after it has been replaced, the circuit probably has a short and the wiring should be checked. 2. Be sure the negative battery terminal is disconnected before replacing a main fuse.
TYPE A TYPE B
SXU00026
Sensors, Switches, and Relays Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.
SXU00029
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ELECTRICAL SYSTEM 3. When replacing a pullout fuse, use the fuse puller. PULLER
Ohmmeter The ohmmeter is used to measure the resistance between two points in a circuit, and to check for continuity and short circuits. Caution Do not connect the ohmmeter to any circuit to which voltage is applied. This will damage the ohmmeter. POWER SOURCE LINE
FUSE SXU00030
ELECTRICAL TROUBLESHOOTING TOOLS Jumper Wire A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch. Caution Do not connect a jumper wire from the power source line to a body ground; this may cause burning or other damage to wiring harnesses or electronic components.
GROUND LINE
OHMMETER
SXU00034
SXU00032
Voltmeter The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (–) probe (black lead wire) to a body ground. VOLTMETER
POWER SOURCE LINE
BLACK LEAD
RED LEAD GROUND
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JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS, SAFETY STAND POSITIONS REAR
JACKING POSITIONS Warning Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle after it has been lifted. FRONT
SAFETY STAND POSITIONS FRONT
REAR
REAR
VEHICLE LIFT (2 SUPPORTS) POSITIONS FRONT
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TOWING (With Manual Transmission) If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use wheel dollies.
TOWING Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed.
(With Automatic Transmission) If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies. If all four wheels are on the ground, the vehicle may be towed only forward. Do not exceed 45 km/h (28 mph) and a distance of 15 km (9.3 miles); you could damage the transmission.
Wheel dollies
If speed must exceed 45 km/h (28 mph) or a towing distance of 15 km (9.3 miles), use one of these methods: Place the rear wheels on dollies. Tow with the rear wheels off the ground. Disconnect the propeller shaft.
Wheel dollies
If the transmission or rear axle is inoperative, tow with the rear wheels off the ground. Caution Follow these instructions when towing the vehicle with all wheels on the ground or with the front wheels on the ground and the rear wheels raised.
Caution Do not tow with sling-type equipment. This could damage your vehicle. Use wheel-lift or flatbed equipment.
(44 Model) 1. Put the transfer case in 2H. 2. Set the transfer case at 2H and the hubs at FREE. (All Models) 1. Set the transmission in neutral. 2. Turn the engine switch to ACC position. 3. Release the parking brake. Remember that power assist for the brakes
and steering will not be available when the engine is not running. If your Ford/Mazda has 44, change to 2-wheel drive before having the vehicle towed. If this is not possible, tow with all four wheels raised.
CONTINUED
GI–15
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TOWING, IDENTIFICATION NUMBER LOCATIONS TOWING HOOKS Caution The towing hooks should be used only in an emergency (e.g. to get the vehicle out of a ditch or a snow bank). When using the towing hooks, always pull the cable or chain in a straight direction with respect to the hook. Apply no sideways force.
IDENTIFICATION NUMBER LOCATIONS VEHICLE IDENTIFICATION NUMBER
FRONT 44
ENGINE IDENTIFICATION NUMBER G6
TIEDOWN HOOKS Caution Do not use the hook loops under the front for towing. They are designed ONLY for tying down the vehicle when it is being transported. Using them for towing will damage the bumper.
WL, WL Turbo
FRONT 42
F2 CIS F2 CARB 44
CONTINUED
GI–16
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NEW STANDARDS
NEW STANDARDS Following is a comparison of the previous standard and the new standard. New Standard Abbreviation AP
Name
Previous Standard Abbreviation
Accelerator Pedal
—
Accelerator Pedal
ACL
Air Cleaner
—
Air Cleaner
A/C
Air Conditioning
—
Air Conditioning
Barometric Pressure
—
Atmospheric Pressure
Battery Positive Voltage
VB
Battery Voltage
—
Brake Switch
—
Stoplight Switch
—
Calibration Resistor
—
Corrected Resistance
Camshaft Position Sensor
—
Crank Angle Sensor
CAC
Charge Air Cooler
—
Intercooler
CLS
Closed Loop System
—
Feedback System
CTP
Closed Throttle Position
—
Fully Closed
Closed Throttle Position Switch
—
Idle Switch
—
Clutch Position
BARO B
CMP sensor
— CPP
Clutch Pedal Position
CIS
Continuous Fuel Injection System
CS sensor CKP sensor
Control Sleeve Sensor
EGI CSP sensor
Remark
Name
#6
Electronic Gasoline Injection System Control Sleeve Position Sensor
Crankshaft Position Sensor
—
Crank Angle Sensor 2
DLC
Data Link Connector
—
Diagnosis Connector
DTM
Diagnostic Test Mode
—
Test Mode
DTC
#6
#1
Diagnostic Trouble Code(s)
—
Service Code(s)
DI
Distributor Ignition
—
Spark Ignition
DLI
Distributorless Ignition
—
Direct Ignition
Electronic Ignition
—
Electronic Spark Ignition
ECT
Engine Coolant Temperature
—
Water Thermo
EM
Engine Modification
—
Engine Modification
—
Engine Speed Input Signal
—
Engine RPM Signal
EVAP
Evaporative Emission
—
Evaporative Emission
EGR
Exhaust Gas Recirculation
—
Exhaust Gas Recirculation
FC
Fan Control
—
Fan Control
FF
Flexible Fuel
—
Flexible Fuel
4GR
Fourth Gear
—
Overdrive
Fuel Pump Relay
—
Circuit Opening Relay
#3
Fuel Cut Valve
#6
EI
— FSO solenoid
Fuel Shut Off Solenoid
FCV
GEN
Generator
—
Alternator
GND
Ground
—
Ground/Earth
HO2S
Heated Oxygen Sensor
—
Oxygen Sensor
Idle Air Control
—
Idle Speed Control
Incorrect Gear Ratio
—
—
IAC —
#2
With heater
#1: Diagnostic trouble codes depend on the diagnostic test mode #2: Controlled by the PCM #3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #6: Part name of diesel engine
CONTINUED
GI–17
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NEW STANDARDS
New Standard Name
Abbreviation
Previous Standard
—
Injection Pump
FIP
Fuel Injection Pump
—
Input/Turbine Speed Sensor
—
Pulse Generator
IAT
Intake Air Temperature
—
Intake Air Thermo
KS
Knock Sensor
—
Knock Sensor
MIL
Malfunction Indicator Lamp
—
Malfunction Indicator Light
MAP
Manifold Absolute Pressure
—
Intake Air Pressure
MAF sensor
Mass Air Flow Sensor
—
Airflow Sensor
MFL
Multiport Fuel Injection
—
Multiport Fuel Injection
OBD
On-Board Diagnostic
—
Diagnosis/Self-Diagnosis
OL
Open Loop
—
Open Loop
—
Output Speed Sensor
—
Vehicle Speed Sensor 1
OC
Oxidation Catalytic Converter
—
Catalytic Converter
O2S
Oxygen Sensor
—
Oxygen Sensor
PNP
Park/Neutral Position
—
Park/Neutral Range
—
Remark
Name
Abbreviation
#6
PCM Control Relay
—
Main Relay
PSP
Power Steering Pressure
—
Power Steering Pressure
PCM
Powertrain Control Module
ECU
—
Pressure Control Solenoid
—
Line Pressure Solenoid Valve
Pulsed Secondary Air Injection
—
Secondary Air Injection System
Pulsed injection
Pump Speed Sensor
—
NE Sensor
#6
Secondary Air Injection
—
Secondary Air Injection System
Injection with air pump
Secondary Air Pulse Valve
—
Reed Valve
Sequential Multipoint Fuel Injection
—
Sequential Fuel Injection
—
1–2 Shift Solenoid Valve
—
Shift A Solenoid Valve
—
2–3 Shift Solenoid Valve
—
Shift B Solenoid Valve
PAIR — AIR SAPV SFI —
Shift Solenoid A
—
Shift Solenoid B
—
Engine Control Unit
Shift Solenoid C
—
3–4 Shift Solenoid Valve
3GR
Third Gear
—
3rd Gear
TWC
Three Way Catalytic Converter
—
Catalytic Converter
Throttle Body
—
Throttle Body
Throttle Position Sensor
—
Throttle Sensor
TB TP sensor TCV
Timer Control Valve
TCC
Torque Converter Clutch
—
Lock-up Position
TCM
Transmission (Transaxle) Control Module
—
EC-AT Control Unit
—
Transmission (Transaxle) Fluid Temperature Sensor
—
ATF Thermosensor
TR
Transmission (Transaxle) Range
—
Inhibitor Position
TC
Turbocharger
—
Turbocharger
Vehicle Speed Sensor
—
Vehicle Speed Sensor
Voltage Regulator
—
IC Regulator
VSS VR
TCV
#4: Device that controls engine and powertrain #6: Part name of diesel engine
Timing Control Valve
#6 #4
#6
CONTINUED
GI–18
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NEW STANDARDS, ABBREVIATIONS
New Standard Abbreviation VAF sensor WU-TWC WOT
Name
Previous Standard Remark
Name
Abbreviation
Volume Air Flow Sensor
—
Air flow Sensor
Warm Up Three Way Catalytic Converter
—
Catalytic Converter
Wide Open Throttle
—
Fully Open
#5
#5: Directly connected to exhaust manifold
ABBREVIATIONS ACC . . . . . . . . . . . . . . ATDC . . . . . . . . . . . . . ATF . . . . . . . . . . . . . . . BTDC . . . . . . . . . . . . . CARB . . . . . . . . . . . . . ELR . . . . . . . . . . . . . . EX . . . . . . . . . . . . . . . FIP . . . . . . . . . . . . . . . HI . . . . . . . . . . . . . . . . HLA . . . . . . . . . . . . . . IG . . . . . . . . . . . . . . . . IN . . . . . . . . . . . . . . . . INT . . . . . . . . . . . . . . . LH . . . . . . . . . . . . . . . . L.H.D. . . . . . . . . . . . . . LO . . . . . . . . . . . . . . . LSD . . . . . . . . . . . . . . LSPV . . . . . . . . . . . . . M ................ MAX . . . . . . . . . . . . . . MFW . . . . . . . . . . . . . MIN . . . . . . . . . . . . . . P/S . . . . . . . . . . . . . . . RFW . . . . . . . . . . . . . . RH . . . . . . . . . . . . . . . R.H.D. . . . . . . . . . . . . SAS . . . . . . . . . . . . . . SST . . . . . . . . . . . . . . TNS . . . . . . . . . . . . . . 2WD . . . . . . . . . . . . . . 4WD . . . . . . . . . . . . . . 42 . . . . . . . . . . . . . . 44 . . . . . . . . . . . . . .
Accessories After top dead center Automatic transmission fluid Before top dead center Carburetor Emergency locking retractor Exhaust Fuel injection pump High Hydraulic lash adjuster Ignition Intake Intermittent Left hand Left hand drive Low Limited slip differential Load sensing proportioning valve Motor Maximum Manual freewheel Minimum Power steering Remote freewheel Right hand Right hand drive Sophisticated air bag sensor Special service tool Tail number side lights 2 wheel drive 4 wheel drive 4 wheel – 2 drive 4 wheel – 4 drive
CONTINUED
GI–19
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PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. UNDER BONNET-ENGINE RUNNING AT OPERATING TEMPERATURE CHECK the following items: Operation of dashpot Initial ignition timing Injection timing Idle speed Operation of throttle position sensor
EXTERIOR INSPECT and ADJUST, if necessary, the following items to the specifications: Glass, exterior bright metal and paint for damage Wheel lug nuts Tire pressures All weatherstrips for damage or detachment Operation of bonnet release and lock Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps UNDER BONNET-ENGINE OFF INSPECT and ADJUST, if necessary, the following items to the specifications: Fuel, coolant and hydraulic lines, fittings, connections and components for leaks Engine oil level Power steering fluid level (if equipped) Brake and clutch master cylinder fluid levels Windshield washer reservoir fluid level Radiator coolant and specific gravity Tightness of water hose clamps Tightness of battery terminals, electrolyte level and specific gravity Drive belt tensions Accelerator cable and linkage for free movement CLEAN the spark plugs INTERIOR INSTALL the following parts Fuse for accessories CHECK the operation of the following items: Seat controls (sliding and reclining) and headrest Door locks Ignition switch (Engine switch) and steering lock All lights including warning and indicator lights Horn, windshield wipers and washers (if equipped) Wiper blades performance Clean the wiper blades and windshield Antenna Cigarette lighter and clock Tilt steering (if equipped) Air conditioner at various modes (if equipped) CHECK the following items: Presence of spare fuse Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: Operation and fit of windows Pedal height and free play of brake and clutch pedals Parking brake
ON HOIST CHECK the following items: Operation of freewheel hubs Manual transmission oil level Transfer oil level Front differential oil level Rear differential oil level Underside fuel, coolant and hydraulic lines, fittings, connections and components for leaks Tires for cuts or bruises Steering linkage, suspension, exhaust system and all underside hardware for looseness or damage ROAD TEST CHECK the following items: Brake operation Clutch operation Steering control Operation of meters and gauges 3 Squeaks, rattles or unusual noise Engine general performance Emergency locking retractors Operation of transfer AFTER ROAD TEST REMOVE seat and floor mat protective covers CHECK for necessary owner's information material, tools and spare tire in vehicle
Gl-20
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ENGINE (G6) DRIVE BELT ................................................................B1-1 DRIVE BELT INSPECTION ................................B1-1/2 DRIVE BELT ADJUSTMENT .............................B1-2 COMPRESSION INSPECTION ..................................B1-2 TIMING CHAIN .............................................................B1-3 TIMING CHAIN REMOVAL/ INSTALLATION ....................................................B1-3/5 CYLINDER HEAD GASKET ..................................B1-6 CYLINDER HEAD GASKET REPLACEMENT .................................................B1-6/9 HYDRAULIC LASH ADJUSTER (HLA).................B1-10 DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has been stopped. Apply pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys.
HLA REMOVAL/INSTALLATION .....................B1-10/11 HLA TROUBLESHOOTING .............................B1-12 FRONT OIL SEAL.......................................................B1-13 FRONT OIL SEAL REPLACEMENT.................B1-13 REAR OIL SEAL .........................................................B1-14 REAR OIL SEAL REPLACEMENT ..................B1-14 ENGINE .......................................................................B1-15 ENGINE REMOVAL/INSTALLATION ..............B1-15/16 ENGINE DISASSEMBLY/ASSEMBLY ..............B1-17
Deflection Drive belt Generator P/S A/C
mm {in} *New
Used
10.0—12.0 {0.40—0.47} 6.6—7.2 {0.26—0.28}
12.0—14.0 {0.48—0.55} 7.2—8.0 {0.29—0.31}
8.5—10.0 {0.34—0.39}
10.0—11.5 {0.40—0.45}
*: A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has been stopped. Using the SST, check the belt tension between any two pulleys.
N {kgf, Ibf} Drive belt Generator P/S
A/C
*New
Used
491-588 {50-60,110-132} 412—470 {42-48,93—105}
393-490 {40-50,88-110} 354—402 {36-41, 80—90}
557—641 {56.7—65.4, 125—143}
471—556 {48.0—56.7, 106—124}
* A belt that has been on a running engine for less than five minutes.
CONTINUED
B1-1
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DRIVE BELT, COMPRESSION INSPECTION 2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten mounting bolts A and B and locknut C.
COMPRESSION INSPECTION Warning • When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during removal/installation of each component. 1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool off for about 10 minutes. 4. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 5. Disconnect the igniter connector. (Refer to section G, IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) 6. Remove the spark plugs. 7. Connect a compression gauge into the No.1 spark plug hole. 8. Fully depress the accelerator pedal and crank the engine. 9. Note the maximum gauge reading. 10. Inspect compression of each cylinder. Compression Item Standard Minimum Maximum difference between
kPa {kgf/cm2, psi} [rpm] Engine type G6 1255 {12.8, 182} [270] 882.6 {9.0, 128} [270] 196 kPa {2.0 kgf/cm 2, 28 psi}
11. If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. (2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required. (3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. 12. Disconnect the compression gauge. 13. Install the spark plugs. Tightening torque 15—22 N.m {1.5—2.3 kgf.m, 11—l6ft.lbf} 14. Connect the igniter connector. 15. Install the fuel pump relay.
CONTINUED B1-2
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TIMING CHAIN
TIMING CHAIN TIMING CHAIN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 4. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 5. Remove the cylinder head. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 6. Remove the water pump. (Refer to section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 7. Remove the oil pan. (Refer to section D, OIL PAN, OIL PAN REMOVAL/INSTALLATION.) 8. Disconnect the oil strainer stay. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Start the engine and check for engine oil and engine coolant leakage.
1
A/C compressor bracket
10
2 3 4
Generator strap P/S oil pump bracket Generator bracket
11
5 6
Pulley lock bolt ☞ Removal/Installation Note Crankshaft pulley
13
7
Chain cover
8
Spacer
9
Balancer chain guide ☞ Installation Note
12
14 15
Balancer chain, idler sprocket, crankshaft sprocket ☞ Installation Note Timing chain, timing sprocket, camshaft sprocket ☞ Installation Note Chain adjuster ☞ Installation Note Key Timing chain lever ☞ Installation Note Timing chain guide
CONTINUED B1-3
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TIMING CHAIN Pulley Lock Bolt Removal/Installation Note • Hold the crankshaft using the SST.
Timing Chain Lever Installation Note • Install the chain lever and verify that it moves smoothly in the direction indicated.
2. Assemble the camshaft sprocket to the timing chain so that the timing mark of camshaft sprocket is aligned with the white link of timing chain as shown.
3. Secure the camshaft sprocket and the timing chain with a wire to prevent disengagement. Balancer Chain, Idler Sprocket, Crankshaft Sprocket Installation Note 1. Install the crankshaft sprocket as shown.
2. Assemble the idler sprocket on to the idler shaft. Chain Adjuster Installation Note • Push the chain adjuster sleeve in (toward the left) and insert the pin as shown into the lever to hold the sleeve.
3. Set the balancer chain on the idler sprocket so that the timing mark of the idler sprocket is aligned with the brown link of the balancer chain as shown. Timing Chain, Timing Sprocket, Camshaft Sprocket Installation Note 1. Install the timing chain and timing sprocket so that the white link of the timing chain is aligned with the timing mark of the timing sprocket as shown.
CONTINUED B1-4
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TIMING CHAIN 4. Install the balancer chain so that the five alignment marks on the chain, sprocket and cylinder block align, and attach the idler sprocket to the cylinder block.
4. Loosen the chain guide C by adjusting bolt E. 5. Push the chain guide C with a force of 49 N {5.0 kgf, 11 Ibf} in the direction of the arrow, then pull back the chain guide 3.2—3.8 mm {0.13—0.14 in] and tighten the adjusting bolt E.
5. Hand-tighten the idler sprocket lock bolt. Balancer Chain Guide Installation Note 1. Install the chain guide A and B.
Note • The balancer chain must be replaced if chain guide C bottoms when adjusting. 6. Measure the timing chain slack. Specification Approx. 3.0 mm {0.12 in}
2. Install the chain guide C, and tighten the bolt D and hand-tighten the adjusting bolt E.
3. Tighten the idler sprocket lock bolt.
CONTINUED
B1-5
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CYLINDER HEAD GASKET
CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan. 5. Remove the front pipe. 6. Remove the air intake pipe and resonance chamber. 7. Disconnect the accelerator cable and bracket. 8. S. Disconnect the vacuum hoses, water hoses, and engine harness connectors. 9. Disconnect the fuel hoses. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the intake manifold bracket. 11. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 12. Remove the high-tension lead. (Refer to section G, IGNITION SYSTEM, HIGH-TENSION LEAD REMOVAL/INSTALLATION.) 13. Remove the spark plug. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Inspect for fuel leakage. 17. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 18. Start the engine and (1) check the pulleys and drive belt for runout and contact. (2) check the ignition timing and idle speed. (Refer to section F1, ENGINE TUNE-UP.)
CONTINUED
B1-6
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CYLINDER HEAD GASKET
1
Upper radiator hose
2
Cylinder head cover ☞ Installation Note
3
Distributor drive gear ☞ Removal Note ☞ Installation Note Camshaft sprocket ☞ Removal Note ☞ Installation Note
4
5
Cylinder head ☞ Removal Note ☞ Installation Note
6
Cylinder head gasket ☞ Installation Note
CONTINUED
B1-7
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CYLINDER HEAD GASKET Distributor Drive Gear Removal Note 1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
2. Verify that the camshaft sprocket mark is aligned with the horizontal surface on the cylinder head.
3. Remove the seal cover. 4. Hold the crankshaft using the SST.
5. Remove the lock bolt. Camshaft Sprocket Removal Note 1. Remove the service cover on the chain cover.
3. Secure the camshaft sprocket and the chain with a wire as shown.
4. Remove the camshaft sprocket off the camshaft dowel pin. Cylinder Head Removal Note 1. Remove the bolts A. 2. Loosen the cylinder head bolts a few turns in the order shown.
Cylinder Head Gasket Installation Note • Apply silicone sealant to the areas shown. Thickness Ø3.0 mm {0.12 in}
2. Push the chain adjuster sleeve in (toward the left) and insert a pin as shown into the lever hole to hold the sleeve.
CONTINUED B1-8
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CYLINDER HEAD GASKET Cylinder Head Installation Note 1. Tighten the cylinder head bolts a few turns in the order shown.
Distributor Drive Gear Installation Note 1. Install the distributor drive gear with a new washer and lock bolt. 2. Hold the camshaft with a screwdriver as shown.
2. Tighten the bolts A. Camshaft Sprocket Installation Note 1. Install the camshaft sprocket onto the camshaft dowel pin. 2. Remove the wire securing the camshaft sprocket and chain.
3. Tighten the lock bolt. 4. Apply silicone sealant to the areas shown.
3. Remove the retaining pin from the chain adjuster. 4. Install the service cover with a new gasket. Tightening torque 7.9—10.7 N.m {80—110 kgf.cm, 69.5—95.4 in.lbf}
5. Install the new seal cover. Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover are free of oil, water, and other foreign material. 2. Coat a new gasket with silicone sealant, and install it onto the cylinder head cover. 3. Apply silicone sealant to the cylinder head as shown.
4. Install the cylinder head cover.
CONTINUED
B1-9
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HYDRAULIC LASH ADJUSTER (HLA)
HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL / INSTALLATION •
Caution Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1. Disconnect the negative battery cable. 2. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 3. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Check the engine oil level, (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) 7. Start the engine and (1) check the engine oil. (2) check the idle speed, (Refer to section F1, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 8. Check the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1
Distributor drive gear ☞ CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Removal Note ☞ CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Installation Note
2
Rocker arm ☞ Removal Note & Installation Note
3
HLA ☞ Installation Note
CONTINUED B1-10
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HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Removal Note 1. Loosen the bolts a few turns in the order shown.
Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed. 3. Remove the rocker arm and shaft assembly together with the bolts. HLA Installation Note 1. Place each HLA in a container filled with clean engine oil. Caution • Do not push the pin too hard. It may damage the HLA. 2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.
Rocker Arm Installation Note Note • The intake side shaft has twice as many oil holes as the exhaust side shaft. 1. Assemble the rocker arm and shaft assembly as shown in the figure according to the cap number and mark.
2.
2. Install the rocker arm and shaft. 3. Tighten the bolts a few turns in the order shown.
3. Pour engine oil into the oil reservoir in the rocker arm.
4. Apply clean engine oil to HLA O-ring
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HYDRAULIC LASH ADJUSTER (HLA) HLA TROUBLESHOOTING Problem
Possible Cause
Action
1.
Noise when engine is started immediately after oil is changed.
2.
Noise when engine is started after sitting one day or more.
3.
Noise when engine is started after new HLA is installed.
Oil leakage in HLA
4.
Noise continues more than 10 minutes.
Insufficient oil pressure
Check oil pressure. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION)
Faulty HLA
Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HLA, HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Incorrect oil amount
Check oil level. (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) Replace new engine oil. (Refer to section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
5.
Noise during idle after high speed running.
Oil leakage in oil passage or in HLA
Deteriorated oil
Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.)
Valve Clearance Inspection 1. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 2. Measure valve clearance. Valve clearance 0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in}, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) 4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
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FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and water pump pulley. 5. Remove the radiator cowling. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
1
2 3
Pulley lock bolt ☞ TIMING CHAIN, TIMING CHAIN ☞ REMOVAL/INSTALLATION, Pulley Lock Bolt ☞ Removal/Installation Note Crankshaft pulley Front oil seal ☞ Removal Note ☞ Installation Note
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
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REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Rear oil seal ☞ Removal Note ☞ Installation Note Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
CONTINUED
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ENGINE ENGINE ENGINE REMOVAL/INSTALLATION Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and fresh-air duct. 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket, heater hoses, and vacuum hoses. 6. Remove the radiator. (Refer to section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 8. Disconnect the fuel hoses. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 9. Remove the transmission. (Refer to section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 10. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 11. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 12. Remove in the order indicated in the table. 13. Install in the reverse order of removal. 14. Start the engine and (1) check the engine oil, engine coolant, transmission oil, and fuel leakage. (2) check the ignition timing, idle speed and idle mixture. (Refer to section F1, ENGINE TUNE-UP.) 15. Perform a road test.
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ENGINE
1
Engine mount nut
2
Engine
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ENGINE ENGINE DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
1 2 3 4 5
Remove the oil cooler. (Refer to section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) Remove the thermostat. (Refer to section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) Remove the spark plug. Remove the oil pressure switch. (Refer to section D, OIL PRESSURE INSPECTION.) Remove the intake-air system. (Refer to section F1, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) Remove the exhaust system. (Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Remove the oil filter. (Refer to section D, OIL FILTER, OIL FILTER REPLACEMENT) Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) Remove the generator. Disassemble in the order indicated in the table. Assemble in the reverse order of disassembly.
Water bypass pipe Water inlet pipe A/C compressor bracket Generator bracket P/S oil pump bracket
6 7 8 9 10
A/C idler P/S idler Oil cooler bypass pipe Generator strap Engine mount
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Engine Workshop Manual F8 FE
CONTENTS
FOREWORD This manual explains the disassembly, inspection, repair, and reassembly procedures for the above-indicated engines. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully. The information in this manual is current up to April, 1997. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing.
© 2001 Ford/Mazda Motor Corporation PRINTED IN JAPAN, APR. 1997 1570-10-97D
Title
Section
General Information
GI
Engine
B
Technical Data
TD
Special Tools
ST
Mazda Motor Corporation HIROSHIMA, JAPAN
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GENERAL INFORMATION HOW TO USE THIS MANUAL .............. ................ Gl- 1 RANGE OF TOPICS .................... .................... Gl- 1 SERVICING PROCEDURE .............. ................ Gl- 1/2 SYMBOLS ............................. .......................... Gl- 3 ADVISORY MESSAGES .................................. Gl- 3 TEXT SEQUENCE ........................................... Gl- 3 UNITS ................................................................... Gl- 4 NEW STANDARDS ............................................... Gl- 5 FUNDAMENTAL PROCEDURES ........... .............. Gl- 7 PREPARATION OF TOOLS AND MEASURING EQUIPMENT .......................... Gl- 7 SPECIAL TOOLS ............................................. Gl- 7 DISASSEMBLY ................................................ Gl- 7
INSPECTION DURING REMOVAL, DISASSEMBLY ............................................. Gl- 7 ARRANGEMENT OF PARTS ........................... Gl- 7 CLEANING OF PARTS .................................... Gl- 7 REASSEMBLY ................................................. Gl- 7 ADJUSTMENT ................................................. Gl- 8 RUBBER PARTS AND TUBING ....................... Gl- 8 HOSE CLAMPS ............................................... Gl- 8 TORQUE FORMULAS ...................................... Gl- 8 VISE ................................................................ Gl- 8 ELECTRICAL SYSTEM ........................................ Gl- 9 CONNECTORS ................................................ Gl- 9 ABBREVIATIONS.................................................. Gl- 10
HOW TO USE THIS MANUAL
SERVICING PROCEDURE Inspection, Adjustment • The procedures .for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.
RANGE OF TOPICS • This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment • Simple operations which can be performed easily just by looking at the vehicle such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.
CONTINUED
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HOW TO USE THIS MANUAL Repair procedure 1. Most repair operations begin with an overview illustration, It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions, 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part.
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HOW TO USE THIS MANUAL SYMBOLS • There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such Symbol
Meaning
TEXT SEQUENCE • The text sequence is as indicated by the arrows shown below. Example:
Kind
Apply oil
New appropriate engine oil or gear oil
Apply brake fluid
New appropriate brake fluid
Apply automatic transaxle / transmission fluid
New appropriate automatic transaxle/transmi ssion fluid
Apply grease
Appropriate grease
Apply sealant
Appropriate sealant
Apply petroleum jelly
Appropriate petroleum jelly
Replace part
O-ring, gasket, etc.
Use SST
Appropriate SST
ADVISORY MESSAGES You'll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual. Warning • A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution • A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note • A Note provides added information that will help you to complete a particular procedure. Specification • The values indicates the allowable range when performing inspections or adjustments. Upper and lower limits • The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
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HOW TO USE THIS MANUAL UNITS Electrical current
A (ampere)
Electric potential
V (volt)
Electric power
W (watt)
Length
2 • The actual converted values for 2.7 kgf/cm are 264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2,7 is used as a lower limit, so its converted values are rounded up to 270 and 39.
mm (millimeter) in (inch) kPa (kilo pascal)
Negative pressure
mmHg (millimeters of mercury) inHg (inches of mercury)
Positive pressure
kPa (kilo pascal) kgf/cm 2 (kilogram force per square centimeter) psi (pounds per square inch)
Resistance
Ω (ohm)
Speed
rpm (revolution per minute) N•m (Newton meter) kgf•m (kilogram force per meter)
Torque
kgf•cm (kilogram force per centimeter) ft•lbf (foot pound) in•lbf (inch pound) L (liter) US qt (U.S. quart) Imp qt (Imperial quart)
Volume
ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce)
Weight
9 (gram) oz (ounce)
Conversion to Sl Units (Système International d'Unités) • All numerical values in this manual are based on 81 units. Numbers shown In conventional units are converted from these values, Rounding off • Converted values are rounded off to the same number of places are the Sl unit value. For example, if the 81 unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and lower limits • When the data indicates upper and lower limits, the converted values are rounded down if the Sl unit value is an upper limit and rounded up if the Sl unit value is a lower limit. Therefore, converted values for the same Sl unit value may differ after 2 conversion. For example, consider 2.7 kgf/cm in the following specifications: 210—260 kPa { 2.1—2.7 kgf/cm2 , 30—38 psi } 270—310 kPa { 2.7—3.2 kgf/cm2 , 39—45 psi }
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NEW STANDARDS NEW STANDARDS • Following is a comparison of the previous standard and the new standard. Previous Standard Abbreviation
Name
New Standard Abbreviation AP
Name
—
Accelerator Pedal
—
Air Cleaner
ACL
—
Air Conditioning
A/C
Air Conditioning
—
Airflow Meter
VAF
Volume Air Flow Sensor
Air Cleaner
—
Airflow Sensor
MAF
Mass Air Flow Sensor
—
Alternator
GEN
Generator
—
ATF Thermosensor
—
Atmospheric Pressure
VB
Battery Voltage
Catalytic Converter
— BARO B+ OC TWC
Transmission (Transaxle) Fluid Temperature Sensor Barometric Pressure Battery Positive Voltage Oxidation Catalytic Converter Three Way Catalytic Converter
FPR
Warm Up Three Way Catalytic Converter Fuel Pump Relay
Clutch Position
CPP
Clutch Pedal Position
Crank Angle Sensor
CMP
Camshaft Position Sensor
Crank Angle Sensor 2
CKP
Crankshaft Position Sensor
WU-TWC —
Circuit Opening Relay
— — — —
Diagnosis Connector
DLC
Data Link Connector
—
Diagnosis/Self-Diagnosis
OBD
On-Board Diagnostic
—
Direct Ignition
DLI
Distributorless Ignition
—
EC-AT Control Unit
TCM
Electronic Gasoline Injection System
CIS
EGI —
Electronic Spark Ignition
ECU
Engine Control Unit
—
Engine Modification
El
Electronic Ignition
#3
Powertrain Control Module
#4
ECM
Engine Control Module
EM
Engine Modification
—
Engine Speed Input Signal
Engine RPM Signal Evaporative Emission
EVAP
Evaporative Emission
—
Exhaust Gas Recirculation
EGR
Exhaust Gas Recirculation
Fan Control Feedback System
—
Flexible Fuel
#2
PCM
—
—
#1
Transmission (Transaxle) Control Module Continuous Fuel Injection System
—
—
Remark
Accelerator Pedal
FC CLS FF
Fan Control Closed Loop System Flexible Fuel
—
Fuel Pump
FP
—
Fully Closed
CTP
Closed Throttle Position
Fuel Pump
—
Fully Open
WOT
Wide Open Throttle
—
Ground/Earth
GND
Ground
—
1C Regulator
VR
Voltage Regulator
#1: Directly connected to exhaust manifold #2: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #3: Controlled by the ECM/PCM #4: Device that controls engine and powertrain
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NEW STANDARDS Previous Standard Abbreviation
Name
New Standard Abbreviation IAC
Name
—
Idle Speed Control
—
Idle Switch
—
Igniter
ICM
Ignition Control Module
—
Inhibitor Position
TR
Transmission (Transaxle) Range
—
Intake Air Pressure
MAP
—
Intake Air Thermo
IAT
—
Intercooler
—
Knock Sensor
—
Line Pressure Solenoid Valve
—
Lock-up Position
TCC
Torque Converter Clutch
—
Malfunction Indicator Light
MIL
Malfunction Indicator Lamp
—
Multiport Fuel Injection
MFI
Multiport Fuel Injection
—
Open Loop
OL
Open Loop
—
Overdrive
4GR
Fourth Gear
—
Oxygen Sensor
—
—
CAC
Closed Throttle Position Switch
Manifold Absolute Pressure Intake Air Temperature Charge Air Cooler
KS
Knock Sensor
—
Pressure Control Solenoid
HO2S
Heated Oxygen Sensor
O2S
Oxygen Sensor
Park/Neutral Range
PNP
Park/Neutral Position
—
Power Steering Pressure
PSP
—
Pulse Generator
—
Reed Valve
—
Secondary Air Injection System
—
—
Power Steering Pressure Secondary Air Pulse Valve
PAIR
Pulsed Secondary Air Injection
AIR
Secondary Air Injection
Sequential Fuel Injection
SFI
Sequential Multipoint Fuel Injection
—
Service Code(s)
DTC
—
Spark Ignition
Dl
Distributor Ignition
—
Stoplight Switch
—
Brake Switch
—
Test Mode
—
Throttle Body
—
Throttle Sensor
TP
Throttle Position Sensor
—
Turbocharger
TC
Turbocharger
—
Vehicle Speed Sensor
—
Vehicle Speed Sensor 1
—
Water Thermo
TB
VSS — ECT
1—2 Shift Solenoid Valve
Shift+B Solenoid Valve —
3—4 Shift Solenoid Valve
—
3rd Gear
—
—
Pulsed injection Inject with compressor
Diagnostic Trouble Code(s)
Diagnostic Test Mode
#5
Throttle Body
Vehicle Speed Sensor Output Speed Sensor Engine Coolant Temperature Shift Solenoid A
Shift+A Solenoid Valve 2—3 Shift Solenoid Valve
With heater
Input/Turbine Speed Sensor
SAPV
DTM
Remark
Idle Air Control
—
Shift Solenoid B
—
Shift Solenoid C
3GR —
Third Gear Incorrect Gear Ratio
#5: Diagnostic trouble codes depend on the diagnostic test mode
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FUNDAMENTAL PROCEDURES FUNDAMENTAL PROCEDURES PREPARATION OF TOOLS AND MESURING EQUIPMENT • Be sure that all necessary tools and measuring equipment are available before starting any work.
ARRANGEMENT OF PARTS • All disassembled parts should be carefully arranged for reassembly. • Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
SPECIAL TOOLS
• Use special tools when they are required.
CLEANING OF PARTS
• All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
DISASSEMBLY
• If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
Warning
• Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear " whenever using compressed air.
INSPECTION DURING REMOVAL, DISASSEMBLY • When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.
REASSEMBLY
• Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones: 1
Oil seals
2
Gaskets
3
O-rings
4
Lockwashers
5
Cotter pins
6
Nylon nuts
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FUNDAMENTAL PROCEDURES HOSE CLAMPS
• When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.
1. Sealant, gasket, or both should be applied to the specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.
TORQUE FORMULAS
• When using a torque wrench-SST combination, the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you. Torque Unit N•m kgf• m kgf•cm ft•lbf in•lbf
ADJUSTMENT
• Use suitable gauges and testers when making adjustments.
Formula N•m x [L/(L+A) ] kgf•m x [L/(L+A) ] kgf•cm x [L/(L+A) ] ft•lbf x [L/(L+A) ] in•lbf x [L/(L+A) ]
A: The length of the SST past the torque wrench drive. L: The length of the torque wrench.
VISE RUBBER PARTS AND TUBING
• Prevent gasoline or oil from getting on rubber parts or tubing.
• When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
I
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ELECTRICAL SYSTEM ELECTRICAL SYSTEM
2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.
CONNECTORS Disconnecting Connectors • When disconnecting two connectors, grasp the connectors, not the wires.
Caution
• To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal.
• Connectors can be disconnected by pressing or pulling the lock lever as shown.
Locking Connector
• When locking connectors, listen for a click that will indicate they are securely locked.
Inspection 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring harness side.
GI-9
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ABBREVIATIONS ABBREVIATIONS EX ............................................ HLA ......................................... IN ............................................. MAX ......................................... SST .........................................
Exhaust Hydraulic lash adjuster lntake Maximum Special service tool
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ENGINE ENGINE OVERHAUL SERVICE WARNING .......... ENGINE MOUNTING/DISMOUNTING ................... MOUNTING ....................................................... DISMOUNTING .................................................. ENGINE DISASSEMBLY/ASSEMBLY .................. TIMING BELT DISASSEMBLY/ASSEMBLY......... CYLINDER HEAD (I) DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER HEAD (II) DISASSEMBLY/ ASSEMBLY .................................................... TIMING CHAIN DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER BLOCK (I) DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER BLOCK (II) DISASSEMBLY/ ASSEMBLY .................................................... ENGINE INSPECTION/REPAIR ............................ CYLINDER HEAD INSPECTION/REPAIR ........... VALVE INSPECTION ......................................... VALVE GUIDE INSPECTION ............................. VALVE GUIDE REPLACEMENT ......................... VALVE SEAT INSPECTION/REPAIR ................. VALVE SPRING INSPECTION ........................... CAMSHAFT INSPECTION ................................. CAMSHAFT OIL CLEARANCE INSPECTION ..................................................
B- 1 B- 1 B- 1/2 B- 2 B- 3 B- 3/5
CAMSHAFT END PLAY INSPECTION ................... B-26 ROCKER ARM AND ROCKER ARM SHAFT INSPECTION ..................................................... B-26/27 CYLINDER BLOCK INSPECTION/ REPAIR ............................................................. B-27 PISTON INSPECTION ........................................... B-27 PISTON CLEARANCE INSPECTION/ REPAIR ............................................................. B-28 PISTON RING CLEARANCE INSPECTION ........... B-28 PISTON PIN CLEARANCE INSPECTION .............. B-28/29 CRANKSHAFT INSPECTION ................................. B-29 CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR ........................................ B-29/30 CRANKSHAFT END PLAY INSPECTION/REPAIR ........................................ B-30 CONNECTING ROD INSPECTION ........................ B-30 CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR ........................................ B-31 CONNECTING ROD SIDE CLEARANCE INSPECTION ..................................................... B-31 PISTON AND CONNECTING ROD INSPECTION ..................................................... B-31 TENSIONER SPRING INSPECTION ..................... B-31 GEAR CLEARANCE INSPECTION ........................ B-31/32 ROTOR CLEARANCE INSPECTION ..................... B-32/33 PLUNGER SPRING INSPECTION ......................... B-33
B- 6/12 B-12/13 B-14/16 B-17/19 B-20/22 B-23 B-23 B-23/24 B-24 B-24 B-25 B-25 B-26 B-26
ENGINE OVERHAUL SERVICE WARNING Warning • Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
ENGINE MOUNTING/DISMOUNTING MOUNTING 1. Install the SST (arms and attachment) to the cylinder block holes as shown, and hand-tighten the SST (bolts).
2. Assemble the SST (bolts, nuts, and plate) to the specified positions.
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ENGINE MOUNTING/DISMOUNTING 3. Adjust the SST (bolts) so that less than 20 mm {0.79 in } of thread is exposed. 4. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 5. Tighten the SST (bolts and nuts) to affix the SST firmly.
Warning
• The self-locking brake system of the engine stand may not be effective when the engine is held In an unbalanced position. This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).
7. Drain the engine oil. 8. Install the oil drain plug. Tightening torque 30–41 N.m {3.0–4.2 kgf.m, 22–30 ft.lbf }
DISMOUNTING
• Dismount in the reverse order of mounting.
CONTINUED
B-2
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ENGINE MOUNTING/DISMOUNTING ENGINE DISASSEMBLY/ASSEMBLY TIMING BELT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2
Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note Upper timing belt cover
3 4 5
Lower timing belt cover Guide plate Spark plug
1
6
7 8
Timing belt • Refer to Disassembly Note • Refer to Assembly Note Tensioner, tensioner spring • Refer to Assembly Note Idler
CONTINUED
B-3
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ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.
Timing Belt Disassembly Note 1. Turn the crankshaft clockwise and align the timing marks as shown.
Timing Belt Assembly Note 1. Turn the crankshaft clockwise and align the timing marks as shown. Camshaft pulley timing mark F8: 4 FE: 2
Camshaft pulley timing mark F8: 4 FE: 2
2. Remove the spark plug. Caution • The following will damage the belt and shorten its life; forcefully twisting it. Turning it inside out, or allowing oil or grease on It. 3. Mark the timing belt rotation on the belt for proper reinstallation.
2. Install the timing belt. 3. Turn the crankshaft clockwise twice and align the timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Assembly Note step 1. 4. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring. 5. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation. 6. Turn the crankshaft clockwise twice and check the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf , 22 Ibf } If it is incorrect repeat from Timing Belt Disassembly Note. Timing belt deflection New : 4.0―5.0 mm {0.16―0.19 In } Used : 5.5―6.5 mm {0.22―0.25 in }
Tensioner, Tensioner Spring Assembly Note 1. Install the tensioner and tensioner spring. 2. Position the tensioner all the way to the intake side and temporarily secure it by tightening the lock bolt.
B-4
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ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Assembly note • Hold the crankshaft by using the SST.
CONTINUED
B-5
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ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD(I) DISASSEMBLY/ASSEMBLY Timing belt drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
3
4
Cylinder head cover • Refer to Assembly Note Rocker arm • Refer to Disassembly Note • Refer to Assembly Note Camshaft pulley • Refer to Disassembly Note • Refer to Assembly Note
5 6
7
Front housing • Refer to Assembly Note Camshaft • Refer to Assembly Note Cylinder head • Refer to Disassembly Note • Refer to Assembly Note Cylinder head gasket
CONTINUED
B-6
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ENGINE DISASSEMBLY/ASSEMBLY Rocker Arm Disassembly Note • Loosen the bolts in two or three steps in the order shown.
Camshaft pulley Disassembly Note • Hold the camshaft by using a screwdriver.
Cylinder Head Disassembly Note • Loosen the cylinder head bolts in two or three steps in the order shown.
Front Housing Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Camshaft Pulley Assembly Note • Install the camshaft pulley on the camshaft with the knock pin fit into the hole at the timing mark. Camshaft pulley timing mark F8: 4 FE: 2
Cylinder Head Assembly Note • Tighten the bolts in two or three steps in the order shown. Rocker Arm Assembly Note 1. Assemble the rocker arms, rocker arm shafts, and camshaft bearing cap as shown in the figure.
Camshaft Assembly Note • Be certain that the knock pin of the camshaft faces straight up. 2. Tighten the bolts in two or three steps in the order shown.
CONTINUED B-7
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ENGINE DISASSEMBLY/ASSEMBLY
3. Tap in the seal cap by using a plastic hammer.
Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the shaded areas. Thickness ∅1.5―2.0 mm {0.060―0.078 in }
2. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
CONTINUED
B-8
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ENGINE DISASSEMBLY/ASSEMBLY Timing chain drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
3 4
5
6
Cylinder head cover • Refer to Assembly Note Chain adjuster • Refer to Disassembly Note • Refer to Assembly Note Camshaft gear • Refer to Disassembly Note Rocker arm • Refer to Disassembly Note • Refer to Assembly Note Camshaft
7
8
B-9
Camshaft sprocket • Refer to Disassembly Note • Refer to Assembly Note Cylinder head • Refer to Disassembly Note • Refer to Assembly Note Cylinder head gasket • Refer to Assembly Note
CONTINUED
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ENGINE DISASSEMBLY/ASSEMBLY Chain Adjuster Disassembly Note 1. Turn the crankshaft until the FE mark of the camshaft pulley is at the top as shown. 2. Check that the crankshaft pulley timing mark is aligned with the indicator pin.
3. Remove the chain adjuster.
Cylinder Head Disassembly Note 1. Remove the bolt A. 2. Loosen the remaining cylinder head bolts in two or three steps in the order shown.
Cylinder Head Gasket Assembly Note 1. Apply silicone sealant to the shaded area.
Camshaft Gear Disassembly Note 1. Pry up the washer tab.
2. Install the cylinder head gasket. 3. Apply silicone sealant to the shaded area of the cylinder head gasket. 2. Hold the camshaft with a screwdriver as shown.
Rocker Arm Disassembly Note • Loosen the rocker arm shaft bolts in two or three steps in the order shown.
Cylinder Head Assembly Note 1. Tighten the cylinder head bolts in two or three steps in the order shown.
2. Tighten the remaining small cylinder head bolts.
B-10
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ENGINE DISASSEMBLY/ASSEMBLY Rocker Arm Assembly Note 1. Apply silicone sealant to the shaded area.
Camshaft Sproket Assembly Note 1. Install the camshaft sprocket to the camshaft, aligning mark on the camshaft sprocket and timing chain.
2. Tighten the bolt in two or three steps in the order shown.
3. Tap in the new seal cap by using a plastic hammer.
2. Hold the camshaft with a screwdriver as shown.
3. Bent the washer tab to lock the locknut.
Chain Adjuster Assembly Note 1. Lift the ratchet pawl and compress the chain adjuster sleeve fully, then lock it with the pin lock.
CONTINUED
B-11
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ENGINE DISASSEMBLY/ASSEMBLY Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the seal cap as shown.
CYLINDER HEAD (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2. Apply silicone sealant to the shaded areas.
1 3. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
2 3
Valve keeper • Refer to Disassembly Note • Refer to Assembly Note Upper valve spring seat Valve spring (FE CIS: Single spring type) • Refer to Assembly Note
4
Lower valve spring seat
5 6
Valve Valve seal • Refer to Disassembly Note • Refer to Assembly Note
Valve Keeper Disassembly Note • Remove the valve keeper by using the SST.
Valve Seal Disassembly Note • Remove the valve seal by using the SST.
CONTINUED
B-12
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ENGINE DISASSEMBLY/ASSEMBLY Valve Spring Assembly Note • Install the valve spring with the closer pitch toward the cylinder head.
Valve Seal Assembly Note 1. Assemble the SST so that depth L is as specified. Depth L F8, FE CARB: 19.2―19.6 mm {0.756―0.771 in } FE CIS: 21.4―22.2 mm {0.843―0.874 in }
Valve Keeper Assembly Note • Install the valve keeper by using the SST.
2. Press the valve seal onto the valve guide by hand. 3. Tap the SST by using a plastic hammer until its lower end touches the cylinder head.
CONTINUED
B-13
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ENGINE DISASSEMBLY/ASSEMBLY TIMING CHAIN DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the order of disassembly.
1 2
3
4 5 6 7
Water pump Crankshaft pulley • Refer to Disassembly Note • Refer to Assembly Note Timing chain cover • Refer to Disassembly Note • Refer to Assembly Note Timing chain • Refer to Assembly Note Timing gear Crankshaft key Timing chain lever
8 9 10
11 12
Timing chain guide Oil strainer Oil pan • Refer to Disassembly Note • Refer to Assembly Note Oil pump cover Inner rotor
13 14
Outer rotor Spring seat
15
Pressure spring
16
Control plunger
CONTINUED
B-14
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ENGINE DISASSEMBLY/ASSEMBLY Timing Chain Assembly Note 1. Install the timing chain as shown in the figure.
Crankshaft Pulley Disassembly Note • Hold the crankshaft by using the SST.
Oil Pan Disassembly Note • Remove the oil pan by using the separator tool.
2. Support the timing chain by using a magnetic base. Timing Chain Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Oil Pan Assembly Note • Apply silicone sealant to the oil pan as shown. Thickness ∅2.5―3.5 mm {0.099―0.137 in }
4. Apply silicone sealant to the mounting surface along the inside of the bolt holes as shown.
_
Timing Chain Cover Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.
5. Tighten the timing chain cover installation bolt.
Tightening torque A: 19―25 N.m {1.9―2.6 kgf.m , 14―18 ft.lbf } B: 38―51 N.m {3.8―5.3 kgf.m , 28―38 ft.lbf }
B-15
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ENGINE DISASSEMBLY/ASSEMBLY Crankshaft Pulley Assembly Note • Hold the crankshaft by using the SST.
CONTINUED
B-16
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ENGINE DISASSEMBLY/ASSEMBLY CYLINDER BLOCK (I) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2
1
Oil pan (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note
2 3
Oil strainer (Timing belt drive type) Oil baffle (FE CIS) • Refer to Disassembly Note • Refer to Assembly Note Timing belt pulley (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note Flywheel • Refer to Disassembly Note • Refer to Assembly Note End plate Oil pump (Timing belt drive type) • Refer to Disassembly Note • Refer to Assembly Note
4
5
6 7
8 9
Oil pump body (Timing belt drive type) Outer gear (Timing belt drive type)
10
Inner gear (Timing belt drive type)
11 12 13 14 15
Oil pump cover (Timing belt drive type) Spring seat (Timing belt drive type) . Pressure spring (Timing belt drive type) Control plunger (Timing belt drive type) Rear cover • Refer to Disassembly Note • Refer to Assembly Note Water pump • Refer to Assembly Note
16
CONTINUED B-17
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ENGINE DISASSEMBLY/ASSEMBLY Oil Pan Disassembly Note Note • Do not insert the separator tool between the oil baffle and cylinder block.
Oil Pump Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.
• Remove the oil pan by using the separator tool.
Oil Baffle Disassembly Note • Remove the oil baffle by using the separator tool.
Timing Belt Pulley Disassembly Note • Hold the crankshaft by using the SST.
Flywheel Disassembly Note • Hold the crankshaft by using the SST.
Rear Cover Disassembly Note • Remove the oil seal by using a screwdriver protected with a rag.
Water Pump Assembly Note 1. Verify that the rubber seal is securely fixed onto the water pump. 2. If not, replace the rubber seal and reapply the bonding agent. 3. Install the water pump.
Rear Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
CONTINUED B-18
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ENGINE DISASSEMBLY/ASSEMBLY Oil Pan Assembly Note • Apply Silicone sealant to the oil pan as shown.
Oil Pump Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Thickness ∅2.0―3.0 mm {0.079―0.118 in }
Flywheel Assembly Note 1. Hold the crankshaft by using the SST. 2. Tighten the flywheel bolt in the order shown.
Timing Belt Pulley Assembly Note • Hold the crankshaft by using the SST.
Oil Baffle Assembly Note • Apply silicone sealant to the oil baffle as shown. Thickness ∅2.0―3.0 mm {0.079―0.118 in }
CONTINUED
B-19
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ENGINE DISASSEMBLY/ASSEMBLY CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 3
4 5 6 7 8
Connecting rod cap Lower connecting rod bearing Piston and connecting rod • Refer to Disassembly Note • Refer to Assembly Note Upper connecting rod bearing Piston ring Piston pin Piston Connecting rod
9
10 11
12 13 14
Main bearing cap • Refer to Disassembly Note • Refer to Assembly Note Lower main bearing Pilot bearing • Refer to Disassembly Note • Refer to Assembly Note Crankshaft Upper main bearing Cylinder block
CONTINUED
B-20
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ENGINE DISASSEMBLY/ASSEMBLY Pilot Bearing Disassembly Note • Remove the pilot bearing by using the SST.
Piston and Connecting Rod Disassembly Note 1. Assemble the SST as shown.
Pilot Bearing Assembly Note • Install the pilot bearing by using a suitable pipe.
2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.
Main Bearing Cap Assembly Note 1. Tighten the bolts in two or three steps in the order shown.
3. Set the piston and connecting rod on the SST as shown.
Piston and Connecting Rod Assembly Note 1. Assemble the SST as shown.
4. Press out the piston pin. Main Bearing Cap Disassembly Note • Loosen the main bearing cap bolts in two or three steps in the order shown.
CONTINUED
B-21
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ENGINE DISASSEMBLY/ASSEMBLY 2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.
8. Verify that the second ring is installed with the scraper face downward. 9. Position the end gap of the oil ring as shown.
3. Set the SST (stopper bolt) so that dimension L is as specified. Dimension L 60.0 mm {2.36 in }
10. F mark facing the front of the engine.
4. Apply clean engine oil to the piston pin. 5. Insert the piston pin and the SST assembled in step 2 into the piston and connecting rod.
6. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt). 7. While inserting the piston pin, check the pressure force. If it is less than the specification, replace the piston pin or the connecting rod. Pressure force 2.94―14.70 KN {300―1500 kgf , 660―3300 Ibf }
CONTINUED
B-22
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ENGINE INSPECTION/REPAIR ENGINE INSPECTION/REPAIR CYLINDER HEAD INSPECTION/REPAIR 1. Carry out cooling flaw detection on the cylinder head surface. Replace the cylinder head if necessary. 2. Inspect for the following and repair or replace if necessary. (1) Sunken valve seats (2) Excessive camshaft oil clearance and end play 3. Measure the cylinder head for distortion in the six directions as shown.
VALVE INSPECTION 1. Measure the valve head margin thickness of each valve. Replace the valve if necessary. Margin thickness FE CIS IN: 1.80―2.20 mm {0.071―0.086 in } EX: 1.30―1.70 mm {0.052―0.006 in } F8, FE CARB IN: 0.8―1.2 mm {0.032―0.047 in } EX: 1.3―1.7 mm {0.052―0.066 in }
Distortion 0.15 mm {0.006 in} max.
2. Measure the length of each valve. Replace the valve if necessary. Standard length FE CIS IN: 115.61―116.01 mm {4.552―4.567 in } EX: 116.01―116.41mm {4.568―4.583 in } F8, FE CARB IN: 111.69―112.09 mm {4.398―4.412} EX: 111.49―111.89 mm {4.390―4.405 in }
4. If the cylinder head distortion exceeds the maximum, repair by grinding the height or replace the cylinder head. If the cylinder head height is not within the specification, replace it. Standard height 91.95―92.05 mm {3.621―3.624 in }
Minimum length
Grinding 0.20 mm {0.008 in } max.
FE CIS
IN: 115.51 mm {4.548 in} EX: 115.71 mm {4.556 in} F8, FE CARB IN: 111.39 mm {4.386 in} EX: 111.19 mm {4.378 in}
5. Measure the manifold contact surface distortion as shown. Distortion 0.15 mm {0.006 in } max. 6. If the distortion exceeds the specification, grind the surface or replace the cylinder head .
3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) shown. Replace the valve if necessary. Standard diameter FE CIS IN: 6.970―6.985 mm {0.2745―0.2749 in } EX: 6.965―6.980 mm {0.2743―0.2748 in } F8, FE CARB IN: 8.030―8.045 mm {0.3162―0.3167 in } EX: 8.025―8.040 mm {0.3160―0.3165 in }
Grinding 0.20 mm {0.008 in } max.
Minimum diameter FE CIS IN: 6.920 mm {0.2724 in } EX: 6.915 mm {0.2722 in } F8, FE CARB IN: 7.980 mm {0.3142 in } EX: 7.975 mm {0.3140 in }
CONTINUED B-23
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ENGINE INSPECTION/REPAIR
VALVE GUIDE INSPECTION 1. Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) shown. Replace the valve guide if necessary. Standard inner diameter FE CIS IN: 7.010―7.030 mm {0.2760―0.2767 in } EX: 7.010―7.030 mm {0.2760―0.2767 in } F8, FE CARB IN: 8.030―8.045 mm {0.3162―0.3167 in } EX: 8.025―8.040 mm {0.3160―0.3165 in }
Valve Guide Installation 1. Assemble the SSTs so that depth L is as specified. Depth L FE CIS: 19.8―20.3 mm {0.780―0.799 in } F8, FE CARB: 19.1―19.6 mm {0.752―0.771 in }
2. Tap the valve guide in from the side opposite the combustion chamber until! the SST contacts the cylinder head. 3. Verify that the valve guide projection height (dimension) is within the specification.
2. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat. Replace the valve guide if necessary.
Standard height FE CIS: 19.8―20.3 mm {0.780―0.799 in } FB, FE CARB: 19.1―19.6mm {0.752―0.771 in }
Standard height FE CIS: 19.8―20.3 mm {0.780―0.799 in } F8, FE CARB: 19.1―19.6mm {0.752―0.711 in }
VALVE GUIDE REPLACEMENT Valve Guide Removal • Remove the valve guide from the combustion chamber side by using the SST.
CONTINUED
B-24
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ENGINE INSPECTION/REPAIR VALVE SEAT INSPECTION/REPAIR 1. Measure the seat contact width. If necessary, resurface the valve seat by using a 45° valve seat cutter and/or resurface the valve face.
VALVE SPRING INSPECTION 1. Apply pressing force to the pressure spring and check the spring height. Replace the valve spring if necessary. Pressing force FE CIS IN: 203.10―229.86 N {20.71―23.44 kgf , 45.57― 51.56 Ibf } EX: 240.37―272.03 N {24.51―27.74 kgf , 53.93―61.02 Ibf } F8, FE CARB Inner: 117.19―136.01 N {11.95―13.87 kgf , 26.29―30.51 Ibf } Outer: 243.70―267.03 N {24.85―27.23 kgf , 54.67―59.90 Ibf }
Standard width IN: 1.2―1.6 mm {0.048―0.062 in } EX: 1.2―1.6 mm {0.048―0.062 in }
Standard height FE CIS IN: 41 mm {1.614 in } EX: 41 mm {1.614 in } F8, FE CARB Inner: 36.5 mm {1.437 in } Outer: 41.0 mm {1.614 in }
2. Verify that the valve seating position is at the center of the valve face. (1) If the seating position is too high, correct the valve seat by using a 75° (FE CIS) or 60° (F8, FE CARB) cutter, and a 45° cutter. (2) If the seating position is too low, correct the valve seat by using a 35° (IN) or 15° (EX) cutter and a 45° cutter.
2. Measure the out-of-square of the valve spring. Replace the valve spring if necessary. Valve spring out-or-square FE CIS IN: 1.70 mm {0.067 in } EX: 1.76 mm {0.069 in } FB, FE CARB Inner: 1.5 mm {0.059 in } Outer: 1.8 mm {0.071 in }
3. Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. Replace the cylinder head if necessary. Standard dimension L F8, FE CARB: 46.5 mm {1.831 in } FE CIS: 49.7 mm {1.957 in } Maximum dimension L F8, FE CARB: 47.0 mm {1.850 in } FE CIS: 51.2 mm {2.016 in }
CONTINUED
B-25
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ENGINE INSPECTION/REPAIR CAMSHAFT INSPECTION
2. Install the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD (II) Camshaft Cap Assembly Note.) 3. Remove the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER HEAD (II) Camshaft Cap Assembly Note.) 4. Measure the oil clearance. Replace the cylinder head if necessary.
1. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary. Runout 0.03 mm {0.0012 in } max. 2. Measure the cam lobe height at the two points as shown. Replace the camshaft if necessary.
Standard clearance No.1, 5: 0.035―0.085 mm {0.00138―0.00334 in } No.2, 3, 4: 0.065―0.115 mm {0.00256―0.00453 in }
Standard height FE CIS IN: 41.340 mm {1.6276 in } EX: 41.847 mm {1.6475 in } F8, FE CARB IN: 38.202 mm {1.5040 in } EX: 38.202 mm {1.5040 in } Fuel pump cam: 39.900 mm {1.5709 in }
3. Measure the journal diameters in X and Y directions at the two points (A and B) as shown. Replace the camshaft if necessary.
Maximum clearance 0.15 mm {0.006 in }
CAMSHAFT END PLAY INSPECTION 1. Install the camshaft and thrust plate. 2. Measure the camshaft end play. Replace the camshaft and/or thrust plate if necessary. Standard end play 0.08―0.16 mm {0.00315―0.00629 in }
Standard diameter No.1, 5: 31.940―31.965 mm {1.2575―1.2585 in } No.2, 3, 4: 31.910―31.935 mm {1 .2563―1.2572 in } Minimum diameter No.1, 5: 31.910 mm {1.2563 in } No.2, 3, 4: 31.880 mm {1.2551 in }
Maximum end play 0.20 mm {0.008 in } ROCKER ARM AND ROCKER ARM SHAFT INSPECTION 1. Measure the rocker arm inner diameter. Diameter FE CIS: 19.000―19.033 mm {0.7481―0.7493 in } F8, FE CARB: 15.966―15.984 mm {0.6286―0.6292 in }
CAMSHAFT OIL CLEARANCE INSPECTION 1. Position a plastigage atop the journals in the axial direction. 2. Measure the rocker arm shaft diameter.
CONTINUED B-26
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ENGINE INSPECTION/REPAIR Diameter FE CIS: 18.959―18.980 mm {0.7465―0.7472 in } F8, FE CARB: 15.966―15.984 mm {0.6286―0.6292 in }
3. If the cylinder bore exceeds the wear limit, replace the cylinder block or rebore the cylinder and install the oversize pistons so that the specified piston-to-cylinder clearance is obtained. Note • Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter.
3. Calculate the rocker arm-to-shaft clearance. Replace the rocker arm and/or rocker arm shaft if necessary. Standard clearance FE CIS: 0.020―0.074 mm {0.00079―0.00291 in } F8, FE CARB: 0.016―0.061 mm {0.00063―0.00240 in }
Cylinder bore Size
86.000―86.019
Standard
CYLINDER BLOCK INSPECTION/REPAIR 1. Measure the distortion of the cylinder block top surface in the six directions as shown. Repair by grinding or replace if necessary.
{3.3859―3.3865}
0.25 {0.01} oversize 0.50 {0.02} oversize
Cylinder block distortion 0.15 mm {0.006 in } max.
mm { in } Diameter
86.250―86.269 {3.3957―3.3964} 86.500―86.519 {3.4056―3.4062}
Wear limit 0.15 mm {0.006 in }
Cylinder block height FE: 288.93―289.07 mm {11.376―11.380 in } F8: 268.43―268.57 mm {10.569―10.573 in }
PISTON INSPECTION • Measure the outer diameter of each piston at a right angle (90°) to the piston pin, 18.0 mm {0.709 in } below oil ring groove. Piston diameter mm { in }
Grinding 0.20 mm {0.008 in } max.
Size Standard 0.25 {0.01} oversize 0.50 {0.02} oversize
Diameter 85.943―85.965 {3.38358―3.38444} 86.193―86.215 {3.39342―3.39428} 86.443―86.465 {3.40327―3.40412}
2. Measure the cylinder bores in X and Y directions at 65 mm {2.56 in } (F8), 70 mm {2.76 in } (FE) below the top surface.
CONTINUED B-27
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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ENGINE INSPECTION/REPAIR PISTON CLEARANCE INSPECTION/REPAIR 1. Calculate the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit an oversized piston if necessary.
PISTON PIN CLEARANCE INSPECTION 1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown. Standard diameter 21.988―21.998 mm {0.8657―0.8660 in }
Standard clearance 0.035―0.076 mm {0.0014―0.0029 in } Maximum clearance 0.15 mm {0.006 in } 2. If the piston is replaced, the piston rings must also be replaced. PISTON RING CLEARANCE INSPECTION 1. Measure the piston ring-to-ring land clearance around the entire circumference. Replace the piston and piston ring if necessary. Standard clearance Top : 0.03―0.07 mm {0.0012―0.0027 in } Second : 0.03―0.07 mm {0.0012―0.0027 in } Oil : 0.03―0.07 mm {0.0012―0.0027 in }
2. Measure each connecting rod small end inner diameter in X and Y directions as shown. Standard diameter 21.943―21.961 mm {0.8639―0.8646 in }
Maximum clearance 0.15 mm {0.006 in }
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. 3. Measure each piston ring end gap by using a feeler gauge. Replace the piston ring if necessary.
3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown. Standard diameter 21.974―21.980 mm {0.8652―0.8653 in }
Standard end gap Top : 0.20―0.35 mm {0.008―0.013 in } Second : 0.15―0.30 mm {0.006―0.011 in } Oil rail : 0.20―0.70 mm {0.008―0.027 in } Maximum end gap 1.0 mm {0.039 in }
4. Calculate the piston pin-to-piston pin bore clearance. Replace the piston and/or piston pin if necessary.
CONTINUED B-28
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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ENGINE INSPECTION/REPAIR Standard clearance 0.008―0.024 mm {0.00032―0.00094 in } 5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin. Standard clearance - 0.037―0.013 mm {-0.0014―0.0006 in } CRANKSHAFT INSPECTION 1. Measure the crankshaft runout. Replace the crankshaft if necessary.
Crank pin Bearing size Standard
50.940―50.955 {2.0056―2.0060}
0.25 {0.01} undersize
50.690―50.705 {1.9957―1.9962}
0.50 {0.02} undersize
50.440―50.455 {1.9859―1.9864}
0.75 {0.03} undersize
50.190―50.205 {1.9760―1.9765}
Runout 0.03 mm {0.0012 in }
Out-of-round 0.05 mm {0.002 in } max.
2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersize bearing if necessary. Main journal
mm { in }
Bearing size
mm { in } Diameter
Diameter
Standard
No.1, 2, 4, 5 : 59.937―59.955 {2.3598―2.3604} No.3 : 59.937―59.955 {2.3598―2.3604}
0.25 {0.01} undersize
No.1, 2, 4, 5 : 59.687―59.697 {2.3499―2.3502} No.3 : 59.687―59.691 {2.3499―2.3500}
0.50 {0.02} undersize
No.1, 2, 4, 5 : 59.437―59.447 {2.3401―2.3404} No.3 : 59.437―59.455 {2.3401―2.3407}
0.75 {0.03} undersize
No.1, 2, 4, 5 : 59.187―59.197 {2.3302―2.3305} No.3 : 59.187―59.205 {2.3302―2.3309}
CRANKSHAFT OIL CLEARANCE INSPECTION/ REPAIR . 1. Position a plastigauge atop the journals in the axial direction. 2. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.) 3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.) 4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained. Standard oil clearance No.1, 2, 4, 5: 0.025―0.074 mm {0.00099―0.00291 in } No.3: 0.031―0.074 mm {0.00123―0.00291 in } Maximum oil clearance 0.10 mm {0.004 in }
Out-of-round 0.05 mm {0.002 in } max.
CONTINUED
B-29
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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ENGINE INSPECTION/REPAIR mm { in } Bearing size
Bearing thickness
Standard
2.004―2.007 {0.07890―0.07901}
0.25 {0.01} undersize
2.129―2.139 {0.08382―0.08421}
0.50 {0.02} undersize
No.1, 2, 4, 5 : 2.254―2.264 {0.08874―0.08913} No.3 : 2.254―2.257 {0.08874―0.08885}
0.75 {0.03} undersize
No.1, 2, 4, 5 : 2.379―2.389 {0.09367―0.09405} No.3 : 2.379―2.382 {0.09367―0.09377}
CRANKSHAFT END PLAY INSPECTION/REPAIR 1. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.) 2. Measure the crankshaft end play. If the end play exceeds the maximum, replace the crankshaft bearing or grind the crankshaft and Install an undersize bearing so that the specified end play is obtained.
3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.) CONNECTING ROD INSPECTION • Measure each connecting rod for bending and distortion. Replace the connecting rod if necessary. Bending 0.15 mm {0.006 in } max. /100 mm {3.937 in }
Standard end play 0.08―0.18 mm {0.00315―0.00708 in }
Distortion 0.180 mm {0.0071 in } max. /50 mm {1.97 in }
Maximum end play 0.30 mm {0.012 in }
Center-to-center distance FE: 151.95―152.05 {5.983―5.986 in } F8: 135.95―136.05 {5.353―5.356 in }
Note • When replacing the No.3 crankshaft bearing replace all of the bearing as a set. mm { in } Bearing size
Bearing thickness
Standard
27.94―27.99 {1.1000―1.1019}
0.25 {0.01} undersize
28.04―28.09 {1.1 040―1.1 060}
0.50 {0.02} undersize
28.12―28.17 {1.1071―1.1090}
0.75 {0.03} undersize
28.20―28.25 {1.1103―1.1122}
CONTINUED B-30
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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ENGINE INSPECTION/REPAIR CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR 1. Position a plastigauge atop the journals in the axial direction. 2. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BlOCK(II) DISASSEMBLY/ASSEMBLY, Piston and Connecting Rod Assembly Note.) 3. Remove the connecting rod cap. 4. Measure the crankpin oil clearance. If the clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained.
PISTON AND CONNECTING ROD INSPECTION • Check the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.
Standard oil clearance 0.027―0.067 mm {0.0011―0.0026 in } Maximum oil clearance 0.10 mm {0.004 in } Bearing size
3. Remove the connecting rod cap.
mm { in } Bearing thickness
Standard
1.505―1.510 {0.0593―0.0594}
0.25 {0.01} undersize
1.630―1.635 {0.0642―0.0643}
0.50 {0.02} undersize
1.755―1.760 {0.0691―0.0692}
0.75 {0.03} undersize
1.880―1.885 {0.0741―0.0742}
TENSIONER SPRING INSPECTION • Measure the free length of the tensioner spring. Replace the tensioner spring if necessary. Free length F8: 63.0 mm {2.48 in } FE CARB: 56.9 mm {2.24 in } FE CIS: 53.9 mm {2.12 in }
CONNECTING ROD SIDE CLEARANCE INSPECTION 1. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY. Piston and Connecting Rod Assembly Note.) 2. Measure the connecting rod large end side clearance. Replace the connecting rod and cap if necessary. Standard clearance 0.110―0.262 mm {0.005―0.010 in }
GEAR CLEARANCE INSPECTION F8, FE CARB Timing Belt Drive Type • Measure the following clearance. Replace the gear and/or pump body if necessary. Standard innergear tooth tip to cresent clearance 0.267―0.380 mm {0.0106―0.0149 in }
Maximum clearance 0.30 mm {0.012 in }
Maximum innergear tooth tip to cresent crearance 0.400 mm {0.0157 in }
B-31
CONTINUED
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ENGINE INSPECTION/REPAIR
Standard outer gear tooth tip to cresent clearance 0.200―0.320 mm {0.0079―0.0125 in }
ROTOR CLEARANCE INSPECTION FE CIS • Measure the following clearance. Replace the rotor and/or pump body if necessary.
Maximum outer gear tooth tip to cresent clearance 0.350 mm {0.0138 in }
Maximum Inner rotor tooth tip to outer rotor clearance 0.18 mm {0.007 in }
Standard side clearance 0.030―0.063 mm {0.00119―0.00248 in }
Standard outer gear to pump body clearance 0.090―0.176 mm {0.0036―0.0069 in }
Maximum side clearance 0.10 mm {0.004 in }
Maximum outer gear to pump body clearance 0.20 mm {0.008 in }
Standard outer rotor to body clearance 0.030―0.063 mm {0.00119―0.00248 in }
Standard side clearance 0.03―0.09 mm {0.0012―0.0035 in }
Maximum body clearance 0.10 mm {0.004 in }
Maximum side clearance 0.10 mm {0.004 in }
CONTINUED
B-32
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ENGINE INSPECTION/REPAIR
FE CARB Timing Chain Drive Type • Measure the following clearance. Replace the rotor and/or pump body if necessary.
PLUNGER SPRING INSPECTION • Measure the free length of the plunger spring. Replace the plunger spring if necessary. Free length 46.4 mm {1.827 in }
Standard Inner rotor tooth tip to outer rotor clearance 0.044―0.084 mm {0.0017―0.0033 in } Maximum Inner rotor tooth tip to outer rotor clearance 0.18 mm {0.007 in }
Standard outer gear to pump body clearance 0.090―0.176 mm {0.0035―0.0069 in } Maximum outer gear to pump body clearance 0.20 mm {0.008 in }
Standard side clearance 0.03―0.09 mm {0.0012―0.0035 in } Maximum side clearance 0.10 mm {0.004 in }
CONTINUED B-33
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TECHNICAL DATA TECHNICAL DATA ......................................... TD-1/4
TECHNICAL DATA Item Cylinder head Height mm Distortion mm Grinding mm Valve clearance (F8, FE CARB) mm { in }
Specification { in } { in } { in }
91.95—92.05 {3.621—3.624} 0.15 {0.006} max. 0.20 {0.008} max.
IN
0.30 {0.012} (Engine hot)
EX
0.30 {0.012} (Engine hot)
IN
FE CIS: 1.80—2.20 {0.071—0.086} F8, FE CARB: 0.8—1.2 {0.032—0.047}
EX
FE CIS: 1.30—1.70 {0.052—0.066} F8, FE CARB: 1.3—1.7 {0.052—0.066}
Valve and valve guide Margin thickness mm { in }
IN Valve length mm { in } EX
IN Valve stem diameter mm { in }
Standard
FE CIS: 115.61—116.01 {4.552—4.567} F8, FE CARB: 111.69—112.09 {4.398—4.412}
Minimum
FE CIS: 115.51 {4.548}, F8, FE CARB: 111.39 {4.386}
Standard
FE CIS: 116.01—116.41 {4.568—4.583} F8, FE CARB: 111.49—111.89 {4.390—4.405}
Minimum
FE CIS: 115.71 {4.556}, F8, FE CARB: 111.19{4.378}
Standard
FE CIS: 6.970—6.985 {0.2745—0.2749} F8, FE CARB: 8.030—8.045 {0.3162—0.3167}
Minimum
FE CIS: 6.920 {0.2724} F8, FE CARB: 7.980 {0.3142}
Standard
FE CIS: 6.965—6.980 {0.2743—0.2748} F8, FE CARB: 8.025—8.040 {0.3160—0.3165}
Minimum
FE CIS: 6.915 {0.2722} F8, FE CARB: 7.975 {0.3140}
EX
Guide inner diameter
IN
FE CIS: 7.010—7.030 {0.2760—0.2767} F8, FE CARB: 8.030—8.045 {0.3162—0.3167}
EX
FE CIS: 7.010—7.030 {0.2760—0.2767} F8, FE CARB: 8.025—8.040 {0.3160—0.3165}
IN
FE CIS: 19.8—20.3 {0.780—0.799} F8, FE CARB: 19.1—19.6 {0.752—0.771}
EX
FE CIS: 19.8—20.3 {0.780—0.799} F8, FE CARB: 19.1—19.6 {0.752—0.771}
IN
1.2—1.6 {0.048—0.062}
EX
1.2—1.6 {0.048—0.062}
IN
45°
Valve guide protrusion height mm { in }
Valve seat Seat contact width mm { in } Seat angle
EX IN
Seat sinking mm { in } (Valve protrusion height) EX
45°
Standard
F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957}
Maximum
F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016}
Standard
F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957}
Maximum
F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016}
CONTINUED
TD-1
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TECHNICAL DATA Item
Specification
Valve spring H: 41.0 mm {1.614 in } (FE CIS) IN
Pressing force at Valve spring height H N { kgf, lbf }
H Inner: 36.5 mm {1.437 in } Outer: 41.0 mm {1.614 in } (F8, FE CARB)
Inner: 117.19—136,01 {11,95—13.87, 26.29—30,51} Outer: 243.70—267.03 {24.85—27.23, 54.67—59.90}
H: 41.0 mm {1.614 in } (FE CIS) EX
Out-of-square mm { in }
H Inner: 36.5 mm {1.437 in} Outer: 41.0 mm {1.614 in } (F8, FE CARB)
Inner: 117.19—136.01 {11.95—13.87, 26,29—30.51} Outer: 243.70—267.03 {24.85—27.23, 54.67—59.90}
FE CIS: 1.70 {0.067} F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071}
EX
FE CIS: 1.76 {0.069} F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071} mm { in }
mm { in } No.1, 5
Journal diameter mm { in }
No.2, 3, 4
Camshaft bearing oil clearance mm { in } Camshaft end play
mm { in }
240.37—272.03 {24.51—27.74, 53.93—61.02}
IN
Camshaft Camshaft runout Lobe height
203.10—229.86 {20.71—23.44, 45.57—51.56}
0.03 {0.0012} max.
IN
FE CIS: 41,340 {1.6276} F8, FE CARB: 38.202 {1.5040}
EX
FE CIS: 41.847 {1.6475} F8, FE CARB: 38.202 {1.5040}
Standard
31.940—31.965 {1.2575—1.2585}
Minimum
31.910 {1.2563}
Standard
31.910—31.935 {1.2563—1.2572}
Minimum
31.880 {1.2551}
No.1, 5
0.035—0.085 {0.00138—0,00334}
No.2, 3, 4
0.065—0.115 {0.00256—0.00453}
Maximum
0.15 {0.006}
Standard
0.08—0.16 {0.00315—0.00629}
Maximum
0.20 {0.008}
Rocker arm and rocker arm shaft Rocker arm inner diameter
mm { in }
FE CIS: 19.000—19.033 {0.7481—0.7493} F8, FE CARB: 15.966—15.984 {0.6286—0.6292}
Rocker arm shaft diameter
mm { in }
FE CIS: 18.959—18.980 {0.7465—0.7472} F8, FE CARB: 15.966—15.984 {0.6286—0.6292}
Rocker arm to shaft clearance
mm { in }
FE CIS: 0.020—0.074 {0.00079—0.00291} F8, FE CARB: 0.016—0.061 {0,00063—0.00240}
Height
mm { in }
FE; 288.93—289.07 {11.376—11.380} F8: 268.43—268.57 {10.569—10.573}
Distortion
mm { in }
0.15 {0.006} max.
Cylinder block
Grinding Cylinder bore diameter mm { in }
mm { in }
86.000—86.019 {3.3859—3,3865}
0.25 {0.01} oversize
86.250—86.269 {3.3957—3.3964}
0.50 {0.02} oversize Wear limit
0.20 {0.008} max.
Standard
86.500—86.519 {3.4056—3.4062} mm { in }
0.15 {0,006}
CONTINUED
TD-2
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TECHNICAL DATA Item
Specification
Piston Piston diameter Measured at 90° to pin bore axis and 18.0 mm {0.709 in } below oil ring groove mm { in }
Standard
85.943—85.965 {3.38358—3.38444}
0.25 {0.01} oversize
86.193—86.215 {3.39342—3.39428}
0.50 {0.02} oversize
86.443—86.465 {3.40327—3.40412}
Piston-to-cylinder clearance mm { in }
Standard
0.035—0.076 {0.0014—0.0029}
Maximum
0.15 {0.006}
Piston ring Top Piston ring-to-ring groove clearance mm { in }
0.03—0.07 {0.0012—0.0027}
Second
0.03—0.07 {0.0012—0.0027}
Oil
0.03—0.07 {0.0012—0.0027}
Maximum End gap (Measured in cylinder) mm { in }
0.15 {0.006}
Top
0.20—0.35 {0.008—0.013}
Second
0.15—0.30 {0.006—0.011}
Oil (rail)
0.20—0.70 {0.008—0.027}
Maximum
1.0 {0.039}
Piston pin Diameter Connecting rod small end-to-piston pin clearance Piston-to-piston pin clearance Crankshaft
mm { in }
21.974—21.980 {0.8652—0.8653}
mm { in }
- 0.037— - 0.013 { -0.0014— - 0.0006}
mm { in }
0.008—0.024 {0.00032—0.00094}
Crankshaft runout
mm { in }
Main journal diameter mm { in }
Standard 0.25 {0.01} undersize
No.1, 2, 4, 5: 59.687—59.697 {2.3499—2.3502} No.3: 59.687—59.691 {2.3499—2.3500}
0.50 {0.02} undersize
No.1, 2, 4. 5: 59.437—59.447 {2.3401—2.3404} No.3: 59.437—59.455 {2.3401—2.3407}
0.75 {0.03} undersize
No.1, 2, 4, 5: 59,187—59.197 {2.3302—2.3305} No.3: 59.187—59.205 {2.3302—2.3309}
Out-of-round Crankpin diameter mm { in }
mm { in }
0.05 {0.002} max.
Standard
50.940—50.955 {2.0056—2.0060}
0.25 {0.01} undersize
50.690—50.705 {1.9957—1.9962}
0.50 {0.02} undersize
50.440—50.455 {1.9859—1.9864}
0.75 {0.03} undersize Out-of-round
50.190—50.205 {1.9760—1.9765} mm { in }
mm { in } mm { in }
0.05 {0.002} max. No.1, 2, 4, 5: 0.025—0.074 {0.00099—0.00291} No.3: 0.031—0.074 {0.00123—0.00291}
Standard
Main journal oil clearance
Crankshaft end play
0.03 {0.0012} max. No.1, 2, 4, 5: 59.937—59.955 {2.3598—2.3604} No.3: 59.937—59.955 {2.3598—2.3604}
Maximum
0.10 {0.004}
Standard
0.08—0.18 {0.00315—0.00708}
Maximum
0.30 {0.012}
CONTINUED
TD-3
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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TECHNICAL DATA Item Connecting rod and connecting rod bearing
Specification
Length (Center to center)
mm { in }
F8: 135.95—136.05 {5,353—5.356} FE: 151.95—152.05 {5.983—5.986}
Bending
mm { in }
0.15 {0.006} max./100 mm {3.937 in}
mm { in }
0.180 {0.0071} max./50 mm {1.97 in }
Distortion Connecting rod side clearance mm { in }
Standard
0.110—0.262 {0.005—0.010}
Maximum
0.30 {0.012}
Connecting rod bearing oil clearance mm { in }
Standard
0.027—0.067 {0.0011—0.0026}
Maximum
0.10 {0.004}
Tensioner spring Free length
mm { in }
F8: 63.0 {2.48}, FE CARB: 56.9 {2.24}, FE CIS: 53.9 {2.12}
Oil pump Inner rotor tooth tip to outer rotor clearance mm { in }
Standard
FE CARB Timing chain drive type: 0.044—0.084 {0.0017—0.0033}
Maximum
0.18 {0.007} (FE CIS, FE CARB Timing chain type)
Outer rotor to body clearance mm { in }
Standard
FE CIS, CARB Timing chain type: 0.090—0.176 {0.0035—0.0069}
Maximum
FE CIS, CARB Timing chain type: 0.20 {0.008}
Standard
F8, FE CARB Timing belt drive type: 0.267—0.380 {0.0106—0.0149}
Maximum
F8, FE CARB Timing belt drive type: 0.400 {0.0157}
Outer gear tooth tip to crescent clearance mm { in }
Standard
P8, FE CARB Timing belt drive type: 0.200—0.320 {0.0079—0.0125}
Maximum
F8, FE CARB Timing belt drive type: 0.350 {0.0138}
Outer gear to pump body clearance mm { in }
Standard
0.030—0.063 {0.00119—0.00248}
Maximum
0.10 {0.004}
Standard
F8, FE CARB Timing belt drive type: 0.030—0.063 {0.00120—0.0024} FE CIS, FE CARB Timing chain drive type: 0.03—0.09 {0.0012—0.0035}
Maximum
0.10 {0.004}
Inner gear tooth tip to crescent clearance mm { in }
Side clearance
mm { in }
Plunger spring Free length
mm { in }
46.4 {1.827}
CONTINUED
TD-4
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SPECIAL TOOLS SPECIAL TOOLS ........................................... ST-1
SPECIAL TOOLS 49 0107 680A
49 L010 1A0
49 0636 100B
Engine stand
Engine hanger set
Valve spring lifter arm
49 B012 0A2
49 0221 251A
49 S120 170
Pivot
Valve guide remover and installer
Valve seal remover
49 L012 0A2
49 L011 0A0B
49 E011 1A0
Valve seal and guide installer
Piston pin setting tool set
Ring gear brake set
49 1285 071
49 P005 204
49 S011 103
Needle bearing puller
Oil seal installer
Oil seal installer
CONTINUED
ST-1
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ENGINE (WL, WL Turbo) DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–1 DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . B2–1/2 DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . B2–2 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . B2–2 VALVE CLEARANCE INSPECTION/ADJUSTMENT . . . . . . . . . . . . . B2–2 COMPRESSION INSPECTION . . . . . . . . . . . . . . . B2–3 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–4 TIMING BELT REMOVAL/INSTALLATION . . . . B2–4/5 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . B2–6 CYLINDER HEAD GASKET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . B2–6/8
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . B2– 9 ROCKER ARM REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . B2– 9/11 FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . B2–11 FRONT OIL SEAL REPLACEMENT . . . . . . . . B2–11/12 REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . B2–12 REAR OIL SEAL REPLACEMENT . . . . . . . . B2–12 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–13 ENGINE REMOVAL/INSTALLATION . . . . . . B2–13/14 ENGINE DISASSEMBLY/ASSEMBLY . . . . . B2–14
DRIVE BELT
Deflection
DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N {10 kgf, 22 lbf} midway between the specified pulleys. GENERATOR
*New
Used
Limit
Generator
7.0—9.0 {0.28—0.35}
8.0—10.0 {0.32—0.39}
16.0 {0.63}
a
5.0—6.2 {0.20—0.24}
6.0—6.5 {0.24—0.25}
11.3 {0.44}
b
9.5—11.8 {0.38—0.46}
11.0—12.5 {0.44—0.49}
18.0 {0.71}
A/C
MEASURING POINT
(mm {in})
Drive belt
* A belt that has been on a running engine for less than five minutes. WATER PUMP
2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) GENERATOR
CRANKSHAFT PULLEY MEASURING POINT a
A/C
CRANKSHAFT PULLEY
Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.
A/C COMPRESSOR
49 9200 020A
MEASURING POINT b WHEN MEASURED
WHEN SET
CONTINUED
B2–1
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DRIVE BELT, VALVE CLEARANCE Tension
(N {kgf, lbf})
Drive belt
*New
Used
Limit
Generator
442—637 {45—65, 99—143}
383—539 {39—55, 86—121}
177 {18, 40}
A/C
403—519 {41—53, 91—116}
354—431 {36—44, 80—96}
181 {18.5, 41}
VALVE CLEARANCE VALVE CLEARANCE INSPECTION/ADJUSTMENT 1. Remove the cylinder head cover. 2. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinder is at TDC of compression. 3. Measure the valve clearances A with the No.1 cylinder at TDC of compression, and those of B with the No.4 cylinder at TDC of compression.
* A belt that has been on a running engine for less than five minutes.
2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen the mounting bolt and locknut A. 2. Adjust the belt deflection or tension by turning adjusting bolt B. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten the mounting bolt and locknut A.
Valve clearance IN: 0.05—0.15 mm {0.0020—0.0059 in} [Engine cold] 0.15 mm {0.0059 in} [Engine hot (Reference)] EX:0.15—0.25 mm {0.0060—0.0098 in} [Engine cold] 0.25 mm {0.0098 in} [Engine hot (Reference)] A
A
A
GENERATOR
ENGINE FRONT
B A 19—25 {1.9—2.6, 14—18}
WATER PUMP
B
B
B
GENERATOR
4. If not within the specification, adjust and recheck the valve clearance. 5. Turn the crankshaft one full turn and measure the remaining valve clearances. Adjust if necessary.
32—46
A {3.2—4.7,
CRANKSHAFT PULLEY
24—33}
B a
A/C
38—51 {3.8—5.3, A 28—38}
Tightening torque (locknut) 16—20 N·m {1.6—2.1 kgf·m, 12—15 ft·lbf} A/C COMPRESSOR
CRANKSHAFT PULLEY
FEELER GAUGE
ADJUST SCREW
LOCKNUT b
N·m {kgf·m, ft·lbf}
4. Inspect the belt deflection or tension. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
6. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
CONTINUED
B2–2
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COMPRESSION INSPECTION
COMPRESSION INSPECTION Warning When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they are cool. 1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool off for about 10 minutes. Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent fuel from spurting out of the injection nozzle hole, do not ground the FCV (fuel cut valve) terminal.
(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. 10. Remove the SST. 11. Install the glow plug. (Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.) 12. Connect the FCV (fuel cut valve) connector.
4. Disconnect the FCV (fuel cut valve) connector. 5. Remove all the glow plugs. (Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.) 6. Install the SSTs into the glow plug hole. 49 S010 1A0 49 S013 102
7. Crank the engine and note the maximum gauge reading. 8. Check each cylinder as above. Compression (kPa {kgf/cm2, psi} [rpm]) Item
Engine WL, WL Turbo
Standard
2942 {30, 427} [200]
Minimum
2648 {27, 384} [200]
9. If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. (2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
CONTINUED
B2–3
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TIMING BELT 3. Remove the tensioner and tensioner spring.
TIMING BELT TIMING BELT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Timing Belt Installation Note 1. Measure the tensioner spring free length. Replace the tensioner spring if necessary. Free length 63.0 mm {2.48 in}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
38—51 {3.8—5.3, 28—38} N·m {kgf·m, ft·lbf}
FREE LENGTH
1
Timing belt cover + Installation Note
2
Tensioner, tensioner spring
3
Timing belt + Removal Note + Installation Note
2. Turn the crankshaft clockwise and align the timing marks as shown. TIMING MARK TENSIONER LOCK BOLT
Timing Belt Removal Note
CAMSHAFT PULLEY
Caution Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life.
TENSIONER SPRING TENSIONER TIMING MARK
FAULTY
FAULTY
Caution Overtensioning of the timing belt can cause breakage of the belt and the camshaft.
FAULTY
ROTATION ARROW
25 mm {1.0 in} MIN.
3. Verify that the FIP attaching bolts and nuts are tightened to the specified torque. This must be done to prevent overtensioning of the timing belt after it has been installed. 4. Install the timing belt. 5. Install the tensioner, tensioner spring, and hand-tighten the lock bolt. 6. Turn the crankshaft clockwise twice, and align the timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Installation Note Step 2. 7. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring. 8. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation. 9. Turn the crankshaft clockwise twice, and check the timing belt deflection as shown. If it is incorrect, repeat from Timing Belt Removal Note.
FAULTY
1. Mark the timing belt rotation on the belt for proper reinstallation. 2. Turn the crankshaft clockwise and align the timing marks as shown. TIMING MARK
CAMSHAFT PULLEY TENSIONER SPRING TENSIONER TIMING MARK
FIP PULLEY
FIP PULLEY
CONTINUED
B2–4
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TIMING BELT Timing belt deflection 9.0—10.0 mm {0.36—0.39 in} at 98 N {10 kgf, 22 lbf} TENSIONER LOCK BOLT
DEFLECTION CHECKING POINT
CAMSHAFT PULLEY TENSIONER SPRING TENSIONER FIP PULLEY
Timing Belt Cover Installation Note Tighten the timing belt cover bolts in the order shown.
CONTINUED
ST
B2–5
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CYLINDER HEAD GASKET
CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E,ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the intake manifold, air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 4. Remove the injection nozzle. (Refer to Section F2, FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 5. Remove the turbocharger. (WL Turbo) (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 7. Remove in the order indicated in the table. 8. Install in the reverse order of removal. 9. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 10. Check the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 11. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 12. Start the engine and (1) Inspect for engine oil, engine coolant, and fuel leakage. (2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, PREPARATION, Idle Speed Adjustment.) 13. Inspect the compression. (Refer to COMPRESSION INSPECTION.)
5.0—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf} 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
18—19 {1.8—2.0, 13.1—14.4} 29 {3.0, 22} + (90°—105°) + (90°—105°)
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
38—51 {3.8—5.3, 28—38}
CONTINUED N·m {kgf·m, ft·lbf}
B2–6
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CYLINDER HEAD GASKET
1
Drive belt
2
Cylinder head cover + Installation Note
3
Cylinder head bolt + Removal Note + Installation Note
4
Cylinder head
5
Cylinder head gasket + Installation Note
LENGTH
Cylinder Head Bolt Removal Note 1. Remove bolts A. 2. Loosen the cylinder head bolts in two or three steps in the order shown.
2. Apply clean engine oil to the threads and the seat face of each bolt and install them. 3. Tighten the bolts in two or three steps in the order shown in the figure.
A
Tightening torque 29 N·m {3.0 kgf·m, 22 ft·lbf} A
A
Cylinder Head Gasket Installation Note Apply silicone sealant to the cylinder head as shown.
A
Thickness ø2.0—3.0 mm {0.08—0.11 in}
4. Put a paint mark on each bolt head. 5. Using the marks as a reference, tighten the bolts by turning each 90°—105° in the sequence shown. 6. Further tighten each bolt by turning another 90°—105°.
16.0 mm {0.63 in} 40.5 mm {1.59 in}
ENGINE FRONT
PAINT MARK 90°—105°
48.5 mm {1.91 in}
90°—105°
9.0 mm {0.35 in}
ST Cylinder Head Bolt Installation Note 1. Measure the length of each bolt. Replace the bolt if necessary.
PAINT MARK
7. Tighten bolts A.
Cylinder head bolt
(mm {in})
Bolt head mark
Standard length
Maximum length
W
101.2—101.8 {3.985—4.007}
102.5 {4.035}
N
113.2—113.8 {4.457—4.480}
114.5 {4.508}
Tightening torque 18—19 N·m {1.8—2.0 kgf·m, 13.1—14.4 ft·lbf}
CONTINUED
B2–7
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CYLINDER HEAD GASKET Cylinder Head Cover Installation Note 1. Apply silicone sealant to the cylinder head as shown. Thickness ø1.5—2.5 mm {0.060—0.098 in}
2. Tighten cylinder head cover bolts A and B. Tightening torque 1.5—2.9 N·m {15—30 kgf·cm, 14—26 in·lbf}
A ENGINE FRONT B
3. Tighten the cylinder head cover bolts in the order shown. Tightening torque 5.0—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf}
CONTINUED
B2–8
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ROCKER ARM
ROCKER ARM ROCKER ARM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
5.0—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf}
R
11.3—14.2 N·m {115—145 kgf·cm, 100—125 in·lbf} 16—20 {1.6—2.1, 12—15}
R SST
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 30—41 {3.0—4.2, 22—30}
123—140 {12.5—14.3, 91—103}
N·m {kgf·m, ft·lbf}
1
2
Cylinder head cover + VALVE CLEARANCE, VALVE CLEARANCE INSPECTION/ADJUSTMENT + CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note
3
Seal plate + Installation Note
4
Camshaft + Removal Note + Installation Note
ST
Camshaft pulley + Removal Note + Installation Note
5
Rocker arm + Installation Note
6
Pivot
CONTINUED
B2–9
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ROCKER ARM Camshaft Pulley Removal Note Hold the camshaft by using a wrench on the cast hexagon.
2. Tighten the camshaft cap bolts gradually in three or four steps in the order shown. Camshaft Removal Note Note Mark the camshaft caps so that they can be reinstalled in the position from which they were removed.
ENGINE FRONT
Loosen the camshaft cap bolts in three or four
steps in the order shown.
ENGINE FRONT
3. Apply clean engine oil to the new oil seal. 4. Push the oil seal slightly in by hand. 5. Tap the oil seal into the cylinder head by using the SST and a hammer. 6. To ensure that the oil seal is installed accurately, measure distance between the end of the cylinder head and the face of the oil seal. 49 S010 001
Rocker Arm Installation Note If a new rocker arm is used, set dimension follows.
as 0.5—1.0 mm {0.02—0.03 in}
Dimension A 0—4 mm {0—0.1 in} HAMMER
CYLINDER HEAD
OIL SEAL
Seal Plate Installation Note Tighten the seal plate bolts in the order shown. A
Camshaft Installation Note 1. Apply silicone sealant to the front camshaft cap mounting surfaces as shown. Prevent sealant from getting onto the camshaft journal, oil seal surface, and camshaft thrust surface.
B2–10
CONTINUED
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ROCKER ARM, FRONT OIL SEAL Camshaft Pulley Installation Note Hold the camshaft by using a wrench on the cast hexagon and tighten the pulley lock bolt.
FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the upper radiator hose. 4. Remove the radiator cowling and cooling fan. (Refer to Section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Inspect the engine oil level. 8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) SST R SST 350—390 {35—40, 260—280}
N·m {kgf·m, ft·lbf}
1
Drive belt
2
Crankshaft pulley + Removal Note + Installation Note
3
Front oil seal + Removal Note + Installation Note
Crankshaft Pulley Removal Note Hold the crankshaft by using the SST. Caution Turning the crankshaft after the crankshaft pulley is removed can cause the timing gear to become dislocated. Removing the key can cause the key groove to become misaligned.
49 S011 102A
CONTINUED
B2–11
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FRONT OIL SEAL, REAR OIL SEAL Front Oil Seal Removal Note 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag.
REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
RAG
Front Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly by using the SST and a hammer. 4. To ensure that the oil seal is installed accurately, measure the distance between the end of the gear case cover and the face of the front oil seal.
SST
1
GEAR CASE COVER
49 S010 301
0—0.4 mm {0—0.01 in}
HAMMER
R
Rear oil seal + Removal Note + Installation Note
Rear Oil Seal Removal Note 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag.
FRONT OIL SEAL
Crankshaft Pulley Installation Note Hold the crankshaft by using the SST.
RAG
49 S011 102A
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly by using the SST and a hammer. 4. To ensure that the oil seal is installed accurately, measure the distance between the end of the rear cover and the face of the rear oil seal. 49 S011 103
REAR COVER
0—0.5 mm {0—0.01 in}
HAMMER
REAR OIL SEAL
CONTINUED
B2–12
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ENGINE
ENGINE ENGINE REMOVAL/INSTALLATION Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures”. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.) 1. Remove the air intake pipe. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.) 3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 4. Remove the front pipe. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the transmission. (Refer to section J2, TRANSMISSION, TRANSMISSION REMOVAL/INSTALLATION.) 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal. 8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 10. Start the engine and (1) Inspect the engine oil, engine coolant, and fuel leakage. (2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed Adjustment.) 11. Perform a road test.
19—25 {1.9—2.6, 14—18}
9.9—14.7 N·m {100—150 kgf·cm, 86.8—130 in·lbf}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
32—46 {3.2—4.7, 24—33}
20—30 {2.0—3.1, 15—22} N·m {kgf·m, ft·lbf}
1
Cooling fan
2
Drive belt
3 4
5
P/S oil pump + Removal Note
Accelerator cable
6
Engine mount nut
A/C compressor + Removal Note
7
Engine + Removal/Installation Note
CONTINUED
B2–13
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ENGINE A/C Compressor Removal Note Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. P/S Oil Pump Removal Note Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. Engine Removal/Installation Note Install the engine hanger (JE48 10 561C) to the cylinder head by using bolt (99794 0820) or (M8 1.25, 6T, length 20 mm {0.79 in}) as shown.
ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the intake-air system. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the exhaust system. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Remove the oil cooler. (Refer to Section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) 4. Disassemble in the ordre indicated in the table. 5. Assemble in the reverse order of disassembly.
12—17 {1.2—1.8, 9—13}
Tightening torque 19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf} 38—51 {3.8—5.3, 28—38}
ENGINE FRONT
32—46 {3.2—4.7, 24—33}
19—25 {1.9—2.6, 14—18}
38—51 {3.8—5.3, 28—38}
N·m {kgf·m, ft·lbf}
1
Drive belt
2
Generator
3
Idler
4
A/C compressor bracket
5
Engine mount bracket
6
Oil pressure switch + Section D, OIL PRESSURE INSPECTION
7
Water pump pulley
CONTINUED
B2–14
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ENGINE (F2) DRIVE BELT .................................................... B3- 1 DRIVE BELT INSPECTION .......................... B3- 1 DRIVE BELT ADJUSTMENT ........................ B3- 2 COMPRESSION INSPECTION ........................ B3- 2/3 TIMING BELT .................................................. B3- 4 TIMING BELT REMOVAL/INSTALLATION ... B3-4/6 CYLINDER HEAD GASKET ............................. B3- 7 CYLINDER HEAD GASKET REPLACEMENT ......................................... B3- 7/9 HYDRAULIC LASH ADJUSTER (HLA) ............ B3-10
DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys.
HLA REMOVAL/INSTALLATION ................ B3-10/12 HLA TROUBLESHOOTING ........................ B3-13 FRONT OIL SEAL ......................................... B3-14 FRONT OIL SEAL REPLACEMENT ........... B3-14 REAR OIL SEAL ............................................. B3-15 REAR OIL SEAL REPLACEMENT ............. B3-15 ENGINE .......................................................... B3-16 ENGINE REMOVAL/INSTALLATION ......... B3-16/17 ENGINE DISASSEMBLY/ASSEMBLY ........ B3-18
Deflection Drive belt Generator P/S A/C
*New
mm {in} Used
7.0—8.0 {0.28—0.31}
8.0—9.0 {0.32—0.35}
5.0—6.0 {0.20—0.23} 10.0—12.0 {0.40—0.47}
5.5—6.5 {0.22—0.25} 12.0—14.0 {0.48—0.55}
* A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.
CONTINUED
B3-1
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DRIVE BELT, COMPRESSION INSPECTION N {kgf, Ibf}
Tension Drive belt
*New
Used
Generator
510—588 {52—60, 115—132}
432—509 44—52, 97—114}
P/S
393—490 {40—50, 88—110}
344—441 {35—45, 77—99}
A/C
373—490 {38—50, 84—110}
275—372 {28—38, 62—83}
* A belt that has been on a running engine for less than five minutes. 2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the generator or adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten mounting bolts A and B, and locknut C.
COMPRESSION INSPECTION
•
• • •
• • • • • •
Warning • When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during removal/installation of each component. Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) Warm up the engine to the normal operating temperature. Stop the engine and allow it to cool off for about 10 minutes. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB). Remove the spark plugs. Connect a compression gauge into the No.1 spark plug hole. Fully depress the accelerator pedal and crank the engine. Note the maximum gauge reading. Inspect compression of each cylinder.
Compression Item Standard Minimum Maximum difference between cylinders
kPa {kgf/cm2, psi} [rpm] Engine type F2 CARB F2CIS 1196 {12.2, 173} 1226 {12.5, 178} [300] [300] 837 {8.54, 121} [300]
858 {8.75, 124} [300]
2 196 kPa {2.0 kgf/cm , 28 psi}
•
If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. • If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. • If the compression stays low, a valve may be stuck or improperly seated and overhaul is required. • If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. • Disconnect the compression gauge. • Install the spark plugs. Tightening torque 15—22 N-m {1.5—2.3 kgf-m, 11—16 ft-lbf}
B3-2
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COMPRESSION INSPECTION • •
Connect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB). Install the fuel pump relay.
CONTINUED
B3-3
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TIMING BELT TIMING BELT TIMING BELT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the spark plugs. 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and cooling fan pulley. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Start the engine and (1) Inspect the pulleys and drive belt for runout and contact. (2) Inspect the ignition timing. (Refer to Section F3-F4, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
1 2 3 4 5
Generator strap Cooling fan bracket Timing belt cover ☞ Installation Note Crankshaft pulley Guide plate
6
7
Timing belt ☞ Removal Note ☞ Installation Note Tensioner, tensioner spring ☞ Installation Note
CONTINUED
B3-4
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TIMING BELT Timing Belt Removal Note 1. Turn the crankshaft clockwise and align the timing marks. Camshaft pulley timing mark 1 2. Install the tensioner. 3. Temporarily secure the tensioner with the spring fully extended.
2. Loosen the tensioner lock bolt. 3. Push the tensioner in the direction of the ar reduce tension of the timing belt and handrow to tighten the tensioner lock bolt. Timing Belt Installation Note 1. Verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks as shown. Camshaft pulley timing mark 1
Caution • Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life. Note • Mark the timing belt rotation on the belt for proper reinstallation. 2. Install the timing belt so that there is no looseness at the tension side.
Tensioner, Tensioner Spring Installation Note 1. Measure the tensioner spring free length. If not as specified, replace the tensioner spring. Free length 63.0 mm {2.48 in}
CONTINUED
B3-5
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TIMING BELT Caution • Applying excessive tension can break the timing belt. Be sure not to apply tension other than that of the tensioner spring. 3. Loosen the tensioner lock bolt to apply tension to the timing belt. 4. Turn the crankshaft clockwise twice and verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks. 5. If not, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.) Caution • Prevent the tensioner from moving with the tensioner lock bolt as it is turned. Otherwise tension will become very high and the timing belt may break. 6. Tighten the tensioner lock bolt. 7. Inspect the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf, 22 Ibf}. Timing belt deflection New : 8.0—9.0 mm {0.32—0.35 in} Used : 9.0—10.0 mm {0.36—0.39 in}
8. If not as specified, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.) Timing Belt Cover Installation Note • Tighten the timing belt cover bolts in the order shown.
CONTINUED
B3-6
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CYLINDER HEAD GASKET CYLINDER HEAD GASKET CYLINDER HEAD GASKET REPLACEMENT Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the timing belt, (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove the front pipe. (Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the air cleaner. (F2 CARB) 6. Remove the air hose. (F2 CIS) 7. Disconnect the PCV hose. 8. Disconnect the accelerator cable and bracket (F2 CIS). 9. Disconnect the vacuum hoses, and engine harness connector. 10. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, AFTER REPAIR PROCEDURE.) 11. Remove the dynamic chamber bracket. (F2 CIS) 12. Disconnect the heater hoses. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Inspect for fuel leakage. 16. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 17. Start the engine and inspect the idle speed. (Refer to Section F3-F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
CONTINUED B3-7
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CYLINDER HEAD GASKET
1
Cylinder head cover ☞ Installation Note
2
Cylinder head ☞ Removal Note ☞ Installation Note
3
Cylinder head gasket
CONTINUED
B3-8
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CYLINDER HEAD GASKET Cylinder Head Bolt Removal Note • Loosen the cylinder head bolts a few turns in the order shown.
Cylinder Head Bolt Installation Note • Tighten the cylinder head bolts a few turns in the order shown.
Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material. 2. Apply sealant all around the cylinder head cover side of the cylinder head cover gasket surface. 3. Install the cylinder head cover gasket into the cylinder head cover. 4. Apply silicone sealant to the shaded area as shown.
CONTINUED
B3-9
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HYDRAULIC LASH ADJUSTER (HLA) HYDRAULIC LASH ADJUSTER (HLA) HLA REMOVAL/INSTALLATION Caution • Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.) 1. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 2. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 6. Start the engine and (1) inspect the engine oil (2) inspect the idle speed. (Refer to Section F3—F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 7. Inspect the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1
Rocker arm component ☞ Removal Note ☞ Installation Note
2
Camshaft cap (F2 CARB) ☞ Installation Note
3
Hydraulic lash adjuster (HLA) ☞ Installation Note
CONTINUED
B3-10
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HYDRAULIC LASH ADJUSTER (HLA) Rocker Arm Component Removal Note 1. Loosen the bolts a few turns in the order shown.
4. Apply clean engine oil to HLA 0-ring. Camshaft Cap (F2 CARS) Installation Note • Apply silicone sealant to the shaded areas of the cylinder head as shown.
Rocker Arm Component Installation Note Note • The intake side shaft has twice as many oil holes as the exhaust side shaft. (F2 CARB)
2. Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed. 3. Remove the rocker arm and shaft assembly together with the bolts.
1. Assemble the rocker arms and shaft assembly as shown in the figure.
Hydraulic Lash Adjuster (HLA) Installation Note 1. Place each HLA in a container filled with clean engine oil. Caution • Do not push the pin too hard. It may damage the HLA. 2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.
3. Pour engine oil into the oil reservoir in the rocker arm.
CONTINUED
B3-11
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HYDRAULIC LASH ADJUSTER (HLA)
2. Apply silicone sealant to the shaded areas of the cylinder head as shown.
3. Install the rocker arm component. 4. Tighten the bolts a few turns in the order shown.
CONTINUED
B3-12
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HYDRAULIC LASH ADJUSTER (HLA) HLA TROUBLESHOOTING Problem Possible Cause 1. Noise when engine is started Oil leakage in oil immediately after oil is passage or in HLA changed. 2. 3.
4.
5.
Action Run engine at 2,000—3,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. * Time required for engine oil to circulate within HLA Noise when engine is started includes tolerance for engine oil condition and after sitting one day or more. ambient temperature. Noise when engine is started Oil leakage in HLA (Refer to HYDRAULIC LASH ADJUSTER (HLA), after new HLA is installed. HLA TROUBLESHOOTING, Valve Clearance Inspection.) Noise continues more than Insufficient oil pressure Check oil pressure. 10 minutes. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION.) Faulty HLA Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.) Noise during idle after high Incorrect oil amount Check oil level. speed running. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) Deteriorated oil Replace new engine oil. (Refer to Section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
Valve Clearance Inspection 1. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 2. Measure valve clearance. Valve clearance 0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in}, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) 4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
CONTINUED
B3-13
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FRONT OIL SEAL FRONT OIL SEAL FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
1 2 3
Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
Timing belt pulley ☞ Removal/Installation Note Key Front oil seal ☞ Removal Note ☞ Installation Note
Timing Belt Pulley Removal/Installation Note • Hold the crankshaft using the SST.
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
CONTINUED B3-14
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REAR OIL SEAL REAR OIL SEAL REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/ INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Rear oil seal • Refer to Removal Note • Refer to Installation Note
Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
CONTINUED
B3-15
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ENGINE ENGINE ENGINE REMOVAL/INSTALLATION Warning • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and air hose (F2, CIS). 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket (F2 CIS), heater hoses, high-tension leads, and vacuum hoses. 6. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the cooling fan and cooling fan pulley. 8. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the transmission. (Refer to Section J1-J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 11. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to Section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 12. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Start the engine and (1) Inspect the engine oil, engine coolant, transmission oil, and fuel leakage. (2) Inspect the ignition timing, idle speed and idle mixture. (Refer to Section F3-F4, ENGINE TUNE-UP.) 16. Perform a road test.
CONTINUED
B3-16
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ENGINE
1
Engine mount nut
2
Engine
CONTINUED
B3-17
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ENGINE ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the distributor. (Refer to Section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 2. Remove the generator. 3. Remove the thermostat. (Refer to Section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) 4. Remove the intake-air system. (Refer to Section F3-F4, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Remove the exhaust system. (Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the oil filter. (Refer to Section D, OIL FILTER, OIL FILTER REPLACEMENT.) 7. Remove the oil pressure switch. (Refer to Section D, OIL PRESSURE INSPECTION.) 8. Disassemble in the order indicated in the table. 9. Assemble in the reverse order of disassembly.
1 2 3 4 5
Generator strap Cooling fan bracket Generator bracket Water inlet pipe Water bypass pipe
6 7 8 9
Dipstick P/S oil pump bracket Gusset plate Engine mount
CONTINUED
B3-18
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LUBRICATION SYSTEM OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL INSPECTION . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . .
D–1 D–2 D–2 D–2 D–2 D–2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER REMOVAL/INSTALLATION . . . . . OIL COOLER BODY INSPECTION . . . . . . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL/INSTALLATION . . . . . . . . .
D–3 D–3/4 D–4 D–4 D–4/5
G6
OIL PRESSURE INSPECTION Warning Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they are cool.
: 305—402 kPa {3.1—4.1 kgf/cm2, 45—58 psi} [3,000 rpm] WL : 452—529 kPa {4.6—5.4 kgf/cm2, 66—76 psi} [3,000 rpm] WL Turbo : 402—480 kPa {4.1—4.9 kgf/cm2, 59—69 psi} [3,000 rpm]
5. If the pressure is not as specified, inspect for the cause and repair or replace as necessary. 6. Stop the engine and wait until it becomes cool. 7. Remove the SST. 8. Apply silicone sealant to the oil pressure switch threads as shown.
1. Remove the oil pressure switch. 2. Screw the SST into the oil pressure switch installation hole. F2, G6
1.0—2.0 mm {0.040—0.078 in}
49 0187 280
4.0—6.0 mm {0.16—0.23 in} WL, WL TURBO
9. Install the oil pressure switch before the sealant hardens. Tightening torque 12—17 N·m {1.2—1.8 kgf·m, 9—13 ft·lbf} 10. Start the engine and inspect for oil leakage. 49 0187 280
3. Warm up the engine to normal operating temperature. 4. Run the engine at the specified speed, and note the gauge readings. Note The oil pressure can vary with viscosity and temperature. Oil pressure F2 : 295—392 kPa {3.0—4.0 kgf/cm2, 43—56 psi} [3,000 rpm]
CONTINUED
D–1
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ENGINE OIL, OIL FILTER
ENGINE OIL
OIL FILTER
ENGINE OIL INSPECTION 1. Position the vehicle on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and inspect for oil level and condition. Verify that the oil level is within the F and L marks on the dipstick. 5. Add or replace oil if necessary.
OIL FILTER REPLACEMENT 1. Remove the oil filter by using the SST or the filter wrench.
49 9014 001
ENGINE OIL REPLACEMENT Warning When the engine and the engine oil are hot, they can badly burn. Don’t burn yourself with either. A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands. Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
2. Use a clean rag to wipe off the mounting surface on the oil filter body. 3. Apply engine oil to the O-ring and tighten the filter according to the installation directions on the side of the oil filter using the SST or the filter wrench. 4. Start the engine and inspect for oil leakage. 5. Inspect for the oil level and add oil if necessary. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
1. Position the vehicle on level ground. 2. Remove the oil filler cap and the oil pan drain plug. 3. Drain the oil into a container. 4. Install the drain plug by using a new washer. Tightening torque 30—41 N·m {3.0—4.2 kgf·m, 22—30 ft·lbf} 5. Refill the engine oil with the specified type and amount of engine oil. 6. Refit the oil filler cap. 7. Run the engine and inspect for oil leakage. 8. Inspect the oil level and add oil if necessary. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.) Note The actual oil level may vary from the specified capacity in some cases. Oil capacity
(L {US qt, Imp qt}) Engine
Item
F2
G6
WL, WL Turbo
Oil replacement
3.9 {4.1, 3.4}
4.5 {4.8, 4.0}
5.6 {5.9, 4.9}
Oil and oil filter replacement
4.2 {4.4, 3.7}
4.7 {5.0, 4.4}
6.3 {6.7, 5.5}
Total (dry engine)
4.6 {4.9, 4.0}
5.5 {5.8, 4.8}
6.7 {7.1, 5.9}
CONTINUED
D–2
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OIL COOLER
OIL COOLER OIL COOLER REMOVAL/INSTALLATION G6, WL, WL Turbo 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the turbocharger. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) (WL Turbo model.) 4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.) 5. Remove in the order shown in the figure. 6. Install in the reverse order of removal. 7. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E, ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.) 8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.) 9. Start the engine and inspect for engine coolant leakage. G6
30—39 {3.0—4.0, 22—28} N·m {kgf·m, ft·lbf}
1
Water hose
2
Nut
3
Oil cooler
WL, WL TURBO R 30—49 {3.0—5.0, 22—36}
R
R
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 19—25 {1.9—2.6, 14—18}
R 19—25 {1.9—2.6, 14—18}
R N·m {kgf·m, ft·lbf}
1
Dipstick pipe
2
Radiator hose
3
Thermostat case
4
Insulator
5
Oil cooler body + Installation Note
6
Oil cooler
CONTINUED
D–3
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OIL COOLER, OIL PAN Oil Cooler Body Installation Note WL, WL Turbo Tighten the mounting bolts and nuts in the order shown.
OIL PAN OIL PAN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. 5. Fill with the specified amount and type of engine oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.) 6. Start the engine and inspect for engine oil leakage. F2, G6
OIL COOLER BODY INSPECTION WL, WL Turbo Measure the spring free length. Replace the spring if necessary. Standard free length Bypass valve spring: 36.7 mm {1.44 in} Pressure control valve spring: 54.7 mm {2.15 in} BYPASS VALVE SPRING
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf} 30—41 {3.0—4.2, 22—30}
38—51 {3.8—5.3, 28—38}
38—51 {3.8—5.3, 28—38}
PRESSURE CONTROL VALVE SPRING
N·m {kgf·m, ft·lbf}
1
Gusset plate
2
Oil pan + Removal Note + Installation Note
CONTINUED
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OIL PAN Oil Pan Installation Note
WL, WL TURBO
Caution If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause bolt hole damage.
94—115 {9.5—11.8, 69—85}
CRACKS
OLD SEALANT
55—80 {5.6—8.2, 41—59}
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf}
1
Crossmember (4WD)
2
Oil pan + Removal Note + Installation Note
1. Apply silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. N·m {kgf·m, ft·lbf}
Thickness Ø2.0—3.0 mm {0.08—0.11 in}
OIL PAN
Oil Pan Removal Note 1. Remove the oil pan mounting bolts. Caution Pry tools can easily scratch the cylinder block or oil baffle and oil pan contact surfaces. Prying off the oil pan can also easily bend the oil pan flange.
2. Install the oil pan before the sealant hardens.
2. Use a separator tool to separate the oil pan. SEPARATOR TOOL
CONTINUED
D–5
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COOLING SYSTEM ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT LEVEL INSPECTION . . . . ENGINE COOLANT REPLACEMENT . . . . . . . . ENGINE COOLANT LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP INSPECTION . . . . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR REMOVAL/INSTALLATION . . . . . . .
E–1 E–1 E–1/2 E–2 E–3 E–3 E–3 E–3
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT REMOVAL/INSTALLATION . . . . THERMOSTAT INSPECTION . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP REMOVAL/INSTALLATION . . . . COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING FAN REMOVAL/INSTALLATION . . . COOLING FAN INSPECTION . . . . . . . . . . . . . . .
E–4 E–4/5 E–5 E–6 E–6 E–7 E–7 E–7
ENGINE COOLANT Warning Removing the radiator cap or loosening the radiator drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you’re sure all the pressure is gone, press down on the cap –still using a cloth– turn it, and remove it. When the engine and the engine coolant are hot, they can badly burn. Turn off the engine and wait until they are cool before draining the engine coolant. ENGINE COOLANT LEVEL INSPECTION 1. Remove the radiator cap. 2. Verify that the coolant level is near the radiator filler neck. 3. Verify that the coolant level in the radiator reservoir is between the FULL and LOW marks. 4. Add coolant if necessary. ENGINE COOLANT REPLACEMENT 1. Drain the coolant in the radiator reservoir. 2. Remove the radiator cap and loosen the radiator drain plug.
TYPE A
DRAIN PLUG TYPE B
3. Drain the coolant into a container. 4. Flush the cooling system with water until all traces of color are gone. 5. Let the system drain completely. 6. Tighten the radiator drain plug. Tightening torque Type A: 1.5—2.9 N·m {15—30 kgf·cm, 14—26 in·lbf} Type B: 0.9—1.1 N·m {9.0—12 kgf·cm, 7.9—10 in·lbf} Caution The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant’s effectiveness. 7. Referring to the following graph and chart, select proper gravity of the coolant. Slowly pour the coolant into the radiator up to the coolant filler port. Filling pace 1.0 L {1.1 US qt, 0.88 Imp qt}/min. [max]
CONTINUED
E–1
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ENGINE COOLANT
SPECIFIC GRAVITY
Caution Applying more than 103 kPa {1.05 kgf/cm2, 14.9 psi} (F2) or 122 kPa {1.25 kgf/cm2, 17.7 psi} (G6, WL, WL Turbo) can damage the hoses, fittings, and other components, and cause leakage.
COOLANT PROTECTION
1,100 1,090 1,080
49 9200 147
1,070 1,060
50% 40%
1,050 30% 1,040 1,030
49 9200 146
1,020 1,010 1,000 0
5. Verify that the pressure is held. If not, inspect the system for coolant leakage.
–10 0 10 20 30 40 50 60 70 80 90 { 14 } { 32 } { 50 } { 68 } { 86 } { 104 }{ 122 } { 140 } { 158 } { 176 } { 194 } COOLANT TEMPERATURE °C { °F }
Antifreeze solution mixture percentage
Water
Coolant
Gravity at 20°C {68°F}
Above –16°C {3°F}
65
35
1,054
Above –26°C {–15°F}
55
45
1,066
Above –40°C {–40°F}
45
55
1,078
Volume percentage Coolant protection
8. Fill the coolant into the reservoir up to the FULL mark. 9. Fully install the radiator cap. 10. Start the engine and let it idle for approx. 10 minutes. If the coolant temperature becomes too high, stop the engine to prevent it from overheating. 11. After the engine warms up, run it at approx. 2,500 rpm for five minutes. 12. Increase the engine speed to approx. 3,000 rpm for five seconds, then return to idle. Repeat several times. 13. Stop the engine and wait until it is cool. 14. Inspect the coolant level. If it is low, repeat Steps 7—12. 15. Inspect for coolant leakage. ENGINE COOLANT LEAKAGE INSPECTION 1. Inspect the coolant level. (Refer to ENGINE COOLANT, ENGINE COOLANT LEVEL INSPECTION.) 2. Remove the radiator cap. 3. Connect a radiator cap tester and the SST to the radiator filler neck. 4. Apply pressure to the radiator. Pressure F2: 103 kPa {1.05 kgf/cm2, 14.9 psi} G6, WL, WL Turbo: 122 kPa {1.25 kgf/cm2, 17.7 psi}
CONTINUED
E–2
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RADIATOR CAP, RADIATOR
RADIATOR CAP
RADIATOR
RADIATOR CAP INSPECTION Warning Removing the radiator cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. When you’re sure all the pressure is gone, press down on the cap –still using a cloth– turn it, and remove it.
RADIATOR REMOVAL/INSTALLATION 1. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove in the order indiacted in the table. 3. Install in the reverse order of removal. 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 18—26 {1.8—2.7, 14—19} 18—26 {1.8—2.7, 14—19}
1. Attach the radiator cap to a radiator cap tester with the SST. Apply pressure gradually. 2. Verify that the pressure becomes stable within the specification. Pressure F2: 74—102 kPa {0.75—1.05 kgf/cm2, 10.7—14.9 psi} G6, WL, WL Turbo: 94—122 kPa {0.95—1.25 kgf/cm2, 13.5—17.7 psi} 3. If the pressure is held for 10 seconds, the radiator cap is normal. 49 9200 147
N·m {kgf·m, ft·lbf}
1
Radiator hose
2
Lower radiator cowling
3
Radiator cowling
4
Radiator
CONTINUED ST
E–3
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THERMOSTAT
THERMOSTAT
1
Upper radiator hose
2
Thermostat cover THERMOSTAT REMOVAL/INSTALLATION 3 Thermostat 1. Drain the engine coolant. (Refer to ENGINE + Installation Note COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. WL, WL TURBO 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) F2
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R
19—25 {1.9—2.6, 14—18}
R 19—25 {1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
1
Upper radiator hose
2
Thermostat cover
3
Thermostat + Installation Note
1
Dipstick pipe
2
Lower radiator hose
3
Thermostat cover
4
Thermostat + Installation Note
Thermostat Installation Note F2, G6 1. Install the thermostat into the cylinder head with the jiggle pin at the top. 2. Install a new gasket with the seal print side facing the cylinder head.
G6
JIGGLE PIN 19—25 {1.9—2.6, 14—18}
A
A–A
R
A
19—25 {1.9—2.6, 14—18}
WL, WL Turbo Install the thermostat into the thermostat cover, aligning the projection on the gasket to the thermostat cover as shown.
CONTINUED
N·m {kgf·m, ft·lbf}
E–4
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THERMOSTAT
GASKET PROJECTION
THERMOSTAT COVER
THERMOSTAT INSPECTION Warning During inspection, the thermostat and water are extremely hot and they can badly burn. Do not touch the thermostat and water directly. Inspect the thermostat for the following and replace as necessary. Open valve in room temperature Opening temperature and lift of the valve Initial-opening temperature F2: 83.5—89.5 °C {183—193 °F} G6: 86.5—89.5 °C {188—193 °F} (Main valve) 83.5—86.5 °C {183—187 °F} (Sub valve) WL, WL Turbo: 80—84 °C {176—183 °F} Full open temperature F2, G6 : 100 °C {212 °F} WL, WL Turbo : 95 °C {203 °F} Full open lift G6 : 8.0 mm {0.31 in} min. (Main valve) 1.5 mm {0.06 in} min. (Sub valve) F2, WL, WL Turbo: 8.5 mm {0.33 in} min.
CONTINUED
ST
E–5
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WATER PUMP
WATER PUMP
WL, WL TURBO
WATER PUMP REMOVAL/INSTALLATION 1. Remove the cooling fan. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.) 19—25 2. Remove the timing belt (F2). {1.9—2.6, 14—18} (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 3. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
R
F2 19—22 {1.9—2.3, 14—16}
N·m {kgf·m, ft·lbf} 19—25 {1.9—2.6, 14—18}
1
Water pump
2
Idler
R
38—51 {3.8—5.3, 28—38} N·m {kgf·m, ft·lbf}
G6
R
19—22 {1.9—2.2, 14—16} N·m {kgf·m, ft·lbf}
CONTINUED
E–6
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COOLING FAN
COOLING FAN COOLING FAN REMOVAL/INSTALLATION 1. Remove the drive belt. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the drive belt (generator) deflection. (Refer to Section B2,DRIVE BELT, DRIVE BELT ADJUSTMENT.)
F2, G6: 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} WL, WL TURBO: 19—25 {1.9—2.6, 14—18} N·m {kgf·m, ft·lbf}
1
Cooling fan
2
Water pump pulley
COOLING FAN INSPECTION 1. Rotate the cooling fan by hand and inspect for abnormal noise and looseness. Replace the cooling fan if necessary. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)
CONTINUED
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FUEL AND EMISSION CONTROL SYSTEMS (G6)
Page 1 of 2
ENGINE TUNE-UP ...............................................................F1-2 ENGINE TUNE-UP PREPARATION............................F1-2 IGNITION TIMING ADJUSTMENT...............................F1-2/3 IDLE SPEED ADJUSTMENT .......................................F1-4 IDLE-UP SPEED INSPECTION ..................................F1-4/5 IDLE MIXTURE INSPECTION .....................................F1-5 INTAKE-AIR SYSTEM ........................................................F1-6 VACUUM HOSE ROUTING DIAGRAM .......................F1-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .................................F1-6/7 BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION .................................F1-8 AIR VALVE INSPECTION ........................................... F1-8 IDLE AIR CONTROL (lAC) VALVE INSPECTION ........................................................F1-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ................................ F1-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT ..............................F1-9 FUEL SYSTEM .................................................................. F1-10 BEFORE REPAIR PROCEDURE ............................. F1-10 AFTER REPAIR PROCEDURE ................................. F1-10 FUEL TANK REMOVAL/INSTALLATION ............................... F1-11/13 NONRETURN VALVE INSPECTION ........................ F1-13 FUEL PUMP UNIT REMOVAL/INSTALLATION ............................... F1-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY .............................. F1-13/14 FUEL PUMP UNIT INSPECTION .............................. F1-14/16 FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION ............................... F1-16/17 FUEL INJECTOR REMOVAL/INSTALLATION ............................... F1-18/19 FUEL INJECTOR INSPECTION ................................ F1-19/21 PRESSURE REGULATOR REMOVAL/INSTALLATION ............................... F1-21 PRESSURE REGULATOR INSPECTION ...................................................... F1-21/22 PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION ................................................. F1-22 PULSATION DAMPER REMOVAL/INSTALLATION ............................... F1-22 PULSATION DAMPER INSPECTION ....................... F1-22 FUEL PUMP RELAY INSPECTION .......................... F1-23 EXHAUST SYSTEM .......................................................... F1-24 EXHAUST SYSTEM INSPECTION ........................... F1-24 EXHAUST SYSTEM REMOVAL/INSTALLATION ............................... F1-24 EMISSION SYSTEM .......................................................... F1-25 EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION .......................................................... F1-25 ROLLOVER VALVE INSPECTION ........................... F1-25 EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION ................................ F1-25
CHECK VALVE (TWO-WAY) INSPECTION ....................................................... F1-25/26 EVAPORATIVE CHAMBER INSPECTION ....................................................... F1-26 CHARCOAL CANISTER INSPECTION ................... F1-26 PURGE SOLENOID VALVE INSPECTION ....................................................... F1-26/27 POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION .............................. F1-27 CONTROL SYSTEM .......................................................... F1-28 CONTROL SYSTEM COMPONENT LOCATION............................................................ F1-28 PCM REMOVAL/INSTALLATION ............................. F1-29 PCM INSPECTION .............................................. F1-29/37 MASS AIR FLOW (MAF) SENSOR INSPECTION........................................................ F1-37 THROTTLE POSITION (TP) SENSOR INSPECTION ....................................................... F1-37/38 THROTTLE POSITION (TP) SENSOR ADJUSTMENT .................................................... F1-38 THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION ................................ F1-38/39 CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION ....................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION ....................................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION ................................ F1-40 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION ............... F1-40 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION ...................................... F1-40/41 CAMSHAFT POSITION (CMP) SENSOR INSPECTION ....................................................... F1-41 OXYGEN SENSOR O2S) INSPECTION ....................................................... F1-41/42 OXYGEN SENSOR O2S) REMOVAL/INSTALLATION................................. F1-42 VARIABLE RESISTOR INSPECTION........................ F1-42 CLUTCH SWITCH INSPECTION .............................. F1-42/43 CLUTCH SWITCH REMOVAL/INSTALLATION ............................... F1-43 NEUTRAL SWITCH INSPECTION ............................ F1-43 NEUTRAL SWITCH REMOVAL/INSTALLATION ................................ F1-43/44 POWER STEERING PRESSURE (PSP) SWITCH INSPECTION ............................ F1-44 MAIN RELAY INSPECTION ....................................... F1-44/45 MAIN RELAY REMOVAL/INSTALLATION ................ F1-45 ON-BOARD DIAGNOSTIC SYSTEM ............................... F1-45 READ/CLEAR DIAGNOSTIC TEST RESULTS ............................................................. F1-45 PARAMETER IDENTIFICATION (PID) ACCESS ............................................................... F1-45 DIAGNOSTIC SUPPORT PROCEDURE .................. F1-45 SIMULATION TEST..................................................... F1-45 ON-BOARD DIAGNOSTIC TEST .............................. F1-45/46 DTC READING PROCEDURE .................................. F1-46/48
F1-1
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FUEL AND EMISSION CONTROL SYSTEMS (G6 ) Page 2 of 2
PID/DATA MONITOR AND RECORD PROCEDURE ...................................................... F1-48 PLAYBACK OF STORED PIDS PROCEDURE ...................................................... F1-48/49 DIAGNOSTIC SUPPORT PROCEDURE .......... F1-49 SIMULATION TEST PROCEDURE ........................ F1-50/51 AFTER REPAIR PROCEDURE ............................. F1-51 DTC INSPECTION .................................................. F1-52/69
ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION Using the SSTs (NGS Tester) 1. Warm up the engine to normal operating temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads. • A/C switch 4. Verify that the steering wheel is at straight ahead position. 5. Connect the SSTs (NQS tester) to the DLC and select "PID/DATA MONITOR AND RECORD". (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.)
6. Access RPM PID. Press the trigger key to enter this selection. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.) 7. Press SETUP (Key 8) and turn the test mode on. 8. Press CANCEL. 9. Press START.
TROUBLESHOOTING ...................................................F1-70 FOREWORD ............................................................F1-70 TROUBLESHOOTING ITEM TABLE .....................F1-70 QUICK DIAGNOSTIC CHART ...............................F1-71/74 SYMPTOM TROUBLESHOOTING .......................F1-75/114 DIAGNOSTIC INSPECTION..................................F1-115/120 ENGINE SYSTEM INSPECTION .........................F1-120/127
Not Using the SSTs (NGS tester) 1. Warm up the engine to normal operating temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads. • A/C switch 4. Verify that the steering wheel is at straight ahead position. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. 5. Connect a dwell tachometer to the DLC terminal IG-.
IGNITION TIMING ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNEUP PREPARATION.) 2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ±20) rpm 3. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 4. Connect the timing light to the high-tension lead of the No. 1 cylinder. 5. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 4°—6°(5° ± 1°)
CONTINUED
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ENGINE TUNE-UP 6. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment. 7. Tighten the distributor lock bolts to the specified torque. Tightening torque 19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf} 8. Press SETUP (Key 8) and turn the test mode off. 9. Press CANCEL. 10. Verify that the timing mark on the crankshaft pulley is within the specification.
4. Verify that the idle speed is within the specification. Specification 730—770 (750 ± 20) RPM 5. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 6. Connect the timing light to the high-tension lead of the No.1 cylinder. 7. Verify that the timing mark on the crankshaft pulley is within the specification.
Specification BTDC 1°—30° Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
Specification BTDC 4°—6° (5° ± 1°) 8. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment. 9. Tighten the distributor lock bolts to the specified torque. Tightening torque 19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf} 10. Disconnect the SST or jumper wire. 11. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 1°—30°
3. If using a jumper wire to turn on the test mode, perform the following: Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. • Use a jumper wire to short terminal TEN of the DLC to body GND.
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ENGINE TUNE-UP IDLE SPEED ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the RPM PID is within the specification. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not be adjusted. Any adjustment will negatively affect the engine performance. 3. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT", then adjust the idle speed by turning the AAS.
Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. • Use a jumper wire to short terminal TEN of the DLC to body GND.
4. Verify that the idle speed is within the specification using the dwell tachometer. Specification 730—770 (750 ± 20) RPM Caution • The TAS is set at the factory and must not be adjusted. Any adjustment will negatively affect the engine performance. 5. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT', then adjust the idle speed by turning the AAS.
4. Press SETUP (Key 8) to turn the test mode off. 5. Press CLEAR to clear previously selected items. 6. Disconnect the SSTs. Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
3. If using a jumper wire to turn on the test mode, perform the following:
6. Disconnect the SST or a jumper wire. 7. Disconnect the dwell tachometer. IDLE-UP SPEED INSPECTION Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Press SETUP (Key 8) and turn the test mode off. 3. Press CANCEL. 4. Press START. 5. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 6. Verify that the RPM PID is within the specification.
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ENGINE TUNE-UP Specification Load condition P/S ON*2 A/C ON*3
Idle-up speed (RPM)*1
•
700—800 (750 ± 50)
1
* : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. : A/C switch and fan switch are on. 7. If not as specified with all load conditions, inspect the IAC valve. 8. If not as specified with some load condition, inspect the related input switches, harnesses, and connectors. Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 3. Verify that the idle-up speed is within the specification. Specification 1 Load condition Idle-up speed (rpm)* P/S ON*2 700—800 (750 ± 50) A/C ON*3 1 * : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. 3 * : A/C switch and fan switch are on. 4. If not as specified with all load conditions, inspect the IAC valve. 5. If not as specified with some load conditions, inspect the related input switches, harnesses, and connectors. IDLE MIXTURE INSPECTION Vehicles With Oxygen Sensor (O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the idle speed and ignition timing are within the specification. (Refer to ENGINE TUNE-UP, IGNITION TIMING INSPECTION.) (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 3. Turn the test mode off. 4. Warm up the engine by holding the engine speed at 2500—3000 rpm for approx. 3 minutes. 5. Insert an exhaust gas analyzer to the tailpipe. 6. Verify that the CO and HC concentrations are within the regulation. 7. If not within the regulation, inspect the following: • On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.) • O2S (Refer to CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION.)
•
•
•
Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Intake Manifold Vacuum Inspection.) Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.) Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.) If the systems and devices are normal, replace the TWC. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
Vehicles Without Oxygen Sensor O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". 2. Verify that the idle speed and ignition timing are within the specification. (Refer to IGNITION TIMING INSPECTION.) (Refer to IDLE SPEED ADJUSTMENT.) 3. Insert an exhaust gas analyzer to the tailpipe. 4. Verify that the CO and HC concentrations are within the regulation. 5. If not, turn the adjust screw to adjust CO and HC concentration using the SST.
6. If not adjusted, inspect the following: • On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.) • Variable resistor (Refer to CONTROL SYSTEM, VARIABLE RESISTOR INSPECTION.) • Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM, INSPECTION, Intake Manifold Vacuum Inspection.) • Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel line Pressure Inspection.) • Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.)
F1-5
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INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning • When the engine and intake-air system are hot, they can badly burn. Turn off engine and wait until they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Disconnect the negative battery cable. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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INTAKE-AIR SYSTEM
1 2 3 4
Air cleaner component Air intake hose MAP sensor Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ ADJUSTMENT
5 6 7
Throttle body component Dynamic chamber Fuel injector ☞ FUEL SYSTEM, FUEL INJECTOR REMOVAL/ INSTALLATION
8
Intake manifold
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INTAKE-AIR SYSTEM BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAC valve connector. 3. Drain the engine coolant from the radiator. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 4. Remove the BAC valve.
6. If not as specified, replace the BAC valve. (Refer to BAC VALVE REMOVAL/INSTALLATION.) If as specified, but IAC valve is failed, inspect for the following: Open circuit • Power circuit (IAC valve connector terminal A and main relay terminal D) 5. Install in the reverse order of removal. AIR VALVE INSPECTION Operation Inspection Note 1. Perform the following test only when directed. 1. Carry out the "Idle Air Control (IAC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.) 2. Remove the BAC valve. (Refer to INTAKE-AIR SYSTEM, BAC VALVE REMOVAL/INSTALLATION.) 3. Add cold water into the engine coolant passage of the BAC valve to reduce the air valve temperature. 4. Verify that the air valve operates when hot water is added into the engine coolant passage of the BAC valve. 5. If not as specified, replace the BAC valve, 6. Install the BAC valve. IDLE AIR CONTROL (IAC) VALVE INSPECTION Resistance Inspection Note 2. Perform the following test only when directed, 1. Carry out the "Idle Air Control (IAC) Inspection", (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.) 2. If not as specified, perform the further inspection for the IAC valve. 3. Disconnect the negative battery cable. 4. Disconnect the IAC valve connector. 5. Measure the resistance between the IAC valve terminals using an ohmmeter.
•
GND circuit (IAC valve connector terminal B and PCM connector terminal 2W) Short circuit • IAC valve connector terminal B and PCM connector terminal 2W to GND 7. Repair or replace faulty areas. 8. Connect the IAC valve connector. 9. Connect the negative battery cable.
Resistance 7.7—9.3 Ω [23 °C {73 °F}]
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INTAKE-AIR SYSTEM ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1
2
Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Measure the free play of the accelerator cable.
Free play 1—3 mm {0.04—0.11 in} 2. If not as specified, adjust by turning the locknut,
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F1-9
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FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". Note • Fuel in the fuel system is under high pressure when the engine is not running. Fuel Line Safety Procedures 1. Remove the fuel-filler cap and release the pressure in the fuel tank. 2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.
3. Start the engine. 4. After the engine stalls, crank the engine several times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and "Fuel Leakage Inspection" described below. Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit the hose onto the pipe over 25 mm {0.98 in}. When the pipe has a stopper, fit the hose until it contacts the stopper.
3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position. CLAMP INSTALLATION RANGE
Fuel Leakage Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 1. Short the DLC terminal F/P to body GND using a jumper wire.
2. Turn the ignition switch on to operate the fuel pump body. 3. Pressurize the system this way for at least 5 minutes to be sure of no leakage. 4. If there is fuel leakage, inspect for damaged fuel hoses, hose clamps, and fuel pipe sealing surface and replace as necessary. 5. After repair, assemble the system and repeat Steps 1 to 3.
F1-10
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FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Level the vehicle. 2. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Drain the fuel from the drain plug. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) STRETCH CAB 2WD, DOUBLE CAB 2WD
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FUEL SYSTEM STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1 2 3 4 5 6 7
Joint hose ☞ Installation Note Breather hose ☞ Installation Note Under guard Fuel hose Fuel tank Evaporative hose ☞ Installation Note Rollover valve
8 Fuel pump unit 9 Fuel-filler pipe 10 Dust cover 11 Fuel inlet pipe 12 Nonreturn valve 13 Evaporative gas check valve (two-way) ☞ Installation Note 14 Check valve (two-way) 15 Evaporative chamber
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FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note • Install the arrow mark of the evaporative gas check valve (two-way) facing the charcoal canister. Evaporative Hose Installation Note • Fit each hose onto the respective fittings within the specification, and install clamps as shown. Length Evaporative hose: 25—30 mm {0.99—1.18 in}
Breather Hose Installation Note • Fit each hose onto the respective fittings within the specification, and install clamp as shown.
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet pipe. 2. Verify that the nonreturn valve opening angle is 50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm {0.06 in} when the nonreturn valve is returned to the closed position.
Length Breather hose: 25—30 mm {0.99—1.18 in}
Joint Hose Installation Note • Fit the joint hose onto the respective fittings within the specification, and install clamps as shown. Length Joint hose: 35—40 mm {1.4—1.5 in}
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAL/INSTALLATION 1. Remove the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) 2. Install the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
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FUEL SYSTEM STRETCH CAB 2WD, DOUBLE CAB 2WD
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1 2 3 4 5 6
Rubber mount Fuel filter (low-pressure) Clamp Fuel hose Fuel pump body Fuel gauge sender unit
FUEL PUMP UNIT INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.)
2. If not as specified, perform the further inspection for the fuel pump unit. Continuity Inspection Note • Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit connector terminals C and D.
5. If there is no continuity, replace the fuel pump body. If as specified but the "Simulation Test" is failed, inspect the following: Fuel pump relay malfunction Open circuit • GND circuit (fuel pump unit connector terminal D and body GND) • Power circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)
Short circuit • Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 6. Repair or replace faulty areas. 7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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FUEL SYSTEM Fuel Pump Maximum Pressure Inspection Warning •
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note •
8. If not as specified, inspect the following: • Fuel pump relay • Fuel filter (low-pressure, high-pressure) for clogging • Fuel line for clogging or leakage 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 10. Disconnect the negative battery cable.
Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose, then plug the opening as shown.
11. Disconnect the fuel pressure gauge. 12. Connect the negative battery cable. 13. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) Fuel Pump Hold Pressure Inspection Warning •
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped.
Note •
Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 4. Connect the negative battery cable.
2. Disconnect the negative battery cable.
Caution •
Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only.
3. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose, then plug the opening as shown.
5. Short the DLC terminal F/P to body GND using a jumper wire.
4. Connect the negative battery cable. Caution 6. Turn the ignition switch on to operate the fuel pump body. Measure the fuel pump maximum pressure. Fuel pump maximum pressure 500—630 kPa {5.0—6.5 kgf/cm2, 72—92 psi} 7. Turn the ignition switch off and disconnect the jumper wire.
F1-15
•
Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only.
5. Short the DLC terminal F/P to body GND using a jumper wire.
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FUEL SYSTEM
6. Turn the ignition switch on for 10 seconds to operate the fuel pump body. 7. Turn the ignition switch off. Measure the fuel pump hold pressure after 5 minutes. Fuel pump hold pressure More than 340 kPa {3.5 kgf/cm2, 50 psi} 8. Disconnect the jumper wire. 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the negative battery cable. 13. If not as specified, carry out the "PRESSURE REGULATOR INSPECTION", "FUEL INJECTOR INSPECTION" (Refer to FUEL SYSTEM, PRESSURE REGULATOR INSPECTION.) (Refer to FUEL SYSTEM, FUEL INJECTOR INSPECTION.) 14. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order or removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 2
Fuel hose Protector
3
Fuel filter (high-pressure) ☞ Removal Note ☞ Installation Note
Fuel Filter (High-pressure) Removal Note • Before removing the fuel filter (high-pressure), paint marks on the fuel filter (high-pressure) and fuel filter bracket for correct reassembly.
Fuel Filter (High-pressure) Installation Note Replacing the fuel filter (high-pressure) 1. Paint a mark on the new fuel filter (high-pressure) at the same spot as the removed fuel filter (highpressure). 2. Align the paint marks and install the fuel filter (high-pressure) as shown.
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FUEL SYSTEM
Replacing the fuel filter bracket 1. Paint a mark on the new fuel filter bracket at the same spot as the removed fuel filter bracket. 2. Align the paint marks and install the fuel filter bracket as shown.
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FUEL SYSTEM FUEL INJECTOR REMOVAL/INSTALLATION Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2. 3. 4. 5. 6.
Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Disconnect the fuel injector connectors and remove the harness from the fuel distributor. Remove in the order indicated in the table. Install in the reverse order of removal. Complete the "AFTER REPAIR PROCEDURE." (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 Dynamic chamber 2 Dynamic chamber gasket
6 Fuel injector ☞ Installation note 7 Grommet 8 Fuel injector insulator
3 Fuel injector connector 4 Fuel hose 5 Fuel distributor
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FUEL SYSTEM Fuel Injector Installation Note 1. Use new fuel injector O-rings. 2. Verify that the O-rings and the fuel injector sealing surfaces are free of foreign materials. Clean with gasoline if necessary. 3. Apply a small amount of engine oil to the O-rings and into the fuel distributor. 4. Install the fuel injectors in the fuel distributor with a light twisting motion so that the O-rings will not be folded.
FUEL INJECTOR INSPECTION Simulation Test 1. Carry out the "Fuel Injector Operation Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Injector Operation Inspection.) 2. If not as specified, perform the further inspection for the fuel injectors. Resistance Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the fuel injector connectors. 3. Measure the resistance of the fuel injector using an ohmmeter.
Resistance 12—16Ω[20°C {68°F}] 4. If not as specified, replace the fuel injector. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) If as specified but "Simulation Test" is failed, inspect for the following:
Open circuit • GND circuit (No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U) • GND circuit (No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2V) • GND circuit (No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U) • GND circuit (No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V) • Power circuit (No.1 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No.2 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No.3 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) • Power circuit (No.4 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)
Short circuit • No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND • No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND • No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND • No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND 5. Repair or replace faulty areas. 6. Reconnect the fuel injector connectors. 7. Reconnect the negative battery cable. Fuel Leakage Test Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note • Perform the following test only when directed.
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FUEL SYSTEM 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel injectors together with the fuel distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) 4. Fasten the fuel injectors firmly to the fuel distributor with wire.
5. Connect the negative battery cable. Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 6. Short the DLC terminal F/P to body GND using a jumper wire.
9. Turn the ignition switch off and remove the jumper wire. 10. If not as specified, replace the fuel injector. 11. Complete the "AFTER REPAIR PROCEDURE", (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) Volume Test Warning •
1.
2. 3.
4. 5.
7. Turn the ignition switch on to operate the fuel pump body. 8. Tilt the fuel injectors approx. 60 degrees and verify that fuel leakage from the fuel injector nozzles is within the specification.
Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note • Perform the following test only when directed. Complete the "BEFORE REPAIR PROCEDURE", (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Remove the fuel injectors together with the fuel distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) Fasten the fuel injectors firmly to the fuel distributor with wire. Connect the SST as shown in the figure.
6. Connect the negative battery cable. Caution • Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 7. Short the DLC terminal F/P to body GND using a jumper wire.
Fuel leakage Less than 1 drop/2 minutes 8. Turn the ignition switch on to operate the fuel pump body. 9. Measure the injection volume of each fuel injector using a graduated container.
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FUEL SYSTEM Injection volume 55—71 ml {55—71 cc, 1.9—2.3 fl oz}/15 sec. 10. Turn the ignition switch off and disconnect the jumper wire. 11. If not as specified, replace the fuel injector. 12. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) PRESSURE REGULATOR REMOVAL/INSTALLATION Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
O 1 Vacuum hose 2 Fuel hose 3 Pressure regulator PRESSURE REGULATOR INSPECTION Simulation Test 1. Carry out the "Fuel Line Pressure Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.) 2. If not as specified, perform the further inspection for the pressure regulator. Operation Inspection Note •
Perform the following test only when directed.
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE".) 2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge between the pulsation damper and fuel main hose.
4. Connect the negative battery cable. 5. Start the engine and let it idle. 6. Measure the fuel line pressure after approx. 2 minutes. Fuel line pressure 2 210—250 kPa {2.1—2.6 kgf/cm , 30—36 psi} 7. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure.
Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi} 8. Turn the ignition switch off. 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.") 10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the fuel main hose to the fuel distributor. 13. Reconnect the negative battery cable. 14. If not as specified, inspect the following: • Fuel pump maximum pressure • Fuel pump hold pressure • Fuel filter for clogging • Fuel injector for leakage • Fuel pump relay • Fuel line for improper routing, clogging, kinks or leakage
CONTINUED F1-21
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FUEL SYSTEM If all items above are okay, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.) 15. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Pressure Regulator Control (PRC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Pressure Regulator Control (PRC) Inspection.) 2. If not as specified, perform the further inspection for the PRC solenoid valve, Airflow Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the PRC solenoid valve. (Refer to INTAKE-AIR SYSTEM, VACUUM HOSE ROUTING DIAGRAM.) 3. Inspect airflow between the ports under the following conditions.
4. If not as spec tied, replace the PRC solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage Open circuit • GND circuit (PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector) • Power circuit (PRC solenoid valve connector terminal A and main relay connector terminal D through common connector)
Short circuit • PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector to GND) 5. Repair or replace faulty areas. 6. Install the PRC solenoid valve. 7. Reconnect the negative battery cable. PULSATION DAMPER REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the pulsation damper. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1
Fuel hose
2 3
Bolt Pulsation damper
PULSATION DAMPER INSPECTION 1. Remove the pulsation damper. (Refer to FUEL SYSTEM, PULSATION DAMPER REMOVAL/INSTALLATION.) 2. Visually inspect the pulsation damper for damage and cracks. Also inspect that there is no extreme rust, which will cause fuel leakage. 3. If either is observed, replace the pulsation damper.
F1-22
CONTINUED
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FUEL SYSTEM •
FUEL PUMP RELAY INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.) 2. If not as specified, perform the further inspection for the fuel pump relay. Continuity Inspection Note • Perform the following test only when directed.
Power circuit (fuel pump relay connector terminal A or C and IG switch connector terminal IG1 through common connector)
1. Disconnect the negative battery cable. 2. Remove the fuel pump relay located under the passenger's side front side trim.
3. Inspect for continuity between the fuel pump relay terminals using an ohmmeter.
Short circuit • Fuel pump relay connector terminal B and PCM connector terminal 1H through common connector to GND • Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 5. Repair or replace faulty areas. 6. Install the fuel pump relay. 7. Reconnect the negative battery cable.
4. If not as specified, replace the fuel pump relay. If as specified but the "Simulation Test" is failed, inspect for the following: Fuel pump unit malfunction Open circuit • GND circuit (fuel pump relay connector terminal B and PCM connector terminal 1H through common connector) • GND circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)
CONTINUED F1-23
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EXHAUST SYSTEM
EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 2 3
After silencer Main silencer TWO (Europe) Presilencer (Except Europe)
4 5 6
Front pipe Insulator Exhaust manifold
CONTINUED
F1-24
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EMISSION SYSTEM
EMISSION SYSTEM EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION
4. If not as specified, replace the rollover valve. EVAPORATIVE GAS CHECK VALVE (TWOWAY) INSPECTION 1. Remove the evaporative gas check valve (twoway). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Inspect airflow of the valve under the following conditions. Apply pressure below +2.9 kPa {+22 mmHg, +0.87 inHg} to port A
1
Charcoal canister
2 3
Purge solenoid valve PCV valve
Apply pressure over +5.9 kPa {+44 mmHg, +1.7 inHg} to port A Apply pressure over -0.98 kPa {-7.36 mmHg, -0.29 inHg} to port A
No airflow Airflow Airflow
ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Hold the valve as shown. Blow air into port A and verify that there is airflow.
3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow.
3. If not as specified, replace the evaporative gas check valve (two-way). CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Inspect airflow of the valve under the following conditions. Apply pressure of -0.98—1-13.7 kPa {-7.3—1-102 mmHg, -0.28— + 4.0 inHg} to port A Apply pressure over +18.6 kPa {+140 mmHg, +5.5 inHg} to port A Apply pressure over -4.9 kPa {-36.8 mmHg, -1.4 inHg} to port B
No airflow Airflow Airflow
CONTINUED
F1-25
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EMISSION SYSTEM
3. If not as specified, replace the check valve (twoway). EVAPORATIVE CHAMBER INSPECTION 1. Remove the evaporative chamber. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow air into port A and verify that air flows out from the holes B on the evaporative chamber.
PURGE SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Purge Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection.) 2. If not as specified, perform the further inspection for the purge solenoid valve, Airflow Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the purge solenoid valve. 3. Inspect airflow between the ports under the following conditions.
3. Visually inspect that there is no damage nor crack on the evaporative chamber. 4. If not as specified, replace the evaporative chamber. 5. Install the evaporative chamber. CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Plug the atmosphere side port and purge solenoid valve side port of the charcoal canister. 3. Blow air into the charcoal canister from the fuel tank side port and verify that there is no air leakage.
4. If not as specified, replace the purge solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage. Open circuit • GND circuit (purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector) • Power circuit (purge solenoid valve connector terminal A and main relay connector terminal D through common connector)
4. If there is air leakage, replace the charcoal canister.
CONTINUED
F1-26
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EMISSION SYSTEM Short circuit • Purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector to GND 5. Repair or replace faulty areas. 6. Install the purge solenoid valve. 7. Reconnect the negative battery cable. POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION
1. Remove the PCV valve. 2. Blow through the valve and verify that air flows as specified. Specification Condition Air applied from port A
Airflow Yes
Air applied from port B
No
3. If not as specified, replace the PCV valve.
CONTINUED
F1-27
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CONTROL SYSTEM
CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION
1 2 3 4 5 6 7
PCM MAF sensor TP sensor CTP switch IAT sensor ECT sensor CMP sensor (In distributor)
8 9 10 11 12 13
O2S (Europe only) Variable resistor (Except Europe) Clutch switch Neutral switch PSP switch Main relay
CONTINUED
F1-28
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CONTROL SYSTEM •
PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the cowl side panel (driver's side). 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
• •
For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM terminal voltage. When measuring the following PID value, perform the following: TP V PID (Refer to Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection.) (Refer to Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection.)
6. If PID value is not within the specification, follow the instruction in action column.
1 PCM 2 PCM connector PCM INSPECTION Using SSTs (NGS tester) Note • PIDs for the following parts are not available on this model. Go to the appropriate part inspection page. 1. Water temperature sender unit (Integrated with ECT sensor) (Refer to CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION.) 2. CMP sensor (Refer to CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION.) 3. Main relay (Refer to CONTROL SYSTEM, MAIN RELAY INSPECTION.) 1. Connect the SSTs (NGS tester) to the DLC. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ONBOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.) 2. Turn the ignition switch on. 3. Select the "PID/DATA MONITOR AND RECORD" function on the NGS tester display and press TRIGGER. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.) 4. Select the appropriate PID on the NGS tester display and press START. 5. Measure the PID value. Note • The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. If a monitored value of an output device is out of specification, inspect the monitored value of the input device related to the output control.
F1-29
Note • Perform the SIMULATION TEST for the output device (A/C RLY, FP RLY, IACV, PRGV) after PID/DATA measurement is completed.
CONTINUED
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CONTROL SYSTEM PID MONITOR Table Monitor item (Definition)
Unit/ Condition
A/C RLY (A/C relay)
ON/OFF
Ignition switch on: OFF A/C switch on and fan switch on at idle: ON
A/C SW (A/C switch)
ON/OFF
A/C switch and fan switch on at ignition Inspect A/C switch. switch on: ON ☞ Section U A/C switch off at ignition switch on: OFF
Condition/Specification
Action
PCM terminal
Inspect following PIDs: RPM, TP V, ECT V, A/C SW. Inspect A/C relay. ☞ Section U
1J
1Q
Constant: B+
Inspect main relay. ☞ CONTROL SYSTEM, MAIN RELAY INSPECTION Inspect battery. ☞ Section G
kPa
Below 400 m {0.25 mile} above sea level: 100—103 kPa {1.01—1.05 kgf/cm2}
DTC P1195 is indicated. Follow DTC Troubleshooting ☞ ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION
-
BARO V*2 (Barometric pressure signal voltage)
V
Below 400 m {0.25 mile} above sea level: 3.9—4.0 V
DTC P1195 is indicated. Follow DTC Troubleshooting ☞ ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION
-
BRKSW (Brake switch)
ON/OFF
Brake pedal depressed: ON Brake pedal released: OFF
Inspect brake switch. ☞ Section P
1O
ON/OFF
Accelerator depressed: OFF Accelerator released: ON
Inspect CTP switch ☞ CONTROL SYSTEM, CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION
1N
°C
Engine coolant temperature 20 °C {68°F}: 20°C {68°F} Engine coolant temperature 60 °C {140°F}: 60°C {140°F}
B+ (Battery positive voltage)
V
BARO*2 (Barometric pressure)
CTP SW (Idle switch)
ECT (Engine coolant temperature) ECT V (ECT signal voltage)
FHO2S*1 (Oxygen sensor)
FPRLY (Fuel pump relay)
IACV (Idle air control valve)
°F
1B
Inspect engine coolant temperature sensor. w CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
2Q
V
Engine coolant temperature 20 °C {68 °F}; 2.2—2.4V After warms up: Below 1.0 V
Inspect engine coolant temperature sensor. ☞ CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
2Q
V
Ignition switch on: 0,1—1.0 V After warm up: 0.1—1.0 V Acceleration (after warm up): 0.5—1.0 V Deceleration (after warm up): 0—0.5V
Inspect O2S. ☞ CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION
2N
Ignition switch on: OFF Idle: ON Cranking: ON
Inspect following PID: RPM. Inspect fuel pump relay. ☞ FUEL SYSTEM, FUEL PUMP RELAY INSPECTION
1H
Idle: 2.4—2.7 ms
Inspect following PIDs: IATV, RPM, ECT V, MAF V, TP V, NL SW, CLT SW, PSP SW, A/C SW, TEN. Inspect idle air control valve. ☞ INTAKE-AIR SYSTEM, IDLE AIR CONTROL (IAC) VALVE INSPECTION
2W
ON/OFF
ms
1
: Europe only *2: Except Europe
CONTINUED F1-30
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CONTROL SYSTEM Monitor item (Definition) IATDC (Intake air temperature (Dynamic chamber)) IATDC V (IAT signal voltage (Dymanic chamber))
IGT (Ignition timing)
Unit/ Condition °C
V
BTC
MAFV (Mass air flow signal voltage) MT/AT*1 (MT/AT distinction signal)
V
Intake air temperature 20 °C {68 °F}: 2.5—2.7 V
Inspect IAT sensor -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
short to ground: A—6 BTC
PCM terminal
2L
2L
Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, PSP SW, NL SW, A/C SW, TEN, Inspect CMP sensor. -CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect idle speed and ignition timing. - ENGINE TUNE-UP. Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, NL SW, FHO2S, PSP SW, BRK SW, A/C SW, B+. Inspect CMP sensor. - CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION
Ignition switch on: 0.0 ms Idle: 3.0—5.0 ms
Ignition switch on: 1.0—2.0 V Idle: 1.9—2.8 V
ON/OFF
Constant: ON
ON/OFF
Neutral position and clutch pedal depressed: ON
NLSW (Load/no load condition signal)
Intake air temperature 20 °C {68 °F}:20°C{68 °F}
Idle: 1—30 BTC
ms
Action Inspect IAT sensor rar -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
Terminal TEN (DLC)
INJ (Fuel injection duration)
Condition/Specification
Inspect mass air flow sensor. CONTROL SYSTEM, MASS AIR FLOW (MAF) SENSOR INSPECTION -
Others: OFF
Inspect neutral switch. - CONTROL SYSTEM, NEUTRAL SWITCH INSPECTION Inspect clutch switch. -CONTROL SYSTEM, CLUTCH SWITCH INSPECTION
2F
2U 2V
20
1L
1V
CONTINUED
*1: Europe only
F1-31
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CONTROL SYSTEM Monitor item (Definition)
Unit/ Condition
Action
PGM terminal
Inspect following PIDs: ECTV, IAT V, RPM,TP V, B+. Inspect PRC solenoid valve. ☞ FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION
2T
Inspect following PIDs: IATV, RPM, ECT V, MAP V, TP V, FHO2S, B+. Inspect purge solenoid valve. ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION
2X
Steering wheel fully turned: ON Steering wheel straight ahead position: OFF
Inspect PSP switch. ☞ CONTROL SYSTEM, POWER STEERING PRESSURE (PSP) SWITCH INSPECTION
1P
Idle: 700—770 RPM
Inspect CMP sensor. ☞ CONTROL SYSTEM, CRANKSHAFT POSITION SENSOR INSPECTION
2E
Inspect wiring from DLC terminal TEN to PCM terminal 1L
1K
V
Closed throttle position: 0.4—0.6 V Wide open throttle: 3.4—4.7 V
Inspect TP sensor. ☞ CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR INSPECTION
2M
V
Turned fully clockwise: below 1.0 V Turned fully counterclockwise: Approx 4.0 V
Inspect variable resistor ☞ VARIABLE RESISTOR INSPECTION
2N
Vehicle speed 20 km/h {mph}: 20 km/h {mph}
☞ Section T, WARNING AND
Ignition switch on: OFF
PRCV (Pressure regulator control)
Condition/Specification
ON/OFF
Idle: OFF Engine start at hot condition: ON
PRGV (Purge solenoid valve duty value)
PSP SW (PSP switch)
RPM (Engine speed)
%
ON/OFF
RPM
TEN (TEN terminal (DLC))
ON/OFF
VRV*2 (Variable resistor)
VS (Vehicle speed)
Idle: 0%
Terminal TEN (DLC) short to ground: ON Terminal TEN (DLC) open: OFF
TP V (TP sensor signal voltage)
Ignition switch on: 0%
KPH
Vehicle speed 40 km/h {mph}: 40 km/h {mph}
Inspect vehicle speedometer sensor INDICATOR SYSTEM, INSTRUMENT CLUSTER INSPECTION Inspect vehicle speed sensor
1M
CONTINUED
*2: Except Europe
F1 -32
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CONTROL SYSTEM Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection 1. 2.
Turn the ignition switch on. Measure the voltage between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal A and body GND using a voltmeter. (1) When measurement voltage is 0 V. ① Turn the ignition switch off. ② Disconnect the TP sensor and variable resistor (Except Europe) connector (applied to constant voltage).
4.
If there is no continuity, repair the related harnesses. Not Using the SSTs (NGS Tester) at Power Supply Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Measure the voltage between the PCM battery power terminal connectors and body GND using an ohmmeter. Power supply terminal 1A Power supply terminal voltage: B+ 4. If not as specified, repair the related harnesses and replace the faulty fuses.
③
④ ⑤
⑥ (2)
(3)
Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and body GND using an ohmmeter. If there is continuity, repair the related harnesses. Using an ohmmeter, inspect for continuity between the PCM connector (vehicle side) terminal 2D and TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C which is applied to constant voltage. If there is continuity, repair the related harness.
When measurement voltage is B+. ① Turn the ignition switch off. ② Disconnect the battery positive harness, then battery negative harness. ③ Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and battery positive harness using an ohmmeter. ④ If there is continuity, repair the related harnesses. When measurement voltage is approx. 5V. • Constant voltage terminal of PCM is okay.
Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Inspect for continuity between the PCM GND terminals and body GND using an ohmmeter.
Not Using the SSTs (NGS Tester) at Serial Communication Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Verify there is continuity between PCM connector terminal 1 D and DLC KLN terminal.
4.
If there is no continuity, repair the related harnesses.
Not Using the SSTs (NGS Tester) at Instrument Cluster (Engine speed signal) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connector and instrument cluster connector (26 pin). 3. Verify there is continuity between PCM connector terminal 2F and instrument cluster connector (20 pin) terminal 3B.
4.
If there is no continuity, repair the related harnesses.
PCM GND terminal 2A 2B 2C
CONTINUED F1-33
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CONTROL SYSTEM Using voltmeter Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made.
Note • With the PCM connector connected, body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage at PCM terminal using a voltmeter. 4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the action column in the terminal voltage list.
1. Remove the PCM. 2. Reconnect PCM connector and battery negative terminal. PCM Terminal Voltage (Reference)
Terminal
Signal
Connected to
1A
Back-up power supply
Battery
1B
Power supply
Main relay
1C
1D
1E
—
Test condition Constant
Voltage (V) B+
Ignition switch off
0
Ignition switch on
B+
—
—
Action • •
Inspect ROOM fuse. Inspect related harness.
•
Inspect related harness.
—
Serial communication
Carry out inspection according to DTC. DTC output is a part of serial DLC communication. (Terminal KLN) Judgement by terminal voltage is not possible.
DTC output
Ignition switch on DLC and terminal TEN (Terminal FEN) (in DLC) short to chassis ground
No DTC stored DTC stored
—
Below 1.0
—
•
Inspect related harness.
•
Inspect related harness.
0-B+
1F
—
—
—
—
—
1G
—
—-
—
—
—
Ignition switch on 1H
Fuel pump control Fuel pump relay
1I
1J
1K
1L*1
—
— A/C relay
B+
Cranking
Below 1.0
Idle
Below 1.0 — A/C switch on
B+
A/C switch off
B+
Ignition switch off
A/C switch on
Diagnostic test mode
DLC Ignition switch (Terminal TEN) on
Transmission distinction
Ground
A/C switch off Terminal TEN (DLC) open Terminal TEN (DLC) short to ground
*1: Europe only
Inspect fuel pump relay. ☞ FUEL SYSTEM,FUEL PUMP INSPECTION Inspect related harness. —
•
Below 1.0 • Below 1.0
Inspect A/C relay. ☞ section U Inspect related harness.
B+ •
Inspect related harness.
•
Inspect related harness.
Below 1.0 0
Constant
•
—
Ignition switch on
A/C control
•
CONTINUED F1-34
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CONTROL SYSTEM Terminal 1M
Signal Vehicle speed
Connected to
Test condition
Vehicle running
1N
CTP
CTP switch
Ignition switch on
Accelerator pedal depressed
B+
Accelerator pedal released
Below 1.0
Brake pedal depressed 1O
Brake
Brake switch Brake pedal released
1P
1Q
Power steering pressure
A/C
PSP switch
A/C switch
Action
• Inspect VSS. 0 or Approx. 5.0 ☞ section T Approx. 5.0 • Inspect related harness.
Vehicle stopped
VSS
Voltage (V)
Steering wheel straight ahead position
Idle
Ignition switch on
•
•
Inspect CTP switch. ☞ CLOSED THROTLE POSITION (CTP) SWITCH INSPECTION Inspect related harness.
• Inspect brake switch. ☞ section P Below 1.0 • Inspect related harness. B+
• B+
Steering wheel fully turned
Below 1.0 •
A/C switch and fan switch on
Below 1.0
•
A/C switch off
B+
•
Inspect PSP switch. ☞ POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Inspect related harness. Inspect A/C switch. ☞ section U Inspect related harness.
1R
—
—
—
—
—
1S
—
—
—
—
—
1T
—
—
—
—
—
1U
—
—
—
—
—
1V
Load/no load distinction
Transmission neutral position or clutch pedal depressed
Below 1.0 •
•
Inspect neutral switch. ☞ NEUTRAL SWITCH INSPECTION Inspect clutch switch. ☞ CLUTCH SWITCH INSPECTION Inspect related harness.
Constant
Below 1.0 •
Inspect related harness.
Neutral/clutch Ignition switch switch on
Other than transmission neutral or clutch pedal released
• B+
2B
Fuel injector ground Power ground
Ground
Constant
Below 1.0 •
Inspect related harness.
2C
System ground
Ground
Constant
Below 1.0 •
Inspect related harness.
Analog ground
MAF sensor, IAT sensor, ECT sensor, O2S,TP sensor
Constant
Below 1.0 •
Inspect related harness.
SGT
Ignition switch on CMP sensor (integrated into distributor) Idle
1.8—2.3
Ignition switch on
Below 1.0
Idle
0.35—0.5
2A
2D
2E
2F
IGT control
Ground
Ignition control module
5.0
•
• •
•
Inspect CMP sensor. ☞ CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect related harness. Inspect ignition control module. ☞ section G Inspect related harness.
2G
—
—
—
—
—
2H 2I 2J
— — —
— — —
— — —
— — —
— — —
2K
Constant voltage TP sensor (Vref)
Ignition switch on
F1-35
4.5—5.5
•
Inspect related harness.
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CONTROL SYSTEM Terminal
Signal
Connected to
Test condition
Voltage (V)
Action •
2L
IAT
IAT sensor
Ignition switch on
IAT 20° C {68°F}
2.15 •
2M
TP
TP sensor
Ignition switch on
Accelerator pedal released
0.4—0.6
•
Accelerator pedal depressed
3,4—4.7
•
Engine cold
0.0—1.0
After warm up
0.5—1.0
Ignition switch on 2N*
1
O2S
•
0.0—1.0
Acceleration Deceleration
•
2N*
Varies according to the variable Variable resistor Variable resistor resistor adjustment
0—4 •
2O
Mass airflow
2P
2Q
—
ECT
MAP sensor
Ignition switch on
1.45
Idle (after warm up)
2.15
Engine speed 3000 rpm (after warm up)
2.73
—
ECT sensor
Inspect O2S. ☞ OXYGEN SENSOR (O2S) INSPECTION Inspect related harness.
0.0—0.5 •
2
Inspect TP sensor. ☞ THROTTLE POSITION (TP) SENSOR INSPECTION Inspect related harness.
0.55
Idle
O2S
Inspect IAT sensor. ☞ INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect related harness.
—
• •
—
Inspect variable resistor. ☞ VARIABLE RESISTOR INSPECTION Inspect related harness. Inspect MAF sensor. ☞ MASS AIR FLOW (MAF) SENSOR INSPECTION Inspect related harness. —
IAT 20°C {68°F}
1.02
•
After warm up
0.58
•
Ignition switch on
Inspect ECT sensor. ☞ ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Inspect related harness.
2R
—
—
—
—
—
2S
—
—
—
—
—
2T
Pressure PRC solenoid regulator control valve
For 120 sec. after ignition switch on
0
For 120 sec. after engine start
0
Ignition switch on
B+
•
Ignition switch on
B+
•
Idle
B+
•
Ignition switch on
B+
•
Idle
B+
•
Ignition switch on
0.2
•
Approx 1.0
•
ECT above 90°C {194°F} (Hot condition) Others
Fuel injector No.1,No.3
2U Fuel injector control
Fuel injector No.2, No.4
2V
2W
IAC
•
IAC valve Idle (after warm up)
*1: Europe only *2: Except Europe
Inspect PRC solenoid valve. ☞ FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION Inspect related harness. Inspect fuel injector. ☞ FUEL SYSTEM,FUEL INJECTOR INSPECTION Inspect related harness. Inspect fuel injector. ☞ FUEL SYSTEM,FUEL INJECTOR INSPECTION Inspect related harness. Inspect IAC valve. ☞ INTAKE-AIR SYSTEM, IAC VALVE INSPECTION Inspect related harness.
CONTINUED F1-36
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CONTROL SYSTEM Terminal
2X
Signal
Purge control
Connected to
Purge solenoid valve
Test condition
Voltage (V)
Ignition switch on
B+
Idle
B+
2Z
— Engine speed output
—
—
—
Short circuit • MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20 to GND) • Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector to GND) 4. Repair or replace faulty areas. 5. Reconnect the MAF sensor connector.
B+ 4.9—7.0
Inspect purge solenoid valve. ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Inspect related harness. —
•
Tachometer Ignition switch on (integrated into instrument cluster) Idle
MASS AIR FLOW (MAF) SENSOR INSPECTION Note • Perform the following test only when directed. MAF Sensor Inspection 1. Visually inspect for the following on the MAF sensor. • Damage • Cracks • Terminal bends • Terminal rust 2. If any of the above are found, replace the MAF sensor. If the MAF sensor PID value is out of specification, inspect as follows and repair or replace as necessary: 3. Disconnect the MAF sensor connector. Open circuit • MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20) • Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector) • GND circuit (MAF sensor connector terminal A and PCM connector terminal 2D through common connector)
•
•
Driving in gear 2Y
Action
•
Inspect instrument cluster. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION Inspect related harness.
THROTTLE POSITION (TP) SENSOR INSPECTION Note • Perform the following test only when directed. Resistance Inspection 1. Verify that the throttle valve is at closed throttle position. 2. Inspect that the accelerator cable free play is within the specification. (Refer to INTAKE-AIR SYSTEM, ACCELERATOR CABLE INSPECTION / ADJUSTMENT.) 3. If as specified but PID valve is out of specification, measure the resistance between TP sensor terminals A and C using an ohmmeter. Specification 4—6KΩ
4. Disconnect the TP sensor connector. 5. If not as specified, replace the TP sensor. If as specified, inspect for the following: Open circuit • Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) • TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M) • GND circuit (TP sensor connector terminal C and PCM connector terminal 2D) Short circuit • Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) • TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M)
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CONTROL SYSTEM 6. Repair or replace faulty areas. 7. Reconnect the TP sensor connector. THROTTLE POSITION (TP) SENSOR ADJUSTMENT Caution • Adjusting the TP sensor with the throttle adjusting screw (TAS) can adversely affect the engine. Do not adjust the TP sensor with the TAS. • Since the TP sensor is adjusted by the manufacturer, adjusting the TP sensor excessively can adversely affect the engine. Do not adjust the TP sensor excessively. 1. Verify that the throttle valve is at closed throttle position. 2. Disconnect the TP sensor connector. 3. Turn ignition switch on. 4. Measure and record the voltage of the disconnected harness side connector terminal C using a voltmeter.
Specification 4.5—5.5 V 5. Reconnect the TP sensor connector. 6. Loosen the TP sensor screw.
7. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to adjust the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is at the closed throttle position.
Specification (CTP) TP sensor terminal C voltage (V)
PCM terminal 2M voltage TP V (NGS tester) (V)
4.5—4.9 4.9—5.1 5.1—5.5 8. Tighten the TP sensor screw.
0.4—0.6 0.4—0.6 0.4—0.6
Tightening torque 1.6—2.3 N.m {16—24 kgf.cm, 14—20 in.lbf} 9. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to verify the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is wide open. Specification (WOT) TP sensor terminal C voltage (V)
PCM terminal 2M voltage TP V (NGS tester) (V)
4.5—4.7 4.7—4.8 4.8—4.9 4.9—5.0 5.0—5.1 5.1—5.3 5.3—5.4 5.4—5.5
3.4—4.4 3.6—4.5 3.7—4.6 3.7—4.8 3.8—4.9 4.0—5.0 4.1—5.1 4.2—5.2
10. If not as specified, replace the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR REMOVAL / INSTALLATION.) THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION 1. Disconnect the TP sensor connector. 2. Remove the TP sensor screws. 3. Remove the TP sensor from the throttle body.
4. Verify that the throttle valve is fully closed. 5. Install the TP sensor to the throttle body. 6. tighten the TP sensor screws. Tightening torque 1.6—2.3 N.m {16—24 kgf.cm, 14—20 in.lbf } 7. Verify that the throttle valve moves smoothly. 8. Reconnect the TP sensor connector.
F1-38
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CONTROL SYSTEM 9. Adjust the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR ADJUSTMENT.) CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION Caution • The CTP switch is set at the factory. Do not try to adjust it. • Removing the closed throttle position switch can negatively affect the engine. Note • Perform the following test only when directed. 1. Disconnect the CTP switch connector. 2. Inspect for continuity between the CTP switch terminal and a GND using an ohmmeter.
Specification Measuring condition Closed throttle position Others
Continuity Yes No
3. If not as specified, replace the throttle body. If the CTP switch is okay, but PI D value is out of specification, inspect as follows and repair or replace as necessary. Open circuit • CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1N) • GND circuit (CTP switch body to GND)
Short circuit • CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1 N to GND) 4. Reconnect CTP switch connector. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Resistance inspection Note • Perform the following test only when directed. 1. Remove the IAT sensor. 2. Heat the IAT sensor using the lamp. 3. Measure the resistance of the IAT sensor using an ohmmeter
Specification Water temperature (°C {°F}) 20 {68} 80 {176}
Resistance (kΩ) 2.09— 2.81 0.274 —0.802
4. If not as specified, replace the IAT sensor. If IAT sensor is okay, but PID value is out of specification, inspect as follows and repair or replace as necessary. Open circuit • IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2L) • GND circuit (IAT sensor connector terminal B and PCM connector terminal 2D)
Short circuit • IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2Lto GND) 5. Reconnect the IAT sensor connector.
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F1-39
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CONTROL SYSTEM INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor connector. 3. Remove the IAT sensor. 4. Install the IAT sensor.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Note • Perform the following test only when directed. ECT Sensor Resistance Inspection 1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove the ECT sensor. 3. Place the ECT sensor in water with a thermometer, and heat the water gradually.
Tightening torque 7.9—11.7 N.m {80—120 kgf.cm, 70—104 in.lbf} 5. Connect the IAT sensor connector. 6. Connect the negative battery cable. ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION Warning • When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before removing or installing the ECT sensor. 1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor.
4. Replace the gasket. 5. Install in the reverse order of removal, Tightening torque 25—29 N.m {2.5—3.0 kgf.m, 19—21 ft.lbf} 6. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
4. Measure the resistance between the ECT sensor terminals A and B using an ohmmeter. Specification Water temperature (°C {°F}) Resistance (kΩ) 20 {68} 2.2—2.8 80 {176} 0.29—0.4 5. If not as specified, replace the ECT sensor. If the ECT sensor is okay, but PID value is out of specification, inspect for the following: Open circuit • ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector) • GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector) Short circuit • ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector to GND) • GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector to GND) 6. Repair or replace faulty areas.
F1-40
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CONTROL SYSTEM 7. Install the ECT sensor. 8. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) CAMSHAFT POSITION (CMP) SENSOR INSPECTION Note • Perform the following test only when directed. Voltage Inspection 1. Remove the distributor. 2. Disconnect the fuel injector connectors. 3. Disconnect the high-tension lead. 4. Connect the distributor connector. Warning • Turning the ignition switch on with the fuel injector connector still connected will actuate the fuel injector. • Turning the ignition switch on with the distributor connector still connected will generate sparks, which can cause electrical shock. Disconnect the connector and prevent it from grounding to the vehicle body. 5. Turn the ignition switch on. 6. Verify the following signal (voltage) from the PCM 2E terminal using a voltmeter when the distributor is rotated by hand. Specification Signal Terminal SGT
2E
Voltage 4 pulses/rev. (Approx. 5.0 V)
7. If not as specified, inspect as follows and repair or replace as necessary. 8. Disconnect the distributor connector. Open circuit • SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E) • Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D) • GND circuit (Distributor harness side connector terminal A and engine GND)
Short circuit • SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E to GND) • Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D to GND) 9. If the harnesses are okay, replace the distributor and adjust the ignition timing. (Refer to ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.) OXYGEN SENSOR (O2S) INSPECTION O2S Voltage Inspection Note • Perform the following test only when directed. 1. Warm up the engine and run it at idle. 2. Disconnect the O2S connector. 3. Connect the voltmeter test leads to the following O2S terminals: • (+) lead-O2S terminal A • (-) lead-O2S terminal B
4. Run the engine at 3000 rpm until the voltmeter increases 0.5—0.7 V. 5. Verify that the voltmeter needle moves when racing the engine several times. Specification Engine condition Voltage (V) Acceleration 0.5—1.0 Deceleration 0—0.5 6. If not as specified, replace the O2S. If the O2S is okay, but PID value is out of specification, inspect for following:
F1-41
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CONTROL SYSTEM Open circuit • O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N) • GND circuit (O2S connector terminal B and PCM connector terminal 2D)
Short circuit • O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N to GND) 7. Repair or replace faulty areas. 8. Reconnect the O2S connector. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION 1. Disconnect the battery negative terminal. 2. Disconnect the O2S connector. 3. Remove the O2S. 4. Install in the reverse order of removal. Tightening torque 29-49 N.m {3—5 kgf.m, 22—36 ft.lbf} VARIABLE RESISTOR INSPECTION 1. Disconnect the connector from the variable resistor. 2. Connect an ohmmeter between the variable resistor terminal B and C.
3. Using the SST, verify that the resistance increases in relation to the turning amount of the variable resistor.
Variable resistor condition
Resistance (kΩ)
Turned fully clockwise Turned fully counterclockwise
4-6 Below 0.1
4. If not as specified, replace the variable resistor. 5. Adjust idle mixture. 6. If the variable resistor is okay, but PCM terminal 2N or 2K voltage is out of specification, inspect for the following: Open circuit • Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) • Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) • GND circuit (Variable resistor connector terminal C and PCM connector terminal 2D) Short circuit • Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) • Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) 7. If there is an open or short circuit, repair or replace wiring harness. 8. If there is no open or short circuit, replace variable resistor. 9. Reconnect the variable resistor connector. CLUTCH SWITCH INSPECTION Continuity Inspection Note • Perform the following test only when directed. 1. Verify that the clutch switch is installed properly. 2. Disconnect the negative battery cable. 3. Remove the clutch switch. (Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLATION.) 4. Inspect the continuity between the clutch switch terminals A and B using an ohmmeter.
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CONTROL SYSTEM
Specification Specification Transmission In neutral Others
5. If not as specified, replace the clutch switch. If the clutch switch is okay, but PID value is out of specification, inspect for the following: Open circuit • Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V through common connector) • GND circuit (Clutch switch connector terminal A and GND) Short circuit • Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V to GND) Neutral switch • The neutral switch operation and related harnesses continuity (Refer to NEUTRAL SWITCH INSPECTION. 6. Repair or replace faulty areas. 7. Install the clutch switch. (Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLTION.) 8. Connect the negative battery cable. CLUTCH SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the clutch switch connector. 3. Loosen the nuts and remove the clutch switch. 4. Install the clutch switch. 5. Adjust the clutch pedal height referring to the above and the height specification. (Refer to Section H, CLUTCH PEDAL, CLUTCH PEDAL INSPECTION/ADJUSTMENT.) 6. Connect the clutch switch connector. 7. Connect the negative battery cable. NEUTRAL SWITCH INSPECTION Continuity inspection Note • Perform the following test only when directed. 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Measure the continuity between the neutral switch terminals A and B using an ohmmeter.
Continuity Yes No
4. If not as specified, replace the neutral switch. If the neutral switch is okay, but PID value is out of specification, inspect for the following: Open circuit • Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector) • GND circuit (neutral switch connector terminal B and GND)
Short circuit • Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector to GND) Clutch switch • The clutch switch operation and related harness continuity. (Refer to CONTROL SYSTEM, CLUTCH SWITCH INSPECTION.) 5. Repair or replace faulty areas. 6. Reconnect the neutral switch connector. NEUTRAL SWITCH REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Remove the neutral switch. 4. Install the new washer and neutral switch.
F1-43
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CONTROL SYSTEM
Tightening torque 25—34 N.m {2.5—3.5 kgf.m, 19—25 ft.lbf} 5. Connect the neutral switch connector. 6. Connect the battery negative cable. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Continuity inspection Note • Perform the following test only when directed. 1. Disconnect the PSP switch connector. 2. Start the engine. 3. Inspect for continuity between the PSP switch terminal and GND using an ohmmeter.
Specification Condition Steering wheel in straight ahead Steering wheel fully turned
Continuity Yes No
4. If not as specified, replace the PSP switch. If the PSP switch is okay, but PID value is out of specification, inspect for the following: Open circuit •
PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector)
•
GND circuit (PSP switch body and GND)
Short circuit • PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector to GND) Power steering fluid (Refer to Section N, engine speed sensing power steering system.) • Fluid level • Fluid leakage • Fluid pressure 5. Repair or replace faulty areas. 6. Reconnect the PSP switch connector. MAIN RELAY INSPECTION Continuity Inspection Note • Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the main relay connector. 3. Inspect for continuity between terminals of the relay using an ohmmeter.
Specification
4. If not as specified, replace the main relay. If the main relay is okay, inspect for the following: Open circuit • Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector) •
PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector)
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CONTROL SYSTEM, ON-BOARD DIAGNOSTIC SYSTEM •
GND circuit (Main relay connector terminal B and GND) Short circuit • Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector to GND) • PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector to GND) 5. Repair or replace faulty areas. 6. Reconnect the main relay. 7. Reconnect the negative battery cable. MAIN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the main relay connector. 3. Remove the main relay. 4. Install the reverse order of removal. Tightening torque 7.9—10.7 N.m {80—110 kgf.cm, 69.5—95.4 in-Ibf}
ON-BOARD DIAGNOSTIC SYSTEM READ/CLEAR DIAGNOSTIC TEST RESULTS • This retrieves all stored DTCs in the PCM and clears the DTC. PARAMETER IDENTIFICATION (PID) ACCESS • The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values and system status information. Since PID values for output devices are PCM internal data values, perform the Simulation Test to identify which output devices are malfunctioning. Note • PID monitor item "PRCV" can be selected and "ON" or "OFF' is displayed for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped. DIAGNOSTIC SUPPORT PROCEDURE • These tests are the ability of the powertrain control system to detect a change in certain input devices by following the instructions on the NGS tester. There are two options: ALL TEST and SINGLE TEST. ALL TEST takes you through all diagnostic support tests. SINGLE TEST enables you to perform specific tests that relate to the particular diagnosis that you are conducting. This test MUST follow the instructions on the NGS tester. If not, a "TEST CONDITIONS NOT CORRECT' message will appear, or else the test result will be FAULTY. SIMULATION TEST • Output devices can be turned on and off by sending simulation command signals from the NGS tester to the PCM. The "Idling Test" and "Ignition ON Test" are available in this test. These tests will verify the PCM status, output devices, and related circuit wiring harnesses. Note • "PRCV" of the simulation item can be selected for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped. ON-BOARD DIAGNOSTIC TEST NGS Tester Hook-up Procedure Note • Make sure the ignition switch is at LOCK position. 1. Insert the vehicle interface module and latest program card into the hand-held NGS control unit.
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ON-BOARD DIAGNOSTIC SYSTEM
3. Move the cursor to SELECT NEW VEHICLE YEAR & MODEL Press the TRIGGER key to enter this selection. 2. Plug the adapter harness connector into the vehicle interface module and the DLC located at the engine compartment. 3. Plug the NGS tester power connector into the cigarette lighter. Alternatively, use a battery hook-up adapter.
4. Listen to the double beep. The NGS tester is now initialized. Begin the powertrain control system functional test. DTC READING PROCEDURE Using the SSTs (NGS Tester) Note
4. Move the cursor to B-SERIES (UN). Press the TRIGGER key to enter this selection. EUROPE
•
Start engine and keep it running. If the engine will not start, turn the ignition switch on during the procedure. 1. Perform the necessary vehicle preparation and visual inspection. Hook the NGS tester up to the vehicle.
2. Move the cursor to VEHICLE & ENGINE SELECTION. Press the TRIGGER key to enter this function.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM EXCEPT EUROPE
Note • Make sure the selected vehicle is correct. 5. A vehicle selection screen showing the selected vehicle will be displayed. Move the cursor to the vehicle selected. Press the TRIGGER key. 6. Move the cursor to DIAGNOSTIC DATA LINK on the main menu screen. Press the TRIGGER key to enter into menu system diagnostics.
9. Move the cursor to READ/CLEAR DIAGNOSTIC TEST RESULTS. Press the TRIGGER key to enter this selection.
10. Press START. 11. Retrieve DTCs. Not Using the SSTs (NGS Tester) Using the SST (self-diagnosis checker) 1. Connect the SSTs to the DLC located in the engine compartment and ground the black (negative) lead to the body.
7. Move the cursor to PCM-POWERTRAIN CONTROL MODULE. Press the TRIGGER key to enter this selection.
8. Move the cursor to DIAGNOSTIC TEST MODES. Press the TRIGGER key to enter this selection.
2. Set the select switch on the SST (self-diagnosis checker) to A. 3. Turn the dial switch on the SST (system selector) to 1, and the test switch to SELF TEST. 4. Turn the ignition switch on. 5. Verify that the buzzer sounds for approximately 3 seconds and code "88" flashes for 5 seconds. If DTC is not detected, "00" will then be indicated. Note • If the "88" does not flash, inspect +B terminal of the DLC, and the related harnesses and connectors. • If the "88" flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect. 6. If any DTCs is indicated, inspect the appropriate area and repair as necessary. Note • A DTC consists of four numbers. They are flashed one by one in the right window on the display. ("1" is always shown on the left window.)
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM 7. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS tester).) 8. Remove the SSTs.
7. If any DTCs is indicated, inspect the appropriate area and repair as necessary. 8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SSTs (NGS Tester).) 9. Remove the voltmeter and jumper wire PID/DATA MONITOR AND RECORD PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 7 from the DTC READING PROCEDURE. 3. Turn the ignition switch on or run the engine. 4. Move the cursor to PID/DATA MONITOR AND RECORD. Press the TRIGGER key to enter this selection.
Using the Voltmeter 1. Turn the ignition switch off. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. 2. Using a jumper wire to short terminal TEN of the DLC to body GND. 3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B.
5. Move the cursor to PID values to view. Press the TRIGGER key. A star symbol will appear next to the item when it is selected. Note • Press the TRIGGER key once again to deselect a PID. • Press the CLEAR to deselect all PIDs. 6. Press START to begin. 7. When ready to capture and store the selected PIDs, press the TRIGGER key. 8. Press the TRIGGER key again when ready to save information. 9. Move the cursor to STORE RECORDING AREA 1. Press the TRIGGER key.
4. Turn the ignition switch on. 5. The voltmeter indicates B+ for approximately 3 seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the voltmeter's needle. If DTC is not detected, the needle does not move. Note • The DTC will be output as shown.
10. Follow the instructions displayed on the NGS tester to save the recording data. PLAYBACK OF STORED PIDS PROCEDURE Note • Look for abnormal behavior or values that are clearly incorrect. Inspect the signals for abrupt or unexpected changes.
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ON-BOARD DIAGNOSTIC SYSTEM • •
Look for agreement in related signals. Make sure signals act in proper sequence.
1. Select VIEW RECORDER AREAS.
2. Select up to four PIDs to review in the table format or two PIDs to review in the graph mode. (1) Table format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the values.
4. Move the cursor to ALL TEST or SINGLE TEST. Press the TRIGGER key. Note • ALL TEST inspects each item according to an established programmed order. With SINGLE TEST, enable to select and inspect any test item in any order, one at a time.
5. Follow the instructions displayed on the NGS tester and press the TRIGGER key. Note • To skip a test item, press OMIT. • Before performing the test, the basic condition on the test vehicle must be set up in order to get exact data. Press BASIC to view the basic condition instruction screen. • If the screen shows PASSED, the system operates correctly. • If the screen shows FAULTY, the system operates incorrectly.
(2) Graph format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the linear lines showing the transformation of values to the line graph.
DIAGNOSTIC SUPPORT PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 8 from the DTC READING PROCEDURE. 3. Move the cursor to DIAGNOSTIC SUPPORT PROCEDURE. Press the TRIGGER key to enter this selection.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM SIMULATION TEST PROCEDURE Idling Test 1. Perform the NGS tester hook-up procedure. 2. Perform the Steps 1 through 7 from the DTC READING PROCEDURE. 3. Start the engine and run it at idle. 4. Move the cursor to SIMULATION TEST. Press the TRIGGER key to enter this selection.
8. Press the TRIGGER key.
9. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
5. Move the cursor to IDLING TEST. Press the TRIGGER key to enter this selection. 10. To perform the simulation again, press the TRIGGER key. To exit the idling test, press the CANCEL key.
6. The screen will display a list of simulation items. Select the appropriate simulation item for testing, then press the TRIGGER key.
Ignition ON Test 1. Perform Steps 1 through 7 from the DTCs READING PROCEDURE. 2. Turn the ignition switch on. Move the cursor to SIMULATION TEST. Press the TRIGGER key to enter this selection.
Note • Only one simulation item can be selected at a time.
3. Move the cursor to IGNITION ON TEST. Press the TRIGGER key to enter this selection. 7. Press START. Note • If the screen displays "TEST CONDITION NOT CORRECT", inspect the following signal conditions and determine whether or not they are normal: • NLSW: ON • RPM; above 550
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM
4. The screen will display a list of simulation items. Select the appropriate simulation item for testing, then press the TRIGGER key.
AFTER REPAIR PROCEDURE Using the SSTs (NGS Tester) 1. After repairs have been made, perform the DTCs READING PROCEDURE. 2. Press CLEAR. 3. Press the TRIGGER key. 4. Press the CANCEL key. 5. Ensure that the customer's concern has been resolved. Not Using the SSTs (NGS Tester) 1. After repairs, disconnect the negative battery cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable. 2. Warm up the engine to normal operating temperature. Note • If the engine will not start, continue to operate the starter for 5-6 seconds.
5. Press START. 6. Press the TRIGGER key.
3. Perform the "DTC READING PROCEDURE" again. 4. Verify that the DTC is not detected.
7. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
8. To perform the simulation again, press the TRIGGER key. To exit the ignition on test, press the CANCEL key.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table DTC No.
Output pattern
Display on the NGS tester
Condition
P0100
MAF/VAF-CIRCUIT MALFUNCTION
MAF sensor circuit malfunction
P0115
ECT-CIRCUIT MALFUNCTION
ECT sensor circuit malfunction
P0120
TP-CIRCUIT MALFUNCTION TP sensor circuit malfunction
P0134
O2S 11-CIRCUITNO ACTIVITY DETECTED
O2S circuit no activity detected
P0340
CAMSHAFT POS SENSORCKT MALFUNCTION
SGT signal is not detected
P0443
EVAP SYSTEM-PURGE CTRL VALVE CKT MALF
Purge solenoid valve circuit malfunction
P0505
IDLE CONTROL SYSTEMMALFUNCTION
IAC valve circuit malfunction
P1110
IATS (D/C)-OPEN OR SHORT IAT sensor circuit malfunction
P1170
HO2S 11-INVERSION
O2S is stuck
P1195
EGRBS-OPEN OR SHORT
Barometric pressure sensor (in PCM) malfunction
P1250
PRC-OPEN OR SHORT
PRC solenoid valve circuit malfunction
P1608
PCM (CPU)-MALFUNCTION
PCM internal circuit malfunction
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ON-BOARD DIAGNOSTIC SYSTEM DTC Troubleshooting DTC P0100
Mass air flow (MAP) sensor circuit malfunction
DETECTION CONDITION
Input voltage from MAF sensor is below 0.7 V or above 5.4 V when ignition switch is turned on.
POSSIBLE CAUSE
• • • • • • • • • •
MAF sensor malfunction Blockage at MAP sensor Poor connection of connectors at MAF sensor and/or PCM Leakage in intake-air system Short to power supply circuit in wiring from MAF sensor terminal B to PCM terminal 20 Short to ground in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal C to main relay terminal D Open circuit in wiring from MAF sensor terminal A to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground.
STEP INSPECTION 1 Verify stored DTC. Have DTCs P0115, P0120, P0134, P0340, P0443, P0505, P1110, P1170, and/or P1250 been stored?
Yes
No
ACTION Inspect for open circuit in following wiring harnesses, then go to Step 12. • Main relay terminal D-purge solenoid valve, PRC solenoid valve, IAC valve CMP sensor • PCM terminal 2D-throttle position sensor, intake-air temperature sensor, engine coolant temperature sensor, oxygen sensor • Between PCM terminal 2C and engine ground Go to next step
2
Does MAP sensor connector or PCM connector have poor connection?
Yes Repair or replace connector, then go to Step 12. No
Go to next step.
3
Is intake-air system okay?
Yes
Go to next step
No
Repair or replace faulty parts, then go to Step 12.
4
Disconnect MAF sensor connector. Turn ignition switch on. Is there battery positive voltage at MAF sensor harness side connector terminal C?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and MAF sensor terminal C), then go to Step 12.
5
6
7 8 9 10
Disconnect PCM connector. MAF sensor connector is Yes disconnected. Is there continuity between MAF sensor harness side No connector terminal A and PCM harness side connector terminal 2D?
Go to next step.
Is there continuity between MAF sensor harness side connector terminal B and PCM harness side connector terminal 20
Yes
Go to next step
No
Repair open circuit, then go to Step 12.
Is there continuity from PCM harness side connector terminals 20 to 1B?
Yes Repair short to power circuit, then go to Step 12.
Is there continuity from PCM harness side connector terminals 20 to body ground.
Yes Repair short to ground circuit, then go to Step 12.
Remove MAF sensor. Is there any foreign material at MAF sensor screen?
Yes Clean MAF sensor screen, then go to Step 12.
Connect MAF sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access MAF V PID. Does MAF V PID change when air is blown into mass airflow sensor? Note • If NGS tester is not used, measure PCM 20 terminal voltage with circuit tester.
No No
Repair open circuit, then go to Step 12.
Go to next step Go to next step.
No Yes
Go to next step. Go to next step.
No
Replace MAF sensor, then go to Step 12.
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ON-BOARD DIAGNOSTIC SYSTEM STEP 11
12
INSPECTION Yes
Go to Step 1.
Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
DTC P0115
Engine coolant temperature (ECT) sensor circuit malfunction
DETECTION CONDITION
Input voltage from ECT sensor is below 0.07 V or above 4.58 V when ignition switch is turned on.
POSSIBLE CAUSE
STEP 1
ACTION
Clear DTC from memory.
• • • • • • •
ECT sensor malfunction Poor connection of connectors at ECT sensor terminal and/or PCM Short to power supply circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Short to ground in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground INSPECTION
ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 9. • PCM terminal 2D-MAF sensor, O2S, IAT sensor, and/or TP sensor • PCM terminal 2C-engine ground
No
Go to next step
Does ECT sensor connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 9.
No
Go to next step
Disconnect ECT sensor connector. Turn ignition switch on. Is there 5V at engine coolant temperature sensor harness side connector terminal A
Yes
Go to next step
No
Disconnect PCM connector. ECT sensor connector is disconnected. Is there continuity between ECT sensor harness side connector terminal B and PCM harness side connector terminal 2D Is there continuity from PCM harness side connector terminals 2Q to 1B?
Yes
Inspect for open or short circuit in wiring harness (between PCM terminal 2Q and ECT sensor terminal A), then go to Step 9. Go to next step.
No
Repair open circuit, then go to Step 9
Yes
Repair short to power circuit, then go to Step 9
No
Go to next step.
6
Is there continuity from PCM harness side connector terminals 2Q to body ground?
Yes
Repair short to ground circuit, then go to Step 9.
No
Go to next step
7
Is ECT sensor okay? ☞ CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
Yes
Go to next step
No
Replace ECT sensor, then go to Step 9. ☞ CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION.
2 3
4
5
Verify stored DTC. Have DTCs P0100, P0120, P0134, P1110, and/or P1170 been stored?
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ON-BOARD DIAGNOSTIC SYSTEM STEP 8
9
INSPECTION Yes
Go to Step 1.
No
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step.
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
DTC P0120
Throttle position (TP) sensor circuit malfunction
DETECTION CONDITION
Input voltage from TP sensor is below 0.09 V or above 4.78 V when ignition switch is turned on.
POSSIBLE CAUSE
STEP 1
2 3
4
5
ACTION
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
• • • • • • • • • • •
TP sensor malfunction Poor connection of connectors at TP sensor and/or PCM Short to power supply circuit in wiring from TP sensor terminal A to PCM terminal 2K Short to power supply circuit in wiring from TP sensor terminal C to PCM terminal 2D Short to power supply circuit in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal C to PCM terminal 2D Open circuit in wiring from TP sensor terminal B to PCM terminal 2M Open circuit in wiring from TP sensor terminal 2C to engine ground INSPECTION
Verify stored DTC. Have DTC P0100, P0115, P0134, P1110 and/or P1170 been stored.
ACTION Yes
No
Inspect for open or short circuit in following wiring harnesses, then go to Step 11. • PCM terminal 2D -MAP sensor, O2S, IAT sensor, and/or ECT sensor • Between PCM terminal 2C and engine ground Go to next step
Does TP sensor connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 11
No
Go to next step.
Disconnect TP sensor connector. Turn ignition switch on. Is there 5V at TP sensor harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2K and TP sensor terminal A), then go to Step 11
Disconnect PCM connector. Yes TP sensor is disconnected. Is there continuity between TP sensor harness side connector terminal No C and PCM harness side connector terminal 2D. Is there continuity between TP sensor harness side connector terminal B and PCM harness side connector terminal 2M.
Go to next step. Repair open circuit, then go to Step 11.
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 11.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM STEP 6
INSPECTION
ACTION
Is there continuity from PCM harness side connector terminals 2D to 1B?
Yes No
Repair short to power supply circuit, then go to Step 11 Go to next step.
7
Is there continuity from PCM harness side connector terminal 2M to 1B
Yes No
Repair short to power supply circuit, then go to Step 11. Go to next step.
8
Is there continuity from PCM harness side connector terminals 2M to body ground?
Yes
Repair short to ground circuit, then go to Step 11.
No
Go to next step.
Connect TP sensor and PCM connectors. Connect NGS tester to DLC. Turn ignition switch on. Access TP V PID. Does TP V increase linear according to throttle valve opening angle?
Yes
Go to next step.
No
Verify TP sensor, then go to Step 11.
Yes
Go to Step 1.
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes
Go to applicable DTC inspection
No
Troubleshooting completed.
9
Note
•
10
11
If NGS tester is not used, measure PCM 2M terminal voltage with circuit tester. Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM DTC P0134
Oxygen sensor (O2S) circuit no activity detected
DETECTION CONDITION
O2S signal does not exceed 0.45 V after the engine is started, or stays below 0.45 V for 180 seconds after the engine has reached normal operating temperature.
POSSIBLE CAUSE
• • • • • • • • • • • • • • •
O2S malfunction Open or short circuit in wiring harness Open or short circuit in wiring harness Poor connection of connector Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose and/or fuel filter clogging or leakage Leakage in intake-air system Leakage in exhaust system Ignition coil and/or igniter malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Vacuum hose damage or looseness
Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
ACTION
1
Verify stored DTC. Have DTC P0100 P0120, P0115 and/or P1110 been stored?
Yes
2
Clear DTC. Verify RPM, ECT and VS PIDs. Drive in normal mode for approx. 2 minutes under same condition. Is DTC P0134 stored? Note • If NGS tester is not used, measure follow PCM terminal voltages with circuit tester. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1M)
Yes
Trouble is in process. Go to next step.
No
Go to 'TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent concerns".
Implement PID/DATA MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK by using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle? Note • If NGS tester is not used, measure following PCM terminal voltages with circuit tester. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2M)
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.
No
Go to next step.
3
No
Inspect and repair DTC P0100, P0115, P0120 or P1110 then go to Step 22. Go to next step
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ON-BOARD DIAGNOSTIC SYSTEM STEP 4
ACTION
INSPECTION Continue monitoring items in previous step. Is there any input signal, which causes drastic changes when it is set to be in trouble condition?
Yes
Implement 'TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.
No
Go to next step.
5
Inspect exhaust system upstream from oxygen sensor. Is there any gas leakage?
Yes
Repair or replace faulty exhaust parts, then go to Step 22. ☞ EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.
No
Go to next step
6
Inspect installation of O2S. Is it okay?
Yes
Go to next step.
No
Implement PID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on oxygen sensor as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean condition Note • If NGS tester is not used, measure PCM 2N terminal voltage with circuit tester.
Yes
Install O2S properly, then go to Step 22. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION. Go to next step.
No
Inspect and repair or replace faulty oxygen sensor harness, connector or terminal, then go to Step 22. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) INSPECTION.
Inspect for open, poor connection, and other problems on following harnesses, connectors and terminals (for fuel injector at each cylinder): • Front main relay to fuel injector Are there any problems?
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 22.
No
Go to next step.
Inspect injection amount of each fuel injector. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION, Fuel Injection Volume Test. Are there any fuel injectors in abnormal condition for amount or condition of injection?
Yes
Replace faulty fuel injectors, then go to Step 22. ☞ FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.
No
Go to next step.
Inspect for air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. Can air suction be confirmed? Inspect for suction in vacuum hose which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed?
Yes
Repair or replace source of air suction, then go to Step 22.
No
Go to next step.
Yes
Repair or replace source of air suction, then go to Step 22.
No
Go to next step.
Inspect fuel line pressure under trouble condition. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pressure Inspection. Is fuel line pressure okay? Inspect fuel pump maximum pressure. ☞ FUEL SYSTEM, FUEL PUMP UNIT INSPECTION, Fuel Pump Maximum Pressure Inspection. Is it okay? Inspect for clogging in fuel filter (high-pressure). Are there foreign materials on fuel side of fuel filter?
Yes
Go to Step 17.
No
Go to next step.
Yes
Go to next step
No
Replace fuel pump, then go to Step 22. ☞ FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/INSTALLATION.
7
8
9
10
11
12
13
14
Yes
Go to next step.
No
Go to Step 16.
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ON-BOARD DIAGNOSTIC SYSTEM STEP 15
16
17
18
19
20
INSPECTION
ACTION
Inspect inside of fuel tank for foreign materials and stains. Is inside of fuel tank okay?
22
Replace fuel filter (high-pressure), then go to Step 22. - FUEL SYSTEM, FUEL FILTER (HIGHPRESSURE) REMOVAL/INSTALLATION.
No
Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter (high-pressure), then go to Step 22. -FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION.
Inspect for leakage and clogging in fuel line from fuel Yes distributor to fuel pump. No Is it okay?
Repair or replace necessary, then go to Step 22.
Inspect for leakage in fuel line fuel filter (highpressure) to fuel tank (return side). Is it okay?
Yes
Replace pressure regulator, then go to Step 22. -FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.
No
Repair or replace as necessary, the go to Step 22.
Go to next step.
Verify blinking condition on each cylinder by setting Yes timing light on high-tension lead under trouble condition. No Does it blink regularly and stably?
Go to Step 19.
Inspect resistance of ignition coil. ☞ Section G, IGNITION COIL INSPECTION. Is it okay?
Yes
Go to next step.
No
Replace ignition coil, then go to Step 22.
Yes
Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 22.
No
Go to next step.
Yes
Go to next step
No
Implement engine overhaul, the go to next step.
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
Warning • Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing the radiator cap, wrap a thick cloth around and turn it slowly. Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles which make engine coolant white at filling opening?
21
Yes
Note • Large bubbles are normal since they are remaining air coming out from engine coolant passage. Inspect engine compression. ☞ Section B1, COMPRESSION INSPECTION. Is it okay? Clear DTC. Verify DTC after running vehicle. Is there any DTC stored?
Go to next step.
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ON-BOARD DIAGNOSTIC SYSTEM DTC P0340
SGT signal is not detected
DETECTION CONDITION
No SGT signal input from CMP sensor when engine is started and 2.1 seconds have passed
POSSIBLE CAUSE
STEP
• • • • • • • •
CMP sensor malfunction CMP sensor air gap incorrect Short to power supply circuit in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal C to PCM terminal 2E Open circuit in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal A to body ground INSPECTION
1
Verify stored DTC. Have DTC PP0100, P0443, P0505, and/or P1250 been stored?
2
Does CMP sensor or PCM connector have poor connection?
3
4
5
Disconnect CMP sensor connector. Turn ignition switch on. Is there battery positive voltage at CMP sensor harness side connector terminal B? Disconnect CMP sensor connector. Turn ignition switch on. Is there 5 V at CMP sensor harness side connector terminal C? Disconnect PCM connector and CMP sensor connector. Is there continuity between CMP sensor harness side connector terminal C and PCM harness side connector terminal 2E?
ACTION Yes
Inspect for open circuit in following wiring harnesses, then go to Step 11. • Main relay terminal D-purg solenoid valve, PRC solenoid valve, IAC solenoid valve, MAF sensor
No
Go to next step.
Yes
Repair or replace connector, then go to Step 11.
No
Go to next step
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and CMP sensor terminal B), then go to Step 11.
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2E and CMP terminal C), then go to Step 11.
Yes
Go to next step.
No
Repair open circuit, then go to Step 11.
6
Is there continuity from PCM harness side connector Yes terminal 2E to 1B? No
Repair short to power circuit, then go to Step 11.
7
Is there continuity from PCM harness side connector Yes terminal 2E to body ground? No
Repair short to ground circuit, then go to Step 11.
8
Is there continuity from CMP sensor harness side terminal A to body ground?
Yes
Go to next step.
No
Repair open circuit, then go to Step 11.
9
Connect CMP sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access RPM PID. Does RPM PID change when engine is running?
Yes
Go to next step.
No
Replace distributor and adjust ignition timing, then go to Step 11.
Yes
Go to Step 1
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
10
11
Note • If NGS tester is not used, measure PCM 2E terminal voltage with circuit tester. Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Go to next step. Go to next step.
CONTINUED
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P0443 DETECTION CONDITION
POSSIBLE CAUSE
STEP
Purge solenoid valve circuit malfunction Open or short circuit is observed in purge solenoid valve system when ignition switch is turned on. • • • • • • •
Purge solenoid valve malfunction Poor connection of connectors at purge solenoid valve and/or PCM Short to power supply circuit in wiring from purge solenoid valve B to PCM terminal 2X Short to ground in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from purge solenoid valve terminal A to main relay terminal D INSPECTION
ACTION
1
Verify stored DTC. Have DTC P0100, P0505, P0340, and/or P1250 been stored?
Yes
No
Go to next step
2
Does purge solenoid valve connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 9.
No
Go to next step.
Disconnect purge solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at purge solenoid valve harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between main relay terminal D and purge solenoid valve terminal A), then go to Step 9.
Disconnect PCM connector Purge solenoid valve is disconnected. Is there continuity between purge solenoid valve harness side connector terminal B and PCM harness side connector terminal 2X?
Yes
Go to next step.
No
Repair open circuit, then go to step 9.
Is there continuity from PCM harness side connector terminal 2X to 1B?
Yes No
Repair short to power supply circuit, then go to Step 9. Go to next step.
3
4
5
Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, IAC solenoid valve, MAF sensor, CMP sensor • Between PCM terminal 2C and engine ground
6
Is there continuity from PCM harness side connector terminal 2X to body ground?
Yes No
Repair short to ground circuit, then go to Step 9. Go to next step.
7
Is purge solenoid valve okay? ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION
Yes
Go to next step
No
Replace purge solenoid valve, then go to Step 9.
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to Step 1.
No
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection.
No
Troubleshooting completed.
8
9
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P0505
Idle air control (IAC) valve circuit malfunction
DETECTION CONDITION
Open or short circuit is observed in idle air control, system
POSSIBLE CAUSE
STEP
IAC valve malfunction Poor connection of connectors at IAC valve and/or PCM Short to ground in wiring from IAC valve terminal B to PCM terminal 2W Short to power supply circuit in wiring from IAC valve terminal B to PCM terminal 2W Short to ground in wiring from IAC valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from IAC valve terminal B to PCM terminal 2W Open circuit in wiring from IAC valve terminal A to main relay terminal D
INSPECTION
ACTION
1
Verify stored DTC. Have DTC P0100, P0340, P0443, and/or P1250 been stored.
Yes
No
Go to next step
2
Does IAC valve connector or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 9.
3
Disconnect IAC valve connector. Yes Turn ignition switch on. No Is there battery positive voltage at IAC valve harness side connector terminal A?
Go to next step.
Disconnect PCM connector IAC valve is disconnected. Is there continuity between IAC valve harness side connector terminal B and PCM harness side connector terminal 2W?
Yes
Go to next step.
No
Repair open circuit, then go to step 9.
4
No
Inspect for open circuit following wiring harnesses, then go to Step 9. • Main relay terminal D-PRC solenoid valve, MAF sensor, CMP sensor, purge solenoid valve • Between PCM terminal 2C and engine ground
Go to next step Inspect for open or short circuit in wiring harness (between main relay terminal D and IAC valve terminal A), then go to Step 9.
5
Is there continuity from PCM harness side connector Yes terminal 2W to 1B? No
Repair short to power supply circuit, then go to Step 9.
6
Is there continuity from PCM harness side connector Yes terminal 2W to body ground? No
Repair short to ground circuit, then go to Step 9,
Is resistance between IAC valve component side connector A and B as specified?
Yes
Go to next step.
No
Replace IAC valve, then go to Step 9.
Yes
Go to Step 1
No
Yes
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection
No
Troubleshooting completed
7
8
9
Specification 8.7—10.5 Ω [23 °C {73.4 °F}] Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
F1-62
Go to next step. Go to next step
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ON-BOARD DIAGNOSTIC SYSTEM
DTC P1110
Intake air temperature (IAT) sensor circuit malfunction
DETECTION CONDITION
Input from IAT sensor is below 0.1 V or above 4.9 V when ignition switch is turned on
POSSIBLE CAUSE
STEP 1
• • • • • • •
IAT sensor malfunction Poor connection of connectors at IAT sensor terminal and/or PCM Short to power supply circuit in wiring from IAT sensor terminal A to PCM terminal 2L Short to GND in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine GND INSPECTION
ACTION
Verify stored DTC. Have DTC P0100, P0115, P0120, P0134, P0335, and/or P1170 been stored?
Yes
No
Inspect for open circuit in following wiring harnesses, then go to Step 7. • PCM terminal 2D-ECT sensor, MAP sensor, O2S, CMP sensor and/or TP sensor • PCM terminal 2C-engine GND Go to next step. Repair or replace connector, then go to Step 9.
2
Does IAT sensor connector or PCM connector have poor connection?
Yes No
Go to next step.
3
Disconnect IAT sensor connector. Turn ignition switch on. Is there 5V at IAT sensor harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness (between PCM terminal 2L and IAT sensor terminal A), then go to Step 9.
Disconnect PCM connector. IAT sensor connector is disconnected. Is there continuity between IAT sensor harness side connector terminal B and PCM harness side connector terminal 2D?
Yes
Go to next step.
No
Repair open circuit, then go to Step 9.
Is there continuity from PCM harness side connector terminals 2L to 1B?
Yes
Repair short to power circuit, then go to Step 9.
No
Go to next step.
Is there continuity from PCM harness side connector terminal 2D to body GND?
Yes
Repair short to ground circuit, then go to Step 9.
No
Go to next step.
Is IAT sensor okay? ☞ CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION
Yes
Go to next step.
No
Replace IAT sensor, then go to Step 9. ☞ CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to Step 1.
No
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection.
No
Troubleshooting completed.
4
5 6 7
8
9
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ON-BOARD DIAGNOSTIC SYSTEM
DTCP1170 DETECTION CONDITION
POSSIBLE CAUSE
Oxygen sensor (O2S) is stuck When O2S signal stays above 0.45V for 20 seconds after engine has reached normal operating temperature. • • • • • • • • • • • • • • •
O2S deterioration Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose clogging or leakage Fuel return hose and/or fuel filter clogging Leakage in intake-air system or exhaust system PCV valve malfunction Purge solenoid valve malfunction or purge solenoid hoses are hooked up incorrectly Ignition coil malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Open or short circuit in wiring harness Poor connection of connector Vacuum hose damage or looseness
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1
INSPECTION Verify stored DTC. Have DTCs P0100, P0110 P0115, and/or P0120 been stored?
ACTION Yes
No
Inspect and repair DTC P0100, P0110, P0115, or P0120. Go to Step 26. Go to next step.
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ON-BOARD DIAGNOSTIC SYSTEM STEP 2
3
INSPECTION
ACTION
Clear DTC. Verify RPM, ECT and VS PIDS. Drive vehicle approx. 1 minute under same condition. Is DTC P1170 stored?
Yes
Trouble is in process. Go to next step.
Note • If NGS tester is not used, measure following PCM terminal voltage with voltmeter. ① SGT (terminal 2E) ② ECT sensor (terminal 2Q) ③ Vehicle speed (terminal 1 M) Implement PID/DATA.MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle?
No
Go to TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent Concerns.
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace then go to Step 26.
No
Go to next step.
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace, then go to Step 26.
Note • If NGS tester is not used, measure following PCM terminal voltage with voltmeter. ① ECT sensor (terminal 2Q) ② SGT (terminal 2E) ③ TP sensor (terminal 2K) 4
Continue monitoring items on previous PIDs. Is there any input signal which causes drastic changes when it is set to be in trouble condition?
Yes
No
Go to next step.
5
Inspect exhaust system, upstream from O2S. Is there any gas leakage?
Yes
Repair or replace faulty exhaust parts, then go to Step 26. ☞ EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.
No
Go to next step.
Yes
Go to next step.
No
Install heated oxygen sensor properly, then go to Step 26. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION.
Implement FID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on O2S as follows while racing engine (in neutral)? • More than 0.45V when accelerator pedal is suddenly pressed: rich condition • Less than 0.45V during fuel cut: lean condition Note • If NGS tester is not used, measure PCM 2N voltages with voltmeter.
Yes
Go to next step.
No
Inspect and repair or replace faulty O2S, harnesses, connector or terminals, then go to Step 26. ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S) INSPECTION.
Inspect for open, poor connection and other problems on the following harnesses, connectors, and terminals (for fuel injector at each cylinder): • From main relay to fuel injector • From fuel injector to PCM Is there any trouble?
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 26.
No
Go to next step.
6
7
8
Is O2S installed properly?
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ON-BOARD DIAGNOSTIC SYSTEM STEP 9
INSPECTION
ACTION
Inspect injection amount of each injector. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION, Volume Test. Are there any injectors operating abnormally? (e.g. injection amount, injection condition) Inspect purge control system. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection. Is it okay?
Yes
Replace faulty fuel injectors, then go to Step 26. ☞ FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.
No
Go to next step.
Yes
Go to next step.
No
By following system inspection, repair or replace faulty parts, then go to Step 26.
Inspect PCV valve operation. ☞ EMISSION SYSTEM, POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION. Is it okay?
Yes
Go to next step.
No
Replace PCV valve, then go to Step 26,
12
Inspect fuel line pressure under trouble condition. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay?
Yes
No
Inspect for leakage and injection amount. ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION. Replace faulty fuel injector, then go to Step 26. Go to next step.
13
Inspect pressure regulator. ☞ FUEL SYSTEM, PRESSURE REGULATOR INSPECTION. Is it okay?
Yes
Go to next step.
No
Inspect air suction: • From air cleaner to throttle body • From throttle body to dynamic chamber • From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. • Can air suction confirmed? Inspect for air suction in vacuum hose, which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed?
Yes
Replace pressure regulator, then go to Step 26. ☞ FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION, Repair or replace source of air suction, then go to Step 26.
10
11
14
15
16
17
18
19
20
No
Go to next step.
Yes
Repair or replace source of air suction, then go to Step 26.
No
Go to next step,
Inspect fuel line pressure under trouble condition. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay? Inspect fuel pump maximum pressure. ☞ FUEL SYSTEM, FUEL PUMP UNIT INSPECTION, Fuel Pump Maximum Pressure Inspection. Is it okay?
Yes
Go to Step 22.
No
Go to next step.
Yes
Go to next step.
No
Replace fuel pump body, then go to Step 26. ☞ FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/ INSTALLATION.
Inspect for clogging in fuel filter (high-pressure). Is there foreign material in fuel on fuel pump side of filter?
Yes
Go to next step.
No
Go to Step 20.
Inspect inside of fuel tank for foreign material and stains. Is inside of fuel tank okay?
Yes
Replace fuel filter (high-pressure), then go to Step 26. ☞ FUEL SYSTEM, FUEL FILTER (HIGHPRESSURE) REMOVAL/INSTALLATION.
No
Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter, then go to Step 26.
Yes
Go to next step.
No
Repair or replace source of fuel leakage or clogging, then go to Step 26.
Inspect for leakage and clogging in fuel line from distributor to fuel pump. Is it okay?
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ON-BOARD DIAGNOSTIC SYSTEM STEP 21
INSPECTION
ACTION
Inspect for leakage in fuel line from fuel filter (highpressure) to fuel tank (return side). Is it okay?
Yes
No 22
23
24
Replace pressure regulator, then go to Step 26. ☞ FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION. Repair or replace source of fuel leakage, then go to Step 26
Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. Does it blink regularly and stably?
Yes
Go to Step 24
No
Go to next step.
Inspect resistance of ignition coil. ☞Section G, IGNITION COIL INSPECTION. Is it okay?
Yes
Go to next step.
No
Replace ignition coil, then go to Step 26.
Warning • Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. • When removing the radiator cap, wrap a thick cloth around and turn it slowly. Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles, which make engine coolant white at filling opening?
Yes
Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 26.
No
Go to next step.
Yes
Go to next step.
No
Implement engine overhaul, then go to next step.
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
Note • Large bubbles are normal since they are remaining air coming out from engine coolant passage. 25
Inspect engine compression. ☞Section B1, COMPRESSION INSPECTION. Is it okay? Clear DTC. Verify DTC after running vehicle. Is there any DTC stored?
26
DTC P1195 DETECTION CONDITION POSSIBLE CAUSE STEP _
Barometric pressure (BARO) sensor (in PCM) Input voltage from barometric pressure sensor is below 1.5 V or above 4.5 V when ignition switch is turned on. • Barometric pressure sensor (in PCM) malfunction. INSPECTION _
ACTION _
Replace PCM ☞ CONTROL SYSTEM, PCM REMOVAL/INSTALLATION
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ON-BOARD DIAGNOSTIC SYSTEM DTC P1250
PRESSURE REGULATOR CONTROL (PRC) solenoid valve circuit malfunction
DETECTION CONDITION
Open or short circuit is observed in PRC solenoid valve when Ignition switch is turned on
POSSIBLE CAUSE
STEP
• • • • • • • •
PRC solenoid valve malfunction Poor connection of connectors at PRC solenoid valve and/or PCM Short to power supply circuit in wiring from PRC solenoid valve B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2T and/or 2C to engine GND Open circuit in wiring from PRC solenoid valve terminal B to PCM terminal 2T Open circuit in wiring from PRC solenoid valve terminal A to man relay terminal D INSPECTION
ACTION
1
Verify stored DTC. Have DTCs P0100, P0335, P0443 and/or P0505 been stored?
Yes
No
Inspect for open circuit in following wiring harnesses, then go to Step 9. • Main relay terminal D-IAC valve, PRC solenoid valve, MAF sensor, CMP sensor, purge solenoid valve • Between PCM terminal 2C and engine ground. Go to next step.
2
Does PRC solenoid valve connector or PCM connector have poor connection?
Yes No
Repair or replace connector, then go to Step 9. Go to next step.
3
Disconnect PRC solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at harness side connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness. (between main relay terminal D and PRC solenoid valve terminal A), then go to Step 9.
Disconnect PCM connector. PRC solenoid valve is disconnected. Is there continuity between PRC solenoid valve harness side connector terminal B and PCM harness side connector terminal 2T?
Yes
Go to next step.
No
Repair open circuit, then go to Step 9.
Is there continuity between PCM harness side connector terminals 2T and 1B?
Yes No
Repair short to power supply circuit, then go to Step 9. Go to next step.
Is there continuity from PCM harness side connector terminal 2T to body GND?
Yes
Repair short to GND circuit, then go to Step 9.
No
Go to next step.
Is PRC solenoid valve okay? ☞ FUEL SYSTEM, PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION
Yes
Go to next step.
No
Replace PRC solenoid valve, then go to Step 9.
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to Step 1.
No
Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
4
5
6 7
8
9
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ON-BOARD DIAGNOSTIC SYSTEM DTCP1608 DETECTION CONDITION POSSIBLE CAUSE
PCM internal circuit malfunction PCM does not read DTC from output devices. • •
PCM does not read DTC from output devices. Short to power supply circuit in wiring from output devices (purge solenoid valve, PRC solenoid valve, IAC solenoid valve and/or fuel injectors) to PCM
STEP INSPECTION 1 Disconnect output devices and PCM connector. Is there continuity between the following connectors? • PCM harness side connector terminal 2X-1B • PCM harness side connector terminal 2E-1B • PCM harness side connector terminal 2W-1B • PCM harness side connector terminal 2U-1B • PCM harness side connector terminal 2V-1B
Yes
No
ACTION Repair short to power supply circuit. Replace PCM. ☞ CONTROL SYSTEM, PCM REMOVAL/INSTALLATION Replace PCM ☞ CONTROL SYSTEM, PCM REMOVAL/INSTALLATION
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TROUBLESHOOTING
TROUBLESHOOTING FOREWORD • Before proceeding with the following troubleshooting. (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If the diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP". TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart. No.
TROUBLESHOOTING ITEM
DESCRIPTION
1
Melting of main or other fuses
2
Will not crank
Starter does not work.
4 5 6
Hard to start/long crank/erratic start/erratic crank Engine stalls After start/at idle Cranks normally but will not start Slow return to idle
Starter cranks engine at normal speed but engine requires excessive cranking time before starting. Engine stops unexpectedly at idle and/or after start. Starter cranks engine at normal speed but engine will not run. Engine takes more time than normal to return to idle speed.
7
Engine runs rough/rolling idle
Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.
8
Fast idle/runs on
Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off.
9
Low idle/stalls during deceleration
3
10
Engine stalls/quits
Acceleration/cruise
Engine runs rough Misses
Acceleration/cruise Acceleration/cruise
—
Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. Engine stops unexpectedly at beginning of acceleration or during acceleration. Engine stops unexpectedly while cruising. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising.
11
Hesitation/stumble Surges Lack/loss of power
Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise
12
Knocking/pinging
Acceleration/cruise
13 14 15
Poor fuel economy Emissions compliance High oil consumption/leakage
Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber). Fuel economy is unsatisfactory. Emission compliance test is failed. Oil consumption is excessive.
16
Cooling system concerns
Overheating
Engine runs at higher than normal temperature/overheats.
17
Cooling system concerns
Runs cold
Engine takes excessive period for reaching normal operating temperature.
18
Exhaust smoke
Buck/jerk
Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output. Performance is poor under load (e.g. power down when climbing hills).
Blue, black, or white smoke from exhaust system
19
Fuel odor (in engine compartment)
Gasoline fuel smell or visible leakage
20
Engine noise
Engine noise from under hood
21
Vibration concerns (engine)
Vibration from under hood or driveline
22
A/C does not work sufficiently
A/C compressor magnetic clutch does not engage when A/C is turned on.
23 24 25 26 27
A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions Exhaust sulphur smell Intermittent concerns Constant voltage
A/C compressor magnetic clutch does not disengage. A/C compressor magnetic clutch does not disengage under WOT. Rotten egg smell (sulphur) from exhaust. Symptom occurs randomly and is difficult to diagnose. Incorrect constant voltage.
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TROUBLESHOOTING QUICK DIAGNOSTIC CHART Engine or transmission mounts improperly installed
Cooling system malfunction (Radiator, hoses, overflow system, thermostat, etc.)
Water and anti-freeze mixed improperly
Improper engine coolant level
Improper tension or damaged drive belts
Flywheel seized
Base engine malfunction
Improper dipstick
Improper engine oil viscosity
Hydrolocked engine
x
Improper valve timing
x
Improper engine compression
Charging system malfunction
x
Low or dead battery
x
Improper engine oil level
Starter circuit including ignition switch open
Troubleshooting item
Starter motor malfunction (Mechanical or electrical)
Possible factor
1 Melting of main or other fuses 2 Will not crank
x
x
3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls After start/at idle 5 Cranks normally but will not start
X X
x x
x
x
x x x
x x x
x x
6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10
Acceleration/cruise Acceleration/cruise Acceleration/cruise
x
x
Hesitation/stumble Surges 11 Lack/loss of power
Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise
x x x
x x x
12 Knocking/pinging
Acceleration/cruise
x
Buck/jerk
x
13 Poor fuel economy
x
x
14 Emissions compliance
x
x
15 High oil consumption/leakage
x x x
x
19 Fuel odor (in engine compartment) 20 Engine noise
x
x
x
x
X
x x x
x
21 Vibration concerns (engine) 22 A/C does not work sufficiently. 23
x
x
16 Cooling system concerns Overheating 17 Cooling system concerns Runs cold 18 Exhaust smoke
x
x x
x
A/C is always on/A/C compressor runs continuously
24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns
x
27 Constant voltage
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TROUBLESHOOTING
High-tension leads malfunction (Cracks , open, low resistance)
CMP sensor damaged (e.g. open or short circuits)
x
Spark plug malfunction
x
Initial ignition timing misadjustment (CMP & crankshaft pulley misadjustment
x
Ignition coil malfunction (e.g. open short or cracks)
x
Vacuum leakage (Vacuum hose damaged, mis-routing)
Air leakage from intake-air system (Tubes looseness, crack, gaskets broken) x
x
Throttle body malfunction
Air cleaner element clogged or restriction x
x
IAC valve improper operation
Engine overheating
Fuel quality
Troubleshooting item
Accelerator cable free play misadjustment
Cooling fan seated improperly
Possible factor
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic star/erratic crank
x
4 Engine stalls
x
5 Cranks normally but will not start 6 Slow return to idle
x
x
7 Engine runs rough/rolling idle 8 Fast idle/runs on
x
After start/at idle
x
x x
x
x
x
x
x
x
9 Low idle/stalls during deceleration Engine stalls/quits
Acceleration/cruise
x
x
x
x
x
x
x
x
Engine runs rough
Acceleration/cruise
x
x
x
x
x
x
x
x
Misses
Acceleration/cruise
x
x
x
x
x
x
x
x
10
x
x
x
x
x
x
x
x
Hesitation/stumble
Acceleration/cruise/ deceleration Acceleration
x
x
x
x
x
x
x
x
Surges
Acceleration/cruise
x
x
x
x
x
x
x
x
11 Lack/loss of power
Acceleration/cruise
x
x
x
x
x
x
x
12 Knocking/pinging 13 Poor fuel economy
Acceleration/cruise
Buck/jerk
x x
14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns
Overheating
17 Cooling system concerns 18 Exhaust smoke
Runs cold
x x
x
x
x
x
x
x
x
x
x
x
x
19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently.
x
x
x
A/C is always on/A/C compressor runs 23 continuously 24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell
x
26 Intermittent concerns
x
x
x
x
27 Constant voltage
F1-72
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ECT sensor malfunction
Main relay malfunction (Mechanical or electrical)
V-reference supply circuit malfunction
PCV valve malfunction
Evaporative emission control system malfunction
Catalytic converter malfunction
Exhaust system restricted or clogged
Improper air/fuel mixture ratio control
PRC solenoid valve improper operation
Fuel filters restricted or clogged
Fuel leakage from fuel system (Including insulator, injector O-ring)
Injectors malfunction (Leakage or clogging, inoperative)
Fuel hoses restricted or clogged
Possible factor
Pressure regulator malfunction
Fuel pump body malfunction (Mechanical or electrical
TROUBLESHOOTING
Troubleshooting item Melting of main or other fuses Will not crank
x x
x x
x x
x
x
x x
x x
x x
x x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Hard to start/long crank/erratic start/erratic crank 3 After start/at idle Engine stalls 4
x x
1 2
x x
Cranks normally but will not start Slow return to idle
5 6
Engine runs rough/rolling idle
7
x
Fast idle/runs on
8
Low idle/stalls during deceleration
9
x
x
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Engine stalls/quits
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Engine runs rough
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Misses
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Acceleration/cruise
Lack/loss of power
11
x x
x x
Knocking/pinging
x
x
12 13
x
x
x
x
x
x
x
x
x
x
x
x
x x
x
x
x
x
Hesitation/stumble
x
Acceleration/cruise
Surges
x x
Emissions compliance
x
High oil consumption/leakage
15
Overheating
Cooling system concerns
16
Runs cold
Cooling system concerns
17
x
x
x
Buck/jerk
Acceleration/cruise Poor fuel economy
x
x
x
x
10
Acceleration/cruise/ deceleration Acceleration
x x
x
x
14
Exhaust smoke
18
Fuel odor (in engine compartment)
19
Engine noise
20
Vibration concerns (engine)
21
A/C does not work sufficiently.
22
A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions
24
Exhaust sulphur smell Intermittent concerns Constant voltage
25 26 27
23
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x
Suspension malfunction
x
Drive line malfunction
x
Wheels and tires improper balance
x
Loose parts
x
Brake dragging
x
Improper ATF level
x
VSS and related circuit malfunction
A/C relay (A/C control signal) circuit malfunction
x
Clutch slippage
Improper refrigerant charging amount
PSP switch and related circuit malfunction
Variable resistor and related circuit malfunction (Except Europe)
TP sensor misadjustment (Including looseness)
TP sensor and related circuit malfunction
Troubleshooting item
MAF sensor and related circuit malfunction
Brake switch and related circuit malfunction
Possible factor
Neutral or clutch switch and related circuit malfunction
TROUBLESHOOTING
x
x
1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank
x
4 Engine stalls after start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle
x
8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits
10
x
x
acceleration/cruise
x
x
x
x
x
x
x
Engine runs rough
acceleration/cruise
x
x
x
x
x
x
x
Misses
acceleration/cruise
x
x
x
x
x
x
x
Buck/jerk Hesitation/stumble Surges
acceleration/cruise/ deceleration acceleration
x
x
x
x
x
x
x
x
x
x
x
x
x
x
acceleration/cruise
x
x
x
x
x
x
x
x
x
x
x
11 Lack/loss of power
acceleration/cruise
12 Knocking/pinging 13 Poor fuel economy
acceleration/cruise
x
x x
x
14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns
overheating
17 Cooling system concerns
runs cold
x
x
18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine)
x x
22 A/C does not work sufficiently. 23
x
A/C is always on/A/C compressor runs continuously
x x
24 A/C is not cut off under WOT conditions
x
x
25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage
x
x
x
x x
x
x
x
CONTINUED F1-74
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SYMPTOM TROUBLESHOOTING: Symptom 1-Melting of main or other fuses
FI-75
Symptom 2-Will not crank
FI-76
Symptom 3-Hard to start/long crank/erratic crank
FI-77-78
Symptom 4-Engine stalls-after start/at idle
FI-79-81
Symptom 5-Cranks normally but will not start
FI-82-84
Symptom 6-Slow return to idle
FI-85
Symptom 7-Engine runs rough/rolling idle
FI-86-88
Symptom 8-Fast idle/runs on
FI-89
Symptom 9-Low idle/stalls during deceleration
FI-90
Symptom 10-Engie stalls/quits-acceleration/cruise - Engine runs rough – acceleration/cruise - Misses-acceleration/cruise - Buck/jerk – acceleration/cruise/deceleration - Hesitation/stumble – acceleration - Surges – acceleration/cruise
FI-91-93
Symptom 11-Lack/loss of power-acceleration/cruise
FI-94-96
Symptom 12-Knocking/pinging-acceleration/cruise
FI-97
Symptom 13-Poor fuel economy
FI-98-99
Symptom 14-Emission compliance
FI-100-101
Symptom 15-High oil consumption/leakage
FI-101
Symptom 16-Cooling system concerns-overheating
FI-102-103
Symptom 17-Cooling system concerns-runs cold
FI-103
Symptom 18-Exhaust smoke
FI-104-105
Symptom 19-Fuel odor (in engine compartment)
FI-106
Symptom 20-Engine noise
FI-107
Symptom 21-Vibration concerns (engine)
FI-107
Symptom 22-A/C does not work sufficiently
FI-108
Symptom 23-A/C is always on (a/c compressor runs continuously
FI-109
Symptom 24-A/C does not cut off under wide open throttle (wot) conditions
FI-110
Symptom 25-Exhaust sulphur smell
FI-111
Symptom 26-Intermittent concerns
FI-112
Symptom 27-Constant voltage
FI-113-114
CONTINUED
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TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1
MELTING OF MAIN OR OTHER FUSES
Damaged Fuse MAIN (80 A)
HEAD (30 A) A/C (10A) WIPER (15 A)
STOP (15 A) FUEL INJ (30 A)
ROOM (10 A) ENGINE (15 A)
METER (15 A)
Related Wiring Harness MAIN fuse Generator Ignition switch Starter Ignition coil Condenser HEAD fuse • Generator A/C relay • Generator WIPER fuse • A/C relay • A/C switch STOP fuse • Brake switch Main relay • Fuel injector • PCM • PRC solenoid valve • Purge solenoid valve • IAC valve • MAF sensor • CMP sensor ROOM fuse • PCM ENGINE fuse • Main relay • Fuel pump relay Fuel pump relay • Fuel pump METER fuse • PCM
CONTINUED
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TROUBLESHOOTING SYMPTOM 2 WILL NOT CRANK DESCRIPTION • Starter does not work. • Open circuit between ignition switch and starter POSSIBLE • Starter malfunction CAUSE • Seized/hydrolocked engine or flywheel STEP INSPECTION RESULTS ACTION 1 Inspect for following: Yes Go to next step. • Battery connection No Service as necessary. • Battery condition Repeat Step 1. • Fuses Are all items okay? 2
Is clicking sound heard from starter when ignition switch is turned to START?
3
Inspect starting system. ☞ Section G, STARTING SYSTEM, STARTER INSPECTION Is starting system okay?
Yes No Yes
Go to next step. Go to Step 4. Inspect for seized/hydrolocked engine or flywheel. ☞ Section H, FLYWHEEL, FLYWHEEL INSPECTION
No
Repair or replace components as required. Go to next step. Inspect charging system. ☞ Section G, CHARGING SYSTEM, GENERATOR INSPECTION No DTC is displayed: Inspect following: • START circuit in ignition switch • Open circuit between ignition switch and starter
4
Do any other electrical accessories work?
Yes No
5
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
6
No
DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay is stuck open. • Open or poor GND circuit at PCM • Poor connection of vehicle body GND
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
F1-76
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TROUBLESHOOTING SYMPTOM 3 DESCRIPTION
POSSIBLE CAUSE
HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK • •
Starter cranks engine at normal speed but engine requires excessive cranking time before starting. Battery in normal condition.
• • • • • • • • • • • •
Spark leakage from high-tension leads Vacuum leakage Poor fuel quality Starting system malfunction Spark plug malfunction Air leakage from intake-air system Erratic signal from CMP sensor Air cleaner restriction PCV valve malfunction Inadequate fuel pressure Purge solenoid valve malfunction MAF sensor contamination Restriction in exhaust system Pressure regulator control (PRC) system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
RESULTS
1
Inspect for following: • Vacuum leakage • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • Loose bands on intake-air system • Cracks on intake-air system parts • Air cleaner restriction Are all items okay?
Yes
Go to next step.
No
Service as necessary.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
3
Is engine overheating?
Yes No
Go to symptom troubleshooting No.16 for "Cooling system concerns - Overheating". Go to next step.
4
Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads?
Yes
Repair suspected high-tension leads.
No
Go to next step.
Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?
Yes
2
5
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Replace malfunctioning parts.
Remove PCV valve and inspect PCV valve. Does PCV valve rattle?
Yes No
Go to next step. Replace PCV valve.
No 6 7
ACTION
F1-77
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TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 8 Install fuel pressure gauge between fuel filter Yes Go to next step. and fuel distributor. No Zero or low: Connect a jumper wire between F/P terminal at Inspect fuel pump circuit. DLC in engine compartment and GND. Inspect for open fuel pump relief valve. ☞ TROUBLESHOOTING, ENGINE SYSTEM Inspect for fuel leakage inside pressure regulator. INSPECTION, Fuel Line Pressure Inspect for clogged main fuel line. Inspection Inspect PRC solenoid valve and related vacuum hose Turn ignition switch on. and harnesses. Is fuel line pressure correct? High: Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 39—45 psi} Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. 9
Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2,21 psi} for 5 min.
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Disconnect vacuum hose from pressure regulator and plug hose. Start engine. Does fuel line pressure remain within ± 20 kPa 2 {0.21 kgf/cm , 3 psi} while driving vehicle?
Yes
Go to next step.
No
Inspect for clogged fuel filter.
Connect vacuum hose to pressure regulator. Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or fuel pressure gauge reading decrease as vacuum gauge reading increases?
Yes
Go to next step.
No
Connect vacuum hose to pressure regulator. Start engine. Verify fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Disconnect a vacuum hose from purge solenoid valve and plug opening end of vacuum hose. Start engine. Is starting condition improved?
Yes
Inspect if purge solenoid valve sticks to open.
No
Go to next step.
13
Inspect for contaminated MAP sensor. Is there any contamination?
Yes
Replace MAP sensor.
No
Go to next step.
14
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
15
Inspect starting system. Yes Inspect for loose connectors or poor terminal contact. ☞ Section G, STARTING SYSTEM, STARTER INSPECTION No Repair or replace components as required. Is starting system normal? Verify test results. If okay, return to diagnostic index to service any additional symptoms.
10
11
12
16
CONTINUED
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TROUBLESHOOTING SYMPTOM 4
ENGINE STALLS - AFTER START / AT IDLE
DESCRIPTION
•
Engine stops unexpectedly at idle and/or after start.
• • • • • • • • • • • • • • • • • • • •
A/C system operation is improper. Air leakage from intake-air system parts Purge solenoid valve malfunction Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or wrong installation Vacuum leakage Low engine compression Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Electrical connector disconnection Open or short circuit in fuel pump body and related harness No battery power supply to PCM or poor GND Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Pressure regulator control (PRC) system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always • keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death • and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE • REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION Verify following: 1 • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Ignition wiring • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay? 2
Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?
RESULTS Yes Go to next step.
No
ACTION
Service as necessary. Repeat Step 11.
Yes
Go to next step.
No
Go to symptom troubleshooting No.27 "Constant voltage".
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TROUBLESHOOTING STEP 3
4 5
6 7 8
9
INSPECTION
RESULTS
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC Is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (terminal 2A, 2B or 2C) • Poor connection of vehicle body GND
Attempt to start engine at part throttle. Does engine run smoothly at part throttle?
Yes
Inspect IAC valve and wiring harness.
No Yes
Go to next step. Go to next step.
No
Inspect for following: • Open or short circuit In CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness okay, go to next step.
Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed during cranking of engine?
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
Inspect for cracks on high-tension leads Are there any cracks on high-tension leads?
Yes
Repair suspected high-tension lead.
No
Go to next step.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Go to next step. If symptom occurs with A/C on, go to Step 14.
No
Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F
Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?
Yes
Remove and shake PCV valve. Does PCV valve rattle?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Replace PCV valve.
Is there any restriction in the exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
No 10 11
ACTION
CONTINUED
F1-80
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TROUBLESHOOTING STEP INSPECTION 12 Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
13
14
15
16
17 18
RESULTS Yes Go to next step. No
ACTION
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid valve, related vacuum hose and related harnesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2,21 psi} for 5 min. Note • The following test is for stall concerns with A/C on. If other symptoms exist, go to next step. Connect pressure gauges to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURE, REFRIGERANT PRESSURE CHECK Is pressure within specifications?
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid side. Plug opening end of vacuum hose. Start engine. Is engine stall now eliminated? Is air leakage felt or heard at intake-air system components while racing engine to higher speed?
Yes
Inspect if purge solenoid valve sticks to open. Inspect evaporative emission control system.
No
Go to next step.
Yes
Repair or replace.
No
Go to next step.
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for cause.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
F1-81
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TROUBLESHOOTING SYMPTOM 5
DESCRIPTION
POSSIBLE CAUSE
CRANKS NORMALLY BUT WILL NOT START • • • •
Starter cranks engine at normal speed but engine will not run. Refer to "Engine stalls" if this symptom appears after engine stall. Fuel in tank. Battery in normal condition.
• • • • • • • • • • • • • • • • • • • •
No battery power supply to PCM Air leakage from intake-air system Open PCM GND or vehicle body GND Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or incorrect installation Low engine compression Vacuum leakage Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connector Open or short circuit in fuel pump body and related harness Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from injector Fuel injector is clogged. Purge solenoid valve malfunction Pressure regulator control (PRO) system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • • ☞ ☞
Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Verify following: • Vacuum connection • External fuel shut off or accessory (kill switch, alarm etc.) • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve
Yes
Go to next step.
ACTION
No
Service as necessary. Repeat Step 11.
Are all items okay?
CONTINUED
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TROUBLESHOOTING STEP 2
3
4 5 6
7 8 9
10
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.5—5.5 V Is voltage okay?
Yes
DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: • Open circuit between main relay and PCM terminal 1B • Open main relay GND circuit • Main relay stuck open • Open PCM GND circuit (PCM terminal 2A, 2B or 2C) • Poor connection of vehicle body GND Go to next step.
No
Go to symptom troubleshooting No.27 "Constant voltage",
Does engine start with throttle closed?
Yes
Go to Step 18.
No
Go to next step.
Will engine start and run smoothly at part throttle?
Yes
Inspect IAC valve and wiring harness.
No
Go to next step.
Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed when cranking engine?
Yes
Go to next step.
No
Inspect for following: • Open or short circuit in CMP sensor • Open or short circuit between CMP sensor and PCM terminal 2E • Open or short circuit in CMP sensor harnesses If CMP sensor and harness are okay, go to next step.
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
Inspect for cracks on high-tension leads. Is there any cracks on high-tension leads?
Yes
Repair suspected high-tension leads.
No
Go to next step.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Go to next step.
No
Inspect for following: • Open or short circuit in ignition coil • Open circuit in high-tension leads • Open circuit between igniter connector GND terminal and body GND • Open circuit between ignition switch and ignition coil • Open circuit between ignition coil and condenser • Open circuit between condenser and igniter • Open circuit between ignition coil and igniter • Open circuit between igniter and PCM terminal 2F
Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?
Yes
If spark plug is wet or covered with carbon, inspect for fuel leakage from injector. If spark plug is grayish white, inspect for clogged fuel injector.
No
Install spark plugs on original cylinders. Go to next step. Go to next step.
11
Remove and shake PCV valve. Does PCV valve rattle?
Yes No
Replace PCV valve.
12
Is there any restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
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TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 13 Install fuel pressure gauge between fuel main Yes Go to next step. pipe and fuel distributor. No Zero or low: Connect jumper wire between F/P terminal at Inspect fuel pump circuit. DLC in engine compartment and GND. Inspect for open fuel pump relief valve. Turn ignition switch on. Inspect for fuel leakage inside pressure regulator. Is fuel line pressure correct when ignition switch Inspect for clogged main fuel line. is cycled on/off five times? Inspect PRC solenoid, related vacuum hose, and harFuel line pressure nesses. High: 270—3-10 kPa Inspect pressure regulator for high pressure cause. {2.7—3.2 kgf/cm 2, 39—45 psi} Inspect for clogged fuel return line. 14
15
16
17 18
Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2, 21 psi} for 5 min. Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Is starting condition improved? Is air leakage felt or heard at intake-air system components while racing engine to higher speed?
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Inspect if purge solenoid valve sticks to open mechanically. Inspect evaporative emission control system.
No
Go to next step.
Yes
Repair or replace.
No
Go to next step.
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for causes.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 6 DESCRIPTION POSSIBLE CAUSE STEP 1
2
3
SLOW RETURN TO IDLE • Engine takes more time than normal to return to idle speed. • • • •
ECT sensor malfunction Thermostat is stuck open. Throttle body malfunction Air leakage from intake-air system INSPECTION
RESULTS
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Remove thermostat and inspect operation. ☞ Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is throttle body free of contamination?
Yes
Yes No
No 4
ACTION
Engine coolant temperature and thermostat are okay. Go to next step. Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT V PID is normal, inspect temperature gauge and heat gauge unit. Inspect for air leakage from intake-air system components while racing engine to higher speed. Clean or replace throttle body.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 7 DESCRIPTION
POSSIBLE CAUSE
ENGINE RUNS ROUGH/ROLLING IDLE • •
Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively. Idle speed is too slow and engine shakes excessively.
• • • • • • • • • • • • • • • • • • •
Air leakage from intake-air system parts A/C system operation is improper. Spark leakage from high-tension leads Purge solenoid valve malfunction (if equipped) Improper operation of IAC valve Low engine compression Erratic signal from CMP sensor Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connectors Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Engine overheating Vacuum leakage Pressure regulator control (PRC) system malfunction
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1
2
3
INSPECTION Verify following: • External fuel shut off or accessory • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • No air leakage from intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Ignition wiring • Electrical connections • Fuses • Smooth operation of throttle valve. Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display? Is engine overheating?
RESULTS
ACTION
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Yes
Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating".
No
Go to next step.
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
4
Note • Following test is for engine running rough idle with A/C on concerns. If other symptoms exist, go to next step. Connect pressure gauge to A/C low and high pressure side lines. Start engine and run it at idle. Turn A/C switch on. Measure low side and high side pressures. ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURE, REFRIGERANT PRESSURE CHECK Are reading pressures within specification?
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Note • Following test is for engine running rough with P/S on. If other symptoms exist, go to next step. Start engine and run it at idle. Access PSP SW PID. Inspect if PSP SW PID is on while turning steering wheel right to left. Is PSP SW PID okay? Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Inspect power steering pressure switch operation and wiring harness between power steering pressure switch connector and PCM connector terminal 1P.
No
Go to next step.
Yes
Go to next step.
No
Replace malfunctioning parts.
7
Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads?
Yes
Repair suspected high-tension leads.
No
Go to next step.
8
Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?
Yes
5
6
Start engine and disconnect IAC valve connector. Does rpm drop or engine stall?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Inspect IAC valve and wiring harness.
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step.
No
Zero or low Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line Inspect PRC solenoid valve, related vacuum hose and harnesses High • Inspect pressure regulator for high pressure cause • Inspect for clogged fuel return line
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1.5 kgf/cm ,21 psi} for 5 min.
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
No 9
10
11
ACTION
CONTINUED
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TROUBLESHOOTING STEP 12
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC, Start the engine and run it at idle. Access FHO2S PID. Is FHO2S PID okay? • More than 0.45 V when accelerator pedal is suddenly depressed: rich condition • Less than 0.45 V during fuel cut: lean condition
Yes
Go to next step.
No
Inspect and repair or replace faulty O2S, harness, connector or terminal, then go to next step.
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Does engine condition improve?
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No
Go to next step.
14
Remove and shake PCV valve. Does PCV valve rattle?
Yes
Go to next step.
No
Replace PCV valve.
15
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
16
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for causes.
17
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
13
CONTINUED
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TROUBLESHOOTING SYMPTOM 8
FAST IDLE/RUNS ON
DESCRIPTION
• •
POSSIBLE CAUSE
• • •
Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off.
ECT malfunction Air leakage from intake-air system Throttle body malfunction STEP INSPECTION RESULTS 1 Connect NGS tester to DLC. Yes Access ECT PID. No Start and warm up engine to normal operating temperature. Is ECT PID reading between 112°C {234°F} and 82°C {180°F}?
2
3
4
ACTION Go to next step. ECT PID is higher than 112°C {234°F}: Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". ECT PID is less than 82°C {180°F}: Go to symptom troubleshooting No.17 "Cooling system concerns - Runs cold".
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is there air leakage felt or heard at intake-air system components while racing engine to higher speed?
Yes
Repair or replace parts as necessary.
No
Verify accelerator cable free play.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 9 DESCRIPTION
•
Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
POSSIBLE CAUSE
• • • • • • •
Vacuum leakage IAC valve malfunction Air leakage from intake-air system MAF sensor or related circuit malfunction TP sensor or related circuit malfunction Brake switch or related circuit malfunction Neutral/clutch switch or related circuit malfunction
STEP 1
2
3
4
5
6
7
LOW IDLE/STALLS DURING DECELERATION
INSPECTION Does engine idle roughly?
RESULTS Yes
ACTION
No
Go to symptom troubleshooting No.7 for "Engine runs rough/Rolling idle". Go to next step.
Verify following: • Proper routing and no damage of vacuum lines • IAC valve is connected properly. • No air leakage from intake-air system Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 2.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Does idle speed drop or stall when disconnecting IAC valve?
Yes
Go to next step.
No
Inspect following: • Circuit from IAC valve to PCM connector terminal 2W for open and short • IAC valve for sticking If okay, go to next step.
Disconnect vacuum hose between purge Yes solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. No Drive vehicle. Does engine condition improve? Connect NGS tester to DLC. Yes Access TP V, MAP V, VS, BRK SW and NL SW PIDs. Monitor each PID while driving vehicle. No • TP V PID • MAF V PID • VS PID BRK • SW PID • NL SW PID Are PIDs okay? ☞ CONTROL SYSTEM, PCM INSPECTION
Inspect evaporative emission control system.
Go to next step. Go to symptom troubleshooting No.26 for "Intermittent concerns".
TP V PID: Inspect TP sensor. MAF V PID: Inspect MAF sensor. VS PID: Inspect VSS. BRK SW PID: Inspect brake switch. NL SW PID: Inspect neutral switch and clutch switch.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING
SYMPTOM 10
DESCRIPTION
POSSIBLE CAUSE
ENGINE STALLS/QUITS - ACCELERATION/CRUISE ENGINE RUNS ROUGH - ACCELERATION/CRUISE MISSES - ACCELERATION/CRUISE BUCK/JERK - ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE - ACCELERATION SURGES - ACCELERATION/CRUISE • Engine stops unexpectedly at beginning of acceleration or during acceleration. • Engine stops unexpectedly while cruising. • Engine speed fluctuates during acceleration or cruising. • Engine misses during acceleration or cruising. • Vehicle bucks/jerks during acceleration, cruising or deceleration. • Momentary pause at beginning of acceleration or during acceleration. • Momentary minor irregularity in engine output. • A/C system operation is improper. • Air leakage from intake-air system parts • Purge solenoid valve malfunction • Improper operation of IAC valve • Erratic signal from CMP sensor • Low engine compression • Vacuum leakage • Poor fuel quality • Spark leakage from high-tension leads • Air cleaner restriction • PCV valve malfunction • Improper valve timing due to jumping out of timing belt • Restriction in exhaust system • Intermittent open or short in fuel pump circuit • Inadequate fuel pressure • Fuel pump mechanical malfunction • Fuel leakage from fuel injector • Fuel injector clogging • Intermittent open or short of MAF sensor, TP sensor and VSS • Clutch slippage Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ ☞
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS Verify following: Go to next step. 1 Yes • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) No Service as necessary. • Ignition wiring Repeat Step 1. • Fuel quality (e.g. proper octane, contamination, winter/summer blend) • Electrical connections • Smooth operation of throttle valve Are all items okay?
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ACTION
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TROUBLESHOOTING STEP 2
3
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is engine overheating?
Yes No
Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". Go to next step.
Connect NGS tester to DLC. Access RPM PID, B+ PID, TP V PID, MAF V PID, and VS PID. • RPM PID • B+PID • TP V PID • MAF V PID • VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? ☞ CONTROL SYSTEM, PCM INSPECTION
Yes
Go to next step.
No
RPM PID: Inspect CMP sensor and related harness for vibration, intermittent open/short circuit. B+ PID: Inspect for open circuit intermittently. MAF V PID: Inspect for open circuit of MAF sensor and related wire harness intermittently. TP V PID: Inspect if output signal from TP sensor changes smoothly. VS PID: Inspect for open circuit of VSS and related wire harness intermittently.
5
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
6
Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?
Yes
4
Remove and shake PCV valve. Does PCV valve rattle?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No
Replace PCV valve.
Verify that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug. Is lever in correct position?
Yes
Go to next step.
No
Adjust as necessary.
Are there restrictions in the exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1.5 kgf/cm , 21 psi} for 5 min.
Yes
Go to next step.
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
No 7 8
9 10
11
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TROUBLESHOOTING STEP INSPECTION RESULTS ACTION 12 Install vacuum gauge to intake manifold. Yes Go to next step. Start engine. No Connect vacuum hose to pressure regulator. Does fuel pressure gauge reading increase as Start engine. vacuum gauge reading decreases and/or does Verify that fuel pressure gauge reading changes as vacuum fuel pressure gauge reading decrease as changes. vacuum reading increases? If it changes, inspect vacuum line. If it does not change, replace pressure regulator. 13
14
15
16
Note • The following test is for engine stalling with A/C on. If other symptoms exist, go to next step. Connect a pressure gauge to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Is pressure within specifications? ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? Is engine compression correct?
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No
Go to next step.
Yes
Inspect following: • Valve timing • Clutch
No
Inspect for cause.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 11
LACK/LOSS OF POWER - ACCELERATION/CRUISE
DESCRIPTION
• • • • • • • • • • • • • • •
POSSIBLE CAUSE
Performance is poor under load e.g. power down when climbing hills).
• •
Improper A/C system operation Air leakage from intake-air system parts Purge control solenoid malfunction Brake dragging Erratic signal from CMP sensor Low engine compression Vacuum leakage Poor fuel quality Spark leakage from high-tension leads Air cleaner restriction PCV valve malfunction Improper valve timing due to jumping out of timing belt Restriction in exhaust system Intermittent open or short in fuel pump circuit Inadequate fuel pressure Fuel pump mechanical malfunction
• • • •
Fuel leakage from fuel injector Fuel injector clogging Intermittent open or short of MAP sensor, TP sensor and VSS Clutch slippage
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
RESULTS
1
Verify following: • Vacuum connection • Air cleaner element • No air leakage from intake-air system • No restriction of intake-air system • Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) • Fuel quality (e.g. proper octane, contamination, winter/summer blend) Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTCs. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC Is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Is engine overheating?
Yes
Go to symptom troubleshooting No. 16 "Cooling system concerns - Overheating".
No
Go to next step.
2
3
ACTION
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TROUBLESHOOTING STEP INSPECTION 4 Connect NGS tester to DLC. Access RPM PID, MAF V PID, TP V PID, and VS PID. • RPM PID • MAP V PID • TP V PID • VS PID
RESULTS Yes Go to next step. No
Drive vehicle while monitoring PIDs. Are PIDs within specification? ☞ CONTROL SYSTEM, PCM INSPECTION
ACTION
RPM PID: Inspect CMP sensor and related harness for vibration and/or intermittent open/short circuit. MAF V PID: Inspect for intermittent open circuit of MAF sensor and related wire harness. TP V PID: Inspect if TP sensor output increases smoothly. VS PID: Inspect for intermittent open circuit of VSS and related wire harness.
5
Visually inspect CMP sensor. Is CMP sensor okay?
Yes
Go to next step.
No
Replace malfunctioning parts.
6
Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?
Yes
Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step.
No 7
Remove and shake PCV valve. Does PCV valve rattle?
Yes No
Replace PCV valve.
8
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
9
Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
Yes
Go to next step.
No
Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
Yes
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Go to next step.
No
Connect vacuum hose to pressure-regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Note • Following test is for engine stalling with A/C on concern. If other symptoms exist, go to next step. Connect pressure gauge to A/C low and high side pressure lines. Turn A/C on and measure low side and high side pressure. Is the pressure within specifications? ☞ Section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK Inspect for A/C cut off operation. Does A/C cut-off work properly?
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C always on/ A/C compressor runs continuously". For other symptoms, inspect following: • Refrigerant charging amount
10
11
12
Yes
Go to next step.
No
Inspect A/C cut-off system components.
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TROUBLESHOOTING STEP 13
14
15
INSPECTION Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? Is engine compression correct?
RESULTS
ACTION
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No
Go to next step.
Yes
Inspect following: • Valve timing • Clutch • Brake system for dragging
No
Inspect for cause.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 12 DESCRIPTION
POSSIBLE CAUSE
STEP 1
KNOCKING/PINGING - ACCELERATION/CRUISE •
Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber).
• • •
Engine overheating due to cooling system malfunction Inadequate engine compression Inadequate fuel pressure
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Access ECT P1D. Verify ECT PID is less than 116°C {241 °F} while driving. Is ECT PID less than specification?
Yes
Go to next step.
No
Inspect cooling system for cause of overheating.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
3
Is engine compression correct?
Yes
Go to next step.
No
Inspect for cause.
4
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Inspect ignition timing.
2
5
6
Install vacuum gauge to intake manifold. Yes Start engine. No Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
Connect vacuum hose to pressure regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 13
POOR FUEL ECONOMY
DESCRIPTION
•
Fuel economy is unsatisfactory.
• • • • • • • • • • • • • •
Contaminated air cleaner element Engine cooling system malfunction Improper automatic transmission fluid level Weak spark Poor fuel quality Improper coolant level Inadequate fuel pressure Spark plug malfunction PCV valve malfunction Brake dragging Improper valve timing due to jumping out of timing belt Contaminated MAF sensor Improper engine compression Exhaust system clogging
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS ACTION 1 Yes Go to next step. Inspect following: • Air cleaner element for contamination • Automatic transmission fluid level No Service as necessary. • Fuel quality • Coolant level Are all items okay? Repeat Step 1. Connect NGS tester to DLC. Yes No DTC is displayed: 2 Turn ignition switch on. Go to next step. Retrieve any DTCs. No DTC is displayed: Is "NO CODES RECEIVED" or "SYSTEM Go to appropriate DTC test. PASSED" display? 3
4
Connect NGS tester to DLC. Access ECT PID. Drive vehicle while monitoring PID. ☞ CONTROL SYSTEM, PCM INSPECTION Is PID within specification?
Yes
Go to next step.
No
Inspect for coolant leakage, cooling fan operation, or thermostat operation.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step. Inspect the following: • High-tension leads • Ignition coil and connector
No
5
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING STEP INSPECTION 6 Remove and shake PCV valve. Does PCV valve rattle?
RESULTS Yes Go to next step. No
Replace PCV valve.
ACTION
7
Is there restriction in exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
8
Is brake system functioning properly?
Yes
Go to next step.
No
Inspect for cause.
9
Inspect for contaminated MAF sensor. Is there any contamination?
Yes
Replace MAP sensor.
No
Go to next step.
10
Is engine compression correct?
Yes
Inspect valve timing.
No
Inspect for cause.
11
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 14 DESCRIPTION
POSSIBLE CAUSE
EMISSION COMPLIANCE • Emission compliance test is failed. • • • • • • • • • • •
Vacuum line leakage or blockage Cooling system malfunction Spark plug malfunction Leakage from intake manifold Inadequate fuel pressure PCV valve malfunction or incorrect valve installation Exhaust system clogging Fuel tank ventilation system malfunction Charcoal canister damage Excessive carbon built up in combustion chamber Improper engine compression Improper valve timing
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP
INSPECTION
RESULTS
1
Inspect following: • Vacuum lines for leakage or blockage • Electrical connections • Proper maintenance schedule followed • Intake-air system and air cleaner element concerns: obstructions, leakage or dirt Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is any other drivability concern present?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
2
3 4
5
6
ACTION
Yes
Go to appropriate symptom troubleshooting.
No
Go to next step.
Connect NGS tester to DLC. Access ECT PID. Warm up engine and run it at idle. Is ECT PID correct?
Yes
Go to next step.
No
Inspect for coolant leakage, cooling fan operation or thermostat operation.
Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Yes
Inspect for following: • Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step.
No
Inspect following: • High-tension leads • Ignition coil and connector Go to next step.
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa { 2.1—2.6 kgf/cm2, 30—36 psi}
Yes No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
7
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi} Remove and shake PCV valve. Does PCV valve rattle?
Yes
Go to next step.
No
Inspect pressure regulator for high pressure cause.
Yes
Go to next step.
No
Replace PCV valve.
Is there restriction in the exhaust system?
Yes
Inspect exhaust system.
No
Go to next step.
Yes
Replace charcoal canister.
No
Inspect fuel tank vent system.
8 9 10
11
Inspect for fuel saturation inside charcoal canister. Is excessive amount of liquid fuel present in canister?
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 15 DESCRIPTION POSSIBLE CAUSE
HIGH OIL CONSUMPTION/LEAKAGE • Oil consumption is excessive. • PCV valve malfunction • Improper dipstick • Improper engine oil viscosity • Engine internal parts malfunction
STEP INSPECTION 1 Remove and shake PCV valve. Does PCV valve rattle? 2
3
ACTION
Inspect for following: • External leakage • Proper dipstick • Proper engine oil viscosity Are all items okay?
RESULTS Yes Go to next step.
ACTION
No
Replace PCV valve.
Yes
Inspect internal engine parts such as valves, valve guides, valve stem seals, cylinder head drain passage, piston rings.
No
Service as necessary. Repeat Step 2.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 16
COOLING SYSTEM CONCERNS - OVERHEATING
DESCRIPTION
•
Engine runs at higher than normal temperature/overheats.
POSSIBLE CAUSE
• • • • • • • • • • • • •
Improper coolant level Blown fuses Coolant leakage/Improper coolant level Excessive A/C system pressure Improper water/anti-freeze mixture Fans reverse rotation Poor radiator condition Thermostat malfunction Radiator hose damage Improper or damaged radiator cap Main cooling fan is inoperative. Coolant overflow system malfunction Improper tension of drive belt Drive belt damage INSPECTION RESULTS
STEP 1
ACTION
Inspect following: • Engine coolant level • Coolant leakage • Water and anti-freeze mixture • Radiator condition • Collapsed or restricted radiator hoses • Radiator pressure cap • Overflow system • Fan rotational direction • Fuses Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 1.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Start engine and run it at idle speed. Turn A/C switch on. Does A/C compressor engage?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine and run it at idle speed. Turn A/C switch on. Does A/C SW PID read ON?
Yes
Go to next step.
No
Inspect for following: • Refrigerant pressure switch operation • A/C switch stuck open • Open or short circuit between refrigerant pressure switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier
5
Is drive belt okay?
Yes No
Go to next step. Replace drive belt.
6
Is there any leakage around heater unit in passenger compartment?
Yes No
Inspect and service heater for leakage. Go to next step.
7
Is there any leakage at coolant hoses and/or radiator?
Yes
Replace malfunctioning parts.
No
Go to next step.
2
3
4
Yes
Go to Step 5.
No
Inspect for following and repair or replace as necessary: • Refrigerant charging amount • Open circuit between A/C relay and PCM terminal 1J • Seized A/C magnetic clutch • A/C magnetic clutch malfunction If all Items are okay, go to next step.
CONTINUED
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TROUBLESHOOTING STEP 8
9
INSPECTION Cool down engine. Remove thermostat and inspect operation. ☞ Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay?
RESULTS
ACTION
Yes
Engine coolant temperature and thermostat are okay, inspect engine block for leakage or blockage.
No
Access ECT V PID on NGS tester. Inspect for both ECT V and temperature gauge readings. If temperature gauge on instrument cluster indicates normal range but ECT V is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates overheating but ECT V is normal, inspect temperature gauge and heat gauge unit.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 17
COOLING SYSTEM CONCERNS - RUNS COLD
DESCRIPTION
•
Engine takes excessive period for reaching normal operating temperature.
POSSIBLE CAUSE STEP
• •
Thermostat malfunction Cooling fan system malfunction INSPECTION RESULTS
ACTION
1
Is customer complaint "Lack of passenger compartment heat" only?
Yes No
Go to next step.
2
Does engine speed continue at fast idle?
Yes
Go to symptom troubleshooting No.8 "Fast idle/runs on".
No
Go to next step.
3
Remove thermostat and inspect operation. ☞ Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay?
Yes
Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT voltage is normal, inspect temperature gauge and heat gauge unit.
No
Replace thermostat.
4
Inspect A/C and heater system.
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 18 DESCRIPTION
POSSIBLE CAUSE
EXHAUST SMOKE • Blue, black, or white smoke from exhaust system. Blue smoke (Burning oil): • PCV valve malfunction • Engine internal oil leakage White smoke (Water in combustion): • Cooling system (coolant loss) malfunction • Engine internal coolant leakage Black smoke (Rich fuel mixture): • Air cleaner restriction • Intake-air system is collapsed or restricted. • Fuel return line is restricted. • Excessive fuel pressure • Improper engine compression • Injector fuel leakage • Ignition system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP 1
2
INSPECTION What color is smoke coming from exhaust system?
Remove and shake PCV valve. Does PCV valve rattle?
RESULTS Blue
ACTION Burning oil is indicated. Go to next step.
White
Water in combustion is indicated. Go to Step 3.
Black
Rich fuel mixture is indicated. Go to Step 4.
Yes
No
Inspect for following: • Damaged valve guide, stems or valve seals • Blocked oil drain passage in cylinder head • Piston rings are not seated, seized or worn • Damaged cylinder bore If other drivability symptoms are present, return to diagnostic index to service any additional symptoms. Replace PCV valve.
3
Does cooling system hold pressure?
Yes
Inspect for following: • Cylinder head gasket leakage • Intake manifold gasket leakage • Cracked or porous engine block If other drivability symptoms are present, return to diagnostic index to service any additional symptoms.
No
Inspect for cause.
4
Inspect for following: • Air cleaner restriction • Collapsed or restricted intake-air system • Restricted fuel return line Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
Go to next step.
No
Service as necessary, Repeat Step 4.
Yes
No DTC Is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
5
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TROUBLESHOOTING STEP INSPECTION 6 Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250 kPa {2.1—2.6 kgf/cm 2,30—36 psi} 7
8
9
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2,30—36 psi} Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
RESULTS Yes Go to next step.
ACTION
No
Zero or low: Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High: Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line
Yes
Go to next step.
No
Inspect pressure regulator for high pressure cause.
Yes
Inspect spark plugs.
No
Inspect following: • High-tension leads • Ignition coil and connector
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 19
FUEL ODOR (IN ENGINE COMPARTMENT)
DESCRIPTION
•
Gasoline fuel smell or visible leakage,
• • •
Excessive fuel pressure Fuel tank vent system blockage Charcoal canister malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Then stop engine. Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on and off? Fuel line pressure 210—250 kPa {2.1—2.6 kgf/cm 2, 30—36 psi}
Yes
Go to next step,
No
Inspect pressure regulator for high pressure cause.
Inspect for blockage/restriction or open between engine vacuum port and charcoal canister. Inspect for blockage in fuel tank vent system. Is fault indicated?
Yes
Replace vacuum hose.
No
Go to next step.
Inspect purge solenoid valve. ☞ EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Is solenoid operating properly?
Yes
Go to next step.
No
Replace purge solenoid valve.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
2
3
4
5
ACTION
No DTC is displayed: Inspect charcoal canister for fuel saturation. If excessive amount of liquid fuel is present, replace charcoal canister. No DTC is displayed: Go to appropriate DTC test. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 20
ENGINE NOISE
DESCRIPTION
•
POSSIBLE CAUSE
Engine noise from under hood
Squealing, clicking or chirping noise: • Improper engine oil level • Improper drive belt tension Rattling noise: • Loose parts Hissing sound noise: • Vacuum leakage • Loose spark plug • Air leakage from intake-air system Rumbling or grinding noise: • Improper drive belt tension Rapping or roar noise: • Exhaust system looseness Other noise: • Camshaft friction gear noise
STEP INSPECTION 1 Is squealing, clicking or chirping sound present? 2 3
Is rumbling or grinding sound present? Is rattling sound present?
RESULTS ACTION Yes Inspect engine oil level or drive belts. No
Go to next step.
Yes
Inspect drive belt.
No
Go to next step.
Yes
Inspect location of rattle for loose parts.
No
Go to next step. Inspect following: • Vacuum leakage • Spark plug looseness • Intake-air system leakage
4
Is hissing sound present?
Yes
No
Go to next step.
5
Is rapping or roaring sound present?
Yes
Inspect exhaust system for loose parts.
No
Go to next step.
Yes
Go to symptom troubleshooting No.12 "Knocking/ pinging".
6
Is knocking sound present?
No
7
If noise comes from inside engine, inspect for friction gear noise. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
SYMPTOM 21 DESCRIPTION
VIBRATION CONCERNS (ENGINE) • Vibration from under hood or driveline
POSSIBLECAU SE
• Loose attaching bolts or worn parts • Component malfunctions such as worn parts
STEP 1
2
INSPECTION Inspect following components for loose attaching bolts or worn parts: • Cooling fan • Drive belt and pulleys • Engine mounts Are all items okay?
RESULTS Yes
ACTION Inspect following systems: • Wheels • Driveline • Suspension
No
Readjust or retighten engine mount installation position. Service as necessary for other parts. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
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TROUBLESHOOTING SYMPTOM 22
A/C DOES NOT WORK SUFFICIENTLY.
DESCRIPTION
•
A/C compressor magnetic clutch does not engage when A/C switch is turned on.
POSSIBLE CAUSE
• • • • • • • •
Improper refrigerant charging amount Open A/C magnetic clutch Open circuit between A/C relay and A/C magnetic clutch Poor GND of A/C magnetic clutch Refrigerant pressure switch is struck open. A/C relay is stuck open. Seized A/C compressor Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
STEP 1
2
3
4
5
INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Disconnect A/C compressor connector. Start engine and turn A/C switch on. Is there correct voltage at terminal of A/C compressor magnetic clutch connector? Specification More than 10.5V
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test,
Yes
Inspect for GND condition of magnetic clutch on A/C compressor. If GND condition is okay, inspect for open circuit of magnetic clutch coil.
No
Go to next step.
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine. Turn A/C switch on and set blower fan at any speed. Does A/C SW PI Dread ON?
Yes
Inspect for stuck open A/C relay. Replace as necessary.
No
Go to next step.
Disconnect refrigerant pressure switch connector. Connect a jumper wire between terminals of refrigerant pressure switch connector. Start engine and turn A/C switch on. Does A/C work?
Yes
Inspect for following: • Refrigerant charging amount • Refrigerant pressure switch operation
No
Inspect for following: • A/C switch is stuck open. • Open circuit between refrigerant pressure switch and PCM terminal 1Q • Open circuit of blower motor fan switch and resistor (if blower motor does not operate) • Evaporator temperature sensor and A/C amplifier • Open circuit between A/C amplifier and refrigerant pressure switch
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 23
A/C IS ALWAYS ON /A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION
• • • • • •
POSSIBLE CAUSE
STEP 1
2
3
4
5
A/C compressor magnetic clutch does not disengage. Stuck engagement A/C relay is stuck closed. Short to GND between A/C switch and PCM Short to GND circuit between A/C relay and PCM A/C relay to magnetic clutch circuit shorts to battery power INSPECTION
RESULTS
ACTION
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Start engine and run it at idle. Turn A/C switch on. Remove A/C relay. Does A/C magnetic clutch disengage?
Yes
Inspect for following: • A/C relay is stuck closed. • Short to GND circuit between A/C relay and PCM terminal 1J If both items okay, go to next step.
No
Inspect if circuit between A/C relay and magnetic clutch shorts to battery power circuit. If circuit is okay, inspect magnetic clutch engagement or clearance.
Yes
Inspect for short to GND circuit between refrigerant pressure switch and PCM terminal 10.
No
Go to next step.
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start the engine and turn A/C switch on. Read A/C SW PID while disconnecting refrigerant pressure switch connector. Note • A/C SW PID should read OFF when disconnecting connector. If A/C SW PID reading remains ON, short to GND circuit may be present. Does A/C SW PID reading remain ON?
Reconnect refrigerant pressure switch Yes Inspect for following: connector. • Short to GND circuit between A/C switch and A/C Read A/C SW PID while turning off A/C switch. amplifier Note • Short to GND circuit between A/C amplifier and • A/C SW PID should read OFF when turnrefrigerant pressure switch ing A/C switch off. If A/C SW PID reading remains ON, short to GND circuit may be No Inspect for stuck closed A/C switch. present. Does A/C SW PID reading remain ON? Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 24 DESCRIPTION POSSIBLE CAUSE
A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE (WOT) CONDITIONS • A/C compressor magnetic clutch does not disengage under WOT. • TP sensor malfunction • TP sensor misadjustment • TP sensor is loosely installed.
STEP INSPECTION 1 Does A/C compressor disengage when A/C switch is turned off? 2
3
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
RESULTS Yes Go to next step.
ACTION
No
Go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously".
Yes
No DTC is displayed: Inspect TP sensor for proper adjustment.
No
DTC is displayed: Go to appropriate DTC test.
Verify test results. If okay, return to diagnostic index to service any additional symptoms,
CONTINUED
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TROUBLESHOOTING SYMPTOM 25
EXHAUST SULPHUR SMELL
DESCRIPTION • • • • •
POSSIBLE CAUSE
Rotten egg smell (sulphur) from exhaust Electrical connectors are disconnected or connected poorly Charcoal canister malfunction Vacuum lines are disconnected or connected improperly. Improper fuel pressure
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Are any drivability or exhaust smoke concerns present?
Yes
Go to appropriate flow chart.
No
Go to next step.
2
Inspect following: • Electrical connections • Vacuum lines Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 2.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No DTC is displayed: Go to next step.
No
DTC is displayed: Go to appropriate DTC test.
Install fuel pressure gauge between fuel filter and fuel distributor. Start engine and run it at idle. Is fuel line pressure correct at idle? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2,30—36 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210—250kPa {2.1—2.6 kgf/cm 2, 30—36 psi} Inspect charcoal canister for fuel saturation. Is excessive amount of liquid fuel present in canister?
Yes
Go to next step.
No
Inspect pressure regulator for high pressure cause.
Yes
Replace charcoal canister.
3
4
5
6
7
ACTION
No
Inspect fuel tank vent system. If fuel tank vent system is okay, since sulfur content can vary in different fuels, suggest trying a different brand. If fuel tank vent system is not okay, repair or replace malfunctioning parts. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING SYMPTOM 26 INTERMITTENT CONCERNS Symptom occurs randomly and is difficult to diagnose. DESCRIPTION • STEP
INSPECTION
RESULTS
1
Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous repairs and components replaced for a certain symptom?
Yes
Go to next step.
No
Go to Symptom Index.
Connect NGS tester to DLC. If input is switch-type component, turn on manually. Turn ignition switch on. Access PIDs for suspect component. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal crimps.
No
Go to next step.
Start engine. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal crimps.
No
Go to next step.
Start engine. Accurately spray water on suspect component wire, component or vacuum line related to possible fault area. Are any PID values out of range, or do they suddenly change and go back into range, or was there a noticeable engine misfire/ stumble?
Yes
Fault occurred while spraying component: Replace part and verify repair. Fault occurred while spraying wiring: Inspect each wire for corrosion, bent or loose terminals and poor wire terminal crimps. Fault occurred while spraying vacuum line: Repair vacuum hoses. Inspect wire and connector at suspect component for corrosion, bent or loose terminals, poor wire terminal crimps and high tension of wire. Repair as necessary.
2
3
4
No
ACTION
CONTINUED
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TROUBLESHOOTING SYMPTOM 27 CONSTANT VOLTAGE DESCRIPTION Incorrect constant voltage POSSIBLE CAUSE
• Constant voltage circuit malfunction Note • TP sensor and variable resistor (Except Europe) use constant voltage.
STEP
INSPECTION
RESULTS
1
Disconnect TP sensor connector. Turn ignition switch on. Measure voltage between following TP sensor and variable resistor (Except Europe) connector terminals: • Constant voltage terminal - GND terminal Is constant voltage greater than 6.0 volts?
Yes
Repair constant voltage circuit short to power in harness.
No
Go to next step.
Is voltage across battery terminals greater than 10.5 volts?
Yes
Go to next step.
No
Inspect charging system.
Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Measure voltage between battery positive terminal and GND circuit at TP sensor connector. Is voltage greater than 10.5 volts and within 1.0 volt of battery voltage?
Yes
Go to next step.
No
Go to Step 8.
Note • The purpose of this step is to determine if NGS tester is communicating with PCM. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed? Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Turn ignition switch on. Measure voltage between PCM connector terminals 1B and 2B. Is voltage greater than 10.5 volts?
Yes
Go to Step 7.
No
Go to next step.
Yes
Go to next step.
No
Repair open circuit between PCM terminal 1B and main relay.
2 3
4
5
6
7
8
ACTION
Leave TP sensor, variable resistor (Except Europe) and PCM connectors disconnected. Disconnect NGS tester from DLC. Measure resistance between PCM connector terminals 2K and 2B. Is resistance greater than 10,000 ohms?
Yes
Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.
No
Repair constant voltage circuit short to GND.
Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Measure resistance between PCM connector terminal 2K and constant voltage circuit at appropriate sensor connector. Is resistance less than 5.0 ohms? Note • The purpose of this step is to determine if NGS tester is communicating with PCM. Reconnect TP sensor and variable resistor (Except Europe) connector. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed?
Yes
Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.
No
Repair open constant voltage circuit.
Yes
Go to next step.
No
Go to Step 10.
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TROUBLESHOOTING STEP 9
10
11
INSPECTION
RESULTS
ACTION
Turn ignition switch off. Disconnect NGS tester from DLC. Disconnect PCM connector. Measure resistance between GND circuit at appropriate sensor connector and PCM connector terminal 2D. Is resistance less than 5.0 ohms?
Yes
Reconnect sensor connector. Go to appropriate DTC test.
No
Repair open GND circuit.
Turn ignition switch off. Disconnect PCM connector. Measure resistance between battery negative terminal and PCM terminals 2A, 2B and 2C. Is each resistance less than 5.0 ohms?
Yes
Go to next step.
No
Repair open GND circuit.
Turn ignition switch off. Measure resistance between GND circuit at following sensor connector and GND: • ECT sensor • O2S • IAT sensor • MAF sensor • TP sensor • Variable resistor (Except Europe) Is each resistance less than 5.0 ohms?
Yes
GND circuits are okay. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again.
No
Inspect for open GND circuit.
CONTINUED
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TROUBLESHOOTING DIAGNOSTIC INSPECTION Spark Plug Condition Inspection Purpose Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or to all cylinders.
Procedure 1. Remove the spark plug. 2. Inspect spark plug condition. 3. Go to appropriate troubleshooting chart for further information.
Spark plug condition Specific plug is wet or covered with carbon.
Symptom 1
Troubleshooting chart Wet/carbon stuck on specific plug
Specific plug looks grayish white.
Symptom 2
Grayish white with specific plug
All plugs are wet or covered with carbon.
Symptom 3
Wet/carbon stuck on all plugs
All plugs look grayish white.
Symptom 4
Grayish white with all plugs
SYMPTOM 1
Wet/carbon stuck on specific plug • • • •
POSSIBLE CAUSE
Spark—No spark visible or spark weak Air/fuel mixture—Excessive fuel injection volume Compression—No compression, low compression Faulty spark plug
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Is spark plug wet/covered with carbon by engine oil? 2
3
4
5
RESULTS ACTION Yes Working up and down inspect all areas related to oil. No
Go to next step.
Inspect spark plug for following: • Cracked insulator • Heating value • Air gap • Worn electrode Is spark plug okay?
Yes
Go to next step.
No
Replace spark plug.
Inspect compression pressure at suspected faulty cylinder. ☞ Section B1, COMPRESSION INSPECTION Is compression pressure correct? Install all spark plugs. Carry out spark test at suspected faulty cylinder. Is strong blue spark visible? (Compare with normal cylinder) Carry out fuel line pressure inspection. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 39—45 psi}
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Yes
Inspect fuel injector for following: • Open or short in injector • Leakage • Injection volume
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
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TROUBLESHOOTING SYMPTOM 2 POSSIBLE CAUSE
Grayish white with specific plug • •
STEP 1
2
INSPECTION
RESULTS
ACTION
Inspect spark plug for following: • Heating value • Air gap Is spark plug okay?
Yes
Go to next step.
No
Replace spark plug.
Remove suspected fuel injector. Inspect for following: ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION • Resistance • Fuel injection volume Are all above items okay?
Yes
Inspect for open circuit between suspected fuel injector terminal and PCM connector terminal.
No
Replace fuel injector.
SYMPTOM 3
Wet/carbon stuck on all plugs • • • •
POSSIBLE CAUSE
STEP
Air/fuel mixture—Insufficient fuel injection volume Faulty spark plug
Spark—Spark weak Air/fuel mixture—Too rich Compression—Low compression Clogging in intake/exhaust system
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
1
Is air cleaner element free of restriction?
Yes
Go to next step.
No
Replace air cleaner element.
2
Carry out spark test. Is strong blue spark visible at each cylinder?
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
3
Carry out fuel line pressure inspection. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 37—45 psi}
Yes
Go to next step.
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Inspect following PIDs: ☞ CONTROL SYSTEM, PID/DATA MONITOR INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Are PIDs okay?
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Carry out purge control inspection. (When engine can be started) Is purge control correct?
Yes
Go to next step.
No
Repair or replace malfunctioning parts.
Carry out compression inspection. Is compression correct?
Yes
Inspect for clogging in exhaust system.
No
Repair or replace malfunctioning parts.
4
5
6
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TROUBLESHOOTING SYMPTOM 4
Grayish white with all plugs •
POSSIBLE CAUSE
Air/fuel mixture—Too lean
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
When engine cannot be started, inspect intake-air system for air leakage. When engine can be started, carry out intake manifold vacuum inspection. Is air sucked in from intake-air system?
Yes
Repair or replace malfunctioning parts.
No
Go to next step.
Carry out fuel line pressure inspection. ☞ TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270—310 kPa {2.7—3.2 kgf/cm 2, 37—45 psi}
Yes
Inspect following PIDs: ☞ CONTROL SYSTEM, PID/DATA MONITOR INSPECTION • MAF V • ECT • FHO2S (When engine can be started) Inspect for PCM GND condition.
No
Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
2
ACTION
CONTINUED
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TROUBLESHOOTING Inspection Using an Oscilloscope (Reference) Purpose Using an oscilloscope, inspection such as stuck solenoid valve is made possible without actually removing parts.
Finding unusual signals While referring to the diagnostic trouble code inspection section of the on-board diagnostic system, use the PID/DATA MONITOR AND RECORD function to inspect the input signal system relating to the problem. 1. Turn the ignition on and run it at idle. You can assume that any signals that are out of specifications by a wide margin are unusual. 2. When recreating the problem, any sudden change in monitor input signals that is not consciously created by the driver can be judged as unusual. Locating the source of unusual signals Caution:
When normal Counter electromotive voltage A, generated when the threeway solenoid valve or the fuel injector is turned off from on, shows irregular convergence because induced electromotive voltage B, generated by the plunger return operation, is added to it.
•
Compare the NGS monitor voltage with the measurement voltage using the DIGITAL MEASUREMENT SYSTEM function. If you use another tester, misreading may occur.
•
When measuring voltage, attach the tester GND to the GND of the PCM that is being tested, or to the engine itself. If this is not done, the measured voltage and actual voltage may differ. After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage, inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do this may result in deterioration of the harness or terminal from water damage, leading to problems with the vehicle.
•
When plunger is stuck When the plunger is stuck, pulse convergence is smooth because no induced electromotive voltage B is generated.
Input Signal System Investigation Procedure 1. Find an unusual signal. (Refer to procedures below) 2. Locate its source. (Refer to procedures below) 3. Repair or replace the defective part. 4. Confirm that the unusual signal has been erased.
Variable resistance type 1 (Throttle position (TP) sensor and variable resistor (Except Europe))
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector.
2.
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•
Female terminal opening loose
•
Coupler (pin holder) damage
•
Pin discoloration (blackness)
• Harness/pin crimp is loose or disconnected. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
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TROUBLESHOOTING (2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. Investigate the standard power supply system (1) Confirm that the #3 terminal is at 5 V. (1) If the measured voltage on the #3 terminal is 5 V, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. (3) Female terminal opening looseness (4) Coupler (pin holder) damage (5) Pin discoloration (blackness) (2) If the #3 terminal measures other than 5 V, inspect for the following. • Open or short circuit in harness • Harness/pin crimp is loose or disconnected. Investigate the GND system 1. Confirm that terminal sensor #5 is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. Open or short circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
(2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. Investigate the electrical supply system 1. Confirm that the sensor #3 terminal is B+. (1) If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) (2) If the #3 terminal measures other than B+, inspect for the following. • Open or short circuit in harness • Harness/pin crimp is loose or disconnected. Investigate the GND system
1. Confirm that terminal sensor #4 is at 0 V. (1) (2)
Variable resistance type 2 (Mass air flow (MAP) sensor)
If it is at 0 V, inspect the sensor. If necessary, replace the sensor. If not at 0 V, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
Thermistor type (Intake air temperature (IAT) and engine coolant temperature (ECT) sensors)
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected. 2. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (2) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (3) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. (1) Female terminal opening looseness (2) Coupler (pin holder) damage (3) Pin discoloration (blackness) (4) Harness/pin crimp is loose or disconnected. 2. When you get an unusual signal, measure the #2 sensor terminal voltage. (3) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
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TROUBLESHOOTING (2)
• •
If the sensor and NGS voltages are the same, inspect for the following points concerning the sensor connector. If there are no problems, proceed to next investigation below, • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
ENGINE SYSTEM INSPECTION Main Relay Operation Inspection 1. Verify that the main relay clicks when the ignition switch is turned to on and off.
Investigate the GND system 1. Confirm that terminal sensor #3 is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Vehicle speed sensor (VSS) 2.
1.
Measure the #1 PCM terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine is at idle. (1) If it is at 0 V or 5 V, proceed to symptom troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the PCM connector. If there are no problem, proceed to next step. • Female terminal opening loose • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
2.
Measure the #2 sensor terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine at idle. (1) If it is at 0 V or 5 V, proceed to symptom troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the sensor connector. If there are no problems, proceed to next step. • Female terminal opening looseness • Coupler (pin holder) damage • Pin discoloration (blackness) • Harness/pin crimp is loose or disconnected.
3.
If there is no operating sound, inspect the following. • Main relay • Harness and connector between ignition switch and main relay
Intake Manifold Vacuum Inspection 1. Verify air intake hoses are installed properly. 2. Start the engine and run it at idle. 3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve on the intake manifold side. 4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.
Specification More than 60 kPa {450 mmHg, 18 inHg} 5.
If not as specified, inspect for the following: Air suction at throttle body, intake manifold and • PCV valve installation points Fuel injector insulator • Accelerator cable free play • Engine compression (Refer to section B1.) • Note
Confirm that the #3 terminal switch voltage is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. • Open circuit in harness • Female terminal opening looseness • Coupler (pin holder) damage
•
Air suction can be located by engine speed change when lubricant is sprayed on the area where suction is occurring.
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TROUBLESHOOTING (3)
Idle Air Control (IAC) Inspection Engine coolant temperature (ECT) compensation inspection 1. Connect the SSTs (NQS tester) to DLC.
4. 2. 3.
4. 5. 6.
Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select the following PIDs. • ECT • IACV • RPM Verify that the engine is cold, then start the engine. Verify that the engine speed decreases as the engine warms up. If the engine speed does not decrease or decreases slowly, carry out the following. • ECT sensor inspection • IAC valve inspection
Load compensation inspection 1. Start the engine and run at idle. 2. Disconnect the IAC valve connector and verify that the engine rotation changes.
5. 6.
Verify that DTC P0505 is not displayed. If DTC P0505 is shown, carry out DTC inspection. (4) Select the SIMULATION TEST function on the NGS display. (5) Change the duty value of the IAC valve to 100% using the IACV PID. (6) Verify that the idle speed increases. ① If the idle speed increases, replace the PCM. ② If the idle speed does not change, inspect the following. • IAC valve air passage • Open or short circuit between IAC valve connector terminals and PCM connector terminal 2W Warm up the engine to normal operating temperature and run it at idle. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select the following PIDs. • A/C SW • IAC V • PSP SW • RPM
7.
Turn the electrical loads on and verify that the engine speed is within the specification.
Engine speed (rpm) Load condition
Idle-up speed (rpm)*
1
2
P/S ON* 700—800 (750 ± 50) A/CON*3 *1 Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. 3 * : A/C switch and fan switch are on. Note • Excludes temporary idle speed drop just after the electrical loads are turned on. 8.
3.
If the engine condition does not change, do as follows. (1) Connect the IAC valve connector. (2) Connect the SSTs (NGS tester) to DLC.
If not as specified, carry out the following. • A/C switch inspection • PSP switch inspection • IAC valve inspection Fuel Line Pressure Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. • To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2.
Disconnect the negative battery cable. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
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TROUBLESHOOTING •
3.
Connect the negative battery cable. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
4.
Short the DLC terminal F/P to body GND using a jumper wire.
5.
Turn the ignition switch on and measure the fuel line pressure.
Fuel Pressure Hold Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. • To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2.
Disconnect the negative battery cable. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
3.
Connect the negative battery cable. Caution • Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
Specification 2 270—310 kPa {2.7—3.2 kgf/cm , 39—45 psi} 6. 7.
8.
Turn off the ignition switch and disconnect the jumper wire. If the pressure is higher than specified, inspect the fuel pump maximum pressure. If normal, inspect fuel return hose or the pressure regulator for clogging. If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.
4.
Short the DLC terminal F/P to body GND using a jumper wire.
5. 6. 7.
•
If the fuel line pressure quickly increases, inspect the pressure regulator and PRC solenoid valve.
If fuel line pressure gradually increases, inspect the fuel pump maximum pressure. If the fuel pump maximum pressure is normal, inspect for clogging between fuel pump body and pressure regulator.
Turn the ignition switch on for approx. 10 sec. to operate the fuel pump body. Turn off the ignition switch and disconnect the jumper wire. Observe the fuel pressure after 5 min. Specification 2 More than 150 kPa {1.5 kgf/cm , 21 psi}
8.
F1-122
If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.
CONTINUED
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TROUBLESHOOTING Inspection 1 1. Connect the SSTs (NGS tester) to the DLC.
•
If the fuel line pressure holds, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.) • If fuel line pressure does not hold, inspect the fuel leakage from fuel line and fuel injector. Pressure Regulator Control Inspection Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. • To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
3. 4.
2. 3.
Start the engine and let it idle. Select the SIMULATION TEST function on the NGS display. 4. Select IDLING TEST mode. 5. Select PRCV PID. 6. Press START. 7. Turn the PRC solenoid valve from off to on and inspect if the fuel pressure changes. (1) If the pressure changes, inspect the following. • ECT, IATDC and TP V PIDs (Refer to CONTROL SYSTEM, PID/DATA MONITOR INSPECTION.) (2) If the pressure does not change, do as follows. ① Select the SIMULATION TEST function on the NGS display. ② Select IDLING TEST mode. ③ Select PRCV PID. ④ Press START. ⑤ Turn the PRC solenoid valve from off to on and inspect if the operation sound of the valve is heard. ⑥ If the operating sound is heard, inspect the pressure regulator. ⑦ It the operating sound is not heard, inspect the PRC solenoid valve. Inspection 2 1. Connect the SSTs (NGS tester) to the DLC.
Connect the negative battery cable. Measure the fuel line pressure under the following conditions.
Specifications Condition Idling
Fuel pressure [kPa {kgf/cm 2, psi}] 210—250 {2.1—2.6, 30—36}
During 120 sec. of hot start
270—310 {2.7—3.2, 39—45}
After 120 sec. of hot start
210—250 {2.1—2.6, 30—36}
Judgment
Normal
210—250 {2.1—2.6, 30—36}
270—310 {2.7—3.2, 3&—45}
2. 3. 4.
Not Normal (Perform Inspection 1)
Not Normal (Perform Inspection 2)
Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Turn the PRC solenoid valve from off to on using the PRCV PID and inspect if the operating sound is heard. (1) If the operating sound is heard, inspect for a loose or damaged vacuum hose. (Pressure regulator—PRC solenoid valve—intake manifold) (2) If the operating sound is not heard, inspect the PRC solenoid valve)
CONTINUED F1-123
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TROUBLESHOOTING Fuel Injector Operation Inspection STEP INSPECTION 1 While cranking engine, inspect for fuel injector operating sound at each cylinder using a soundscope. Is operating sound heard?
2
3
4
Carry out main relay operation inspection. Is main relay operation okay?
Yes
Inspect following: • Fuel injector power system related wiring harnesses and connectors • PCM connectors • Fuel injector GND and related wiring harnesses and connectors
No
Repair or replace malfunctioning parts.
Change fuel injector connector of not operating fuel injector and operating fuel injector. Is operating sound heard?
Yes
Go to next step.
No
Replace fuel injector.
Are wiring harnesses and connectors of not operating fuel injector okay? (Open or short)
Yes
Inspect PCM terminal voltage of fuel injector signal.
No
Repair or replace malfunctioning parts.
Fuel Cut Control Inspection 1. Warm up engine and let it idle. 2. Turn off the electrical loads and A/C switch. 3. Connect the SSTs (NGS tester) to the DLC.
4. 5. 6. 7.
8.
RESULTS ACTION Yes Fuel injector operation is okay. Not heard at all cylinders: No Go to next step. Not heard at some cylinders: Go to Step 3.
Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select RPM and INJ PIDs. Press START. Monitor both PIDs while performing the following steps. (1) Depress the accelerator pedal and increase the engine speed to 4000 rpm. (2) Release the accelerator pedal (brake pedal is not depressed) and inspect that the fuel injector duration time is 0 msec., and 2—5 msec. when the engine speed drops below 1200 rpm. If not as specified, carry out the following. • ECT sensor inspection • Neutral/clutch switch inspection
Fuel Pump Operation Inspection 1. Connect the SSTs (NGS tester) to the DLC.
2. 3. 4. 5. 6.
Remove the fuel-filler cap. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Turn the fuel pump relay from off to on using the FP RLY PID and inspect if the operating sound is heard. If no operating sound is heard, measure the voltage at harness side fuel pump unit connector terminal B. Specification Battery positive voltage (Ignition switch on)
CONTINUED
F1-124
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TROUBLESHOOTING 7.
8.
If the voltage is as specified, inspect the following. • Fuel pump continuity • Fuel pump GND • Wiring harness between fuel pump relay and PCM terminal 1 H If not as specified, inspect the following. 1. Fuel pump relay 2. Wiring harness and connector (Main relay—fuel pump relay—fuel pump unit)
Fuel Pump Control Inspection 1. Connect the SSTs (NGS tester) to the DLC.
4. 5.
2. 3. 4. 5. 6. 7.
8. 9.
Increase the engine speed and verify the ignition timing is advanced. If the ignition timing is not advanced, carry out the following. • CMP sensor inspection • MAP sensor inspection
Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Select IG ON TEST mode. Select FP RLY PID. Press START. Turn the fuel pump relay from off to on and inspect if the operating sound of the fuel pump relay is heard.
If no operating sound is heard, inspect the fuel pump relay. If the fuel pump relay is normal, inspect the following. • Wiring harnesses and connectors (Main relay—fuel pump relay—PCM)
Ignition Timing Control Inspection 1. Connect a timing light to the engine. 2. Crank the engine. 3. Verify that the timing mark (yellow) on the crankshaft pulley is within the specification. Specification BTDC 9°—11°(10° ± 1°)
CONTINUED F1-125
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TROUBLESHOOTING Spark Test 1. Remove the fuel pump relay. 2. Verify that each high-tension lead and connector is connected properly. 3. Inspect the ignition system in the following procedure. Warning • High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test. STEP INSPECTION 1 Remove high-tension lead from spark plug. Hold high-tension lead with pliers installed 5—10 mm {0.20—0.39 in} from GND. Crank the engine and verify that there is a strong blue spark. (Inspect each cylinder.) 2
3 4 5 6 7
RESULTS ACTION Yes Ignition system is okay.
No
Some cylinders do not spark: Go to next step. All cylinders do not spark: Go to Step 3. Inspect for cracks or damage of high-tension lead, distributor and Ignition coil. Replace the high-tension lead.
Does PCM or ignition coil connector have poor connection?
Yes
Repair or replace connector.
No
Go to next step.
Is igniter okay?
Yes
Go to next step.
No
Replace igniter.
Is high-tension lead resistance correct?
Is ignition coil winding resistance okay? Are distributor cap and rotor okay? Are following parts okay? • CMP sensor • PCM terminal 2F voltage Specification Approx. 1.5 V
No
Yes
Yes
Go to next step.
No
Replace ignition coil.
Yes
Go to next step.
No
Replace distributor cap or rotor.
Yes
Inspect for open or short in wiring harness and connector of CMP sensor.
No
Repair or replace malfunctioning part.
CONTINUED
F1-126
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TROUBLESHOOTING Purge Control Inspection 1. Start the engine. 2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister. 3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold. 4. If there is a vacuum, inspect the following. • Wiring harness and connectors (Purge solenoid valve—PCM terminal 2X) • Purge solenoid valve 5. Warm up the engine to the normal operating temperature. 6. Stop the engine. 7. Connect the SSTs (NGS tester) to DLC.
8. 9. 10. 11. 12. 13. 14. 15. 16.
A/C CUT-OFF CONTROL INSPECTION 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch actuates. 4. If it does not actuate, go to symptom troubleshooting No.22 "A/C does not work sufficiently".
5.
6.
Turn the ignition switch on. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select ECT PID. Verify that the engine coolant temperature is above 60°C {140°F}. If the SSTs (NGS tester) indicates below 60 °C {140 °F}, carry out the ECT sensor inspection. Select the SIMULATION TEST function on the NGS display. Select PRGV PID. Press START. Increase the duty value of the purge solenoid valve to 50% and inspect if the operating sound of the valve is heard. (1) If the operating sound is heard, inspect the loose or damaged vacuum hose. (Intake manifold— purge solenoid valve—charcoal canister) (2) If the operating sound is not heard, carry out the purge solenoid valve inspection.
F1-127
Note • Specification of A/C cut-off control time is from 2 to 5 seconds. Fully open the throttle valve in a short period and verify that the A/C compressor magnetic clutch does not actuate. If it actuates, inspect the following. (1) Connect the SSTs (NGS tester) to DLC.
(2) (3) (4)
Turn the A/C switch off. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. (5) Select IG ON TEST mode. (6) Select A/C RLY PID (7) Press START. (8) Turn the A/C relay from off to on and inspect if the operating sound of the relay is heard. (9) If the operating sound is heard, inspect TP V PID. (10) If the operating sound is not heard, inspect the following. • /C relay • Open or short to GND circuit in wiring harnesses and connectors (Main relay—A/C relay—PCM terminal 1J) • A/C related parts
CONTINUED
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FUEL AND EMISSION CONTROL SYSTEMS (WL, WL Turbo) ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . F2– 2 ENGINE TUNE-UP PREPARATION . . . . . . . . F2– 2 IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . F2– 2 IDLE-UP SPEED ADJUSTMENT . . . . . . . . . . . F2– 2 INJECTION TIMING ADJUSTMENT . . . . . . . . F2– 3 INTAKE-AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . F2– 4 VACUUM HOSE ROUTING DIAGRAM . . . . . F2– 4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 5/7 TURBOCHARGER INSPECTION . . . . . . . . . . F2– 8/9 GLOW PLUG REMOVAL/INSTALLATION . . . F2– 9 GLOW PLUG INSPECTION . . . . . . . . . . . . . . . F2– 9 GLOW PLUG RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 9 GLOW PLUG RELAY INSPECTION . . . . . . . . F2–10 GLOW PLUG CORD INSPECTION . . . . . . . . F2–10 ACCELERATOR PEDAL REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . F2–10/11 ACCELERATOR CABLE INSPECTION/ADJUSTMENT . . . . . . . . . . . . F2–11 IDLING KNOB, IDLING CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–11 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–12 BEFORE REPAIR PROCEDURE . . . . . . . . . . F2–12 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–12 FUEL TANK REMOVAL/INSTALLATION . . . . F2–13/15 FUEL FILTER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–15/16 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–16 FUEL GAUGE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–16 FUEL FILTER AIR BLEEDING . . . . . . . . . . . . . F2–16 SEDIMENTOR WATER DRAINING . . . . . . . . . F2–16 SEDIMENTOR SWITCH INSPECTION . . . . . F2–16/17 FUEL WARMER INSPECTION . . . . . . . . . . . . F2–17 FUEL INJECTION PUMP (FIP) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–17 FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–17/18 INJECTION NOZZLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–18
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . F2–19 INJECTION NOZZLE INSPECTION . . . . . . . . F2–19/20 FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–20 FUEL CUT VALVE (FCV) INSPECTION . . . . . F2–20/21 FICD SOLENOID VALVE NO.1, NO.2 INSPECTION F2–21 TIMER CONTROL VALVE (TCV) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–22 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . F2–23 EXHAUST SYSTEM INSPECTION . . . . . . . . . F2–23 EXHAUST SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–23/25 EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–25 ROLLOVER VALVE INSPECTION . . . . . . . . . F2–25 EVAPORATIVE CHAMBER INSPECTION . . . F2–25 EGR VALVE INSPECTION . . . . . . . . . . . . . . . . F2–26 EGR SOLENOID VALVE INSPECTION . . . . . F2–26 EGR PIPE, EGR VALVE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . F2–26 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–27 COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . F2–27 POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–28 POWERTRAIN CONTROL MODULE (PCM) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–28/31 NE SENSOR INSPECTION . . . . . . . . . . . . . . . F2–32 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION . . . . . . . . . . . . . . . . . F2–32/33 IDLE SWITCH INSPECTION . . . . . . . . . . . . . . F2–33 CONTROL LEVER POSITION SENSOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–33/34 ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . F2–35 DTC READING PROCEDURE . . . . . . . . . . . . . F2–35 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–35 DTC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . F2–36/38 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . F2–39 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–39 TROUBLESHOOTING ITEM TABLE . . . . . . . . F2–39 SYMPTOM TROUBLESHOOTING . . . . . . . . . F2–40/60 SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . F2–61/64
CONTINUED
F2–1
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ENGINE TUNE-UP 4. After adjusting the idle speed, tighten the locknut securely.
ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating temperature. 2. Turn the all electrical loads off. 3. Connect a tachometer. IDLE SPEED ADJUSTMENT WL 1. Perform “Engine tune-up preparation”. 2. Verify that the idle speed is within the specification.
IDLE-UP SPEED ADJUSTMENT 1. Perform “Engine tune-up preparation”. 2. Turn all electrical loads off in neutral shift position. 3. Apply vacuum of –53.3 kPa {–400 mmHg, –15.8 inHg} or over to actuator B, and measure the idle-up speed. WL
ADJUSTING SCREW B ADJUSTING SCREW C
Specification 700—740 (72020) rpm LOCKNUT B
3. If not within the specification, adjust the idle speed by turning the IAS (idle adjustment screw). ACTUATOR A
LOCKNUT 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
ACTUATOR B
WL, WL Turbo IAS
ADJUSTING SCREW B
ADJUSTING SCREW C
LOCKNUT B
4. After adjusting the idle speed, tighten the locknut securely.
ACTUATOR A ACTUATOR B
WL Turbo 1. Perform “Engine tune-up preparation”. 2. Verify that the idle speed is within the specification. Specification General (L.H.D.) : 760—800 (78020) rpm Europe and UK : 700—740 (72020) rpm
Specification 1200—1500 (1,350150) rpm 4. If not within the specification, do as follows; (1) Loosen the locknut B. (2) Adjust the idle-up speed by turning the adjusting screw B. (3) Tighten the locknut B.
Caution Turning the idle switch (Europe and UK only) with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation.
Tightening torque 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
3. If not as specified, loosen the idle switch locknut and adjust the idle speed by turning the idle switch.
5. Release actuator B to atmosphere and apply vacuum of –53.3 kPa {–400 mmHg, –15.8 inHg} or over to actuator A, and measure the idle-up speed. Specification WL vehicle: 805—855 (83025) rpm WL Turbo, WL (Europe only): 825—875 (85025) rpm
LOCKNUT 11.8—14.7 N·m {120—150 kgf·cm, 104—130 in·lbf}
6. If not as specified, adjust the idle-up speed by turning adjusting screw C.
IDLE SWITCH
CONTINUED
F2–2
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ENGINE TUNE-UP INJECTION TIMING ADJUSTMENT
6. Turn the crankshaft counterclockwise to approx. 30° BTDC. (Align the SST installation hole on the crankshaft pulley.) 7. Turn the crankshaft lightly right and left, and verify that the dial gauge indicator does not move. Then set the indicator to 0 mm {0 in}. 8. Turn the crankshaft clockwise to position the indicator pin to 10° ATDC (white mark) and read the dial indicator.
Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always observe the “Fuel Line Safety Procedures”, “Fuel Hose Installation”.
INDICATOR PIN BTDC 0° (YELLOW MARK)
Caution After tightening the FIP mounting nuts and bolt after loosening them, be sure to inspect the timing belt tension. If the belt tension is not inspected, the timing belt and the camshaft may become damaged. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
ATDC 10° (WHITE MARK)
Specification 0.95—1.05 mm {0.038—0.041 in} (1.00.05 mm {0.0390.019 in})
1. Remove the injection pipes (Refer to FUEL SYSTEM, FUEL INJECTION PUMP (FIP) 9. If not as specified, adjust by loosening the FIP REMOVAL/INSTALLATION.) mounting nut and bolt and turn the FIP. 2. Remove the cooling fan 10. Tighten the FIP mounting nuts and then the bolt. (Refer to Section E, COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.) Tightening torque 3. Turn the crankshaft pulley at slow rotation to align 19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf} the timing mark (BTDC 0° : yellow mark) with MOUNTING NUT indicator pin. INDICATOR PIN
BTDC 0 ° (YELLOW MARK)
MOUNTING BOLT ATDC 10 ° (WHITE MARK)
4. Remove the hydraulic head plug from the injection pump. 5. Mount the SST into the plug hole on the hydraulic head so that the dial indicator probe touches the plunger end of the pump and the dial indicator indicates approx. 2.0 mm {0.079 in}. 49 9140 074
11. Remove the SST. 12. Install the hydraulic head plug and a new gasket. Tightening torque 14—19 N·m {1.4—2.0 kgf·m, 11—14 ft·lbf} 13. Connect the injection pipes. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 14. Bleed the air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 15. Inspect for fuel leakage. 16. Check the timing belt tension. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
CONTINUED
F2–3
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INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM TO POWER BRAKE UNIT
WL
FICD SOLENOID VALVE No.1 FICD SOLENOID VALVE No.2
FICD ACTUATOR
VACUUM PUMP
WL TURBO
TO POWER BRAKE UNIT FICD SOLENOID VALVE No.2
TO RFW ACTUATOR
4WD ONLY FICD SOLENOID VALVE No.1
EGR VALVE
EGR SOLENOID VALVE
FICD ACTUATOR
VACUUM PUMP
CONTINUED
F2–4
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INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system. WL 1. Disconnect the negative battery cable. 2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
7.9—10.7 N·m {80—110 kgf·cm, 70—95 in·lbf}
18.7—25.4 {1.9—2.6, 13.8—18.8} 2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}
2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf} 7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
18.7—25.4 {1.9—2.6, 13.8—18.8}
R
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf} N·m {kgf·m, ft·lbf}
1
Fresh-air duct
6
FICD solenoid valve No.1
2
Air cleaner
7
FICD solenoid valve No.2
3
Air hose
8
FICD solenoid valve bracket
4
Resonance chamber
9
Intake manifold
5
Air intake pipe
CONTINUED
F2–5
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INTAKE-AIR SYSTEM WL Turbo 1. Disconnect the negative battery cable. 2. Drain the engine coolant from radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 3. Remove the front mud guard. (Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Refill the engine coolant to radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) STEP 1
A
4.9 N·m {50 kgf·cm, 43 in·lbf}
4.9 N·m {50 kgf·cm, 43 in·lbf}
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf} 4.9 N·m {50 kgf·cm, 43 in·lbf}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
A
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf} 8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
1
Fresh-air duct
5
Air intake pipe
2
Air cleaner
6
Air hose
3
Air intake hose
7
Charge air cooler
4
Air hose
8
Air hose
CONTINUED
F2–6
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INTAKE-AIR SYSTEM
STEP 2
19—25 {1.9—2.6, 14—18}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
19—25 {1.9—2.6, 14—18}
R
19—25 {1.9—2.6, 14—18} 19—25 {1.9—2.6, 14—18}
R
N·m {kgf·m, ft·lbf}
1
FICD solenoid valve No.1
4
FICD solenoid valve bracket
2
FICD solenoid valve No.2
5
Air intake pipe
3
EGR solenoid valve
6
Intake manifold
CONTINUED
F2–7
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INTAKE-AIR SYSTEM TURBOCHARGER INSPECTION Wastegate Actuator Inspection Caution Compressed air used in the workshop is highly pressurized and can damage the actuator. Adjust the air pressure with a transformer, and inspect the actual pressure by using an air blower before actual use. Stop blowing air if the rod moved.
A
MIRROR TURBOCHARGER
4. Inspect all fins of compressor wheel while rotating the compressor wheel by hand. 5. If the compressor wheel is interfering with the housing, it is likely that more than two fins are damaged, cracked or bent. Replace the turbocharger. Note If scratches are found inside the housing but the fins are okay, the turbocharger is okay. Scratches are made in the turbocharger made by factory.
1. Disconnect the air hose of the wastegate actuator on the compressor housing side. 2. Apply the compressed air using the air gun. 3. Note the air pressure when the wastegate actuator is moved. Specification 107—115 kPa {1.09—1.18 kgf/cm2, 15.5—16.8 psi} WASTEGATE ACTUATOR
Turbine Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the turbine wheel from view B.
ROD
4. If not within the specification, replace the turbocharger. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Compressor Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the compressor wheel from view A.
Note To make work accurate, use a penlight to inspect.
B
MIRROR
Note To make work accurate, use a penlight to inspect.
TURBOCHARGER
4. Inspect all fins of turbine wheel while rotating the turbine wheel by hand.
CONTINUED
F2–8
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INTAKE-AIR SYSTEM 5. If the turbine wheel is interfering with the housing, it is likely that one or more fins are damaged, cracked or bent. Replace the turbocharger.
GLOW PLUG INSPECTION 1. Remove the glow plug cord. 2. Inspect the resistance between the glow plug terminal and the cylinder head.
Note Grinding marks on the shaft are normal. This mark is for adjusting the shaft balance at the factory.
Specification Glow plug resistance Approx. 0.75 Ω [20 °C {68 °F}] GLOW PLUG
GRINDING MARK
GLOW PLUG REMOVAL/INSTALLATION 3. If not as specified, replace the glow plug. Caution Do not damage the heated section of the glow plug. Do not reuse a glow plug that has been dropped over a height of 10 cm {0.4 in}. When removing the glow plug, first loosen it over one pitch by using a tool, then loosen by hand.
GLOW PLUG RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove glow plug relay. 3. Install the glow plug relay. 8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
GLOW PLUG RELAY
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf} 0.8—15 N·m {8—15 kgf·cm, 7—13 in·lbf}
4. Connect the negative battery cable.
1
Glow plug cord
2
Glow plug
CONTINUED
F2–9
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INTAKE-AIR SYSTEM GLOW PLUG RELAY INSPECTION System Inspection 1. Carry out the “Glow system inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Glow System Inspection.) 2. If not as specified, perform the further inspection for the glow plug relay.
GLOW PLUG CORD INSPECTION 1. Remove the glow plug cord. (Refer to GLOW PLUG REMOVAL/INSTALLATION.) 2. Verify that the glow plug cord is not broken or bent. 3. Verify there is continuity at both ends of the glow plug cord. 4. If there is no continuity, replace the glow plug cord.
Continuity Inspection Note Perform the following test only when directed.
ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. (Refer to Section N, MANUAL STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. General (R.H.D.)
1. Remove the glow plug relay. 2. Inspect for continuity between terminals C and D of the glow plug relay under the following conditions. C
D C
D R
A
B
19—25 {1.9—2.6, 14—18}
B
A
: Continuity Step
A
B
1
B+
GND
C
D
2 19—25 {1.9—2.6, 14—18}
3. If there is no continuity, replace the glow plug relay. (Refer to GLOW PLUG RELAY REMOVAL/INSTALLATION.) If as specified but the System Inspection is failed, inspect following: Open circuit Power circuit (Glow plug relay connector terminal A (1-pin: R/B) and battery) Power circuit (Glow plug relay connector terminal A 123456567 (2-pin) and PCM connector terminal O) GND circuit (Glow plug relay connector terminal A (1-pin: R) and glow plug cord) GND circuit (Glow plug relay connector terminal B (2-pin) and engine GND) Signal circuit (Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I) Short circuit Glow plug relay connector terminal A (1-pin: R/B) and battery to GND. Glow plug relay connector terminal A (2-pin) and PCM connector terminal O to GND. Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I to GND. 4. Repair or replace faulty areas. 5. Install the glow plug relay.
R 5.0 N·m {50 kgf·cm, 44 in·lbf}
1
Idling knob
2
Idling cable
3
Brake switch connector
4
Accelerator cable + Installation Note
5
Spring pin
6
Clevis pin
7
E clip
8
Pin
9
Bushing
10
Push rod
11
Clevis
12
Nut
13
Nut
14
Pedal component + Installation Note
N·m {kgf·m, ft·lbf}
CONTINUED
F2–10
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INTAKE-AIR SYSTEM Except General (R.H.D.)
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Warm up the engine, then turn the engine switch off. 2. Measure the free play of the accelerator cable.
LOCKNUT
Free play 1—3 mm {0.04—0.11 in}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
3. If not as specified, adjust by turning locknut. IDLING KNOB, IDLING CABLE INSPECTION General (R.H.D.) 1 Accelerator cable 1. Verify that the accelerator pedal is in the idling + Installation Note position, when the idling knob is not turned. 2 Accelerator pedal 2. Verify that the accelerator pedal moves in the direction that engine speed increases, when the Pedal Component Installation Note idling knob is turned to the right. Carry out the “BRAKE PEDAL HEIGHT 3. Verify that the accelerator pedal returns to the INSPECTION” procedure after installing the pedal idling position when the idling knob is turned to the component. left. (Refer to Section P, BRAKE PEDAL HEIGHT INSPECTION.) Carry out the “CLUTCH PEDAL INSPECTION” procedure after installing the pedal component. (Refer to Section H, CLUTH PEDAL INSPECTION/ADJUSTMENT.) Accelerator Cable Installation Note Carry out the “ACCELERATOR CABLE INSPECTION/ADJUSTMENT” procedure after installing the accelerator cable. (Refer to ACCELERATOR CABLE INSPECTION/ADJUSTMENT.)
IDLING KNOB
CONTINUED
F2–11
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FUEL SYSTEM
FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fuel system is under high pressure
when the engine is not running. Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following “Fuel Line Safety Procedures”. Fuel Line Safety Procedures Avoid fuel line spills and leaks by completing the following procedures. (1) Remove the fuel-filler cap and release the pressure in the fuel tank. (2) When disconnecting a fuel hose, wrap a rag around it to protect against fuel leakage. (3) Plug the fuel hose after removal. AFTER REPAIR PROCEDURE Warning Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe “Fuel Hose Installation” described below. Fuel Hose Installation Verify that there is no damage or deformation on the fuel hose and fuel pipe when installing.
CONTINUED
F2–12
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FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the drain plug and drain the fuel from the fuel tank. 4. Remove the rear flap. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) STRETCH CAB 2WD, DOUBLE CAB 2WD 1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
7.9–10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R
WITH BOX
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
A
B
R
R
SEAL RUBBER R
2.5—4.6 N·m {25—47 kgf·cm, 22—40 in·lbf} 2.5—3.5 N·m {25—36 kgf·cm, 22—26 in·lbf}
11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf} 11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
1.1—2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
WITHOUT BOX
R
32—46 {3.2—4.7, 24—33}
EUROPE
DRAIN PLUG 26—32 {2.6—3.3, 19—23} 32—46 {3.2—4.7, 24—33}
EXCEPT EUROPE N·m {kgf·m, ft·lbf}
CONTINUED
F2–13
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FUEL SYSTEM
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf} 1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
SEAL R RUBBER 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R WITH BOX
A
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
B
R 2.5—4.6 N·m {25—47 kgf·cm, 22—40 in·lbf} 2.5—3.5 N·m {25—36 kgf·cm, 22—26 in·lbf}
11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf} 11.8—16.6 N·m {120—170 kgf·cm, 105—147 in·lbf}
16—22 {1.6—2.3, 12—16} 1.1—2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
WITHOUT BOX
16—22 {1.6—2.3, 12—16}
R
32—46 {3.2—4.7, 24—33}
EUROPE DRAIN HOSE 26—32 {2.6—3.3, 19—23}
32—46 {3.2—4.7, 24—33}
EXCEPT EUROPE N·m {kgf·m, ft·lbf}
1
Evaporative chamber (If equipped)
7
2
Joint hose + Installation Note
Evaporative hose + Installation Note
8
Fuel gauge sender unit
Breather hose + Installation Note
9
Rollover valve
10
Fuel-filler pipe
3 4
Under guard
11
Dust cover
5
Fuel hose + Installation Note
12
Fuel inlet pipe
6
Fuel tank
13
Check valve (two–way)
14
Evaporative chamber
CONTINUED
F2–14
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FUEL SYSTEM Evaporative Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamps as shown. Length Evaporative hose: 25 mm {0.98 in}
9—12 mm {0.36—0.47 in}
10 mm {0.39 in}
9—12 mm {0.36—0.47 in}
VIEW A
EVAPORATIVE HOSE
Fuel Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamp as shown. Length Fuel hose: 25 mm {0.98 in}
VIEW B
FUEL FILTER DISASSEMBLY/ASSEMBLY 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disassemble in the order indicated in the table. 4. Assemble in the reverse order of removal. 5. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 6. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 7. Start the engine and verify that fuel does not leak from the fuel system. 8. If fuel leaks, reassemble the fuel filter. WITH FUEL WARMER
10 mm {0.39 in}
19—25 {1.9—2.6, 14—18}
WITHOUT FUEL WARMER
FUEL HOSE
Breather Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamp as shown.
N·m {kgf·m, ft·lbf}
Length Breather hose: 25 mm {0.98 in}
R
10 mm {0.39 in}
BREATHER HOSE
Joint Hose Installation Note Fit the joint hose onto the respective fittings within the specification, and install clamps as shown. Length Joint hose: 35 {1.4 in}
CONTINUED
F2–15
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FUEL SYSTEM
1
Connector
2
Fuel hose
3
Priming pump
4
Fuel filter + Assembly Note
5
Sedimentor switch + Assembly Note
6
Drain plug
7
Fuel warmer
SEDIMENTOR SWITCH INSPECTION Continuity Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Drain fuel from the fuel filter. (Refer to FUEL SYSTEM, SEDIMENTOR WATER DRAINING.) 3. Remove the sedimentor switch. 4. Inspect continuity of the sedimentor switch by using an ohmmeter.
Sedimentor Switch Assembly Note Apply a small amount of fuel to a new O-ring. Tighten the sedimentor switch enough to the fuel filter by hand. Fuel Filter Assembly Note Apply a small amount of fuel to the fuel filter O-ring. Tighten the fuel filter approx. 3/4 by hand after the O-ring contacts the priming pump.
Float
Continuity
Up
Yes
Down
No UP DOWN
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION)
FLOAT
FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.) FUEL FILTER AIR BLEEDING Caution Continuously cranking the engine for over 30 seconds can damage the battery and the starter.
5. If not as specified, replace the sedimentor switch. If as specified, inspect following: Open circuit GND circuit (Sedimentor switch connector terminal B and body GND) Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C)
Repeat cranking the engine for 30 seconds and
stop for 5—10 seconds until the engine starts.
SEDIMENTOR SWITCH
SEDIMENTOR WATER DRAINING 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Loosen the drain plug located at the bottom of the fuel filter. 4. Pump the priming pump and drain the water. 5. After all the water has been drained, tighten the drain plug. 6. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 7. Reconnect the negative battery cable.
B
A
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
ENGINE SWITCH A
B
A
C
B
D
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–16
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FUEL SYSTEM Short circuit GND circuit (Sedimentor switch connector terminal B and body GND to power circuit) Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C to GND)
FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION Caution After removing/installing the FIP, be sure to inspect the timing belt tension. If the belt tension is not inspected, the timing belt and the camshaft may become damaged. (Refer to section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
6. Repair or replace faulty areas. 7. Install the sedimentor switch. 8. Reconnect the negative battery cable. 9. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 1. Disconnect the negative battery cable. FUEL WARMER INSPECTION 2. Complete the “BEFORE REPAIR PROCEDURE”. With fuel warmer (Refer to FUEL SYSTEM, BEFORE REPAIR 1. Disconnect the negative battery cable. PROCEDURE.) 2. Complete the “BEFORE REPAIR PROCEDURE”. 3. Remove the FICD solenoid valve bracket. (Refer to FUEL SYSTEM, BEFORE REPAIR (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM PROCEDURE.) REMOVAL/INSTALLATION.) 3. Remove the fuel warmer. 4. Remove the air intake pipe. (Refer to FUEL SYSTEM, FUEL FILTER (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM DISASSEMBLY/ASSEMBLY.) REMOVAL/INSTALLATION.) 4. Verify that the resistance between terminal A and 5. Set the No.1 cylinder to TDC. the fuel warmer body is within the specification 6. Remove in the order indicated in the table. when vacuum of –26.6—–40.0 kPa 7. Install in the reverse order of removal. {–200—–300mmHg, –7.9—–11.8 inHg} is applied 8. Complete the “AFTER REPAIR PROCEDURE”. to port A of the fuel warmer. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 9. Inspect injection timing. (Refer to ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT.) 10. Check the timing belt tension. (Refer to Section B2,TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
Specification Water temperature °C {°F}
Resistance (Ω)
20 {68}
0.5—1.5
2.4—3.4 N·m {25—35 kgf·cm, 22—30 in·lbf}
A 19—25 {1.9—2.6, 14—18}
5. If not as specified, replace the fuel warmer.
59—68 {6.0—7.0, 44—50}
FUEL INJECTION PUMP (FIP) INSPECTION Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. Consult your distributor for disassembly if any FIP
internal parts are possibly malfunctioning.
A R
25—29 {2.5—3.0, 19—21}
19—25 {1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf}
CONTINUED
F2–17
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FUEL SYSTEM
59—68 {6.0—7.0, 44—50}
1
Injection pipe
2
Accelerator cable
3
Fuel hose
4
Connector
5
Vacuum hose
6
Timing belt cover + Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Cover Installation Note.
7
FIP mounting bolt
8
FIP mounting nut
9
FIP + Removal Note
10
Key
27—32 {2.7—3.3, 20—23}
R
R R
2.4—3.4 N·m {25—35 kgf·cm, 22—30 in·lbf}
FIP Removal Note 1. Remove the two FIP pulley mounting bolts. 2. Loosen the FIP pulley locknut. 3. Remove the pulley with the SST.
25—29 {2.5—3.0, 19—21}
N·m {kgf·m, ft·lbf}
49 S120 215A
FIP PULLY LOCKNUT
1
Injection pipe
2
Fuel leak pipe
3
Fuel leak washer
4
Injection nozzle + Installation Note
5
Nozzle washer
6
Corrugated gasket + Installation Note
Corrugated Gasket Installation Note Install the bead side facing combustion chamber.
INJECTION NOZZLE REMOVAL/INSTALLATION Caution Cover the outlet of the injection pipe and fuel hose with a rag. Catch the fuel with a rag.
Injection Nozzle Installation Note Install each injection nozzle onto the FIP, matching their identification color rings as shown. INJECTION NOZZLE
1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
FIP
COLOR RING
CONTINUED
F2–18
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FUEL SYSTEM Injection Starting Pressure 1. Connect the injection nozzle to a nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Slowly lower the nozzle tester handle and note the pressure when injection starts.
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY Caution The injection port is very small so it must be kept clean. Otherwise, foreign material may get stuck in the injection nozzle, causing damage.
Injection starting pressure 11.4—12.1 MPa {116—124 kgf/cm2, 1650—1760 psi} (New) More than 10.0 MPa {102 kgf/cm2, 1450 psi} (Inspection)
1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
4. If the injection starting pressure is not within the specification, adjust it by installing the correct shim. Note Adding/subtracting 0.02 mm {0.0008 in} thickness shim increases/decreases the starting pressure approx. 470 kPa {4.8 kgf/cm2, 68 psi}.
29—49 {3.0—5.0, 22—36} N·m {kgf·m, ft·lbf}
1
Nozzle holder body + Disassembly Note
2
Ring
3
Shim
4
Nozzle spring
5
Spring seat
6
Spacer
7
Needle valve + Assembly Note
8
Nozzle body
9
Retaining nut
ADJUSTING SHIM
Atomization 1. Connect the injection nozzle to the nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Lower the handle several times as quickly as possible so that a pulsating whistling sound is heard, and note the atomization pattern. (1) Uniform, proper atomization (2) Incorrect injection angle and direction
Nozzle Holder Body Disassembly Note Secure the retaining nut in a vise and remove the nozzle holder body. Needle Valve Assembly Note When the nozzle body or the needle valve is damaged, replace them as a set.
(1)
(2)
INJECTION NOZZLE INSPECTION Caution Fuel and fuel tank used for the nozzle tester must be kept clean. Otherwise, foreign material may get stuck between the nozzle and the nozzle tester, causing damage. NORMAL
FAULTY ANGLE
FAULTY DIRECTION
4. If necessary, disassemble and clean or replace the injection nozzle.
CONTINUED
F2–19
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FUEL SYSTEM Nozzle Leakage 1. Connect the injection nozzle to the nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Apply 8.8 MPa {90 kgf/cm2, 1,280 psi} pressure to the injection nozzle, and inspect for fuel leakage from the nozzle spray port.
CORRECT
4. Remove the needle valve from the nozzle body. 5. Clean the needle valve and the nozzle body with clean light oil. 6. Verify that the needle valve moves smoothly in the nozzle body. 7. If not, replace the nozzle assembly.
WRONG
4. If fuel leaks, disassemble and clean or replace the injection nozzle. Operating Inspection 1. Verify that the needle valve and nozzle body are not damaged. 2. Verify that the nozzle body is not damaged. Hold the nozzle body upright and insert approximately two thirds of the needle valve; then see if the needle valve drops to the valve seat by its own weight when released.
FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION Without immobilizer system 1. Disconnect the negative battery cable. 2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the FCV. 4. Install in the reverse order of removal. NUT 2.0—2.4 N·m {20—25 kgf·cm, 18—21 in·lbf}
NEEDLE VALVE
FCV 15—25 {1.5—2.6, 11—18}
N·m {kgf·m, ft·lbf}
FUEL CUT VALVE (FCV) INSPECTION Without immobilizer system On-vehicle Inspection
NOZZLE BODY
Injection Nozzle Cleaning 1. Inspect the outer and inner surfaces of the injection nozzle for carbon accumulation. 2. If carbon is observed on the outer surface, remove it by using a hard wood chip. 3. If carbon is observed inside of the nozzle, remove it by using a toothpick.
Note Perform the following test only when directed. 1. With the engine idling, disconnect the FCV connector and verify that the engine stops. 2. If the engine does not stop, carry out the following inspection. Off-vehicle Inspection 1. Disconnect the negative battery cable. 2. Remove the FCV. 3. Connect the battery positive voltage to the FCV terminal and GND the FCV body, 4. Verify that the FCV stem is drawn into the FCV.
CONTINUED
F2–20
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FUEL SYSTEM : Continuity Terminal
Step
: Airflow Port
A
B
A
B+
GND
B
C
1 2
B GND
5. Replace the FCV if not as specified. If as specified, inspect following: Open circuit GND circuit (FCV body and engine switch connector terminal IG1) Power circuit (FCV connector terminal and engine switch connector terminal IG1)
B
A
C
B
D
A 123456567
AIR FILTER
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Short circuit GND circuit (FCV body and engine switch connector terminal IG1 to GND) Power circuit (FCV connector terminal and engine switch connector terminal IG1 to GND)
4. If not as specified, replace the faulty FICD solenoid valve. If as specified but the “System Inspection” is failed, inspect following: Vacuum hose improper routing, kinks or leakage. Open circuit GND circuit (FICD solenoid valve No.1 connector terminal B and PCM connector terminal C) GND circuit (FICD solenoid valve No.2 connector terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector terminal A and engine switch connector terminal IG1) Power circuit (FICD solenoid valve No.2 connector terminal A and engine switch connector terminal IG1) ENGINE SWITCH
6. Repair or replace faulty areas. 7. Install the FCV. 8. Reconnect the negative battery cable. FICD SOLENOID VALVE NO.1, NO.2 INSPECTION System Inspection 1. Carry out the “FICD System Inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, FICD System Inspection.) 2. If not as specified, perform the further inspection for the FICD solenoid valve No.1, No.2. Airflow Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the FICD solenoid valve No.1, No.2. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Inspect for airflow between ports of the solenoid valve.
B
B+
C
ENGINE SWITCH A
A
A
B
A
C
B
D
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Short circuit GND circuit (FICD solenoid valve No.1 connector terminal B and PCM connector terminal IG1) GND circuit (FICD solenoid valve No.2 connector terminal B and PCM connector terminal P) Power circuit (FICD solenoid valve No.1 connector terminal A and engine switch connector terminal IG1 to GND) Power circuit (FICD solenoid valve No.2 connector terminal A and engine switch connector terminal IG1 to GND) 5. Repair or replace faulty areas. 6. Install the FICD solenoid valve No.1, No.2. 7. Reconnect the negative battery cable.
CONTINUED
F2–21
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FUEL SYSTEM TIMER CONTROL VALVE (TCV) INSPECTION Europe and UK 1. Carry out the “Timer Control Valve (TCV) Control Inspection”. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Timer Control Valve (TCV) Control Inspection.) 2. If not as specified, perform the further inspection for the TCV. Continuity Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the FIP connector (8–pin terminal). 3. Verify that there is continuity between the FIP connector terminal D and TCV body. FIP
A
C
E
G
B
D
F
H
COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
4. If not as specified, send TCV to a distributor for replacement. If the TCV is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. Open circuit Power circuit (FIP connector terminal D and PCM connector terminal H) Short circuit FIP connector terminal D and PCM connector terminal H to GND 5. Repair or replace faulty areas. 6. Reconnect the FIP connector.
F2–22
CONTINUED
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EXHAUST SYSTEM
EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. WL
TURKEY and GENERAL (R.H.D., L.H.D.)
EUROPE and UK
N·m {kgf·m, ft·lbf}
1
Tail pipe
4
Front pipe
2
Main silencer
5
Exhaust manifold insulator
6
Exhaust manifold
3
Middle pipe (Turkey and General (R.H.D.,
L.H.D.) OC (Europe and UK)
CONTINUED
F2–23
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EXHAUST SYSTEM
WL TURBO
EUROPE and UK
TURKEY and GENERAL (R.H.D., L.H.D.)
N·m {kgf·m, ft·lbf}
1
Tail pipe
6
Joint pipe
2
Main silencer
7
Turbocharger + Removal Note
8
Oil pipe + Installation Note
9
Exhaust manifold
3
Middle pipe (General (L.H.D.)) OC (Europe and UK)
4
Front pipe
5
Exhaust manifold insulator
CONTINUED
F2–24
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EXHAUST SYSTEM, EMISSION SYSTEM Oil Pipe Installation Note Be sure to confirm that the turbocharger is installed correctly, then install the oil pipe. Water pipe Install the water pipe and tighten to the specified torque.
EMISSION SYSTEM ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow from port A and verify that there is airflow.
Tightening torque 24—35 N·m {2.4—3.6 kgf·m, 18—26 ft·lbf} OIL PIPE
WATER PIPE
A
3. Turn the valve over and blow from port A. Verify that there is no airflow.
Turbocharger Removal Note Do not drop the turbocharger. Do not bend the wastegate actuator mounting or rod. Cover the intake, exhaust and oil passages to prevent dirt or other objects from entering. A
4. If not as specified, replace the rollover valve. EVAPORATIVE CHAMBER INSPECTION If equipped 1. Remove the evaporative chamber. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow from port A and verify that there is airflow from port B.
A
B
3. If not as specified, replace the evaporative chamber.
CONTINUED
F2–25
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EMISSION SYSTEM EGR VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection Note Perform the following test only when directed. 1. Remove the EGR valve. 2. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the figure.
4. If not as specified, replace the EGR solenoid valve. If the EGR solenoid valve is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. Vacuum hose improper routing, kinks or leakage. Open circuit Power circuit (EGR solenoid valve connector terminal A and PCM connector terminal 1R) GND circuit (EGR solenoid valve connector terminal B and body GND through common connector) EGR SOLENOID VALVE
A
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Vacuum (kPa {mmHg, inHg})
Airflow
Below –21.3—–25.3 {–160— –190, –6.3— –7.4}
Yes
Except above
No
Short circuit EGR solenoid valve connector terminal A and PCM connector terminal 1R. 5. Repair or replace faulty areas. 6. Install the EGR solenoid valve connector.
3. If not as specified, replace the EGR valve.
EGR PIPE, EGR VALVE REMOVAL/INSTALLATION WL Turbo for Europe and UK 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
EGR SOLENOID VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the EGR solenoid valve (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION, WL Turbo.) 3. Inspect for airflow between ports of the solenoid valve. : Continuity Terminal
Step
A
19—25 {1.9—2.6, 14—18}
: Airflow N·m {kgf·m, ft·lbf}
A
B
C
1 2
B+
B GND
35—40 {3.5—4.0, 25—29}
Port
B
19—25 {1.9—2.6, 14—18}
GND
1
EGR pipe
2
EGR valve
A B
B+
A
C 123456567
CONTINUED
AIR FILTER
F2–26
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CONTROL SYSTEM
CONTROL SYSTEM COMPONENT PARTS
WL TURBO
WL TURBO
*1: *2:
1
Glow indicator light
10
A/C relay
2
Temperature control dial
11
TCV*2
3
Engine switch
12
Control lever position sensor*2
4
PCM
13
Glow plug
5
FICD solenoid valve No.2
14
NE sensor
6
FICD solenoid valve No.1
15
Idle switch*2
16
Starter
17
Glow plug relay
7
EGR solenoid
8
ECT sensor
9
DLC
valve*1
CONTINUED
WL Turbo for Europe and UK Europe and UK
F2–27
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CONTROL SYSTEM POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Remove the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
8.9—12.7 N·m {90—130 kgf·cm, 78—112 in·lbf}
1
PCM connector
2
PCM installation nut
3
PCM
POWERTRAIN CONTROL MODULE (PCM) INSPECTION Caution The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. 1. Remove the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 2. Remove the PCM with the connector connected. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.) Note With the PCM connector connected, body ground the voltmeter negative (–) lead and measure the voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage of each PCM terminals by using a voltmeter. 4. If the output voltage is not normal while each input voltage is normal, inspect the related device systems. When they are normal, replace the PCM. 5. Install the PCM. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.) 6. Install the driver’s side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
F2–28
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CONTROL SYSTEM Terminal Voltage (Reference) Europe and UK S T Terminal
A A*1
B C
Q R
Signal – Constant voltage
System ground FICD control
O P
Turkey and General (R.H.D. ,L.H.D.)
M
K
I
G
E C
A
N
L
J
H
F
B
Connected to – Control lever position osition sensor EGR valve position sensor
D
O M K I G E C A P N L J H F D B
Test condition – Engine switch
ON OFF
Idle
Ground
Constant
FICD solenoid valve No.1
Idle
E
Start
ECT
ECT is below 20°C {68°F}.
Engine switch (Starter)
Engine switch is on.
ECT sensor
Engine switch is on.
While cranking ECT is 20°C {68°F}. After warm-up
F
G
Engine speed (Input)
NE sensor
A/C (With A/C)
Temperature control dial
Engine switch is on. Idle Engine switch is on.
Temperature control dial is off and fan switch is off.
Temperature control dial is at position other than off and fan switch is on.
H H*1
*1:
– Idle (Control lever open or close)
– Idle switch
Engine switch is on.
Below 1.0
Action – Inspect related harness.
Inspect PCM. Inspect related harness.
Approx. 5.0
ECT is above 20°C {68°F}. D
Voltage (V) – Approx. 5.0
– Accelerator pedal is depressed. Accelerator pedal is released.
Below 1.0 Below 1.0 B+ Below 1.0 Approx. 10 Approx. 3.1 Approx. 0.8 Approx. 0 Approx. 0.05 B+
Below 1.0
– B+ Below 1.0
Inspect related harness. Inspect FICD solenoid
valve No.1. + FUEL SYSTEM, FICD SOLENOID VALVE No No.1, 1 No.2 INSPECTION Inspect related harness Inspect related harness
Inspect engine coolant
temperature sensor. + ECT SENSOR INSPECTION Inspect related harness Inspect NE sensor. + NE SENSOR INSPECTION Inspect related harness Inspect microswitch. + Section U, CONTROL SYSTEM, HEATER CONTROL UNIT INSPECTION Inspect fan switch. + Section U, CONTROL SYSTEM, HEATER CONTROL UNIT INSPECTION Inspect related harness – Inspect idle switch. + IDLE SWITCH INSPECTION Inspect related harness.
Europe and UK
CONTINUED
F2–29
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CONTROL SYSTEM
Terminal
I
Signal Glow plug voltage
Connected to Glow plug
Test condition ECT is below 60°C {140°F}.
For less than approx. 15 seconds after turning engine switch on. Over approx. 15 seconds after turning engine switch on.
ECT is above 60°C {140°F}.
For less than 10 minutes after starting engine. Over 10 minutes after starting engine. While cranking For less than approx. 2 seconds after turning engine switch on. Over approx. 2 seconds after turning engine switch on. While cranking
J
J*1
K
L*1
L*2
Power supply
Control lever position ((Detection))
Engine switch
Control lever position sensor
Engine switch
Engine switch is on.
Approx. 4.2
Accelerator pedal is fully closed.
Approx. 0.8—1.5
Engine switch
Engine switch
N*1
Glow indicator light g control
A/C control (With A/C)
Glow indicator light g
B+
Idle OFF
Below 1.0
ON
B+
Engine switch is on.
B+
Idle
B+
A/C is not operating
Engine switch is off.
–
Below 1.0 Below 1.0
Engine switch is on and within approx. 4.5 sec. (25 °C {77 °F}).
A/C relay
Over 4.5 seconds (25 °C {77 °F}) after turning engine switch on.
B+
Engine switch is on.
B+
Idle
B+
–
Inspect engine switch. + Section T, POWER SYSTEM,, IGNITION SWITCH INSPECTION Inspect related harness. Inspect control lever posi-
tion sensor. + CONTROL LEVER POSITION SENSOR INSPECTION Inspect related harness. Inspect related harness.
6.9—7.1
A/C is not operating A/C is operating
N*2
B+
Accelerator pedal is fully open.
A/C is operating M
Below 1.0
B+
Power supply
A/C relay
Below 1.0 B+ B+
ON
Engine switch is on.
Inspect related harness
B+
Below 1.0
Instrument cluster
Action
Below 1.0
OFF
Engine speed (Out(Out put)
A/C control (With A/C)
Voltage (V) B+
–
Below 1.0 –
Inspect engine switch. + Section T, POWER SYSTEM,, IGNITION SWITCH INSPECTION Inspect related harness. Inspect A/C relay. + S Section ti U, U CONTROL SYSTEM, A/C RELAY INSPECTION Inspect related harness. Inspect glow indicator
g light + Section T, WARNING AND INDICATOR SYSTEM, WARNING AND INDICATOR LIGHT BULB REPLACEMENT Inspect related harness. Inspect A/C relay. + S Section ti U, U CONTROL SYSTEM, A/C RELAY INSPECTION Inspect related harness.
–
*1:
Europe and UK *2: Turkey and General (R.H.D., L.H.D.)
CONTINUED
F2–30
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CONTROL SYSTEM
Terminal
O
Signal Glow system
Connected to Glow plug relay
Test condition Engine coolant temperature is below 60°C {140°F}.
For less than approx. 15 seconds after turning engine switch on. Over approx. 15 seconds after turning engine switch on. For less than 10 minutes after starting engine. Over 10 minutes after starting engine.
Engine coolant temperature is above 60°C {140°F}.
FICD control
FICD solenoid valve No.2
Idle
B+
Below 1.0
B+ B+
Over approx. 2 seconds after turning engine switch on.
Below 1.0
is not at OFF Engine coolant temperature is below 60°C {140°F}. Temperature control dial
Inspect glow plug relay. + INTAKE-AIR SYSTEM, GLOW PLUG RELAY INSPECTION Inspect related harness.
Below 1.0
For less than approx. 2 seconds after turning engine switch on.
Temperature control dial
Action
B+
While cranking
While cranking P
Voltage (V)
B+ Below 1.0
Inspect FICD solenoid
B+
valve No.2. + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION Inspect related harness.
–
–
B+
Inspect TCV. + CONTROL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION Inspect related harness.
is not at OFF Engine coolant temperature is above 60°C {140°F}. Q Q*1
– Timer control
– TCV
– Engine switch is on. Idle
R
–
R*3
EGR valve control
S S*1
– Diagnostic test mode
Below 1.0
– EGR solenoid valve
– Engine switch is on. Idle
– Data link connector (DLC) (Terminal TEN)
T
–
–
T*1
DTC output
Data link connector (DLC) (Ter (Terminal FEN)
Below 1.0 –
Engine switch is on on.
– B+
–
Open terminal TEN
B+
Short terminal TEN
Below 1.0
–
–
No DTC output
Below 1.0
DTC output
0—B+
– Inspect EGR solenoid
valve. + EMISSION SYSTEM, SYSTEM EGR SOLENOID VALVE INSPECTION Inspect related harness. – Inspect related harness.
– Inspect related harness.
*1:
Europe and UK Turkey and General (R.H.D., L.H.D.) *3: WL Turbo for Europe and UK
CONTINUED
*2:
F2–31
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CONTROL SYSTEM ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
NE SENSOR INSPECTION Note Perform the following test only when directed. 1. Disconnect the NE sensor connector. 2. Measure the resistance between the NE sensor connector terminals A and B by using an ohmmeter.
A
Note Perform the following test only when directed. 1. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor. 4. Place the sensor in water with a thermometer, and heat the water gradually.
B
Specification 800—920 Ω 3. If not as specified, replace the NE sensor. Tightening torque 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
A
4. If NE sensor is okay, but PCM terminal F voltage is out of specification, inspect the following: Open circuit Engine speed (input) circuit (NE sensor connector terminal A and PCM connector terminal F) GND circuit (NE sensor connector terminal B and PCM connector terminal B) Short circuit NE sensor connector terminal A and PCM connector terminal F to GND 5. Repair or replace faulty areas. 6. Reconnect the NE sensor connector.
B
5. Measure the resistance between engine coolant temperature sensor terminals A and B by using an ohmmeter. Specification Water temperature (°C {°F})
Resistance (kΩ)
20 {68}
2.27—2.73
80 {176}
0.29—0.34
6. If not as specified, replace the ECT sensor. 7. Refill the radiator with the specified engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 8. Install the ECT sensor. Tightening torque 16—23 N·m {1.6—2.4 kgf·m, 12—17 in·lbf} 9. If ECT sensor is okay, but PCM terminal E voltage is out of specification, inspect as follows:
CONTINUED
F2–32
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CONTROL SYSTEM Open circuit Reference voltage circuit (ECT sensor connector terminal A and PCM connector terminal E through common connector) GND circuit (ECT sensor connector terminal B and PCM connector terminal B through common connector) Short circuit ECT sensor connector terminal A and PCM connector terminal E through common connector to GND 10. Repair or replace faulty areas. 11. Reconnect the ECT sensor connector.
Open circuit Power supply circuit (Idle switch connector terminal E and PCM connector terminal 2H through common connector) GND circuit (Idle switch connector terminal and body GND)
IDLE SWITCH INSPECTION Europe and UK Continuity Inspection
E
C
A
H
F
D
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the 8-pin connector of FIP. 3. Inspect for continuity between the idle switch terminal E and ground using an ohmmeter.
A
C
E
G
B
D
F
H
Short circuit Power supply circuit (Idle switch connector terminal E and PCM connector terminal H through common connector to GND) 6. Repair or replace faulty areas. 7. Reconnect the 8-pin connector of FIP. CONTROL LEVER POSITION SENSOR INSPECTION Europe and UK Output Voltage Inspection Note Perform the following test only when directed.
COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
1. Verify that the FIP control lever is fully closed. 2. Turn the engine switch on and measure the PCM terminal J voltage.
Specification
Specification : Continuity
Measuring g condition
G
Terminal E
GND
Not accelerated Other
Measuring condition
Voltage (V)
Accelerator pedal is fully open.
Approx. 4.2
Accelerator pedal is fully closed.
Approx. 0.8—1.5
3. If not as specified, replace the control lever position sensor. When the reading is out of specification, send the FIP with the control lever position sensor to a distributor to repair. If the PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary.
Caution Turning the idle switch with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation. 4. If not as specified, loosen the idle switch locknut and adjust the continuity by turning the idle switch. 5. If not as specified, replace the idle switch. If the idle switch is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary.
Open circuit Constant voltage circuit (Control lever position sensor connector terminal B and PCM connector terminal A through common connector) Control lever position signal circuit (Control lever position sensor connector terminal A and PCM connector terminal J through common connector) GND circuit (Control lever position sensor connector terminal C and PCM connector terminal B through common connector)
CONTINUED
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CONTROL SYSTEM
G
E
C
A
H
F
D
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Short circuit Control lever position sensor connector terminal B and PCM connector terminal A through common connector to GND Control lever position sensor connector terminal A and PCM connector terminal J through common connector to GND 4. Repair or replace faulty areas. 5. Reconnect the 8-pin connector of FIP.
CONTINUED
F2–34
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ON-BOARD DIAGNOSTIC SYSTEM Using the Voltmeter 1. Turn the engine switch off. 2. Connect the DLC located in the engine compartment terminal TEN and GND using a jumper wire.
ON-BOARD DIAGNOSTIC SYSTEM Europe and UK only DTC READING PROCEDURE Using the SST (Self-Diagnosis Checker) 1. Connect the SSTs to the DLC located in the engine compartment and GND the black (negative) lead to the body.
Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
49 B019 9A0 DLC
3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B. 49 H018 9A1A
FEN
2. Set the select switch on the SST (self-diagnosis checker) to A. 3. Turn the dial switch on the SST (system selector) to 1, and the test switch to SELF TEST. 4. Turn the engine switch on. 5. Verify that the buzzer sounds for approximately 3 seconds and code “88” flashes for 5 seconds. If DTC is not detected, “00” will then be indicated. Note If the “88” does not flash, inspect +B terminal of the data link connector, and the related harnesses and connectors. If the “88” flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect. 6. If any DTCs are indicated, inspect the appropriate areas and repair as necessary. Note A DTC consists of four numbers. They are flashed one by one in the right window on the display. (“1” is always shown on the left window.) When there are multiple malfunctions, the codes are displayed in numerical order. 7. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE.) 8. Remove the SSTs.
DLC TEN
+B
GND
4. turn the engine switch on. 5. The voltmeter indicates the battery positive voltage for approximately 3 seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the voltmeter’s needle. If DTC is not detected, the needle does not move. 7. If any DTCs are indicated, inspect the appropriate areas and repair as necessary. 8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE.) 9. Remove the voltmeter and the jumper wire. AFTER REPAIR PROCEDURE 1. After repairs, disconnect the negative battery cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable. 2. Warm up the engine to normal operating temperature. Note If the engine will not start, keep the starter operated for 5-6 seconds. 3. Perform the “DTC READING PROCEDURE” again. 4. Verify that the DTC is not detected.
CONTINUED
F2–35
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ON-BOARD DIAGNOSTIC SYSTEM DTC INSPECTION DTC Table DTC No.
Indicator Pattern
09
Engine coolant temperature (ECT) sensor malfunction
12
Control lever position sensor malfunction
36
Glow plug relay malfunction
DTC 09 DETECTION CONDITION POSSIBLE CAUSE
ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION Input value to PCM is excessively high or low for more than 2.0 sec. ECT sensor malfunction Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B
STEP 1 2
3 4
5
6
Condition
INSPECTION
ACTION
Does ECT sensor or PCM connector have poor connection?
Yes
Repair or replace connector, then go to Step 6.
No
Go to next step.
Disconnect ECT sensor connector. Turn engine switch on. Is there 5 V at connector terminal A?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness. (PCM terminal B–ECT sensor terminal B)
Is there continuity between connector terminal A and PCM terminal E?
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 6.
Is ECT sensor okay? + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
Yes
Go to next step.
No
Replace ECT sensor, then go to Step 6.
Clear DTC from memory. Is same code No. present after performing “After Repair Procedure”?
Yes
Go to Step 1.
No
Intermittent poor connection in harnesses or connector. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing “After Repair Procedure”?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
PCM (20 PIN) ECT SENSOR E J
A
B
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–36
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ON-BOARD DIAGNOSTIC SYSTEM
DTC 12 DETECTION CONDITION
CONTROL LEVER POSITION SENSOR MALFUNCTION Input voltage from control lever positIon sensor is below 0.1 V or above 4.75 V when continued for 1.0
sec. When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V. Control lever position sensor malfunction Idle switch malfunction Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-
POSSIBLE CAUSE
nal B Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to
PCM terminal J Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to
PCM terminal A Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H
STEP 1
INSPECTION
ACTION
Does control lever position sensor connector or PCM connector have poor connection?
Yes
Repair or replace connectors, then go to Step 7.
No
Go to next step.
Disconnect control lever position sensor connector. Turn engine switch on. Is there 5 V at connector terminal B?
Yes
Go to next step.
No
Inspect for open or short circuit in wiring harness. (PCM terminal A–control lever position sensor terminal B)
Is there continuity between connector terminal A and PCM terminal J?
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 7.
Is there continuity between connector terminal C and PCM terminal B?
Yes
Replace control lever position sensor, then go to Step 7.
No
Repair or replace wiring harness, then go to Step 7.
5
Is there continuity between connector terminal E and PCM terminal H?
Yes
Go to next step.
No
Repair or replace wiring harness, then go to Step 7.
6
Is idle switch okay? + CONTROL SYSTEM SYSTEM, IDLE SWITCH INSPECTION
Yes
Go to next step.
No
Replace idle switch.
Clear DTC from memory. Is same code No. present after performing “After Repair Procedure”?
Yes
Go to Step 1.
No
Intermittent poor connection in harness or connector. Repair connector and/or harness, then go to next step.
Clear DTC from memory. Is there any DTC present after performing “After Repair Procedure”?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed.
2
3 4
7
8
CONTROL LEVER POSITION SENSOR PCM (20 PIN) A J
B
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
G
E
C
A
H
F
D
B
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–37
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ON-BOARD DIAGNOSTIC SYSTEM
DTC 36
GLOW PLUG RELAY MALFUNCTION When the glow plug relay is on, current voltage signal of the relay below 1.0 V is inputted to the PCM
DETECTION CONDITION
continuously for more than 1.0 sec. When the glow plug relay is off, signal of the relay current voltage above 4.0 V is inputted to the PCM
continuously for more than 1.0 sec. POSSIBLE CAUSE STEP 1 2
3 4 5
6
7
Glow plug relay malfunction Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR) Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B) Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse INSPECTION
ACTION
Does glow plug relay connector or PCM connector have poor connection?
Yes
Repair or replace connectors, then go to Step 5.
No
Go to next step.
Remove glow plug relay. Is there continuity between connector terminal A and PCM terminal O? Is there continuity between connector terminal A (B) and PCM terminal I?
Yes
Go to next step.
No
Repair or replace wiring harness.
Is there continuity between connector terminal B and body GND?
Yes
Go to next step.
No
Repair or replace wiring harness.
Is there continuity between connector terminal A (R) and glow fuse?
Yes
Go to next step.
No
Repair or replace wiring harness.
Is glow plug relay okay? + INTAKE-AIR INTAKE AIR SYSTEM, SYSTEM GLOW PLUG RELAY INSPECTION
Yes
Go to next step.
No
Replace glow plug relay.
Clear DTC from memory. Is same code No. present after performing “After Repair Procedure”?
Yes
Go to Step 1.
No
Intermittent poor connection in harnesses or connectors. Repair connectors and/or harnesses, then go to next step.
Clear DTC from memory. Is there any DTC present after performing “After Repair Procedure”?
Yes
Go to applicable DTC inspection.
No
Troubleshooting completed. GLOW PLUG RELAY
PCM (20 PIN)
A A O
A B
I
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
(WIRE COLOR: R)
(WIRE COLOR: B)
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–38
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TROUBLESHOOTING
TROUBLESHOOTING FOREWORD Before processing with the following troubleshooting, refer to section GI to understand the basic troubleshooting procedure. No.
TROUBLESHOOTING ITEM TABLE Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart. If a diagnostic trouble code is displayed, proceed with inspection steps for the code.
TROUBLESHOOTING ITEMS
DESCRIPTION
1
Melts main or other fuse
2
Will not crank
Starter does not work.
—
3
Hard start/long crank/erratic start/erratic crank
Starter cranks engine at normal speed but engine requires excessive cranking. Battery is in normal condition.
4
Engine stalls
Engine stops unexpectedly at idle and/or after start.
5
Cranks normally but will not start
Starter cranks engine at normal speed but engine will not run. Refer to “ENGINE STALLS” if this symptom appears after engine stall. Fuel is in tank Battery is in normal condition.
6
Slow return to idle/fast idle
Engine takes more time than normal to return to idle speed. Engine speed continues at fast idle after warm-up.
7
Engine runs rough/rolling idle
Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. Idle speed is too slow and engine shakes excessively.
8
Runs on
Engine runs after engine switch is turned off.
9
Engine stalls/quits
Acceleration/cruise
Engine stops unexpectedly at beginning of acceleration during acceleration or while cruising.
Engine runs rough
Acceleration/cruise
Engine speed fluctuates during acceleration or cruising.
Misses
Acceleration/cruise
Engine misses during acceleration or cruising.
Buck/jerk
Acceleration/cruise/ deceleration
Vehicle bucks/jerks during acceleration, cruising, or deceleration.
Hesitation/stumble
Acceleration
Momentary pause at beginning of acceleration or during acceleration.
After start At idle
Surges
Acceleration/cruise
Momentary minor irregularity in engine output.
10
Lack/loss of power
Acceleration/cruise
Performance is poor under load (i.e. power down when climbing hills).
11
Poor fuel economy
Fuel economy is unsatisfactory.
12
High oil consumption/leaks
Oil consumption is excessive.
13
Cooling system concerns
Overheating
Engine runs at higher than normal temperature/overheats.
14
Cooling system concerns
Runs cold
Engine does not reach normal operating temperature.
15
Excessive black smoke
Excessive black smoke is observed in exhaust gas.
16
Engine noise
Engine noise from under hood.
17
Vibration concerns (engine)
Vibration from under hood or driveline.
18
A/C does not work.
A/C compressor magnetic clutch does not engage when A/C is turned on.
19
A/C always on/A/C compressor runs continuously.
A/C compressor magnetic clutch does not disengage.
20
Intermittent concerns
Symptom occurs randomly and is difficult to diagnose.
CONTINUED
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SYMPTOM TROUBLESHOOTING: Symptom 1-Melts main or other fuse
F2-40
Symptom 2-Will not crank
F2-41
Symptom 3-Hard start/long crank/erratic start/erratic crank
F2-42-43
Symptom 4-Engine stalls-after start/at idle
F2-43-44
Symptom 5-Cranks normally but will not start
F2-45-46
Symptom 6-Slow return to idle/fast idle
F2-46
Symptom 7-Engine runs rough/rolling idle
F2-47-48
Symptom 8-Runs on
F2-49
Symptom 9-Engie stalls/quits-acceleration/cruise -
Engine runs rough – acceleration/cruise
-
Misses-acceleration/cruise
-
Buck/jerk – acceleration/cruise/deceleration
-
Hesitation/stumble – acceleration
-
Surges – acceleration/cruise
F2-49-50
Symptom 10-Lack/loss of power-acceleration/cruise
F2-51-52
Symptom 11-Poor fuel economy
F2-53
Symptom 12-High oil consumption/leaks
F2-54
Symptom 13-Cooling system concerns-overheating
F2-55
Symptom 14-Cooling system concerns-runs cold
F2-55
Symptom 15-Excessive black smoke
F2-56
Symptom 16-Engine noise
F2-56-58
Symptom 17-Vibration concerns (engine)
F2-58
Symptom 18-A/C does not work
F2-58-59
Symptom 19-A/C is always on/a/c compressor runs continuously
F2-59-60
Symptom 20-Intermittent concerns
F2-60
CONTINUED
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TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1
MELTS MAIN OR OTHER FUSE
TROUBLESHOOTING HINTS Inspect the condition of the fuse.
Deterioration
Shorted harness
Repair shorted harness and replace fuse
fuse
Damaged Fuse
Replace fuse
Related Wiring Harness
MAIN (100 A)
Main fuse Engine switch Generator PCM Blower relay Blower fan motor A/C relay Refrigerant pressure switch
HEAD (30 A)
HEAD fuse Generator Glow plug relay Glow plugs
GLOW (60 A) ENGINE (15 A)
Engine fuse PCM FICD solenoid valve No.1 FICD solenoid valve No.2 FCV
CONTINUED
F2–40
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TROUBLESHOOTING
SYMPTOM 2 DESCRIPTION
WILL NOT CRANK Starter does not work. Open starter circuit between battery and starter through engine switch Starter malfunction Seized/hydrolocked engine, flywheel
POSSIBLE CAUSE STEP 1
INSPECTION
ACTION
RESULTS
Verify the following: Battery condition Battery connection Fuses Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
2
Turn engine switch to START. Is clicking sound heard from starter?
Yes
Go to next step.
No
Go to Step 6.
3
Do any other electrical accessories work?
Yes
Go to next step.
No
Inspect the charging system. + Section G, CHARGING SYSTEM
Disconnect battery negative cable. Disconnect engine switch and starter connectors. Inspect for electrical connections, loose wire, bent or corroded terminals. Inspect Ins ect for continuity on following circuits: Engine switch connector terminal STA and starter terminal S Battery positive cable and starter magnet switch terminal B. Are all circuits okay?
Yes
Go to next step.
No
Repair or replace open circuit.
Inspect engine switch. + Section T, POWER SYSTEM, IGNITION SWITCH INSPECTION. Is engine switch okay?
Yes
Go to next step.
No
Replace engine switch.
Inspect starting system. Is starting system okay?
Yes
Inspect for seized/hydrolocked engine, flywheel. + Section H, CLUTCH, FLYWHEEL INSPECTION
No
Service as required. + Section G, STARTING SYSTEM, STARTER INSPECTION
4
5
6
CONTINUED
F2–41
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TROUBLESHOOTING
SYMPTOM 3 DESCRIPTION
HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK Starter cranks engine at normal speed but engine requires excessive cranking. Battery is in normal condition.
POSSIBLE CAUSE
STEP 1
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating Glow system malfunction
INSPECTION
Fuel leakage Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Fuel line clogging ACTION
RESULTS
Verify the following: Fuel quality including water contamination Loose bands on intake-air system y Cracks on intake-air system parts Air cleaner element restriction Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
2
Is engine overheating?
Yes
Go to flowchart No.13 for “COOLING SYSTEM CONCERNS OVERHEATING”.
No
Go to next step.
3
Does engine start normally after warm-up?
Yes
Inspect glow system operation. + SYSTEM INSPECTION, Glow System Inspection Replace any defective parts as necessary. If quick start system is okay, go to next step.
No
Go to next step.
Yes
Go to next step.
No
Adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect for fuel leakage from fuel pipe. Is any fuel leakage found in fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
7
Measure engine compression. Is compression okay?
Yes
Go to Step 9.
No
Go to next step.
8
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat. Worn valve stem or valve guide. Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace the timing belt.
Yes
Go to next step.
No
Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
4
5 6
9
Is idle speed correct?
Is there any restriction in exhaust system?
Inspect injection timing. Is injection timing okay?
CONTINUED
F2–42
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TROUBLESHOOTING
STEP 10
INSPECTION Remove and inspect injection nozzle as follows: Clogged nozzle Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
SYMPTOM 4 DESCRIPTION POSSIBLE CAUSE
STEP 1
ACTION
RESULTS Yes
Remove FIP. Inspect FIP. If FIP okay, inspect fuel line for clogging.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
ENGINE STALLS – AFTER START/AT IDLE Engine stops unexpectedly at idle and/or after start.
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction
INSPECTION Note: The following test should be performed on vehicles with immobilizer system. Go to next step for vehicles without immobilizer system. system
Fuel leakage Fuel filter clogging Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction ACTION
RESULTS Yes
Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.
No
Go to next step.
Verify the following: Fuel quality including water contamination Loose bands on intake-air system y Cracks on intake-air system parts Air cleaner element restriction Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 2.
3
Is engine overheating?
Yes
Go to flowchart No.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”.
No
Go to next step.
4
Does engine run normally after warm-up?
Yes
Go to next step.
No
Go to Step 6
5
Inspect glow system operation, + SYSTEM INSPECTION, Glow System Inspection. Is quick start system operation normal?
Yes
Go to next step.
No
Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C always ON/A/C compressor runs continuously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
Does immobilizer indicator light flash and indicate? 2
6
Note: If the following test cannot be performed due to engine stalls, go to step. next ste Connect the pressure gauge to A/C lines. Turn the fan switch on. Is pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
CONTINUED
F2–43
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TROUBLESHOOTING
STEP 7
INSPECTION
ACTION
RESULTS
Inspect FICD system operation. + SYSTEM INSPECTION, FICD System Inspection Is FICD operation normal?
Yes
Go to next step.
No
Inspect the following: Engine coolant temperature sensor + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE SENSOR INSPECTION Vacuum pump Vacuum leakage around vacuum pump or fittings FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION FICD actuator PCM terminal voltage, J Open circuit between FICD solenoid No.1 connector terminal B and PCM connector terminal C Open circuit between FICD solenoid No.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. If FICD system is okay, go to next step.
Depress accelerator pedal slightly. Crank the engine.
Yes
Inspect and adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT If symptom still appears, go to next step.
Does engine start now?
No
Go to next step.
9
Inspect fuel leakage from fuel pipe. Is any fuel leakage found in fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
10
Measure engine compression. Is compression okay?
Yes
Go to Step 12.
No
Go to next step.
11
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve seat or valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt.
Inspect injection timing. Is injection timing okay?
Yes
Go to next step.
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Inspect fuel filter for clogging. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
Is valve clearance correct?
Yes
Remove FIP. Inspect FIP.
No
Adjust valve clearance.
8
12
13 14
15
CONTINUED
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TROUBLESHOOTING
SYMPTOM 5
POSSIBLE CAUSE
STEP 1
CRANKS NORMALLY BUT WILL NOT START
DESCRIPTION
Starter cranks engine at normal speed but engine will not run. Refer to “ENGINE STALLS” if this symptom appears after engine stall. Fuel is in tank. Battery is in normal condition. Poor fuel quality Fuel filter clogged Air cleaner restriction Incorrect injection timing FCV malfunction FIP malfunction Low engine compression Injection nozzle malfunction Fuel leakage
INSPECTION Note: The following test should be performed on vehicles with immobilizer system. Go to next step for vehicles without immobilizer system. system
ACTION
RESULTS Yes
Go to “ON-BOARD DIAGNOSTIC FUNCTION” of immobilizer system.
No
Go to next step.
Verify the following: Fuel quality including water contamination Loose bands on intake-air system Cracks on intake-air system parts Air cleaner element restriction Fuses Are all items okay?
Yes
Go to next step.
No
Service as necessary. Repeat Step 2.
3
Turn engine switch to ON. Is FCV operation sound heard?
Yes No
4
Measure engine compression. Is compression okay?
5
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes No Yes
Go to next step. Inspect for the following: Stuck FCV Open circuit in FCV Open wiring harness between engine switch and FCV. Poor ground of FCV. Go to step 6. Go to next step. Inspect for the following: Burnt valve Worn piston, piston ring or cylinder Damaged cylinder head gasket. Damaged valve seat Worn valve stem or valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt. Go to next step. Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Does immobilizer indicator light flash and indicate? 2
No
6
Inspect injection timing. Is injection timing okay?
Yes No
7
Inspect fuel filter for clogging. Is fuel filter okay?
8
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
Yes No Yes No
Go to next step. Replace fuel filter cartridge. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
CONTINUED
F2–45
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TROUBLESHOOTING
STEP 9
INSPECTION Is valve clearance correct?
RESULTS Yes No
SYMPTOM 6
Engine takes more time than normal to return to idle speed. Engine speed continues at fast idle after warm-up. Malfunction of ECT sensor Thermostat stuck open FICD malfunction
POSSIBLE CAUSE
1
2
3
Remove FIP. Inspect FIP. Adjust valve clearance.
SLOW RETURN TO IDLE/FAST IDLE
DESCRIPTION
STEP
ACTION
INSPECTION
Injection timing is incorrect. Accelerator cable free play incorrect adjustment Idle speed incorrect adjustment
ACTION
RESULTS
Inspect FICD system operation. + SYSTEM INSPECTION, FICD System Inspection. Is FICD operation normal?
Yes
Go to next step.
No
Inspect the following: ECT sensor + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION FICD actuators. PCM terminal voltage (J) + CONTROL SYSTEM, PCM INSPECTION Short to ground circuit between FICD solenoid valve No.1 connector terminal B and PCM connector terminal C. Short to ground circuit between FICD solenoid valve No.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. If FICD system is okay, go to next step.
Inspect injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT. Is injection timing okay?
Yes
Go to next step.
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Remove thermostat and inspect operation. + section E, THERMOSTAT, THERMOSTAT INSPECTION.
Yes
Inspect for free play of accelerator cable. Adjust free play as necessary. If free play is okay, inspect and adjust idle and/or idleup speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
No
Replace thermostat.
Is thermostat okay?
CONTINUED
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TROUBLESHOOTING
SYMPTOM 7 DESCRIPTION
POSSIBLE CAUSE
STEP 1
2
3 4
ENGINE RUNS ROUGH/ROLLING IDLE Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. Idle speed is too slow and engine shakes excessively.
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction
INSPECTION
ACTION
Verify the following: Fuel quality including water contamination Air cleaner element restriction
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
Is engine overheating?
Yes
Go to flowchart No.13 for “COOLING SYSTEM CONCERNS-OVERHEATING”.
No
Go to next step.
Yes
Go to next step.
No
Go to Step 5.
Yes
Go to Step 6.
No
Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C always ON/ A/C compressor runs continuously”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
Yes
Go to next step.
No
Inspect the following: Engine coolant temperature sensor + CONTROL SYSTEM, ECT SENSOR INSPECTION Vacuum pump Vacuum leaks around vacuum pump or fittings FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION Inspection FICD actuators PCM terminal voltage (J) + CONTROL SYSTEM, PCM INSPECTION Open circuit between FICD solenoid valve No.1 connector terminal B and PCM connector terminal C. Open circuit between FICD solenoid valve No.2 connector terminal B and PCM connector terminal P. Repair or replace any defective part as necessary. If FICD system is okay, go to next step.
Does engine run normally after warm-up? Inspect glow system operation. + SYSTEM INSPECTION INSPECTION, Glow System Inspection.
Note: If the following test cannot be performed due to engine stalls, go to step. next ste Connect the pressure gauge to A/C (if equipped) lines. Turn the blower switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
6
Fuel leakage Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction
RESULTS
Is glow system operation normal? 5
Inspect for FICD system operation. + SYSTEM INSPECTION, FICD System Inspection Is FICD operation normal?
CONTINUED
F2–47
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TROUBLESHOOTING
STEP 7
8 9
INSPECTION
ACTION
RESULTS
Depress accelerator pedal slightly. Crank the engine.
Yes
Inspect and adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT. If symptom still appears, go to next step.
Does engine start now?
No
Go to next step.
Inspect fuel leakage from fuel pipe. Is any fuel leakage found on fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
Yes
Go to next step.
No
Repair or replace as necessary.
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
10
Measure engine compression. Is compression okay?
Yes
Go to Step12.
No
Go to next step.
11
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect follows: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem or valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace timing belt.
Inspect injection timing. Is injection timing okay?
Yes
Go to next step.
No
Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
13
Inspect fuel filter for clogging. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
14
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the fuel injection nozzle. Incorrect valve opening pressure: Adjust fuel injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
Is valve clearance correct?
Yes
Remove fuel injection pump. Inspect fuel injection pump.
No
Adjust valve clearance.
12
15
CONTINUED
F2–48
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TROUBLESHOOTING
SYMPTOM 8
RUNS ON
DESCRIPTION
Engine runs after engine switch is turned off. FCV malfunction
POSSIBLE CAUSE STEP 1
INSPECTION Run the engine at idle speed. Disconnect the FCV connector. Verify that the engine stops. Does the engine stop?
POSSIBLE CAUSE
2
3 4
5
6
Inspect for the following: Short to power line between engine switch and FCV. Repair or replace wire harness.
No
Inspect for FCV stuck to open.
Engine stops unexpectedly at beginning of acceleration, during acceleration or while cruis-
DESCRIPTION
1
Yes
ENGINE STALLS/QUITS-ACCELERATION/CRUISE ENGINE RUNS ROUGH-ACCELERATION/CRUISE MISSES-ACCELERATION/ CRUISE BUCK/JERK-ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE-ACCELERATION SURGES-ACCELERATION/CRUISE
SYMPTOM 9
STEP
ACTION
RESULTS
ing. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output.
Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Fuel leakage
INSPECTION Is idle speed stable?
Glow system malfunction Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression Clutch slippage ACTION
RESULTS Yes
Go to next step.
No
Go to flowchart No.7 “ENGINE RUNS ROUGH/ROLLING IDLE”.
Yes
Go to flowchart No.13 “COOLING SYSTEM CONCERNS OVERHEATING”.
No
Go to next step.
Yes
Go to next step.
No
Go to Step 5.
Inspect for glow system operation. + SYSTEM INSPECTION, Glow System Inspection. Is glow system operation normal?
Yes
Go to next step.
No
Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection
Connect the pressure gauge to A/C lines. Turn the blower switch on. Is the pressure within specifications? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”. For other symptoms, inspect following: Refrigerant charging amount. Cooling fan operation.
Inspect air cleaner for clogging. Is air cleaner okay?
Yes
Go to next step.
No
Clean or replace air cleaner element.
Is engine overheating?
Does symptom disappear after warm-up?
CONTINUED
F2–49
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TROUBLESHOOTING
STEP 7
INSPECTION Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 9.
ACTION
RESULTS Yes
Retighten the hose band. If the concern is resolved, complete the inspection. If the concern still exists, go to next step.
No
Go to next step.
Inspect for improper operation, kinks, clogs, or disconnection on the wastegate actuator. + INTAKE-AIR SYSTEM, WASTEGATE ACTUATOR INSPECTION. Is actuator okay?
Yes
Turbocharger is okay. Go to next step.
No
Repair or replace as necessary. If the concern is resolved, complete the inspection. If the concern still exists, the turbocharger is okay. Go to next step.
Remove injection nozzle. Inspect injection nozzle for the following Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket. Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
Is there any restriction in exhaust system?
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect for fuel leakage from pipe. Is any fuel leakage found in fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect fuel filter for clogs. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
13
Measure engine compression. Is compression okay?
Yes
Go to Step 15.
No
Go to next step.
14
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace timing belt.
Yes
Inspect follows: Clutch slippage FIP
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Inspect the hose band between the following parts: T b h i and d air i Turbocharger compressor h housing cleaner Turbocharger compressor housing and charge air cooler. Is the hose band loose? 8
9
10 11 12
15
Inspect injection timing. Is injection timing okay?
CONTINUED
F2–50
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TROUBLESHOOTING
SYMPTOM 10
LACK/LOSS OF POWER-ACCELERATION/CRUISE
DESCRIPTION
Performance is poor under load (i.e. power down when climbing hills).
POSSIBLE CAUSE
STEP 1
Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Clutch slippage Fuel leakage
INSPECTION Is idle speed stable?
Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Turbocharger malfunction Brake system drags EGR system malfunction (WL Turbo) ACTION
RESULTS Yes
Go to next step.
No
Go to flowchart No.7 “ENGINE RUNS ROUGH/ROLLING IDLE”.
2
Is engine overheating?
Yes
Go to flowchart No. 13 “COOLING CONCERNS OVERHEATING”.
No
Go to next step.
3
Connect the pressure gauge to A/C lines. Turn the fan switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”. For other symptoms, inspect the following: Refrigerant charging amount. Cooling fan operation.
Inspect air cleaner for clogging. Is air cleaner okay?
Yes
Go to next step.
No
Clean or replace air cleaner element.
Yes
Retighten the hose band. If the concern is resolved, complete the inspection. If the concern still exists, go to next step.
No
Go to next step.
Inspect the wastegate actuator for improper operation, kinks, clogs, or disconnection. + INTAKE-AIR SYSTEM, WASTEGATE ACTUATOR INSPECTION. Is actuator okay?
Yes
Go to next step.
No
Repair or replace as necessary. If the concern is resolved, complete the inspection. If the concern still exists, the turbocharger is okay. Go to next step.
Remove the parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger primary compressor wheel is bent,, damaged, g , or interfering g with the housing on the vehicle. + INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Turn the turbocharger compressor wheel by hand hand. Does the wheel turn easily and smoothly?
Yes
Go to next step.
No
Replace the turbocharger.
4 5
Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 13. Inspect the hose band between the following parts: Turbocharger T b h compressor h housing i and d air i cleaner Turbocharger compressor housing and charge air cooler. Is the hose band loose?
6
7
8
9
CONTINUED
F2–51
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TROUBLESHOOTING
STEP 10
INSPECTION Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicles. Note: Inspect all fins on each turbine wheel.
ACTION
RESULTS Yes
Replace the turbocharger.
No
Go to next step.
Is there any problem? 11
Is any engine oil found inside the turbocharger turbine housing?
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step.
No
Go to next step.
12
Is any engine oil found inside the turbocharger compressor housing?
Yes
Wipe the oil off the vehicle and install all removed parts in Step 7. Then, go to next step.
No
The turbocharger is okay. Install all removed parts in Step 7. Then, go to next step.
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket. Is injection nozzle okay?
Yes
Go to next step.
No
Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
14
Is there any restriction in exhaust system?
Yes
Repair or replace as necessary.
No
Go to next step.
15
Inspect fuel leakage from pipe. Is any fuel leakage found on fuel pipe?
Yes
Repair or replace as necessary.
No
Go to next step.
Inspect fuel filter for clogging. Is fuel filter okay?
Yes
Go to next step.
No
Replace fuel filter cartridge.
Yes
Go to next step.
Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
No
Repair or replace as necessary.
Measure engine compression. Is compression okay?
Yes
Go to Step 20.
No
Go to next step.
Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
Yes
Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide Repair or replace as necessary.
No
If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt.
Yes
Inspect follows: Brake system dragging Clutch slippage FIP
No
Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
13
16 17
18 19
20
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system.
Inspect injection timing. Is injection timing okay?
F2–52
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TROUBLESHOOTING
SYMPTOM 11 DESCRIPTION POSSIBLE CAUSE
STEP 1
2
POOR FUEL ECONOMY Fuel economy is unsatisfactory. Idle speed or idle-up speed incorrect adjustment Accelerator cable free play incorrect adjustment Air cleaner restriction Engine cooling system malfunction Improper transmission fluid level Poor fuel quality Improper coolant level Improper engine compression INSPECTION
Inspect the following: Fuel quality including water contamination Air cleaner element for restriction Transmission fluid level Coolant level Are all items okay? Inspect for idle speed and idle-up speed. + ENGINE TUNE-UP, TUNE-UP IDLE-UP SPEED ADJUSTMENT. Is idle-up speed within specifications?
3
Inspect fuel leakage from pipe. Is any ffuel leakage ffound in ffuel pipe? ?
4
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure. Faulty nozzle gasket. Is injection nozzle okay?
5
Is there restriction in exhaust system?
6
Is brake system functioning properly?
7
8 9
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay? Measure engine compression. Is compression okay? ? Inspect timing belt for the following: Chipping of gear teeth Low tension Breakage, damage, or cracks Is timing belt okay?
RESULTS Yes
Inspect injection timing. Is injection timing okay?
Exhaust system clogged Injection timing incorrect Injection nozzle malfunction FIP malfunction High idle speed High idle-up speed FICD malfunction Fuel leakage Brake dragging EGR system malfunction (WL Turbo) ACTION
Go to next step.
No
Service as necessary and repeat Step 1.
Yes
Go to next step.
No
Go to flowchart No.6 “SLOW RETURN TO IDLE/FAST IDLE”.
Yes No Yes No
Yes No Yes No Yes
Repair or replace as necessary. Go to next step. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Inspect exhaust system. Go to next step. Go to next step. Inspect for cause. Go to next step.
No
Repair or replace as necessary.
Yes No Yes
Go to Step 10. Go to next step. Inspect for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder head gasket Damaged valve seat Worn valve stem and valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing belt . If timing belt is broken, damaged or cracked, replace timing belt.
No
10
Yes
Inspect for the following: FIP
No
Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
F2–53
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TROUBLESHOOTING
SYMPTOM 12
HIGH OIL CONSUMPTION/LEAKS
DESCRIPTION
Oil consumption is excessive. Improper engine oil level Improper dipstick Improper engine oil viscosity
POSSIBLE CAUSE STEP 1
2
INSPECTION Inspect the following: Proper dipstick Pro Proper er engine viscosity Engine oil level Are all items okay?
4
5
ACTION
RESULTS Yes
Go to next step.
No
Service as necessary and repeat Step 1.
Yes
Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Turn the turbocharger compressor wheel by hand hand. Does the wheel turn easily and smoothly?
Yes
Go to next step.
No
Replace the turbocharger.
Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicles.
Yes
Replace the turbocharger.
No
Go to next step.
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step.
No
Go to next step.
Is any engine oil found inside the turbocharger compressor housing?
Yes
Wipe the oil off the vehicle. Then, go to next step.
No
Go to next step.
Is any engine oil found around oil pipes attached on the turbocharger center housing?
Yes
If the oil leaked from the damaged pipe, replace the oil pipe. Then, go to next step.
No
Go to next step.
Is any engine oil found inside the air intake pipes or Hoses?
Yes
Wipe the engine oil off.
No
The turbocharger is okay. Install all parts removed in step 2. Then, go to next step.
Measure engine compression. Is compression okay?
Yes
Inspect oil leakage from outside of engine.
No
Inspect for the following: Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder. Service as necessary.
Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 10. Remove the parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger primary compressor wheel is bent, damaged, or interfering with the housing on the vehicle. + INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION Is there any problem?
3
Engine internal part malfunction Oil leak Turbocharger malfunction
Note: Inspect all fins on each turbine wheel. Is there any problem? 6
7 8
9
10
Is any engine oil found inside the turbocharger turbine housing?
F2–54
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TROUBLESHOOTING
SYMPTOM 13
COOLING SYSTEM CONCERNS—OVERHEATING
DESCRIPTION
Engine runs at higher than normal temperature/overheats.
POSSIBLE CAUSE
STEP 1
2
3
Water temperature gauge or sender unit malfunc-
Cooling fan malfunction Low drive belt tension Drive belt damage Improper coolant level Thermostat malfunction Radiator clogging A/C system malfunction
INSPECTION
tion Improper or damaged radiator cap Radiator hose damage Coolant leakage (engine internal, turbocharger, ex-
ternal) ACTION
RESULTS
Inspect the following: Engine coolant level Coolant leakage Radiator condition Collapsed or restricted radiator hoses Radiator pressure cap Drive belt tension Drive belt Are all items okay?
Yes
Go to next step.
No
Service as necessary and repeat Step 1.
Connect the pressure gauge to A/C lines. Turn the blower switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY”. For other symptoms, inspect the following: Refrigerant charging amount Cooling fan operation
Inspect water temperature sender unit. Is water temperature sender unit okay?
Yes
Inspect thermostat. + section E, THERMOSTAT, THERMOSTAT INSPECTION
No
Replace water temperature sender unit.
SYMPTOM 14
COOLING SYSTEM CONCERNS—RUNS COLD
DESCRIPTION
Engine does not reach normal operating temperature.
POSSIBLE CAUSE STEP 1
Thermostat malfunction
INSPECTION Remove the thermostat from vehicle. Inspect thermostat. + section E, THERMOSTAT, THERMOSTAT INSPECTION INSPECTION. Is thermostat okay?
RESULTS
ACTION
Yes
Inspect water temperature sender unit operation. + section T, INSTRUMENT CLUSTER, WATER TEMPERATURE SENDER UNIT INSPECTION
No
Replace thermostat.
CONTINUED
F2–55
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TROUBLESHOOTING
SYMPTOM 15
EXCESSIVE BLACK SMOKE
DESCRIPTION
Excessive black smoke is observed in exhaust gas.
POSSIBLE CAUSE STEP
Air cleaner element restriction Incorrect fuel injection timing Injection nozzle malfunction
INSPECTION
1
Does any other symptom exist?
2
Inspect air cleaner element for clogging. Is air cleaner element okay?
3
Inspect injection timing. Is injection timing okay?
4
Remove injection nozzle. Inspect injection nozzle for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Is injection nozzle okay?
5
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
6
Measure engine compression. Is compression okay?
RESULTS Yes No Yes No Yes No
Yes
No
Repair or replace as necessary.
Yes No
Inspect fuel injection pump. Inspect for the following: Damaged valve seat. Worn valve stem and valve guide. Worn or stuck piston ring. Worn piston, piston ring, or cylinder. Service as necessary.
Yes No
ENGINE NOISE
DESCRIPTION
Engine noise from under hood.
ACTION Go to appropriate flow chart. Go to next step. Go to next step. Repair or replace air cleaner element. Go to next step. Inspect TCV (if equipped). + FUEL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Go to next step.
SYMPTOM 16 POSSIBLE CAUSE
FIP malfunction Low engine compression EGR system malfunction (WL Turbo)
Engine internal damage Timing belt displacement Injection nozzle malfunction Loose attaching bolts or worn parts
Improper drive belt tension Air leaks from intake-air system Turbocharger operating noise EGR system malfunction (WL Turbo)
CONTINUED
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TROUBLESHOOTING
STEP 1
INSPECTION Note: The following test should be performed on turbocharger equipped model. For other models, go to Step 9. Remove the necessary parts arts to inspect ins ect the turbocharger. Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with the housing on the vehicle. Is there any problem?
2
3
4
5
ACTION Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Turn the turbocharger compressor wheel by hand hand. Does wheel turn easily and smoothly?
Yes
Go to next step.
No
Replace the turbocharger.
Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicle. Is there any problem?
Yes
Replace the turbocharger.
No
Go to next step.
Is any engine oil found inside the turbocharger turbine housing?
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step. Go to next step. Wipe the oil off of the vehicle. Then, go to next step. Go to next step. Remove turbocharger. Inspect for cracks on center housing inlet surface. If cracks are found, replace turbocharger. If no cracks are found, DO NOT replace turbocharger. Replace gaskets, bolts, and nuts only. Then, go to next step. Go to next step. Retighten the loose bolts. If any bolt is missing, attach the appropriate new bolt. Turbocharger is okay. Install all removed parts in Step1. Go to next step. Inspect engine oil level or drive belt. Go to next step. Inspect drive belt. Go to next step. Inspect location of rattle for loose parts. Go to next step. Inspect for the following: Vacuum leaks Intake-air system leaks
6
Is any engine oil found inside the turbocharger compressor housing?
7
Is any exhaust gas leakage found around the location where the turbocharger is attached to the exhaust manifold?
8
RESULTS Yes
Are any of the attaching bolts of center housing and turbine housing loose?
No Yes No Yes
No Yes No
9
Is squeal, click, or chirp sound present?
10
Is rumble or grind sound present?
11
Is rattle sound present?
12
Is hiss sound present?
13
Is rap or roar sound present?
Yes No Yes No Yes No Yes
No Yes No
Go to next step. Inspect exhaust system for loose parts. Go to next step.
CONTINUED
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TROUBLESHOOTING
STEP
INSPECTION
RESULTS Yes No
ACTION
14
Inspect the injection timing. Is injection timing okay?
15
Note: The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
Yes
Go to next step. Inspect TCV (if equipped) + FUEL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step.
No
Repair or replace as necessary.
Remove the fuel injection nozzle. Inspect for the following: Clogged nozzle. Seized needle valve Incorrect valve opening pressure Faulty nozzle gasket Fuel dripping (fuel leakage) Is injection nozzle okay?
Yes
Inspect for the following: Metal flow Bent connecting rod Damaged valve seat After-leakege, clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
16
SYMPTOM 17
VIBRATION COCNERNS (ENGINE)
DESCRIPTION
Vibration from under hood or driveline.
POSSIBLE CAUSE STEP 1
No
Loose attaching bolts or worn parts Components malfunctions such as worn parts
INSPECTION Inspect the following components for loose attaching bolts or worn parts: Cooling fan Drive belt and pulley Engine mounts Exhaust system Are all items okay?
ACTION
RESULTS Yes
Inspect the following: Wheels Transmission and mounts Driveline Suspension Service as necessary.
No
Readjust or retighten engine mount installation position. Service as necessary for other parts.
SYMPTOM 18
A/C DOES NOT WORK.
DESCRIPTION
A/C compressor magnetic clutch does not engage when A/C is turned on.
POSSIBLE CAUSE
Improper refrigerant charging
amount Microswitch is stuck open. Open A/C magnetic clutch Open circuit in related wire harnesses Poor ground of A/C magnetic clutch A/C low/high pressure switch is stuck open.
A/C relay is stuck open. Seized A/C compressor Frost switch is stuck open. Open circuit in blower resistor Poor blower switch ground ECT sensor malfunction Improper magnet clutch clearance
CONTINUED
F2–58
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TROUBLESHOOTING
STEP
INSPECTION
RESULTS
1
Turn engine switch on. Set the fan switch to 1st, 2nd, 3rd, or 4th position. Verify the blower motor is operating. Is blower motor okay?
Yes
Go to next step.
No
Inspect for the following: Poor ground of fan switch Open circuit in blower resistor Poor contact of fan switch Blower relay is stuck open. Open circuit in blower relay coil Seized blower motor Open circuit in blower motor coil. Open circuit between blower motor and resistor Open circuit between fan switch and resistor Repair or replace as necessary.
Turn the engine switch on. Set the fan switch to 1st, 2nd, 3rd, or 4th position. Measure the voltage at PCM connector terminal G. + CONTROL SYSTEM, PCM INSPECTION Specification: Less than 2.7 V Is voltage correct?
Yes
Go to next step.
No
Inspect for the following: Frost switch is stuck open. Poor contact of microswitch in heater control unit Open circuit between PCM connector terminal G and frost switch connector terminal. Open circuit between frost switch connector terminal and fan switch connector terminal. Repair or replace as necessary.
Start the engine and run it at idle speed. Set the fan switch to 1st position. Measure the voltage at terminal of A/C relay connector terminal C. Specification: More than 10.5 V Is voltage correct?
Yes
Go to next step.
No
Inspect for the following: Open circuit in A/C relay coil Poor contact in A/C relay A/C relay stuck open Open circuit between PCM connector terminal L and A/C relay connector terminal. Open circuit in battery supply line Open circuit between engine switch and A/C relay connector terminal Engine coolant temperature sensor malfunction Repair or replace as necessary.
Disconnect the A/C magnetic clutch connector, Measure the A/C magnetic clutch connector terminal voltage. Specification: More than 10.5 V Is voltage okay?
Yes
Inspect for the following: Poor ground of A/C magnetic is clutch Open circuit in magnet is clutch coil Refrigerant charging amount Repair or replace as necessary.
No
Inspect for the following: Open circuit between pressure switch connector terminal and A/C magnetic clutch connector terminal Refrigerant charging amount A/C pressure switch is stuck open. Magnetic clutch clearance A/C compressor is seized. Repair or replace as necessary.
2
3
4
ACTION
SYMPTOM 19
A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY.
DESCRIPTION
A/C compressor magnetic clutch does not disengage.
POSSIBLE CAUSE
Improper magnetic clutch clear-
Short to power line between A/C relay and pressure
ance Short to ground circuit between PCM and frost switch Short to ground circuit between PCM and A/C relay
A/C low/high pressure switch is stuck to close. A/C relay is stuck to close. Frost switch is stuck to close.
switch
CONTINUED
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TROUBLESHOOTING
STEP
INSPECTION
RESULTS
1
Turn the engine switch on. Turn the blower switch off. Measure the voltage at PCM connector terminal G. Specification: More than 2.7 V Is voltage correct?
Yes
Go to next step.
No
Inspect for the following: Short to ground circuit between PCM connector terminal G and frost switch Short to ground circuit between frost switch and blower switch connector terminal Repair or replace as necessary.
Start the engine and run it at idle speed. Turn the blower switch off. Measure the voltage at terminal of A/C relay connector terminal C. Specification: 0V Is voltage correct?
Yes
Inspect for magnetic is clutch clearance. Adjust it as necessary.
No
Inspect for the following: Short to ground circuit between PCM connector terminal L and A/C relay terminal C A/C relay is stuck to close. Short to power line between A/C relay connector terminal C and A/C pressure switch Short to power line between pressure switch and A/C compressor magnetic is clutch connector Repair or replace as necessary.
2
SYMPTOM 20
INTERMITTENT CONCERNS
DESCRIPTION
Symptom occurs randomly and is difficult to diagnose.
STEP 1
2
3
4
ACTION
INSPECTION
ACTION
RESULTS
Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous revious repairs and components replaced for a certain symptom?
Yes
Go to next step.
No
Go to symptom index.
Key off. If input is switch-type component, turn on manually. Turn engine switch off. Connect the voltmeter to the PCM terminals. Lightly ta tap on sus suspect ect com component onent, wiggle and pull each wire/connector at suspect component or PCM. Is any voltage out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal clamps.
No
Go to next step.
Start the engine and run it at idle speed. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM PCM. Are any voltages out of range, or do they suddenly change and go back into range?
Yes
Inspect each wire for corrosion, bent or loose terminal clamps.
No
Go to next step.
Accurately spray water on suspect component wire, component, or vacuum line related to possible fault area. Is any voltage out of range, or suddenly change and go back into range, or was there a noticeable engine stumble?
Yes
Fault area is identified. If fault occurred while spraying on component: Replace part and verify repair. If fault occurred while spraying water: Inspect each wire for corrosion, bent, loose terminals, or poor wire terminal clamps. If fault occurred while spraying vacuum line: Repair vacuum hoses.
No
Inspect wire and connector at suspect component for corrosion, bent, loose terminals, or poor wire terminal crimps and high tension wire. Repair as necessary.
CONTINUED
F2–60
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TROUBLESHOOTING SYSTEM INSPECTION FICD System Inspection Fast-Idle Function 1. Verify that the FICD actuator rod is not pulled. 2. Verify that the engine is cold (ECT is below 20 °C {68 °F}). 3. Turn fan switch off. 4. Start the engine. 5. Verify that the FICD actuator rod is pulled.
11. If not, disconnect vacuum hose A from the FICD actuator and inspect if there is vacuum. VACUUM HOSE A
6. If not, disconnect the vacuum hoses from the FICD actuator and inspect if there is vacuum as shown. FICD ACTUATOR
Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction.
Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 7. If there is vacuum, consult your distributor for replacement of the FICD actuator. 8. If there is no vacuum, inspect the following. FICD solenoid valve No.1 and No.2 Loose or damaged vacuum hoses between FICD actuator, FICD solenoid valve No.1 and No.2, and vacuum pump. PCM terminal C, E and P voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wiring harness between FICD solenoid valve No.1 and PCM terminal C. Wiring harness between FICD solenoid valve No.2 and PCM terminal P. 9. Warm up the engine. (ECT above 20 °C {68 °F}). 10. Verify that the FICD actuator rod returns for one notch.
12. If there is no vacuum, consult your distributor for replacement of the FICD actuator. 13. If there is vacuum, inspect the following. FICD solenoid valve No.1 PCM terminal C, E voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wire harness between FICD solenoid valve No.1 and PCM terminal C 14. Warm up the engine (ECT is above 60 °C {140 °F}). 15. Verify that the FICD actuator rod returns completely.
16. If not, disconnect vacuum hose B from the FICD actuator and inspect if there is vacuum.
CONTINUED
F2–61
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TROUBLESHOOTING 7. If there is no vacuum, inspect the following: FICD solenoid valve No.2 PCM terminal G and P voltages
VACUUM HOSE B
(Refer to CONTROL SYSTEM,POWERTRAIN CONTROL MODULE (PCM) INSPECTION) Wiring harness between FICD solenoid valve No.2 connector terminal B and PCM terminal P Turbocharger Boost Pressure 1. Disconnect the air hose between the intake pipe and the boost compensator. 2. Connect a pressure gauge (range of measurement is 93.3 kPa {700 mmHg, 27.6 inHg}). BOOST COMPENSATOR PRESSURE GAUGE
Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 17. If there is no vacuum, consult your distributor for replacement of the FICD actuator. 18. If there is vacuum, inspect the following. FICD solenoid valve No.2 PCM terminal E, G and P voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wiring harness between FICD solenoid valve No.2 and PCM terminal P. A/C Idle-up Function 1. Start the engine. 2. Warm up the engine to normal operating temperature and run it at idle speed. 3. Set the fan switch at 1st position. 4. Verify that the FICD rod is pulled for one notch. 5. If not, disconnect the vacuum hose B from the FICD actuator and inspect if there is vacuum as shown.
TO INTAKE PIPE
3. Warm up the engine. 4. With the accelerator at the wide open throttle, increase the engine speed to 4800—5000 rpm and verify that the boost pressure is within the specification. Specification 60.0—73.3 kPa {0.62—0.74 kgf/cm2, 8.82—10.52 psi} 5. If not as specified, inspect the exhaust system. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM INSPECTION.) 6. If the exhaust system is normal, inspect the wastegate actuator. (Refer to INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION, Wastegate Actuator Inspection.) 7. If the wastegate actuator is normal, inspect the turbocharger. (Refer to INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION.)
VACUUM HOSE B
TCV Control Inspection (Europe and UK) 1. Crank the engine and verify that the TCV operation sound is heard. WL Caution FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction.
TCV
6. If there is vacuum, consult your distributor for replacement of the FICD actuator.
CONTINUED
F2–62
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TROUBLESHOOTING WL Turbo
TCV
2. If no operation sound is heard, inspect the TCV (in the FIP). 3. If the TCV is normal, inspect the following: PCM terminal Q voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION) Wire harness between TCV and PCM terminal Q EGR System Inspection (if equipped) 1. Make sure that all hoses are securely connected in the proper position. 2. Disconnect the vacuum hose from the EGR valve. 3. Start the engine at cold condition. 4. Verify that there is no vacuum at vacuum hose. 5. If there is vacuum, inspect the following: EGR solenoid valve PCM terminal R voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wire harness between EGR solenoid valve and PCM terminal R 6. Warm up the engine to the normal operating temperature and run it at idle speed. 7. Verify that there is vacuum at vacuum hose. 8. If there is no vacuum, inspect the following: EGR solenoid valve PCM terminal R voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) Wire harness between EGR solenoid valve and PCM terminal R 9. Connect the vacuum pump to the EGR valve. 10. Apply the vacuum to the EGR valve and inspect if the engine speed becomes unstable or the engine stalls. 11. If the engine speed does not change, stop the engine and inspect the EGR valve.
F2–63
CONTINUED
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TROUBLESHOOTING Glow System Inspection STEP 1
2
3
4
5
6
INSPECTION
ACTION
RESULTS
Connect NGS tester to DTC. Turn engine switch on and retrieve DTC. Are any of the following DTCs displayed? 09 (ECT sensor) 12 (Control lever position sensor) 36 (Glow plug relay)
Yes
Go the appropriate DTC test. After repair is completed, go to next step.
No
Go to next step.
Turn engine switch on while engine is cold. Does glow indicator light illuminate for approx. 1—9 seconds.?
Yes
Go to next step.
No
Inspect the following according to indication condition of glow indicator light: 1. Will not go out Short circuit between glow indicator light and PCM connector terminal M Short circuit in instrument cluster print plate 2. Illuminates for approx. 1 second (same condition after engine is warmed up and cold) Extremely low resistance of engine coolant temperature sensor Short circuit between engine coolant temperature sensor and PCM connector terminal E 3. Will not illuminate Glow indicator light Open circuit between glow indicator light and PCM connector terminal M Open circuit in instrument cluster print plate 4. Illuminates for approx. 9 seconds (same condition after engine is warmed up and cold) Extremely high resistance of engine coolant temperature sensor Open circuit between engine coolant temperature sensor and PCM connector terminal E
Leave engine switch on while engine is cold. Does glow plug voltage indicate B+ for approx. 15 seconds.?
Yes
Go to next step.
No
Inspect for open or short circuit in harnesses and connectors between battery, glow plug relay, and glow plug. Inspect if glow plug relay is stuck open or closed. Inspect glow plug relay ground circuit. Inspect for open circuit between glow relay and PCM terminal O.
Does glow plug voltage indicate B+ while cranking engine?
Yes
Go to next step.
No
Inspect for open or short to ground circuit in harness and connectors between engine switch (starter) and PCM connector terminal D.
Is power supplied to the glow plug for maximum 10 minutes after engine started when engine is cold?
Yes
Go to next step.
No
Inspect for open or short circuit in harnesses and connectors between NE sensor and PCM connector terminal F.
Remove the glow plug wire from glow plugs. Measure resistance between glow plug and body ground. yg Is glow plug resistance approx. 1 Ω or less? + INTAKE-AIR SYSTEM, GLOW PLUG INSPECTION
Yes
Glow system is okay.
No
Replace glow plug.
CONTINUED
F2–64
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FUEL AND EMISSION CONTROL SYSTEMS (F2 CARB) ENGINE TUNE-UP .........................................................F4-2 ENGINE TUNE-UP PREPARATION ........................F4-2 IGNITION TIMING ADJUSTMENT ...........................F4-2 IDLE SPEED ADJUSTMENT ...................................F4-2 IDLE MIXTURE ADJUSTMENT ...............................F4-2/3 DASHPOT (D/P) ADJUSTMENT ..............................F4-3 THROTTLE POSITIONER (T/P) ADJUSTMENT ........................................................F4-3/4 A/C IDLE-UP ADJUSTMENT ...................................F4-4/5 INTAKE-AIR SYSTEM .................................................F4-6 VACUUM HOSE ROUTING DIAGRAM ...................F4-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION ..................................F4-7 AIR CLEANER ELEMENT INSPECTION ..........................................................F4-8 IDLE COMPENSATOR INSPECTION ....................F4-8 AIR THERMO VALVE INSPECTION ..........................................................F4-8 VACUUM CONTROL DIAPHRAGM INSPECTION ..........................................................F4-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ..................................F4-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT .............................. F4-9 FUEL SYSTEM ..............................................................F4-10 BEFORE REPAIR PROCEDURE.............................F4-10 AFTER REPAIR PROCEDURE ...............................F4-10 FUEL TANK REMOVAL/INSTALLATION ...............F4-11/13 NONRETURN VALVE INSPECTION ......................F4-13 FUEL PUMP UNIT REMOVAL/INSTALLATION...................................F4-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY ................................F4-13/14 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION ..................................F4-14 FUEL GAUGE SENDER UNIT INSPECTION ..........................................................F4-14 FUEL PUMP INSPECTION ......................................F4-14/15 FUEL LINE PRESSURE INSPECTION ..................F4-15 FUEL LINE FLOW AMOUNT INSPECTION ..........................................................F4-15/16 FAST IDLE SPEED ADJUSTMENT ........................F4-16 DASHPOT (D/P) INSPECTION ................................F4-16 FUEL PUMP RELAY INSPECTION ........................F4-16/17 SERVO DIAPHRAGM REMOVAL/INSTALLATION ..................................F4-17 CARBURETOR REMOVAL/INSTALLATION ..................................F4-17
CARBURETOR DISASSEMBLY/ASSEMBLY ............................... F4-18/21 CARBURETOR INSPECTION/ADJUSTMENT .............................. F4-21/24 HIGH-ALTITUDE COMPENSATOR INSPECTION ......................................................... F4-24 PTC HEATER INSPECTION ................................... F4-24 SLOW FUEL CUT SOLENOID VALVE INSPECTION ......................................................... F4-24 EXHAUST SYSTEM .................................................... F4-25 EXHAUST SYSTEM INSPECTION ........................ F4-25 EXHAUST SYSTEM REMOVAL/INSTALLATION ................................. F4-25 EMISSION SYSTEM .................................................... F4-26 N0.1 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26 N0.2 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26 WATER THERMO VALVE INSPECTION .............. F4-26 AIR VENT SOLENOID INSPECTION ...................... F4-26 CHECK VALVE (TWO-WAY) INSPECTION ......................................................... F4-26 CHARCOAL CANISTER INSPECTION ................. F4-26 ROLLOVER VALVE INSPECTION ......................... F4-26/27 WATER THERMO VALVE REMOVAL/INSTALLATION ................................. F4-27 PCV VALVE INSPECTION ...................................... F4-27 CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT ...................................... F4-27 FLANGE THERMOSWITCH INSPECTION ......................................................... F4-27 CONTROL SYSTEM .................................................... F4-28 COMPONENT LOCATION ...................................... F4-28 PCM REMOVAL/INSTALLATION ........................... F4-29 PCM INSPECTION .................................................... F4-29 PTC HEATER RELAY INSPECTION ..................... F4-30 THROTTLE POSITIONER T/P) SOLENOID VALVE INSPECTION ........................................... F4-30 WATER THERMOSWITCH (INTAKE MANIFOLD SIDE) INSPECTION ......................... F4-30/31 WATER THERMOSWITCH REMOVAL/INSTALLATION ................................. F4-31 TROUBLESHOOTING ................................................ F4-32 FOREWORD ............................................................. F4-32 TROUBLESHOOTING ITEM TABLE ...................... F4-32 QUICK DIAGNOSTIC CHART ................................. F4-33 SYMPTOM TROUBLESHOOTING ......................... F4-34/47
CONTINUED
F4-1
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ENGINE TUNE-UP ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION 1. Check the condition of the engine (plugs, leaks in hoses, etc.) 2. Make sure all accessories are OFF. 3. Connect a tacho dwell tacho tester to the engine. 4. Warm up the engine and run it for three minutes at 2,500—3,000 rpm in neutral. IGNITION TIMING ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION. 2. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it.
3.
While checking the ignition timing by using a timing light, adjust the crankshaft pulley alignment mark position (yellow paint) by turning the distributor as specified. Specification BTDC: 5°—7°(6°±1°)
IDLE MIXTURE ADJUSTMENT 1. Attach an exhaust gas analyzer and measure the CO concentration.
2. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 3. Verify that CO concentration in exhaust gas at the tail pipe during idling is as specified in the table below. For GULF General
CO concentration (%) 2.0—2.5 (2.0 ) 2.0—3.0 (2.5 ±0.5)
5.
If not within the specification, adjust the CO concentration by turning the MAS (mixture adjust screw). Remove the blind cap. (GULF)
6.
Remove the spring pin.
4.
Reconnect the proper vacuum hose to the port. IDLE SPEED ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION. 2. Verify that the idle speed is within the specification. 4.
3.
If not within the specification, adjust the idle speed by turning the TAS (throttle adjust screw)
CONTINUED F4-2
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ENGINE TUNE-UP DASHPOT (D/P) ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT" 2. Increase the engine speed to 2,500 rpm. 3. Pull the throttle lever until the rod and arm of the dashpot separate. 4. Slowly return the throttle lever from the position above, then verify that the engine speed is as specified when the arm contacts the rod. Specification 1,900—2,100 (2,000 ± 100) rpm 5. If not as specified, loosen the dashpot locknut and turn the dashpot body to adjust.
Reconfirm that the engine speed is within the specification. 8. If not within the specification, adjust the idle speed by turning the TAS (throttle adjust screw). Note GULF only • Run the engine at idle for 3—5 seconds, then fit a blind cap to the MAS (mixture adjust screw) of the vehicles for the following markets. 7.
•
6. After adjustment, tighten the locknut. Tightening torque 9.8—17.6 N.m {100—180 kgf.cm, 87—156 in.lbf} 7. Race the engine and again verify that the engine speed returns smoothly to idle speed. 8. If not, repeat the above procedure to adjust the idle speed or D/P inspect (Refer to FUEL SYSTEM, DASHPOT (D/P) INSPECTION) THROTTLE POSITIONER (T/P) ADJUSTMENT GULF only 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. 3. Disconnect the vacuum hose from the servo diaphragm.
Run the engine at idle for 3—5 seconds, then tap in the spring pin as shown.
4. Connect the intake manifold vacuum directly to the servo diaphragm, and verify that the engine speed is as specified. Specification 1,050—1,250 (1,150 ± 100) rpm
CONTINUED F4-3
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ENGINE TUNE-UP 5. If not within the specification, adjust the engine speed by the adjust screw.
6. After adjusting the engine speed, reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the engine speed is raced at 2,000 rpm or more. 7. If the servo diaphragm does not operate, inspect the T/P solenoid valve. 8. If the solenoid valve is okay, replace the servo diaphragm. A/C IDLE-UP ADJUSTMENT GULF only with, A/C 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from port A.
3. Connect the intake manifold vacuum directly to port A, and verify that the engine speed is as specified. Specification 1,400—1,600 (1,500 ± 100) rpm 4. If not within the specification, adjust the engine speed by the adjust screw.
6. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. 7. Disconnect the vacuum hose from port B.
8. Connect the intake manifold vacuum directly to port B, and verify that the engine speed is as specified. Specification 1,050—1,250 (1,150 ±100) rpm 9. If not within the specification, adjust the engine speed by the adjust locknut on the dual servo diaphragm head.
10. Reconnect the proper vacuum hose to port B. 11. After adjusting the engine speed reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated. 12. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve or T/P solenoid valve. 13. If the solenoid valve is okay, replace the dual servo diaphragm. Except GULF, with A/C 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from the servo diaphragm. 3. Connect the intake manifold vacuum directly to the servo diaphragm, and verify that the engine speed is as spec tied.
5. Reconnect the proper vacuum hose to port A.
CONTINUED F4-4
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ENGINE TUNE-UP
Specification 1,400—1,600 (1,500 ± 100) rpm 4. If not within the specification, adjust the engine speed by adjust screw.
5. Reconnect the proper vacuum hose to port. 6. After adjusting the engine speed reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated. 7. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve. 8. If the solenoid valve is okay, replace the servo diaphragm.
CONTINUED
F4-5
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INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM
1
Air cleaner
12 Distributor
2 3 4 5 6 7 8 9 10 11
Carburetor Vacuum control diaphragm Idle compensator Air thermos sensor FICB solenoid valve High-altitude compensator FICB diaphragm Charcoal canister No.1 purge control valve Water thermo valve
13 14 15 16 17 18 19 20 21 22
T/P solenoid valve Servo diaphragm A/C idle-up solenoid valve Dual servo diaphragm To intake manifold Fuel main line (to fuel tank) Fuel return line (to fuel tank) To charcoal canister or ventilation To carburetor To check valve (two-way)
CONTINUED
F4-6
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INTAKE-AIR SYSTEM INTAKE - AIR SYSTEM REMOVAL/INSTALLATION Warning • When the engine and intake-air system are hot, they can badly bum. Turn off the engine and wait until they are cool before removing the intake-air system. • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant from the radiator. (Refer to Section E.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 2
Air cleaner (in idle compensator, vacuum control diaphragm, shutter valve, air thermo sensor) Air cleaner element
8
Intake manifold
9
Water thermoswitch ☞ CONTROL SYSTEM, WATER THERMOSWITCH REMOVAL/INSTALLATION
3
Carburetor
4
Fuel hose
10
Intake manifold gasket
5
Accelerator cable
11
6 7
PTC heater gasket PTC heater
12
Water thermo valve ☞ FUEL SYSTEM, WATER THERMO VALVE REMOVAL/INSTALLATION Servo diaphragm
CONTINUED F4-7
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INTAKE-AIR SYSTEM AIR CLEANER ELEMENT INSPECTION • Visually check the air cleaner element for excessive dirt, damage or oil, replace if necessary. IDLE COMPENSATOR INSPECTION 1. Confirm that the valve is in the closed position when the bimetal temperature is lower than the specified temperature. Opening temperature 63—71 °C {145.4—159.8 °F}
AIR THERMO VALVE INSPECTION Note Perform the following test only when directed. • 1. Disconnect the vacuum hose from the vacuum control diaphragm. 2. Verify that vacuum is felt at the vacuum hose when the engine is cold (below 30 °C {86 °F}) and idling. 3. Warm up (above 30 °C {86 °F}) the engine and verify that vacuum is not felt.
2. To check, suck air from the tube A. If excessive air leakage is found, replace the idle compensator.
4. If vacuum condition is not as specified in Steps 2 and 3, replace the air thermo valve. VACUUM CONTROL DIAPHRAGM INSPECTION 1. Disconnect the vacuum hose from the vacuum control diaphragm. 2. Connect a vacuum pump to the vacuum control diaphragm. 3. Apply more than 24 KPa {180 mmHg, 7.087 inHg} vacuum and verify that the shutter valve is opened to the hot position.
3. When the bimetal temperature is more than approx. 71 °C {159.8 °F}, confirm that the valve is in the open position. If the valve is not open, replace the idle compensator as an assembly.
4. Replace the vacuum control diaphragm if not as specified.
CONTINUED
F4-8
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INTAKE-AIR SYSTEM ACCELERATOR PEDAL REMOVAL/INSTALLATION
1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1
2
Accelerator cable ☞ ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Verify that the throttle valve is entirely closed. 2. Measure the free play of the accelerator cable. Free play 1—3 mm {0.04—0.11 in} 3. If not as specified, adjust by turning locknut A.
CONTINUED
F4-9
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FUEL SYSTEM FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". Fuel Line Safety Procedures Note Fuel in the fuel system is under high • pressure also when the engine is not running. 1. Remove the fuel-filler cap and release the pressure in the fuel tank. 2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.
3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position.
3. Start the engine. 4. After the engine stalls, crank the engine several times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and described below. Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit the hose onto the pipe over 25 mm {0.98 in}. When the pipe has a stopper, fit the hose until it contacts the stopper.
F4-10
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FUEL SYSTEM FUEL TANK REMOVAL/INSTALLATION Warning • Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. 2. 3. 4. 5. 6. 7.
Level the vehicle. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Drain the fuel from the drain plug. Remove in the order indicated in the table. Install in the reverse order of removal. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
DOUBLE CAB
CONTINUED
F4-11
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FUEL SYSTEM REGULAR CAB
1
Joint hose ☞ Installation Note
2
Breather hose w Installation Note
3
Under guard
4 5
Fuel hose Fuel tank
6
Evaporative hose - Installation Note
7 8
Rollover valve Fuel pump unit
9
Fuel-filler pipe
10 Dust cover 11 Fuel inlet pipe 12 Non return valve Evaporative gas check valve (two-way) 13 ☞ Installation Note
CONTINUED
F4-12
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FUEL SYSTEM Evaporative Gas Check Valve (Two-way) Installation Note Install the arrow mark of the evaporative gas • check valve (two-way) facing the charcoal canister. Evaporative Hose Installation Note Fit each hose onto the respective fittings within • the specification, and install clamps as shown. Length Evaporative hose: 25 mm {0.98 in}
Breather Hose Installation Note Fit each hose onto the respective fittings within • the specification, and install clamp as shown.
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet pipe. 2. Verify that the nonreturn valve opening angle is 50—56° when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm {0.06 in} when the nonreturn valve is returned to the closed position.
Length Breather hose: 25—30 mm {0.99—1.18 in}
Joint Hose Installation Note Fit the joint hose onto the respective fittings • within the specification, and install clamps as shown. Length Joint hose: 35—40 mm {1.4—1.5 in}
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAUINSTALLATION 1. Remove the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Install the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
F4-13
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FUEL SYSTEM DOUBLE CAB
Fuel Pump Assembly Note After installing the fuel pump body to the • bracket; pull the pump down so that it is tight against the bracket.
Fuel Hose Assembly Note 1. Do not apply excessive side force when pushing the fuel hose onto the fuel pump nipple. 2. Install the clamps as shown. REGULAR CAB
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.)
1 2 3 4 5 6 7
Fuel pump unit connector Rubber mount Fuel filter (low-pressure) Clamp Fuel hose ☞ Assembly Note Fuel pump body ☞ Assembly Note Fuel gauge sender unit
FUEL PUMP INSPECTION Continuity Inspection Note Perform the following test only when • directed, 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit connector terminals C and D.
F4-14
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FUEL SYSTEM 4. Connect the C and D terminals of the fuel pump relay with a jumper wire.
5. If there is no continuity, replace the fuel pump body. If there is continuity in the fuel pump but the fuel pump does not operate, inspect as follows and repair or replace as necessary. Open circuit • GND circuit (fuel pump unit connector terminal C and body GND) • Power circuit (fuel pump relay connector terminal C and fuel pump unit connector terminal D through common connector)
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit Fuel pump relay connector terminal C and • fuel pump unit connector terminal D through common connector to GND 6. Repair or replace faulty areas. If the harnesses are okay, inspect the fuel pump relay. (Refer to FUEL SYSTEM, FUEL PUMP RELAY INSPECTION.) 7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) FUEL LINE PRESSURE INSPECTION Note • Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and connect a fuel pressure gauge to it.
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) 5. Connect the negative battery cable. 6. Turn the ignition switch ON, and verify that fuel pressure is as specified. Specification 2 20—25kPa {0.20—0.25 kgf/cm , 2.8—3.6 psi} 7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.) FUEL LINE FLOW AMOUNT INSPECTION Note • Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and insert the end into a measuring beaker. 4. Connect the C and D terminals of the fuel pump relay with a jumper wire.
CONTINUED F4-15
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FUEL SYSTEM
5. Connect the negative battery cable. 6. Turn the ignition switch on. Drive the fuel pump for a minute and verify that the fuel flow amount is within the specification. Specification More than 1.150 cc {70.2 cu in} min. 7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.) FAST IDLE SPEED ADJUSTMENT 1. Warm up the engine to normal operation temperature. 2. Stop the engine. 3. Plug the hoses of the idle compensator. 4. While holding the throttle valve slightly open, push the choke fully closed; then release the choke valve after releasing the throttle valve. 5. Start the engine, but do not touch the accelerator pedal. 6. Verify that the engine speed is 3,000—4,000 rpm. If the engine speed is not as specified, turn the adjust screw to adjust.
DASHPOT (D/P) INSPECTION 1. Open the throttle valve fully then push the dash pot rod with a finger and make sure the rod goes into the dash pot slowly. 2. Release the finger and make sure the rod comes out quickly.
FUEL PUMP RELAY INSPECTION On-Vehicle Inspection Note • Perform the following test only when directed. 1. Remove the front left side trim. 2. Crank the engine while touching the fuel pump relay by hand. 3. Verify that clicking sound is heard or vibration is felt from the fuel pump relay white cranking the engine. 4. If there is no clicking sound or vibration, inspect the harness for the following, Open circuit •
Power circuit (fuel pump relay connector terminal A, D and ignition switch IG1)
•
GND circuit (fuel pump relay connector terminal B and PCM terminal H)
Short circuit Fuel pump relay connector terminal A, D • and ignition switch IG1 to GND. 5. If the harnesses are okay, perform the following off-vehicle inspection. Off-Vehicle Inspection 1. Remove the fuel pump relay. 2. Inspect for continuity between the fuel pump relay terminals by using an ohmmeter.
CONTINUED
F4-16
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FUEL SYSTEM Tightening torque 9.8—24 N.m {100—250 kgf.cm-cm, 87—216 in.lbf} CARBURETOR REMOVAL/INSTALLATION (Refer to INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. If not as specified, replace the fuel pump relay. SERVO DIAPHRAGM REMOVAL/INSTALLATION 1. Loosen the servo diaphragm installation nut.
2. Remove the servo diaphragm and the servo diaphragm bracket from the intake manifold.
3. Separate the servo diaphragm from the bracket. 4. Install the servo diaphragm onto the bracket, then hand-tighten the installation nut. 5. Install the servo diaphragm bracket to the intake manifold. Tightening torque 19—25N.m {1.9—2.6 kgf.m, 14—18ft.lbf} 6. Tighten the installation nut to the specification.
CONTINUED F4-17
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FUEL SYSTEM CARBURETOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. (Refer to Carburetor After Assembly Note.) •
Caution Replace the O-rings, gaskets, and washers when assembling the carburetor. If not, it will possibly cause a malfunction.
CONTINUED
F4-18
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FUEL SYSTEM 1
Accelerator pump connecting rod
2
Connect spring
3
Air vent solenoid valve
4
Choke rod
5
Air horn
6
Float
7
Needle valve assembly
8
Accelerator pump plunger
9
Closed throttle position (CTP) switch (GENERAL (LH.D.), high-altitude models)
4
Air vent solenoid valve lead (separate from the connector)
5
Disconnect choke rod
10 Slow fuel cut solenoid valve 11 Accelerator pump outlet check ball and spring 12 Accelerator pump inlet check ball 13 Primary slow jet 14 Secondary slow jet 15 Primary main jet 16 Secondary main jet 17 Primary venturi and nozzle 18 Secondary venturi and nozzle 19 Primary main air bleed 20 Secondary main air bleed 21 Main body
6
Air horn and automatic choke assembly (separate from main body)
7
Air vent solenoid valve, spring, and gasket, if necessary
22 Vacuum diaphragm 23 Throttle body 24 Mixture adjust screw 25 Bimetal 26 Choke breaker diaphragm 27 Power jet
Needle Valve and Float Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Air Horn and Automatic Choke Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Vacuum hose
2
Accelerator pump connecting rod, spring, and lever
3
Connect spring
1
Float and pin
2
Needle valve assembly
CONTINUED
F4-19
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FUEL SYSTEM Air Bleeds and Jets Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
Secondary slow jet Secondary slow air bleed (No.1)
3
Secondary main air bleed
4
Secondary main jet
5
Primary main air bleed
6
Slow jet and plug
7
Primary slow air bleed (No.1)
8
Primary main jet
9
Primary slow air bleed (No.2)
1
CTP switch and spring
2
Slow fuel cut solenoid valve, needle valve, spring, and gasket.
3
Accelerator pump plunger assembly and spring
4
Retaining clip
5
Strainer and accelerator pump inlet check ball
6 7
Check valve plug Accelerator pump outlet check ball and spring
10 Power jet
•
Caution Note the size of all jets and air bleeds so that they will be reassembled in the correct position
Note • One bolt is inside the throttle body
11 Coasting richer air bleed (No.2) 12 Secondary slow air bleed (No.2) 13 Coasting richer air bleed (No.1) 14 Coasting richer jet
Main Body Disassembly/Assembly Caution • After installing the idle switch, be sure to adjust it. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
8 9
Disconnect vacuum diaphragm connecting rod Throttle body (separate from main body)
10 Vacuum diaphragm assembly and gasket
CONTINUED
F4-20
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FUEL SYSTEM
11 Diaphragm cover screws and cover 12 Spring and diaphragm 13 Accelerator cable hanger Throttle Body Disassembly/Assembly Caution • Do not remove the throttle valve and shaft, the Venturis, or the choke valve and shaft. 1. Disassemble in the following order. 2. Assemble in the reverse order of disassembly. (1) When removing the mixture adjust screw, tap out the spring pin as shown in the figure.
(4) Adjust the CTP switch. (5) After the idle adjustment has been completed, check the fast idle speed as follows. CARBURETOR INSPECTION/ADJUSTMENT Body, Valve, Jet 1. Check for cracks on the air horn, distortion on the installing surface attached to the main body, and wear on the contact surface of the choke valve shaft. If necessary, replace it. 2. Check for cracks and distortion on the throttle body, and wear on the contact surface of the throttle valve shaft. If necessary, replace it. 3. Check for deformity, bends, and wear on the levers, arms, and connecting rods. If necessary, replace it. Caution • Do not use a piece of wire to clean the jets. The wire may scratch, crack, or deform the port of the jets and become the cause of malfunctions. 4. Check for clogging in jets and air bleeds. If necessary, clean with clean gasoline or kerosene and dry with compressed air. 5. Check the taper part of the MAS, solenoid valves, and needle valve (float) for cracks and dents, and wear. If necessary, replace it. 6. Check the rubber part of the accelerator pump for cracks and damage. If necessary, replace it.
Carburetor After Assembly Note • Install the carburetor in the reverse order of removal. After installation, note the following. (1) Start the engine and check for leaks. (2) Make the idle adjustment. (3) After the idle adjustment is completed, press in the spring pin.
CONTINUED F4-21
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FUEL SYSTEM Diaphragms 1. Push the rod fully and plug the port by hand. 2. Verify that the rod does not return when the port is plugged.
Clearance L 44—45 mm {1.732—1.772 in} 4. If not as specified, bend the float stopper B until the proper clearance is obtained. 3. If the rod returns to the original position, replace the diaphragm. Float Level Adjusting 1. Measure the clearance H between the float and air horn. Choke Valve 1. Use a vacuum pump to apply approximately 53 kPa {400 mmHg, 15.7 inHg} vacuum to the choke diaphragm. 2. Push the choke valve lightly to close it, and check the clearance R,
Clearance H 8—9 mm {0.315—0.354 in} 2. If not as specified, bend the float seat lip A until the proper clearance is obtained.
Clearance R 1.72—2.22 mm {0.068—0.087 In} 3. Measure the clearance L between the bottom of the float and air horn.
3. If the clearance is not as specified, adjust by bending the choke lever D.
CONTINUED
F4-22
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FUEL SYSTEM Fast-idle cam 1. Set the fast-idle cam to the second highest position. 2. Adjust the throttle valve clearance G by turning the adjust screw. (The clearance becomes larger as the screw is turned clockwise.)
Clearance G 0.64—0.84 mm {0.025—0.033 in} 3. Set the fast idle cam at the second highest position. 4. Check the choke valve clearance R. Clearance R 2.82—3.70 mm {0.111—0.146 in} 3. If the clearance is not as specified, adjust by bending tab A. Secondary throttle valve 1. The secondary throttle valve should start to open when the primary throttle valve opens 48 ° —52 ° and should be completely open at the same time the primary throttle valve is fully open. 2. Check the clearance between the primary throttle valve and the throttle bore when the secondary throttle valve starts to open. 3. If the clearance is not as specified, bend tab B to adjust.
Clearance R 0.60—1.20 mm {0.024—0.047 in} 5. If necessary, adjust the choke valve clearance R by bending the starting arm B. If large adjustments are required, the choke rod should be bent. Unloader system 1. Open the primary throttle valve fully. 2. Measure the choke valve clearance R.
CONTINUED
F4-23
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FUEL SYSTEM Clearance R 7.35—8.25 mm {0.289—0.325 in} HIGH-ALTITUDE COMPENSATOR INSPECTION 1. Disconnect each air hose from the carburetor. 2. Check the high-altitude compensator by blowing through each hose.
500m {1,640 ft} or higher (High altitude): Air passes. Less than 500 m {1,640 ft } (Low altitude): Air does not pass. 3. If not as specified, replace the high-altitude compensator. PTC HEATER INSPECTION 1. Disconnect the PTC heater connector. 2. Connect an ohmmeter between the connector and the intake manifold, and verify continuity. 3. If it is not correct, replace the PTC heater. SLOW FUEL CUT SOLENOID VALVE INSPECTION Operation Inspection
1. 2. 3. 4.
Note • Perform the following test only when directed. Run the engine at idle speed. Disconnect the carburetor connector (6-pin). Disconnect the carburetor connector and verify that the engine stops. If the engine does not stop, replace the slow fuel cut solenoid valve.
CONTINUED
F4-24
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EXHAUST SYSTEM EXHAUST SYSTEM EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning • When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1 2
After pipe Main silencer
3
Pre-silencer
4 5
Front pipe Exhaust manifold
CONTINUED
F1-25
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EMISSION SYSTEM 3. Turn the ignition switch to "ON" and "OFF". If there is a "clicking" noise, the air vent solenoid valve is working properly.
EMISSION SYSTEM N0.1 PURGE CONTROL VALVE INSPECTION 1. Blow through port A and verify that air does not flow. 2. Connect a vacuum pump and apply vacuum of -14.7 KPa {-110 mmHg, -4.33 inHg} or above and blow through port A again. 3. Verify that air flows from port A.
CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). 2. Inspect airflow of the valve under the following conditions. Condition
N0.2 PURGE CONTROL VALVE INSPECTION 1. Disconnect vacuum hose B from the pipe. 2. Blow into the hose and make sure air flows freely.
Apply pressure below +2.9 kPa {+22 mmHg, +0.87 inHg} to port A Apply pressure over +5.9 kPa {+44 mmHg, +1.7 inHg} to port A Apply pressure over -0.98 KPa {-7.36 mmHg, -0.29 inHg} to port A
3. If not as specified, replace the charcoal canister. WATER THERMO VALVE INSPECTION 1. Remove the water thermo valve. 2. Put the threaded part in a water-filled container and slowly increase the water temperature. 3. Check the airflow of the valve under the following conditions.
Port A-B C-D
Condition Below 50°C {122°F} Above50°C {122°F} No Airflow Airflow Airflow No Airflow
Airflow No Yes Yes
3. If not as specified, replace the check valve (twoway). CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Visually check the charcoal canister for damage and leakage. 3. Shake the charcoal canister upside down and verify that no pieces of charcoal falls from either nipple. 4. Replace the charcoal canister if necessary. ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) 2. Hold the valve as shown. Blow air into port A and verify that there is airflow.
4. If not as specified, replace the water thermo valve. AIR VENT SOLENOID INSPECTION 1. Remove the air cleaner. 2. Touch the finger onto the air vent solenoid valve.
CONTINUED F4-26
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EMISSION SYSTEM CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT 1. Warm up the engine and run it at idle. 2. Connect a dwell tacho tester to the engine. 3. Connect a voltmeter to the CTP switch terminal. 4. Increase the engine speed to more than 2,000 rpm; decelerate gradually and verify that the volt meter indicates as follows.
3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow.
4. If not as specified, replace the rollover valve. WATER THERMO VALVE REMOVAL/NSTALLATION 1. Drain the engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove the water thermo valve from the intake manifold. 3. Wrap sealing tape two or three times around the threaded part of the valve before installing.
4. Use a new washer and install in the reverse order of removal. Tightening torque 25—39 N.m {2.5—4.0 kgf.m-m, 19—28 ft.lbf} PCV VALVE INSPECTION 1. Remove the PCV valve. 2. Check the airflow of the valve under the following conditions.
Condition Blow from port A
Engine speed At idle 1,000—1,200 (1,100 ±100) rpm
Voltage Approx. 12 V Less than 1.5 V
5. If not as specified, turn the adjust screw to adjust.
FLANGE THERMOSWITCH INSPECTION Note • Perform the following test only when directed. Continuity Inspection 1. Drain the coolant into a container. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 2. Remove the flange thermoswitch from the carburetor. 3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
Airflow Yes
Blow from port B No 3. If not as specified, replace the PCV valve.
4. Inspect the thermoswitch terminals by using an ohmmeter. Specification Water temperature (°C {°F}) Below 67 {153} Above 67 {153}
Continuity Yes No
5. If not as specified, replace the flange thermoswitch.
CONTINUED F4-27
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CONTROL SYSTEM CONTROL SYSTEM COMPONENT LOCATION
1 2 3
Ignition coil Water thermoswitch PCM
4 5 6
T/P solenoid valve (GULF only) PTC heater relay Fuel pump relay
CONTINUED
F4-28
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CONTROL SYSTEM PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front left side trim. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1. Remove the PCM. 2. Reconnect PCM connector and battery negative terminal. Note •
With the PCM connector connected, body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage at PCM terminal using a voltmeter. 4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the Action column in the terminal voltage list.
PCM INSPECTION Caution • The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. PCM Terminal Voltage (Reference)
Terminal *A
Signal Throttle positioner control
B
C
—
FICB control
Connected to
Test condition
T/P solenoid valve
Engine speed
GND
Constant
FICB solenoid valve
Coolant temperature Ignition SW
B+
•
Above 1500 rpm
Below 1.0
•
Below 1.0
•
Related wiring harnesses
•
FICB solenoid valve
•
Related wiring harnesses
Approx 11V •
Igniter Related wiring harnesses —
Below 40°C {104°F}
Below 1.0
Igniter Ignition SW ON
E F
— IG1
G
H
I
J
B+
ON
Idle Ignition
— Ignition SW
—
Fuel pump relay
•
PTC heater control
•
PTC heater relay
Fuel pump control
•
PTC heater control
—
ON
B+
OFF
Below 1.0
Ignition SW
ON
•
•
—
—
Fuel pump control
Coolant temperature
Below 1.0
—
•
Water thermoswitch
•
Fuel pump relay
•
PTC heater relay
Action
Below 1500 rpm
Other D
Voltage (V)
Coolant temperature
• •
Ignition SW Related wiring harnesses —
• •
Fuel pump relay
•
Related wiring
— B+
Ignition SW OFF
•
Below 1.0
T/P solenoid valve Related wiring harnesses
PTC heater relay
Below 40°C {104°F}
B+
•
Water thermoswitch
Above 40°C {104°F}
0V
•
Related wiring harnesses
ON
B+
• •
OFF
Below 1.0
•
Fuel pump relay PTC heater relay Related wiring harnesses
Ignition SW
*: GULF only
F4-29
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CONTROL SYSTEM PTC HEATER RELAY INSPECTION 1. Remove the PTC heater relay. 2. Inspect for continuity between the PTC heater relay terminals by using an ohmmeter.
3. If not as specified, replace the PTC heater relay. THROTTLE POSITIONER (T/P) SOLENOID VALVE INSPECTION Voltage Inspection Note • Perform the following test only when directed. 1. Run the engine at idle. 2. Connect a voltmeter to terminals of the T/P solenoid valve as shown. 3. Measure the voltage as shown.
Engine speed (rpm) Below 1,500 Above 1,500
4. If not as specified, replace the T/P solenoid valve. If as specified, inspect the following: Vacuum hose improper routing, kinks or leakage. Open circuit • Power circuit (T/P solenoid valve connector terminal A and ignition switch IG1 through common connector.) • GND circuit (T/P solenoid valve connector terminal B and PCM connector terminal A.) Short circuit • T/P solenoid valve connector terminal A and ignition switch IG1 through common connector to GND 5. Repair or replace faulty areas. 6. Install the T/P solenoid valve. 7. Connect the negative battery cable. WATER THERMOSWITCH INSPECTION Note • Perform the following test only when directed. Continuity Inspection 1. Drain the coolant into a container. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 2. Remove the water thermoswitch from the under side of the intake manifold. 3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
Voltage (V) B+ Below 1.0
8. If output voltage is as shown in the table above but there is no airflow in the T/P solenoid valve, perform the following airflow inspection. Airflow Inspection 1. Disconnect the negative battery cable. 2. Remove the T/P solenoid valve. 3. Inspect for airflow between each port under the following condition.
4. Inspect the thermoswitch terminals by using an ohmmeter.
F4-30
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CONTROL SYSTEM Specification Water temperature (°C {°F}) Below 40 {104} Above 40 {104}
Continuity Yes No
5. If not as specified, replace the water thermoswitch. WATER THERMOSWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the water thermoswitch from the radiator. 4. The wrap sealing tape two or three times around the threaded part of the switch before installing.
5. Use a new washer and install in the reverse order of removal. Tightening torque 5.9—8.8 N.m {60—90 kgf.cm-cm, 53—78 in.lbf}
F4-31
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TROUBLESHOOTING TROUBLESHOOTING FOREWORD • Before proceeding with the following troubleshooting; (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If a diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP". TROUBLESHOOTING ITEM TABLE • Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart. No. 1
TROUBLESHOOTING ITEM Cranks normally but won't start or hard start
DESCRIPTION No combustion
2
Cranks normally but won't start or hard start (always) Requires excessive cranking time (more than 5 seconds)
3
Cranks normally but won't start or hard start (engine Requires excessive cranking of longer than 5 seconds for cold) more than 3 times for engine to start.
4 5
Cranks normally but won't start or hard start (engine Requires excessive cranking time (more than 5 seconds) warm) Rough idle/engine stalls at idle (always) —
6
Rough idle/engine stalls at idle (engine cold)
Idling is stable when engine is warm.
7
Rough idle/engine stalls at idle (engine warm)
Idling is stable when engine is cold.
8 9
Rough idle/engine stalls at idle when A/C or P/S ON Engine runs normally at idle with no load, but stalls or vibrates (if equipped) excessively when load (A/C or P/S) is ON. Engine suddenly stalls often —
10
High idle speed after warm-up
—
11
Engine stalls at drive away
—
12
Engine stalls on deceleration
—
13
Hesitation
—
14
Poor acceleration
—
15
No power, fastest speed is low
—
16
Knocking
—
17
Afterburn occurs during deceleration
—
18
Poor fuel economy
—
CONTINUED
F4-32
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TROUBLESHOOTING
Emission system
Carburetor
Engine
Item
Fuel system
Control system
Engine electrical system
1
Cranks normally but won't start or hard start
O
O O
O O
O O
O
O O O O
2
Cranks normally but won't start or hard start (always)
O
O O
O O
O O
O
O O O O
3
Cranks normally but won't start or hard start (engine cold)
O
O O O
O O
O O
O
O O O O
4
Cranks normally but won't start or hard start (engine warm)
O O
O
O O
O O O
5
Rough idle/engine stalls at idle (always)
O O O
O
O O O
6
Rough idle/engine stalls at idle (engine cold)
O
O
7
Rough idle/engine stalls at idle (engine warm)
O
O O
8
Rough idle/engine stalls at idle when A/C or P/S ON (If equipped)
9
Engine suddenly stalls often
O
O
O
O O
O O O
O O O O
10 High idle speed after warm-up
O O
O O O
O
O
O
O O
12 Engine stalls on deceleration 13 Hesitation
O O O
O O O O O
14 Poor acceleration
O O O
O
O O O O
O O
15 No power, fastest speed is low
O O O
O
O
O O
O
O
O
O
O O O
16 Knocking
Measure compression pressure Spark inspection
O O
O
O
O
O
O
O
O O O O O
Lower than specification No spark
Malfunctioning spark plug
Malfunctioning ignition coil
Malfunctioning distributor
Malfunctioning slow cut solenoid valve
O O
Malfunctioning air vent solenoid valve
Engine internal damage
Malfunctioning water switch
O
Malfunctioning fuel pump
Malfunctioning fuel line
Misadjusted CO, HC concentration
Malfunctioning choke system
Float lever
O O O O
Manufacturing accelerator pump
Clogged secondary main
O
Clogged secondary slow
Clogged primary main
O
Clogged primary slow
Malfunctioning hoses
Misadjusted accelerator cable
O O O
Clogged air cleaner
17 Afterburn occurs during deceleration 18 Poor fuel economy
O
Battery
11 Engine stalls at drive away
O O
Malfunctioning starter
No
Intake-air system
QUICK DIAGNOSTIC CHART
O O O O
F4-33
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SYMPTOM TROUBLESHOOTING: Symptom 1-Cranks normally but will not start or hard start
F4-34
Symptom 2-Cranks normally but will not start or hard start (always)
F4-35
Symptom 3-Cranks normally but will not start or hard start (engine cold)
F4-36-37
Symptom 4-Cranks normally but will not start or hard start (engine warm)
F4-37
Symptom 5-Rough idle/engine stalls at idle (always)
F4-38
Symptom 6-Rough idle/engine stalls at idle (engine cold)
F4-39
Symptom 7-Rough idle/engine stalls at idle (engine warm)
F4-39
Symptom 8-Rough idle/engine stalls at idle-when a/c or p/s on (if equipped)
F4-40
Symptom 9-Engine suddenly stalls often
F4-40
Symptom 10-High idle speed after warm-up
F4-41
Symptom 11-Engine stalls at drive away
F4-41-42
Symptom 12-Engine stalls on deceleration
F4-42
Symptom 13-Hesitation
F4-42-43
Symptom 14-Poor acceleration
F4-43-44
Symptom 15-No power, fastest speed is low
F4-44-45
Symptom 16-Knocking
F4-46
Symptom 17-Afterburn occurs during deceleration
F4-46
Symptom 18-Poor fuel economy
F4-47
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TROUBLESHOOTING SYMPTOM TROUBLESHOOTING SYMPTOM 1
CRANKS NORMALLY BUT WON'T START OR HARD START 1.
POSSIBLE CAUSE
Air/Fuel mixture too lean Air leak • 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and teaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check if there is any air leakage. Is there any?
RESULTS ACTION Yes Repair or replace appropriate parts. No
Go to next step.
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder?
Yes
Go to next step.
No
Refer to section G.
Check float level. Is it okay?
Yes
Go to next step.
No
4
Open and close throttle valve 2-3 times. Does engine start?
Yes No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step.
5
Check each spark plug. Are they okay?
Yes
Go to next step.
No
Repair or replace spark plug.
Check ignition timing at idle. Is it okay?
Yes
Go to step 8.
No
Go to next step.
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
8
Check slow fuel cut solenoid. Is it okay?
Yes
Go to step 10.
No
Go to next step.
9
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.
2
3
6 7
No 10 11
12
Check compression pressure. Is it okay?
Yes
Go to step 12.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear,
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Check primary main, slow system. Is it okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each jet and air bleed.
No
F4-34
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TROUBLESHOOTING SYMPTOM 2
POSSIBLE CAUSE
CRANKS NORMALLY BUT WON'T START OR HARD START (ALWAYS) 1. Air/Fuel mixture too lean • Air leak • Fuel level incorrect • Restricted primary main, slow system 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich • Float level incorrect • Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. " ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP
INSPECTION
RESULTS
1
Check if there is any air leakage. Is there any?
2
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder?
Yes No Yes
3
Check ignition timing at idle. Is it okay?
4
Perform ignition timing adjustment. Can timing be adjusted?
5
Check float level. Is it okay?
6
Open and close throttle valve 2-3 times. Does engine start?
7
Check each spark plug. Are they okay?
8
Check slow fuel cut solenoid. Is it okay?
9
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
10
Check compression pressure. Is it okay?
11
Add oil through plug hole. Does engine start?
12
Check primary main, slow system. Is it okay?
ACTION Repair or replace appropriate parts. Go to next step. Go to next step.
No
Refer to Section G.
Yes No Yes No Yes
Go to Step 8. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step.
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Yes No Yes No Yes No
Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to Step 10. Go to next step.
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to Step 12. Go to next step. Check pistons and cylinders for wear.
No Yes No Yes No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace each jet and air bleed.
F4-35
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TROUBLESHOOTING SYMPTOM 3
CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE COLD) 1.
POSSIBLE CAUSE
Air/Fuel mixture too lean • Air leak 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich • Choke system malfunction • Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check if there is any air leakage. Is there any?
RESULTS ACTION Yes Repair or replace appropriate parts. No
Go to next step.
Disconnect high-tension lead at idle, then check engine speed, Does it decrease equally at each cylinder?
Yes
Go to next step.
No
Refer to Section G.
Check float level. Is it okay?
Yes
Go to next step.
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Open and close throttle valve 2-3 times. Does engine start?
Yes
Check each jet and air bleed for clogging.
No
Go to next step.
5
Check each spark plug. Are they okay?
Yes
Go to next step.
No
Repair or replace spark plug.
6
Check ignition timing at idle. Is it okay?
Yes
Go to Step 9.
No
Go to next step.
7
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
8
Check choke system. Is it okay?
Yes
Go to next step.
No
Repair or replace choke system.
9
Check slow fuel cut solenoid. Is it okay?
Yes
Go to Step 11.
No
Go to next step.
10
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.
2
3
4
No 11 12
Check compression pressure. Is it okay?
Yes
Go to Step 13.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
F4-36
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TROUBLESHOOTING STEP 13
INSPECTION Check primary main, slow system. Is it okay?
SYMPTOM 4
POSSIBLE CAUSE
ACTION
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace each jet and air bleed.
CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE WARM) 1. Percolation • Air vent solenoid valve malfunction 2. Air/Fuel mixture too rich • High float level • Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Inspect spark plugs. 2
RESULTS
RESULTS Yes Repair or replace
Are spark plugs wet or covered with carbon?
No
Go to next step.
Check choke system.
Yes
Go to next step.
ACTION
Is it okay?
No
Repair or replace choke system.
3
Check air vent solenoid valve.
Yes
Go to next step.
Is it okay?
No
Replace air vent solenoid valve.
4
Check float level? Is it okay? (float level is high.)
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Inspect both float and needle valve.
No
CONTINUED
F4-37
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TROUBLESHOOTING SYMPTOM 5
ROUGH IDLE/ENGINE STALLS AT IDLE (ALWAYS) 1.
POSSIBLE CAUSE
Air/Fuel mixture too rich • High float level • Loose primary main jet • Restricted primary slow air bleed 2. Poor ignition or misfire 3. Air/Fuel mixture too lean • Air leakage • Restricted primary main jet 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check if there is any air leakage. Is there any?
RESULTS ACTION Yes Repair or replace appropriate parts. No
Go to next step.
Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder?
Yes
Go to next step.
No
Refer to Section G.
Check idle-up system. Is it okay?
Yes
Go to next step.
No
Repair or adjust system.
Check ignition timing at idle. Is it okay?
Yes
Go to Step 6.
No
Go to next step.
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
Check idling speed. Is it okay?
Yes
Go to Step 8.
No
Go to next step.
7
Perform idling speed adjustment. Can idling speed be adjusted?
Yes
Adjust idling speed.
No
Adjust or inspect idling mixture.
8
Check pcv valve. Is it okay?
Yes
Go to next step.
No
Repair or replace pcv valve.
9
Check compression pressure? Is it okay?
Yes
Go to Step 11.
No
Go to next step.
Drive vehicle. Does engine stop at takeoff?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Check primary main, slow system. Is it okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace each jet and air bleed.
2
3 4 5 6
10
11
CONTINUED F4-38
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TROUBLESHOOTING SYMPTOM 6
POSSIBLE CAUSE
STEP 1
ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE COLD) Choke system malfunction • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
Check choke system (quick release). Is it okay?
SYMPTOM 7
POSSIBLE CAUSE
3 4 5
ACTION
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Repair or replace choke system.
ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE WARM) 1. Choke system malfunction 2. Float level incorrect 3. Air vent solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Start and warm engine. Check choke valve. Is it fully open? 2
RESULTS
RESULTS Yes Go to next step. No
ACTION
Repair or replace choke system.
Inspect spark plugs. re spark plugs wet or covered with carbon?
Yes
Repair or replace spark plugs.
No
Go to next step.
Check air vent solenoid valve. Is it okay?
Yes
Go to next step.
No
Replace valve.
Check fuel check valve. Is it okay?
Yes
Go to next step.
No
Repair or replace valve.
Check float level. Is it okay? (float level is high.)
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Inspect both float and needle valve.
No
F4-39
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TROUBLESHOOTING SYMPTOM 8
ROUGH IDLE/ENGINE STALLS AT IDLE - WHEN A/C OR P/S ON (IF EQUIPPED 1.
POSSIBLE CAUSE
STEP 1
Idle-up system malfunction • Solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious Injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
Inspect idle-up system. Is it okay?
SYMPTOM 9
POSSIBLE CAUSE
Follow steps for troubleshooting item "Rough idle/engine stalls at idle (Always)".
No
Adjust or repair system,
ENGINE SUDDERLY STALLS OFTEN 1. Disconnected starter connector 2. Poor connection of starter connector Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check starter connector. Is it disconnected or is it not properly connected? 2 Check slow fuel cut valve. Is it okay?
RESULTS Yes Go to next step.
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
ACTION
No
Properly connect connector, or repair or replace if necessary.
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Go to next step.
No 3
ACTION
Yes
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
No
Repair or replace slow fuel cut solenoid valve.
CONTINUED
F4-40
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TROUBLESHOOTING SYMPTOM 10
POSSIBLE CAUSE
HIGH IDLE SPEED AFTER WARM-UP • Idle-up system malfunction • Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check throttle wiring. Is there sufficient slack in wiring? 2 3 4
RESULTS Yes Go to next step.
ACTION
No
Adjust or repair accelerator cable.
Check idle-up system. Is it okay?
Yes
Go to next step.
No
Adjust or repair.
Check secondary throttle valve. Is it closed?
Yes
Go to next step.
No
Repair or inspect secondary diaphragm link.
Check float level. Is it okay? (float level is high.)
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Inspect both float and needle valve.
SYMPTOM 11
POSSIBLE CAUSE
ENGINE STALLS AT DRIVE AWAY • Restricted primary main system • Accelerator pump malfunction • Poor ignition or misfire • Malfunctioning unloader system Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check system for air leakage. Is there any?
RESULTS ACTION Yes Repair or replace parts as necessary. No
Go to next step.
2
Check throttle wiring. Is there sufficient slack in wiring?
Yes
Go to next step.
No
Adjust or repair accelerator cable.
3
Check accelerator pump. Is fuel pumped out when accelerator pump is depressed?
Yes
Go to next step.
No
Repair or replace accelerator pump.
4
Check distributor's vacuum advance. Is it correct?
Yes
Go to next step.
No
Replace distributor vacuum control unit.
5
Check unloader system. Is it okay?
Yes
Go to next step.
No
Repair or replace unloader system.
F4-41
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TROUBLESHOOTING STEP 6
INSPECTION
RESULTS
Check primary main, slow system. Is it okay?
Yes
No SYMPTOM 12
POSSIBLE CAUSE
ENGINE STALLS ON DECELERATION Slow fuel cut solenoid valve malfunction • Throttle positioner (T/P) malfunction (GULF only) • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
STEP INSPECTION 1 Check idle-up system. Is it okay? 2 3
4
No
ACTION Go to next step. Repair or replace any parts as necessary.
Yes
Go to Step 4.
No
Go to next step.
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor.
No
Repair or replace slow fuel cut solenoid valve.
Check dashpot's touch speed. Is it correct?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Adjust dashpot.
POSSIBLE CAUSE
2
RESULTS Yes
Check slow fuel cut valve. Is it okay?
SYMPTOM 13
STEP 1
ACTION Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace each Jet and air bleed.
HESITATION Spark advance control malfunction • Restricted jets • Air leakage • Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE
INSPECTION Check system for air leakage. Is there any? Check throttle wiring. Is there sufficient slack in wiring?
RESULTS ACTION Yes Repair or replace any parts as necessary. No Go to next step. Yes
Go to next step.
No
Adjust or repair accelerator cable.
CONTINUED F4-42
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TROUBLESHOOTING STEP 3
INSPECTION
RESULTS
ACTION
Check centrifugal spark advance control. Is it okay?
Yes
Go to next step.
No
Check accelerator pump. Is fuel pumped out when accelerator pump is depressed?
Yes
Check for the following: • Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op eration.) Go to next step.
No
Repair or replace pump.
Check secondary diaphragm. Is it okay?
Yes
Go to next step.
No
Replace secondary diaphragm.
6
Inspect spark plugs? Are they okay?
Yes
Go to next step.
No
Clean or replace spark plugs.
7
Is linkage of primary and secondary valve smooth?
Yes
Go to next step.
No
Repair or replace any parts as necessary.
Inspect every jet. Are they okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace jets. Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
4
5
8
No
SYMPTOM 14
POOR ACCELERATION 1. 2. 3.
POSSIBLE CAUSE
STEP
Spark advance control malfunction Restricted intake/exhaust system Air/Fuel mixture too lean • Low float level • Restricted jets, air bleeds • Accelerator pump malfunction 4. Secondary diaphragm malfunction • RPM limiter malfunction 5. Low engine compression 6. Poor ignition Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
1
Check throttle wiring. Is there sufficient slack in wiring?
Yes No
Adjust or repair accelerator cable.
2
Inspect intake system. Is it restricted? (especially air cleaner)
Yes
Go to next step.
No
Repair or replace intake system.
3
Check choke valve. Is it fully open after warm-up?
Yes No
Go to next step. Repair or replace choke system.
4
Check distributor, (centrifugal spark advance, vacuum spark advance) It is okay?
Yes
Go to next step.
No
Repair or replace distributor.
F4-43
Go to next step.
CONTINUED
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
ACTION
5
Inspect exhaust system. Is it okay?
Yes No
Repair or replace exhaust system.
6
Inspect accelerator pump. It is okay?
Yes
Go to next step.
No
Repair or replace accelerator pump.
7
Check float level. Is it okay?
Yes
Go to next step.
No
If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
8
Inspect spark plugs. Are they okay?
Yes
Go to next step.
No
Clean or replace spark plugs.
9
Check secondary diaphragm. Is it okay?
Yes
Go to next step.
No
Replace secondary diaphragm.
10
Check compression pressure. Is it okay?
Yes
Go to Step 12.
No
Go to next step.
11
Add oil through plug hole. Does engine start?
Yes
Check pistons, rings, and cylinders for wear.
No
Check the following: • Cylinder heads, gaskets • Valve clearance
Inspect all jets and air bleeds (including high speed richer) of both primary and secondary main passage. Is there blockage?
Yes
Clean or replace each jet and air bleed.
No
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
12
SYMPTOM 15
POSSIBLE CAUSE
STEP 1
Go to next step.
NO POWER, FASTEST SPEED IS LOW • Restricted primary main, slow system • Centrifugal spark advance malfunction • Restricted exhaust system • Restricted air cleaner Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can Ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
Check system for air leakage. Is there any
Yes
Go to next step.
No
Repair or replace any part as necessary.
2
Check engine. Does it seem to be overheating?
Yes
Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil.
No
Go to next step.
3
Check throttle wiring. Is there sufficient slack in wiring?
Yes
Go to next step.
No
Adjust or repair accelerator cable.
4
Check choke valve. Is it fully open after warm-up?
Yes
Go to next step.
No
Repair or replace choke valve.
5
Check intake system. Is it restricted? (especially air cleaner)
Yes No
Go to next step. Repair or replace intake system.
CONTINUED F4-44
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TROUBLESHOOTING STEP
INSPECTION
RESULTS
ACTION
6
Check exhaust system. Is it restricted?
Yes No
Repair or replace exhaust system.
7
Check float level. Is it okay? (float level is low.)
Yes
Go to next step.
No
If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank.
Inspect spark plugs. Are they okay?
Yes
Go to next step.
No
Clean or replace spark plugs.
Check secondary diaphragm. Is it okay?
Yes
Go to next step.
No
Replace secondary diaphragm.
Check centrifugal spark advance control. Is it okay?
Yes
Go to next step.
No
Check compression pressure. Is it okay?
Yes
Check for the following: Over advance (Inspect for governor spring damage.) • Under advance (Inspect governor weight, cam op• eration.) Go to Step 13.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Check main (primary) system. Is it okay?
Yes
Go to next step.
No
Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
Check main (secondary) system. Is it okay?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Check the following: • Main jet • Air bleed Note • Dirt and grime can be removed from jets by covering the air horn with your hand.
8 9 10
11 12
13
14
No
Go to next step.
CONTINUED
F4-45
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TROUBLESHOOTING SYMPTOM 16 KNOCKING 1. Air/Fuel mixture too lean • Restricted primary main, slow system • Poor ignition or misfire • Insufficient engine coolant Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1
2
INSPECTION Check engine Does it seem to be overheating? Inspect spark plugs. Are spark plugs electrode free of carbon accumulation?
RESULTS Yes
ACTION
No
Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil, Go to next step.
Yes
Replace fuel,
No
Clean or replace spark plugs.
SYMPTOM 17 AFTERBURN OCCURS DURING DECELERATION • Poor ignition or misfire • Slow fuel cut solenoid valve malfunction • Throttle position (T/P) malfunction (GULF only) • Dashpot malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. CAUSE Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION 1 Check ignition timing at idle. Is it okay? 2
Perform ignition timing adjustment. Can timing be adjusted?
3
Inspect distributor, (centrifugal spark advance, vacuum spark advance) It is okay?
4
Check thermostat. Is it okay?
5
Inspect every jet. Are they okay?
RESULTS Yes No Yes No Yes
ACTION Go to Step 3. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step.
No
Repair or replace distributor.
Yes No Yes
Go to next step. Repair or replace thermostat. Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust)
No
Clean or replace jets.
CONTINUED
F4-46
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TROUBLESHOOTING SYMPTOM 18
POSSIBLE CAUSE
STEP 1
POOR FUEL ECONOMY • Incorrect adjustment of main adjust screw • Incorrect adjustment of idle speed • High float level • Poor ignition or misfire Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. • Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. ☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE ☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION
RESULTS
ACTION
Check system for air leakage. Is there any?
Yes
Go to next step.
No
Repair or replace any part as necessary.
Check ignition timing at idle. Is it okay?
Yes
Go to Step 4.
No
Go to next step.
Perform ignition timing adjustment. Can timing be adjusted?
Yes
Adjust ignition timing.
No
Check both distributor and timing belt.
Check idling speed. Is it correct?
Yes
Go to Step 6.
No
Go to next step.
Perform idling speed adjustment. Can it be adjusted?
Yes
Adjust idling speed.
No
Adjust or repair any part as necessary.
Check slow fuel cut solenoid valve. Is it okay?
Yes
Go to Step 8.
No
Go to next step.
7
Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard?
Yes No
Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.
8
Check both CO and HC concentration. Are they okay?
Yes
Go to next step.
No
Adjust CO and HC concentrations.
Check choke valve. Is it fully open after warm-up?
Yes
Go to next step.
No
Repair or replace choke system.
Check float level. Is it okay? (float level is high.)
Yes
Go to next step.
No
Check the following: • Float • Needle valve
Check distributor, (centrifugal spark advance, vacuum spark advance) Is it okay?
Yes
Go to next step.
No
Repair or replace distributor.
Check compression pressure. Is it normal?
Yes
Go to Step 14.
No
Go to next step.
Add oil through plug hole. Does engine start?
Yes
Check pistons and cylinders for wear.
No
Check for the following: • Burnt valve • Worn piston, piston ring, or cylinder • Damaged cylinder gasket
Is main jet loose?
Yes
Check for the following: • Fuel filter (clogging) • Float room (dust) • Fuel hose (clogging) • Fuel tank (dust) Clean or replace jets.
2 3 4 5 6
9 10
11
12 13
14
No
F4-47
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ENGINE ELECTRICAL SYSTEM CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . BATTERY REMOVAL/INSTALLATION . . . . . . BATTERY INSPECTION . . . . . . . . . . . . . . . . . . BATTERY RECHARGING . . . . . . . . . . . . . . . . . GENERATOR REMOVAL/INSTALLATION . . . GENERATOR INSPECTION . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . IGNITER INSPECTION . . . . . . . . . . . . . . . . . . . IGNITION COIL REMOVAL/INSTALLATION .
G– 1 G– 1 G– 1/2 G– 2 G– 2/3 G– 3/4 G– 5 G– 5 G– 5
IGNITION COIL INSPECTION . . . . . . . . . . . . . DISTRIBUTOR REMOVAL/INSTALLATION . . DISTRIBUTOR DISASSEMBLY/ASSEMBLY . DISTRIBUTOR INSPECTION (F2 CARB) . . . HIGH-TENSION LEAD REMOVAL/INSTALLATION . . . . . . . . . . . . . . STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . STARTER REMOVAL/INSTALLATION . . . . . . STARTER INSPECTION . . . . . . . . . . . . . . . . . .
G–5/6 G–6/7 G–8 G–9 G–9 G–10 G–10 G–10/11
Battery Clamp Installation Note (RH) Install the battery clamp as shown.
CHARGING SYSTEM BATTERY REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
3.5—4.9 {35—50, 31—43}
FRONT
75D26R
FRONT N·m {kgf·cm, in·lbf}
1
Negative battery cable
2
Positive battery cable
3
Battery clamp + Installation Note (RH)
4
Battery
5
Battery tray
BATTERY INSPECTION Battery ST Inspect the battery in the following procedure. Step
Inspection
1
Measure open circuit voltage of battery.
2
Quick charge for 30 minutes and recheck voltage.
3
Apply test load (see test load chart) to battery using a battery y load tester and record battery voltage after 15 seconds. Is voltage more than specification?
Action Above 12.4 V
Go to Step 3.
Below 12.4 V
Go to next step.
Above 12.4 V
Go to next step.
Below 12.4 V
Replace battery.
Yes
Battery is okay.
No
Replace battery.
CONTINUED
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CHARGING SYSTEM 1. Place a battery in a pan of water to prevent it from overheating. The water level should come up about halfway on the battery. Keep water off the top of the battery.
Test load chart Battery
Load (A)
34B19R
110
55D23R
180
75D26L
195
75D26R
195
80D26R
195
95D31R
250
BATTERY
Battery positive voltage with load Approximate battery temp.
Minimum voltage(V)
21 °C {70 °F}
9.6
15 °C {60 °F}
9.5
10 °C {50 °F}
9.4
4 °C {40 °F}
9.3
– 1 °C {30 °F}
9.1
Battery type (5–hour rate)
Slow charge (A)
Quick charge (A)/(30 min.)
– 7 °C {20 °F}
8.9
34B19R (27)
3.0—4.0
20
–12 °C {10 °F}
8.7
55D23R (48)
4.5—5.5
30
–18 °C { 0 °F}
8.5
2. Connect a battery charger to the battery. 3. Adjust the charging current as follows.
Back-up Current 1. Verify that the ignition switch (engine switch) is at the OFF position and that the key has been removed. 2. Disconnect the negative battery cable.
5.5—6.5
35
5.5—6.5
35
80D26R (55)
5.5—6.5
35
95D31R (64)
6.5—8.0
40
4. After the battery has been recharged, measure the battery positive voltage and verify that the battery keeps specified voltage for more than 1 hour.
Caution Operating electrical loads while measuring the back-up current can damage the circuit tester.
Specification Above 12.4 V
3. Measure the back-up current between the negative battery terminal and the negative battery cable. Back-up current 20 mA max.
75D26L (52) 75D26R (52)
5. If not as specified, replace the battery. GENERATOR REMOVAL/INSTALLATION Warning When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery before performing the following operation.
4. If the current exceeds the maximum, remove the fuse in the main fuse block and the fuse block one by one while measuring the back-up current. 5. Inspect and repair harnesses and connectors of the fuse at which the current reduces. BATTERY RECHARGING
1. Disconnect the negative battery cable. 2. Remove the fresh-air duct, air intake pipe and air hose. (WL, WL Turbo) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the drive belt deflection/tension. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.)
Caution When disconnecting the battery, remove the negative cable first and install it last to prevent damage to electrical components or the battery. To avoid deformation or damage to the battery, remove the battery plugs while charging the battery. Do not quick charge for over 30 minutes. It will damage the battery.
CONTINUED
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CHARGING SYSTEM
G6
WL, WL Turbo
5.0—6.8 N·m {50—70 kgf·cm, 44—60 in·lbf}
20—30 {2.0—3.1, 15—22}
A B C 19—25 {1.9—2.6, 14—18}
38—51 {3.8—5.3, 28—38}
A 5.0—6.8 N·m {50—70 kgf·cm, 44—60 in·lbf}
B
38—51 {3.8—5.3, 28—38}
C 38—51 {3.8—5.3, 28—38} N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
F2 CARB, F2 CIS 5.0—6.8 N·m {50—70 kgf·cm, 44—60 in·lbf} 16—22 {1.6—2.3, 12—16}
1
Terminal B wire
2
Connector
3
Drive belt (generator)
4
Generator strap (G6)
5
Generator
GENERATOR INSPECTION Generator Warning Light 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is correct. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Turn the ignition switch (engine switch) on and verify that the generator warning light illuminates. 4. If not, inspect the generator warning light and wiring harnesses between the battery and generator warning light and between the battery and generator terminal L (G6, F2 CARB, F2 CIS), I (WL, WL Turbo). 38—51 {3.8—5.3, 28—38}
ST G6, F2 CARB, F2 CIS
N·m {kgf·m, ft·lbf}
S
G–3
L
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CHARGING SYSTEM Standard voltage
WL, WL Turbo
Engine switch ON (V)
Idle (V) [20°C {68°F}]
WL, WL Turbo
WL, WL Turbo
B
B+
14.05—14.85
A
B+
14.05—14.85
S
0
7.025—7.425
I
2.0—4.0
13.00—14.85
Terminal
A
S
I
6. If not as specified, disassemble and inspect the generator. 5. Verify that the generator warning light goes out after engine starts. 6. If not, inspect the wiring harness between the S terminals of the generator (WL, WL Turbo) and the generator. Generator Voltage 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is within the specification. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Turn off all electrical loads. 4. Turn the ignition switch (engine switch) to START position and verify that the generator turns smoothly without any noise while the engine is running. 5. Measure the voltage at the terminals shown in the table.
Current 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is correct. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Disconnect the negative battery cable. 4. Connect an ammeter, capable of reading 120 A or over, between generator terminal B and the wiring harness. 5. Connect the negative battery cable. 6. Turn all electrical loads off. 7. Start the engine and increase the engine speed to 2,000—2,500 rpm. 8. Turn the following electrical loads on and verify that the current reading increases. Headlights Blower motor Rear window defroster Note Current required for generating power varies with electrical loads applied.
G6, F2 CARB, F2 CIS
Standard current (Reference) S
L
Measuring conditions Room temperature: 20 °C {68 °F} Voltage: 13.5 V Engine hot Engine speed (rpm)
Standard voltage Ignition switch ON (V)
Idle [20°C {68°F}] (V)
G6, F2 CARB, F2 CIS
G6, F2 CARB, F2 CIS
B
B+
14.1—14.7
L
Approx. 1
13.0—14.0
S
B+
14.1—14.7
Terminal
*:
S
G6, F2 CARB, F2 CIS
WL, WL Turbo
1,000
Approx. 0—43
Approx. 0—58
2,000
Approx. 0—62
Approx. 0—74
Must not be 0 A.
9. If generator terminal B current will not increase, disassemble and inspect the generator.
WL, WL Turbo
A
Terminal B current (A)*
I
CONTINUED
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IGNITION SYSTEM
IGNITION SYSTEM
G6, F2 CIS 8.9—12.7 {90—130, 79—112}
IGNITER INSPECTION G6, F2 CIS 1. Disconnect the igniter connector. 2. Turn the ignition switch on and measure the voltage at connector terminal A using the voltmeter.
1.5—1.9 {15—20, 14—17}
G6, F2 CIS
Specification Battery positive voltage
6.87—9.80 {70—100, 60.8—86.8] N·m {kgf·cm, in·lbf}
3. Turn the ignition switch off and verify that there is continuity between terminal B and the body ground. 4. While cranking the engine, measure the voltage at terminal C using the voltmeter.
F2 CARB 8.9—12.7 {90—130, 79—112}
Specification Approx. 0.5 V 5. If voltage and continuity are okay, replace the igniter. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.)
2.0—2.9 {20—30, 18—26}
IGNITION COIL REMOVAL/INSTALLATION G6, F2 CARB, F2 CIS 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
6.87—9.80 {70—100, 60.8—86.8]
ST N·m {kgf·cm, in·lbf}
1
Center lead
2
Connector
3
Ignition coil bracket
4
Condenser
5
Ignition coil
6
Igniter
IGNITION COIL INSPECTION G6, F2 CARB, F2 CIS Primary Coil Winding 1. Disconnect the ignition coil connector.
CONTINUED
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IGNITION SYSTEM 2. Measure the resistance at the primary coil using an ohmmeter.
F2 CARB
Specification [20 °C {68 °F}] G6, F2 CIS: 0.81—0.99 Ω F2 CARB: 1.035—1.265 Ω
(+)
G6, F2 CIS
4. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) DISTRIBUTOR REMOVAL/INSTALLATION G6, F2 CARB, F2 CIS 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the ignition timing. (Refer to Section F2, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
F2 CARB
G6
3. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) Secondary Coil Winding 1. Disconnect the ignition coil connector. 2. Disconnect the center lead. 3. Measure the resistance at the secondary coil using an ohmmeter. Specification 10—16 k [20 °C {68 °F}] 19—25 {1.9—2.6, 14—18} G6, F2 CIS N·m {kgf·m, ft·lbf}
CONTINUED
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IGNITION SYSTEM Distributor Installation Note Verify that the No.1 cylinder is at top dead center, and align the distributor matching marks.
F2 CARB
MATCHING MARKS
19—25 {1.9—2.6, 14—18}
N·m {kgf·m, ft·lbf}
F2 CIS
19—25 {1.9—2.6, 14—18}
ST N·m {kgf·m, ft·lbf}
1
Vacuum hose
2
High-tension lead + HIGH-TENSION LEAD REMOVAL/INSTALLATION
3
Connector
4
Distributor + Installation Note
CONTINUED
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IGNITION SYSTEM DISTRIBUTOR DISASSEMBLY/ASSEMBLY G6, F2 CARB, F2 CIS 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. F2 CIS
G6
R
R
F2 CARB
R
1
Cap
8
Coupling set
2
Rotor
9
Governor set
3
Cover
10
Oil seal
4
Signal rotor
11
Bearing
5
Pick-up coil with igniter
12
Distributor body
6
Vacuum control unit
13
O-ring
7
Breaker
CONTINUED
G–8
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IGNITION SYSTEM DISTRIBUTOR INSPECTION (F2 CARB) Centrifugal Spark Advance Control 1. Warm up the engine to the normal operating temperature. 2. Check to be sure that the idle speed and ignition timing are correct. (Refer to Section F2, ENGINE TUNE-UP.) 3. Turn off all electrical loads. 4. Disconnect the vacuum hose to the vacuum control unit, and plug the end of the hose.
TIMING LIGHT DIAPHRAGM A
( ° ) 11—15
VACUUM HOSE
0—2 0
5. While gradually increasing the engine speed, use the timing light to check the advance angle on crankshaft pulley.
20 53.3 {150, 5.9} {400, 15.7}
ADVANCE (DEGREE) VACUUM ( kPa { mmHg , inHg })
6. If necessary, disassemble and inspect the distributor.
19—23
Pick-up Coil With Igniter Inspection 1. Connect an ohmmeter to the pick-up coil.
(°) 9—13
0—2 ADVANCE (DEGREE) 0
1,200 2,200 6,000 ENGINE SPEED ( rpm )
(1) Excess advance . . . weak governor spring (if the governor spring is broken, the advance will rise very high) (2) Insufficient advance . governor weight or cam malfunction 6. If necessary, disassemble and inspect the distributor.
2. Measure the resistance.
ST Resistance 900—1,200 Ω
Vacuum Spark Advance Control 1. Warm up the engine to normal operating temperature. 2. Check to be sure that the idle speed and ignition timing are correct. (Refer to section F2, ENGINE TUNE-UP.) 3. Turn off all electrical loads. 4. Disconnect the vacuum hose to the vacuum control unit, and plug the end of the hose. 5. Attach a vacuum pump to the diaphragm A and check using the timing light while applying vacuum.
3. If it is not within specification, replace it. HIGH-TENSION LEAD REMOVAL/INSTALLATION Caution D The high-tension leads must be reinstalled to their original positions. Incorrect installation can damage the leads and cause power loss, and negatively affect the electronic components.
CONTINUED
G–9
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STARTING SYSTEM
STARTING SYSTEM WL, WL Turbo
STARTER REMOVAL/INSTALLATION 9.9—11.7 N·m {100—120 kgf·cm, 87—104 in·lbf}
Warning When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery before performing the following operation. 1. Disconnect the negative battery cable. 2. Remove the battery. (WL, WL Turbo) (Refer to CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.) 3. Remove the intake manifold bracket. (G6) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. G6, F2 CARB, F2 CIS 38—51 {3.8—5.3, 28—38}
38—51 {3.8—5.3, 28—38}
9.9—11.7 N·m {100—120 kgf·cm, 87—104 in·lbf}
N·m {kgf·m, ft·lbf}
1
Terminal B wire
2
Terminal S wire
3
Starter
STARTER INSPECTION On-vehicle Inspection 1. Verify that the battery is fully charged. 2. Crank the engine and verify that the starter turns smoothly without any noise. 3. If not as specified, measure the voltage at terminals S and B when the ignition switch (engine switch) is at START position. Specification Above 8 V 4. If the voltage is within the specification, remove the starter and inspect the magnetic switch and the starter. 5. If the voltage is not as specified, inspect the wiring harness, ignition switch (engine switch).
N·m {kgf·m, ft·lbf}
No Load Test 1. Verify that the battery is fully charged. 2. Connect the starter, battery, voltmeter, and ammeter as shown. A B M
IGNITION SWITCH (ENGINE SWITCH)
V STARTER BATTERY
TERMINAL S
CONTINUED
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STARTING SYSTEM 3. Operate the starter and verify that it turns smoothly. 4. Measure the voltage and current while the starter is operating. Specification Engine type Item
G6
F2 CARB, F2 CIS
WL, WL Turbo
Voltage (V)
11.5
11.5
11
Current (A)
Below 100
Below 60
Below 130
5. If not as specified, repair or replace the inner parts as necessary.
G–11
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CLUTCH GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH FLUID INSPECTION . . . . . . . . . . . . . CLUTCH FLUID REPLACEMENT/AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL INSPECTION/ ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
H– 1 H– 1 H– 1 H– 1/2 H– 2 H– 2/3 H– 3 H– 4 H– 5
CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . H– 7 CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . H– 7 CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . H– 7 CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 8 CLUTCH UNIT REMOVAL/INSTALLATION . . . H– 8/10 CLUTCH COVER INSPECTION . . . . . . . . . . . . H–10 CLUTCH DISC INSPECTION . . . . . . . . . . . . . . . H–11 CLUTCH RELEASE COLLAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . H–11 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–11 PILOT BEARING INSPECTION . . . . . . . . . . . . . H–11 FLYWHEEL INSPECTION . . . . . . . . . . . . . . . . . H–11
H– 5 H– 5/6
GENERAL PROCEDURES
CLUTCH FLUID
Clutch Pipe Removal/Installation 1. If any clutch pipe has been disconnected any time during the procedure, add brake fluid, bleed the air, and inspect for leakage after the procedure has been completed. 2. If removing the clutch pipe, remove it using the SST (49 0259 770B). If installing the clutch pipe, modify the clutch pipe tightening torque to allow for the use of a torque wrench–SST (49 0259 770B) combination, and then tighten the clutch pipe using the SST (49 0259 770B).
CLUTCH FLUID INSPECTION Note The fluid in the reservoir must be maintained between the MIN/MAX level during replacement. CLUTCH FLUID REPLACEMENT/AIR BLEEDING Caution Clutch fluid will damage painted surfaces, be careful not to spill clutch fluid on a painted surface. If this should happen, wash it off immediately. Do not mix different brands of clutch fluid. Do not reuse the clutch fluid that was drained out. 1. Draw the fluid from the reserve tank with a suction pump. 2. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug. 3. Place the other end of the vinyl hose into a container. 4. Slowly pump the clutch pedal several times. 5. With the clutch pedal depressed, loosen the bleeder screw using the SST to let fluid escape. Close the bleeder screw using the SST. BLEEDER SCREW
49 0259 770B
CONTINUED
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CLUTCH FLUID, CLUTCH PEDAL 1.Repeat steps 4 and 5 until only clean fluid is seen. 2.Tighten the bleeder screw. Tightening torque 5.9—8.8 N·m {60—90 kgf·cm, 52—78 in·lbf}
CLUTCH PEDAL CLUTCH PEDAL INSPECTION/ADJUSTMENT Clutch Pedal Height 1. Measure the distance from the upper surface of the pedal pad to the carpet.
3.Add fluid to the MAX mark. 4.Check for correct clutch operation.
Pedal height 241.6—246.6 mm {9.52—9.70 in}
B
A 14—17 {1.4—1.8, 11—13}
PEDAL HEIGHT
CARPET
N·m {kgf·m, ft·lbf}
2.If necessary, adjust the pedal height by turning stopper bolt A and clutch switch (or adjust bolt) B.
CONTINUED
H–2
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CLUTCH PEDAL CLUTCH PEDAL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2.Remove in the order indicated in the table. 3.Install in the reverse order of removal. 4.After installation, adjust the clutch pedal. (Refer to CLUTCH PEDAL INSPECTION/ADJUSTMENT)
Clutch Pedal Free Play 1. Depress the clutch pedal by hand until clutch resistance is felt, and measure the pedal free play. Pedal free play 3.0—8.0 mm {0.12—0.31 in}
L.H.D. D 19—25 {1.9—2.6, 14—18}
C 12—16 {1.2—1.7, 8.7—12.3}
19—25 {1.9—2.6, 14—18}
PEDAL FREE PLAY N·m {kgf·m, ft·lbf}
6.9—9.80 N·m {70—100 kgf·cm, 61—86.8 in·lbf}
2.If necessary, adjust the pedal free play by turning locknut C and adjusting push rod D. Clutch Release Point Inspection 1. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. 2.Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position.
1
Clutch switch connector (G6, F2 CIS)
2
Spring pin
3
Clevis pin
4
Nut
5
Clutch pedal component
R.H.D. G6, F2 CIS, F2 Carb Refer to section F2, INTAKE-AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION.
Standard distance A: 14.6—37.5 mm {0.58—1.47 in} (reference value) A
WL, WL Turbo Refer to section F2, INTAKE-AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION.
RELEASE POINT FULL STROKE END POSITION
N·m {kgf·m, ft·lbf}
PEDAL STROKE
3.If the clutch pedal disengagement stroke is outside of the specification, adjust the pedal height and pedal free play, and verify the pedal stroke. Pedal stroke 146.5—151.5 mm {5.8—5.9 in} (reference value)
CONTINUED
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CLUTCH PEDAL CLUTCH PEDAL DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. Note Apply lithium-based grease to the spring and bush when assembling. 2. Assemble in the reverse order of disassembly.
12—16 {1.2—1.7, 8.7—12.3}
14—17 {1.4—1.8, 11—13}
R
N·m {kgf·m, ft·lbf}
1
Clutch switch (G6, F2 CIS)
2
Adjustment bolt (WL, WL Turbo, F2 Carb)
3
Nut
4
Stopper rubber
5
Retaining ring
6
Washer
7
Bush
8
Pin
9
Fork
10
Push rod
11
Nut
12
Pedal pad
13
Clutch pedal component
CONTINUED
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CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 6.9—9.8 {70—100, 60.8—86.7}
R
SST * 12.8—21.5 {130—220, 113—190}
* 49 0259 770B
N·m {kgf·cm, in·lbf}
1
Clutch pipe
3
Clutch master cylinder
2
Nut
4
Gasket
CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R
R
R
84—112 N·m {8.5—11.5 kgf·m, 61.5—83.1 ft·lbf}
CONTINUED
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CLUTCH MASTER CYLINDER
1
Snap ring + Disassembly Note + Assembly Note
2
Piston
3
Protector
4
Primary cap
5
Return spring
6
Tank cap
7
Reservoir
8
Bushing
9
Joint bolt
10
Gasket
11
One-way valve piston
12
Return spring
13
One way valve pin
14
Clutch master cylinder body
Snap Ring Disassembly Note Hold the piston down using a cloth-wrapped pin punch.
Snap Ring Assembly Note Hold the piston down using a cloth-wrapped pin punch.
CONTINUED
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CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
22—26 {2.2—2.7, 16—19}
16—22 {1.6—2.3, 12—16}
(LITHIUM BASED GREASE)
1
E-clip
3
Bolt
2
Clutch hose
4
Clutch release cylinder
N·m {kgf·m, ft·lbf}
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
G6
R
5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
EXCEPT G6
1
Boot
5
Bleeder cap
2
Push rod
6
Bleeder screw
3
Piston and cap
7
Steel ball
4
Return spring
8
Clutch release cylinder body
CONTINUED
H–7
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CLUTCH UNIT
CLUTCH UNIT CLUTCH UNIT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
G6 :92—98 {9.3—10.0, 67.3—72.3} EXCEPT G6 :97—102 {9.8—10.5, 70.9—75.9} ENGINE SIDE
TRANSMISSION SIDE
SST
18—26 {1.8—2.7, 14—19}
SST SST SST
(MOLYBDENUM SULFIDE) N·m {kgf·m, ft·lbf}
1
2
Transmission + Section J1, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION + Section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION Clutch release collar
3
Clutch release fork
4
Clutch cover + Removal Note + Installation Note
5
Clutch disc + Installation Note
6
Pilot bearing + Removal Note + Installation Note
7
Flywheel + Removal Note + Installation Note
CONTINUED
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CLUTCH UNIT Clutch Cover Removal Note 1. Install the SSTs. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released. 49 E011 1A0
Flywheel Installation Note 1. Install the flywheel to the crankshaft. 2. Hand-tighten the flywheel lock bolts. 3. Install the SST to the flywheel. 4. Apply sealant to the bolt threads before installing the bolt to prevent oil leakage from the bolt. 5. Gradually tighten the flywheel lock bolts in a crisscross pattern. G6 1
5
49 SE01 310A
7
3
49 E011 1A0
4 6
8
2
Pilot Bearing Removal Note Note The pilot bearing does not need to be removed unless you are replacing it.
EXCEPT G6
Use the SSTs to remove the pilot bearing. 3
1 6
49 E011 1A0 4
5 2
49 1285 071
Flywheel Removal Note 1. Hold the flywheel using the SST. 2. Remove the bolts evenly and gradually in a crisscross pattern.
Pilot Bearing Installation Note G6, F2 CIS, F2 Carb Install a new pilot bearing using a pipe until depth is as follows: Depth 4.0 mm {0.16 in}
G6 PILOT BEARING CRANK SHAFT
Ä ÀÆ Â Ã Å Ç Á
49 E011 1A0
EXCEPT G6
3
1 6
49 E011 1A0
4
5 2
CONTINUED
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CLUTCH UNIT WL, WL Turbo Install a new pilot bearing using a pipe until protrusion height is as follows:
CLUTCH COVER INSPECTION 1. Measure the wear of the diaphragm spring figures. Depth 0.6 mm {0.024 in} min.
Protrusion height 0—0.2 mm {0—0.008 in}
DEPTH PILOT BEARING FLY WHEEL
2. Measure the flatness of the pressure plate using a straight edge and a feeler gauge.
Clutch Disc Installation Note Hold the clutch disc in position using the SST.
Clearance 0.5 mm {0.020 in} max.
49 SE01 310A
Clutch Cover Installation Note 1. Install the SSTs. 2. Tighten the bolts evenly and gradually in a crisscross pattern.
3. When checking the diaphragm spring fingers, mount a dial indicator on the cylinder block. 4. Rotate the flywheel and check for misaligned diaphragm spring fingers.
49 E011 1A0
Misalignment 0.6 mm {0.030 in} max.
49 SE01 310A
5. Replace the clutch cover if not as specified.
CONTINUED
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CLUTCH UNIT CLUTCH DISC INSPECTION 1. Using vernier calipers, measure the thickness of the lining at a rivet head on both sides. 2. If clutch disc thickness is less than the minimum, replace the clutch disc.
FLYWHEEL PILOT BEARING INSPECTION 1. Without removing the pilot bearing from the flywheel, turn the bearing while applying force in the axial direction.
Thickness 0.3 mm {0.012 in} min. 0.3 mm {0.012 in}
2. If the bearing sticks or has excessive resistance, replace it. 3. Measure the clutch disc runout using a dial indicator.
FLYWHEEL INSPECTION 1. Install a dial indicator on the cylinder block. 2. Measure the flywheel runout using a dial indicator.
Runout 0.7 mm {0.027 in} max.
Runout 0.2 mm {0.079 in} max.
4. If runout is excessive, replace the clutch disc. CLUTCH RELEASE COLLAR INSPECTION
3. If runout is excessive, replace the flywheel.
Caution Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing. Otherwise, clutch release collar may not operate properly. 1. Turn the collar while applying force in the axial direction.
2. If the collar sticks or has excessive resistance, replace the clutch release collar.
CONTINUED
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MANUAL TRANSMISSION (M15M-D, M15MX-D) MANUAL TRANSMISSION .............................. J1-1 TRANSMISSION OIL INSPECTION ................ J1-1 TRANSMISSION OIL REPLACEMENT ........... J1-1/2 OIL SEAL (M15M-D) REPLACEMENT............. J1-2 VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION ........................ J1-2
VEHICLE SPEEDOMETER SENSOR INSPECTION .....................................................J1-2 MANUAL TRANSMISSION REMOVAL/INSTALLATION ................................J1-3/7
MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. Remove the check plug A.
2.
Verify that the oil is at the brim of the check plug hole as shown. If it is low, add the specified oil from the check plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D) 2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D) 3. Install a new check plug A.
2. 3. 4.
5.
Drain the oil into a container. Clean the drain plug B. Install the drain plug B with new washer. Tightening torque B: 40—58 N.m {4.0—6.0 kgf.m, 29—43 ft.lbf} Add the specified oil from check plug A port until the level reaches the brim of check plug hole.
Tightening torque A: 25—39 N.m {2.5-4.0 kgf.m, 19—28 ft.lbf} TRANSMISSION OIL REPLACEMENT 1. Remove the drain plug B with washer and the check plug A.
Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D) 2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D)
6. Install a new check plug A. Tightening torque A: 25—39 N.m {2.5—4.0 kgf.m, 19—28 ft.lbf}
CONTINUED J1-1
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MANUAL TRANSMISSION 6.
Install the vehicle speedometer sensor. Tightening torque 7.9—10.7 N.m {80—110 kgf.cm, 69.5—95.4 in.Ibf}
7. 8.
9.
OIL SEAL (M15M-D) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.) 3. Remove the oil seal using a screwdriver.
Connect the vehicle speedometer sensor connector. Add the specified type and amount of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) Connect the negative battery cable.
VEHICLE SPEEDOMETER SENSOR INSPECTION 1. Remove the vehicle speedometer sensor. (Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.) 2. Measure voltage between terminals of the vehicle speedometer sensor while the gear is turning. Meter needle
4. 5.
Action
Moves slightly under 5 V
Speedometer sensor is normal. Inspect wiring harness. (Instrument cluster-Vehicle speedometer sensor)
Does not move
Replace vehicle speedometer sensor.
Apply the specified oil to new oil seal. Install the oil seal until it touches the case using a suitable piece of pipe.
3.
Install the vehicle speedometer sensor. (Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.)
6.
Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.) 7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the transmission oil. 3. Disconnect the vehicle speedometer sensor connector. 4. Remove the vehicle speedometer sensor. 5. Apply transmission oil to new O-ring and install it on new vehicle speedometer sensor.
J1-2
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MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 4x2(M15M-D) 1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1
Shift lever knob
12
Speedometer sensor connector
2
Console
13
Back-up light switch connector
3
Dust boot
14
Neutral switch connector (F2 CIS)
4
Change boot upper plate
15
Front pipe bracket
5
Boot
16
Clutch release cylinder
6
Dust boot
17
7
Gasket
Crossmember ☞ Removal Note
8
Wave washer
9
Change bush
18 19
10
Change lever
Transmission lower mount Transmission ☞ Removal Note ☞ Installation Note
11
Change seat
CONTINUED J1-3
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MANUAL TRANSMISSION
1
Shift lever knob
12
Speedometer sensor connector
2
Console
13
Back-up light switch connector
3
Dust boot
14
Front pipe bracket
4
Change boot upper plate
15
Clutch release cylinder
5
Boot
16
6
Dust boot
Crossmember ☞ Removal Note
7
Gasket
17
Dynamic damper
8
Wave washer
18
Transmission lower mount
19
Transmission ☞ Removal Note & Installation Note
9
Change bush
10
Change lever
11
Change seat
CONTINUED
J1-4
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MANUAL TRANSMISSION Crossmember removal note • Securely support the transmission on a transmission jack, then remove the crossmember. Transmission removal note • Maintain the stability of the transmission while removing it.
Transmission installation note Warning • A transmission that is not securely supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. 2.
Place the transmission on a transmission jack. Maintain the stability of the transmission while installing it.
CONTINUED
J1-5
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MANUAL TRANSMISSION 4x4(M15MX-D) 1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft, (Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission and transfer oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1
Shift lever knob
12
Transfer under cover
2
Console
13
Speedometer sensor connector
3
Dust boot
14
Back-up light switch connector
4
Change boot upper mount
15
4x4 indicator switch connector
5
Boot
16
Front pipe bracket
6
Dust boot
17
Clutch release cylinder
7
Gasket
18
8
Wave washer
9
Change bush
Crossmember ☞ MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 4x2 (M15M-D), Crossmember removal Note
10
Change lever
11
Change seat
CONTINUED
J1-6
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MANUAL TRANSMISSION 19
Transmission lower mount
20
Transmission and transfer ☞ Removal Note & Installation Note
Transmission and transfer removal note • Maintain the stability of the transmission and transfer while removing them .
Transmission and transfer installation note Warning • A transmission and transfer that are not securely supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while installing them.
CONTINUED
J1-7
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MANUAL TRANSMISSION (R15M–D, R15MX–D) MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . TRANSMISSION OIL INSPECTION . . . . . . . . . TRANSMISSION OIL REPLACEMENT . . . . . . OIL SEAL (R15M–D) REPLACEMENT . . . . . . VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
J2–1 J2–1 J2–1/2 J2–2
VEHICLE SPEEDOMETER SENSOR INSPECTION...J2–2 MANUAL TRANSMISSION REMOVAL/INSTALLATION . . . . . . . . . . . . . . . J2–3/9
J2–2 TRANSMISSION OIL REPLACEMENT 1. Remove drain plugs A and B, and drain the oil into a container. 2. Clean the drain plug A. 3. Install the drain plug A with new washer and a new drain plug B.
MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. Remove the filler plug. FILLER PLUG
Tightening torque A: 40—58 N·m {4.0—6.0 kgf·m, 29—43 ft·lbf} B: 21—31 N·m {2.1—3.2 kgf·m, 16—23 ft·lbf} FILLER PLUG
2. Verify that the oil is at the brim of the filler plug hole as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL–4 or GL–5 Viscosity: SAE 75W–90 (All season) or SAE 80W–90 (Above 10°C {50°F})
DRAIN PLUG A
DRAIN PLUG B
4. Remove the filler plug and add the specified oil through the filler plug port until the level rises to the bottom of the port. Specified oil Grade: API service GL–4 or GL–5 Viscosity: SAE 75W–90 (All season) or SAE 80W–90 (Above 10°C {50°F}) Capacity: 2.8 L {3.0 US qt, 2.5 lmp qt} (R15M–D) 3.2 L {3.4 US qt, 2.8 lmp qt} (R15MX–D)
FILLER PLUG HOLE
3. Install a new filler plug. Tightening torque 25—39 N·m {2.6—4.0 kgf·m, 19—28 ft·lbf}
FILLER PLUG HOLE
CONTINUED
J2–1
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MANUAL TRANSMISSION 1. Install a new filler plug. Tightening torque 25—39 N·m {2.6—4.0 kgf·m, 19—28 ft·lbf} OIL SEAL (R15M–D) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove the oil seal using a screwdriver.
4. Apply the specified oil to the new oil seal. 5. Install the oil seal until it touches the case using a suitable piece of pipe.
PIPE
6. Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION (Refer to section J1, MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION.) VEHICLE SPEEDOMETER SENSOR INSPECTION (Refer to section J1, MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR INSPECTION.)
CONTINUED
J2–2
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MANUAL TRANSMISSION MANUAL TRANSMISSION REMOVAL/INSTALLATION 42 (R15M–D) 1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified amount and type of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation. 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
F2
R
69—88 {7.0—9.0, 51—65}
19—25 {1.9—2.6, 14—18}
A
69—88 {7.0—9.0, 51—65} 16—22 {1.6—2.3, 12—16}
38—51 {3.8—5.3, 28—38}
69—88 {7.0—9.0, 51—65} 69—88 {7.0—9.0, 51—65}
16—22 {1.6—2.3, 12—16}
A
ST 38—51 {3.8—5.3, 28—38}
38—51 {3.8—5.3, 28—38}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
38—46 {3.8—4.7, 28—33}
32—46 {3.2—4.7, 24—33} 22—28 {2.2—2.9, 16—20}
N·m {kgf·m, ft·lbf}
1
Shift lever knob
12
Vehicle speedometer sensor connector
2
Console
13
Back–up light switch connector
3
Dust boot
14
Neutral switch connector (F2 CIS)
4
Change boot upper plate
15
Front pipe bracket
5
Boot
16
Clutch release cylinder
6
Dust boot
17
7
Gasket
Crossmember + Removal Note
8
Wave washer
18
Transmission lower mount
9
Change bush
19
10
Change lever
Transmission + Removal note + Installation note
11
Change seat
CONTINUED
J2–3
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MANUAL TRANSMISSION G6
1
Shift lever knob
12
Vehicle speedometer sensor connector
2
Console
13
Back-up light switch connector
3
Dust boot
14
Neutral switch connector
4
Change boot upper plate
15
Front pipe bracket
5
Boot
16
Clutch release cylinder
6
Dust boot
17
7
Gasket
Crossmember ☞ Removal Note
8
Wave washer
18
Transmission lower mount
9
Change bush
19
10
Change lever
Transmission ☞ Removal note ☞ Installation note
11
Change seat
CONTINUED
J2-4
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MANUAL TRANSMISSION WL, WL TURBO 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R
38—51 {3.8—5.3, 28—38}
19—25 {1.9—2.6, 14—18}
38—51 {3.8—5.3, 28—38}
A 16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
A
32—46 {3.2—4.7, 24—33} 22—28 {2.2—2.9, 16—20}
38—46 {3.8—4.7, 28—33}
N·m {kgf·m, ft·lbf}
1
Shift lever knob
11
Change seat
2
Console
12
Vehicle speedometer sensor connector
3
Dust boot
13
Back-up light switch connector
4
Change boot upper plate
14
Front pipe bracket
5
Boot
15
Clutch release cylinder
6
Dust boot
16
7
Gasket
Crossmember + Removal Note
8
Wave washer
17
Transmission lower mount
9
Change bush
18
10
Change lever
Transmission + Removal note + Installation note
CONTINUED
J2–5
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MANUAL TRANSMISSION Crossmember removal note Securely support the transmission on a transmission jack, then remove the crossmember. Transmission removal note Warning Do not allow the transmission to fall from the transmission jack. Maintain the stability of the transmission while
removing it.
Transmission installation note Warning A transmission that is not securely supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission on a transmission jack. 2. Maintain the stability of the transmission while installing them.
ST
CONTINUED
J2–6
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MANUAL TRANSMISSION 44 (R15MX–D) 1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the front pipe. (G6 engine) (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal. 8. Add the specified type and amount of transmission and transfer oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.) 9. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation. G6 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R R
38—51 {3.8—5.3, 28—38}
19—25 {1.9—2.6, 14—18}
A 38—51 {3.8—5.3, 28—38}
16—22 {1.6—2.3, 12—16}
69—88 {7.0—9.0, 51—65}
38—51 {3.8—5.3, 28—38}
32—46 {3.2—4.7, 24—33}
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
A
37—50 {3.7—5.1, 27—36}
44—53 {4.4—5.3, 32—39}
38—51 {3.8—5.3, 28—38}
N·m {kgf·m, ft·lbf}
CONTINUED
J2–7
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MANUAL TRANSMISSION 1
Shift lever knob
14
Back–up light switch connector
2
Console
15
Neutral switch connector
3
Dust boot
16
4x4 indicator switch connector
4
Change boot upper mount
17
Transfer neutral switch connector (RFW model)
5
Boot
18
Front pipe bracket
6
Dust boot
19
Clutch release cylinder
7
Gasket
20
8
Wave washer
Crossmember + MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 42 (R15M–D), Crossmember removal note
9
Change bush
10
Change lever
21
Transmission lower mount
11
Change seat
22
12
Transfer under cover
13
Vehicle speedometer sensor connector
Transmission and transfer + Removal note + Installation note
WL, WL TURBO
7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R R
38—51 {3.8—5.3, 28—38}
19—25 {1.9—2.6, 14—18}
ST
38—51 {3.8—5.3, 28—38}
A 32—46 {3.2—4.7, 24—33} 16—22 {1.6—2.3, 12—16}
A
37—50 {3.7—5.1, 27—36}
44—53 {4.4—5.3, 32—39} 22—28 {2.2—2.9, 16—20}
N·m {kgf·m, ft·lbf}
CONTINUED
J2–8
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MANUAL TRANSMISSION 1
Shift lever knob
2
Console
3
Dust boot
4
Change boot upper mount
5
Boot
6
Dust boot
7
Gasket
8
Wave washer
9
Change bush
10
Change lever
11
Change seat
12
Transfer under cover
13
Vehicle speedometer sensor connector
14
Back–up light switch connector
15
Transfer neutral switch connector (RFW model)
16
4x4 indicator switch connector
17
Front pipe bracket
18
Clutch release cylinder
19
Crossmember + MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 42 (R15M–D), Crossmember removal note
20
Transmission lower mount
21
Transmission and transfer + Removal note + Installation note
Transmission and transfer removal note Warning Do not allow the transmission to fall from the transmission jack. Maintain the stability of the transmission and
transfer while removing them.
Transmission and transfer installation note Warning A transmission and transfer that are not securely supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while installing them.
CONTINUED
J2–9
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TRANSFER TRANSFER ..................................................................J3-1 TRANSFER OIL INSPECTION ...............................J3-1 TRANSFER TRANSFER OIL INSPECTION 1. Remove the filler plug with washer.
2.
Verify that the oil is at the brim of the filler plug hole as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 USqt,1.8 lmp qt}
TRANSFER OIL REPLACEMENT................ J3-1
TRANSFER OIL REPLACEMENT 1. Remove the filler plug with washer and drain plug with washer.
2. 3. 4.
Drain the oil into a container. Clean the filler and drain plugs. Install the drain plug with new washer. Tightening torque 40—58 N.m {4.0—6.0 kgf.m, 29—43 ft.lbf}
5.
Add the specified oil from filler plug port until the level reaches the brim of filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 °C {50 °F}) Capacity: 2.0 L {2.1 USqt,1.8lmpqt}
3. 4.
Clean the filler plug. Install the filler plug with new washer. Tightening torque 40—58 N-m {4.0—6.0 kgf.m, 29—43 ft.lbf} 6.
Install the filler plug with new washer. Tightening torque 40—58 N-m {4.0-6.0 kgf.m, 29—43 ft.lbf}
CONTINUED
J3-1
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PROPELLER SHAFT PROPELLER SHAFT (42) . . . . . . . . . . . . . . . . . . PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT INSPECTION . . . . . . . . . . FRONT PROPELLER SHAFT (44) . . . . . . . . . . . FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
L–1 L–1 L–2 L–2 L–2
FRONT PROPELLER SHAFT INSPECTION . . FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . REAR PROPELLER SHAFT (44) . . . . . . . . . . . . REAR PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR PROPELLER SHAFT INSPECTION . . . .
L–3 L–3/4 L–5 L–5 L–5
PROPELLER SHAFT (42) PROPELLER SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 50—58 {5.0—6.0, 37—43}
SST
37—52 {3.7—5.4, 27—39} N·m {kgf·m, ft·lbf}
1
Bolt, nut
2
Nut + Installation Note
3
Propeller shaft + Removal Note + Installation Note
WL TURBO, G6:
49 S120 440
WL, F2 CIS, F2 CARB:
49 0259 440
Propeller Shaft Installation Note Align the marks made during removal, and install the propeller shaft. If installing a new propeller shaft, align the differential companion flange precast marking with the tag on the propeller shaft. TAG
MARK
Propeller Shaft Removal Note 1. Before removing the propeller shaft, put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation. TAG
MARK
Nut Installation Note ST Tighten the center bearing installation nuts with the vehicle *unloaded. *unloaded...Fuel tank is full; engine coolant and engine oil are at specified levels; spare tire, jack and tools are in designated position.
2. Remove the propeller shaft from the extension housing and immediately install the SST to prevent oil leakage.
CONTINUED
L–1
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PROPELLER SHAFT (42), FRONT PROPELLER SHAFT (44) PROPELLER SHAFT INSPECTION 1. Measure the propeller shaft runout using a dial indicator.
FRONT PROPELLER SHAFT (44) FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
Runout 0.4 mm {0.016 in} max.
28—30 {2.8—3.1, 21—22}
2. If the runout is excessive, replace the propeller shaft. 3. Move the universal joint in the direction shown, and inspect joint play. Note Starting torque 0.3—1.1 N·m {3.0—12.0 kgf·cm, 2.7—10.4 in·lbf}
N·m {kgf·m, ft·lbf}
1
Bolt, nut
2
Front propeller shaft + Removal Note + Installation Note
Front Propeller Shaft Removal Note Before removing the front propeller shaft, put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation. 4. If there is excessive play or the starting torque is not within the specification, replace the propeller shaft.
TAG
MARK
Front Propeller Shaft Installation Note Align the marks made during removal, and install the front propeller shaft. If installing a new propeller shaft, align the precast marking with the tag on the front propeller shaft.
CONTINUED
L–2
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FRONT PROPELLER SHAFT (44)
TAG
MARK
FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. R
R
R
FRONT PROPELLER SHAFT INSPECTION 1. Measure the front propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.
R
1
Snap ring + Disassembly Note
2
Universal joint yoke
3
Universal joint + Disassembly Note + Assembly Note
4
Sliding yoke
5
Propeller shaft
Snap ring Disassembly Note 1. Mark the yoke and propeller shaft for proper reassembly. 2. If the runout is excessive, replace the front propeller shaft. 3. Move the universal joint in the direction shown, and inspect the joint play.
MARK
Note Starting torque 0.3—0.7 N·m {3.0—8.0 kgf·cm, 2.7—6.9 in·lbf}
2. Clamp the propeller shaft in a vise. 3. Remove the snap ring.
ST
Universal joint Disassembly Note 1. Push one bearing cup out of the propeller shaft by tapping the yoke with a plastic hammer.
BEARING CUP
4. If there is excessive play or the starting torque is not within the specification, repair the front propeller shaft. (Refer to FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY.) YOKE
CONTINUED
L–3
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FRONT PROPELLER SHAFT (44) 1. Remove the opposite bearing cup in the same manner. 2. Separate the propeller shaft and yoke. 3. Clamp the yoke in a vise. 4. Remove the bearing cups and the spider from the yoke in the same manner as in Steps 1 and 2. Universal joint Assembly Note 1. Verify that the inside of the bearing cup is filled with 1.15—1.45g {0.04—0.05 oz} grease. Add the specified amount of disulphide molybdem grease as necessary. 2. Set the new spider into the yoke and tap in a new bearing cup until the snap ring groove is exposed.
6. If there is excessive play or the starting torque is not within the specification, replace the front propeller shaft.
SPIDER
3. Measure the snap ring clearance, then select and install two new snap rings of equal thickness. Snap ring thicknesses mm {in} 1.22 {0.0480}
1.32 {0.0520}
1.24 {0.0488}
1.34 {0.0528}
1.26 {0.0496}
1.36 {0.0536}
1.28 {0.0504}
1.38 {0.0543}
1.30 {0.0512} BEARING CUP YOKE
SNAP RING CLEARANCE
SPIDER
4. Install the remaining bearing cups and snap rings as in Steps 1—3. 5. Move the universal joint in the direction shown, and inspect joint play. Note Starting torque 0.3—0.7 N·m {3.0—8.0 kgf·cm, 2.7—6.9 in ·lbf}
CONTINUED
L–4
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REAR PROPELLER SHAFT (44)
REAR PROPELLER SHAFT (44)
TAG
MARK
REAR PROPELLER SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
50—58 {5.0—6.0, 37—43}
REAR PROPELLER SHAFT INSPECTION 1. Measure the rear propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.
37—52 {3.7—5.4, 27—39} 50—58 {5.0—6.0, 37—43} N·m {kgf·m, ft·lbf}
1
Bolt, nut
2
Nut + PROPELLER SHAFT (42), PROPELLER SHAFT REMOVAL/INSTALLATION, Nut Installation Note
3
Rear propeller shaft + Removal Note + Installation Note
4
Dynamic damper (WL Turbo)
2. If the runout is excessive, replace the rear propeller shaft. 3. Move the universal joint in the direction shown. Inspect starting torque and joint play. Note Starting torque 0.3—1.1 N·m {3.0—12.0 kgf·cm, 2.7—10.4 in·lbf}
Rear Propeller Shaft Removal Note 1. Before removing the rear propeller shaft, put marks on the yoke and the companion flange on the rear propeller shaft tag side for proper reinstallation. TAG
ST
MARK
4. If there is excessive play or the starting torque is not within the specification, replace the rear propeller shaft.
Rear Propeller Shaft Installation Note Align the marks made during removal, and install the rear propeller shaft. If installing a new propeller shaft, align precast marking with the tag on the rear propeller shaft.
CONTINUED
L–5
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FRONT AND REAR AXLES GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . FRONT AXLE (42) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . FRONT AXLE (44) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE INSPECTION . . . . . . . . . . . . . . . . AXLE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION . . . . . . . . . . . . . . OUTPUT SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL OIL INSPECTION . . . . REAR DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL ASSEMBLY . . .
M– 2 M– 2 M– 2 M– 3/5 M– 5 M– 5 M– 6/8 M– 9 M– 9 M– 9/11 M–12 M–12 M–13/15 M–16 M–17/18 M–19 M–19 M–19 M–20 M–21/23 M–24/27
MANUAL FREEEWHEEL (MFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–32 ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . M–32
REMOTE FREEWHEEL (RFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 INDICATOR SWITCH INSPECTION . . . TRANSFER NEUTRAL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW SWITCH INSPECTION . . . . . . . . . . . . . . RFW MAIN SWITCH REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . RFW MAIN SWITCH INSPECTION . . . . . . . . ONE-WAY CHECK VALVE INSPECTION . . . LOCK AND FREE SOLENOID VALVES INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW ACTUATOR INSPECTION . . . . . . . . . . . RFW CONTROL MODULE INSPECTION . . . . RFW CONTROL MODULE REMOVAL/ INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT REMOVAL/INSTALLATION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . JOINT SHAFT INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT ASSEMBLY . . . CONTROL BOX REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL BOX DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT FORK INSPECTION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL DISASSEMBLY . . . . FRONT DIFFERENTIAL ASSEMBLY . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . REMOTE FREEWHEEL (RFW) . . . . . . . . . . . .
M–32 M–32 M–32/33 M–33 M–33 M–33 M–34 M–34 M–34 M–35 M–35/36 M–37 M–38/39 M–39 M–40/42 M–42 M–43/44 M–44 M–45 M–45 M–45 M–45 M–46/47 M–48/50 M–51/55 M–56 M–56/62
CONTINUED
M–1
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GENERAL PROCEDURES, FRONT AXLE (42)
GENERAL PROCEDURES
FRONT AXLE (42)
Wheel and tire removal/installation The removal and installation procedure for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to the specified torque. (Refer to section TD, SUSPENSION, Wheels and Tires.)
WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection After jacking up the vehicle and supporting it at the specified places with safety stands, inspect for noticeable bearing play by holding the top and bottom of the tire.
Suspension arm removal/installation Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and unloaded.*
Wheel bearing axial play 0 mm {0 in} Preload Adjustment 1. Verify that the tire rotates smoothly when rotated strongly, and that there is no rough feeling or is abnormal noise from the bearing. 2. Remove the brake caliper component and suspend it by a rope. 3. Remove the hub cap, pull out the cotter pin and remove the set cover. 4. Loosen the locknut to the extent that it can be turned by hand. 5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount.
*Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Brake line disconnection/connection Caution Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off immediately. Tighten the brake pipe flare nut using the
SST (49 0259 770B). Be sure to modify the brake pipe fIare nut tightening torque to allow use of a torque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.) If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and inspect leakage after the procedure has been completed.
Preload Frictional force plus 5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf} 7. Install the set cover, and secure with a new cotter pin. 8. Install the hub cap and brake caliper component.
Connectors disconnection/connection Disconnect the negative battery cable before doing any work that requires the handling of connectors. Reconnect the negative battery cable only after the work is completed.
M–2
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FRONT AXLE (42) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
54—68 {5.5—7.0, 40—50}
SST
108—127 {11—13, 80—94}
R
SST
R
30—50 {3.0—5.2, 22—50} 80—100 {8.1—10.2, 59—73}
R SST
R SST R R
R SST
SST
R
R
45—58 {4.5—6.0, 33—43} 118—156 {12—16, 87—115}
19—25 {1.9—2.6, 14—18}
R
R
N·m {kgf·m, ft·lbf}
1
Hub cap
2
Cotter pin
11
Lower arm ball joint + section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note
3
Set cover
4
Locknut
5
Washer
12
Hub and disc plate component + Installation Note
Upper arm ball joint + section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note
6
Brake caliper component + Removal Note
7
13
Steering knuckle
8
Dust cover
14
9
Tie-rod end ball joint + section N, MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note
Disc plate + Removal Note
15
Wheel hub + Removal Note
16
Hub bolt + Removal Note + Installation Note
10
Knuckle arm
CONTINUED
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FRONT AXLE (42)
17
Outer bearing inner race
18
Oil seal + Installation Note
19
Inner bearing inner race
20
Inner bearing outer race + Removal Note + Installation Note
21
Outer bearing outer race + Removal Note + Installation Note
Brake Caliper Component Removal Note Remove the brake caliper component, and suspend it by a rope.
Outer Bearing Outer Race, Inner Bearing Outer Race Installation Note Install the bearing outer race using the SSTs and a press. For the other side, reverse the wheel hub and install the outer race.
OUTSIDE BEARING
49 H033 101 INSIDE BEARING
49 B025 001
Disc Plate, Wheel Hub, Hub Bolt Removal Note Note The hub bolt does not need to be removed unless it is being replaced. 1. After putting markings on the disc plate and the wheel hub, remove the bolt and disassemble the plate and hub.
Oil Seal Installation 1. After inserting the bearing in the hub, use the SST to tap in the oil seal until it is flush with the hub end surface. 2. Apply grease to the oil seal lip.
49 F019 001 MARK
2. Remove the hub bolt using a press as necessary.
Hub Bolt Installation Note Press new hub bolts into the wheel hub using a press.
Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note Note When the inner bearing outer race is removed, the inner race and oil seal are removed together. Remove the bearing outer race using a suitable
round bar and a hammer. For the other side, reverse the wheel hub and remove the outer race.
CONTINUED
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FRONT AXLE (42), FRONT AXLE (44) Hub and Disc Plate Component Installation Note 1. Apply grease to the areas indicated in the figure.
FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Wheel Bearing Play Inspection.) Preload Adjustment Caution When replacing the locknut, tighten it using the SST and turn the wheel hub a few times to seat the bearing. Then, perform the preload adjustment.
2. Install the hub and disc plate component, then adjust the preload. (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment.)
1. For RFW model, remove the hub cap and drive shaft end flange. For MFW model, remove the freewheel hub component. 2. Remove the spacer and set plate. 3. Remove the brake caliper component, and suspend it by a rope. 4. Loosen the locknut to the extent that it can be turned by hand using the SST. 49 S231 635
5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount. Preload Frictional force plus 5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf} 7. Install the set plate, spacer, freewheel hub or drive shaft end flange, hub cap and brake caliper component.
CONTINUED
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FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
55—80 {5.6—8.2, 41—59}
R SST
R SST
SST
55—67 {5.6—6.9, 41—49}
54—68 {5.5—7.0}
R
R
R
SST
30—51 {3.0—5.2, 22—37}
R SST R
R R
SST SST SST
R SST R
R
19—25 {1.9—2.6, 14—18} 118—156 {12—16, 87—115} 40—44 {4.0—4.5, 29—32} 45—58 {4.5—6.0, 33—43}
(RFW MODEL)
(MFW MODEL) 25—29 {2.5—3.0, 19—21}
N·m {kgf·m, ft·lbf}
1
Hub cap
9
Dust cover
2
Drive shaft end flange
10
3
Freewheel hub component
4
Spacer
5
Set plate
Tie-rod end ball joint + Section N, MANUAL STEERING, STEERIG GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note
6
Locknut + Removal Note + Installation Note
11
7
Brake caliper component + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Brake Caliper Component Removal Note.
Disc plate + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Disc Plate Removal Note
12
Wheel hub + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Wheel Hub Removal Note
8
Hub and disc plate component
CONTINUED
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FRONT AXLE (44)
13
Hub bolt + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Removal Note + FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Installation Note
14
Outer bearing inner race
15
Oil seal + Installation Note
16
Inner bearing inner race
17
Inner bearing outer race + FRONT AXLE (42) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note
18
Outer bearing outer race + FRONT AXLE (42) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note
19
Nut + Section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Nut Installation Note
20
Shock absorber bolt
21
Upper arm ball joint + Section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note
22
Steering knuckle component + Removal Note
23
Lower arm ball joint
24
Oil seal + Removal Note + Installation Note
25
Spacer
26
Needle bearing + Removal Note + Installation Note
27
Steering Knuckle Component Removal Note 1. Remove the lower arm ball joint from the knuckle using the SST. (Refer to section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (42) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note.) 2. Remove the lower arm installation bolt and remove the lower arm with the knuckle. Oil Seal Removal Note Remove the oil seal using a screwdriver.
Needle Bearing Removal Note Remove the needle bearing using the SST. 49 S231 660
Needle Bearing Installation Note 1. Install the needle bearing using the SST and a press. 2. Apply grease to the needle bearing.
49 S033 108
Steering knuckle
Locknut Removal Note Remove the locknut using the SST. 49 S231 635
CONTINUED
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FRONT AXLE (44) Oil Seal Installation Note 1. Install the new oil seal using the SST and a press. 2. Apply grease to the oil seal lip.
Locknut Installation Note 1. Install the locknut using the SST. 49 S231 635
49 S033 107
2. Adjust the preload. (Refer to FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment)
Outer Bearing Outer Race Installation Note Install the outer bearing outer race using the SST and press.
49 F027 005
Inner Bearing Outer Race Installation Note Install the inner bearing outer race using the SST and a press.
49 F027 007
Oil Seal Installation Note Install the new oil seal using the SST and a press.
49 S033 106
CONTINUED
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REAR AXLE 4. If not as specified, adjust the bearing play. (Refer to REAR AXLE, AXLE SHAFT REMOVAL/INSTALLATION, Bearing Inner Race, Bearing Locknut Installation Note, Bearing play adjustment.)
REAR AXLE REAR AXLE INSPECTION Wheel Bearing Play Inspection 1. Jack up the rear end and support it with safety stands. 2. Verify that there is no abnormal noise and that the tire rotates smoothly when forcefully rotated by hand. 3. With a hand on top of the tire, inspect the bearing play. Wheel bearing axial play 0.05—0.25 mm {0.002—0.010 in} AXLE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
SST *
SST
16—21 N·m {1.6—2.2 kgf·cm, 12—15 in·lbf}
275—313 {28—32, 203—231}
R
R
SST
R SST SST
SST R
108—127 {11—13, 80—94}
SST R
CONTINUED *49
0259 770B N·m {kgf·m, ft·lbf}
M–9
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REAR AXLE Bearing Housing Removal Note Remove the bearing and bearing housing using the SSTs.
1
Brake drum
2
Parking brake connecting pin
3
Brake pipe
4
Nut
5
Axle shaft and back plate component
6
Shim
7
Bearing locknut + Removal Note + Installation Note
8
Lock washer
9
Bearing housing + Removal Note
10
Bearing inner race + Installation Note
11
Bearing spacer
12
Oil seal (bearing housing side) + Installation Note
13
Bearing outer race + Removal Note + Installation Note
14
Back plate component
15
Axle shaft
16
Hub bolt
17
Baffle
18
Oil seal (axle casing side) + Removal Note + Installation Note
49 S026 204 49 S026 205
49 S026 208
Bearing Outer Race Removal Note After removing the bearing inner race and oil seal from the rear wheel hub, tap lightly using a suitable round bar to force out the outer race.
Oil Seal (Axle Casing Side) Removal Note Remove the oil seal from the axle casing using a screwdriver.
Bearing Locknut Removal Note Note Be careful when removing or installing the bearing locknuts for the left wheels because they are left threaded (tightened by turning counterclockwise).
OIL SEAL
Set the SSTs as shown in the figure, and remove
the bearing locknut from the rear axle shaft. AXLE CASING
49 0603 635A 49 S120 645A
Oil Seal (Axle Casing Side) Installation Note 1. Use the SST to tap the oil seal in until it is flush with the end of the axle casing. 2. After installation, apply grease to the oil seal lip. OIL SEAL
49 H025 001
AXLE CASING
CONTINUED
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REAR AXLE Bearing Outer Race, Oil Seal (Bearing Housing Side) Installation Note Press the bearing outer race and the oil seal using the SSTs. OIL SEAL
BEARING OUTER RACE
49 U027 003 49 F027 004
Bearing play adjustment Adjust the bearing play in the axial direction (only when the bearing is replaced). (1) First insert one side of the rear axle shaft component and push the end of the shaft to the thrust block, then insert a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.65—0.95 mm {0.026—0.037 in}. (2) Next insert the opposite shaft component and push the end of the shaft to the thrust block. (3) Use a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.05—0.25 mm {0.002—0.010 in}. Bearing play in axial direction 0.05—0.25 mm {0.002—0.010 in}
Bearing Inner Race, Bearing Locknut Installation Note Caution The torque wrench must be attached perpendicular to the SST.
PINION SHAFT A
1. Set the SST and then press the bearing inner race in until 3 to 5 threads of the bearing locknut mounting screw of the axle shaft are visible above the top of the bearing outer race.
SHIM
THRUST BLOCK
49 S120 748
2. Remove the SST, and then install the bearing locknut to the axle shaft. 3. Tighten the bearing locknut using the SST to press in the bearing inner race. 4. Remove the SST and install the lock washer so that its tab fits into the groove of the axle shaft. 5. Tighten the bearing locknut to the specified torque. Bearing locknut tightening torque 275—313 N·m {28.0—32.0 kgf·m, 203—231 ft·lbf}
49 0603 635A 49 S120 645A
CONTINUED
M–11
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DRIVE SHAFT
DRIVE SHAFT DRIVE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
R
1
2
Wheel hub, steering knuckle + FRONT AXLE (44), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION
3
Snap ring
4
Clip + Installation Note
Drive shaft + Removal Note + Installation Note
Drive Shaft Removal Note Caution Do not damage the dust cover or oil seal. Remove the drive shaft by prying with a bar
inserted between the differential casing and the drive shaft.
Clip Installation Note Left side Install a new clip to the output shaft clip groove with the opening facing upward. Right side Install a new clip to the clip groove of the drive shaft end with the opening facing upward. CLIP
OPENING 28 mm {1.1 in}
Drive Shaft Installation Note Be careful not to damage the oil seal with the shaft spline when installing the drive shaft.
CONTINUED
M–12
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DRIVE SHAFT DRIVE SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of removal.
R RIGHT SIDE
R
R R
R R
LEFT SIDE
1
Boot band + Disassembly Note + Assembly Note
6
Inner ring + Disassembly Note + Assembly Note
2
Clip
7
3
Outer ring + Disassembly Note + Assembly Note
Cage + Disassembly Note + Assembly Note
8
Boot + Disassembly Note + Assembly Note
9
Bell joint component
10
Drive shaft
4
Snap ring + Assembly Note
5
Balls + Disassembly Note + Assembly Note
CONTINUED
M–13
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DRIVE SHAFT Boot Band Disassembly Note
3. Disassemble the balls, inner ring, cage from the drive shaft as component. 4. Turn the cage by approximately 30 degrees and pull the cage and balls away from the inner ring.
Note D The wheel side boot band does not need to be removed unless replacing it.
30_
1. Pry up the locking clip using a screwdriver and remove the band using pliers. 2. Slide the boot along the shaft to expose the joint.
Boot Disassembly Note Note D The wheel side boot does not need to be removed unless it is being replaced. Outer Ring Disassembly Note 1. Wrap the shaft splines with tape. 2. Remove the boot.
Caution D Mark with paint; do not use a punch. 1. Mark the cage and outer ring for proper assembly. 2. Remove the clip using a screwdriver. 3. Remove the outer ring from the inner ring and the balls. 4. Clean the grease away.
TAPE
MARKS
Boot Assembly Note Note D The wheel side and differential side boots are different. Balls, Inner Ring, Cage Disassembly Note Caution D Mark with paint; do not use a punch. 100.5 mm {4.0 in}
1. Mark the drive shaft and inner ring for proper assembly.
WHEEL SIDE
99.2 mm {3.9 in}
DIFFERENTIAL SIDE
1. With the splines of the shaft still wrapped in tape from disassembly, assemble the boot. 2. Temporarily assemble the wheel side boot, new boot bands, and differential side boot to the drive shaft. 3. Remove the tape.
MARKS
2. Disassemble the snap ring from the drive shaft using a snap-ring pliers.
CONTINUED
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DRIVE SHAFT Cage, Inner Ring, Balls, Snap Ring Assembly Note 1. Align the marks, and install the balls and cage to the inner ring in the direction shown in the figure. Caution Install the cage with the offset facing the snap ring groove. If incorrectly installed, the drive shaft may become disengaged.
LEFT SIDE
RIGHT SIDE
2. Install a new snap ring. BALLS CAGE
Standard length Right side : 619.0—629.0 mm {24.4—24.7 in} Left side : 551.0—561.0 mm {21.7—22.0 in} 3. Release trapped air from inside the boot using a screwdriver covered with a rag. SNAP RING GROOVE
INNER RING
Outer Ring Assembly Note Note Use the specified grease supplied in the boot kit. 1. Apply grease to the cage, inner ring, balls, and the outer ring. 4. Set the new boot band to the boot groove. 5. Fold the band back and use pliers to pull it tight. 6. Lock the end of the band by bending the locking clips.
Wheel side : 110—130 g {3.8—4.6 oz} Differential side : 95—105 g {3.4—3.7 oz} 2. Align the marks, and install the outer ring onto the shaft. 3. Install a new clip. MARKS
Boot Band Assembly Note Caution Do not damage the boot. For wheel side, apply grease only when assembling the boot. 1. Apply grease to the inside of the boot. 2. Set the drive shaft to the standard length.
CONTINUED
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DRIVE SHAFT OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
37—57 {3.7—5.5, 27—39}
N·m {kgf·m, ft·lbf}
1
2
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION
3
Screw
4
Output shaft component + Removal Note
Bolt
Output Shaft Component Removal Note Remove the output shaft by prying with a bar inserted between the bearing housing of the output shaft and the differential casing.
CONTINUED
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DRIVE SHAFT OUTPUT SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R SST R R R
R
1
Clip + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Clip Assembly Note
4
Bearing + Disassembly Note + Assembly Note
2
Output shaft component + Disassembly Note + Assembly Note
5
Output shaft
6
Bearing housing
7
Oil seal + Assembly Note
8
O-ring
3
Oil seal + Assembly Note
Output Shaft Component Disassembly Note Disassemble the output shaft component using a press.
CONTINUED
M–17
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DRIVE SHAFT Bearing Disassembly Note Remove the bearing from the output shaft component using a press.
Oil Seal Assembly Note Assemble the new oil seal by lightly tapping it using a plastic hammer.
Oil Seal Assembly Note Use the SST to assemble the new oil seal until it is flush with the bearing housing end using the SST.
Output Shaft Component Assmebly Note Press the output shaft and bearing to the bearing housing.
49 M005 796
Bearing Assembly Note Caution Press the bearing center and shaft center vertically. Press the new bearing to the output shaft.
CONTINUED
M–18
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REAR DIFFERENTIAL Specified oil Type Standard differential: API service GL–5, SAE 90 LSD: API service GL–6, SAE 90 Capacity: 42: 1.40 L {1.48 US qt, 1.23 lmp qt} 44: 1.85 L {1.96 US qt, 1.63 lmp qt}
REAR DIFFERENTIAL REAR DIFFERENTIAL OIL INSPECTION Caution Position the vehicle level. 1. Remove the filler plug. 2. Verify that the oil is at the brim of the filler plug hole. If it is low, add the specified oil. Specified oil Type Standard differential: API service GL–5, SAE 90 LSD: API service GL–6, SAE 90 Capacity 42: 1.40 L {1.48 US qt, 1.23 lmp qt} 44: 1.85 L {1.96 US qt, 1.63 lmp qt}
6. Install a new washer and the filler plug. Tightening torque 40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf}
FILLER PLUG
WASHER
3. Install a new washer and the filler plug. Tightening torque 40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf} REAR DIFFERENTIAL OIL REPLACEMENT 1. Remove the filler and drain plugs. 2. Drain the differential oil into a container.
3. Wipe the plugs clean. 4. Install a new washer and the drain plug. Tightening torque 40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf} 5. Add the specified oil from the filler plug hole until it reaches the brim of the hole.
M–19
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REAR DIFFERENTIAL REAR DIFFERENTIAL REMOVAL/INSTALLATION Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil. 1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) 2. Remove the rear propeller shaft. (Refer to section L, REAR PROPELLER SHAFT (44), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
26—28 {2.6—2.9, 19—20}
50—58 {5.0—6.0, 37—43}
N·m {kgf·m, ft·lbf}
1
Axle shaft and back plate component + REAR AXLE, AXLE SHAFT REMOVAL/ INSTALLATION
2
Differential + Removal Note
Differential Removal Note To prevent the differential from dropping, leave the two bolts loosely tightened. Then hit the differential carrier using a wooden hammer.
CONTINUED
M–20
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REAR DIFFERENTIAL STANDARD DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table.
SST SST
SST SST
SST
1
Differential component + Disassembly Note
14
Adjusting shim
15
Front bearing cup + Disassembly Note
2
Bearing cap + Disassembly Note
16
Oil buffle
3
Adjusting shim
17
4
Side bearing cup
Rear bearing cup + Disassembly Note
5
Side bearing cone + Disassembly Note
18
Carrier
19
Hex screw
6
Pinion nut + Disassembly Note
20
Ring gear
21
Roll pin + Disassembly Note
22
Pinion shaft
23
Thrust block
7
Companion flange + Disassembly Note
8
Oil seal + Disassembly Note
9
Thrust washer
24
Pinion gear
10
Drive pinion + Disassembly Note
25
Pinion gear thrust washer
26
Side gear
11
Front bearing cone
27
Side gear thrust washer
12
Collapsible spacer
28
Case
13
Rear bearing cone + Disassembly Note
CONTINUED
M–21
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REAR DIFFERENTIAL Differential Component Disassembly Note Mount a carrier component to the SST or equivalent.
Pinion Nut Removal Note Hold the companion frange and remove the pinion nut.
T57L–500–B
Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that the left and right bearing caps won’t get mixed up. Use the mark for matching at the time of assembly.
Companion Flange Disassembly Note Remove the companion flange using universal puller.
MARK
Oil Seal Disassembly Note Pull out the oil seal using the SST.
Side Bearing Cone Disassembly Note Warning When pulling the side bearing cone, do not allow differential component to fall. It can strike legs or feet and may cause serious injury. Caution Mark the left bearing in order to install in the same position.
308–047 T77F–1102–A
Remove the side bearing cone using a press and
the SST.
Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic hammer. 205–D064 D84L–1123–A
CONTINUED
M–22
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REAR DIFFERENTIAL Rear Bearing Cone Disassembly Note Note Mark or otherwise distinguish between the front and rear cones so that they are not mixed up at the time of reassembly. Remove the rear bearing cone using the SST.
205–D064 D84L–1123–A
Front Bearing Cup, Rear Bearing Cup Disassembly Note Note Mark or otherwise distinguish between the front and rear cups so that they are not mixed up at the time of reassembly. Remove the bearing races using the SSTs (308 047 T77F–1102A and 100 001 T50T–100–A).
Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note Note • Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the time of reassembly. • Remove the bearing outer races by using the two grooves on the carrier and tapping the outer races alternately.
100–001 T50T–100–A
3308–047 T77F–1102–A
Knock Pin Disassembly Note Caution • Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. • Secure the gear case in a vise and remove the knock pin by using a 4 mm {0.16 in} diameter bar.
Roll Pin Disassembly Note Caution Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. Secure the gear case in a vise and remove the roll
pin using a small drift.
CONTINUED
M–23
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REAR DIFFERENTIAL STANDARD DIFFERENTIAL ASSEMBLY Assemble in the order indicated in the table.
75—95 {7.6—9.7, 55—70}
SST
SST
R
SST 130—150 {13.2—15.3, 96—110}
R SST
R R
SST
R
R
R SST
R R
SST
298—500 {30.3—50.9, 220—368}
N·m {kgf·m, ft·lbf}
1
Case + Assembly Note
16
Adjusting shim + Assembly Note
2
Side gear thrust washer + Assembly Note
17
Rear bearing cone + Assembly Note
3
Side gear
18
4
Pinion gear thrust washer
Drive pinion + Assembly Note
5
Pinion gear
19
Collapsible spacer
6
Thrust block
20
Front bearing cone
7
Pinion shaft
21
Thrust washer
8
Roll pin
22
9
Ring gear
Oil seal + Assembly Note
10
Hex screw
23
Companion flange
11
Side bearing cone + Assembly Note
24
Pinion nut
25
12
Carrier
Side bearing cup + Assembly Note
13
Oil buffle
26
Adjusting shim + Assembly Note
14
Front bearing cup + Assembly Note
27
Bearing cap + Assembly Note
15
Rear bearing cup + Assembly Note
CONTINUED
M–24
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REAR DIFFERENTIAL Adjusting Shim Assembly Note Pinion height Adjustment 1. Assemble the rear bearing cone over the SST and insert it into the rear bearing cup of the carrier. 2. Assemble the front bearing cone into the front bearing cup and assemble the SSTs.
6. This measurement is the thickness needed for the selective shim if there was no marking on the drive pinion. If the drive pinion is marked with a plus (+) reading, the amount marked should be subtracted from the feeler gauge measurement. If the drive pinion is marked with a minus (–) reading, the amount marked should be added to the feeler gauge measurement.
205–456
Rear Bearing Cone Assembly Note Assemble the selected spacer on the drive pinion and press the rear bearing inner race until it is firmly seated on the shaft.
205–110, T76P–4020–A10 205–457
205–105, T76P–4020–A3
205–090 T75L–1165–B
205–109, T76P–4020–A9
Drive Pinion Assembly Note Drive pinion preload adjustment
205–111, T76P–4020–A11
3. Roll the SST component back and forth a few times to seat the bearings while tightening the SST by hand. Tightening torque 27 N·m {2.8 kgf·m, 20 ft·lbf}
Caution Never loosen pinion nut to decrease drive pinion preload torque, and never exceed specified preload torque. If preload torque is exceeded, a new collapsible spacer must be installed and the torque sequence repeated. 1. Install the drive pinion, collapsible spacer and companion flange to the carrier, and tighten the pinion nut until all end play is removed. 2. Continue to tighten in small increments until the specified preload can be obtained.
4. Center the SST (205–456) into the side bearing bore. Install the bearing caps and tighten the bolt. Tightening torque 75—95 N·m {7.6—9.7 kgf·m, 55—70 ft·lbf} Note There should be drag on the feeler gauge when it is inserted between the SSTs (205–110, T76P–4020–A10 and 205–456). 5. Insert the thickest feeler gauge possible between the SSTs (205–110, T76P–4020–A10 and 205–456).
Drive pinion preload 1.2—1.5 N·m {12.2—15.3 kgf·cm, 10.6—13.2 in·lbf} 3. If the specified preload can’t be obtained within the specified tightening torque range, replace the collapsible spacer and inspect again.
205–110 T76P–4020–A10 FEELER GAUGE
205–456
CONTINUED
M–25
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REAR DIFFERENTIAL Case Assembly Note Assemble the side gears, thrust washer, thrust block, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case.
Front Bearing Cup, Rear Bearing Cup Assembly Note 1. Install the oil baffle in the outer bearing cup bore of the carrier. 2. Install the outer bearing cup and inner bearing cup using the SST. 205–024 T76P–4616–A
Side Gear Thrust Washer Assembly Note Adjust the backlash of the side gears and pinon gear as follows. (1) Set a dial gauge to the pinion gear as shown in the figure. (2) Secure one of the side gears. (3) Move the pinion gear and measure the backlash at the end of the pinion gear.
Oil Seal Assembly Note 1. Apply a light coat of oil to the lip of a new oil seal. 2. Assemble the new oil seal using the SST.
205–007 T56T–4676–B
Standard backlash 0—0.1 mm {0—0.004 in} (4) If the backlash exceeds the standard, use the thrust washers to adjust. Side Bearing Cone Assembly Note Caution Bearings should be assembled to the original positions. Press the side bearings into the gear case using
the SST.
205–092 T75L–1165–DA
Side Bearing Cup, Adjusting Shim, Bearing Cap Assembly Note Ring gear backlash adjustment 1. Install the gear case component on the carrier. 2. Push the gear case component to the left side of the carrier and measure the clearance between the side bearing and carrier. This measurement is the left and right total shim thickness. 3. Divide the amount of shim in step 2 appropriately between the right and left side, then install the bearing cap. 4. Adjust the drive pinion, ring gear backlash and the side bearing preload as follows. (1) Mark the ring gear at four points at approx. 90° intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90° angle with one of the ring gear teeth.
CONTINUED
M–26
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REAR DIFFERENTIAL DIAL INDICATOR WITH BRACKETRY RING GEAR
5. Inspect the backlash at the three other marked points and make sure that the minimum backlash is more than 0.12 mm {0.005 in} and difference of the maximum and minimum backlash value is less than 0.08 mm {0.003 in}.
6. If backlash is not as specified, correct the backlash by switching shims from one side of the differential case to the other. 7. Using a torque wrench, inspect the total rotating torque of the pinion and differential component by rotating the pinion three complete revolutions, and then reading the rotating torque. The readings should not exceed 2.4 N·m {24.0 kgf·cm, 20.8 in·lbf}. If the backlash is within specification but the rotating torque is to high, the preload may be adjusted by removing an equal amount of shims from both sides of the differential. 8. Inspect the drive pinion and ring gear tooth contact. (1) Coat both surfaces of 6—8 teeth of the ring gear uniformly with a thin red lead coating. (2) While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact. (3) If the tooth contact is good, wipe off the red lead coating. (4) If it is not good, adjust the pinion height, then adjust the backlash.
M–27
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MANUAL FREEWHEEL (MFW) MECHANISM REMOTE FREEWHEEL (RFW) MECHANISM
MANUAL FREEWHEEL (MFW) MECHANISM
REMOTE FREEWHEEL (RFW) MECHANISM
ON-VEHICLE INSPECTION 1. Jack up the front of the vehicle and support it on safety stands. 2. Set the select lever in “2H” position. 3. Set the freewheel hub control handle to the “FREE” position, then turn the handle clockwise and counterclockwise by hand, and inspect that it turns smoothly. 4. Set the freewheel hub control handle to “LOCK” position and inspect that the wheel turns with considerable force applied to make it turn. 5. If not as specified, replace the freewheel hub component as necessary.
44 INDICATOR SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Remove the transfer case switch (44 indicator switch).
3. Inspect for continuity between the terminals as shown using an ohmmeter. Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
4. If not correct, replace the switch. TRANSFER NEUTRAL SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Remove the transfer case switch (neutral switch).
CONTINUED
M–32
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REMOTE FREEWHEEL (RFW) MECHANISM 1. Inspect for continuity at the switch using an ohmmeter. Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
OFF
RFW MAIN SWITCH REMOVAL/INSTALLATION 1. Remove the meter hood. (Refer to Section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
ON
12 mm {0.472 in} 13 mm {0.512 in}
À
2. If not correct, replace the switch.
1
RFW SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Disconnect the RFW switch connector and remove the switch.
RFW main switch
RFW MAIN SWITCH INSPECTION 1. Remove the RFW main switch. 2. Inspect for continuity between the terminals as shown using an ohmmeter. : Continuity Switch
Terminal A
B
D
F
OFF ON
3. Inspect for continuity at the switch using an ohmmeter. Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
123456567
3. If not correct, replace the switch.
4. If not correct, replace the switch.
CONTINUED
M–33
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REMOTE FREEWHEEL (RFW) MECHANISM ONE–WAY CHECK VALVE INSPECTION 1. Remove the one–way check valve. 2. Blow through A and inspect that air flows from B. 3. Blow through B and inspect that air does not flow from A. B
RFW ACTUATOR INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Disconnect the vacuum hoses from the actuator. 3. Connect a vacuum pump tester to the actuator (free side) as shown. 4. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum, and verify that the rod moves toward the left (driver’s side).
A
4. If not correct, replace the one–way check valve. LOCK AND FREE SOLENOID VALVES INSPECTION 1. Disconnect the vacuum hoses and the connector from each solenoid valve. 2. Blow through each valve from port B. 3. Inspect that air flows from the air filter. BLOW B
5. Disconnect the vacuum pump tester. 6. Connect the vacuum pump tester to the actuator (lock side) as shown. 7. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum, and inspect that the rod moves toward the right (passenger side).
A
AIR FILTER
4. Connect 12V and a ground to the terminals of each valve. 5. Blow through each valve from port B. 6. Inspect that air flows from port A. B
8. If not correct, replace the actuator.
A
7. If not correct, replace the solenoid valve(s).
CONTINUED
M–34
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REMOTE FREEWHEEL (RFW) MECHANISM RFW CONTROL MODULE INSPECTION 1. Remove the scuff plate. (Refer to section S, TRIM, SCUFF PLATE REMOVAL/INSTALLATION.) 2. Remove the front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Turn the ignition switch on and inspect the RFW control module terminal voltages, referring to the Terminal Voltage Chart. RFW CONTROL MODULE
4. If not correct, replace the component(s), wiring, and/or RFW control module. REW CONTROL MODULE REMOVAL/INSPECTION 1. Remove the scuff plate. (Refer to section S, TRIM, SCUFF PLATE REMOVAL/INSTALLATION.) 2. Remove the front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Connector
2
Nut
3
Bolt
4
RFW control module
CONTINUED
M–35
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REMOTE FREEWHEEL (RFW) MECHANISM Terminal Voltage Chart
RFW CONTROL MODULE TERMINAL
B+: Battery positive voltage Terminal
Signal name
Connected to
A
Lock solenoid
Lock solenoid
B
Ground
Body
C
Free solenoid
Free solenoid
D
–
Condition
Inspection point
Solenoid OFF
B+
Harness (Lock solenoid—RFW
Solenoid ON
Below 0.5 V
Lock solenoid
CM) –
–
Voltage
Below 0.5 V
Harness to ground point
Solenoid OFF
B+
Harness (Free solenoid—RFW
Solenoid ON
Below 0.5 V
Free solenoid
CM) –
–
–
44 indicator light
44 indicator light
44 indicator light OFF
B+
Harness (44 indicator
44 indicator light ON
Below 0.5 V
44 indicator light
Lock indicator light
LOCK indicator light
Lock indicator light OFF
B+
Harness (Lock indicator
Lock indicator light ON
Below 0.5 V
Lock indicator light
H
Battery
Battery
Ignition swtich ON
B+
Ignition swtich OFF
Below 0.5 V
RFW main switch
RFW main switch released (OFF)
B+
Harness (RFW main
I
RFW main switch
RFW main switch depreased (ON)
Below 0.5 V
RFW main switch
RFW switch
RFW switch
RFW switch OFF
B+
RFW switch ON
Below 0.5 V
Harness ((RFW switch—RFW CM)) RFW switch
44 indicator switch OFF
B+
Harness (44 indicator
44 indicator switch ON
Below 0.5 V
44 indicator switch
Transfer neutral switch OFF
B+
Harness (Transfer neutral
Transfer neutral switch ON
Below 0.5 V
Transfer neutral switch
E
F
J
K
L
44 indicator switch
44 indicator switch
Transfer neutral switch
Transfer neutral switch
light RFW CM) light—RFW
light RFW CM) light—RFW Harness,, Fuse ((Battery-Ignition y g switch—RFW CM)
switch—RFW switch RFW CM)
switch—RFW switch RFW CM)
switch—RFW switch RFW CM)
CONTINUED
M–36
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REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT REMOVAL/INSTALLATION 1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, DIFFERENTIAL OIL REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
23—26 {2.3—2.7, 17—19}
R
SST
37—53 {3.7—5.5, 27—39} 37—53 {3.7—5.5, 27—39}
N·m {kgf·m, ft·lbf}
1
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION
2
Vacuum hose
3
RFW switch connector
4
Snap pin
5
Joint shaft component, control box component
6
Gear sleeve
7
Output shaft + Removal Note
Output Shaft Removal Note Remove the output shaft using the SST.
49 0813 215A
CONTINUED
M–37
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REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT DISASSEMBLY Disassemble in the order indicated in the table.
SST
SST
SST
1
Control box
2
Clip
9
Bearing + Disassembly Note
3
Remote freewheel hub + Disassembly Note
10
Oil seal + Disassembly Note
4
Spacer
11
Joint shaft
5
Retaining ring
12
Needle bearing
Ball bearing + Disassembly Note
13
Clip
14
Casing
7
Adjustment shim (s)
15
Output shaft and gear sleeve
8
Dust seal
6
CONTINUED
M–38
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REMOTE FREEWHEEL (RFW) MECHANISM Remote Free Wheel Hub Disassembly Note Remove the remote free wheel hub using the SST.
Oil Seal Disassembly Note Remove the oil seal using the SST.
49 U027 004
49 0710 520
Ball Bearing Disassembly Note 1. Remove the ball bearing and the joint shaft using a press.
JOINT SHAFT INSPECTION 1. Measure the joint shaft runout. Maximum runout 0.03 mm {0.0012 in}
2. Remove the ball bearing using a press. 2. If not correct, replace the joint shaft.
Bearing Disassembly Note Remove the dust seal and bearing using the SST and a suitable bar.
49 W027 001
CONTINUED
M–39
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REMOTE FREEWHEEL (RFW) MECHANISM JOINT SHAFT COMPONENT ASSEMBLY Assemble in the order indicated in the table.
16—22 {1.6—2.3, 12—16}
SST SST
R
SST R R SELECTIVE
R
SST SELECTIVE SST
R
SST
R
SST N·m {kgf·m , ft·lbf}
1
Output shaft and gear sleeve
2
Casing
9
Spacer + Assembly Note
3
Oil seal + Assembly Note
10
Remote freewheel hub + Assembly Note
4
Adjustment shim(s) + Assembly Note
11
Clip
12
5
Ball bearing + Assembly Note
Dust seal + Assembly Note
13
Needle bearing
14
Clip
15
Control box
6
Joint shaft + Assembly Note
7
Bearing + Assembly Note
8
Retaining ring
CONTINUED
M–40
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REMOTE FREEWHEEL (RFW) MECHANISM Oil Seal Assembly Note 1. Apply differential oil to a new oil seal. 2. Install the new oil seal using the SST and a press.
Joint Shaft Assembly Note Install the joint shaft using the SST and a press.
49 U027 006 49 U027 006
Bearing Assembly Note Install the bearing using the SSTs and a press.
Ajustment Shim(s), Ball Bearing Assembly Note 1. Install the removed shim(s) and the ball bearing using the SST and a press.
49 U027 005
49 U027 006
49 U027 006
Spacer, Remote FreeWheel Hub Assembly Note 1. Install the removed spacer and the remote freewheel hub using a suitable pipe and the SST and a press.
2. Install a new retaining ring. 3. Measure the clearance between the ball bearing and the retaining ring.
49 U027 005
4. If not as specified, adjust by adding or removing shims. Use no more than two shims on either side.
2. Install a new clip. 3. Measure the clearance between the remote freewheel hub and the clip.
Maximum clearance 0.15 mm {0.0059 in} Available shim thickness 0.15 mm {0.0059 in}, 0.30 mm {0.0118 in}, 0.35 mm {0.0138 in}, 0.40 mm {0.0157 in}, 0.50 mm {0.0197 in} 5. Remove the retaining ring.
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM 4. If not as specified, adjust by adding or removing spacers. Use no more than two spacers on either side. Maximum clearance 0.15 mm {0.0059 in} Available shim thickness 0.15 mm {0.0059 in}, 0.30 mm {0.0118 in}, 0.35 mm {0.0138 in}, 0.40 mm {0.0157 in}, 0.50 mm {0.0197 in} Dust Seal Assembly Note 1. Install the new dust seal using the SST and a press.
49 M005 796
CONTROL BOX REMOVAL/INSTALLATION 1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 23—26 {2.3—2.7, 17—19}
Á À
16—22 {1.6—2.3, 12—16}
1
Vacuum hose
2
RFW switch connector
3
Control box
Â
N·m {kgf·m , ft·lbf}
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM CONTROL BOX DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. R
R
R
R SST
R
R
N·m {kgf·m , ft·lbf}
1
Snap pin
9
Change rod
2
Washer
10
Shift fork
3
RFW actuator
11
4
RFW switch and washer
Boot + Assembly Note
5
Spring cap
12
6
Spring and ball
Oil seal + Assembly Note
7
Washer
13
Control box
8
Roll pin + Disassembly Note + Assembly Note
CONTINUED
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REMOTE FREEWHEEL (RFW) MECHANISM Roll Pin Disassembly Note Remove the roll pin as shown in the figure.
SHIFT FORK INSPECTION 1. Measure the clearance between the gear sleeve and the shift fork. Standard clearance 0.1—0.40 mm {0.0040—0.0157 in} Maximum clearance 0.50 mm {0.0197 in}
Oil Seal Assembly Note Install a new oil seal using the SST and a press.
49 U027 007
2. Inspect the output shaft and gear sleeve of the splines for damage and wear. 3. If not correct, replace the output shaft and gear sleeve as necessary.
Boot Assembly Note Install the boot as shown in the figure.
Roll Pin Assembly Note Install a new roll pin as shown in the figure.
CONTINUED
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FRONT DIFFERENTIAL
FRONT DIFFERENTIAL FRONT DIFFERENTIAL OIL INSPECTION (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL INSPECTION.) Specified oil Type Above –18 °C {0 °F}: API GL–5, SAE 90 Below –18 °C {0 °F}: API GL–5, SAE 80 Capacity MFW: 1.2 L {1.3 US qt, 1.1 lmp qt} RFW: 1.5 L {1.6 US qt, 1.3 lmp qt} FRONT DIFFERENTIAL OIL REPLACEMENT (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) Specified oil Type Above –18 °C {0 °F}: API GL–5, SAE 90 Below –18 °C {0 °F}: API GL–5, SAE 80 Capacity MFW: 1.2 L {1.3 US qt, 1.1 lmp qt} RFW: 1.5 L {1.6 US qt, 1.3 lmp qt} FRONT DIFFERENTIAL OIL SEAL REPLACEMENT 1. Remove the drive shaft. (Refer to DRIVE SHAFT, DRIVE SHAFT REMOVAL/INSTALLATION, Drive shaft removal Note.) 2. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) 3. Remove the oil seal using a screwdriver. 4. Tap in the new oil seal to the differential using the SST. 49 G030 795
5. Install the drive shaft. (Refer to DRIVE SHAFT, DRIVE SHAFT REMOVAL/INSTALLATION, Drive Shaft Installation Note.) 6. Add the differential oil to the specified level. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)
CONTINUED
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FRONT DIFFERENTIAL FRONT DIFFERENTIAL REMOVAL/INSTALLATION 1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.) 2. Remove the propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. MFW
APPLY SCREW LOCK AGENT 95—115 {9.5—11.8, 69—85}
37—53 {3.7—5.5, 27—39}
63—93 {6.4—9.5, 47—68}
55—80 {5.6—8.2, 41—59} N·m {kgf·m, ft·lbf}
1
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Drive Shaft Removal Note
2
Front differential component + Removal Note
3
Differential bracket
CONTINUED
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FRONT DIFFERENTIAL
RFW
APPLY LOCKING COMPOUND 94.2—115.7 {9.5—11.8, 68.8—85.3}
28—30 {2.8—3.1, 21—22}
23—26 {2.3—2.7, 17—19}
94.2—115.7 {9.5—11.8, 68.8—85.3}
62.8—93.1 {6.4—9.5, 46.3—68.7} 37—53 {3.7—5.5, 27—39}
APPLY SCREW LOCK AGENT
N·m {kgf·m, ft·lbf}
1
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Drive Shaft Removal Note
4
Front differential, joint shaft component + Removal Note
5
Joint shaft, crossmember
2
Vacuum hose
6
Front differential
3
RFW switch component
Front Differential, Joint Shaft Component Removal Note 1. Set the transmission jack on the differential. 2. Remove the bolts and nuts indicated by arrows.
3. Remove the front differential and joint shaft component from the vehicle using the transmission jack.
CONTINUED
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FRONT DIFFERENTIAL FRONT DIFFERENTIAL DISASSEMBLY Disassemble in the order indicated in the table. SST
À
SST
É
Å
È
Ä
Ã
SST
SST
Ç
Æ
SST
Â
Á
SST
1
Bolt
7
Adjusting screw
2
Differential casing
8
Side bearing outer race
3
Oil baffle
9
4
Differential component + Disassembly Note
Locknut + Disassembly Note
10
Washer
5
Lock plate
11
6
Bearing cap + Disassembly Note
Companion flange + Disassembly Note
CONTINUED
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FRONT DIFFERENTIAL Locknut Disassembly Note Hold the companion flange using the SST and remove the locknut.
12
Oil seal + Disassembly Note
13
Drive pinion + Disassembly Note
14
Front bearing inner race
15
Collapsible spacer
16
Rear bearing inner race + Disassembly Note
17
Spacer
18
Front bearing outer race + Disassembly Note
19
Rear Bearing outer race + Disassembly Note
20
Carrier
21
Bolt
22
Ring gear
23
Knock pin + Disassembly Note
24
Pinion shaft
25
Pinion gear
26
Thrust washer
27
Side gear
28
Thrust washer
29
Side bearing inner race + Disassembly Note
30
Gear case
49 S120 710
Companion Frange Disassembly Note Pull the companion flange out using the SST.
49 0839 425C
Oil Seal Disassembly Note Remove the oil seal using a screw driver.
Differential Component Disassembly Note Install the differential component on the SSTs. 49 M005 561
49 0107 680A
Bearing Cap Disassembly Note Place a mark on one of the bearing caps so that the left and right bearing caps won’t get mixed up. Use the mark for matching at the time of assembly.
Drive Pinion Disassembly Note Remove the drive pinion by tapping with a plastic hammer.
MARK
CONTINUED
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FRONT DIFFERENTIAL Rear Bearing Inner Race Disassembly Note Note Mark or otherwise distinguish between the front and rear inner races so that they are not mixed up at the time of reassembly. Remove the rear bearing inner race using the SST.
Side Bearing Inner Race Disassembly Note Caution Mark the left bearing in order to install in the same position.
49 H027 002
Remove the side bearing inner race from the gear
case using the SST. Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note
49 0839 425C
Note Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the time of reassembly. Remove the bearing outer races using the two
grooves on the carrier and tapping the outer races alternately.
Knock Pin Disassembly Note Caution Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. Secure the gear case in a vise and remove the
knock pin using a 4 mm {0.16 in} diameter bar.
CONTINUED
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FRONT DIFFERENTIAL FRONT DIFFERENTIAL ASSEMBLY Caution Clean away the old sealant before applying the new sealant. Install the differential carrier within 10 minutes after applying sealant. Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oll. Assemble in the order indicated in the table. 184—284 {13—29, 95—209} 23—27 {2.3—2.7, 17—19}
R SST
14—51 {3.8—5.3, 28—38}
R R
18—25 {1.8—2.6, 14—18}
R
SST
SST R SST 69—83 {7.0—8.5, 51—61}
SST
R
R
SST
SST
R SST SST R
N·m {kgf·m, ft·lbf}
1
Gear case + Assembly Note
9
Side bearing inner race + Assembly Note
2
Thrust washer + Assembly Note
10
Bolt
11
Carrier
3
Side gear
12
4
Thrust washer
Front Bearing outer Race + Assembly Note
5
Pinion gear
13
6
Pinion shaft
Rear bearing outer race + Assembly Note
7
Knock pin
14
8
Ring gear + Assembly Note
Spacer + Assembly Note
15
Rear bearing inner race + Assembly Note
CONTINUED
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FRONT DIFFERENTIAL
16
Drive pinion + Assembly Note
17
Collapsible spacer
18
Front bearing inner race
19
Oil seal + Assembly Note
20
Companion flange
21
Washer
22
Locknut + Assembly Note
23
Side bearing outer race + Assembly Note
24
Adjusting screw + Assembly Note
25
Bearing cap + Assembly Note
26
Lock plate
27
Baffle plate
28
Differential casing
29
Bolt
Standard backlash 0—0.1 mm {0—0.004 in} 4. If the backlash exceeds the standard, use the thrust washers to adjust. Ring Gear Assembly Note 1. Coat the ring gear and gear case facing surfaces with locking agent. 2. Install the ring gear and tighten the bolt to the specified torque. Side Bearing Inner Race Assembly Note Caution Bearings should be assembled to the original positions. Press the side bearings into the gear case using
the SST.
49 G030 338
Gear Case Assembly Note Assemble the side gears, thrust washer, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case. Front Bearing Outer Race Assembly Note Press the front bearing outer race into the carrier using the SST and a press.
49 F027 005
Thrust Washer Assembly Note 1. Set a dial gauge to the pinion gear as shown in the figure. 2. Secure one of the side gears. 3. Move the pinion gear and measure the backlash at the end of the pinion gear.
Rear Bearing Outer Race Assembly Note Press the rear bearing outer race into the carrier using the SST and a press.
49 F027 004
CONTINUED
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FRONT DIFFERENTIAL Spacer Assembly Note Pinion height adjustment
49 0727 570
Notes Use the same spacer and nut. Be careful to install collars A and B in the correct position and facing in the correct direction. 1. Assemble the spacer, rear bearing inner race and SST (49 8531 568) on to the SST (49 8531 565). Secure the collar with the O-ring. Then install this to the carrier. 2. Assemble the front bearing inner race, SST (49 8531 567), companion flange, washer and nut to the SST (49 8531 565). 3. Tighten the nut to the extent that the SST (49 8531 565) can be turned by hand.
49 0350 555
7. Add the two (left and right) values obtained by the measurements taken in Step 6 and then divide the total by 2. From this result, subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value. Note For example, the measured results obtained at Step 6 are 0.06 mm and 0.04 mm, and the figure inscribed on the end of the drive pinion is –2:
49 0350 555 49 8531 565
pinion height 0.06+0.04 – –2 = 0.07 = adjustment value 2 100
SPACER REAR BEARING
Therefore, replace it with a spacer 0.07 mm {0.003 in} thicker than the currently used one.
49 8531 568 O RING
49 8531 567 FRONT BEARING
4. Place the SST on the surface plate and set the dial indicator to zero.
Rear Bearing Inner Race Assembly Note Caution Press in until the force required suddenly increases. Install the spacer selected for the pinion height adjustment, confirm that the installation direction is correct. Press the rear bearing inner race in using the
49 0727 570
SSTs. SPACER
5. Place the SST (49 0350 555) on top of the SST (49 8531 565), and then set the SST (49 0727 570) on top of the SST (49 0350 555). 6. Place the measuring probe of the dial indicator so that it contacts the place where the side bearing is installed in the carrier. Then measure left and right side of the lower position.
49 F401 331 49 G030 338
CONTINUED
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FRONT DIFFERENTIAL Drive Pinion Assembly Note Drive pinion preload adjustment
Locknut Assembly Note 1. Assemble the companion flange and washer. 2. Tighten the new locknut using the SST with the determined torque while performing drive pinion preload adjustment. 3. Verify that the preload is within the specification.
Caution Do not install the oil seal. 1. Install the drive pinion, spacer, front bearing, collapsible spacer and companion flange to the carrier, and temporarily tighten the locknut. 2. Adjust the preload of the drive pinon bearing as follows. (1) Turn the companion flange by hand to seat the bearing. (2) Use a torque wrench to tighten the locknut temporarily tightened in Step 1, and confirm that the specified preload can be obtained within the specified tightening torque range. The torque applied at this time will be used after the oil seal is installed. Locknut tightening torque 128—284 N·m {13—29 kgf·m, 95—209 ff·lbf} Drive pinion preload 0.9—13.4 N·m {9—14 kgf·cm, 7.9—12.1 in·lbf} 49 S120 710
Preload 0.9—1.3 N·m {9—14 kgf·cm, 7.9—12.1 in·lbf}
49 S120 710
Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note Ring gear backlash adjustment 1. Install the differential gear component to the carrier. After loosely tightening the bearing outer race and bearing cap mounting bolts, completely tighten the adjustment screw by hand. Then, while turning the ring gear, alternately tighten the left and right adjustment screws using the SST.
49 0259 720
(3) If the specified preload can’t be obtained within the specified tightening torque range, replace the collapsible spacer and inspect again. (4) Remove the locknut, washer and companion flange. Oil Seal Assembly Note Apply differential oil to the oil seal lip and press the oil seal in until it touches the end of the differential carrier using the SST.
2. Adjust the drive pinion, ring gear backlash and the side bearing preload as follows. (1) Mark the ring gear at four points at approx. 90° intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90° angle with one of the ring gear teeth. (2) Turn both bearing adjusters equally until the backlash becomes 0.09—0.11 mm {0.0035—0.0043 in} using the SST.
49 0259 720 49 U027 003
CONTINUED
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FRONT DIFFERENTIAL (3) Inspect for the backlash at the three other marked points and make sure that the minimum backlash is more than 0.05 mm {0.002 in} and difference of the maximum and minimum backlash value is less than 0.07 mm {0.0028 in}.
Toe and flank contact Replace the spacer with a thinner one, and move the drive pinion outward. TOE CONTACT
FLANK CONTACT
Heel and face contact Replace the spacer with a thicker one. Bring the drive pinion inward. (4) After adjusting the backlash, tighten the adjustment screws equally until the distance between both pilot sections on the bearing caps (L) become as specified.
HEEL CONTACT
FACE CONTACT
Bearing cap bolt tightening torque 38—51 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
Standard distance 185.43—185.50 mm {7.300—7.303 in} 3. The inspection and adjustment procedure is as follows: (1) Coat both surfaces of 6—8 teeth of the ring gear uniformly with a thin red lead coating. (2) While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact. (3) If the tooth contact is good, wipe off the red lead coating. (4) If it is not good, adjust the pinion height, then adjust the backlash. RED LEAD
CONTINUED
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TROUBLESHOOTING
TROUBLESHOOTING REMOTE FREEWHEEL (RFW) Foreword Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read and understand the basic flow of troubleshooting in order to properly perform the basic procedures. Precaution This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary for trouble caused by other sources. Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.) Diagnostic Index No
TROUBLESHOOTING ITEM
DESCRIPTION
1
No RFW operation from free to lock (RFW indicator light does not illuminate)
Free solenoid valve malfunction RFW indicator light bulb malfunction RFW actuator malfunction RFW switch malfunction Print plate in instrument cluster malfunction METER 15 A fuse malfunction ENGINE 15 A fuse malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction
2
No RFW operation from lock to free (RFW indicator light does not go off)
Lock solenoid valve malfunction RFW switch malfunction RFW actuator malfunction Print plate in instrument cluster malfunction Engine 15 A fuse malfunction RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction
3
Noise
Joint shaft bearing abrasion or damage RFW hub abrasion Joint shaft abrasion
4
Oil leakage
RFW control box is poorly installed.
CONTINUED
M–56
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TROUBLESHOOTING Quick Diagnosis Chart Possible factor
Troubleshooting item No RFW operation from free to lock
R R R Pr M EN Tr 4 Ę Ę Ę Ę Ę Ę Ę Ę
No RFW operation from lock to free
Ę Ę Ę
R
R Lo Fr R O Ę Ę Ę Ę Ę
Jo R
Jo Con Va R Ę Ę
Ę Ę Ę Ę Ę Ę Ę Ę Ę
Ę Ę Ę Ę Ę
Noise Ę
Oil leakage
Ę Ę
Symptom Troubleshooting 1
NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)
DESCRIPTION
RFW does not change from free to lock.
[TROUBLESHOOTING HINTS]
Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction Free solenoid valve malfunction RFW indicator light bulb malfunction RFW control box malfunction
STEP 1
2
3
4
5
6
METER 15 A fuse and/of ENGINE 15 A fuse malfunction Print plate in instrument cluster malfunction RFW switch malfunction RFW actuator malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harnesses malfunction
INSPECTION
ACTION
Disconnect RFW control module connector. Turn ignition (engine) g ( g ) switch on. Measure voltage between RFW control module connector terminal F and ground. Is the voltage greater than 10 V?
Yes
Go to Step 6.
No
Turn ignition (engine) switch off. Then go to next step.
Is the METER 15 A fuse okay?
Yes
Go to next step.
No
Replace 15 A METER fuse. Then go to Step 31.
Inspect RFW indicator light bulb. Is it okay?
Yes
Go to next step.
No
Replace RFW indicator light bulb. Then go to Step 31.
Measure voltage between instrument cluster connector terminal 1J and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between METER 15 A fuse and instrument cluster. Then go to Step 31.
Measure voltage between instrument cluster connector terminal 2H and ground. Is the voltage greater than 10 V?
Yes
Repair wiring harness between instrument cluster and RFW control module. Then go to Step 31.
No
Replace print plate in instrument cluster. Then go to Step 31.
Yes
Go to Step 8.
No
Turn ignition (engine) switch off. Then go to next step.
Measure voltage between RFW control module connector terminal H and ground. Is the voltage greater than 10 V?
CONTINUED
M–57
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TROUBLESHOOTING
STEP 7
INSPECTION
ACTION Yes
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31.
No
Replace the ENG 15 A fuse. Then go to Step 31.
Disconnect free solenoid valve connector. Measure voltage between free solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect free solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31.
Measure voltage between free solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Inspect free solenoid valve. Then go to Step 31.
Measure voltage between RFW control module connector terminal C and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between free solenoid valve and RFW control module. Then go to Step 31.
Disconnect lock solenoid valve connector. Measure voltage between lock solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect lock solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31.
Measure voltage between lock solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Inspect lock solenoid valve. Then go to Step 31.
Measure voltage between RFW control module connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between lock solenoid valve and RFW control module. Then go to Step 31.
Turn ignition (engine) switch off. Is there continuity between RFW control module connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW control module and ground. Then go to Step 31.
Shift select lever to N position. Is there continuity between RFW control module connector terminal L and ground?
Yes
Go to Step 19.
No
Go to next step.
16
Is there continuity between transfer neutral switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and transfer neutral switch. Then go to Step 31.
No
Go to next step.
17
Inspect transfer neutral switch. Is it okay?
Yes
Go to next step.
No
Replace transfer neutral switch. Then go to Step 31.
Is there continuity between transfer neutral switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between transfer neutral switch and ground. Then go to Step 31.
Shift select lever to 44 indicator position. Is there continuity between RFW control module connector terminal K and ground?
Yes
Go to Step 23.
No
Go to next step.
Is there continuity between 44 indicator switch connector terminal A and ground?
Yes
Repair wiring harness between 44 indicator switch and RFW control module. Then go to Step 31.
No
Go to next step.
8
9
10
11
12
13
14
15
18
19
20
Is the ENG 15 A fuse okay?
CONTINUED
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TROUBLESHOOTING
STEP 21
22
23
24
25
26
27
28
29
30
31
2
INSPECTION
ACTION
Inspect 44 indicator switch. Is it okay?
Yes
Go to next step.
No
Replace 44 indicator switch. Then go to Step 31.
Is there continuity between 44 indicator switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between 44 indicator switch and ground. Then go to Step 31.
Shift select lever to 4H position. Is there continuity between RFW control module connector terminal J and ground?
Yes
Go to Step 27
No
Go to next step.
Is there continuity between RFW switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and RFW switch. Then go to Step 31.
No
Go to next step.
Inspect RFW switch. Is it okay?
Yes
Go to next step.
No
Replace RFW switch. Then go to Step 31.
Is there continuity between RFW switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW switch and ground. Then go to Step 31.
Inspect one-way check valve. Is it okay?
Yes
Go to next step.
No
Replace one-way check valve. Then go to Step 31.
Inspect RFW control box. Is it okay?
Yes
Go to next step.
No
Replace RFW control box. Then go to Step 31.
Inspect vacuum in vacuum hoses. Is it okay?
Yes
Go to next step.
No
Repair vacuum in vacuum hoses. Then go to Step 31.
Inspect RFW control module. Is it okay?
Yes
Go to next step.
No
Repair or replace RFW control module. Then go to next step.
Turn ignition (engine) switch on. Shift select lever from 2H to 4H position. Does RFW operate from free to lock?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)
DESCRIPTION
RFW does not change from lock to free.
[TROUBLESHOOTING HINTS]
RFW main switch malfunction Transfer neutral switch malfunction 44 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction Lock solenoid valve malfunction RFW control box malfunction
STEP 1
ENGINE 15 A fuse malfunction RFW main switch malfunction RFW actuator malfunction RFW switch malfunction Air leakage from vacuum reservoir or actuator system One-way check valve Print plate in instrument cluster malfunction Related fuses and/or harnesses malfunction
INSPECTION
ACTION
Disconnect RFW control module connector. Is there continuity between RFW control module connector terminal F and ground?
Yes
Go to next step.
No
Go to Step 3.
CONTINUED
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TROUBLESHOOTING
STEP 2
INSPECTION
ACTION Yes
Repair wiring harness between RFW control module and instrument cluster. Then go to Step 32.
No
Inspect for no continuity between Instrument cluster terminal 2H and ground.
Turn ignition (engine) switch off. Disconnect RFW control module connector. Turn ignition (engine) switch on on. Measure voltage between RFW control module connector terminal H and ground. Is the voltage greater than 10 V?
Yes
Go to Step 5.
No
Turn ignition (engine) switch off. Then go to next step.
Is the ENG 15 A fuse okay?
Yes
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32.
No
Replace the ENG 15 A fuse. Then go to Step 32.
Disconnect free solenoid valve connector. Measure voltage between free solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect free solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32.
Measure voltage between free solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Inspect free solenoid valve. Then go to Step 32.
Measure voltage between RFW control module connector terminal C and ground. Is the voltage greater than 10 V?
Yes
Go to next step.
No
Repair wiring harness between free solenoid valve and RFW control module. Then go to Step 32.
Disconnect lock solenoid valve connector. Measure voltage between lock solenoid valve connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Connect lock solenoid valve. Then go to next step.
No
Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32.
Measure voltage between lock solenoid valve connector terminal B and ground. Is the voltage greater than 10 V?
Yes
Go next step.
No
Inspect lock solenoid valve. Then go to Step 32.
Measure voltage between RFW control module connector terminal A and ground. Is the voltage greater than 10 V?
Yes
Go next step.
No
Repair wiring harness between lock solenoid valve and RFW control module. Then go to Step 32.
Turn ignition (engine) switch off. Is there continuity between RFW control module connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW control module and ground. Then go to Step 32.
Shift select lever to N position. Is there continuity between RFW control module connector terminal L and ground?
Yes
Go to Step 16.
No
Go to next step.
13
Is there continuity between transfer neutral switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and transfer neutral switch. Then go to Step 32.
No
Go to next step.
14
Inspect transfer neutral switch. Is it okay?
Yes
Go to next step.
No
Replace transfer neutral switch. Then go to Step 32.
3
4
5
6
7
8
9
10
11
12
Disconnect instrument cluster connector No.2. Is there continuity between instrument cluster terminal 2H and ground?
CONTINUED
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TROUBLESHOOTING
STEP 15
16
17
18
19
20
21
22
23
24
25
INSPECTION
ACTION
Is there continuity between transfer neutral switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between transfer neutral switch and ground. Then go to Step 32.
Shift select lever to 2H position. Is there continuity between RFW control module connector terminal K and ground?
Yes
Go to Step 20.
No
Go to next step.
Is there continuity between 44 indicator switch connector terminal A and ground?
Yes
Repair wiring harness between RFW control module and 44 indicator switch. Then go to Step 32.
No
Go to next step.
Inspect 44 indicator switch. Is it okay?
Yes
Go to next step.
No
Replace 44 indicator switch. Then go to Step 32.
Is there continuity between 44 indicator switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between 44 indicator switch and ground. Then go to Step 32.
Shift select lever to 4H position. Is there continuity between RFW control module connector terminal J and ground?
Yes
Go to Step 28.
No
Go to next step.
Is there continuity between RFW switch connector terminal A and ground?
Yes
Repair wiring harness between RFW switch. Then go to Step 32.
No
Go to next step.
Inspect RFW switch. Is it okay?
Yes
Go to next step.
No
Replace RFW switch. Then go to Step 32.
Is there continuity between RFW switch connector terminal B and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW switch and ground. Then go to Step 32.
Push RFW main switch on. Is there continuity between RFW main switch connector terminal I and ground?
Yes
Go to Step 28.
No
Go to next step.
Is there continuity between RFW main switch connector terminal F and ground?
Yes
Repair wiring harness between RFW main switch and RFW control module. Then go to Step 32.
No
Go to next step.
26
Inspect RFW main switch. Is it okay?
Yes
Go to next step.
No
Replace RFW main switch.
27
Is there continuity between RFW main switch connector terminal D and ground?
Yes
Go to next step.
No
Repair wiring harness between RFW main switch and ground. Then go to Step 32.
Inspect one-way check valve. Is it okay?
Yes
Go to next step.
No
Replace one-way check valve. Then go to Step 32.
Inspect RFW actuator. Is it okay?
Yes
Go to next step.
No
Replace RFW actuator. Then go to Step 32.
Inspect vacuum in vacuum hoses. Is it okay?
Yes
Go to next step.
No
Repair vacuum in vacuum hoses. Then go to Step 32.
28
29
30
CONTINUED
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TROUBLESHOOTING
STEP 31
32
3
INSPECTION
ACTION
Inspect RFW control module. Is it okay?
Yes
Go to next step.
No
Repair or replace RFW control module. Then go to next step.
Turn ignition (engine) switch on. Move selector lever from 2H to 4H position. Does RFW operate from free to lock?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
NOISE
DESCRIPTION
Noise is heard from front differential.
[TROUBLESHOOTING HINTS] Joint shaft bearing abrasion or damage RFW hub abrasion
STEP 1 2 3 4
5
4
Joint shaft abrasion Conventional front differential parts malfunction
INSPECTION
ACTION
Inspect joint shaft bearing. Is it okay?
Yes
Go to next step.
No
Replace joint shaft bearing.
Inspect RFW hub. Is it okay?
Yes
Go to next step.
No
Replace RFW hub.
Inspect joint shaft. Is it okay?
Yes
Go to next step.
No
Replace joint shaft.
Malfunction is caused by other than RFW. Inspect conventional front differential parts. parts Are they okay?
Yes
Go to next step.
No
Replace defective part(s).
Has front differential noise stopped?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
OIL LEAKAGE
DESCRIPTION
The oil leaks from front differential.
[TROUBLESHOOTING HINTS] Poor installation of the RFW control box
STEP 1
2
3
Malfunction of conventional front differential parts
INSPECTION Is RFW control box installed completely?
ACTION Yes
Go to next step.
No
Install RFW control box securely. Then go to Step 3.
Malfunction is caused by something other than RFW. Inspect conventional front differential parts. Are they okay?
Yes
Go to next step.
No
Replace defective part(s).
Is there any oil leakage from front differential?
Yes
Inspect malfunction symptoms again, then repeat from Step 1 if malfunction still occurs.
No
Troubleshooting completed. Explain repairs to customer.
CONTINUED
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STEERING SYSTEM GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N–1 MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N–1 STEERING WHEEL AND COLUMN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1/2 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N–3/4 STEERING SHAFT INSPECTION . . . . . . . . . . . N–4 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–5/6 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–7/9 STEERING GEAR AND LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–9 POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . N–10 AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N–10 POWER STEERING FLUID INSPECTION . . . N–10/12
GENERAL PROCEDURES
STEERING WHEEL AND COLUMN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–12 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–12 STEERING SHAFT INSPECTION . . . . . . . . . . . N–12 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–13 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–14/15 STEERING GEAR AND LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–15 POWER STEERING OIL PUMP REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–16/18 POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N–19/20 POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–21
MANUAL STEERING
Wheels and tires removal/installation STEERING WHEEL AND COLUMN INSPECTION The removal and installation procedures for the Steering Wheel Play Inspection wheels and tires are not mentioned in this section. If the play exceeds specification, either the steering When a wheel is removed, retighten it to the joints are worn or the backlash of the steering gear specified torque. is excessive. With the wheels in the straight-ahead (Refer to section TD,SUSPENSION, Wheels and Tires.) position, gently turn the steering wheel to the left and right and verify that the play is within Power steering components removal/installation specification. If any power steering fluid line has been disconnected anytime during the procedure, add Steering wheel play ATF M–III or equivalent (e.g. Dexron II), bleed 0—30 mm {0—1.18 in} the fluid lines, and inspect for leakage after the procedure has been completed. Steering Wheel Looseness Inspection Move the steering wheel as shown in the figure to Connectors disconnection/connection inspect for column bearing wear, steering shaft Disconnect the negative battery cable before doing joint play, steering wheel looseness, and column any work that requires handling of connectors. looseness. Reconnect the negative battery cable only after the work is completed.
CONTINUED
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MANUAL STEERING Steering Wheel Effort Inspection 1. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 2. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Measure the steering wheel effort using a torque wrench.
Steering wheel effort 4.5 N·m {460 kgf·cm, 399 in·lbf} max. 4. If not as specified, inspect the following: rotation starting torque of pinion, rotation torque of each ball joint, and steering joints.
CONTINUED
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MANUAL STEERING STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 40—50 {4.0—5.0, 29—36}
40—50 {4.0—5.0, 29—36}
AIR BAG MODEL
R
16—22 {1.6—2.3, 12—16} 16—22 {1.6—2.3, 12—16} 20—26 {2.0—2.7, 15—19} 18—24 {1.8—2.5, 14—18}
20—26 {2.0—2.7, 15—19}
N·m {kgf·m, ft·lbf}
1
Horn cap
6
Combination switch
2
Air bag module (with air bag) + section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION
7
Steering shaft + Installation Note
8
Universal joint
3
Locknut
9
Boot
4
Steering wheel + Removal Note + Installation Note
10
Intermediate shaft
11
Steering lock component + Removal Note + Installation Note
5
Column cover
CONTINUED
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MANUAL STEERING Steering Wheel Removal Note Caution Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse. Set the wheels in the straight-ahead position,
remove the steering wheel using a suitable puller. Steering Lock Component Removal Note Use a chisel to make a groove in the heads of the steering lock mounting bolts. Remove the bolts using a screwdriver. Remove the steering lock component.
Steering Lock Component Installation Note Install the new steering lock mounting bolts. Tighten the bolts until the heads break off.
A
B
Steering Wheel Installation Note 1. For vehicles with air bags, adjust the clock spring. (Refer to section T, CLOCK SPRING, CLOCK SPRING ADJUSTMENT.) 2. Install the steering wheel with the vehicle in the straight-ahead position. STEERING SHAFT INSPECTION Inspect the following, and replace the column component as necessary. 1. Needle and ball bearing damage. 2. Steering shaft length. Length 816.9—819.9 mm {32.17—32.27 in}
Steering Shaft Installation Note 1. Temporarily tighten the bolt A. 2. Tighten the nut B to the specified torque. 3. Tighten the bolt A to the specified torque. Tightening torque 16—22 N·m {1.6—2.3 kgf·m, 12—16 ft·lbf} 3. Dust boot damage.
CONTINUED
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MANUAL STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1. With the wheels in the straight-ahead position, remove in the order indicated in the table. 2. Install in the reverse order of removal.
37—54 {3.7—5.5, 27—39} 20—26 {2.0—2.7, 15—19}
45—58 {4.5—6.0, 33—43}
SST 69—78 {7.0—8.0, 51—57}
R
R
45—58 {4.5—6.0, 33—43}
SST
79—157 {8.0—16.0, 58—115}
R
45—58 {4.5—6.0, 33—43}
R
SST
37—54 {3.7—5.5, 27—39} 45—58 {4.5—6.0, 33—43}
R
SST
SST N·m {kgf·m, ft·lbf}
1
Cotter pin
9
Washer
2
Nut
10
Bolt, nut, washer
3
Ball joint + Removal Note
11
Idler arm bracket
12
Bolt, nut, washer
4
Locknut
13
Bolt
5
Tie rod
14
6
Center link
Steering gear and pitman arm + Removal Note
7
Idler arm + Removal Note
15
8
Bushing
Dust boot + Removal Note + Installation Note
CONTINUED
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MANUAL STEERING Ball Joint, Idler Arm, Steering Gear and Pitman Arm Removal Note Remove the ball joint from the knuckle and center link, the idler arm from the center link, and steering gear and pitman arm from the center link using the SST. 49 T028 3A0
Dust Boot Removal Note 1. Place the chisel against the boot and hold it at the angle shown. 2. Remove the dust boot by tapping it with a hammer.
Dust Boot Installion Note 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot using the SST and a press.
49 1243 785A
CONTINUED
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MANUAL STEERING STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 25—34 {2.5—3.5, 25—34} 15—21 {1.5—2.2, 11—15}
15—24 {1.5—2.5, 11—18}
R
128—166 {13.0—17.0, 95—122}
R SST
R
R R
197—235 {20.0—24.0, 145—173}
SST
R
1
Nut
9
Adjusting screw
2
Pitman arm + Disassembly Note
10
Oil seal
11
Retaining ring
3
Clip
12
4
Dust boot + Assembly Note
Locknut + Disassembly Note
13
Oil seal
5
Locknut (side cover) + Disassembly Note
14
Adjusting nut + Disassembly Note
6
Sector shaft + Disassembly Note + Assembly Note
15
Bearing
16
Worm ball nut + Assembly Note
17
Bearing
7
Side cover
8
Adjusting shim
N·m {kgf·m, ft·lbf}
CONTINUED
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MANUAL STEERING Pitman Arm Disassembly Note Separate the pitman arm from the steering gear using the SST.
Adjusting Nut Disassembly Note Remove the adjusting nut using the SST.
49 UB39 585A
49 U032 3A0
Locknut (Side Cover), Sector Shaft Disassembly Note 1. Loosen the locknut. 2. Remove the side cover attaching bolts. 3. Set the sector shaft in the middle position. 4. Tap the sector shaft lower end using a plastic hammer to loosen the sector shaft. 5. Lift and remove the sector shaft with the locknut and the side cover from the gear housing.
Worm Ball Nut Assembly Note 1. Inspect the worm ball nut preload using the SST.
49 0180 510B
Worm ball nut preload 1.0—1.3 N·m {10—14 kgf·cm, 8.7—12.1 in·lbf} [Without the sector shaft] 2. If not as specified, adjust the preload. (1) Loosen the locknut and turn the adjusting screw using the SST. Locknut Disassembly Note Remove the locknut using the SST.
49 U032 201 49 U032 201
CONTINUED
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MANUAL STEERING (2) Tighten the locknut to the specified torque using the SST. Tightening torque 128—166 N·m {13—17 kgf·m, 95—122 ft·lbf} 49 U032 201 49 U034 209
5. Wipe away excessive grease. STEERING GEAR AND LINKAGE INSPECTION Steering Gear Backlash Adjustment Caution Adjust the backlash while keeping the steering gear in the center position. Otherwise, the backlash becomes excessively small and gears may be damaged.
(3) Inspect the worm ball nut preload again. Sector Shaft Assembly Note 1. Set the adjusting screw and shim, in the “T” groove. 2. Measure the clearance in the axial direction.
Turn the adjusting screw to adjust steering gear
backlash. Backlash 0 mm ADJUSTING SHIM
3. Adjust the clearance to the specified value if the clearance is more than the specified value. Clearance 0—0.1 mm (0—0.004 in) Adjusting shim thickness 1.97 mm {0.077 in} 2.00 mm {0.079 in} 2.03 mm {0.079 in} 2.06 mm {0.081 in} 2.09 mm {0.082 in} Caution Be careful not to damage the oil seal and bearing. 4. Assemble the sector shaft in such a way that the teeth of the sector shaft mesh with the center part of the teeth of the worm ball nut. Dust Boot Assembly Note 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot onto the ball joint. 4. Set the SST over the boot and install a new clip.
CONTINUED
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POWER STEERING
POWER STEERING AIR BLEEDING 1. Inspect the fluid level. (Refer to POWER STEERING, POWER STEERING FLUID INSPECTION, Fluid Level Inspection.) 2. Jack up the front of the vehicle and support it on safety stands. 3. Turn the steering wheel fully to the left and right several times with the engine not running. 4. Reinspect the fluid level. If it has dropped, add fluid. 5. Repeat Steps 3 and 4 until the fluid level stabilizes. 6. Lower the vehicle. 7. Start the engine and let it idle. 8. Turn the steering wheel fully to the left and right several times. 9. Verify that the fluid is not foamy and that the fluid level has not dropped. 10. Add fluid as necessary and repeat Steps 8 and 9.
POWER STEERING FLUID INSPECTION Fluid Level Inspection Inspect the power steering fluid level. Add fluid to the specified level as necessary. Fluid specification ATF M–III or equivalent (e.g. Dexron II) Fluid Leakage Inspection Caution To prevent damage to the steering system, do not keep the steering wheel in the fully turned position for more than 5 seconds. 1. Start the engine and let it idle. Turn the steering wheel fully to the left and right to apply fluid pressure. Note The points where fluid leakage may occur are indicated in the figure. 2. Inspect for fluid leakage.
R.H.D.
L.H.D.
F2 CIS F2 CARB
F2 CIS F2 CARB
WL WL TURBO
WL WL TURBO
G6
G6
CONTINUED
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POWER STEERING Fluid Pressure Inspection 1. Assemble the SSTs as shown in the figure.
7. Close the gauge valve completely. Increase the engine speed to 1,000—1,500 rpm and measure the fluid pressure generated by the oil pump. If the pressure is not within the specification, replace the oil pump component.
49 1232 670A
Oil pump fluid pressure 8.9—9.3 MPa {90—95 kgf/cm2, 1280—1350 psi} THERMOMETER 50—60 °C {122—140 °F}
49 H002 671
GAUGE CLOSE VALVE COMPLETELY
2. Mark both hose connections to ensure that the hose is reinstalled in its original position. 3. Disconnect the pressure hose from the oil pump. Attach the SST (49 G032 304). Tightening torque G6: 32—47 N·m {3.2—4.8 kgf·m, 24—34 ft·lbf} F2 CIS, F2 CARB, WL, WL Turbo: 30—44 N·m {3.0—4.5 kgf·m, 22—32 ft·lbf}
Caution If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid temperature will rise excessively and adversely affect the oil pump.
4. Connect the SSTs (49 1232 670A and 49 H002 671) to the SST (49 G032 304). G6
8. Open the gauge valve fully and increase the engine speed to 1,000—1,500 rpm. 9. Turn the steering wheel fully to left and right and measure the fluid pressure generated at the gear housing. If the pressure is not within the specification, repair or replace the steering gear component.
49 B032 304
Gear housing fluid pressure 8.9—9.3 MPa {90—95 kgf/cm2, 1280—1350 psi} F2 CIS, F2 CARB, WL, WL TURBO
THERMOMETER 50—60 °C {122—140 °F}
49 G032 3A4
GAUGE OPEN VALVE COMPLETELY
49 H002 671
5. Bleed the air from the system. 6. Open the gauge valve fully. Start the engine and turn the steering wheel fully left and right to raise the fluid temperature to 50—60 °C {122—140 °F}. Caution If the valve is left closed for more than 5 seconds, the fluid temperature will increase excessively and adversely affect the oil pump.
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque. Tightening torque 30—44 N·m {3.0—4.5 kgf·m, 22—32 ft·lbf} 11. Bleed the air from the system.
CONTINUED
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POWER STEERING Note To determine whether the steering effort is satisfactory or not, perform the inspection on another vehicle of the same model and under the same conditions, and compare the results. The steering wheel effort varies with conditions as shown below. 1. Road conditions, such as dry or wet, and asphalt or concrete. 2. Tire conditions, such as brand, wear, and tire pressure. 12. If not as specified, inspect the following points: Air in system Fluid leakage at hose or connectors Function of oil pump and steering gear STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) STEERING SHAFT INSPECTION (Refer to MANUAL STEERING, STEERING SHAFT INSPECTION.) STEERING WHEEL AND COLUMN INSPECTION Steering Wheel Play Inspection (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN INSPECTION, Steering Wheel Play Inspection.) Steering Wheel Looseness Inspection (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN INSPECTION, Steering Wheel Looseness Inspection.) Steering Wheel Effort Inspection 1. Inspect the following points: Tire size and tire pressure Fluid level 2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 3. Start the engine and warm the power steering fluid to 50—60 °C {122—140 °F}. 4. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 5. Measure the steering wheel effort using a torque wrench.
Steering wheel effort 7.8 N·m {80 kgf·cm, 69 in·lbf} max.
CONTINUED
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POWER STEERING STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 32—47 {3.2—4.8, 24—34} 24—35 {2.4—3.6, 18—26} 37—54 {3.7—5.5, 27—39}
20—26 {2.0—2.7, 15—19}
SST 69—78 {7.0—8.0, 51—57}
SST
R
79—157 {7.0—16.0, 58—115}
R
R 37—54 {3.7—5.5, 27—39}
45—58 {4.5—6.0, 33—43}
SST
R 45—58 {4.5—6.0, 33—43}
SST
SST N·m {kgf·m, ft·lbf}
1
Cotter pin
11
Idler arm bracket
2
Locknut
12
Pressure pipe
3
Ball joint + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Ball Joint Removal Note
13
Return pipe
14
Bolt
15
Bolt, nut, washer
4
Locknut
16
5
Tie rod
6
Center link
Steering gear and pitman arm + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Steering Gear and Pitman Arm Removal Note
7
Idler arm + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Idler Arm Removal Note
17
8
Bushing
9
Washer
Dust boot + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Dust Boot Disassembly Note + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Dust Boot Assembly Note
10
Bolt, nut, washer
CONTINUED
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POWER STEERING STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 57—64 {5.7—6.5, 42—47} 30—44 {3.0—4.5, 22—32}
R R
R R
R
R R
R
R R 56—63 {5.7—6.5, 42—47}
SST R
R
R
197—235 {20.0—24.0, 145—173}
SST
1
Nut
8
O-ring
2
Pitman arm + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Pitman Arm Disassembly Note
9
Y packing
10
Back up ring
11
Oil seal
3
Clip
12
Back up ring
4
Dust boot + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Dust Boot Assembly Note
13
Y packing
14
Dust cover
15
Snap ring
16
Washer
17
Oil seal
18
Valve and piston component + Assembly Note
19
O-ring
20
Seal ring
21
Gear housing
5
6
7
Locknut + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Locknut (Side Cover), Sector Shaft Disassembly Note Sector shaft + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Locknut (Side Cover) Sector Shaft Disassembly Note Side cover
N·m {kgf·m, ft·lbf}
CONTINUED
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POWER STEERING Valve and Piston Component Assembly Note Caution Do not scratch the seal ring and O-ring on the piston against the entrance to the housing. Insert the piston by slightly turning to the left and right so as not to create flection at the O-ring and seal ring. Insert the valve and piston component to the gear
housing.
STEERING GEAR AND LINKAGE INSPECTION (Refer to MANUAL STEERING, STEERING GEAR AND LINKAGE INSPECTION, Steering Gear Backlash Adjustment.)
N–15
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POWER STEERING POWER STEERING OIL PUMP REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. For F2 CIS, F2 Carb and G6 engine model, adjust the drive belt. (Refer to Section B2, DRIVE BELT,DRIVE BELT ADJUSTMENT.) F2 CIS, F2 CARB
30—44 {3.0—4.5, 22—32}
R
30—39 {3.0—4.0, 22—28}
SST 50—59 {5.0—6.0, 37—43} N·m {kgf·m, ft·lbf}
CONTINUED
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POWER STEERING
G6
19—25 {1.9—2.6, 14—18}
32—46 {3.2—4.7, 24—33}
32—47 {3.2—4.8, 24—34}
50—59 {5.0—6.0, 37—43}
SST
CLAMP POSITION
30 mm {1.2 in}
N·m {kgf·m, ft·lbf}
1
Drive belt
5
Return hose
2
Locknut + Removal Note
6
Power steering fluid pressure switch connector (except F2 Carb)
3
Oil pump pulley
7
Power steering oil pump component
4
Pressure pipe (F2 CIS, F2 Carb), pressure hose (G6)
Locknut Removal Note Secure the pulley using the SST and remove the locknut.
49 G032 354
CONTINUED
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POWER STEERING
WL, WL TURBO
30—44 {3.0—4.5, 22—32}
R
19—25 {1.9—2.6, 14—18}
19—25 {1.9—2.6, 14—18}
R
N·m {kgf·m, ft·lbf}
1
Pressure pipe
4
Power steering oil pump
2
Return hose
5
O-ring
3
Bolt and nut
CONTINUED
N–18
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POWER STEERING POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY 1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs are necessary. 2. Disassemble in the order indicated in the table. 3. Assemble in the reverse order of disassembly.
R
9.9—13.7 N·m {100—140 kgf·cm, 87—121 in·lbf}
15—19 {1.5—2.0, 11—14}
7.9—11.7 N·m {80—120 kgf·cm, 70—104 in·lbf}
G6
R
22—25 {2.2—2.6, 16—18}
R
R
R F2 CIS 50—68 {5.0—7.0, 37—50}
R
R
F2 CARB
18—21 {1.8—2.2, 14—16}
16—23 {1.6—2.4, 12—17}
22—25 {2.2—2.6, 16—18}
À N·m {kgf·m, ft·lbf}
SST
1
Power steering oil pump component + Disassembly Note
13
Rear body + Assembly Note
2
Pressure switch component
14
O-ring
3
O-ring
15
4
Nut (G6)
Cam ring + Assembly Note
5
Connector (G6)
16
Rotor
6
Connector bolt
17
7
O-ring
Vane + Assembly Note
8
Control valve component
18
Pin
9
Spring
19
Side plate + Assembly Note
10
Suction pipe
20
O-ring
11
O-ring
21
Oil seal
12
Shaft component
22
Front body
CONTINUED
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POWER STEERING Power Steering Oil Pump Disassembly Note
3. Install the vanes in the rotor with the rounded edges outward.
Caution To secure the oil pump in a vise, use the SST as shown to prevent damage to the pump.
ROUND EDGE
49 F032 301
Rear Body Assembly Note After installing the rear body, manually turn the shaft to verify that it rotates smoothly. Side Plate Assembly Note 1. Install a new O-ring and the side plate to the front body. 2. Position the side plate using the rear body.
Vane, Cam Ring Assembly Note 1. Install the cam ring with the marks facing the front body.
2. Install the rotor with the mark facing the rear body. MARK
CONTINUED
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POWER STEERING POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY 1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs are necessary. 2. Disassemble in the order indicated in the table. 3. Assemble in the reverse order of disassembly. R
7.9—11.7 N·m {80—120 kgf·cm, 69.5—104.1 in·lbf}
22—25 {2.2—2.6, 16—18}
R SST
R R
50—68 {5.0—7.0, 37—50} N·m {kgf·m, ft·lbf}
1
Power steering oil pump component + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Power Steering Oil Pump Component Disassembly Note
10
Cam ring + POWER STEERING POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Cam Ring Assembly Note
2 3
Suction pipe
11
Rotor
O-ring
12
Vane + POWERSTEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Vane Assembly Note
4
Connector
5
O-ring
6
Control valve
7 8
Spring
13
Rear body + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Rear Body Assembly Note
Side plate + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Side Plate Assembly Note
9
14
O-ring
O-ring
15
Front body
CONTINUED
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BRAKING SYSTEM GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . CONVENTIONAL BRAKE SYSTEM . . . . . . . . . . . AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM LINE INSPECTION . . . . . . . . . . . . . . BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . BRAKE PEDAL REMOVAL/INSTALLATION . . BRAKE SWITCH INSPECTION . . . . . . . . . . . . . MASTER CYLINDER REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FLUID LEVEL SENSOR INSPECTION . . . . . . MASTER CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER BRAKE UNIT INSPECTION . . . . . . . . POWER BRAKE UNIT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM SWITCH INSPECTION . . . . . . . . . . . VACUUM SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . VACUUM PUMP INSPECTION . . . . . . . . . . . . . VACUUM PUMP REMOVAL/INSTALLATION . LOAD SENSING PROPORTIONING VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . LOAD SENSING PROPORTIONING VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . .
P– 1 P– 2 P– 2 P– 2 P– 2 P– 3 P– 4 P– 4/6 P– 6 P– 7/8 P– 8 P– 9 P– 9 P–10 P–10 P–10 P–11
LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION . . . . . . . . . FRONT BRAKE (DISC) INSPECTION . . . . . . . FRONT BRAKE (DISC) REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . DISC PAD (FRONT) REPLACEMENT . . . . . . . CALIPER (FRONT) DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE (DRUM) INSPECTION . . . . . . . REAR BRAKE (DRUM) REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DRUM INSPECTION . . . . . . . . . . . . . . . WHEEL CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . PARKING BRAKE (STICK TYPE) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE (STICK TYPE) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
P–11 P–12 P–13/14 P–14 P–14 P–15 P–15 P–16 P–16 P–16 P–16 P–16 P–17 P–18/19
P–11
GENERAL PROCEDURES Wheel and tires removal/installation The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, retighten it to the specified tightening torque, referring to section TD. Brake lines disconnection/connection Caution Brake fluid will damage painted surfaces. If brake fluid get on a painted surface, wipe it off immediately.
Brake pipe flare nut tightening Tighten the brake pipe flare nut by using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.) Connectors disconnection Disconnect the negative battery cable before doing any work that requires handling of connectors. Reconnect the negative battery cable only after the work is completed.
If any brake line has been disconnected anytime
during the procedure, add brake fluid, bleed the brakes, and inspect leakage after the procedure has been completed. Fluid specification SAE J1703 or FMVSS116 DOT–3 or DOT–4
CONTINUED
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CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM AIR BLEEDING Note The reservoir should be kept 3/4 full during bleeding. The brakes should be bled whenever a brake line is disconnected. If a hydraulic line is disconnected at the master cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the next farthest slave cylinder until all four cylinders have been bled. If the disconnection point is anywhere except the master cylinder, start at the point closest to the disconnection, and move to the next closest slave cylinder until all four cylinders have been bled. 1. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. 2. Place the other end of the vinyl tube in a clear fluid-filled container. 3. One person should depress the brake pedal a few times, and then hold it in the depressed position. 4. A second person should loosen the bleeder screw, drain out the fluid and retighten the screw using the SST.
VACUUM LINE INSPECTION 1. Remove the clamps and the vacuum hose. 2. Apply both suction and pressure to the engine-side hose (Gasoline) or vacuum pump side of the hose (Diesel), and verify that air blows only toward that side. If air flows in both directions or not at all, replace the vacuum hose.
CHECK VALVE
ENG
BRAKE PEDAL INSPECTION Brake Pedal Height Inspection Verify that the distance from the center of the upper surface of the pedal pad to the floor pannel is as specified.
Tightening torque Front: 9—14 N·m {92—142 kgf·cm, 80—123 in·lbf} Rear: 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
Pedal height L.H.D.: 214—219 mm {8.43—8.81 in} R.H.D.:219—224 mm {8.63—8.81 in}
PEDAL HEIGHT
49 0259 770B
5. Repeat steps 3 and 4 until no air bubbles are seen. 6. After air bleeding, inspect the following: (1) brake operation (2) fluid leakage (3) fluid level
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Brake Pedal Height Adjustment 1. Disconnect the brake switch connector. 2. Loosen locknut B and turn switch A until it does not contact the pedal. 3. Loosen locknut D and turn rod C to adjust the height. 4. Tighten the bolt with locknut B so that clearance between the bolt for brake light switch A and pedal stopper is within the specification.
D
C
Specification 0.1—1.0 mm {0.004—0.039 in} Tightening torque 14—17 N·m {140—180 kgf·cm, 122—156 in·lbf} 5. Connect the brake switch connector. 6. After adjustment, inspect the pedal play and the brake light operation.
D
5. After adjustment, inspect the pedal height and the brake light operation. Pedal-to-floor Clearance Inspection 1. Start the engine and verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is depressed with a force of 589 N {60 kgf, 132 lbf}.
A
Clearance 105 mm {4.2 in} min. C
B
Brake Pedal Play Inspection 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Remove the snap pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin. 3. Gently depress the pedal by hand until resistance is felt (approx. 20N {2 kgf, 4.4 lbf}) and inspect the free play.
PEDAL-TO-FLOOR CLEARANCE
2. If the distance is less than specified, inspect the following: (1) Air in brake system (2) Malfunction of the automatic adjuster (3) Excessive shoe clearance
Pedal play 3—8 mm {0.12—0.31 in}
Brake Pedal Play Adjustment 1. Remove the snap pin and clevis pin. 2. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal. 3. Install the clevis pin and the snap pin. 4. Tighten locknut D.
BRAKE PEDAL REMOVAL/INSTALLATION R.H.D. The brake pedal is mounted on the bracket integrated with the clutch pedal and accelerator pedal. Refer to section F2, INTAKE AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION for the brake pedal removal/installation. L.H.D. The brake pedal is mounted on the bracket integrated with the clutch Pedal. Refer to section H, CLUTCH PEDAL REMOVAL/ INSTALLATION for the brake pedal removal/installation.
Tightening torque 24—34 N·m {2.4—3.5 kgf·m, 18—25 ft·lbf}
CONTINUED
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CONVENTIONAL BRAKE SYSTEM BRAKE SWITCH INSPECTION 1. Disconnect the brake switch connector. 2. Inspect for continuity between the terminals of the brake switch connector using the circuit tester. : Continuity
R.H.D.
Terminal
Condition
A
SST
B
R
When the brake pedal is depressed. When the brake pedal is not depressed.
SST * 12.9—21.5 {130—220, 113—190}
A
9.81—15.6 {100—160, 87—138}
B * 49 0259 770B
3. If not as specified, replace the brake switch. MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. L.H.D.
N·m {kgf·cm, in·lbf}
1
Brake fluid level sensor connector
2
Brake pipe
3
Bracket (R.H.D.)
4
Master cylinder + Installation Note
5
O-ring
Master Cylinder Installation Note 1. Loosen the adjusting nut of the SST. 2. Place the SST on the power brake unit and tighten the nut and washer. Tightening torque 9.81—15.6 N·m {100—160 kgf·cm, 87—138 in·lbf}
SST
R
3. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum to the power brake unit using a vacuum pump.
9.81—15.6 {100—160, 87—138}
SST * 12.9—21.5 {130—220, 113—190}
* 49 0259 770B
N·m {kgf·cm, in·lbf}
49 B043 001
CONTINUED
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CONVENTIONAL BRAKE SYSTEM 4. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and SST body. 5. Remove the SST from the power brake unit.
Clearance at B 1. Measure and record the height D1 of the gauge rod.
(D1)
TOUCHING
49 B043 001
49 B043 001
2. Turn the adjusting nut until the SST body sets closely on the master cylinder. Turn only enough for the body to touch. 3. Measure and record height D2 of the gauge rod.
TOUCHING ADJUSTING NUT
6. Remove the SST from the power brake unit without disturbing the adjusting nut. Set the SST onto the master cylinder as shown in the figure. 7. Push lightly on the end of the SST gauge rod to be sure that it is contacting the bottom of the master cylinder piston, but do not push so hard that the piston moves. Note any clearance between the SST body and the adjusting nut: clearance B, or between the body and the master cylinder: clearance C. Adjust the push rod as necessary as outlined in “Adjustment” below. Adjustment Measurement
Push rod
Clearance at B
Too long
Clearance at C
Too short
No clearance at B or C
Okay
ADJUSTING NUT (D2)
CLEARANCE (B)
49 B043 001
4. Subtract D1 from D2. Using the SST, turn the nut to shorten the power brake unit push rod an amount equal to the difference. 49 B043 004
CLEARANCE (C)
49 B043 001 49 E043 003A
CLEARANCE (B)
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Clearance at C 1. Push lightly on the end of the SST gauge rod, and measure the clearance between the adjusting nut and the SST body.
CLEARANCE (C)
49 B043 001
2. Using the SSTs, turn the nut to lengthen the power brake unit push rod an amount equal to the clearance measured at B. 49 B043 004
49 E043 003A
FLUID LEVEL SENSOR INSPECTION 1. Disconnect the sensor connector. 2. Connect an ohmmeter to the connector. 3. Starting with the fluid level above MIN, verify that there is no continuity. 4. Remove the brake fluid and verify that there is continuity when the level is below MIN. : Continuity Terminal
Fl id level Fluid
A
B
Below MIN. Above MIN.
5. If not as specified, replace the sensor.
A B
CONTINUED
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CONVENTIONAL BRAKE SYSTEM MASTER CYLINDER DISASSEMBLY/ASSEMBLY Caution If the master cylinder body is damaged, replace the unit as a component. When securing the master cylinder in a vise, tighten only the flange of the master cylinder. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R
À
R
R
R
R
1.0—1.5 {10—15, 8.7—13}
R 2.0—2.4 {20—25, 18—21}
N·m {kgf·cm , in·lbf}
1
Cap set
10
Cup
2 3
Screw
11
Primary piston stopper
Reservoir
12
Primary piston
4
Joint bushing
13
5
Fluid level sensor
Stop screw + Assembly Note
6
Snap ring
14
O-ring
7
Spacer
15
Secondary piston
8
Piston guide
16
Master cylinder body
9
O-ring
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Stop Screw and O-ring Assembly Note 1. Install a new O-ring onto the stop screw. 2. Push the primary piston component in full. 3. Install and tighten the stop screw.
(Inspection using the testers) 1. Connect the SSTs, vacuum gauge, and pedal depression force gauge as shown in the figure. Note Use commercially available gauges and pedal depression force gauge. Bleed the air from the SST at gauge A.
Tightening torque 2.0—2.4 N·m {20—25 kgf·cm, 18—21 in·lbf}
49 U043 004
A A
49 U043 006
POWER BRAKE UNIT INSPECTION Power Brake Unit Function Inspection (Simple method)
PEDAL DEPRESSION FORCE GAUGE VACUUM GAUGE
2. After bleeding the air from the SST, conduct the test as described in the following steps. a) Inspection for vacuum loss Unloaded condition 1. Start the engine. 2. Stop the engine when the vacuum gauge reading reaches 66.7 kPa {500 mmHg, 19.7 inHg}. 3. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3—66.7 kPa {475—500 mmHg, 18.7—19.7 inHg}, the unit is operating.
Note Replace power brake unit component as necessary. Step 1 1. With the engine stopped, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. If the pedal moves down slightly, immediately after the engine starts, the unit is operating. Step 2 1. Start the engine. 2. Stop the engine after it has run for 1 or 2 minutes. 3. Depress the pedal with the usual force. 4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating. Note If a problem is found, inspect for damage on the check valve or vacuum hose, and examine the installation. Repair as necessary, and inspect it again.
49 U043 005
Loaded condition 1. Start the engine. 2. Depress the brake pedal with a force of 196 N {20 kgf, 44 lbf}. 3. With the brake pedal depressed, stop the engine when the vacuum gauge reading reaches 66.7 kPa {500 mmHg, 19.7 inHg}. 4. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.3—66.7 kPa {475—500 mmHg, 18.7—19.7 inHg}, the unit is operating. b) Inspection for hydraulic pressure 1. When the engine is stopped (vacuum 0 kPa {0 mmHg, 0 inHg}) and the fluid pressure is within the specification, the unit is operating.
Step 3 1. Start the engine. 2. Depress the pedal with the usual force. 3. Stop the engine with the pedal held depressed. 4. Hold the pedal down for about 30 seconds. 5. If the pedal height does not change, the unit is operating.
Pedal force
Fluid pressure
196 N {20 kgf, 44 lbf}
790 kPa {8 kgf/cm2, 114 psi} min
2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg}. If the fluid pressure is within the specification, the unit is operating. Pedal force
Fluid pressure
196 N {20 kgf, 44 lbf}
8,240 kPa {84 kgf/cm2, 1,200 psi} min
CONTINUED
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CONVENTIONAL BRAKE SYSTEM POWER BRAKE UNIT REMOVAL/INSTALLATION 1. Remove the master cylinder. (Refer to CONVENTIONAL BRAKE SYSTEM, MASTER CYLINDER REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. L.H.D.
R
19—25 {1.9—2.6, 14—18}
1
Vacuum switch connector (Diesel)
2
Vacuum hose
3
Snap pin
4
Clevis pin
5
Nut
6
Power brake unit
7
Gasket
8
Fork
9
Nut
VACUUM SWITCH INSPECTION (DIESEL) 1. Remove the vacuum hose from the power brake unit. 2. Set the vacuum pump hose (commercially available on the market) onto the power brake unit as shown.
24—34 {2.4—3.5, 18—25}
N·m {kgf·m, ft·lbf}
3. Turn the engine switch on. 4. Release the parking brake. 5. Apply vacuum to the power brake unit using the vacuum pump (commercially available on the market) and verify the operating condition of the brake light warning light.
R.H.D.
Vacuum kPa {mmHg, inHg}
R
19—25 {1.9—2.6, 14—18}
Brake warning light
Below 10.71.3 {8010, 3.20.4}
ON
Above 10.71.3 {8010, 3.20.4}
OFF
6. The vacuum switch is functioning normally if it corresponds to the above specifications. Replace the vacuum switch as necessary.
24—34 {2.4—3.5, 18—25}
N·m {kgf·m, ft·lbf}
CONTINUED
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CONVENTIONAL BRAKE SYSTEM VACUUM SWITCH REMOVAL/INSTALLATION (DIESEL) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
VACUUM PUMP INSPECTION (DIESEL) 1. Warm up the engine. 2. Disconnect the vacuum hose from the vacuum pump and connect a vacuum gauge as shown in the figure, then inspect the vacuum.
L.H.D.
Vacuum specification (In 20 seconds) Engine speed 1,500 rpm 73.3 kPa {550 mmHg, 21.7 inHg} Maximum vacuum Engine speed 3,000 rpm 93.3 kPa {700 mmHg, 27.6 inHg}
20—24 {2.0—2.5, 15—18}
N·m {kgf·m, ft·lbf}
R.H.D.
3. If the pressure is less than the specification, inspect for the following. (1) Malfunction of the vacuum pump (2) Shortage of the lubrication oil pressure
20—24 {2.0—2.5, 15—18} N·m {kgf·m, ft·lbf}
1
Vacuum switch connector
2
Vacuum switch + Installation Note
VACUUM PUMP REMOVAL/INSTALLATION (DIESEL) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
Vacuum Switch Installation Note 1. Remove the old sealant. Caution Do not apply sealant to the tip of the vacuum switch as a malfunction may occur. 2. Apply sealant to the area shown before installation of the vacuum switch onto the power brake unit, and then tighten it to the specified torque. Tightening torque 20—24 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
R DO NOT APPLY SEALANT ON THIS AREA
19—25 {1.9—2.6, 14—18} N·m {kgf·m, ft·lbf}
1
Vacuum hose
2
Bolt
3
Vacuum pump
4
O-ring
CONTINUED
P–10
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CONVENTIONAL BRAKE SYSTEM LOAD SENSING PROPORTIONING VALVE INSPECTION 1. Place the vehicle on level ground. 2. Inspect the tire inflations and set them to the recommended pressure as necessary. 3. Prepare the vehicle with a person in the driver’s seat; include the standard vehicle tools, the spare wheel and tire, and a full tank of fuel. 4. Connect pressure gauges (commercially available) to the front and rear calipers.
LOAD SENSING PROPORTIONING VALVE ADJUSTMENT 1. Place the unloaded vehicle on level ground. Unloaded condition: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated position. Note A change of 5 mm {0.197 in} dimension L results in a change of 853 kPa {8.7 kgf/cm2, 124 psi} for 42 and 1020 kPa {10.4 kgf/cm2, 148 psi} for 44. 2. Adjust main spring dimension L between the LSPV and the adjustment link by loosening and repositioning the LSPV. (1) Decrease dimension L if the fluid pressure is low. (2) Increase dimension L if the fluid pressure is high. Reference value Dimension L 42: 147.5—154.5 mm {5.808—6.082 in} 44: 175.5—182.5 mm {6.910—7.185 in}
Note When applying the specified pressure, the brake pedal must not be “double pumped” or released. Approximately two seconds after setting the front wheel cylinder fluid pressure, read the rear pressure. 5. Bleed the air from the brake system. 6. Slowly depress the brake pedal until the front pressure gauge indicates the specified pressure shown in the table, then note the reading on the rear pressure gauge. kPa {kgf/cm2, psi} Front pressure
Rear pressure
4,900 {50, 711}
2,550 {26, 370}
9,810 {100, 1,422}
3,530 {36, 512}
MAIN SPRING
ADJUSTMENT LINK
AXLE CASING
LOADED A PERSON IN DRIVER’S SEAT BOLT 4,900 {50, 711} 9,810 {100, 1,422} REAR PRESSURE FRONT PRESSURE
3. After adjustment, recheck the fluid pressure. If not as specified, replace the LSPV as a component.
kPa {kgf/cm2, psi}
7. If not as specified, replace and adjust the LSPV.
LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION Caution Do not disassemble the LSPV. Do not move the nut A. 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
CONTINUED
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CONVENTIONAL BRAKE SYSTEM 3. After installation, adjust the main spring dimension. (Refer to CONVENTIONAL BRAKE SYSTEM, LOAD SENSING PROPORTIONING VALVE ADJUSTMENT.)
Disc Plate Thickness Inspection 1. Measure the thickness of the disc plate. Caution When it is necessary to machine the disc plate, if the disc plate is removed from the vehicle then machined, excessive runout may result. Machine the disc plate with it installed on the vehicle.
12.8—21.5 N·m {130—220 kgf·cm, 113—190 in·lbf}
SST * 12.8—21.5 N·m
SST *
{130—220 kgf·cm, 113—190 in·lbf}
A
Standard 24 mm {0.94 in} Minimum 22 mm {0.87 in} Minimum thickness after machining by using a brake lathe on-vehicle 22.8 mm {0.90 in}
19—25 {1.9—2.6, 14—18}
2. If the thickness is not within the specification, replace the disc plate. 19—25 {1.9—2.6, 14—18}
* 49 0259 770B
1
Brake pipe
2
Nut
3
Bolt
4
Load sensing proportioning valve
N·m {kgf·m, ft·lbf}
FRONT BRAKE (DISC) INSPECTION Disc Pad Thickness Inspection 1. Jack up the front of the vehicle and support it on safety stands. 2. Remove the wheel and tires. 3. Look through the caliper inspection hole and inspect the remaining thickness of the pads.
Disc Plate Runout Inspection 1. Verify that there is no wheel bearing looseness. 2. Measure the runout at the outer edge of the contact surface of the disc pad.
Thickness 2.0 mm {0.08 in} min.
Runout 0.05 mm {0.002 in} max. 3. If the runout is not within the specification, repair or replace the disc plate.
4. Replace the pads as a set (right and left wheels) if either is at or less than the minimum thickness.
CONTINUED
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CONVENTIONAL BRAKE SYSTEM FRONT BRAKE (DISC) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
22—29 {2.2—3.0, 16—29}
R 29—34 {2.9—3.5, 21—25}
R
108—127 {10.4—14.0, 80—94}
SST
N·m {kgf·m, ft·lbf}
1
Brake hose
6
Disc pad + Installation Note
2
Bolt
3
Guide pin
7
Plate
4
Dust boot
8
Guide plate
5
Caliper
9
Mounting support
CONTINUED
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CONVENTIONAL BRAKE SYSTEM Disc Pad Installation Note 1. Push the piston fully inward using the SST. 2. Install the disc pad.
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
* SST 9—14 {92—143, 80–123}
49 0221 600C SST
DISC PAD (FRONT) REPLACEMENT 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. R 29—34 {2.9—3.5, 21—25}
*49 0259 770B
N·m {kgf·cm, in·lbf}
R
1
Piston + Disassembly Note
2
Dust seal
3
Piston seal + Disassembly Note
4
Bleeder cap, screw
5
Caliper body
Piston Disassembly Note SST
Caution Blow the compressed air slowly to prevent the piston from suddenly popping out.
N·m {kgf·m, ft·lbf}
1
Bolt
2
Caliper
3
Disc pad + CONVENTIONAL BRAKE SYSTEM, FRONT BRAKE (DISC) REMOVAL/INSTALLATION, Disc Pad Installation Note
4
Plate
5
Guide plate
Place a piece of wood in the caliper, then blow
compressed air through the hole to force the piston out of the caliper. WOOD
Piston Seal Disassembly Note Remove the piston seal from the brake caliper using the SST.
CONTINUED
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CONVENTIONAL BRAKE SYSTEM REAR BRAKE (DRUM) INSPECTION Brake Lining Thickness Inspection 1. Remove the brake drum. 2. Inspect the remaining thickness of the lining. Thickness 1.0 mm {0.04 in} min. 3. Replace both left and right brake shoes if either is at or less than the minimum thickness.
REAR BRAKE (DRUM) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation. (1) Depress the brake pedal a few times, then verify that the brakes do not drag. (2) Inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION, Parking Brake Lever Stroke Inspection.) 9.8—12.7 {100—130, 87—112}
* SST 12.8—21.5 {130—220, 113—190}
APPLY
*49 0259 770B
1
Brake drum
2 3 4 5
TO SHADED EREA
N·m {kgf·cm, in·lbf}
8
Adjust strut
Hold spring, washer
9
Brake shoe
Hold pin
10
Parking brake cable
Lower return spring
11
Operating lever
Upper return spring
12
Brake pipe
6
Pawl lever spring
13
Wheel cylinder
7
Pawl lever
14
Gasket
CONTINUED
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CONVENTIONAL BRAKE SYSTEM, PARKING BRAKE SYSTEM BRAKE DRUM INSPECTION 1. Measure the inner diameter of the drum.
PARKING BRAKE SYSTEM PARKING BRAKE (STICK TYPE) INSPECTION Parking Brake Lever Stroke Inspection 1. Pull the parking brake lever a few times. 2. Verify that the stroke is within the specification when the parking brake lever is pulled with a force of 98 N {10 kgf, 22 ibf}.
Maximum diameter 42: 271.5 mm {10.68 in} 44: 296.5 mm {11.67 in} 2. Apply chalk to the inside of the brake drum. 3. Inspect for scratches and uneven or abnormal wear inside the drum as shown in the figure.
Stroke 1—7 notches 3. If not as specified, adjust the parking brake lever stroke. PARKING BRAKE (STICK TYPE) ADJUSTMENT Parking Brake Lever Stroke Adjustment 1. Before adjustment, depress the brake pedal several times while the vehicle is moving in reverse. 2. Loosen the locknut A and turn the adjustment nut B so that the stroke is within the above range. 3. After adjustment, tighten the locknut A.
4. Repair or replace the drum as necessary. Repair if the problem is minor. 5. When repairing or replacing the drum, check the contact with the shoes. 6. Wipe the chalk off after inspection. WHEEL CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Tightening torque 6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
B A
R SST *
R
4. After adjustment, inspect the following points. (1) Turn the ignition (engine) switch on, pull the parking brake lever one notch, and verify that the brake warning light illuminates. (2) Verify that the rear brakes do not drag when the wheels are turned by hand.
5.9—8.8 { 60—90 , 53—78 }
R
R
* 49 0259 770B
1
Dust boot
2
Piston
3
Piston cap
4
Spring
5
Bleeder cap, screw
6
Cylinder body
N·m { kgf·cm , in·lbf }
CONTINUED
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PARKING BRAKE SYSTEM PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
12.8—18.6 {130—190, 113—164}
6.9—9.8 {70—100, 43—86}
N·m {kgf·cm, in·lbf}
1
Clip
9
Pin and clip
2
Joint pin
10
Spring
3
Cable connector
11
Rachet pawl
4
Parking brake switch
12
Stopper
5
Clip
13
Fork joint
6
Pin
14
Spring
7
Clip and joint pin
15
Guide
8
Lever
16
Rod
CONTINUED
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PARKING BRAKE SYSTEM PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION 1. Remove the under guard. (Refer to section F1–F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.) 4x2
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
4x4
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
N·m {kgf·m, ft·lbf}
CONTINUED
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PARKING BRAKE SYSTEM LHD model with F2 and G6 engine
1
Nut
7
Grommet
2
Bolt
8
Bolt
3
Spring
9
Spring (44)
4
Front brake cable
10
Clip
5
Bolt (44)
11
Rear cable (left)
6
Bracket (44)
12
Rear cable (right)
CONTINUED
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SUSPENSION GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT PREINSPECTION . . . . . FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . VEHICLE HEIGHT ADJUSTMENT . . . . . . . . . . FRONT SHOCK ABSORBER REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBER INSPECTION . . TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2) . . . . . . . . .
R–1 R–1 R–1 R– 2/3 R–3 R–3 R–5 R–5 R– 6/8
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4) . . . . . . . . . R– 9/11 LOWER ARM INSPECTION . . . . . . . . . . . . . . . . R–11 UPPER ARM REMOVAL/INSTALLATION . . . . R–12 UPPER ARM INSPECTION . . . . . . . . . . . . . . . . R–13 STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2) . . . . . . . . . R–13/14 STABILIZER REMOVAL/INSTALLATION (4 4) . R–14 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . R–15 REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION . . . . . . . R–15
GENERAL PROCEDURES
WHEEL ALIGNMENT
Wheels and tires removal/installation D The removal and installation procedures for the wheels and tires are not mentioned in this section. If a wheel is removed, retighten it to the specified tightening torque, referring to section TD.
WHEEL ALIGNMENT PREINSPECTION 1. Inspect the inflation of each tire, and set to the recommended pressure, as necessary. 2. Inspect the front wheel bearing play. Adjust the bearing preload or replace bearing(s) as necessary. (Refer to section M, FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE INSPECTION or FRONT AXLE (4 4), WHEEL HUB, STEERING KNUCKLE INSPECTION.) 3. Inspect the wheel and tire runout at all wheels. (Refer to section TD, SUSPENSION, Wheels and Tires.) 4. Inspect the ball joints and steering linkage for excessive looseness. 5. Place the vehicle on level ground with no luggage and passenger load. 6. The difference in height between the left and right sides from the center of the wheel to the fender brim must not exceed 10 mm {0.39 in}. If not within the specification, adjust the vehicle height. (Refer to FRONT SUSPENSION, VEHICLE HEIGHT ADJUSTMENT.)
Suspension arms removal/installation D Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded*. * Unloaded condition: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated position.
7. Shake the vehicle to settle the suspension.
CONTINUED
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WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT Specifications Specification
Item
4 2 (mm {in})
Total toe toe-in in
Front wheel heel alignment (*1Unloaded condition)
Maximum steering g angle
3"3 {0.12"0.12} 0° 16’ "16’
(degree) Inner
35° 00’
+2° –3°
Outer
33° 00’
+2° –3°
*2 *3
0° 14’ "14’ 33° 30’
+2° –3°
30° 00’
+2° –3°
Camber angle*2
0° 56’ "30’
1° 06’ "30’
Caster angle*3
1° 37’ "45’
2° 02’ "45’
8° 04’
10° 15’
Steering axis inclination (reference value) *1
4 4
Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Difference between left and right must not exceed 30’. Difference between left and right must not exceed 45’.
Maximum Steering Angle Adjustment 1. Loosen the adjusting bolt locknut. 2. Turn the adjusting bolt to provide the correct turning angle. 3. After adjustment, tighten the locknut to the specified torque.
Total Toe-in Adjustment 1. Loosen the tie-rod end locknuts. 2. Turn the tie rods by the same amount in the opposite direction. Note D One turn of the tie rod (both sides) changes the toe-in by about 30 mm {1.18 in}. D The left and right tie rods are both right threaded. To increase the toe-in, turn the right tie rod toward the front of the vehicle and the left tie rod equally toward the rear.
Tightening torque 40—58 N·m {4.0—6.0 kgf·m, 29—43 ft·lbf} 4 2
3. Tighten the tie-rod end locknuts. Tightening torque 69—78 N·m {7.0—8.0 kgf·m, 51—57 ft·lbf} TIE ROD
ADJUSTING BOLT 4 4
ADJUSTING BOLT
CONTINUED
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WHEEL ALIGNMENT, FRONT SUSPENSION Caster and Camber Adjustment 1. Loosen the upper arm shaft bolt and insert or remove adjustment shims to provide the correct angle. No.1—5 No.6—11
FRONT SUSPENSION VEHICLE HEIGHT ADJUSTMENT 1. Place the vehicle on level ground. 2. Inspect the front and rear tire pressure and adjust it as necessary. 3. Measure the distance from the center of each front wheel to the fender brim.
FRONT
Left/right difference 10 mm {0.39 in} max. Standard vehicle height (reference value) 4 2 Adjustment shim No.
Thickness (mm {in})
No.
Thickness (mm {in})
1
1.0 {0.039}
7
1.0 {0.039}
2
1.6 {0.063}
8
1.6 {0.063}
3
2.0 {0.079}
9
2.0 {0.079}
4
3.2 {0.126}
10
3.2 {0.126}
5
4.0 {0.157}
11
4.0 {0.157}
6
0.6 {0.024}
mm {in}
Cab type
Vehicle height
Regular Cab, Stretch Cab
427 {16.8}
Double Cab
422 {16.6}
4 4 Cab type
Tire size
Vehicle height
Regular g Cab,, Stretch Cab
205R16
519 {20.4}
235/75R15
515 {20.3}
205R16
510 {20.1}
235/75R15
506 {19.9}
Double Cab
Note D Shims No.1—5 are used on either side. Do not use more than two. D Shims No.6—11 are used at the front and rear of either sides. Do not use more than one. D Camber: A change of shim thickness (at front and rear) of 1 mm {0.039 in} results in a change of about 15’. D Caster: A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results in a change of about 30’. 2. After adjustment, tighten the upper arm shaft bolt to the specified torque. Tightening torque 94—116 N·m {9.5—11.9 kgf·m, 69—86 ft·lbf}
CONTINUED
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FRONT SUSPENSION 1. If the difference between left and right is not within the specification, adjust the vehicle height by turning the torsion bar spring anchor bolt. 4 2
4 4
ANCHOR BOLT
ANCHOR BOLT
CONTINUED
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FRONT SUSPENSION FRONT SHOCK ABSORBER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
6—8 mm {0.24—0.31 in}
55—80 {5.6—8.2, 41—59}
N·m {kgf·m, ft·lbf}
1
Nut + Installation Note
3
Bolt
4
Washer and nut
2
Retainer, bushing
5
Shock absorber
Nut Installation Note Tighten the nut so that the exposed thread of the shock absorber piston is 6—8 mm {0.24—0.31 in}.
FRONT SHOCK ABSORBER INSPECTION 1. Remove the front shock absorber from the vehicle. 2. Inspect for damage and oil leakage. 3. Inspect the rubber bushing for deterioration and wear. 4. Compress and extend the shock absorber piston at least three (3) times. Verify that the operational force does not change and that there is no unusual noise. 5. Compress the shock absorber piston and release it. Verify that the piston extends fully at a normal speed.
CONTINUED
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FRONT SUSPENSION TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Inspect the vehicle height and adjust it as necessary.
APPLY THREAD LOCKING COMPOUND
APPLY THREAD LOCKING COMPOUND
118—156 {12.0—16.0, 87—115} 118—156 {12.0—16.0, 87—115}
SST R
N·m {kgf·m, ft·lbf}
1
Cotter pin
11
Torque plate
2
Nut
12
Lower arm spindle, washer, and nut
3
Lower arm ball joint/Knuckle arm + Removal Note
13
4
Bolt, washer, and nut (shock absorber)
Rubber bushing + Removal Note + Installation Note
5
Anchor bolt + Removal Note + Installation Note
14
Tension rod bolt
15
Stabilizer bolt, bushing, retainer, spacer, and nut + Installation Note
6
Anchor swivel
16
Lower arm
7
Bolt and washer
17
Bound bumper, washer, and nut
8
Torsion bar component
18
Bolts and washer (ball joint)
9
Anchor arm
19
Lower arm ball joint
10
Torsion bar spring + Removal Note + Installation Note
20
Clip + Installation Note
21
Lower arm ball joint boot
CONTINUED
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FRONT SUSPENSION Lower Arm Ball Joint/Knuckle Arm Removal Note Separate the ball joint from the knuckle arm using the SST.
Clip Installation Note 1. Install the SST to the ball joint stud with the stud stands straight up. 2. Install the clip in the dust boot groove.
KNUCKLE
49 T028 3A0
Anchor Bolt Removal Note Mark the anchor bolt and swivel for reference during installation.
49 U034 208
Stabilizer Bolt, Bushing, Retainer, Spacer And Nut Installation Note Tighten the nuts so that 18—21 mm {0.71—0.82 in} of thread is exposed at the end of the bolt.
MATCHING MARK
18—21 mm {0.71—0.82 in}
Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation.
MATCHING MARK
Rubber Bushing Installation Note Install a new bushing using the SST.
MATCHING MARK
49 UB39 615
Rubber Bushing Removal Note Remove the rubber bushing from the body using the SST.
49 UB39 615
CONTINUED
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FRONT SUSPENSION Torsion Bar Spring Installation Note 1. Before installation, check the identification mark on the end of the torsion bar spring. L: Left bar, R: Right bar 2. Align the marks made during removal, and connect the torsion bar spring to the torque plate.
MATCHING MARK
MATCHING MARK
Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks made during removal are aligned.
MATCHING MARK
Note If the anchor bolt was not marked during removal, install it as follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper. (2) Install the anchor arm so that the angle A is 34° "4.5°. (3) Install the anchor bolt and tighten it 27.3 turns.
A
CONTINUED
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FRONT SUSPENSION TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (44) 1. Remove the driveshaft snap ring. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Inspect the vehicle height and adjust it as necessary.
118—156 {12.0—16.0, 87—115}
118—156 {12.0—16.0, 87—115}
SST
APPLY THREAD LOCKING COMPOUND
R
R
1
Cotter pin
13
Lower arm spindle (front), washer and nut
2
Nut
14
3
Lower arm ball joint/Knuckle arm + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Lower Arm Ball Joint/Knuckle Arm Removal Note
Stabilizer bolt, bushing, retainer, spacer and nut + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note
4
Bolt, washer and nut (shock absorber)
15
Lower arm
Anchor bolt and washer + Installation Note
16
Bound bumper, washer, and nut
17
Bolt, washer and nut
6
Anchor swivel
18
Lower arm ball joint
7
Bolt and washer
19
8
Torsion bar spring component
9
Anchor arm + Removal Note + Installation Note
Clip + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Clip Installation Note
10
Torsion bar spring + Removal Note + Installation Note
20
Lower arm ball joint boot
21
11
Torque plate
Lower arm bushing + Removal Note + Installation Note
12
Lower arm spindle (rear), washer and nut
5
CONTINUED
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FRONT SUSPENSION Anchor Arm Removal Note Mark the anchor arm and body for reference during installation.
Lower Arm Bushing Installation Note 1. Apply soapy water to the new bushing. 2. Install the bushing using the SST. 49 U034 2A0
Torsion Bar Spring Removal Note Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation.
Torsion Bar Spring Installation Note 1. Before installation, inspect the identification mark on the end of the torsion bar spring. L: Left bar, R: Right bar 2. Align the marks made during removal, and connect the torsion bar spring to the torque plate.
Anchor Arm Installation Note Align the marks made during removal, and install the anchor arm onto the torsion bar spring.
Lower Arm Bushing Removal Note Remove the lower arm bushing using the SST. 49 U034 2A0
CONTINUED
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FRONT SUSPENSION Anchor Bolt Installation Note Install the anchor bolt, and tighten it until the marks made during removal are aligned.
Note If the anchor bolt was not marked during removal, install it at follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper. (2) Install the anchor arm so that the angle A is 60°"4.5°. (3) Install the anchor bolt and tighten it 26.9 turns.
A
LOWER ARM INSPECTION 1. Remove the lower arm from the vehicle. 2. Inspect for damage, cracks, and bending. 3. Check the ball joint rotation torque. (1) Rotate the ball joint five times. (2) Connect the SST to the ball stud, and measure the rotation torque using a pull scale. (3) Replace it if not within the specification. Pull scale reading 20—34 N {2.0—3.5 kgf, 4.4—7.7 lbf} 49 0180 510B
CONTINUED
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FRONT SUSPENSION UPPER ARM REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Inspect the wheel alignment and adjust it as necessary.
R SST
1
Clip
6
Upper arm component
2
Cotter pin and nut
7
Bolt and washer
3
Upper arm ball joint/Knuckle arm + Removal Note
8
Upper arm ball joint
9
4
Bolt and washer
Clip + Installation Note
5
Adjustment shim + Removal Note
10
Upper arm ball joint boot
Upper Arm Ball Joint/Knuckle Arm Removal Note Separate the upper arm ball joint from the knuckle arm using the SST.
Clip Installation Note 1. Install the SST to the ball joint stud with the stud stands straight up. 2. Install the clip in the dust boot groove.
49 T028 3A0
49 U034 209
KNUCKLE
Adjustment Shim Removal Note Note the number, amount and position of the shims so that they are reinstalled in the correct positions.
R–12
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FRONT SUSPENSION UPPER ARM INSPECTION 1. Remove the upper arm from the vehicle. 2. Inspect for damage, cracks, and bending. 3. Check the ball joint rotation torque. (1) Rotate the ball joint five times. (2) Connect the SST to the ball stud, and measure the rotation torque using a pull scale. (3) Replace it if not within the specification.
49 0180 510B
Pull scale reading 5.0—24 N {0.5—2.5 kgf, 1.2—5.5 lbf} STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (42) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
22—26 {2.2—2.7, 16—19}
APPLY THREAD LOCKING COMPOUND
94—116 {9.5—11.9, 69—86}
94—127 {9.5—13.0, 69—94} N·m {kgf·m, ft·lbf}
1
Nut + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note
6
Stabilizer bracket
7
Bushing
8
Stabilizer bar
9
Tension rod nut + Installation Note
2
Retainer
10
Bushing and retainer
3
Bolt
11
Bolt
4
Bushing, retainer and spacer
12
Tension rod
5
Bolt
CONTINUED
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FRONT SUSPENSION Tension Rod Nut Installation Note Tighten the tension rod nuts so that length L is 98.5 mm {3.88 in}.
L
STABILIZER REMOVAL/INSTALLATION (44) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
22—26 {2.2—2.7, 16—19}
N·m {kgf·m, ft·lbf}
1
Nut + FRONT SUSPENSION, STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (42), Nut Installation Note
5
Retainer, bushing, and spacer
6
Bolt
7
Stabilizer bracket
2
Retainer and bushing
8
Bushing
3
Bolt
9
Stabilizer bar
4
Retainer and bushing
CONTINUED
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REAR SUSPENSION
REAR SUSPENSION REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION 1. Support the frame with safety stands and place a jack under the differential casing. Remove in the order indicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary. 2. Install in the reverse order of removal. 42
R
64—78 {6.5—8.0, 48—57}
59—78 {6.0—8.0, 44—57}
APPLY THREAD LOCKING COMPOUND
R
78—98 {8.0—10.0, 58—72}
R 20—26 {2.0—2.7, 15—19.5}
54—73 {5.5—7.5, 40—54}
N·m {kgf·m, ft·lbf}
1
Nut, washer, retainer, and bushing
10
Spring pin
2
Nut, washer, retainer, and bushing
11
Nut and washer
3
Shock absorber
12
Shackle pin
4
Nut and washer
13
Shackle plate
5
Nut and washer
14
Leaf spring component
6
U-bolt
15
7
Spring clamp
8
Stopper rubber
Leaf spring bushing + Removal Note + Installation Note
9
Bolt and washer
CONTINUED
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REAR SUSPENSION
44
99.1—112 {10.1—11.5, 73.1—83.1}
APPLY THREAD LOCKING COMPOUND
R
64—78 {6.5—8.0, 48—57}
59—78 {6.0—8.0, 44—57}
R 78—98 {8.0—10.0, 58—72}
20—26 {2.0—2.7, 15—19.5}
N·m {kgf·m, ft·lbf}
1
Bolt and nut
11
Bolt and washer
2
Washer, retainer, and bushing
12
Spring pin
3
Nut, washer, retainer, and bushing
13
Nut and washer
4
Shock absorber
14
Shackle pin
5
Nut and washer
15
Shackle plate
6
Nut and washer
16
Leaf spring component
7
U-bolt
17
8
Set plate
9
Spring clamp
Leaf spring bushing + Removal Note + Installation Note
10
Stopper rubber
CONTINUED
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REAR SUSPENSION Leaf Spring Bushing Removal Note Secure the leaf spring in a vise and remove the bushing using a chisel.
Leaf Spring Bushing Installation Note Press in the bushing using a suitable pipe.
CONTINUED
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PAGE 1 OF 2 BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BONNET REMOVAL/INSTALLATION . . . . . . . . BONNET ADJUSTMENT . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL . . . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DOOR REMOVAL/INSTALLATION . . . FRONT DOOR DISASSEMBLY/ASSEMBLY . . FRONT DOOR ADJUSTMENT . . . . . . . . . . . . . REAR DOOR REMOVAL/INSTALLATION . . . . REAR DOOR DISASSEMBLY/ASSEMBLY . . . REAR DOOR ADJUSTMENT . . . . . . . . . . . . . . . DOOR LOCK STRIKER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REGULATOR HANDLE REMOVAL . . . . . . . . . . REGULATOR HANDLE INSTALLATION . . . . . POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . POWER WINDOW MOTOR INSPECTION . . . POWER DOOR LOCK SYSTEM . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH INSPECTION . . . DOOR LOCK ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK ACTUATOR INSPECTION . . . . . DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK TIMER UNIT INSPECTION . . . . FUEL-FILLER LID AND OPENER . . . . . . . . . . . . FUEL-FILLER LID REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FUEL-FILLER LID ADJUSTMENT . . . . . . . . . . BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BUMPER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT BUMPER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . REAR BUMPER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR BUMPER DISASSEMBLY/ASSEMBLY . .
TO. MODEL .INDEX
BODY S– 2 S– 2/3 S– 3 S– 4 S– 4 S– 5 S– 5 S– 6 S– 7 S– 7 S– 8/9 S– 9 S– 9 S– 9 S– 9 S–10 S–10 S–10/12 S–12 S–12/13 S–13 S–13 S–13/14 S–14 S–14 S–15 S–15 S–15 S–15 S–15 S–15 S–16 S–16 S–17 S–19 S–19 S–19 S–19 S–19 S–19 S–20 S–20/21
EXTERIOR ATTACHMENT . . . . . . . . . . . . . . . . . . . RADIATOR GRILLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COWL GRILLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD GARNISH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . SIDE PROTECTOR REMOVAL . . . . . . . . . . . . . SIDE PROTECTOR INSTALLATION . . . . . . . . OVER FENDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . TAILGATE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . TAILGATE ADJUSTMENT . . . . . . . . . . . . . . . . . ROPE HOOK REMOVAL/INSTALLATION . . . . MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD SIDE MOLDING REMOVAL . . . WINDSHIELD SIDE MOLDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BELTLINE MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR BELTLINE MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . ROOF MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . OUTSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR INSPECTION . . POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . FILAMENT INSPECTION . . . . . . . . . . . . . . . . . . FILAMENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD REMOVAL . . . . . . . . . . . . . . . . . . WINDSHIELD INSTALLATION . . . . . . . . . . . . . . QUARTER WINDOW GLASS REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW GLASS REMOVAL . . . . . . . . REAR WINDOW GLASS INSTALLATION . . . . DASHBOARD AND CONSOLE . . . . . . . . . . . . . . .
S–1
S–21 S–21 S–21 S–21/22 S–22 S–22/23 S–23 S–23 S–23 S–24 S–24 S–24 S–24 S–24 S–24 S–24 S–25 S–25 S–25 S–25 S–25 S–25/26 S–26 S–26 S–27 S–27 S–27 S–27 S–27 S–27/28 S–28 S–28 S–28 S–29 S–29/30 S–30/31 S–32 S–33 S–33 S–34
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BONNET
BODY
PAGE 2 OF 2 DASHBOARD REMOVAL/INSTALLATION . . . DASHBOARD DISASSEMBLY/ASSEMBLY . . DASHBOARD MEMBER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COLUMN COVER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT CONSOLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . REAR CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR CONSOLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . GLOVE COMPARTMENT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . METER HOOD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-PILLAR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SIDE TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SCUFF PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR SCUFF PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
S–34 S–35 S–36 S–36 S–36 S–36 S–36 S–37 S–37 S–37 S–38 S–38 S–38 S–38 S–38 S–39 S–39 S–39
C-PILLAR TRIM REMOVAL/INSTALLATION . . S–39 QUARTER UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–39/40 QUARTER LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40 BACK UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40 BACK LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40 FRONT DOOR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–41 REAR DOOR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–41 HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–42 HEADLINER REMOVAL/INSTALLATION . . . . . S–42 FLOOR COVERING . . . . . . . . . . . . . . . . . . . . . . . . . S–42 FLOOR COVERING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–42/43 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–44 SEAT BELT REMOVAL/INSTALLATION . . . . . . S–44/45 SEAT BELT INSPECTION . . . . . . . . . . . . . . . . . S–45/46 BUCKLE REMOVAL/INSTALLATION . . . . . . . . . S–46 BUCKLE SWITCH INSPECTION . . . . . . . . . . . . S–47 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–48 FRONT SEAT REMOVAL/INSTALLATION . . . . S–48 FRONT SEAT DISASSEMBLY/ASSEMBLY . . . S–49/50 CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . S–51 REAR SEAT REMOVAL/INSTALLATION . . . . . S–51/52 REAR SEAT DISASSEMBLY/ASSEMBLY . . . . S–52/53 SEAT WARMER SWITCH REMOVAL . . . . . . . S–54 SEAT WARMER SWITCH INSTALLATION . . . S–54 SEAT WARMER SWITCH INSPECTION . . . . . S–54 SEAT WARMER UNIT INSPECTION . . . . . . . . S–54
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BONNET 3.0—3.9 {30—40, 27—34}
Warning D Removing the bonnet without supporting it can be dangerous. The bonnet may fall and injure you. Always perform these procedures together with at least another person.
Á
À
Â
A A
BONNET REMOVAL/INSTALLATION 1. Pull out the windshield washer pipe. 2. To remove the bonnet hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 3. To remove the bonnet lock, remove the radiator grille. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the bonnet. (Refer to BONNET ADJUSTMENT.)
Å
Ã
Ä
Æ 7.9—10.7 {80—110, 69.5—95.4}
N·m {kgf·cm, in·lbf}
S–2
1
Shroud seal weatherstrip
2
Bonnet
3
Bonnet hinge
4
Bonnet stay
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BONNET
5
Bonnet lock
6
Bonnet release lever
7
Bonnet release cable
Height Adjustment 1. Loosen the bonnet lock installation bolts and move the bonnet lock to reposition the bonnet. BOLT
BONNET ADJUSTMENT 1. Measure the gap and height between the bonnet and the body. Clearance a: 2.7—5.3 mm {0.11—0.20 in} b: –1.8—0.8 mm {–0.07—0.03 in} (sec. A—A) c: –2.3—0.8 mm {–0.09—0.03 in} (sec. B—B) d: –2.3—0.3 mm {–0.09—0.01 in} (sec. C—C) e: 6.0—10.0 mm {0.24—0.39 in} f: 7.0—13.0 mm {0.28—0.51 in}
50 {2.0}
A A
30 {1.2} E
D D
2. Tighten the bonnet lock installation bolts.
B B C C
E
a e b , c, d
SEC. A—A SEC. B—B SEC. C—C
f SEC. D—D
SEC. E—E mm {in}
2. If not as specified, adjust the gap and height. (Refer to Gap Adjustment.) (Refer to Height Adjustment.) Gap Adjustment 1. Loosen the bonnet installation bolts and reposition the bonnet.
BOLT
2. Tighten the bonnet installation bolts.
CONTINUED
S–3
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FRONT FENDER PANEL
FRONT FENDER PANEL FRONT FENDER PANEL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front side turn light. 3. Remove the front bumper. 4. Remove the front turn light. 5. Remove the front flap. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
B B
A
A
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
1
Mud guard
2
Front fender panel
CONTINUED
S–4
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DOOR DOOR FRONT DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. To remove the front door hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 4. To remove the checker, remove the speaker. (Refer to section T, AUDIO, SPEAKER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Adjust the front door. (Refer to FRONT DOOR ADJUSTMENT.)
Front Door Harness Removal Note 1. Disconnect the connectors indicated in the table, if equipped. Symbol A B C D E
Connector name Passenger's side Driver's side Door lock-link switch Door lock actuator Power window main Power window switch subswitch Power outside mirror Front power window regulator Speaker
← ← ←
2. Disengage the clips.
3. Remove the rubber boot and pull out the door harness. 1 2 3 4 5
Front door harness ☞ Removal Note Checker pin Front door hinge Front door Checker
CONTINUED
S-5
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DOOR FRONT DOOR DISASSEMBLY/ASSEMBLY 1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position. 2. Disconnect the negative battery cable. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. To remove the inner handle, peel off the door screen partially. 5. Disassemble in the order indicated in the table. 6. Assemble in the reverse order of disassembly. WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
B B A D
E
6.87–9.80 {70–100, 60.8–86.7}
H
4.3–6.1 {43–63, 38–54}
C
C 6.87–9.80 {70–100, 60.8–86.7}
D H
WITH POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
A
F
J
8.9–12.7 {90–130, 79–112}
G I
F
G
E
4.3–6.1 {43–63, 38–54}
2.0–2.9 {20–30, 18–26}
6.87–9.80 {70–100, 60.8–86.7}
J I
N·m {kgf·cm, in·lbf}
1
Inner handle
8
Front power window regulator
2 3
Door screen
9
Outer handle
Front door glass
10
Retainer
4 5
Glass run channel
11
Door key cylinder
Front glass guide
12
Front door lock (manual)
6
Rear glass guide
13
Front door lock (power)
7
Front manual window regulator
14
Door lock knob
CONTINUED
S–6
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DOOR FRONT DOOR ADJUSTMENT 1. Measure the clearance between the door and the body.
22—30 {2.2—3.1, 16—22}
Clearance a: 4.0—6.0 mm {0.16—0.23 in} b: –1.5—1.0 mm {–0.059—0.039 in} c: –2.0—0.5 mm {–0.078—0.019 in} d: 4.5—8.5 mm {0.18—0.33 in} e: 1.2 mm {0.047 in} f: 3.5—6.5 mm {0.14—0.25 in} g: 2.7 mm {0.11 in} h: 5.5 mm {0.22 in}
D
D
C
C
E E
8.9—12.7 N·m {90—130 kgf·cm, 79—112 in·lbf}
A A B B
a
(+)
N·m {kgf·m, ft·lbf}
d
F F
e (+)
a b
c
(–) SEC. B—B
SEC. A—A
(+) b
f
(–)
SEC. C—C
f
1
Connector
2
Checker pin
3
Rear door hinge
4
Rear door
5
Checker
g (–) SEC. D—D
h SEC. E—E
SEC. F—F
2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation screws, and move them to reposition the door. (Refer to FRONT DOOR REMOVAL/INSTALLATION.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.) 3. Tighten the bolts or the screws. REAR DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. To remove the checker, remove the ashtray bracket. (Refer to REAR DOOR DISASSEMBY/ASSEMBLY.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the rear door. (Refer to REAR DOOR ADJUSTMENT.)
S–7
CONTINUED
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DOOR REAR DOOR DISASSEMBLY/ASSEMBLY 1. Close the rear door glass completely. 2. Disconnect the negative battery cable. 3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.) 4. Disassemble in the order indicated in the table. 5. Assemble in the reverse order of disassembly. WITH POWER WINDOW SYSTEM
6.87—9.80 {70—100, 60.8—86.7}
E WITHOUT POWER WINDOW SYSTEM
E
6.87—9.80 {70—100, 60.8—86.7}
B
2.5—3.5 {25—36, 22—31}
B
4.3—6.1 {43—63, 38—54}
D A C
D
6.87—9.80 {70—100, 60.8—86.7}
C
A
N·m {kgf·cm, in·lbf}
1
Inner handle
7
Rear door glass + Removal Note
2
Door screen
3
Ashtray bracket
8
Glass run channel
4
Glass hole lid
9
Glass guide
5
Rear manual window regulator
10
Door lock knob
6
Rear power window regulator
11
Rear door lock
12
Outer handle
CONTINUED
S–8
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DOOR Rear Door Glass Removal Note D Draw out the rear door glass through the glass hole.
DOOR LOCK STRIKER REMOVAL/INSTALLATION 1. Remove the screws. 2. Remove the door lock striker. DOOR LOCK STRIKER
SCREW
18–26 {1.8–2.7, 14–19}
REAR DOOR
REAR DOOR GLASS N·m {kgf·m, ft·lbf}
REAR DOOR ADJUSTMENT 1. Measure the clearance between the door and the body. Clearance a: 3.5—6.5 mm {0.14—0.25 in} b: –1.5—1.0 mm {–0.059—0.039 in} c: 5.5 mm {0.22 in}
3. Install in the reverse order of removal. REGULATOR HANDLE REMOVAL 1. Remove the regulator handle clip using a rag as shown.
DD A A E E B B RAG
a
C C
2. Remove the regulator handle. a
(+)
(+)
b (–)
b (–)
SEC. A–A
SEC. B–B a
(+) b
CLIP
(+)
c SEC. C–C
REGULATOR HANDLE INSTALLATION 1. Install the clip in the regulator handle. 2. Set the door glass at the fully raised position and push the regulator handle on as shown.
a
b (–)
(–)
SEC. D–D
SEC. E–E
2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation CLIP screws, and move them to reposition the door. (Refer to REAR DOOR REMOVAL/INSTALLATION.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.)
FRONT
3. Tighten the bolts or screws.
CONTINUED
S–9
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POWER WINDOW SYSTEM
POWER WINDOW SYSTEM POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disengage the clip using a tape-wrapped flathead screwdriver. 3. Pull the switch panel forward, and disengage the hook.
POWER WINDOW MAIN SWITCH INSPECTION Regular Cab, Stretch Cab 1. Remove the switch panel. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. 3. When inspecting the driver’s side, connect the battery positive voltage to terminal F and connect the ground to terminal D. 4. When inspecting the passenger’s side, turn the power-cut switch to ON. Power window switch Driver’s side : Continuity
BODY
SWITCH PANEL
Switch position
Terminal F
D
A (H)
B (I)
BODY CLIP
Manual close
HOOK
Off Auto open Manual open
( ): R.H.D. Passenger’s side : Continuity Switch position
Terminal F
D
H (A)
I (B)
Close
4. Disconnect the power window main switch connector. 5. Remove the screws to remove the power window main switch from the switch panel.
Off Open
SWITCH PANEL
( ): R.H.D. Power-cut switch : Continuity
POWER WINDOW MAIN SWITCH
Switch position
Terminal D
A (H)
B (I)
H (A)
I (B)
ON OFF
( ): R.H.D.
SCREW
6. Install in the reverse order of removal.
CONTINUED
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POWER WINDOW SYSTEM Rear left : Continuity
F
POWER-CUT SWITCH
D
MANUAL OPEN
MANUAL CLOSE
A
H
K
I
Close
OPEN
CLOSE AUTO OPEN
AUTO CIRCUIT
Terminal
Switch position
Off O en Open
( ): R.H.D.
I (B) H (A) PASSENGER’S SIDE
Rear right : Continuity
OPEN
CLOSE A (H) B (I) DRIVER’S SIDE H I
Terminal
Switch position
∗ D
H
E
C
Close
∗ A
F
A
B
Off
( ) : R.H.D.
O en Open
5. If not as specified, replace the power window main switch.
( ): R.H.D. Power-cut switch
Double Cab 1. Remove the switch panel. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. 3. When inspecting the driver’s side, connect the battery positive voltage to terminal A (L.H.D.) or F (R.H.D.) and connect the ground to terminal H. 4. When inspecting the passenger’s side and rear, turn the power-cut switch to ON.
: Continuity Terminal Switch position
L (D )
H
J (B )
D (L )
B (J)
E
C
K
I
K
I
ON OFF
( ): R.H.D. L.H.D.
Power window switch Driver’s side : Continuity Switch position
Terminal A (F)
H
L (D)
J (B)
Manual close
A H
Off Auto open Manual open
( ): R.H.D. D B PASSENGER’S
Passenger’s side : Continuity Switch position
Terminal A (F)
H
D (L)
B (J)
E
C RIGH T
J
Close Off Open O en
( ): R.H.D.
CONTINUED
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POWER WINDOW SYSTEM R.H.D.
Rear 1. Disconnect the negative battery cable. 2. Remove the hook by inserting a tape-wrapped, flathead screwdriver between the switch and the rear door trim. A
F H
HOOK
J PASSENGER’S B
D
K
I
L
J
E
H
C
K
I
E
C
A
F
D
B
POWER WINDOW SUBSWITCH
3. Disconnect the connector, and remove the power window subswitch. 4. Install in the reverse order of removal.
5. If not as specified, replace the power window main switch. POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION Passenger’s side 1. Disconnect the negative battery cable. 2. Disengage the clip using a tape-wrapped flathead screwdriver. 3. Pull the power window subswitch forward, and disengage the hook.
POWER WINDOW SUBSWITCH INSPECTION 1. Remove the power window subswitch. (Refer to POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window subswitch terminals using an ohmmeter. Passenger’s side : Continuity Switch position
Terminal A
B
D
E
F
Off Close Open O en
BODY CLIP
BODY
POWER WINDOW SUBSWITCH
E
A
F
CLOSE OPEN
D
B
HOOK
Rear : Continuity Switch position
Terminal A
B
D
E
F
Close Off
4. Disconnect the power window subswitch connector. 5. Install in the reverse order of removal.
Open
CONTINUED
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POWER WINDOW SYSTEM
F
B
D F
E
D
B
A
CLOSE OPEN E
A
3. If not as specified, replace the power window subswitch. FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position. 2. Disconnect the negative battery cable. 3. Remove the front glass guide and the rear glass guide. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 4. Remove in the order indicated in the table. 1 Bolt 5. Install in the reverse order of removal.
B
2
Power window motor + Disassembly Note + Assembly Note
3
Frame
3.0—4.9 N·m {30—50 kgf·cm, 27—43 in·lbf}
A 8.9—12.7 {90—130, 79—112}
D C
Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor.
A B
BASE MARK
D C 6.87—9.80 {70—100, 60.8—86.7}
GEAR
N·m {kgf·cm, in·lbf}
1
Front power window regulator connector
2
Bolt
3
Nut
4
Front power window regulator
FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Power Window Motor Assembly Note D Align the marks of the gear and the frame to install the power window motor. REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. Raise the rear door glass completely. 2. Disconnect the negative battery cable. 3. Remove the door screen. (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
CONTINUED
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POWER WINDOW SYSTEM Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor. MARK A
A
BASE
GEAR
D C
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
1
Rear power window regulator connector
2
Bolt
3
Rear power window regulator
REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Power Window Motor Assembly Note D Align the marks of the gear and base of the frame to install the power window motor. POWER WINDOW MOTOR INSPECTION 1. Remove the power window motor. (Refer to FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY.) (Refer to REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY.) 2. Apply battery positive voltage to the power window motor terminals and inspect the operation of the power window motor. B+: Battery positive voltage Connection
3.1—4.8 N·m {31—49 kgf·cm, 27—42 in·lbf}
Motor operation
B+
GND
A
B
Up
B
A
Down
UP
DOWN
A B
A
B
3. If not as specified, replace the power window motor.
1
Bolt
2
Power window motor + Disassembly Note + Assembly Note
3
Frame
CONTINUED
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POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION Note • The door lock-link switch is mounted to the driver-side door lock. 1. Disconnect the negative battery cable. 2. Remove the driver-side door lock. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Remove the door lock-link switch from the front door lock.
5. If not as specified, replace the door lock-link switch. DOOR LOCK ACTUATOR REMOVAL/INSTALLATION Front Note • The front door lock actuator is mounted to the passenger-side door lock. 1. Disconnect the negative battery cable. 2. Remove the passenger-side door lock. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Remove the front door lock actuator from the front door lock.
5. Install in the reverse order of removal. DOOR LOCK-LINK SWITCH INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side door screen. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Disconnect the door lock-link switch connector. 4. Inspect for continuity between the door lock-link switch terminals using an ohmmeter. 5. Install in the reverse order of removal.
CONTINUED S-15
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POWER DOOR LOCK SYSTEM Rear Note • The rear door lock actuator is mounted to the rear door lock. 1. Disconnect the negative battery cable. 2. Remove the rear door lock. (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Disconnect the rod. 5. Remove the rear door lock actuator from the rear door lock.
5. If not as specified, replace the door lock actuator. DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the flasher unit. (Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
6. Install in the reverse order of removal. DOOR LOCK ACTUATOR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. Disconnect the door lock actuator connector. 4. Apply battery positive voltage to the door lock actuator terminals and inspect the operation of the door lock actuator.
1 2 3
Door lock timer unit connector Nut Bracket
4
Door lock timer unit
B+: Battery positive voltage Terminal A GND B+
B B+ GND
Actuator operation Lock Unlock
CONTINUED S-16
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POWER DOOR LOCK SYSTEM DOOR LOCK TIMER UNIT INSPECTION 1. Remove the flasher unit. (Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 2. Measure the voltage at the door lock timer unit terminals as indicated below. 3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals A, C, D, and H. 4. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock timer unit. Terminal Voltage List (Reference) B+: Battery positive voltage
Terminal
Signal
Connection
Test condition
Voltage (V) /Continuity
Inspection area
A
GND
Body ground
Constant: inspect for continuity to ground
Yes
-
B
Power supply
D/L 30 A fuse
B+
D/L 30 A fuse
C
Unlock input
Door lock-link switch
Constant Door lock-link switch is at lock: inspect for continuity to terminal H Door lock-link switch is at unlock: inspect for continuity to terminal H Door lock-link switch is at lock: inspect for continuity to terminal H Door lock-link switch is at unlock: inspect for continuity to terminal H Door lock actuators are locked
0 → B+ → 0
Other Door lock actuators are unlocked Other
0 0 → B+ → 0 0
D
Lock input
Door lock-link switch
E
Lock output
Door lock actuator
F
Unlock output
Door lock actuator
G H
GND
Not used Terminal A of door lock timer unit
Constant: inspect for continuity to terminal A
No Yes Yes No
Door lock-link switch
Door lock-link switch Door lock actuator Door lock actuator
-
-
Yes
-
CONTINUED
S-17
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FUEL-FILLER LID AND OPENER, BUMPER
FUEL-FILLER LID AND OPENER
BUMPER
FUEL-FILLER LID REMOVAL/INSTALLATION 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
FRONT BUMPER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
63—93 {6.4—9.5, 47—68} 6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
1
Fuel-filler lid
FUEL-FILLER LID ADJUSTMENT 1. Measure the gap and height between the fuel-filler lid and the body.
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
Clearance a: 3.5—5.5 mm {0.14—0.21 in} b: –0.5—2.0 mm {–0.01—0.07 in}
63—93 {6.4—9.5, 47—68} N·m {kgf·m, ft·lbf}
A a
b A
1
Front bumper
2
Front bumper stay
FRONT BUMPER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 0.2—0.8 {2—9, 2—7}
SEC.A–A
2. If not as specified, loosen the fuel-filler lid installation bolts and reposition the fuel-filler lid. 3. Tighten the fuel-filler lid installation bolts.
6.87—9.80 {70—100, 60.8—86.7}
0.2—0.3 {2—4, 2—3}
12345678
N·m {kgf·cm, in·lbf}
1
Front bumper side fascia
2
Front bumper upper fascia
3
Front bumper lower fascia
CONTINUED
S–19
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BUMPER REAR BUMPER REMOVAL/INSTALLATION With Step 1. Remove the bolts, then remove the rear bumper.
REAR BUMPER DISASSEMBLY/ASSEMBLY With Step 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf} 32—46 {3.2—4.7, 24—33} A A
B
A B
BOLT 79—116 {8.0—11.9, 58.0—86.0}
6.87—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
REAR BUMPER
A B
0.30—0.78 N·m {3.0—8.0 kgf·cm, 2.7—6.9 in·lbf}
N·m {kgf·m, ft·lbf}
B
N·m {kgf·m, ft·lbf}
2. Install in the reverse order of removal. Without Step 1. Disconnect the negative battery cable. 2. Disconnect the rear fog light connector. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Side bumper step + Removal Note
2
Center bumper step + Removal Note
3
Rear bumper fascia
4
Rear bumper stay
5
Rear bracket
6
Set plate
Side Bumper Step Removal Note 1. Disengage clips A using pliers. 2. Pull the side bumper step upward, then remove it.
A
A
A
A
A
A SIDE BUMPER STEP
79—116 {8.0—11.9, 58.0—86.0}
16—22 {1.6—2.3, 12—16} N·m {kgf·m, ft·lbf}
1
Rear bumper stay
3
Rear bumper fascia
CLIP A
Center Bumper Step Removal Note 1. Remove the screws. 2. Disengage clips A using pliers. 3. Disengage clips B, then remove the center bumper step. 12345678
CONTINUED
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BUMPER, EXTERIOR ATTACHMENT B
SCREW
B A
A
A
B
A
SCREW A
A
CENTER BUMPER STEP
SCREW
CLIP B
B
EXTERIOR ATTACHMENT RADIATOR GRILLE REMOVAL/INSTALLATION 1. Pull the radiator grille toward you, then disengage clips A to remove the radiator grille.
A
A
A
A
A
SCREW
A
CLIP A
A
A CLIP
RADIATOR GRILLE
A
2. Install in the reverse order of removal. COWL GRILLE REMOVAL/INSTALLATION 1. Remove the windshield wiper arm and blade. (Refer to section T, WIPER AND WASHER, WIPER ARM AND BLADE REMOVAL/INSTALLATION.) 2. Remove the weatherstrip. 3. Remove the screws, then remove the cowl grille.
SCREW
COWL GRILLE
WEATHERSTRIP
4. Install in the reverse order of removal. WINDSHIELD GARNISH REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the windshield garnish upward, then disengage hook A from the cowl grille.
CONTINUED
S–21
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EXTERIOR ATTACHMENT CENTER SIDE PROTECTOR (REGULAR CAB)
FRONT SIDE PROTECTOR d
b c
d
d ca
a e
SCREW
a
a
c
c
a
c DOUBLE-SIDED ADHESIVE TAPE CENTER SIDE REAR SIDE PROTECTOR PROTECTOR (STRETCH CAB) d d d b c c a a
WINDSHIELD GARNISH COWL GRILLE
e e
e
A
a
c
A
a c c
c
HOOK
1. Install in the reverse order of removal.
a
c
4. Peel off the backing paper from the double-sided adhesive tape and attach the side protector onto the body as shown.
SIDE PROTECTOR REMOVAL Warning D Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife.
Clearance a : 4.8—5.8 mm {0.19—0.22 in} b : 5.0—6.0 mm {0.20—0.23 in} c : 13.0—14.0 mm {0.51—0.55 in} d : 16.5—17.0 mm {0.65—0.66 in} e : 12.3—13.3 mm {0.49—0.52 in} f : 6.0—8.0 mm {0.24—0.31 in}
1. Pry the side protector end 20—30 mm {0.8—1.1 in} using a flathead screwdriver or a razor knife. 2. Pull the side protector, then remove it.
Regular Cab Note D The side protector is installed with double-sided adhesive tape. If the side protector is difficult to remove, soften the double-sided adhesive tape using a hot air blower.
CENTER SIDE PROTECTOR
Clearance a : 0—3.0 mm {0—0.11 in} b : 37.5 mm {1.48 in} c : 10.0 mm {0.39 in} d : 2.0—5.0 mm {0.08—0.19 in} e : 25.0 mm {0.98 in}
f
a
A A
SIDE PROTECTOR INSTALLATION 1. Remove the adhesive remaining on the side protector (if it will be reused) and the body using a razor knife. 2. Remove any grease or dirt from the adhesion surface of the side protector (if it will be reused) and the body. 3. Attach double-sided adhesive tape to the side protector as shown (if it will be reused).
REAR SIDE PROTECTOR
FRONT SIDE PROTECTOR
b
c
SEC. A—A
Stretch Cab CENTER SIDE PROTECTOR REAR SIDE PROTECTOR
FRONT SIDE PROTECTOR a
A A
f
b
d
SEC. A—A
CONTINUED
S–22
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EXTERIOR ATTACHMENT Double Cab NUT REAR SIDE PROTECTOR f
FRONT SIDE PROTECTOR
e
A A
b TAILGATE LOCK
SEC. A—A
ROD
5. Remove the bolts, then remove the latch guide, latch and rod.
5. After installing the side protector to the body, apply pressure of 50 N·m {5.0 kgf·m, 37 ft·lbf} or more with a roller, etc.
BOLT
OVER FENDER REMOVAL/INSTALLATION 1. Remove the screws. 2. Remove the fasteners. 3. Disengage clips A of the over fender using a fastener remover, then remove the over fender.
ROD
LATCH GUIDE
LATCH
FRONT CLIP A
A
A A
TAILGATE ADJUSTMENT 1. Loosen the bolts. 2. Move the striker forward and rearward until the tailgate will lock properly. 3. After the correct adjustment is made, tighten the bolts securely.
OVER FENDER FASTENER REAR A A
SCREW A
6. Remove the handle. 7. Assemble in the reverse order of disassembly.
A
A
CLIP A
A
BOLT
A
A
OVER FENDER
STRIKER
SCREW FASTENER
4. Install in the reverse order of removal. TAILGATE DISASSEMBLY/ASSEMBLY 1. Remove the cover. 2. Remove the nuts attaching the tailgate lock. 3. Disconnect the rods from the tailgate lock. 4. Remove the tailgate lock.
CONTINUED
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EXTERIOR ATTACHMENT, MOLDING ROPE HOOK REMOVAL/INSTALLATION 1. Remove the screws and bolts, then remove the rope hook.
ROPE HOOK SCREW
MOLDING WINDSHIELD UPPER MOLDING REMOVAL D Remove the windshield upper molding from the windshield. (Refer to WINDOW GLASS, WINDSHIELD REMOVAL.) WINDSHIELD UPPER MOLDING INSTALLATION D Install the windshield upper molding to the windshield. (Refer to WINDOW GLASS, WINDSHIELD INSTALLATION.) WINDSHIELD SIDE MOLDING REMOVAL D Remove the windshield side molding from the windshield. (Refer to WINDOW GLASS, WINDSHIELD REMOVAL.)
ROPE HOOK
WINDSHIELD SIDE MOLDING INSTALLATION D Install the windshield side molding to the windshield. (Refer to WINDOW GLASS, WINDSHIELD INSTALLATION.)
BOLT
2. Install in the reverse order of removal.
FRONT BELTLINE MOLDING REMOVAL/INSTALLATION 1. Lower the front door glass fully. 2. Remove the manual outside mirror or the power outside mirror. (Refer to OUTSIDE MIRROR, MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION.) (Refer to OUTSIDE MIRROR, POWER OUTSIDE MIRROR REMOVAL/INSTALLATION.) 3. Pull the rear end of the front beltline molding to disengage the hook. FRONT BELTLINE MOLDING
HOOK
4. Pull the front beltline molding upward, then remove clips A. A
BELTLINE MOLDING
CLIP A
A
A
5. Install in the reverse order of removal.
CONTINUED
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MOLDING, OUTSIDE MIRROR REAR BELTLINE MOLDING REMOVAL/INSTALLATION 1. Lower the rear door glass fully. 2. Pull the rear end of the rear beltline molding to disengage the hook.
OUTSIDE MIRROR MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION 1. Remove the inner garnish. 2. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 3. Remove the screws. 4. Remove the manual outside mirror.
REAR BELTLINE MOLDING
MANUAL OUTSIDE MIRROR SCREW
HOOK
3. Pull the rear beltline molding upward, then remove clips A. 5. Install in the reverse order of removal.
A
BELTLINE MOLDING CLIP A
A
A
4. Install in the reverse order of removal.
POWER OUTSIDE MIRROR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the inner garnish. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. Partially peel off the door screen. 5. Disconnect the power outside mirror connector. 6. Remove the screws. 7. Remove the power outside mirror.
ROOF MOLDING REMOVAL/INSTALLATION 1. Pull the rear edge of roof molding upward, then disengage clips A.
SCREW
A
A
A
POWER OUTSIDE MIRROR
ROOF MOLDING ROOF MOLDING
POWER OUTSIDE MIRROR CONNECTOR
CLIP BODY A
2. Install in the reverse order of removal.
8. Install in the reverse order of removal. POWER OUTSIDE MIRROR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the inner garnish. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. Partially peel off the door screen. 5. Disconnect the power outside mirror connector. 6. Apply battery positive voltage to the power outside mirror and inspect the operation of the power outside mirror.
CONTINUED
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OUTSIDE MIRROR B+: Battery positive voltage Connection B+
GND
Mirror operation
A
C
Up
C
A
Down
C
D
Left
D
C
Right
: Continuity Switch position
Terminal I
L
A
D
C
B
K
Up Down LH Left
C
A
D
Right Up
DOWN UP
M LEFT
Down *
123456567
RH
RIGHT
Left
M
Right
1. If not as specified, replace the power outside mirror. POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the fuse block cover. 3. Remove the fuse block installation screws, and push the fuse block into the dashboard. 4. Insert your hand into the hole for the fuse block, and press the hooks of the power outside mirror switch. 5. Push the power outside mirror switch out, then remove it. 6. Disconnect the power outside mirror switch connector. POWER OUTSIDE MIRROR SWITCH POWER OUTSIDE MIRROR SWITCH CONNECTOR
3. If not as specified, replace the power outside mirror switch.
7. Install in the reverse order of removal. POWER OUTSIDE MIRROR SWITCH INSPECTION 1. Remove the power outside mirror switch. (Refer to POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power outside mirror switch terminals using an ohmmeter.
CONTINUED
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REARVIEW MIRROR, REAR WINDOW DEFROSTER
REARVIEW MIRROR
REAR WINDOW DEFROSTER
REARVIEW MIRROR REMOVAL/INSTALLATION Regular Cab
REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. 3. Press the hooks of the rear window defroster switch and push the switch out.
Note D The rearview mirror is attached to the interior light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION, Regular Cab.) Stretch Cab, Double Cab 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
HOOK
REAR WINDOW DEFROSTER SWITCH
2.0—3.9 {20—40, 18—34}
N·m {kgf·cm, in·lbf}
1
Cover
2
Screw
3
Rearview mirror
METER HOOD
4. Install in the reverse order of removal. REAR WINDOW DEFROSTER SWITCH INSPECTION 1. Remove the rear window defroster switch. 2. Inspect for continuity between the rear window defroster switch terminals using an ohmmeter. : Continuity : Bulb Switch position
Terminal A
B
C
D
ON OFF
D
C
A
:
C
A
:
D
B
B
3. If not as specified, replace the rear window defroster switch. FILAMENT INSPECTION 1. Turn the ignition switch to ON position. 2. Turn the rear window defroster switch on. Caution D Directly touching the rear window defroster filament with the lead of the circuit tester will damage it. Wrap aluminum foil around the end of the lead and test the filament by touching it with the foil.
CONTINUED
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REAR WINDOW DEFROSTER Caution D Do not use the rear window defroster until the paint is completely dry. It may cause other malfunctions if it is used before the paint is dry.
LEAD OF THE CIRCUIT TESTER PUSH
5. Use a hot air blower heated to 150°C {302°F} for 30 minutes or let the paint set for 24 hours at 25°C {77°F} to allow it to dry completely.
FILAMENT
ALUMINUM FOIL
1. Connect the positive ()) lead of the voltmeter to the positive side of each filament and the negative (*) lead to ground. 2. Gradually, slide the positive ()) lead from the positive side to the negative side and measure the voltage. Verify that the voltage decreases accordingly. Measurement place
Voltage (Reference value)
(1) (2)
Approx. 12 V Approx. 0 V
(2) NEGATIVE SIDE
REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the rear window defroster relay connector. 3. Slide the rear window defroster relay upward, then remove it.
REAR WINDOW DEFROSTER RELAY
REAR WINDOW DEFROSTER RELAY CONNECTOR
(1) POSITIVE SIDE
4. Install in the reverse order of removal. REAR WINDOW DEFROSTER RELAY INSPECTION 1. Remove the rear window defroster relay. (Refer to REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the rear window defroster relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage
3. If the voltage is not as specified or it changes rapidly, the filament is faulty. Repair the filament. FILAMENT REPAIR 1. Use white gasoline to clean around the damaged section of the filament. 2. Attach tape above and below the damaged section of the filament. BROKEN FILAMENT
Terminal
Step
A
B
C
B)
GND
D
1 2
TAPE
C
A
D
B
D
A
C
B
SECTION TO BE REPAIRED
3. Using a small brush or marking pen, repair the filament with silver paint or equivalent. 4. After approximately 2—3 minutes, carefully remove the tape without disturbing the repaired area.
3. If not as specified, replace the rear window defroster relay.
CONTINUED
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WINDOW GLASS Reusing Windshield 1. Make a hole through the sealant from the inside of the vehicle using an awl. 2. Pass the SST (piano wire) through the hole.
WINDOW GLASS WINDSHIELD REMOVAL 1. Remove the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.) 2. Apply protective tape to the headliner, the body and the dashboard.
PROTECTIVE TAPE
WINDSHIELD UPPER MOLDING R
Warning D Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife.
SEALANT
HEADLINER PROTECTIVE TAPE
3. Wind each end of the wire around a bar.
3. Cut the lip of the windshield upper molding using a razor knife. R
WINDSHIELD DAM
Note D The windshield upper molding and windshield side molding are replacement parts.
PROTECTIVE TAPE
49 0305 870A
WINDSHIELD UPPER MOLDING
Note D Use the entire length of piano wire to prevent it from breaking when cutting through the sealant. 4. Working with another person, saw through the sealant around the edge of the glass, being careful not to damage the body.
LIP
Not Reusing Windshield Warning D Using a piano wire with bare hands can cause injury. Always wear gloves when using a piano wire.
49 0305 870A
Note D For the areas of the sealant that are difficult to cut, use a piano wire and follow the procedures under “Reusing Windshield”.
5. Remove the windshield. 6. Remove the spacers from the body. 7. Remove the spacer and the dam from the glass. CENTER
1. Use a tool like that shown in the figure, and insert the blade into the sealant. 2. Pull through the sealant around the edge of the glass.
DAM
SPACER
R
R
8. Remove the windshield upper molding and the windshield side molding from the windshield.
3. Remove the windshield. 4. Remove the spacers from the body.
CONTINUED
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WINDOW GLASS
WINDSHIELD UPPER MOLDING
GLASS MARK
R
WINDSHIELD
WINDSHIELD SIDE MOLDING
R
WINDSHIELD SIDE MOLDING
WINDSHIELD
WINDSHIELD INSTALLATION
7. Securely bond a dam along the circumference of the glass 8.5 mm {0.33 in} from the upper edge and 14.5 mm {0.57 in} from the lower and side edge. 8. Install the spacer to the glass.
Warning Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife.
CENTER 8.5 {0.33}
Caution To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened. 1. Cut away the old sealant using a razor knife so that 1—2 mm {0.04—0.07 in} thickness of sealant remains around the circumference of the frame. If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer. 2. Clean and degrease an approximately 50 mm {1.97 in} wide strip around the circumference of the glass and the bonding area on the body. 3. Align the center mark on the windshield upper molding with the glass mark. 4. Install the windshield upper molding from the center toward both sides.
14.5 {0.57} 6.0 {0.24}
DAM
SPACER
CERAMIC PARTING LINE
14.5 {0.57}
14.5 {0.57}
mm {in}
9. Install spacers into the hole of the body. 10. Temporarily install the glass onto the body and adjust the glass to body clearance. 11. Make a mark on the glass directly above the V-notch of spacers. 12. Verify that the gap along the upper edge is 7.5 mm {0.30 in}. 7.5 {0.30}
CENTER
MARKING
BODY
WINDSHIELD UPPER MOLDING MARK
SPACER
GLASS MARK
mm {in}
13. Remove the windshield. WINDSHIELD
Caution Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur.
5. Align the upper edge of the windshield side molding with the glass mark. 6. Install the windshield side molding from the upper part towards the lower part.
14. Use a brush to apply primer to the bonding area of the glass and body within the region shown. Use only glass primer on the glass and body primer on the body and molding. Allow it to dry for approximately 30 minutes.
CONTINUED
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WINDOW GLASS
8.5 {0.33}
UPPER
GLASS PRIMER
14.5 {0.57}
BODY
WINDSHIELD
GLASS PRIMER BODY PRIMER
BODY PRIMER
13.0 {0.51}
UPPER
SEALANT
SIDE
14.5 {0.57}
ADJUST SEALANT IN THIS AREA
SIDE
GLASS PRIMER BODY PRIMER
DAM
19.0 {0.75}
BODY PRIMER 19.0 {0.75}
WINDSHIELD
BODY
16.0 {0.63}
LOWER
DAM
WINDSHIELD SIDE MOLDING WINDSHIELD UPPER MOLDING
BODY PRIMER
ADJUST SEALANT IN THIS AREA mm {in}
15. Once the primer is dry, apply a 11.0 mm {0.43 in} high, 5.0 mm {0.20 in} wide bead of sealant along the dam around the entire circumference to fill the gap between the dam and the edge of the windshield.
Hardening time of sealant
5.0 {0.20}
11.0 {0.43}
Temperature
Surface hardening time
Time required until car can be put into service
5 °C {41 °F}
Approx. 1.5 h
Approx. 12 h
20 °C {68 °F}
Approx. 1 h
Approx. 4 h
35 °C {95 °F}
Approx. 10 min
Approx. 2 h
20. Use white gasoline to remove any sealant that oozes out. 21. Install the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.)
DAM
mm {in}
16. Align the glass marks with the V-notches in spacers and install the glass onto the body. 17. Press firmly inward on the glass to compress the sealant. 18. Verify that the gap along the upper and side edge is 7.5 mm {0.30 in}. 19. Adjust the sealant as indicated in the figure.
CONTINUED
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WINDOW GLASS QUARTER WINDOW GLASS REMOVAL/INSTALLATION Stretch Cab 1. To remove the quarter window hinge, remove the quarter upper trim. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Hinge cover
4
Quarter window glass
2
Quarter window hinge
5
Quarter window glass weatherstrip
3
Quarter window lock
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WINDOW GLASS REAR WINDOW GLASS REMOVAL 1. Remove the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.) 2. Remove the rear window defroster connector if equipped. 3. While another person presses the rear window glass, use the SST to push the lip of the rear window weatherstrip from the inside.
REAR WINDOW WEATHERSTRIP BODY
REAR WINDOW WEATHERSTRIP SOAPY WATER
5. Align the rear window glass with the rear window weatherstrip and body. 6. While another person lightly taps the outside of the rear window glass near the rear window weatherstrip all around its circumference, pull one end of the SST and install the rear window glass.
LIP
49 0259 866A
4. After the top of the rear window weatherstrip is removed, push the rear window glass outside and remove it with the rear window weatherstrip attached. 5. Remove the rear window weatherstrip from the rear window glass. 49 0259 866A
REAR WINDOW GLASS INSTALLATION 1. Clean and degrease the body and the rear window glass. 2. Install the rear window weatherstrip to the rear window glass. REAR WINDOW WEATHERSTRIP
7. Install the rear window defroster connector if equipped. 8. Install the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.)
3. Fit the SST into the rear window weatherstrip and cross the ends as shown, leave 200 mm {7.87 in}. REAR WINDOW WEATHERSTRIP
49 0259 866A 200 {7.87}
mm {in}
4. Apply soapy water as shown.
CONTINUED
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DASHBOARD AND CONSOLE
DASHBOARD AND CONSOLE DASHBOARD REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Remove the passenger-side air bag module. (Refer to section T, AIR BAG SYSTEM, PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 4. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 5. Remove the installation bolts then lower the assembled steering shaft from the dashboard. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 6. Remove the meter hood. 7. Remove the instrument cluster. 8. Remove the front console. (Refer to FRONT CONSOLE REMOVAL/INSTALLATION.) 9. Remove the glove compartment. 10. Remove the bonnet release cable installation nut. 11. Remove the A-pillar trims. (Refer to TRIM, A-PILLAR TRIM REMOVAL/INSTALLATION.) 12. Disconnect the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT REMOVAL.) (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT INSTALLATION.) 13. Remove the fuse block. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Adjust the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT ADJUSTMENT.)
7.9—11.7 {80—120, 70—104}
7.9—11.7 {80—120, 70—104}
7.9—11.7 {80—120, 70—104}
N·m {kgf·cm, in·lbf}
1
Bolt
2
Dashboard
CONTINUED
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DASHBOARD AND CONSOLE DASHBOARD DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Defroster nozzle
4
Duct
2
Side demister nozzle
5
Dashboard crash pad
3
Center duct
CONTINUED
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DASHBOARD AND CONSOLE DASHBOARD MEMBER REMOVAL/INSTALLATION 1. Remove the dashboard. (Refer to DASHBOARD REMOVAL/INSTALLATION.) 2. Remove the bolts, then remove the dashboard member.
FRONT CONSOLE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
DASHBOARD MEMBER 16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
BOLT
16—22 {1.6—2.3, 12—16} N·m {kgf·m, ft·lbf}
3. Install in the reverse order of removal. COLUMN COVER REMOVAL/INSTALLATION 1. Remove the screws, then remove the column cover.
COLUMN COVER
1
Screw
2
Front console
3
Boot
4
Set plate
REAR CONSOLE REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the rear console upward, then remove it.
SCREW
2. Install in the reverse order of removal. FRONT CONSOLE REMOVAL/INSTALLATION 1. Remove the rear console. 2. For manual transaxle vehicle, remove the shift lever knob. 3. Remove the screws, then remove the front console.
REAR CONSOLE
Caution In order to prevent noise caused by interference with the dashboard, install the screws to the rear of the front console before installing the front of the front console. FRONT CONSOLE SCREW
SCREW
3. Install in the reverse order of removal. 4. Install in the reverse order of removal.
CONTINUED
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DASHBOARD AND CONSOLE METER HOOD REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the meter hood toward you, then disengage clips A and pins B.
REAR CONSOLE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
SCREW
A B
A B A
A
B A
A
A
CLIP B PIN A
3. Disconnect the connectors, then remove the meter hood. 4. Install in the reverse order of removal.
1
Screw
2
Console lid outer
3
Console lid inner
4
Rear console
5
Console lid lock
6
Console lid hinge
7
Console lid bracket
GLOVE COMPARTMENT REMOVAL/INSTALLATION 1. Open the glove compartment and bend the sides inward to disengage the pins. 2. Pull the glove compartment downward, then disengage clips A. PIN PIN
A
A CLIP A
GLOVE COMPARTMENT
3. Install in the reverse order of removal.
CONTINUED
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TRIM
TRIM A-PILLAR TRIM REMOVAL/INSTALLATION 1. Remove the quarter upper trim. (Regular cab, stretch cab) (Refer to QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove the B-pillar upper trim. (Double cab) (Refer to B-PILLAR UPPER TRIM REMOVAL/INSTALLATION.) 3. Pull the A-pillar trim toward you, then disengage clips A and pin B. 4. Pull the A-pillar trim upward, then disengage the hook. A
B-PILLAR LOWER TRIM REMOVAL/INSTALLATION Double Cab 1. Remove the front scuff plate. 2. Remove the rear scuff plate. 3. Turn over the seaming welt. 4. Pull the B-pillar lower trim indicated by the arrow, then disengage clips A and pin B. 5. Remove the seat belt from B-pillar trim. 6. Pull the B-pillar lower trim upward, then disengage hooks C from the body.
CLIP
A
A A-PILLAR TRIM
B
A
A CLIP
PIN
A
B PIN A
A B A
A
B-PILLAR LOWER TRIM
HOOK B
A
HOOK
5. Install in the reverse order of removal. B-PILLAR TRIM REMOVAL/INSTALLATION Regular Cab 1. Turn over the seaming welt. 2. Remove the seat belt upper anchor installation bolt. 3. Remove the back upper trim. 4. Pull the B-pillar trim toward you, then disengage clips A and pins B. 5. Remove clip C. 6. Remove the seat belt from the B-pillar trim.
B A A CLIP A A
C C
C
7. Install in the reverse order of removal. B-PILLAR UPPER TRIM REMOVAL/INSTALLATION Double Cab 1. Remove the B-pillar lower trim.(Refer to B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove the front seat belt upper anchor installation bolt. 3. Remove the C-pillar trim. (Refer to C-PILLAR TRIM REMOVAL/INSTALLATION.) 4. Remove the fastener. 5. Pull the B-pillar upper trim toward you, then disengage clips A and pins B from the body. A
A
A
A PIN
B
CLIP C A
CLIP A
B-PILLAR TRIM
HOOK B
A B
A
A B
A
B-PILLAR UPPER TRIM
A
FASTENER
B
6. Install in the reverse order of removal. 7. Install in the reverse order of removal.
CONTINUED
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TRIM FRONT SIDE TRIM REMOVAL/INSTALLATION 1. Remove the scuff plate. 2. Loosen the nut. 3. Pull the front side trim in the direction indicated by the arrow, then remove it.
SCREW REAR SCUFF PLATE B
A A
NUT
B
A CLIP
PIN
3. Install in the reverse order of removal.
FRONT SIDE TRIM
4. Install in the reverse order of removal. FRONT SCUFF PLATE REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the front scuff plate upward, then disengage pin A.
C-PILLAR TRIM REMOVAL/INSTALLATION Double Cab 1. Turn over the seaming welt. 2. Remove the rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Double Cab, Rear.) 3. Remove the rear seat belt upper anchor installation bolt. 4. Remove the fasteners. 5. Pull the C-pillar trim toward you, then disengage clips A and pin B. 6. Remove the seat belt from C-pillar trim. A A
SCREW
A B
CLIP A
A
PIN
A
B
PIN C-PILLAR TRIM A A FRONT SCUFF PLATE
FASTENER
3. Install in the reverse order of removal. REAR SCUFF PLATE REMOVAL/INSTALLATION Double Cab 1. Remove the screw. 2. Pull the rear scuff plate upward, then disengage clips A and pin B.
7. Pull the C-pillar trim upward, then remove it from the body. 8. Install in the reverse order of removal. QUARTER UPPER TRIM REMOVAL/INSTALLATION Stretch Cab 1. Remove the back upper trim. 2. Remove the upper anchor of the seat belt. 3. Remove the quarter window lock. (Refer to WINDOW GLASS, QUARTER WINDOW GLASS REMOVAL/INSTALLATION.) 4. Remove the hook. 5. Remove the fasteners. 6. Pull the quarter upper trim toward you, then disengage clips A and pins B.
CONTINUED
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TRIM BACK UPPER TRIM REMOVAL/INSTALLATION 1. Pull the back upper trim toward you, then disengage clips A and pins B.
A
A
A B
A
A
HOOK A
B A
A
A
PIN
A
A A
A
B
A
A
B
A
A
BACK UPPER TRIM
CLIP
A
B
PIN
FASTENER
A A
CLIP
A A B
A
QUARTER UPPER TRIM
A
A
7. Install in the reverse order of removal.
B
QUARTER LOWER TRIM REMOVAL/INSTALLATION Stretch Cab 1. Remove the quarter upper trim. (Refer to QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove the back lower trim. 3. Remove the fasteners. 4. Pull the quarter lower trim toward you, then disengage clips A and pins B.
2. Install in the reverse order of removal. BACK LOWER TRIM REMOVAL/INSTALLATION 1. Remove the fasteners, then remove the back lower trim.
QUARTER LOWER TRIM FASTENER
B A
B
A A A
CLIP PIN
A FASTENER
BACK LOWER TRIM A
B
2. Install in the reverse order of removal. 5. Install in the reverse order of removal.
CONTINUED
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TRIM FRONT DOOR TRIM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable if equipped with a power window system. 2. Remove the regulator handle if equipped. 3. Remove the inner garnish. 4. Remove the power window switch if equipped. 5. Remove the screws and the fastener. 6. Pull the front door trim toward you, then disengage clips A. 7. Pull the front door trim upward, then disengage hook B. FASTENER
7. Extract the inner handle from the rear door trim. 8. Pull the rear door trim upward, then disengage hooks B. 9. Install in the reverse order of removal.
FRONT DOOR TRIM
B A
A
CLIP
A A
A
A
A SCREW
B
A
A A
FASTENER
HOOK
FRONT DOOR TRIM
B A
A A
SCREW
CLIP A
A B
A A
A
A A
HOOK
8. Install in the reverse order of removal. REAR DOOR TRIM REMOVAL/INSTALLATION Double cab 1. Disconnect the negative battery cable if equipped with power window. 2. Remove the regulator handle if equipped. 3. Remove the power window switch if equipped. 4. Remove the screws. 5. Remove the ashtray. 6. Pull the door trim toward you, then disengage clips A. INNER HANDLE B
SCREW A
A
CLIP A
A A ASHTRAY
A A A
A A
B HOOK
A
REAR DOOR TRIM
CONTINUED
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HEADLINER, FLOOR COVERING
HEADLINER
FLOOR COVERING
HEADLINER REMOVAL/INSTALLATION 1. Remove the A-pillar trims. 2. Remove the B-pillar upper trims. (Refer to TRIM, B-PILLAR UPPER TRIM REMOVAL/INSTALLATION, Double Cab.) 3. Remove the quarter upper trims. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION, Stretch Cab.) 4. Remove the C-pillar trims. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION, Double Cab.) 5. Remove the assist handle. 6. Remove the rearview mirror. 7. Remove the sunvisors and adapters. 8. Remove the interior light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION.) 9. Remove the fasteners, then remove the headliner.
FLOOR COVERING REMOVAL/INSTALLATION Regular Cab, Stretch Cab 1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.) 2. Remove the quarter lower trims. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION, Stretch Cab.) 3. Remove the back lower trim. 4. Remove the front seats. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Regular Cab.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.) 5. Remove the rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.) 6. Remove the rear console bracket. 7. Remove the lower anchor installation bolts of front seat belts. 8. Remove the front side trims. 9. Remove the air outlet ducts. (Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.) 10. Remove the footrest. 11. Remove the fasteners, then remove the floor covering.
HEADLINER
FASTENER
ASSIST HANDLE FASTENER
ADAPTER SUNVISOR
10. Remove the headliner from the vehicle through the passenger-side door.
FLOOR COVERING
12. Install in the reverse order of removal.
HEADLINER
11. Install in the reverse order of removal.
Double cab 1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.) 2. Remove the B-pillar lower trims. (Refer to TRIM, B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.) 3. Remove the C-pillar trims. (Refer to TRIM,C-PILLAR TRIM REMOVAL/INSTALLATION)
CONTINUED
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FLOOR COVERING 4. Remove the front seats and rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.) 5. Remove the rear console bracket. 6. Remove the lower anchor installation bolts of front seat belts and rear seat belts. 7. Remove the front side trim. 8. Remove the air outlet duct. (Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.) 9. Remove the footrest. 10. Remove the fasteners, then remove the floor covering. Type 1
FASTENER
FLOOR COVERING Type 2 FLOOR COVERING FASTENER
11. Install in the reverse order of removal.
CONTINUED
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SEAT BELT
SEAT BELT SEAT BELT REMOVAL/INSTALLATION Caution The ELR has a spring that will unwind if the retractor’s cover is removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the retractor.
Stretch Cab Front 1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
Regular Cab Driver’s side and passenger’s side 1. Remove the B-pillar trim if equipped with a B-pillar trim. (Refer to TRIM, B-PILLAR TRIM REMOVAL/INSTALLATION, Regular Cab.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Anchor cover
2
Retractor cover (if equipped)
3
Seat belt
1
Anchor cover
2
Seat belt
N·m {kgf·m, ft·lbf}
Rear 1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Except driver’s side and passenger’s side Except Europe and UK 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Seat belt
CONTINUED
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SEAT BELT Rear 1. Remove the C-pillar trim. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Anchor cover
2
Seat belt
Double Cab Front 1. Remove the B-pillar lower trim. (Refer to TRIM, B-PILLAR LOWER TRIM REMOVAL/INSTALLATION, Double Cab.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
Anchor cover
2
Seat belt
SEAT BELT INSPECTION Belt 1. Inspect the webbing for scars, tears, and wear. 2. Inspect the fitting for deformation or damage. 3. If a problem is found, replace the seat belt. ELR 1. Verify that the belt can be pulled out smoothly, and that it moves smoothly when worn. 2. Verify that the retractor locks when the belt is quickly pulled.
39—78 {3.9—8.0, 29—57}
1
Anchor cover
2
Seat belt
3. Remove the retractor. 4. Make sure that the seat belt does not lock when the retractor is tilted slowly up to 15° from the mounted position. Make sure that the seat belt locks when the retractor is tilted 40° or more.
N·m {kgf·m, ft·lbf}
CONTINUED
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SEAT BELT
RETRACTOR
39—78 {3.9—8.0, 29—57} N·m {kgf·m, ft·lbf}
5. If any of the above-mentioned steps are not as specified, replace the seat belt. BUCKLE REMOVAL/INSTALLATION Bench Seat Driver’s side and passenger’s side 1. Disconnect the negative battery cable. 2. Remove as indicated in the table. 3. Install in the reverse order of removal.
1
Front buckle
Stretch Cab Rear 1. Remove as indicated in the table. 2. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
1
N·m {kgf·m, ft·lbf}
1
Buckle
Except driver’s side and passenger’s side Except Europe and UK 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
Rear buckle
Double Cab Rear 1. Remove the seat cushion. (Refer to SEAT, REAR SEAT REMOVAL/INSTALLATION, Double Cab.) 2. Remove as indicated in the table. 3. Install in the reverse order of removal. 39—78 {3.9—8.0, 29—57}
39—78 {3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
1
1
Buckle
Bucket Seat Front 1. Disconnect the negative battery cable. 2. Remove the side cover. (Refer to SEAT, FRONT SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
Rear buckle
CONTINUED
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SEAT BELT BUCKLE SWITCH INSPECTION
1. Disconnect the negative battery cable. 2. Disconnect the buckle switch connector. 3. Inspect for continuity between the buckle switch terminals using an ohmmeter.
4. If not as specified, replace the buckle.
CONTINUED
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SEAT Bucket Seat 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
SEAT FRONT SEAT REMOVAL/INSTALLATION Bench Seat 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
35—63 {3.5—6.5, 26—47} 35—63 {3.5—6.5, 26—47}
35—63 {3.5—6.5, 26—47} 35—63 {3.5—6.5, 26—47}
N·m {kgf·m, ft·lbf}
N·m {kgf·m, ft·lbf}
1
Front seat + Installation note
Front seat installation note 1. To install the seat, tighten the bolts in the order indicated in the figure. FRONT
LEFT SIDE
1
Connector
2
Cover
3
Front seat + Installation note
Front seat installation note 1. To install the seat, tighten the bolts in the order indicated in the figure. FRONT
RIGHT SIDE
DOOR SIDE
2. Verify that the seat slider is securely locked in position before fully tightening the bolts. 3. After installing the seat, slide it forward and backward and verify that the seat slider securely locks in position.
TUNNEL SIDE
2. Verify that the seat slider is securely locked in position before fully tightening the bolts. 3. After installing the seat, slide it forward and backward and verify that the seat slider securely locks in position.
CONTINUED
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SEAT FRONT SEAT DISASSEMBLY/ASSEMBLY Bench Seat 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
A 32—46 {3.2—4.7, 24—33}
A
N·m {kgf·m, ft·lbf}
1
Headrest
8
Seat back frame
2
Pole guide
9
Seat cushion trim
3
Recliner lever
10
Seat cushion pad
4
Side cover
11
Seat cushion frame
5
Lower cover
12
Cable
6
Seat back trim
13
Slide adjuster
7
Seat back pad
14
Connecting rod
CONTINUED
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SEAT Bucket Seat 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 3. When removing the cable (passenger’s seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)
39—78 {3.9—8.0, 29—57}
PASSENGER’S SEAT
A
37—53 {3.7—5.5, 27—39}
B A
C B 39—78 {3.9—8.0, 29—57}
C
N·m {kgf·m, ft·lbf}
1
Headrest
11
Slide adjuster No.3
2
Recliner lever
12
Pole guide
3
Side cover
13
Seat back trim
4
Front buckle
14
Seat back warmer unit (Europe only)
5
Spring (stretch cab)
15
Seat back pad
6
Cable (stretch cab)
16
Seat cushion trim
7
Wire
17
Seat cushion warmer unit (Europe only)
8
Connecting rod
18
Seat cushion pad
9
Slide adjuster No.1
19
Seat cushion frame
10
Slide adjuster No.2
CONTINUED
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SEAT CABLE ADJUSTMENT Verify the slide adjuster slides and locks smoothly when the slide adjuster lever is operated.
SEAT BACK
LEVER
BOLT 16—22 {1.6—2.3, 12—16}
SLIDE LOCK
SCREW 2.0—2.9 N·m {20—30 kgf·cm, 18—26 in·lbf}
LEVER
N·m {kgf·m, ft·lbf}
REAR SEAT REMOVAL/INSTALLATION Stretch Cab Seat back 1. Remove the back upper trim. 2. Remove the bolts. 3. Lift the seat back up in the direction of the arrow, then unhook it from the body.
Hinge 1. Remove the back lower trim. (Refer to TRIM, BACK LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove the fasteners, and then turn over the floor covering. 3. Remove the bolts, and then remove the hinge. BOLT 16—22 {1.6—2.3, 12—16}
SEAT BACK
HOOK
HOOK
HOOK HINGE
BOLT 6.87—9.80 {70—100, 60.8—86.7}
N·m {kgf·m, ft·lbf}
N·m {kgf·cm, in·lbf}
Seat cushion 1. Lift up the rear seat cushion. 2. Remove the screws. 3. Remove the bolts, and then remove the seat cushion.
CONTINUED
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SEAT Double Cab 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 35—63 {3.5—6.5, 26—47}
1
Seat cushion trim
2
Seat cushion pad
16—22 {1.6—2.3, 12—16}
PULL
16—22 {1.6—2.3, 12—16}
16—22 {1.6—2.3, 12—16}
35—63 {3.5—6.5, 26—47} N·m {kgf·m, ft·lbf}
1
Seat cushion
2
Seat back + Installation note
3
Hinge
4
Striker
Seat back installation note After installing the seat back, verify that it securely locks to the striker. REAR SEAT DISASSEMBLY/ASSEMBLY Stretch Cab 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
CONTINUED
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SEAT Double Cab 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Headrest
6
Side cover
2
Pole guide
7
Stopper
3
Seat back trim
8
Seat back frame
4
Seat back pad
9
Seat cushion trim
5
Rear back catch
10
Seat cushion pad
CONTINUED
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SEAT SEAT WARMER SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the seat warmer switch and pull it forward to remove it. 3. Disconnect the seat warmer switch connector, and then remove the seat warmer switch.
SEAT WARMER UNIT INSPECTION 1. Remove the front seat. (Refer to FRONT SEAT REMOVAL/INSTALLATION, Bucket Seat.) 2. Inspect seat warmer unit at roor temperature of 20 °C {68 °F}. 3. Apply battery positive voltage to the seat warmer unit terminal A, connect the ground to terminal B, and measure the temperature of the thermometal switch with a thermometer. A
HOOK
A B SEAT WARMER SWITCH
CONNECTOR
SEAT WARMER SWITCH INSTALLATION 1. Connect the seat warmer switch connector. 2. Insert the seat warmer switch in the hole to install it. 3. Connect the negative battery cable.
B
THERMOMETER
SEAT WARMER SWITCH INSPECTION 1. Remove the seat warmer switch. (Refer to SEAT WARMER SWITCH REMOVAL.) 2. Inspect for continuity between the seat warmer switch terminals using an ohmmeter. : Continuity
: Bulb
Terminal
Switch position
D
C
F
On Off
D
C
:
:
F
:
F
3. If not as specified, replace the seat warmer switch.
THERMOMETAL SWITCH
4. When the temperature of the thermometal switch is approximately 40 °C {104 °F}, inspect the resistance between the seat warmer unit terminals using an ohmmeter. Verify that the resistance changes from approximately 4.8 Ω to approximately 13.0 Ω. 5. Remove battery positive voltage from seat warmer unit terminals. 6. When the temperature of the thermometal switch is approximately 30 °C {86 °F}, inspect the resistance between the seat warmer unit terminals using an ohmmeter. Verify that the resistance changes from approximately 13.0 Ω to approximately 4.8 Ω. 7. If any of the above-mentioned steps are not as specified, replace the seat back pad (with seat warmer unit) and seat cushion pad (with seat warmer unit).
CONTINUED
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BODY ELECTRICAL SYSTEM PAGE 1 OF 2 POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE SERVICE CAUTION . . . . . . . . . . . . . . . . . MAIN FUSE REMOVAL/INSTALLATION . . . . . IGNITION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . IGNITION SWITCH INSPECTION . . . . . . . . . . . KEY REMINDER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . KEY REMINDER SWITCH INSPECTION . . . . CIGARETTE LIGHTER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . CIGARETTE LIGHTER INSPECTION . . . . . . . EXTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . FRONT COMBINATION LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HEADLIGHT AIMING . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PARKING LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT TURN LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT TURN LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SIDE TURN LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR COMBINATION LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR COMBINATION LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . LICENSE PLATE LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COMBINATION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COMBINATION SWITCH DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . LIGHT SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . HAZARD WARNING SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HAZARD WARNING SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH REMOVAL . . . . . REAR FOG LIGHT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH INSPECTION . . . .
T– 3 T– 3 T– 3 T– 3 T– 3 T– 3 T– 4 T– 4 T– 4 T– 5 T– 5 T– 5 T– 5/6 T– 6 T– 6 T– 6 T– 6 T– 7 T– 7 T– 7 T– 7 T– 8 T– 8 T– 8 T– 8 T– 8/9 T– 9 T– 9 T–10 T–10 T–10 T–10 T–10 T–10 T–11 T–11
FLASHER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FLASHER UNIT INSPECTION . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY INSPECTION . . . . RUNNING LIGHT RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . RUNNING LIGHT RELAY INSPECTION . . . . . INTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . . INTERIOR LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . INTERIOR LIGHT INSPECTION . . . . . . . . . . . . DOOR SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR SWITCH INSPECTION . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WIPER AND WASHER . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER LINK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER TANK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION . . . . . . . WINDSHIELD WIPER AND WASHER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . WARNING AND INDICATOR SYSTEM . . . . . . . . INSTRUMENT CLUSTER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . INSTRUMENT CLUSTER INSPECTION . . . . . INSTRUMENT CLUSTER REPAIR . . . . . . . . . .
T–11 T–12 T–12 T–13 T–14 T–14 T–14 T–14/15 T–16 T–16 T–16 T–17 T–17 T–17 T–18 T–19 T–19 T–19 T–19 T–19 T–20 T–20 T–20 T–20 T–20 T–20 T–21 T–21 T–21 T–21 T–22 T–22 T–22 T–22/24 T–24
CONTINUED
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POWER SYSTEM
BODY ELECTRICAL SYSTEM PAGE 2 OF 2 WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . FUEL GAUGE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH INSPECTION . . . . . HORN REMOVAL/INSTALLATION . . . . . . . . . . HORN RELAY REMOVAL/INSTALLATION . . . HORN RELAY INSPECTION . . . . . . . . . . . . . . . CLOCK REMOVAL/INSTALLATION . . . . . . . . . AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUDIO UNIT REMOVAL . . . . . . . . . . . . . . . . . . . AUDIO UNIT INSTALLATION . . . . . . . . . . . . . . . SPEAKER REMOVAL/INSTALLATION . . . . . . . SPEAKER INSPECTION . . . . . . . . . . . . . . . . . . . ROOF ANTENNA REMOVAL . . . . . . . . . . . . . . . ROOF ANTENNA INSTALLATION . . . . . . . . . . ROOF ANTENNA INSPECTION . . . . . . . . . . . . ANTENNA FEEDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . ANTENNA FEEDER INSPECTION . . . . . . . . . . CONDENSER REMOVAL/INSTALLATION . . .
T–24 T–24/25 T–25 T–25 T–25 T–25 T–25 T–25/26 T–26 T–26 T–26 T–26 T–26 T–26/27 T–27 T–27 T–27 T–27/28 T–28 T–28 T–28
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POWER SYSTEM
POWER SYSTEM FUSE SERVICE CAUTION Caution Determine and correct the cause of the burnt fuse before replacing it with the specified type. If the fuse is replaced before doing this, it may burn again.
IGNITION SWITCH INSPECTION 1. Remove the column cover. 2. Disconnect the ignition switch connectors. 3. Inspect for continuity between the ignition switch terminals using an ohmmeter. : Continuity Ignition g key y position
Terminal 2A
2B
1D
1C
1B
1A
LOCK
MAIN FUSE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
ACC ON START
G6, WL, WL TURBO, F2 CIS
2A
2B
2B
2A
123456567
START START LOCK LOCK ON ON ACC ACC 1A 1B 1C 1D
1C
1A
1D
1B
F2 CARB
4. If not as specified, replace the ignition switch. KEY REMINDER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key reminder switch connector. 4. Remove the key reminder switch. KEY REMINDER SWITCH
1
Nut
2
Bolt
3
Main fuse
IGNITION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the ignition switch connectors. 4. Remove the screw to remove the ignition switch.
STEERING LOCK
5. Install in the reverse order of removal.
IGNITION SCREW SWITCH CONNECTOR
IGNITION SWITCH
5. Install in the reverse order of removal.
CONTINUED
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POWER SYSTEM KEY REMINDER SWITCH INSPECTION 1. Remove the column cover. 2. Disconnect the key reminder switch connector. 3. Inspect for continuity between the key reminder switch terminals using an ohmmeter. : Continuity Key position
Socket Removal Note 1. Pry up the stopper with a tape-wrapped screwdriver. 2. Pull the socket by prying up the stopper.
Terminal A
B
Inserted Removed A
B
CIGARETTE LIGHTER INSPECTION Verify that the cigarette lighter plug will move normally within 10—20 seconds, after pressing the plug into the socket. If the plug does not move, replace the cigarette lighter.
A
B
4. If not as specified, replace the key reminder switch. CIGARETTE LIGHTER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the center panel. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Cigarette lighter plug
2
Connector
3
Socket + Removal Note
4
Ring
CONTINUED
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EXTERIOR LIGHTING SYSTEM If it is difficult to remove front combination light with pliers Remove the adjusting screws and the screw by loosening them.
EXTERIOR LIGHTING SYSTEM FRONT COMBINATION LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the radiator grille. (Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.) 3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the headlight aiming. (Refer to HEADLIGHT AIMING.)
ADJUSTING SCREW SCREW
ADJUSTING SCREW
HEADLIGHT AIMING 1. Adjust the tire air pressure to the specification. 2. Position the unloaded vehicle on a level surface. 3. Seat one person in the driver’s seat. 4. Start the engine and charge the battery fully. 5. Position the vehicle straight ahead and perpendicularly to a wall. 6. Set the headlights 7.6 m {25 ft} from the wall. 7. While adjusting one headlight, disconnect the connector of the other. 1
Front combination light connector
2
Front combination light + Removal Note
3
Spring
Caution Always tighten the adjusting screws last. When loosening the adjusting screws, loosen the screws first and then tighten them. If the adjusting screws are tightened first, then loosened, they will continue to loosen when the vehicle is in motion and may cause the headlights to become misaligned.
Front Combination Light Removal Note Removal with pliers Caution When pressing the hook of the adjusting screws and the screw with the pliers, do not damage the front combination light mounting.
8. Adjust the headlights by turning the adjusting screws as shown in the figure. Loosen the screws first, then tighten them.
1. Press the hook of the adjusting screws and the screw with the pliers. 2. Pull the front combination light out of the adjusting screws and the screw.
ADJUSTING SCREW
OUTWARD
INWARD
UP
HOOK
DOWN SCREW
HEADLIGHT BULB REMOVAL/INSTALLATION Caution A halogen bulb generates extremely high heat when it is used. If the surface of the bulb is soiled, excessive heat will build up and the light’s life will be shortened. When replacing the bulb, hold the metal flange, not the glass.
FRONT COMBINATION LIGHT MOUNTING
CONTINUED
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EXTERIOR LIGHTING SYSTEM 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Headlight bulb connector
2
Cover + Installation Note
3
Headlight bulb
Cover Installation Note Align the TOP mark with top side.
1
Screw
2
Front turn light
3
Front turn light connector
FRONT TURN LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
TOP MARK
PARKING LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Socket
2
Front turn light bulb
FRONT SIDE TURN LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
FRONT
1
Socket
2
Parking light bulb
REAR
FRONT TURN LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Front side turn light
2
Front side turn light connector
3
Socket
4
Front side turn light bulb
CONTINUED
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EXTERIOR LIGHTING SYSTEM REAR COMBINATION LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
REAR FOG LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. WITHOUT REAR BUMPER
Screw
2
Rear combination light
3
Rear combination light connector
REAR COMBINATION LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the rear combination light. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Screw
2
Lens + Removal Note
3
Rear turn light bulb
4
Back-up light bulb
5
Brake light/taillight bulb
1
Rear fog light connector
2
Nut
3
Spring washer
4
Rear fog light
WITH REAR BUMPER
1
Rear fog light connector
2
Screw
3
Rear fog light
REAR FOG LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Lens Removal Note Push the hook upward with your finger. HOOK
1
Screw
2
Lens
3
Rear fog light bulb
CONTINUED
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EXTERIOR LIGHTING SYSTEM LICENSE PLATE LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
COMBINATION SWITCH DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1
Screw
1
Screw
2
License plate light
2
Windshield wiper and washer switch
3
License plate light bulb
3
Light switch
4
Socket
4
Body
5
License plate light connector
COMBINATION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. For vehicles without air bag system, remove the horn cap. For vehicles with air bag system, remove the driver-side air bag module. (Refer to AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 4. For vehicles with air bag system, remove the clock spring. (Refer to AIR BAG SYSTEM, CLOCK SPRING REMOVAL/INSTALLATION.) 5. Remove the column cover. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
LIGHT SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Light switch connector
2
Screw
3
Light switch
LIGHT SWITCH INSPECTION Headlight Switch 1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)
1
Screw
2
Combination switch
3
Combination switch connector
Note When the flash-to-pass switch is on, the contact of the low-high switch is at neutral. 2. Inspect for continuity between the light switch terminals using an ohmmeter.
CONTINUED
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EXTERIOR LIGHTING SYSTEM : Continuity Switch position Light
Dimmer
OFF
–
TNS
–
HeadHead light
Low
Terminal
Flashto-pass
P (B)
D (N)
L (H)
F (J)
3. If not as specified, replace the light switch. HAZARD WARNING SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
H (L)
Off On Off On Off On
High
–
( ): Light switch right side lever (J)
(N)
F
D
OFF OFF TNS FLASH -TO -PASS
HIGH
HOOK
HEADLIGHT
HEADLIGHT TNS
1
H
L
P
(L)
(H)
(B)
* (O)
* (M)
* (K)
N
L
P (*)
Hazard warning switch
LOW
E
(*)
* (J)
H
F (*)
HAZARD WARNING SWITCH INSPECTION 1. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Inspect for continuity between the hazard warning switch terminals using an ohmmeter. : Continuity : Bulb
C
(*)
D
* (B)
Terminal
Switch position
A
(*)
F
D
B
A
C
I
K
H
J
Off On
( ): LIGHT SWITCH RIGHT SIDE LEVER
3. If not as specified, replace the light switch. Turn Switch 1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the light switch terminals using an ohmmeter. : Continuity Switch position
H
K
F
D
Terminal C (M)
A (K)
E (O)
Right Off
J
A
K
I
*
J
C
I
B
Left
( ): Light switch right side lever (M) C
* * * (M) (O) (K) * H P N L (J) (*) A
E
(*)
F (*)
C
(*)
D
H
F
C
A
D
B
A
(*)
* (B)
3. If not as specified, replace the hazard warning switch.
E
(K) (O) ( ): LIGHT SWITCH RIGHT SIDE LEVER
CONTINUED
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EXTERIOR LIGHTING SYSTEM REAR FOG LIGHT SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the rear fog light switch and pull it forward to remove it. 3. Disconnect the connector to remove the rear fog light switch.
HEADLIGHT LEVELING SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the headlight leveling switch and pull it forward to remove it. 3. Disconnect the connector to remove the headlight leveling switch.
HOOK
HOOK CONNECTOR
CONNECTOR REAR FOG LIGHT SWITCH
HEADLIGHT LEVELING SWITCH
REAR FOG LIGHT SWITCH INSTALLATION 1. Connect the rear fog light switch connector. 2. Insert the rear fog light switch in the hole to install it. 3. Connect the negative battery cable.
HEADLIGHT LEVELING SWITCH INSTALLATION 1. Connect the headlight leveling switch connector. 2. Insert the headlight leveling switch in the hole to install it. 3. Connect the negative battery cable.
REAR FOG LIGHT SWITCH INSPECTION 1. Remove the rear fog light switch. (Refer to REAR FOG LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the rear fog light switch terminals using an ohmmeter. : Continuity
HEADLIGHT LEVELING SWITCH INSPECTION 1. Remove the headlight leveling switch. (Refer to HEADLIGHT LEVELING SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the headlight leveling switch terminals using an ohmmeter. : Continuity : Resistance : Bulb
Switch position
Terminal A
D
F
Terminal
Switch position
C
Off Neutral
0 1 2
R3
3
D
R1:1600 Ω
A
B
R2+R3
F
F
A
R1+ R2+ R3
On
A
D
3. If not as specified, replace the rear fog light switch.
0
1
2
3:300
Ω
3 *
R1 R2 R3
D
560 Ω
A
C
D
2:
*
*
*
C
A
D
B
B
3. If not as specified, replace the headlight leveling switch.
CONTINUED
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EXTERIOR LIGHTING SYSTEM BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
FLASHER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
25—34 {2.5—3.4, 19—24}
R
DRIVER-SIDE FRONT SIDE TRIM
N·m {kgf·m, ft·lbf}
1
Back-up light switch connector
2
Back-up light switch
3
Gasket
BACK-UP LIGHT SWITCH INSPECTION 1. Disconnect the back-up light switch connector. 2. Inspect for continuity between the back-up light switch terminals using an ohmmeter. : Continuity Terminal
Shift lever position
A
B
Reverse
1
Nut
2
Flasher unit
3
Flasher unit connector
Other
A
A
B
B
3. If not as specified, replace the back-up light switch.
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EXTERIOR LIGHTING SYSTEM FLASHER UNIT INSPECTION 1. Measure the voltage at the flasher unit terminals as indicated below. 2. Disconnect the flasher unit connector before inspecting for continuity at terminal C. 3. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses. 4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the flasher unit. Terminal Voltage List (Reference) B+: Battery positive voltage A C
Terminal
Signal
Connection
B
Test condition Hazard warning switch on
A
Flasher unit out ut output
Hazard warning switch
Hazard warning switch off
B
C
Power supply su ly
Flasher unit ground
Hazard warning switch off
B+
Ignition switch at LOCK or ACC position
0
Inspection area
Hazard
warning switch Turn signal
light
B+
Ignition switch at ON position
B+
Ignition switch at LOCK or ACC position
0
Constant: inspect for continuity to ground
GND
Alternates B+ and 0
Ignition switch at ON position
Hazard warning switch on Hazard warning switch
Voltage (V) /Continuity
HAZARD 10 A
fuse METER 15 A
fuse
Yes
Hazard
warning switch GND
HEADLIGHT LEVELING ACTUATOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the radiator grille. (Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.) 3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.) 4. Remove the front combination light. (Refer to FRONT COMBINATION LIGHT REMOVAL/INSTALLATION.) 5. Remove the headlight leveling actuator connector from the bracket. 6. Disconnect the headlight leveling actuator connector. 7. Remove the nuts. 8. Remove the headlight leveling actuator. HEADLIGHT LEVELING ACTUATOR
HEADLIGHT LEVELING ACTUATOR CONNECTOR
9. Install in the reverse order of removal.
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EXTERIOR LIGHTING SYSTEM HEADLIGHT LEVELING ACTUATOR INSPECTION 1. Measure the voltage at the headlight leveling actuator terminals as indicated below. Note Because the headlight leveling actuator connector is waterproof, it is impossible to measure the voltage at the headlight leveling actuator terminals. When inspecting, measure the voltage at the terminal of the part which is connected to the headlight leveling actuator. (1) To measure the voltage at the terminal A of the headlight leveling actuator, remove the column cover and measure the voltage at the terminal N of the light switch connector. (Refer to LIGHT SWITCH INSPECTION.) (2) To measure the voltage at the terminal B of the headlight leveling actuator, remove the headlight leveling switch with the connector connected and measure the voltage at the terminal C of the headlight leveling switch connector. (Refer to HEADLIGHT LEVELING SWITCH INSPECTION.) (3) Disconnect the headlight leveling actuator connector before inspecting for continuity at terminal C. 2. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses. 3. If the parts and wiring harnesses are okay but the system still does not work properly, replace the headlight leveling actuator. Terminal Voltage List (Reference) B+: Battery positive voltage
A
Terminal
Signal
A
Headlight leveling g actuator power supply
B
C
Headlight leveling switch position
Headlight leveling actuator ground
Connection
Combination switch
g Headlight leveling switch
GND
B
C
Test condition Headlight illuminated
Voltage ( V ) /Continuity
Inspection area
B+ Combination switch
Headlight unilluminated
g Headlight switch on
0
Headlight leveling switch at 0
6.2
Headlight leveling switch at 1
4.2
Headlight leveling switch at 2
2.1
Headlight leveling switch at 3
0
Constant : inspect for continuity to ground
Headlight leveling switch
Yes
GND
CONTINUED
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EXTERIOR LIGHTING SYSTEM REAR FOG LIGHT RELAY REMOVAL/INSTALLATION
RUNNING LIGHT RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the washer tank from the bracket. 3. Remove the running light relay with the cover attached.
Note Because the lock section of the relay is damaged easily, do not remove the relay from the bracket unless replacement is necessary. Always perform an inspection of the rear fog light relay before removal.
NUT
1. Disconnect the negative battery cable. 2. Disconnect the rear fog light relay connector. 3. Remove the rear fog light relay by prying the lock section of the upper part with a flathead screwdriver.
RUNNING LIGHT RELAY WITH COVER
4. Remove the cover. 5. Disconnect the running light relay connector.
REAR FOG LIGHT RELAY
COVER
BRACKET
REAR FOG LIGHT RELAY CONNECTOR
RUNNING LIGHT RELAY
4. Install in the reverse order of removal. REAR FOG LIGHT RELAY INSPECTION 1. Remove the bracket and pull it toward you. 2. Inspect for continuity between the rear fog light relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage Terminal
Step
A
B
B+
GND
C
D
1 2
C
D
RUNNING LIGHT RELAY CONNECTOR
6. Install in the reverse order of removal. RUNNING LIGHT RELAY INSPECTION 1. Remove the running light relay. (Refer to RUNNING LIGHT RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the running light relay terminals using an ohmmeter. : Continuity : Diode
C
A
Test cond condi tion
D
B
Constant
A
Terminal A
B
C
D
E
F
B B
A
C
3. If not as specified, replace the rear fog light relay.
F
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E
D
E
C
A
F
D
B
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EXTERIOR LIGHTING SYSTEM 3. Connect the terminal A to the positive battery terminal and the terminal D to the negative battery terminal. 4. Verify that there is continuity between terminals A and E, and that there is no continuity between terminals B and F. B
A
C
F
E
E
C
A
F
D
B
D
5. Connect the terminal C to the positive battery terminal and the terminal D to the negative battery terminal. 6. Verify that there is no continuity between terminals B and F, and between terminals A and E. B
F
A
C
E
E
C
A
F
D
B
D
7. If not as specified, replace the running light relay.
CONTINUED
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INTERIOR LIGHTING SYSTEM
INTERIOR LIGHTING SYSTEM INTERIOR LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. ALL VEHICLES EXCEPT REGULAR CAB
Interior Light Installation Note Regular cab Note The spacer acts as a ground. If the spacer is not installed in the position shown in the figure, the interior light may not illuminate. REGULAR CAB
1. Tighten the screw fully. (More than 4 mm {0.2 in} of thread should be exposed.) 2. Install the interior light. SCREW
4.0 mm {0.2 in}
1
Lens + Removal Note
2
Interior light bulb
3
Screw
4
Spacer
5
Interior light + Installation Note
6
Interior light connector
SPACER INTERIOR LIGHT
INTERIOR LIGHT INSPECTION 1. Remove the interior light. (Refer to INTERIOR LIGHT REMOVAL/INSTALLATION.) 2. Inspect for continuity between the interior light terminals using an ohmmeter. : Bulb
Lens Removal Note All vehicles except regular cab 1. Insert a tape-wrapped flathead screwdriver into the lens. 2. Twist the screwdriver to remove the lens.
Terminal
Step
A
B
Body GND
ON DOOR OFF B
A OFF
B
ON
DOOR A
Regular cab Push the areas indicated by the arrows to pull out the lens.
3. If not as specified, replace the interior light.
CONTINUED
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INTERIOR LIGHTING SYSTEM DOOR SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1
Screw
2
Door switch
3
Door switch connector
1
Panel light control switch
DOOR SWITCH INSPECTION 1. Remove the door switch. 2. Inspect for continuity between the door switch terminals using an ohmmeter. : Continuity Terminal
Switch condition
A
Body GND
Pressed Released
A
A
BODY GND
3. If not as specified, replace the door switch. PANEL LIGHT CONTROL SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
HOOK
CONTINUED
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INTERIOR LIGHTING SYSTEM PANEL LIGHT CONTROL SWITCH INSPECTION 1. Remove the meter hood without disconnecting the panel light control switch connector. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Measure the voltage at the panel light control switch as indicated below. 3. Disconnect the panel light control switch connector before inspecting for continuity at terminal G. 4. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the panel light control switch. Terminal Voltage List (Reference) B+: Battery positive voltage G H
Terminal A B D F G H
Signal Panel light control output
Connection Each illumination
— Power supply
F
g switch Light
D
B
Voltage (V)/ Continuity
Test condition Inspect using an oscilloscope + A terminal inspection
Not used
—
— Headlight switch at TNS or headlight position
Not used
—
—
Not used
—
0
Light switch TAIL 10 A fuse
—
—
A Terminal Inspection 1. Measure the wave pattern of the A terminal on the panel light control switch using an oscilloscope.
Each illumination
B+
Constant: Inspect for continuity to ground
GND
Inspection area
—
Headlight switch at OFF position
— Panel light control switch ground
A
—
Yes
GND
—
—
V
0
PANEL LIGHT CONTROL SWITCH
5. Verify that the pattern on the screen matches the pattern shown in the figure as the panel light control switch is gradually turned to the darkest position.
OSCILLOSCOPE
2. Set the headlight switch to either the TNS or headlight position. 3. Set the panel light control switch to the brightest position. 4. Verify that the pattern of the screen is as shown in the figure.
V B+ 0
1—3.2 ms 5—15.4 ms
CONTINUED
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WIPER AND WASHER WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Adjust the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.)
WIPER AND WASHER WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Loosen the bolts. 4. Pull the windshield wiper motor forward until the connection between the windshield wiper motor and windshield wiper link is in the engine room. 5. Pry off the connection between the windshield wiper motor and windshield wiper link. 6. Remove the windshield wiper motor.
16—19 {1.6—2.0, 12—14}
WINDSHIELD WIPER MOTOR
N·m {kgf·m, ft·lbf}
CONNECTOR
WINDSHIELD WIPER LINK
BOLT 4.0—6.8 {40—70, 35—60}
1
Cap
2
Nut
3
Windshield wiper arm + Installation Note
4
Windshield wiper blade
5
Rubber brush
N·m {kgf·cm, in·lbf}
7. Install in the reverse order of removal. WINDSHIELD WIPER MOTOR INSPECTION 1. Disconnect the windshield wiper motor connector. 2. Connect battery positive voltage and inspect the operation of the windshield wiper motor as indicated below. Terminal
Operation
A
High
C
Low
A B
Windshield Wiper Arm Installation Note Clean the windshield wiper arm connector shafts with a wire brush before installing the windshield wiper arms.
WINDSHIELD WIPER ARM CONNECTOR SHAFT
C D
3. Connect battery positive voltage to terminal C of the windshield wiper motor to operate the windshield wipers at low speed. 4. Disconnect battery positive voltage from terminal C of the motor while the wipers are operating. 5. Verify that the wipers do not stop in the park position. 6. Short between terminal C and B of the motor, and connect battery positive voltage to terminal D of the motor. 7. Verify that the wipers operate at low speed again, then stop in the park position. 8. If not as specified, replace the windshield wiper motor.
WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT 1. Operate the windshield wiper motor to set the windshield wipers in the park position. 2. Align both ends of the wiper blades to the marks on the ceramic section.
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CERAMIC SECTION
MARK
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WIPER AND WASHER WINDSHIELD WIPER LINK REMOVAL/INSTALLATION 1. Remove the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.) 2. Remove the cowl grille. 3. Remove the windshield wiper motor. (Refer to WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.) 6.87—9.80 {70—100, 60.8—86.7}
1
Windshield washer motor
2
Grommet
WINDSHIELD WASHER MOTOR INSPECTION 1. Disconnect the windshield washer motor connector. 2. Connect battery positive voltage to terminal B and ground to terminal A of the motor. 3. Verify that the windshield washer motor operates. B N·m {kgf·cm, in·lbf}
1
Bolt
2
Windshield wiper link
M A
WINDSHIELD WASHER TANK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Disconnect the windshield washer pipe from the windshield washer motor. 4. Pull the windshield washer tank up and slide it off the bracket.
WINDSHIELD WASHER TANK
CONNECTOR WINDSHIELD WASHER PIPE
B A
4. If the motor does not operate, replace the windshield washer motor. WINDSHIELD WASHER NOZZLE REMOVAL 1. Disconnect the windshield washer pipe from the windshield washer nozzle. 2. Remove the windshield washer nozzle using a 10 mm {0.4 in} deep socket wrench from underneath the bonnet. DEEP SOCKET WRENCH
WINDSHIELD WASHER NOZZLE
BRACKET
5. Install in the reverse order of removal. WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the windshield washer tank. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
WINDSHIELD WASHER NOZZLE INSTALLATION 1. Connect the windshield washer pipe to the windshield washer nozzle. 2. Push the windshield washer nozzle into the installation hole. 3. Adjust the windshield washer nozzle. (Refer to WINDSHIELD WASHER NOZZLE ADJUSTMENT.)
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WIPER AND WASHER WINDSHIELD WASHER NOZZLE ADJUSTMENT Insert a needle or equivalent tool into the spray holes of the windshield washer nozzle and adjust the nozzle direction as shown.
SCREW
WINDSHIELD WIPER AND WASHER SWITCH
CENTER
320 {12.6}
CONNECTOR
390 {15.4}
6. Install in the reverse order of removal.
100 100 {3.9} {3.9}
290 {11.4} 290 {11.4}
270 {10.6}
180 {7.1}
WINDSHIELD WIPER AND WASHER SWITCH INSPECTION 1. Remove the column cover. 2. Remove the windshield wiper and washer switch. 3. Inspect for continuity between the windshield wiper and washer switch terminals using an ohmmeter. : Continuity
WINDSHIELD GLASS END LINE
MOLDING END LINE
Switch position
WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION 1. Disconnect the windshield washer pipe from the windshield washer nozzle and the windshield washer motor. 2. Remove the clips. 3. Remove the windshield washer pipe.
Wiper switch
L(F)
G(E )
M(C )
N(D )
C(M )
123
Off
OFF
mm {in}
Terminal
Onetouch
On
INT LO HI
Washer switch
On
( ): Wiper and washer switch left side lever (D) N ONE-TOUCH WIPER SWITCH HI OFF
OFF
HI LO
INT INT
LO CLIP
INT RELAY
WINDSHIELD WASHER PIPE
L (F)
H (J)
4. Install in the reverse order of removal.
M (C)
G (E)
C (M) WASHER SWITCH
WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the connector. 4. Remove the screws. 5. Remove the windshield wiper and washer switch.
0 (*) *
G (*)
M N (*)
L (*)
* (J)
H (*)
* (E) * (F)
C
* (A)
* (D)
*
( ): WIPER AND WASHER SWITCH LEFT SIDE LEVER
4. If not as specified, replace the windshield wiper and washer switch.
CONTINUED
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WARNING AND INDICATOR SYSTEM
WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1
Screw
2
Instrument cluster connector
3
Instrument cluster
INSTRUMENT CLUSTER INSPECTION Speedometer 1. Adjust the tire air pressure to the specification. 2. Using a speedometer tester, verify that the speedometer indication is within the allowable range indicated in the table. Allowable range (km/h)
20
18—22
40
36—44
60
54—66
80
72—88
100
90—110
120
108—132
140
126—154
160
144—176
180
162—198
3. Verify that fluctuation of the speedometer needle is within the allowable range. Needle fluctuation allowable range Within 0.5 km/h
INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY
4. If the speedometer needle does not move or if the indication is outside of the allowable range, inspect the vehicle speedometer sensor and related wiring harness. 5. If the vehicle speedometer sensor and related wiring harness are normal, replace the instrument cluster.
Caution If the print plate on the back of the instrument cluster is damaged, the system will not operate properly and it may become the cause of trouble or malfunction. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Speedometer tester p indication (km/h)
Tachometer Using the SSTs (NGS kit) or a dwell tacho tester Caution If the engine speed exceeds the allowable range, the engine could be damaged. Therefore, when inspecting the tachometer, do not allow the engine speed to exceed the allowable range indication on the tachometer. 1. Follow the appropriate procedure for using the SSTs (NGS kit) or dwell tacho tester.
1
Screw
2
Bulb
3
Alarm
4
Front lens
5
Instrument cluster
Using the SSTs (NGS kit) (1) Connect the SSTs (NGS kit) to the data link connector and battery.
DIAGNOSTIC PROGRAM CARD
NGS KIT
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WARNING AND INDICATOR SYSTEM (2) Select “VEHICLE & ENGINE SELECTION” and press TRIGGER. (Select the model and specifications of the vehicle you are testing.) (3) Select “PCM-POWERTRAIN CTRL MODULE” and press TRIGGER. (4) Select “PID/DATA MONITOR AND RECORD” and press TRIGGER. (5) Select “RPM” and press TRIGGER. (6) Press START.
: Resistance Step 1
FUEL –
GND
COM
R1 R2
2
R1, R2: 140—200 Ω
Using a dwell tacho tester Connect a dwell tacho tester to the terminals K and B of the PCM connector.
GND FUEL+ COM
2. Verify that the tachometer indication is within the allowable range indicated in the table. Dwell tacho tester indication (rpm)
Terminal FUEL +
FUEL–
Allowable range (rpm)
650
583—705
1000
926—1060
2000
1954—2120
3000
2980—3180
4000
4008—4240
12. Verify that the difference in resistance between R1 and R2 is less than 6 Ω. 13. If not as specified, replace the instrument cluster.
3. If the tachometer needle does not move or if the indication is outside of the allowable range, inspect the PCM and related wiring harness. 4. If the PCM and related wiring harness are normal, replace the instrument cluster.
Water Temperature Gauge 1. Disconnect the water temperature sender unit connector. 2. Turn the ignition switch to ON position. 3. Verify that the needle is below C. 4. Ground terminal A of the water temperature sender unit’s vehicle side connector.
Fuel Gauge 1. Disconnect the fuel gauge sender unit connector. 2. Connect the red lead of SST (Fuel And Thermometer checker) to terminal B of the fuel gauge sender unit connector and black lead to ground. 3. Set the resistance of SST (Fuel And Thermometer checker) to 180 Ω.
A
49 N088 0A0 49 0839 285
5. Verify that the needle is above H. 6. If the needle does not move or moves irregularly, remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 7. Measure the resistance between the water temperature gauge terminals using an ohmmeter. : Resistance
*
C
B
4. Turn the ignition switch to ON position. 5. Verify that the needle is below E. 6. Turn the ignition switch to LOCK position. 7. Set the resistance of SST (Fuel And Thermometer checker) to 10 Ω. 8. Turn the ignition switch to ON position. 9. Verify that the needle is above F. 10. If the needle does not move or moves irregularly, remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 11. Measure the resistance between the fuel gauge terminals using an ohmmeter.
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Step 1 2
Terminal TEMP +
TEMP –
V+
COM
R1 R2
R1, R2: 140—200 Ω
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WARNING AND INDICATOR SYSTEM WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 3. Turn the socket counterclockwise to remove the bulb as shown in the figure.
TEMP+ COM
V+
TEMP–
8. Verify that the difference in resistance between R1 and R2 is less than 6 Ω. 9. If not as specified, replace the instrument cluster.
BULB
INSTRUMENT CLUSTER REPAIR Note The needle of speedometer or tachometer may continue to rotate clockwise until it rests on the mask plate. If a customer complains of this concern, repair the needle position according to the following steps. 1. Verify the concern. TACHOMETER
SPEEDOMETER
4. Install in the reverse order of removal. FUEL GAUGE SENDER UNIT INSPECTION 1. For G6, F2 CIS, or F2 Carb engine vehicles, remove the fuel pump unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) For WL or WL Turbo engine vehicles, remove the fuel gauge sender unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Using an ohmmeter, measure and verify that the resistance between terminals B and C (WL, WL Turbo) or A and B (G6, F2 CIS, F2 Carb) of the fuel gauge sender unit is as shown in the following chart while slowly moving the unit arm from empty to full.
2. Turn the ignition switch to LOCK position. 3. Remove the ROOM fuse, then wait for 10 minutes or more until the power supply in the instrument cluster is spent. 4. Turn the ignition switch to ON position. 5. Verify that the needle returns to zero. TACHOMETER
Measuring point
Resistance (Ω)
Full
18.4—26.4
1/2
81.5—93.5
Empty
136—154
WL, WL TURBO 87.0 {3.43} * 65.5 {2.58}
SPEEDOMETER
* DOUBLE CAB 2WD, STRETCH CAB 2WD
FULL
169.7 {6.681} * 158.1 {6.224}
1/2 253.7 {9.988}
EMPTY
6. After the needle returns to zero, install the ROOM fuse with the ignition switch at ON position. If the needle does not return to zero, remove the front lens and carefully move the needle to zero by hand. (Refer to INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY.)
* B C mm {in}
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WARNING AND INDICATOR SYSTEM WATER TEMPERATURE SENDER UNIT INSPECTION 1. Remove the water temperature sender unit. 2. Place the sender unit in a container of water. 3. Heat the water gradually. 4. Using an ohmmeter, measure and verify that the resistance between terminal of the sender unit and the sender unit body is as shown below.
G6, F2 CIS, F2 CARB 67.5 {2.66}
FULL
160.1 {6.303}
1/2 A B
255.7 {10.067}
EMPTY
Water temperature (°C {°F })
Resistance (Ω)
49.8—50.2 {121.7—122.3}
189.4—259.6
mm {in}
3. If not as specified, replace the fuel gauge sender unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) (Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY.) (Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/INSTALLATION.) WATER TEMPERATURE SENDER UNIT REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Remove the water temperature sender unit. CONNECTOR
WATER TEMPERATURE SENDER UNIT
WATER TEMPERATURE SENDER UNIT INSTALLATION 1. Apply sealant from the third thread to the top thread.
5. If not as specified, replace the water temperature sender unit. OIL PRESSURE SWITCH INSPECTION 1. Verify that the oil pressure warning light illuminates when the ignition switch is turned to ON position. 2. Verify that the oil pressure warning light goes off when the engine is started. 3. If the oil pressure warning light does not illuminate or remains illuminated, inspect the oil pressure warning light bulb and related wiring harness. 4. If the oil pressure warning light bulb and related wiring harness are normal, inspect the oil pressure. (Refer to section D, LUBRICATION SYSTEM, OIL PRESSURE INSPECTION.) 5. If the oil pressure is normal, replace the oil pressure switch. HORN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the horn connector. 3. Remove the bolt. 4. Remove the horn.
BOLT THIRD THREAD
6—8 {0.24—0.31}
mm { in }
HORN
2. Install the water temperature sender unit. Tightening torque 11.8—17.6 N·m {120—180 kgf·cm, 105—156 in·lbf} 3. Connect the water temperature sender unit connector. 4. Connect the negative battery cable.
HORN CONNECTOR
5. Install in the reverse order of removal. HORN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
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WARNING AND INDICATOR SYSTEM, AUDIO 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
AUDIO AUDIO UNIT REMOVAL 1. Disconnect the negative battery cable. 2. With the beveled parts of the SST (Removing tool) facing inward, insert them into the unit. 3. Pull the SST (Removing tool) outward and rearward to slide out the unit. 49 D066 801A
1
Nut
2
Horn relay connector
3
Horn relay
HORN RELAY INSPECTION 1. Remove the horn relay. (Refer to HORN RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the horn relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage
4. Disconnect the connectors and antenna jack. AUDIO UNIT INSTALLATION Caution If the harness or the antenna feeder is caught between the unit and dashboard, it may become the cause of trouble or malfunctions. Make certain that the wiring harness and antenna feeder are not caught between the unit and dashboard.
Terminal
Step
A
B
B+
GND
C
D
1 2
D
C
1. Connect the connectors and antenna jack. 2. Insert the unit until each clip clicks. 3. Connect the negative battery cable.
A C
A
D
B
SPEAKER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front door trim. (Refer to section S, TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.)
B
3. If not as specified, replace the horn relay. CLOCK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove the screws and remove the clock. SCREW
CLOCK
Caution When removing or installing a speaker, touching the radio cone paper could cause poor sound quality. When removing or installing a speaker, hold the speaker’s bracket and handle with care. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
SCREW
4. Install in the reverse order of removal.
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AUDIO
1
Screw
2
Speaker + Installation Note
3
Connector
SCREW
Speaker Installation Note When installing the speakers, position the speakers so that the terminals face downward. ROOF ANTENNA
SPEAKER INSPECTION 1. Remove the speaker. (Refer to SPEAKER REMOVAL/INSTALLATION.) 2. Inspect for resistance between the speaker terminals using an ohmmeter.
ROOF ANTENNA INSTALLATION 1. Tape the antenna jack to the antenna drain hose.
: Resistance Test condition
Terminal A
B R
Constant
R: 4 Ω
2. Pass the roof antenna and antenna drain hose through the A-pillar from the hole in the roof. 3. Connect the antenna feeder. 4. Install the screws. 5. Install the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 6. Connect the negative battery cable.
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3. Touch the leads of an ohmmeter to the speaker terminals and verify that the speaker clicks. Range 1 Ω 4. If not as specified, replace the speaker. ROOF ANTENNA REMOVAL 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the roof antenna and the antenna feeder.
ROOF ANTENNA INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the roof antenna and the antenna feeeder. 4. Verify that there is no continuity between roof antenna terminals A and B using an ohmmeter. 5. Inspect for continuity between the roof antenna terminals using an ohmmeter. : Continuity Terminal
Step
A
B
C
D
1 2 C
ANTENNA FEEDER
D
ROOF ANTENNA B A
4. Remove the screws and pull out the roof antenna.
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AUDIO 6. If not as specified, replace the roof antenna.
CONDENSER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
ANTENNA FEEDER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the antenna feeder and the roof antenna. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
1
Clip
2
Antenna feeder
IGNITION COIL
1
Screw
2
Clip
3
Nut
4
Condenser
ANTENNA FEEDER INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the antenna feeder and the roof antenna. 4. Verify that there is no continuity between the antenna feeder terminals A and B using an ohmmeter. 5. Inspect for continuity between the antenna feeder terminals using an ohmmeter. : Continuity Terminal
Step
A
B
C
D
1 2
B D A
C
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6. If not as specified, replace the antenna feeder.
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HEATER AND AIR CONDITIONER SYSTEMS SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . U– 2 STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U–19 HANDLING REFRIGERANT . . . . . . . . . . . . . . . . U– 2 MAGNETIC CLUTCH STORING REFRIGERANT . . . . . . . . . . . . . . . . . U– 2 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U–20 SERVICE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . U– 2 MAGNETIC CLUTCH CLEARANCE HANDLING COMPRESSOR OIL . . . . . . . . . . . . U– 2 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U–20/21 REFRIGERANT SYSTEM SERVICE MAGNETIC CLUTCH INSPECTION . . . . . . . . . U–21 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3 A/C RELAY No.1 MANIFOLD GAUGE SET INSTALLATION . . . . U– 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–21 RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3 A/C RELAY No.1 INSPECTION . . . . . . . . . . . . . U–22 CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3/5 A/C RELAY No.2 REFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 5/6 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–22 REFRIGERANT CHARGE CHECK . . . . . . . . . . U– 6/7 A/C RELAY No.2 INSPECTION . . . . . . . . . . . . . U–22 REFRIGERANT PRESSURE CHECK . . . . . . . U– 7 REFRIGERANT PRESSURE SWITCH PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . U– 7 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–22 BASIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 8 REFRIGERANT PRESSURE SWITCH STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U– 8/9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . U–23 BLOWER UNIT REMOVAL/INSTALLATION . . U–10 THERMOSWITCH INSPECTION . . . . . . . . . . . U–23/24 BLOWER UNIT DISASSEMBLY/ASSEMBLY . U–10 BLOWER MOTOR COOLING UNIT REMOVAL/INSTALLATION . . U–10/11 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–24 COOLING UNIT DISASSEMBLY/ASSEMBLY . U–12 BLOWER MOTOR INSPECTION . . . . . . . . . . . U–24 EVAPORATOR INSPECTION . . . . . . . . . . . . . . U–13 RESISTOR REMOVAL/INSTALLATION . . . . . . U–24 HEATER UNIT REMOVAL/INSTALLATION . . . U–13 RESISTOR INSPECTION . . . . . . . . . . . . . . . . . . U–25 HEATER UNIT DISASSEMBLY/ASSEMBLY . . U–14 CLIMATE CONTROL UNIT REMOVAL . . . . . . U–25 HEATER CORE INSPECTION . . . . . . . . . . . . . . U–15 CLIMATE CONTROL UNIT INSTALLATION . . U–25 A/C COMPRESSOR CLIMATE CONTROL UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–15 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U–25/26 CONDENSER REMOVAL/INSTALLATION . . . U–16 CLIMATE CONTROL UNIT WIRE CONDENSER INSPECTION . . . . . . . . . . . . . . . U–16 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U–26/27 RECEIVER/DRIER CLIMATE CONTROL UNIT INSPECTION . . . . U–27 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–16/17 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . U–28 REFRIGERANT LINES FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U–28 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–17/18 TROUBLESHOOTING INDEX . . . . . . . . . . . . . . U–28 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . U–19 SYMPTOM TROUBLESHOOTING . . . . . . . . . . U–28/39
CONTINUED
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SERVICE WARNINGS, SERVICE CAUTIONS
SERVICE WARNINGS
SERVICE CAUTIONS
HANDLING REFRIGERANT D Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. If accidental system discharge occurs, ventilate work area before resuming service. D Do not pressure test or leak test R-134a service equipment and/or vehicle air conditioning system with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. D Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources and maintain adequate ventilation. D Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor.
HANDLING COMPRESSOR OIL D Use FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil for this vehicle. Using a PAG oil other than FD46XG (G6, WL, WL turbo) or ZXL 100PG compressor oil can damage the A/C compressor. D Do not spill compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately. D FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil (PAG oil) has a higher moisture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. Therefore, install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption.
STORING REFRIGERANT D The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at temperatures below 40 °C {104 °F}.
FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) COMPRESSOR OIL
MINERAL OIL
TIME MOISTURE ABSORPTION
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES
REFRIGERANT SYSTEM SERVICE PROCEDURES
TAP PIN SIDE
49 C061 001 49 C061 005
MANIFOLD GAUGE SET INSTALLATION 1. Fully close the valves of the SST (49 C061 001). 2. Connect the SSTs (49 C061 002, 49 C061 003) to the high- and low-pressure side joints of the SST (49 C061 001). 3. Connect the SSTs (49 C061 006A, 49 C061 007) to the ends of the SSTs (49 C061 002, 49 C061 003). 4. Connect the SSTs (49 C061 006A, 49 C061 007) to the charging valves.
49 C061 004 REFRIGERANT TANK SCALE VACUUM PUMP
7. Open all the valves of the SST (49 C061 001).
49 C061 001
Caution Close the SST (49 C061 001) valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner.
49 C061 002 49 C061 003
49 C061 006A CAP
49 C061 007 CAP CHARGING VALVE OF LOW-PRESSURE SIDE
AIR PURGE VALVE
CHARGING VALVE OF HIGH-PRESSURE SIDE
8. Start the vacuum pump and let it operate for 15 minutes. 49 C061 001
RECOVERY Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer’s instructions.
CLOSE
CHARGING Charging Recycled R-134a Refrigerant Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer’s instructions. Charging New R-134a Refrigerant
9. Verify that high- and low-pressure side readings of the SST (49 C061 001) are at –101 kPa {–760 mmHg, –29.9 inHg}. Close each valve of the SST (49 C061 001).
Caution Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts.
49 C061 001
1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49 C061 001). 3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001). 4. Connect the SST (49 C061 005) to the vacuum pump. 5. Connect the SST (49 C061 004) to the refrigerant tank. 6. Place the refrigerant tank on the scale. Regular amount of refrigerant 550 g {19.4 oz}
10. Stop the vacuum pump and wait for 5 minutes. 11. Check the high- and low-pressure side readings of the SST (49 C061 001). If the reading has changed, inspect for leakage and then repeat from step 7. If the reading has not changed, go to step 12. 12. Open the valve of the refrigerant tank. 13. Weigh the refrigerant tank.
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES Warning If the refrigerant system is charged with a large amount of refrigerant when checking for gas leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In order to prevent the accidental release of refrigerant which can destroy the ozone layer in the stratosphere, follow the proper procedures and charge with only a small amount of refrigerant when checking for gas leakage. If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
Warning If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. 17. Open the high-pressure side valve of the SST (49 C061 001) and charge with refrigerant until the weight of refrigerant tank has decreased 300 g {10.6 oz} from the amount in step 13. 49 C061 001 OPEN
14. Open the high-pressure side valve of the SST (49 C061 001). 49 C061 001 OPEN
18. Close the high-pressure side valve of the SST (49 C061 001). 49 C061 001
15. When the low-pressure side reading increases to 0.098 MPa {1.0 kgf/cm2, 14 psi}, close the high-pressure side valve of the SST (49 C061 001). 49 C061 001
16. Inspect for leakage from the cooler pipe/hose connections using the SST (Gas leak tester). If there is no leakage, go to step 17. If a leakage is found at a loose joint, tighten the joint and inspect for leakage again. If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 7. If there is no leakage after tightening the joint, go to step 17.
Warning If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. 19. Start the engine and actuate the A/C compressor. 20. Open the low-pressure side valve of the SST (49 C061 001) and charge with refrigerant until the refrigerant tank is empty.
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES
49 C061 001
TAP PIN SIDE
AIR PURGE VALVE
49 C061 001
OPEN
49 C061 005 49 C061 004 REFRIGERANT TANK
VACUUM PUMP
21. Close the low-pressure side valve of the 6. Open only the center valve of the SST (49 C061 SST (49 C061 001) and the valve of the refrigerant tank. (49 C061 001). 22. Stop the engine and A/C compressor. 23. Inspect for leakage using the SST (Gas leak Caution tester). If there is no leakage, go to step 24. If Close the SST (49 C061 001) valve leakage is found at a loose joint, tighten the joint immediately after stopping the vacuum and inspect for leakage again. If there is still a leak pump. If the valve is left open, the vacuum at the same joint, discharge the refrigerant and pump oil will flow back into the refrigeration then repair the joint. Repeat the charging cycle and cause a decrease in the efficiency procedure from step 7. If there is no leakage after of the air conditioner. tightening the joint, go to step 24. 24. Disconnect the SSTs (49 C061 006A, 7. Start the vacuum pump and let it run for 1 minute. 49 C061 007) from the charging valves. 49 C061 001 25. Install the caps to the charging valves. CLOSE
49 C061 006A 49 0061 007 CAP
CAP
8. Close the center valve of the SST (49 C061 001). REFILLING
49 C061 001
Caution Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts. 1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49 C061 001). 3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001). 4. Connect the SST (49 C061 005) to the vacuum pump. 5. Connect the SST (49 C061 004) to the refrigerant tank.
9. Stop the vacuum pump. 10. Open the valve of the refrigerant tank. Warning If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES 11. Start the engine and actuate the A/C compressor. 12. Open the low-pressure side valve of the SST (49 C061 001).
49 C061 007
49 C061 006A
CAP
49 C061 001 OPEN CAP
REFRIGERANT CHARGE CHECK Caution The FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil will separate from refrigerant at high temperatures of 50 °C {122 °F} or more. If this happens, the sight glass will change to a milky-white color, and there is a possibility that you might mistakenly believe the refrigerant amount to be insufficient and recharge with additional refrigerant. If the system is overcharged with refrigerant, the sight glass will become clear and give a false indication. You will mistakenly believe that the refrigerant amount is correct. Therefore, when checking the refrigerant amount, verify the refrigerant pressure and cooler pipe temperature in addition to the sight glass condition.
13. Refer to refrigerant charge check and refill with refrigerant. L.H.D.
SIGHT GLASS
R.H.D. (WL, G6, F2 Cab)
1. Warm up the engine and run it at a constant 1,500 rpm. 2. Set the fan switch at 4th. 3. Set the temperature control dial to MAX COLD. 4. Close all the doors and windows. 5. Check the refrigerant amount condition according to the following table.
SIGHT GLASS
R.H.D. (WL turbo)
SIGHT GLASS
14. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank. 15. Stop the engine and the A/C compressor. 16. Disconnect the SSTs (49 C061 006A, 49 C061 007) from the charging valves. 17. Install the caps to the charging valves.
CONTINUED
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REFRIGERANT SYSTEM SERVICE PROCEDURES
Amount
Condition of sight glass
Mpa {kgf/cm2, psi}
Other conditions
Insufficient Bubbles
pipe is warm; low-pressure side cooler pipe is cool. High- and low-pressure side readings are lower than normal. Air cooling ability is low.
1.5 {15, 213} 1.0 {10, 142}
0.2 {2.0, 28}
High-pressure side cooler
Clear Correct
Milky white
pipe is hot; low-pressure side cooler pipe is cold. High- and low-pressure side readings are normal. * If sight glass is milky-white, pour water into condenser for approximately 20 seconds to cool it off, then the sight glass will clear.
Clear
LOW-PRESSURE SIDE
0.1 {1.0, 14}
PRESSURE READING OF MANIFOLD GAUGE 20 {68}
25 {77}
30 {86}
35 {95}
40 °C {104} {°F}
AMBIENT TEMPERATURE
High-pressure side cooler
Over
HIGH-PRESSURE SIDE
2.0 {21, 299}
High-pressure side cooler
9. If not as specified, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
pipe is hot; low-pressure side cooler pipe is cold. High- and low-pressure side reading are higher than normal. Air cooling ability is low.
PERFORMANCE TEST Note After servicing the refrigerant system, the test is performed.
6. If not as specified, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
1. Install the SSTs (manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Open the bonnet. 3. Close all the doors and windows. 4. Warm up the engine and run it at a constant 1,500 rpm. 5. Set the fan switch at 4th. 6. Set the temperature control dial to MAX COLD. 7. Record center ventilator right side temperature. 8. Determine and record ambient temperature. 9. Verify that the temperature reading is in the shaded zone.
REFRIGERANT PRESSURE CHECK 1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Open the bonnet. 3. Close all the doors and windows. 4. Warm up the engine and run it at a constant 1,500 rpm. 5. Set the fan switch at 4th. 6. Set the temperature control dial to MAX COLD. 7. Measure the ambient temperature and the highand low-pressure side reading of the SST (49 C061 001). 8. Verify that the intersection of the pressure reading of the SST (49 C061 001) and ambient temperature is in the shaded zone.
°C {°F} 6 {43} 5 {41} 4 {39} 3 {37} 2 {36} 1 {34} 0 {32} 20 {68}
CENTER VENTILATOR TEMPERATURE
25 {77}
30 {86}
35 {95}
40 °C {104} {°F}
AMBIENT TEMPERATURE
10. If the performance is not within the shaded zone, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
CONTINUED
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BASIC SYSTEM
BASIC SYSTEM STRUCTURAL VIEW BLOWER UNIT
L.H.D. (G6)
COOLING UNIT HEATER UNIT
COOLER PIPE (LOW) COOLER PIPE (HIGH)
HEATER HOSE A/C COMPRESSOR
L.H.D. (WL, WL turbo)
COOLER HOSE (LOW)
BLOWER UNIT COOLING UNIT
CONDENSER
HEATER UNIT
RECEIVER/DRIER
COOLER PIPE (LOW)
HEATER HOSE COOLER PIPE (HIGH)
A/C COMPRESSOR
COOLER HOSE (HIGH) CONDENSER
RECEIVER/DRIER
L.H.D. (F2, F2 Cab) BLOWER UNIT COOLING UNIT HEATER UNIT
COOLER PIPE (LOW)
HEATER COOLER HOSE PIPE A/C (HIGH) COMPRESSOR COOLER HOSE (HIGH)
CONDENSER
RECEIVER/DRIER
CONTINUED
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BASIC SYSTEM
R.H.D. (G6) HEATER UNIT COOLING UNIT
HEATER HOSE A/C COMPRESSOR
BLOWER UNIT COOLER HOSE (LOW)
COOLER PIPE (HIGH)
CONDENSER COOLER HOSE (HIGH)
RECEIVER/DRIER
R.H.D. (WL, WL turbo) HEATER UNIT HEATER HOSE
COOLING UNIT
A/C COMPRESSOR
BLOWER UNIT COOLER HOSE (LOW)
COOLER PIPE (HIGH)
SIGHT GLASS
CONDENSER
R.H.D. (F2 Cab)
RECEIVER/DRIER
COOLER HOSE (HIGH)
WL turbo
HEATER UNIT HEATER HOSE
COOLING UNIT
A/C COMPRESSOR
BLOWER UNIT COOLER HOSE (LOW)
COOLER PIPE (HIGH) CONDENSER
CONTINUED
RECEIVER/DRIER
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BASIC SYSTEM BLOWER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove the cooling unit. (Refer to COOLING UNIT REMOVAL/INSTALLATION.) 4. Remove the passenger’s side front side trim (L.H.D. only.) 5. Remove as indicated in the table. 6. Install in the reverse order of removal.
R.H.D.
B C A
A B C
1
Connector
2
Blower unit
BLOWER UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. L.H.D.
Blower motor
2
Resistor
3
Blower harness
4
Polyurethane protector
5
Inlet duct case (front)
6
Inlet duct case (rear)
7
Blower case (upper)
8
Blower case (lower)
9
Air intake door
10
Air intake link
11
Air intake crank
COOLING UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the glove compartment. 4. Disconnect the air intake wire from the cooling unit. (Refer to CONTROL SYSTEM, CLIMATE CONTROL UNIT WIRE ADJUSTMENT.) Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
B C A
1
A
CONTINUED
B C
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BASIC SYSTEM 5. Remove in the order indicated in the table. Do not allow compressor oil to spill. 6. Install in the reverse order of removal. 7. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
1
Cooler hose (low) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Removal Note + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
2
Cooler pipe (high) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Removal Note + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
3
Connector
4
Cooling unit + Removal Note + Installation Note
L.H.D.
R
15—21 N·m {1.5—2.2 kgf·m, 130.2—190.9 in·lbf}
R
6.9—9.8 N·m {0.7—1.0 kgf·m, 60.8—86.7 in·lbf}
R.H.D. 20—29 N·m {2.0—3.0 kgf·m, 15—21 ft·lbf}
Cooling Unit Removal Note (R.H.D. only) Turn the cooling unit 90 degrees to the right, and remove the cooling unit.
R
R 9.81—19.61 N·m {100—200 kgf·cm, 86.8—173.5 in·lbf}
Cooling Unit Installation Note When installing a new cooling unit (evaporator), add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplement amount 40 ml {40 cc, 1.4 fl oz}
CONTINUED
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BASIC SYSTEM COOLING UNIT DISASSEMBLY/ASSEMBLY Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. L.H.D.
1
Cooler case (upper)
2
Cooler case (lower)
3
Thermoswitch clip
4
Thermoswitch + Assembly Note
5
Evaporator
6
Expansion valve + Assembly Note
7
High pressure pipe
Expansion Valve Assembly Note Replace the O-rings at the expansion valve joints and apply compressor oil to the O-rings and connect the joints. Tighten the joint to the specified torque using two open-end wrenches. Assemble the heat-sensing tube as shown in the figure. 20—24 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
11.8—14.7 N·m {120—150 kgf·cm, 105—130 in·lbf}
R.H.D.
HEAT-SENSING TUBE
Thermoswitch Assembly Note 1. Insert the thermoswitch probe in location as shown in the figure. EVAPORATOR
40 mm {1.6 in}
CONTINUED
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BASIC SYSTEM EVAPORATOR INSPECTION 1. Remove the cooling unit. (Refer to COOLING UNIT REMOVAL/INSTALLATION.) 2. Remove the evaporator from the cooling unit. 3. Inspect for cracks, damage, and oil leakage. If any problems are found, replace the evaporator. 4. Inspect for bent fins. If they are bent, use a flat-head screwdriver to straighten them. HEATER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) (With heater core only) 3. Remove the dashboard. (Refer to section S, DASHBOARD AND CONSOLE, DASH BOARD REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
*
*
WITH HEATER CORE ONLY
1
Heater hose
2
Heater unit
CONTINUED
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BASIC SYSTEM HEATER UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
*
*
*
*
* * *
WITH HEATER CORE ONLY
1
Heater core
9
Airflow mode crank (2)
2
Air mix rod
10
Airflow mode crank (3)
3
Air mix link
11
Airflow mode crank (4)
4
Air mix crank (1)
12
Airflow mode sub link (1)
5
Air mix crank (2)
13
Airflow mode sub link (2)
6
Air mix shaft
14
Heater case (1)
7
Airflow mode main link
15
Heater case (2)
8
Airflow mode crank (1)
16
Heater case (3)
CONTINUED
U–14
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BASIC SYSTEM HEATER CORE INSPECTION 1. Remove the heater unit. (Refer to HEATER UNIT REMOVAL/INSTALLATION.) 2. Remove the heater core from the heater unit. 3. Inspect for cracks, damage, and coolant leakage. If any are found, replace the heater core. 4. Inspect for bent fins. If any are bent, use a flathead screwdriver to straighten them. 5. Verify that the heater core inlet and outlet are not distorted or damaged. Repair with pliers if necessary.
G6, WL, WL turbo 15—21 {1.5—2.2, 11—15}
R
A/C COMPRESSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the drive belt (P/S + A/C). 4. Remove the air cleaner and air hose. (WL turbo only) (Refer to section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Loosen the A/C compressor bolts, then slide the A/C compressor. (WL turbo only) Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
R
24—35 {2.4—3.6, 18—26}
N·m {kgf·m, ft·lbf}
F2, F2 Cab
R 30—39 {3.0—4.0, 22—28}
6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Adjust the drive belt (P/S + A/C). (Refer to section B2, DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
N·m {kgf·m, ft·lbf}
1
Connector
2
Cooler hose (high) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
3
Cooler hose (low) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
4
A/C compressor + Installation Note
A/C Compressor Installation Note Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C compressor. Compressor oil to be removed = 180 ml {180 cc, 6.08 fl oz} – [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz} ]
CONTINUED
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BASIC SYSTEM CONDENSER REMOVAL/INSTALLATION Condenser Installation Note When installing a new condenser, add FD46XG 1. Disconnect the negative battery cable. (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) 2. Discharge the refrigerant from the system. compressor oil into the refrigeration cycle. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE Supplemental amount PROCEDURES, CHARGING.) 30 ml {30 cc, 1.0 fl oz} 3. Remove the radiator grille. 4. Remove the charge air cooler and air hose. (WL CONDENSER INSPECTION turbo only) 1. Inspect for cracks, damage, and oil leakage. If any (Refer to section F2, INTAKE-AIR SYSTEM, problems are found, replace the condenser. INTAKE-AIR SYSTEM 2. Inspect for fins clogged by dust. If any are clogged, REMOVAL/INSTALLATION.) remove the dust from the fins. 5. Remove the receiver/drier. 3. Inspect for bent fins. If any are bent, use a flathead (Refer to RECEIVER/DRIER REMOVAL/INSTALLATION.) screwdriver to straighten them. Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
RECEIVER/DRIER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the radiator grille.
6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
4. Remove in the order indicated in the table. Do not allow compressor oil to spill. 5. Install in the reverse order of removal. 6. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
15—21 N·m {1.5—2.2 kgf·m, 11—15 ft·lbf}
B
Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
6.85—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}
A
B C C
A
D R
D
1
Cooler pipe + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
2
Bonnet lock stay
3
Condenser + Installation Note
R
R
CONTINUED
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BASIC SYSTEM
1
Connector
2
Cooler pipe + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note
3
Condenser + CONDENSER REMOVAL/INSTALLATION, Condenser Installation Note
4
Receiver/drier + Installation Note
Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 3. Remove the radiator grille. 4. Remove the front bumper. (Refer to section S, BUMPER, FRONT BUMPER REMOVAL/INSTALLATION.) 5. Remove the radiator. (WL turbo only) 6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
Receiver/drier Installation Note When installing a new receiver/drier, add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplemental amount 35 ml {35 cc, 1.2 fl oz} REFRIGERANT LINES REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) L.H.D.
R
R
B
R
A
B C
R
E
D F
B
R R
R
D
A
C
D F
A C
B A R
R R
B A
E
E
C
CONTINUED
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BASIC SYSTEM
R.H.D.
B R
R
R D
E B R B
C
C A R A
D B A
R
D C
A: 6.85—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf} B: 15—21 N·m {1.5—2.2 kgf·m, 11—15 ft·lbf} C: 20—29 N·m {2.0—3.0 kgf·m, 15—21 ft·lbf} D: 9.81—19.61 N·m {100—200 kgf·cm, 86.8—173.5 in·lbf} E: 24—35 N·m {2.4—3.6 kgf·m, 18—26 ft·lbf}
1
Cooler hose (low) + Removal Note + Refrigerant Lines Removal Note + Refrigerant Lines Installation Note
2
Cooler hose (high) + Removal Note + Refrigerant Lines Installation Note
3
Cooler pipe (high) + Refrigerant Lines Removal Note + Refrigerant Lines Installation Note
Refrigerant Lines Installation Note 1. When installing a new cooler pipe or hose, add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplemental amount Cooler hose (low): 8 ml {8 cc, 0.3 fl oz} Cooler hose (high): 5 ml {5 cc, 0.2 fl oz} Cooler pipe: 3 ml {3 cc, 0.1 fl oz} 2. Apply compressor oil to the O-rings and connect the joints. 3. Tighten the joints. (1) Tighten the nut or bolt of the joint by hand. (2) Tighten the joint to the specified torque. If it is a nut joint, tighten the nut using a spanner and torque wrench.
Cooler Hose Removal Note WL turbo only Loosen the A/C compressor bolts, then slide the A/C compressor, and remove the cooler hose bolt from the A/C compressor. Refrigerant Lines Removal Note Loosen the nut using two spanners, then remove the cooler pipe or hose.
CONTINUED
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CONTROL SYSTEM
CONTROL SYSTEM STRUCTURAL VIEW L.H.D. A/C RELAY No.2*
A/C RELAY No.1
REFRIGERANT PRESSURE SWITCH
MAGNETIC CLUTCH
CLIMATE CONTROL UNIT
THERMOSWITCH RESISTOR
BLOWER MOTOR
R.H.D.
REFRIGERANT PRESSURE SWITCH MAGNETIC CLUTCH A/C RELAY No.2*
A/C RELAY No.1
CLIMATE CONTROL UNIT
THERMOSWITCH
RESISTOR BLOWER MOTOR
CONTINUED * F2 Cab only
U–19
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CONTROL SYSTEM MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 3. Adjust the magnetic clutch clearance. (Refer to MAGNETIC CLUTCH CLEARANCE ADJUSTMENT.)
Stator Removal Note Set a straight-socket (17 mm {0.67 in}) on the shaft of the A/C compressor to protect it. Remove the stator using a pulley puller as shown in the table. STRAIGHT-SOCKET (17 mm {0.67 in})
10.1—15.0 N {102—153 89—132 kgf in·lbf}
Stator Installation Note Install the stator perpendicularly using the SST and a pulley puller as shown in the table.
49 H061 005
1
Bolt + Removal/Installation Note
2
Pressure plate + Installation Note
3
Shim
4
Snap ring
5
A/C compressor pulley
6
Stator + Removal Note + Installation Note
Pressure Plate Installation Note When installing the pressure plate, carry out magnetic clutch clearance adjustment.
Bolt Removal/Installation Note When removing or installing the bolt, hold the pressure plate in place as shown in the table. BOLT
A/C COMPRESSOR
MAGNETIC CLUTCH CLEARANCE ADJUSTMENT G6, WL, WL turbo Only 1. Set the A/C compressor on a level block. 2. Turn on the magnetic clutch by connecting the battery positive voltage to the magnetic clutch connector terminal and the ground to the A/C compressor body. 3. Fix a dial gauge on a magnetic base and set the measuring probe onto point A on the pressure plate surface.
CONTINUED
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CONTROL SYSTEM 3. If not within the specification, remove the pressure plate and adjust the clearance by changing the shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5 mm {0.020 in}) or the number of shims.
4. Turn off the magnetic clutch by disconnecting the ground from the A/C compressor body, then measure the dial gauge readings. 5. Measure the clearance for point B and C on the pressure plate surface by repeating the above steps 2 through 4.
MAGNETIC CLUTCH INSPECTION 1. Disconnect the magnetic clutch connector. 2. Connect battery positive voltage to terminal A of magnetic clutch and ground to the A/C compressor body.
Clearance 0.35—0.75 mm {0.014—0.029 in} MEASURING POINT A
B
C
6. If the clearance is not as specified, adjust it by changing the shim.
A
Note The seven shim sizes from 0.7 mm {0.028 in} to 1.3 mm {0.051 in} differ in 0.1 mm {0.004 in} increments.
A
3. Verify that the magnetic clutch operates. 4. If not as specified, replace the stator. A/C RELAY No.1 REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. F2, F2 Cab Only 1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a thickness gauge.
1
Connector
2
A/C relay No.1
2. Verify that the clearance is within the specification. Clearance 0.3—0.6 mm {0.01—0.02 in}
CONTINUED
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CONTROL SYSTEM A/C RELAY No.1 INSPECTION 1. Remove the A/C relay No.1. 2. Inspect for continuity between the A/C relay No.1 terminals using an ohmmeter. : Continuity B+: Battery positive voltage
A
B C
A
D
B
Terminal
Step
A
B
B+
GND
C
D
1
C
2
3. If not as specified, replace the A/C relay No.2.
A
C
D
D
C
A
D
B
REFRIGERANT PRESSURE SWITCH REMOVAL/ INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the radiator grille.
B 123456567
3. If not as specified, replace the A/C relay No.1.
Caution If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
A/C RELAY NO.2 REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
4. Remove as indicated in the table. 5. Install in the reverse order of removal. 6. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
À 5.9—7.8 N·m {60—80 kgf·cm, 53—69 in·lbf}
1
Connector
2
A/C relay No.2
A/C RELAY NO.2 INSPECTION 1. Remove the A/C relay No.2. 2. Inspect for continuity between the A/C relay No.2 terminals using an ohmmeter. : Continuity B+: Battery positive voltage Step
R
Terminal B
D
A
C
1 2
B+
GND
1
Connector
2
Refrigerant pressure switch + Installation Note
Refrigerant Pressure Switch Installation Note Apply compressor oil to the O-ring and connect the joint.
CONTINUED
123456567
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CONTROL SYSTEM REFRIGERANT PRESSURE SWITCH INSPECTION 1. Install the SSTs (manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Disconnect the refrigerant pressure switch connector. 3. Verify the high-pressure side reading of the SST (Manifold gauge). 4. Inspect for continuity between the terminals of the refrigerant pressure switch using an ohmmeter. 0.18—0.21 {1.8—2.2, 26—31}
WITH HEATER CORE A
B
C
WITHOUT HEATER CORE A
3.0—3.3 {30—34, 427—483}
CONTINUITY
B
7. If not as specified, inspect on/off points of the thermoswitch.
NO CONTINUITY 0.02 {0.25, 3.56} OR LESS
0.4—0.7 {4.0—8.0, 57—113} MPa { kgf/cm2 , psi }
B
A
B
A
5. If not as specified, replace the refrigerant pressure switch. THERMOSWITCH INSPECTION To Determine if the Switch is Functioning 1. Remove the glove compartment. 2. Start the engine. 3. Turn the fan switch on. 4. Turn the A/C switch on. 5. Connect the positive (+) and negative (–) probes of the voltmeter to terminal A and terminal B of the thermoswitch respectively. (The wiring harness connector must be connected to the thermoswitch connector.) 6. Inspect the voltage as shown below.
To Inspect On/Off Points of the Thermoswitch 1. Disconnect the negative battery cable. 2. Remove the cooling unit (Refer to BASIC SYSTEM, COOLING UNIT REMOVAL/INSTALLATION.) 3. Remove the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNIT DISASSEMBLY/ASSEMBLY.) 4. Connect the negative battery cable. 5. Connect the thermoswitch connector to the wiring harness connector. 6. Turn the ignition switch to ON position. 7. Turn the A/C switch on. 8. Turn the fan switch on. 9. Immerse the sensor part of thermoswitch in a container of ice water. 10. Connect the positive (+) and negative (–) probes of the voltmeter to terminal A and terminal B of the thermoswitch respectively. 11. Inspect the voltage as shown below. WITH HEATER CORE
: Continuity Water temperature temperat re
C
1°C {34°F} or less WITHOUT HEATER CORE
: Continuity
: Continuity Temperature control dial position MAX COLD
Terminal A
A
3°C {37°F} or more
WITH HEATER CORE
Magnetic clutch cl tch
Terminal
C
1/2
On Off
MAX WARM
Water temperature temperat re
Terminal A
B
0—3°C {32—37°F} 3°C {37°F} or more 7—11°C {45—52°F}
123456567
11°C {52°F} or more 14—18°C {57—64°F} 18°C {64°F} or more
WITHOUT HEATER CORE
: Continuity Magnetic clutch cl tch
Terminal A
B 123456567
On Off
CONTINUED 123456567
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CONTROL SYSTEM
WITH HEATER CORE A
B
C
BLOWER MOTOR INSPECTION 1. Remove the glove compartment. 2. Disconnect the blower motor connector. 3. Connect battery positive voltage to terminal B and ground to terminal A of the blower motor, and verify its operation.
WITHOUT HEATER CORE A
B
12. If not as specified, replace the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNIT DISASSEMBLY/ASSEMBLY.) BLOWER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
1
Connector
2
Blower motor
4. If not as specified, replace the blower motor. RESISTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
1
Connector
2
Resistor
CONTINUED
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CONTROL SYSTEM RESISTOR INSPECTION 1. Remove the glove compartment. 2. Disconnect the resistor connector. 3. Verify that the resistance between the terminals of the resistor is as shown in the table. Terminal
Resistance (Ω)
1A–1B (2A)
R1: 0.43—0.47
1A–1C
R2: 1.04—1.16
1C–1D
R3: 1.47—1.63
R3
1D
R2
1C
R1
1A
1B
2A
1C
1A
1D
1B
CLIMATE CONTROL UNIT INSTALLATION 1. Connect the climate control unit connectors. 2. Insert the climate control unit until each clip clicks.
3. Adjust the wire of the climate control unit. (Refer to CLIMATE CONTROL UNIT WIRE ADJUSTMENT.) 4. Install the glove compartment. 5. Connect the negative battery cable.
2A
Climate Control Unit Removal/Installation Note With heater core Set the temperature control dial at MAX COLD, the airflow mode control dial at DEF.
4. If not as specified, replace the resistor. CLIMATE CONTROL UNIT REMOVAL 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Disconnect the air intake wire from the blower unit. 4. Disconnect the air mix wire and airflow mode wire from the heater unit. 5. With the beveled parts of the SST facing inward, insert them into the climate control unit. 6. Pull the SST outward and rearward to slide out the climate control unit.
CLIMATE CONTROL UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. WITH HEATER CORE
49 D066 801A
7. Disconnect the climate control unit connectors.
CONTINUED
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CONTROL SYSTEM WITHOUT HEATER CORE
CLIMATE CONTROL UNIT WIRE ADJUSTMENT Air Intake Wire 1. Set the air intake lever at FRESH. 2. Set the air intake link to FRESH in the direction of the arrow and insert a screwdriver into the set hole. L.H.D.
AIR INTAKE WIRE
SET HOLE
R.H.D. AIR INTAKE WIRE
1
Dial
2
Knob + Removal Note
3
A/C switch
4
Panel
5
Fan switch
6
Climate control unit harness
7
Illumination bulb
8
A/C amplifer
9
Air mix wire
10
Airflow mode wire
11
Air intake wire
11
Cap
13
Body
SET HOLE
3. Connect the air intake wire to the air intake link. 4. Clamp the air intake wire to wire clamp. 5. Verify that the air intake lever moves its full stroke. Air Mix Wire (With heater core only) 1. Set the temperature control dial at MAX COLD. 2. Set the air mix link to MAX COLD in the direction of the arrow and insert a screwdriver into the set hole.
SET HOLE
Knob Removal Note Use a wire to push the knob from the reverse side and remove it as shown in the figure.
AIR MIX WIRE
WIRE
3. Connect the air mix wire to the air mix link. 4. Clamp the air mix wire to wire clamp. 5. Verify that the temperature control dial moves its full stroke.
KNOB
CONTINUED
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CONTROL SYSTEM Airflow Mode Wire 1. Set the airflow mode control dial at DEF. 2. Set the airflow mode link to DEF in the direction of the arrow and insert a screwdriver into the set hole. SET HOLE
Fan Switch 1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.) 2. Inspect for continuity between the fan switch terminals using an ohmmeter. : Continuity Terminal
Switch position
A
B
C
D
E
F
0 1 2 3
AIRFLOW MODE WIRE
4
3. Connect the airflow mode wire to the airflow mode link. 4. Clamp the airflow mode wire to wire clamp. 5. Verify that the airflow mode control dial moves its full stroke. CLIMATE CONTROL UNIT INSPECTION A/C Switch 1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.) 2. Inspect for continuity between the A/C switch terminals using an ohmmeter. : Continuity
F
E
B C
4
D
3
A
2
1
123456567 E C A
F
D
B
0
3. If not as specified, replace the fan switch.
Terminal
Switch position
A
B
OFF ON
A
C
B
C
B
A
3. Connect battery positive voltage to terminal C and 123456567 ground to the terminal A. 4. Turn the A/C switch on. 5. Verify that the LED illuminaltes. 6. If not as specified, replace the A/C switch.
CONTINUED
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TROUBLESHOOTING
TROUBLESHOOTING FOREWORD Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly perform the procedures. When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged. The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area. TROUBLESHOOTING INDEX No.
Malfunction symptom
1
Insufficient blown air volume and/or no blown air depending on airflow mode.
2
No blown air in any airflow mode. Blown air volume does not change at any fan speed.
3
Airflow mode does not change.
4
Improper air circulation and/or no air circulation.
5
No temperature control.(For climate control unit without variable thermistor only)
6
Air from vent not cold enough.
7
No cool air.
8
Noise while operating A/C system.
SYMPTOM TROUBLESHOOTING 1
Insufficient blown air volume and/or no blown air depending on airflow mode.
TROUBLESHOOTING HINTS 1 Malfunction in VENT mode system Steps 1—4 2 Malfunction in HEAT mode system Step 5 3 Malfunction in DEFROSTER mode system Steps 6—8 STEP 1
2 3 4
INSPECTION
ACTION
When airflow mode control dial is operated, is appropriate resistance felt and can it be moved throughout its full range?
Yes
Go to next step.
No
Go to Step 1 of troubleshooting index No. 3.
Does air blow out when in VENT mode?
Yes
Go to Step 5.
No
Go to next step.
Yes
Remove obstruction, then go to Step 9.
No
Go to next step.
Yes
Inspect duct for clogging, deformity and air leakage, then go to Step 9.
No
Install duct securely in the proper position, then go to Step 9.
Is vent clogged? Is duct in dashboard properly installed?
5
Does air blow out when in HEAT mode?
Yes
Go to next step.
No
Inspect vent for clogging, then go to Step 9.
6
Does air blow out when in DEFROSTER mode?
Yes
Operation is okay. Recheck malfunction symptoms.
No
Go to next step.
7
Is vent clogged?
Yes
Remove obstruction, then go to Step 9.
No
Go to next step.
8
Is defroster duct properly installed?
Yes
Inspect duct for clogging, deformity, and air leakage, then go to next step.
No
Install duct securely in the proper position, then go to next step.
CONTINUED
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CONTROL SYSTEM
STEP 9
2
INSPECTION
ACTION
Does air blow out?
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
No blown air in any airflow mode. Blown air volume does not change at any fan speed.
TROUBLESHOOTING HINTS 1 Blower motor, resistor, fan switch malfunction Step 1 2 Blower unit malfunction Steps 2—4 STEP 1
2
3
4
5
3
INSPECTION
ACTION
Inspect the following systems and electrical parts: Blower motor, resistor, fan switch. Are they okay?
Yes
Go to next step.
No
Repair or replace malfunctioning part, then go to Step 5.
Turn ignition switch to ON position. Turn fan switch on. on Is noise coming from blower unit?
Yes
Go to next step.
No
Go to Step 4.
Inspect fan in blower unit. Is fan free of interference from blower unit case? Is fan free of foreign material and obstructions? Is fan okay?
Yes
Go to next step.
No
Remove obstruction, repair or replace fan and blower unit case, then go to Step 5.
Is blower unit intake vent clogged?
Yes
Remove obstruction, then go to next step.
No
Inspect if there are any obstructions in passage between blower unit and heater unit, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
Does air blow out?
Airflow mode does not change.
TROUBLESHOOTING HINTS 1 Malfunction in heater unit’s airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow mode wire or wire clamp Steps 1, 2 2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunction Step 3 3 Malfunction in one or more heater unit doors Steps 4, 5 STEP 1
INSPECTION
ACTION
Inspect heater unit’s airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub links, airflow mode wire and wire clamp. Is there g grease on airflow mode main link,, airflow mode cranks and airflow mode sub links? Are airflow mode main link, airflow mode rod, airflow mode cranks, and airflow mode sub links installed securely and in the proper position? Is wire clamp free of deformation? Are above items all okay?
Yes
Go to next step.
No
Apply grease or install airflow mode main link, airflow mode rod, airflow mode cranks and airflow mode sub links securely in their proper positions, repair wire clamp, then go to Step 6.
CONTINUED
U–29
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 2
3
4 5
6
4
INSPECTION
ACTION
Is airflow mode wire positioned securely and correctly in relation to the heater unit’s airflow mode main link?
Yes
Go to next step.
No
Adjust airflow mode wire or install it correctly, then go to Step 6.
Inspect climate control unit. Is bevel g gear set properly y engaged? g g Is airflow mode wire properly installed in correct direction on bevel gear? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Properly engage bevel gear set or install airflow mode wire in correct direction, repair or replace wire clamp, then go to Step 6.
Is there any foreign material or obstruction in any of heater unit’s doors?
Yes
Remove obstruction, then go to Step 6.
No
Go to next step.
Are all doors within heater unit securely and properly positioned?
Yes
Inspect each door for cracks or damage, then go to next step.
No
Install malfunction doors securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
Does airflow mode change?
Improper air circulation and/or no air circulation.
TROUBLESHOOTING HINTS 1 Malfunction in blower unit’s air intake crank, air intake link, air intake wire or wire clamp Steps 1, 2 2 Climate control unit air intake wire or wire clamp malfunction Step 3 3 Blower unit air intake door malfunction Steps 4, 5 STEP 1
INSPECTION
ACTION
Inspect blower unit’s air intake crank, air intake link and wire clamp. Is there grease g on air intake crank and air intake link? Are air intake crank and air intake link securely and properly positioned? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Apply grease or install air intake crank and air intake link properly and securely, repair wire clamp, then go to Step 6.
Is air intake wire positioned securely and correctly in relation to the blower unit’s air intake link?
Yes
Go to next step.
No
Adjust air intake wire or install securely in correct position, then go to Step 6.
Inspect climate control unit. Is air intake wire properly installed in correct direction in relation to the air intake lever of climate control unit? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Install air intake wire securely in correct position, repair or replace wire clamp, then go to Step 6.
4
Is there any foreign material or obstruction in blower unit’s air intake door?
Yes
Remove obstruction, then go to Step 6.
No
Go to next step.
5
Is blower unit’s air intake door securely and properly positioned?
Yes
Inspect air intake door for cracks or damage, then go to next step.
No
Install air intake door securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
2
3
6
Does air circulate?
CONTINUED
U–30
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
CONTROL SYSTEM
5
No temperature control.(Without variable thermistor in climate control unit only)
TROUBLESHOOTING HINTS 1 Malfunction in heater unit’s air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp Steps 2, 3 2 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction Step 4 3 Heater unit air mix door malfunction Steps 5, 6 STEP
INSPECTION
ACTION
1
Is coolant sufficiently warmed up?
Yes
Go to next step.
No
Warm engine up, then go to Step 7.
2
Inspect heater unit’s air mix rod, air mix link, air mix cranks, air mix shaft and wire clamp. Is there grease g on air mix rod,, air mix link and air mix cranks? Are air mix rod, air mix link, air mix cranks, and air mix shaft securely installed in their proper positions? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Apply grease or install air mix rod, air mix link, air mix cranks, and air mix shaft securely in their proper positions, repair wire clamp, then go to Step 7.
Is air mix wire securely installed in the correct position in relation to heater unit’s air mix link?
Yes
Go to next step.
No
Adjust air mix wire or install securely in correct position, then go to Step 7.
Inspect climate control unit. Is bevel g gear set properly y engaged? g g Is air mix wire properly installed in correct position in relation to bevel gear? Is wire clamp free of deformation? Are above items okay?
Yes
Go to next step.
No
Properly engage bevel gear set or install air mix wire in correct position, repair or replace wire clamp, then go to Step 7.
5
Is there any foreign material or obstruction in heater unit’s air mix door?
Yes
Remove obstruction, then go to Step 7.
No
Go to next step.
6
Is heater unit’s air mix door securely and properly installed?
Yes
Inspect door for cracks or damage, then go to next step.
No
Install door securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
3
4
7
6
Does unit operate in every temperature setting?
Air from vent not cold enough.
TROUBLESHOOTING HINTS 1 Drive belt malfunction Step 1 2 Malfunction in blower unit or condenser Steps 4, 5 3 Malfunction in receiver/drier or expansion valve (valve closes too much) Steps 8, 9 4 Malfunction in refrigerant lines Steps 10, 11 5 Malfunction in piping connections Steps 1, 2, 13 6 A/C compressor system malfunction, insufficient compressor oil Steps 15, 16 7 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system Steps 17—20
CONTINUED
U–31
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
TROUBLESHOOTING
STEP
INSPECTION
ACTION Yes
Go to next step.
No
Adjust or replace drive belt, then go to Step 21. + Section B2, DRIVE BELT, DRIVE BELT ADJUSTMENT
Carry out refrigerant system performance test. + REFRIGERANT SYSTEM SERVICE PROCEDURES PERFORMANCE TEST PROCEDURES, Is operation normal?
Yes
Operation is normal. (Recheck malfunction symptoms.)
No
Go to next step.
Are refrigerant’s high-pressure and low-pressure values both high?
Yes
Go to next step.
No
Go to Step 6.
4
Is blower unit intake clogged?
Yes
Remove obstruction, then go to Step 21. (If air does not reach evaporator within cooling unit, heat exchange does not occur and refrigerant pressure rises. Therefore, removal of obstruction is necessary.)
No
Go to next step.
5
Inspect condenser. + BASIC SYSTEM, CONDENSER INSPECTION Is it okay?
Yes
Add or subtract refrigerant to make specified amount, then go to Step 21. (Excessive amount of refrigerant.)
No
Replace condenser, or repair and clean condenser fins, then go to Step 21.
Are refrigerant’s high-pressure and low-pressure values both low?
Yes
Go to next step.
No
Go to Step 14.
Immediately after A/C compressor operates, does refrigerant’s high-pressure value momentarily g g y rise to correct value, then fall and stay below it? (Is there negative pressure on low-pressure side?)
Yes
Go to next step.
No
Go to Step 10.
Turn A/C switch off and let air conditioner stop for 10 minutes. min tes Start engine. Turn both A/C switch and fan switch on. Does malfunction occur after A/C compressor turns on?
Yes
Go to next step.
No
Start vacuum pump for 30 minutes and replace receiver/drier, then go to Step 21. (Since receiver/drier has become saturated with water, replacement is necessary.)
Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?
Yes
Replace expansion valve, then go to Step 21. (Since valve closes too much, replacement is necessary.)
No
Install heat-sensing tube securely in proper position, then go to Step 21.
Yes
Go to next step.
No
If piping or an A/C component is damaged or cracked, replace it. Then go to Step 21. If there is no damage, go to Step 13.
1
Inspect drive belt. + Section B2, DRIVE BELT, DRIVE BELT INSPECTION
Is it okay? 2
3
6 7
8
9
10
Inspect refrigerant lines. Is piping free of damage and cracks? Are piping connections free of oil grime? (Visual inspection) Are piping connections free of gas leakage? Are piping installation points on condenser free of gas g leakage? g Are piping installation points on receiver/drier free of gas leakage? Are piping installation points on A/C compressor free of gas leakage? Are piping installation points on cooling unit free of gas leakage? *Perform gas leak inspection using gas leak tester. Are above items okay?
CONTINUED
U–32
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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TO. MODEL .INDEX
CONTROL SYSTEM
STEP 11
12
13
14 15 16
17 18
INSPECTION
ACTION
Are piping connections for evaporator in cooling unit free of gas leakage?
Yes
If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Add or subtract refrigerant to make specified amount, then go to Step 21.
No
If piping is damaged or cracked, replace it. Then go to Step 21. If there is no damage, go to next step.
Yes
Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.
No
If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.
Yes
Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21.
No
If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21.
Does refrigerant’s high-pressure value hardly increase?
Yes
Go to next step. (Pressure hardly increases.)
No
Go to Step 17.
When engine is racing, does high-pressure value increase?
Yes
Return to Step 3.
No
Go to next step.
After compressor oil is replenished each 10 ml {10 cc, 0.34 fl oz}, does high-pressure value increase?
Yes
Troubleshooting completed. (Explain to customer that cause was insufficient compressor oil.)
No
Replace A/C compressor, then go to Step 21. (Cause is defective A/C compressor.)
Is only refrigerant low-pressure value high?
Yes
Go to Step 20.
No
Go to next step.
Yes
Go to next step.
No
Repair or install air mix rod, air mix link, air mix cranks and air mix shaft securely in proper position, then go to Step 21.
Are piping connections for evaporator in cooling unit loose?
Are piping connections loose?
Are heater unit’s air mix rod, air mix link, air mix cranks and air mix shaft securely and properly installed?
CONTINUED
U–33
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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TO. MODEL .INDEX
TROUBLESHOOTING
STEP 19
20
21
7
INSPECTION
ACTION
1. 2. 3. 4. 5. 6.
Set the fan switch at 4th position. Turn the A/C switch on. Set to FRESH mode. Set the temperature control to MAX COLD. Set to VENT mode. Run engine at a constant 1,500 rpm for 10 minutes. 7. Run engine at idle speed for 1 minute. 8. 1 engine speed cycle is defined as going from idle speed to 4,000 rpm and back to idle speed over a period of 12 seconds. Perform 5 cycles cycles. 9. Run engine at idle speed for 30 seconds. 10. Remove all compressor oil from A/C compressor and verify that it is 105 ml {105 cc, 3.55 fl oz}. 11. If it is more than 105 ml {105 cc, 3.55 fl oz}, put only 105 ml {105 cc, 3.55 fl oz} back into A/C compressor. 12. Carry out above steps 1 to 10 again and verify that compressor oil is 105 ml {105cc, 3.55 fl oz}. Is there 105 ml {105 cc, 3.55 fl oz} of compressor oil in A/C compressor?
Yes
Go to Step 21.
No
Carry out 1 to 10 of step 19 again until compressor oil is 105 ml {105 cc, 3.55 fl oz}.
Is expansion valve heat-sensing tube within cooling unit securely installed in proper position?
Yes
Replace expansion valve, then go to next step. (Since valve opens too much, replacement is necessary.)
No
Install heat-sensing tube securely in proper position, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
Does cool air blow out? (Are results of refrigerant system performance test okay?)
No cool air.
TROUBLESHOOTING HINTS 1 A/C compressor system malfunction Step 2 2 Incorrect amount of refrigerant Step 3 3 A/C switch indicator light malfunction Steps 4—6 4 A/C relay system malfunction (WL, WL turbo, F2 Cab) Steps 7, 11—13 (G6, F2) Steps 7, 11, 12 5 Refrigerant pressure switch malfunction Step 8 6 PCM A/C cut-off control system (WL, WL turbo) Steps 9, 26 (G6, F2) Step 9 7 PCM (IG1 signal) system malfunction Steps 10, 25 8 Magnetic clutch system malfunction Step 14 9 PCM (A/C signal) system malfunction (WL, WL turbo) Steps 15, 20 (G6, F2) Steps 15, 19, 20 (F2 Cab) Step 15 10 Thermoswitch, A/C switch malfunction (WL, WL turbo, G6, F2) Steps 21—24 (F2 Cab) Steps 16—18
CONTINUED
U–34
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
CONTROL SYSTEM
STEP 1 2
3
4 *5
*6
7
*8
*9
INSPECTION
ACTION
Does air blow out?
Yes
Go to next step.
No
Go to Step 1 of troubleshooting indexes 1, 2.
Start engine. Turn both A/C switch and fan switch on on. Does A/C compressor operate?
Yes
Go to Step 1 of troubleshooting index 6.
No
Go to next step.
Inspect refrigerant amount. + REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST Is it okay?
Yes
Go to next step.
No
Add or subtract refrigerant to specified level, then go to Step 27.
Does A/C switch indicator light illuminate?
Yes
Go to Step 7.
No
Go to next step
Turn ignition switch to ON position. (With air mix wire) Remove airflow mode wire, air intake wire and air mix wire. Remove climate control unit. (Without air mix wire) Remove airflow mode wire and air intake wire. Remove climate control unit. Remove A/C switch from climate control unit and connect A/C switch connector. Test voltage at A/C switch terminal C (IG2 signal). Is voltage approximately 12 V?
Yes
Go to next step.
No
Repair wiring harness between fuse block and A/C switch, then go to Step 27.
Inspect A/C switch. + CONTROL SYSTEM, CLIMATE CONTROL UNIT INSPECTION Is it okay?
Yes
Inspect wiring harness between A/C switch and resistor, then go to Step 27.
No
Replace A/C switch, then go to Step 27.
Are A/C relay power supply fuses okay?
Yes
Go to next step.
No
Check for a short to ground on blown fuse’s circuit. Repair or replace as necessary. Install appropriate amperage fuse.
Remove radiator grille. Disconnect refrigerant pressure switch connector. When refrigerant pressure switch connector terminals A and B (on wiring harness side) are shorted, does cool air blow out?
Yes
Inspect refrigerant pressure switch, then go to Step 27.
No
WL for ISRAEL: Undo short, reconnect refrigerant pressure switch connector, then go to Step 10. Other models: Undo short, reconnect refrigerant pressure switch connector, then go to next step.
Check the DTC for the PCM ON-BOARD DIAGNOSTIC SYSTEM. Are the following DTCs displayed? DTC 09 (WL or WL turbo) DTC 0120 (F2 or G6)
Yes
Go to appropriate inspection procedure. (The engine coolant temperature sensor (DTC 09) or throttle position sensor (DTC 0120), which sends the PCM’s A/C cut off control input signal, may be the cause of the trouble.)
No
Go to next step.
Yes
Go to Step 15.
No
Go to next step.
+ Section F2, ON-BOARD DIAGNOSTIC SYSTEM, DIAGNOSTIC TROUBLE CODE INSPECTION
*10
Turn ignition switch to ON position. Does magnetic clutch operate when A/C relay connector terminal B (IG2 signal) is grounded?
CONTINUED
U–35
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TO. MODEL .INDEX
TROUBLESHOOTING
STEP *11
*12
*13
*14
*15
*16
*17
*18
*19
INSPECTION
ACTION
Turn ignition switch to ON position. Test voltage at the following A/C relay connector terminals: Terminal A (IG2 signal) Terminal C (A/C control signal) Is voltage approximately 12 V?
Yes
Go to next step.
No
Repair wiring harness between fuse block and A/C relay, then go to Step 27.
Test voltage at A/C relay terminal D (A/C control signal). Is voltage approximately 12 V?
Yes
G6 or F2: Go to Step 14. Other models: Go to next step.
No
Inspect A/C relay, then go to Step 27.
Disconnect refrigerant pressure switch connector. Test voltage at refrigerant pressure switch connector (on wiring harness side) terminal A (A/C control signal). Is voltage approximately 12 V?
Yes
Reconnect refrigerant pressure switch connector, then go to next step.
No
Repair wiring harness between A/C relay and refrigerant pressure switch, then go to Step 27.
Test voltage at magnetic clutch connector terminal A (A/C control signal). Is voltage approximately 12 V?
Yes
Inspect magnetic clutch, then go to Step 27.
No
G6 or F2: Repair wiring harness between A/C relay and magnetic clutch, then go to Step 27. Other models: Repair wiring harness between refrigerant pressure switch and magnetic clutch, then go to Step 27.
Turn A/C switch off. Remove glove compartment. Turn ignition switch to ON position. Test voltage at the following thermoswitch connector terminal (A/C signal): Terminal B (with variable thermistor in climate control unit) Terminal A (without variable thermistor in climate control unit) Is voltage approximately 12 V?
Yes
F2 Cab: Go to next step. Other models: Go to Step 21.
No
F2 Cab: Repair wiring harness between A/C relay and thermoswitch, then go to Step 27. G6 or F2: Go to Step 19. Other models: Go to Step 20.
Turn ignition switch to LOCK position. Disconnect thermoswitch connector. Start engine. Turn both A/C switch and fan switch on. When following thermoswitch connector terminals shorted does cool (on wiring harness side) are shorted, air blow out? Terminal A—C (with variable thermistor in climate control unit) Terminal B—C (without variable thermistor in climate control unit)
Yes
Undo short, then go to next step.
No
Undo short, then go to Step 18.
Turn ignition switch to ON position. Test voltage at the following thermoswitch connector terminals (IG2 signal): Terminal B (with variable thermistor in climate control unit) Terminal A (without variable thermistor in climate control unit) Is voltage approximately 12 V?
Yes
Inspect thermoswitch, then go to Step 27.
No
Repair wiring harness between fuse block and thermoswitch, then go to Step 27.
Turn ignition switch to ON position. Turn A/C switch on. Turn fan switch off. Test voltage at A/C switch connector terminal A (A/C signal). Is voltage approximately 12 V?
Yes
Inspect wiring harness between thermoswitch and A/C switch, then go to Step 27.
No
Inspect A/C switch, then go to Step 27.
Disconnect refrigerant pressure switch connector. Test voltage at refrigerant pressure switch connector ((on wiring g harness side)) terminal A (A/C control signal). Is voltage approximately 12 V?
Yes
Repair wiring harness between thermoswitch and refrigerant pressure switch, then go to Step 27.
No
Go to next step.
CONTINUED
U–36
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
CONTROL SYSTEM
STEP *20
*21
22
*23
*24
*25
*26
27
INSPECTION
ACTION
Turn ignition switch to ON position. Test voltage at the following PCM connector terminals (A/C signal): Terminal G (WL or WL turbo) Terminal Q (G6 or F2) Is voltage approximately 12 V?
Yes
G6 or F2: Repair wiring harness between PCM and refrigerant pressure switch, then go to Step 27. Other models: Repair wiring harness between PCM and thermoswitch, then go to Step 27.
No
Inspect PCM, then go to Step 27.
Turn ignition switch to LOCK position. Disconnect thermoswitch connector. Start engine. Turn both A/C switch and fan switch on. When following thermoswitch connector terminals (on wiring harness side) are shorted, shorted does cool air blow out? Terminal B—C (without variable thermistor in climate control unit) Terminal A—C (with variable thermistor in climate control unit)
Yes
Undo short, then go to next step.
No
Go to Step 23.
Turn ignition switch to ON position. Test voltage at the following thermoswitch ( g ) connector terminals (IG2 signal): Terminal A (without variable thermistor in climate control unit) Terminal B (with variable thermistor in climate control unit) Is voltage approximately 12 V?
Yes
Inspect thermoswitch, then go to Step 27.
No
Repair wiring harness between fuse block and thermoswitch, then go to Step 27.
Turn ignition switch to ON position. Turn A/C switch on. Turn fan switch off. Test voltage at A/C switch connector terminal A (A/C signal). Is voltage approximately 12 V?
Yes
Go to next step.
No
Inspect A/C switch, then go to Step 27.
Test voltage at thermoswitch connector terminal C (A/C signal). Is voltage approximately 12 V?
Yes
Go to next step.
No
Repair wiring harness between thermoswitch and A/C switch, go to Step 27.
Test voltage at the following PCM connector terminals (A/C signal): Terminal L (WL or WL turbo) Terminal J (G6 or F2) Is voltage approximately 12 V?
Yes
WL or WL turbo: Go to next step. Other models: Recheck malfunction symptoms.
No
Repair wiring harness between A/C relay and PCM, then go to Step 27.
Inspect the following input signal components: Engine coolant temperature sensor and PCM wiring harness (A/C cut-off control). Are they okay?
Yes
Recheck malfunction symptoms.
No
Replace input signal components, then go to next step.
Does cool air blow out? (Is refrigerant system performance test result correct?)
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
CONTINUED
U–37
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
TROUBLESHOOTING
8
Noise while operating A/C system.
TROUBLESHOOTING HINTS 1 Magnetic clutch operation noise Step 3 2 A/C compressor operation noise Steps 4—8 3 A/C compressor slippage noise Steps 9—11 4 Hose or refrigerant line interference noise Step 12 STEP 1
INSPECTION
ACTION
Is there a squeaking or whirling sound (A/C compressor slippage noise)?
Yes
Go to Step 9.
No
Go to next step.
Is there a rattling or vibrating sound (interference noise)?
Yes
Go to Step 12.
No
Go to next step.
3
Is there a clicking sound (magnetic clutch operation noise)?
Yes
Adjust clearance between magnetic clutch pressure plate and A/C compressor pulley, then go to Step 13. + CONTROL SYSTEM, MAGNETIC CLUTCH CLEARANCE ADJUSTMENT
No
Go to next step.
4
Is noise heard continuously for more than 3 seconds after A/C compressor comes on?
Yes
Go to next step.
No
Condition is normal. (Noise normally occurs for 2—3 seconds immediately after A/C compressor turns on.)
Inspect idle speed. + Section F2, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
Yes
Go to next step.
No
Adjust idle speed, then go to Step 13.
2
5
Is it okay? 6
Drain compressor oil. Is it contaminated with metal particles?
Yes
Go to next step.
No
Replace A/C compressor, then go to Step 13.
7
Is compressor oil whitish and mixed with water?
Yes
Replace entire A/C system (excluding heater), then go to Step 13.
No
Go to next step.
8
Is compressor oil darker than normal and contaminated with aluminum chips?
Yes
Replace A/C compressor and receiver/drier, then go to Step 13. (Since A/C compressor may be worn and receiver/drier may be clogged, replacement of receiver/drier is necessary.)
No
Condition is normal. Recheck malfunction symptoms.
Yes
Go to next step.
No
Adjust or replace drive belt, then go to Step 13.
Yes
Remove obstruction, remove oil, or replace drive belt, then go to Step 13.
No
Go to next step.
9
Inspect drive belt. + Section B2, DRIVE BELT, DRIVE BELT INSPECTION
Is it okay? 10
Is drive belt worn? Does it have foreign material imbedded in it, or have oil on it?
CONTINUED
U–38
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
CONTROL SYSTEM
STEP
INSPECTION
ACTION
11
Inspect magnetic clutch. + CONTROL SYSTEM, MAGNETIC CLUTCH INSPECTION Is it okay?
Yes
Replace A/C compressor (excluding pressure plate, A/C compressor pulley, and stator), then go to Step 13.
No
Replace magnetic clutch, then go to Step 13.
12
Is noise coming from A/C compressor?
Yes
Visually inspect A/C compressor, replace appropriate parts if necessary, then go to next step.
No
If noise is coming from refrigerant lines, repair any detached or missing clips, tighten loose bolts, then go to next step.
Yes
Troubleshooting completed. Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
13
Has A/C compressor noise stopped?
CONTINUED
U–39
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BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
TECHNICAL DATA TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . TD– 1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD– 1/3 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . TD– 4 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD– 4 FUEL AND EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD– 5/6 ENGINE ELECTRICAL SYSTEM . . . . . . . . . TD– 6/10 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD–10 MANUAL TRANSMISSION . . . . . . . . . . . . . . . TD–10/11
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . TD–11 FRONT AND REAR AXLES . . . . . . . . . . . . . . TD–11 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . TD–12 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD–12 SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . TD–13/14 BODY ELECTRICAL SYSTEM . . . . . . . . . . . TD–14/15 HEATER AND AIR CONDITIONER SYSTEMS . . . . . . . . . . . . . TD–15
TECHNICAL DATA ENGINE Engine
Item Generator Drive belt deflection [[Applied pressure 98 N {10 kgf, 22 lbf}] ( (mm {i {in}) })
P/S A/C Generator
Drive belt tension (N {kgf, lbf})
P/S A/C
Compression
(kPa {kgf/cm2, psi} [rpm])
Pushing distance of the front oil seal (from the edge of the chain cover) Pushing distance of the rear oil seal (from the edge of the rear cover)
G6 New
10.0—12.0 {0.40—0.47}
Used
12.0—14.0 {0.48—0.55}
New
6.6—7.2 {0.26—0.28}
Used
7.2—8.0 {0.29—0.31}
New
8.5—10.0 {0.34—0.39}
Used
10.0—11.5 {0.40—0.45}
New
491—588 {50—60, 110—132}
Used
393—490 {40—50, 88—110}
New
412—470 {42—48, 93—105}
Used
354—402 {36—41, 80—90}
New
557—641 {56.7—65.4, 125—143}
Used
471—556 {48.0—56.7, 106—124}
Standard
1255 {12.8, 182} [270]
Minimum
882.6 {9.0, 128} [270]
(mm {in}) (mm {in})
0—0.7 {0—0.027} 0—0.5 {0—0.019}
CONTINUED
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TECHNICAL DATA
Engine
Item
WL, WL Turbo
Generator Drive belt deflection [A li d pressure 98 [Applied kgf 22 lbf}] N {10 kgf, ((mm {{in}) })
A/C (meas (measuring ring point oint a)
A/C (meas (measuring ring point oint b)
Generator Drive belt tension (N {kgf, lbf}) A/C
New
7.0—9.0 {0.28—0.35}
Used
8.0—10.0 {0.32—0.39}
Limit
16.0 {0.63}
New
5.0—6.2 {0.20—0.24}
Used
6.0—6.5 {0.24—0.25}
Limit
11.3 {0.44}
New
9.5—11.8 {0.38—0.46}
Used
11.0—12.5 {0.44—0.49}
Limit
18.0 {0.71}
New
442—637 {45—65, 99—143}
Used
383—539 {39—55, 86—121}
Limit
177 {18, 40}
New
403—519 {41—53, 91—116}
Used
354—431 {36—44, 80—96}
Limit Valve clearance [Engine cold]
Compression
Timing belt deflection [Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in}) Bolt head mark W Cylinder y head bolt length (mm {in})
IN EX
0.15—0.25 {0.0060—0.0098} (0.20"0.05 {0.0079"0.0020}) 0.25 {0.0098} [Engine hot (Reference)]
(mm {in})
(kPa {kgf/cm2, psi} [rpm])
Bolt head mark N
181 {18.5, 41} 0.05—0.15 {0.0020—0.0059} (0.10"0.05 {0.0039"0.0020}) 0.15 {0.0059} [Engine hot (Reference)]
Standard
2,942 {30, 427} [200]
Minimum
2,648 {27, 384} [200]
Standard
9.0—10.0 {0.36—0.39}
Standard
101.2—101.8 {3.985—4.007}
Minimum
102.5 {4.035}
Standard
113.2—113.8 {4.457—4.480}
Minimum
114.5 {4.508}
Camshaft oil seal tapping amount
(mm {in})
0.5—1.0 {0.02—0.03}
Front oil seal tapping amount
(mm {in})
0—0.4 {0—0.01}
Rear oil seal tapping amount
(mm {in})
0—0.5 {0—0.01}
CONTINUED
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TECHNICAL DATA
Engine
Item Generator Drive belt deflection [[Applied pressure 98 N {10 kgf, 22 lbf}] ( (mm {i {in}) })
P/S A/C Generator
Drive belt tension (N {kgf, lbf})
P/S A/C
Compression
(kPa {kgf/cm2, psi} [rpm])
Timing g belt deflection [Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in}) Pushing distance of the front oil seal (from the edge of the chain cover) Pushing distance of the rear oil seal (from the edge of the rear cover)
F2 CARB
F2 CIS
New
7.0—8.0 {0.28—0.31}
Used
8.0—9.0 {0.32—0.35}
New
5.0—6.0 {0.20—0.23}
Used
5.5—6.5 {0.22—0.25}
New
10.0—12.0 {0.40—0.47}
Used
12.0—14.0 {0.48—0.55}
New
510—588 {52—60, 115—132}
Used
432—509 {44—52, 97—114}
New
393—490 {40—50, 88—110}
Used
344—441 {35—45, 77—99}
New
373—490 {38—50, 84—110}
Used
275—372 {28—38, 62—83}
Standard
1196 {12.2, 173} [300]
1226 {12.5, 178} [300]
Minimum
837 {8.54, 121} [300]
858 {8.75, 124} [300]
New
8.0—9.0 {0.32—0.35}
Used
9.0—10.0 {0.36—0.39}
(mm {in}) (mm {in})
0 {0} 0—0.5 {0—0.019}
CONTINUED
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TECHNICAL DATA LUBRICATION SYSTEM Engine
Item
Oil pressure
F2
G6
WL
WL Turbo
295—392 {3.0—4.0, 43—56} [3000]
305—402 {3.1—4.1, 45—58} [3000]
452—529 {4.6—5.4, 66—76} [3000]
402—480 {4.1—4.9, 59—69} [3000]
Oil replacement
3.9 {4.1, 3.4}
4.5 {4.8, 4.0}
5.6 {5.9, 4.9}
Oil and oil filter replacement
4.2 {4.4, 3.7}
4.7 {5.0, 4.4}
6.3 {6.7, 5.5}
Total (dry engine)
4.6 {4.9, 4.0}
5.5 {5.8, 4.8}
6.7 {7.1, 5.9}
(kPa
Oil capacit capacity (L {US qt, qt lmp lm qt})
{kgf/cm2,
psi} [rpm])
Engine oil
API service SG
API service CD
SAE 40
—
0°C—40_C {32_F—104°F}
SAE 30
—
–10°C—20_C {14_F—68°F}
SAE 20W-20
—
Above 30_C {86_F}
Above –25_C {–13_F} Viscosity
SAE
10W-30*,
10W-40, 10W-50
—
Above –10_C {14_F}
SAE 20W-40, 20W-50
—
Below –20_C {–4_F}
SAE 5W-20
—
Below 0_C {32_F}
SAE
–15°C—40_C {5_F—104°F}
5W-30*
—
— —
SAE 10W-30
Below 10_C {50_F} — — D European specification vehicles use only those oils marked with an asterisk
SAE 5W-30
COOLING SYSTEM Engine
Item Coolant capacity ca acity
(L {US qt, qt lmp lm qt})
F2
G6
9.4 {9.9, 8.3}
Without heater
6.9 {7.3, 6.1}
8.8 {9.3, 7.7}
(_C {_F})
Full-open temperature
(_C {_F})
83.5—89.5 {183—193}
Thermostat
Radiator cap
WL Turbo
7.5 {7.9, 6.6}
Opening temperature
Full-open lift
WL
With heater
100 {212} 8.5 {0.33} min.
(mm {in})
Cap valve opening pressure (kPa {kgf/cm2, psi})
Sub: 83.5—86.5 {183—187} Main: 86.5—89.5 {188—193}
74—102 {0.75—1.05, 10.7—14.9}
80—84 {176—183}
95 {203}
Sub: 1.5 {0.06} min. Main: 8.0 {0.31} min.
8.5 {0.33} min.
94—122 {0.95—1.25, 13.5—17.7}
CONTINUED
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TECHNICAL DATA FUEL AND EMISSION CONTROL SYSTEMS CIS vehicles Engine
Item Idle speed
(rpm)
F2
730—770 (750"20)
730—770 (750"20)
4—6/750
5—7/750
700—800 (750"50)
780—880 (830"50)
(BTDC °/rpm)
Injection timing Idle speed*11
G6
(rpm)
A/C
ON*2
P/S
ON*3
700—800 (750"50)
CO concentration
Within the regulation
HC concentration
Within the regulation
Fuel pressure (kPa {kgf/cm2, psi})
Hold pressure
More than 340 {3.5, 50}
Fuel pump maximum pressure
500—630 {5.0—6.5, 72—92}
Fuel leakage
Less than 1
(drop/2 minutes) Injection volume (ml {cc, fl oz}/15 sec.)
Fuel injector
55—71 {55—71, 1.9—2.3}
Resistance
12—16
(Ω) [20°C {68°F}]
Pressure regulator *1: *2: *3: *4:
46—60 {46—60, 1.6—2.0}
Fuel pressure (at vacuum ON) (kPa {kgf/cm2, psi})
210—250 {2.1—2.6, 30—36}
Fuel pressure (at vacuum OFF*4) (kPa {kgf/cm2, psi})
270—310 {2.7—3.2, 39—45}
Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on. A/C switch and fan switch are turned on. Steering wheel is fully turned. Hot condition at start.
DIESEL vehicles Engine
Item
WL Turbo
Idle speed
(rpm)
WL
(780"20)*1
760—800 700—740 (720"20)*2
Injection timing
ATDC 10° 107—115 {1.09—1.18, 15.5—16.8}
—
When A/C is operated
825—875 (850"25)
805—855 (830"25) 825—875 (850"25)*3
When P/S is operated
—
—
(kPa {kgf/cm2, psi})
Boost relief pressure
Idle-up Idle u sspeed eed (rpm)
When engine is cold Injection pump
Injection nozzle
Cam lift
1200—1500 (1350"150) (mm {in})
Diesel smoke
2.48 {0.098}
Injection starting pressure (MPa {kgf/cm2, psi})
New: 11.4—12.2 {116—124, 1650—1760} Inspection: More than 10.0 {102, 1450} No leakage when pressure of 8.8 MPa {90 kgf/cm2, 1280 psi}) is applied.
Nozzle leakage *1: *2: *3:
700—740 (720"20)
(%)
Within the regulation
General (L.H.D.) Europe and UK Europe
CONTINUED
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TECHNICAL DATA CARB vehicles Engine
Item
F2 CARB
Idle speed
800—850 (800 +50 –0 )
(rpm)
Injection timing
(BTDC°)
Idle up speed Idle-up
(rpm)
5—7 (6"1)
A/C Operated
1400—1600 (1500"100)
P/S Operated
—
D/P Operated
1900—2100 (2000"100)
T/P Operated CO concentration HC concentration Fuel pump um
Carburetor
(ppm) Discharge pressure
(kPa
Discharge amount Float level
(mm {in})
{kgf/cm2,
—
psi})
20—25 {0.2—0.25, 2.8—3.6}
cc {cu in} min.
1150 {70.2}
H
8—9 {0.315—0.354}
L
Primary throttle opening angle *1: *2:
1050—1250 (1150"100) 1 2 2.0—2.5 (2.0 +0.5 –0 )* , 2.0—3.0 (2.5"0.5)*
(%)
44—45 {1.732—1.772} (°)
48—52 {50"2}
GULF General
ENGINE ELECTRICAL SYSTEM Engine
Item
G6
Electrolyte gravity
1.27—1.29
Back-up current *1 Test load chart
(mA)
Max. 20
Battery type
80D26R
(A)
Battery type (5-hour rate)
80D26R (55)
5.5—6.5
Quick charge (A/30 min.)
Battery type (5-hour rate)
80D26R (55)
35
(A)
Battery Slow charge
195
Rotor resistance (Between slip rings)
(Ω)
Standard
Brush length Brush sspring ring force
(mm {in})
Standard
(N {kgf, lbf})
4.8—6.0 {0.48—0.62, 1.06—1.36}
Minimum
(N {kgf, lbf})
2.2 {0.22, 0.48}
Terminal
Standard voltage g (V) Idle [20C [20 C {68F}] {68 F}] Generated current*2 (Reference) (A)
18.5 {0.73}
Minimum
Ignition switch ON
Generator
(mm {in})
3.7—4.4
Engine speed s eed
Terminal
5.0 {0.20}
B
B+
L
Approx. 1
S
B+
B
14.1—14.7
L
13.0—14.0
S
14.1—14.7
1000
Approx. 0—43
2000
Approx. 0—62
(r (rpm) m)
*1:
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is at OFF position and the ignition key is removed. *2: Must not be 0 A. CONTINUED
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TECHNICAL DATA
Engine
Item Ignition g coil
G6
Primary coil
Resistance [20C {68F}]
(Ω)
Secondary coil
(kΩ) NGK DENSO
KJ16CR11*3, *5, KJ20CR11*4, *5 K16PR–U*3, K20PR–U*4
Plug gap
(mm {in})
Resistance
(kΩ)
Tightening torque
High Hightension l d lead
(kΩ ) [20 C C {68 F}] F}]
Commutator diameter Brush length Starter
Brush sspring ring force
1.0—1.1 {0.040—0.043}*5, 0.7—0.8 {0.028—0.031} 3 0—7 5 3.0—7.5
DENSO
15—22 {1.5—2.3, 11—16}
No.1 lead
2.9—7.7
No.2 lead
4.3—10.8
No.3 lead
5.4—13.5
No.4 lead
6.6—16.2
Center lead
4.5—11.2
Standard
(mm {in})
29.4 {1.16}
Minimum
(mm {in})
28.8 {1.14}
Standard
(mm {in})
12.3 {0.48}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
180—243 {18.3—24.8, 40.3—54.5}
Minimum
(N {kgf, lbf})
57.7 {5.88, 12.9}
Pinion gap No load test
NGK (N·m {kgf·m, ft·lbf})
Resistance
10—16 ZFR5F–11*3, *5, ZFR6F–11*4, *5, BKR5E*3, BKR6E*4
Type Ty e Spark S plug
0.81—0.99
(mm {in})
7.0 {0.28}
3.0 {1.118}
Voltage
(V)
11.5
Current
(A)
Below 100
*3:
Standard plug *4: Cold type plug *5: Europe
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TECHNICAL DATA
Engine
Item
F2 CARB
F2 CIS
Electrolyte gravity Back-up current Test load chart (A)
Battery
1.27—1.29
*1
(mA) Battery ty type e
34B19R
180
(A)
Battery y type y (5-hour rate)
Quick charge g (A/30 min.)
Battery y type y (5-hour rate)
34B19R (27)
3.0—4.0
Brush sspring ring force
4.5—5.5 20 30 (Ω)
18.5 {0.73}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
4.8—6.0 {0.48—0.62, 1.06—1.36}
Minimum
(N {kgf, lbf})
2.2 {0.22, 0.48}
B
B+
L
Approx. 1
S
B+
B
14.1—14.7
L
13.0—14.0
S
14.1—14.7
Terminal
(V) Idle [20C [20 C {68F}] {68 F}]
Ignition g coil
Engine speed s eed
Terminal
1000
Approx. 0—43
2000
Approx. 0—62
(r m) (rpm)
Primary coil
Resistance [20C {68F}]
(Ω)
Secondary coil
0—2/1200, 9—13/2200, 19—23/6000
—
°/kPa {mmHg, inHg}
0—2/20 {150, 5.9}, 11—15/53.3 {400, 15.7}
—
BKR5E*5 BKR6E*3 BKR7E*4
BPR5ES–11*3 BPR6ES–11*4
K16PR–U*5 K20PR–U*3 K22PR–U*4
W16EXR–U11*3 W20EXR–U11*4
0.7—0.8 {0.028—0.031}
1.0—1.1 {0.040—0.043}
NGK Type Ty e DENSO
Spark plug lug Plug gap
(mm {in}) (kΩ)
Tightening torque
High Hightension l d lead
Resistance (kΩ ) [20 C C {68 F}] F}]
NGK
*2: *3: *4: *5:
30 75 3.0—7.5
DENSO (N·m {kgf·m, ft·lbf})
15—22 {1.5—2.3, 11—16}
No.1 lead
2.75—7.07
No.2 lead
4.19—10.43
No.3 lead
4.38—10.88
No.4 lead Center lead
*1:
0.81—0.99 10—16
°/rpm
Distributor Vacuum spark advance
1.035—1.265
(kΩ)
Centrifugal spark advance
Resistance
3.7—4.4
(mm {in})
Standard voltage g
Generated current*2 (Reference) (A)
—
55D23R (48)
Standard
Ignition switch ON
Generator
—
55D23R (48)
Rotor resistance (Between slip rings) Brush length
—
55D23R 34B19R (27)
Slow charge g
Max. 20 110
5.73—14.08 2.00—5.33
3.9—9.9
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is at OFF position and the ignition key is removed. Must not be 0 A. Standard plug Cold type plug Hot type plug
CONTINUED
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TECHNICAL DATA
Engine
Item Commutator diameter Brush length Starter
Brush sspring ring force
F2 CARB
Standard
(mm {in})
32.0 {1.26}
Minimum
(mm {in})
31.4 {1.24}
Standard
(mm {in})
17.0 {0.67}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
19.2 {1.95, 4.25}
Minimum
(N {kgf, lbf})
8.83 {0.90, 1.98}
Pinion gap
11.5 {0.46}
(mm {in})
No load test
0.5—2.0 {0.020—0.078}
Voltage
(V)
11.5
Current
(A)
Below 60 Engine
Item
WL, WL Turbo
Electrolyte gravity
1.27—1.29
Back-up current *1 Test load chart (A)
(mA) Battery type
Battery Slow charge (A)
Quick charge (A/30 min.) min )
Battery type (5-hour rate)
Battery type (5-hour rate)
195
75D26R
195
95D31R
250
75D26L (52)
5.5—6.5
75D26R (52)
5.5—6.5
95D31R (64)
6.5—8.0
75D26L (52)
35
75D26R (52)
35
95D31R (64)
Brush sspring ring force
40 (Ω) (mm {in})
17.9 {0.70}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
2.65 {0.27, 0.59}
(N {kgf, lbf})
1.18 {0.12, 0.26}
Minimum
B
B+
A
B+
S
0
I
2.0—4.0
B
14.05—14.85
A
14.05—14.85
S
7.025—7.425
I
13.00—14.85
1000
Terminal B current
Approx. 0—58
2000
Terminal B current
Approx. 0—74
Terminal
Standard voltage g (V) Idle [20C {68F}]
Generated current*2 (Reference) (A)
2.50
Standard
Engine g switch ON G Generator
20 max.
75D26L
Rotor resistance (Between slip rings) Brush length
F2 CIS
Engine g speed (rpm)
Terminal
*1: Back-up
current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine switch is at OFF position and the engine key is removed. *2: Must not be 0 A.
CONTINUED
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TECHNICAL DATA
Engine
Item Commutator diameter Brush length Starter
Brush sspring ring force
WL, WL Turbo
Standard
(mm {in})
29.5 {1.16}
Minimum
(mm {in})
27.3 {1.07}
Standard
(mm {in})
17.7 {0.70}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
27.0—33.0 {2.75—3.37, 6.05—7.41}
Minimum
(N {kgf, lbf})
—
Pinion gap
(mm {in})
No load test
8.7 {0.34}
3.0 {0.12}
Voltage
(V)
11
Current
(A)
Below 130
CLUTCH Item
Specification
Clutch pedal Height
(mm {in})
241.6—246.6 {9.52—9.70}
Pedal free play
(mm {in})
3.0—8.0 {0.12—0.31}
(mm {in})
0.7 {0.027} max.
Clutch disc Runout limit Clutch fluid Type
SAE J1703 or FMVSS116 DOT-3 or DOT-4
MANUAL TRANSMISSION M15M-D Item
Specification
Type Transmission oil
Viscosity Capacity
API service GL-4 or GL-5 All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
M15MX-D Item
Specification
Type Transmission oil
Viscosity Capacity
API service GL-4 or GL-5 All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
Type Transfer oil
Viscosity Capacity
2.5 {2.6, 2.2} API service GL-4 or GL-5
All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
R15M-D Item
Specification
Type Transmission oil
Viscosity Capacity
API service GL-4 or GL-5 All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
(L {US qt, lmp qt})
2.8 {3.0, 2.5}
CONTINUED
TD–10
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TECHNICAL DATA R15MX-D Item
Specification
Type Transmission oil
API service GL-4 or GL-5
Viscosity
All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
Capacity
(L {US qt, lmp qt})
3.2 {3.4, 2.8}
Type Transfer oil
API service GL-4 or GL-5
Viscosity
All-season
SAE 75W-90
Above 10 C {50 F}
SAE 80W-90
Capacity
(L {US qt, lmp qt})
2.0 {2.1, 1.8}
PROPELLER SHAFT Item Runout limit
Propeller shaft (42)
Front propeller shaft (44)
Rear propeller shaft (44)
0.4 {0.016}
0.4 {0.016}
0.4 {0.016}
0.3—1.1 {3.0—12.0, 2.7—10.4}
0.3—0.7 {3.0—8.0, 2.7—6.9}
0.3—1.1 {3.0—12.0, 2.7—10.4}
(mm {in})
Starting torque of universal (N·m {kgf·cm, in·lbf})
FRONT AND REAR AXLES Item
42 Play Preload
Front axle
Wheel bearing
(N·m {kgf·cm, in·lbf}) Pull scale reading (N {kgf, lbf})
Rear axle
Wheel bearing play
Drive shaft
Shaft length g (mm {in})
(mm {in})
0.4—0.7 {4.0—8.0, 3.5—6.9} 5.9—10.7 {0.6—1.1, 1.4—2.4} 0.05—0.25 {0.002—0.010} 551.0—561.0 {21.7—22.0}
Right side
619.0—629.0 {24.4—24.7} (mm {in})
Backlash of side gear g and differential pinion (mm {in}) Drive pinion inion preload reload (N·m {kgf·cm, {kgf·cm in·lbf})
Differential
0 {0}
Left side
Pinion height
Backlash of drive pinion inion and ring gear (mm {in})
Front
–0.032—0.032 {–0.001—0.001}
Rear
–0.254—0.254 {–0.010—0.010}
Front
0—0.1 {0—0.003}
Rear
—
Front
0.9—1.3 {9.0—14.0, 7.9—12.1}
Rear
1.8—2.6 {18.0—27.0, 15.7—23.4}
Standard
0.09—0.11 {0.0036—0.0043} [Front] 0.12—0.20 {0.005—0.008} [Rear]
Minimum
0.05 {0.002} [Front], 0.12 {0.008} [Rear]
Allowance variation
0.07 {0.003} [Front], 0.08 {0.005} [Rear]
Grade
API service GL-5 Front
Viscosity y Standard
SAE 90 1.20 {1.27, 1.06} [MFW] 1.50 {1.59, 1.32} [RFW]
Front
—
Rear
1.40 {1.48, 1.23}
Grade LSD
Above-18C {0F}: SAE 90 Below-18C {0F}: SAE 80
—
Rear Capacity (L {US qt qt, lmp qt})
Oil
44
(mm {in})
Viscosity Capacity
1.85 {1.96, 1.63}
API service GL-6 SAE 90 (L {US qt, lmp qt})
1.40 {1.48, 1.23}
1.85 {1.96, 1.63}
CONTINUED
TD–11
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TECHNICAL DATA STEERING SYSTEM Item Play
Steering wheel
(mm {in})
Effort
0—30 {0—1.18}
(N·m {kgf·cm, in·lbf})
Backlash
45 {460, 399} max.
(mm {in})
Worm shaft preload
Steering gear
(N·m {kgf·cm, in·lbf})
Grade Capacity
Power steering oil pump
7.8 {80, 69} max. 0 {0}
1.0—1.3 {10—14, 8.7—12.1}
0.7—1.2 {6.5—12.5, 5.7—10.8}
—
8.9—9.3 {90—95, 1280—1350}
API service GL-4, SAE 90
ATF M-III or equivalent (e.g. DexronRII)
0.34 {0.36, 0.30}
1.1 {1.2, 1.0}
—
8.9—9.3 {90—95, 1280—1350}
Gear housing pressure (MPa {kgf/cm2, psi}) Oil
Engine speed sensing power steering
Manual steering
(L {US qt, lmp qt})
Oil pump fluid pressure (MPa {kgf/cm2, psi})
BRAKING SYSTEM 42
Item
F2, G6
44
WL, WL Turbo
Brake pedal Brake pedal height
(mm {in})
L.H.D.: 214—219 {8.43—8.81} R.H.D.: 219—224 {8.63—8.81}
Brake pedal play
(mm {in})
3—8 {0.12—0.31}
Brake pedal-to-floor clearance
(mm {in})
105 {4.2} min.
Power brake unit Fluid pressure when pedal depressed at 196 N {20 kgf ,44 lbf}) (kPa {kgf/cm2, psi})
Power brake unit at 0 kPa {0 mmHg, 0 in Hg}
790 {8, 114} min.
Power brake unit at 66.7 kPa {500 mmHg, 19.7 in Hg}
8,240 {84, 1,200} min.
Vacuum pump Vacuum specification [In 20 seconds] [When engine speed 1,500 rpm] (kPa {mmHg, in Hg})
73.3 {550, 21.7}
Maximum vacuum [When engine speed 3,000 rpm] (kPa {mmHg, in Hg})
93.3 {700, 27.6}
Braking force control device Type
LSPV
Rear fluid pressure when front pressure is 4,900 kPa {50 kgf/cm2, 711 psi} (kPa {kgf/cm2, psi})
2,550 {26, 370}
Front disc brake Disc pad thickness limit
(mm {in})
2.0 {0.08}
Thickness limit
(mm {in})
22 {0.87}
Runout limit
(mm {in})
0.05 {0.002}
Brake lining thickness limit
(mm {in})
1.0 {0.04}
Drum maximum diameter
(mm {in})
Disc plate late
Rear drum brake 271.5 {10.68}
296.5 {11.67}
Parking brake Parking brake lever stroke [When pulled at 98 N {10 kgf, 22 lbf}] (notches)
1—7
Brake fluid Type
SAE J1703 or FMVSS116 DOT-3 or DOT-4
TD–12
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TECHNICAL DATA SUSPENSION Suspension Item
4 2 (mm {in})
Total toe-in Front wheel alignment li [unloaded*1]
4 4 3"3 {0.12"0.12}
0_16’ "16’
(Degree)
0_14’ "14’
Camber angle
+2_ 35_00’ –3_ 33_00’ +2_ –3_ 0_56’"30’
33_30’ +2_ –3_ 30_00’ +2_ –3_ 1_ 06’"30’
Caster angle*2
1_37’"45’
2_02’"45’
Inner
Maximum steering angle
Outer
Exposed thread of shock absorber piston
(mm {in})
Lower arm ball joint rotation torque (Pull scale reading)
(N {kgf, lbf})
Upper arm ball joint rotation torque (Pull scale reading)
(N {kgf, lbf})
Exposed thread of stabilizer control link bolt
6—8 {0.24—0.31} 14—44 {0.7—4.5, 1.6—9.9} 3.4—32.5 {0.4—3.2, 0.9—7.0}
(mm {in})
18—21 {0.71—0.82}
*1:
Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated positions. Adjust to the median when carrying out wheel alignment. *2: Difference between left and right must not exceed 45’.
Wheels and Tires Europe Item
4 2 Front
Size
Front Tire
195R14C-8PR
Rear
Air pressure ressure (kPa {kgf/cm2, psi}) Rear Wear limit
Up to full passenger Full loaded Up to full passenger Full loaded
Offset
(mm {in})
Pitch circle diameter
(mm {in})
(N·m {kgf·cm, in·lbf}) Runout limit (mm {in}) Imbalance limit
235/75R15 105S
200 {2.0, 28} 8 26} 180 {1 {1.8,
180 {1.8, 26}
205R16C-8PR 180 {1.8, 26}
8 26} 180 {1 {1.8, 220 {2.2, 31} 200 {2.0, 28}
450 {4.5, 63}
200 {2.0, 28} 180 {1.8, 26}
180 {1.8, 26}
250 {2.5, 35}
450 {4.5, 63}
1.6 {0.06} 14 5J 14 5 1/2J
Tightening torque Wheel and tire
205/75R14C
(mm {in})
Size Wh l Wheel
4 4
14 5 1/2J
15 6 1/2JJ
16 6JJ
25 {0.98}
35 {1.38}
40 {1.57}
139.7 {5.45} Standard wheel: 89—117 {9—12, 65—86} Styled wheel (16 6JJ): 118—147 {12—15, 87—108}
Horizontal
2.0 {0.078}
Vertical
1.5 {0.059} (g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}. D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim. D Do not use more than two balance weights on either side of the wheel.
CONTINUED
TD–13
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TECHNICAL DATA General Item Size
42 Front
185R14C 185R14C8PR
Rear Unloade d (Up to full Front passenger )
Tire
Air pressure ressure (kPa {kgf/cm2, psi})
Loaded (Full loaded)
44
195R14C 195R14C8PR
180 {1.8, 26} 200 {2.0, 28}
205R16C 235/75R15 P235/75R1 P235/75R1 205R16C8PR 105S 5 105S 5 106S
180 {1.8, 26} 180 {1.8, 26} 200 {2.0, 28}
Unloade d (Up to full Rear passenger )
180 {1.8, 26}
Loaded (Full loaded) Wear limit
(mm {in})
Size Wheel (mm {in})
Pitch circle diameter
(mm {in})
Tightening torque (N·m {kgf·cm, in·lbf}) Wheel Horizontal and tire Runout limit (mm {in}) Vertical Imbalance limit
240 {2.4, 34}
260 {2.6, 36}
1.6 {0.06} 145J
Offset
250 {2.5, 35}
450 {4.5, 63}
145J 145 1/2J
40 {1.57}
166JJ
156 1/2JJ
35 {1.38}
25 {0.98}
139.7 {5.45} Standard wheel: 89—117 {9—12, 65—86} Styled wheel (166JJ): 118—147 {12—15, 87—108} 2.0 {0.078} 1.5 {0.059}
(g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}. D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim. D Do not use more than two balance weights on the inner or outer side of the wheel.
BODY ELECTRICAL SYSTEM Item Headlight
Exterior light bulb capacity ca acity
Interior light bulb capacity
(W)
(W)
Specification High beam/Low beam*
60/552
Parking light
52
Front turn light
212
Brake light/taillight
21/52
Rear turn light
212
Back-up light
212
Rear fog light
211
License plate light
52
Interior light
Stretch cab, Double cab
101
Regular cab
81
Instrument cluster illumination
3.44
CONTINUED
TD–14
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TECHNICAL DATA
Warning and indicator light bulb capacity
(W)
Oil pressure warning light
1.41
Generator warning light
1.41
Sedimentor warning light
1.41
Brake system warning light
1.41
Rear window defroster indicator light
1.41
Glow indicator light
1.41
High beam indicator light
1.41
Turn indicator light
1.42
Air bag system warning light
1.41
44 indicator light
1.41
LOCK indicator light
1.41
*: Also remains illuminated when high beam turned on. HEATER AND AIR CONDITIONER SYSTEMS Specification
Item Refrigerant
Regular amount Lubricating oil
A/C compressor com ressor
G6, WL (g {oz}) Sealed volume (ml {cc, fl oz})
Magnetic clutch clearance (mm {in})
F2 550 {19.4} 180 {180, 6.08}
0.35—0.75 {0.014—0.029}
0.3—0.6 {0.012—0.023}
CONTINUED
TD–15
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SPECIAL TOOLS SPECIAL TOOLS.............................................. ST-1 ENGINE ........................................................ ST-1 LUBRICATION SYSTEM ............................... ST-1 COOLING SYSTEM ...................................... ST-2 FUELAND EMISSION CONTROL SYSTEMS ................................. ST-2 CLUTCH ....................................................... ST-2 PROPELLER SHAFT .................................... ST-3
FRONT AND REAR AXLES ......................... ST-3/5 STEERING SYSTEM ...................................ST-6 BRAKING SYSTEM ......................................ST-7 SUSPENSION ..............................................ST-7 BODY ...........................................................ST-7 BODY ELECTRICAL SYSTEM .....................ST-8 HEATER AND AIR CONDITIONER SYSTEMS ......................ST-8
SPECIAL TOOLS
CONTINUED
ENGINE 49 S013 1A1
49 9200 020A
49 S011 103
Compression gauge set
Belt tension gauge
Oil seal installer
49 8010301
49 S010 001
49 S011 102A
Oil seal installer
Oil seal installer
Crankshaft lock tool
49 B025 001
49 G033 107A
49 S120 710
Body
Dust cover installer
Coupling flange holder
49 P005 204
49 H011 101A
Oil seal installer
Crankshaft lock tool
—
LUBRICATION SYSTEM 490187280
49 G014 001 Oil filter wrench
Oil pressure gauge
—
CONTINUED
ST-1
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SPECIAL TOOLS COOLING SYSTEM 49 9200 145 —
Radiator cap tester adapter set
—
FUEL AND EMISSION CONTROL SYSTEMS 49 8120 215B
49L018901
Pulley puller
Injector checker
49H01S9A1A
Self-diagnosis checker 49 B019 9A0
499140074
System selector
Cam lift measuring device
Program card
1
49 T088 0A3* 2 49 T088 0A5* NGS set
SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031 E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)
• • • • • • •
49 T088 037B (English & Danish) 49 T088 038B (English & Norwegian) 49 T088 039B (English & Czech) 49 T088 041 B (English & Greek) 49 T088 042B (English & Hungarian) 49 T088 043B (English & Polish) 49 T088 044B (English & Spanish) 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only CLUTCH 49 0259 770B
49 E011 1A0
Flare nut wrench
Ring gear brake set
49 SE01 310A Clutch disc centering tool
49 1285 071 Needle bearing puller
—
—
CONTINUED
ST-2
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SPECIAL TOOLS PROPELLER SHAFT 49 0259 440
49 S 120 440
Mainshaft holder
Mainshaft holder
—
FRONT AND REAR AXLES 49 T028 3A0
49 T028 303
49 T028 304
Ball joint puller set
Body (Part of 49 T028 3A0)
Attachment (Part of 49 T028 3A0)
49 H033 101
49 B025 001
49 F019 001
Bearing remover
Body
Oil seal installer
49 S231 635
49 S231 660
49 S033 108
Front hub locknut wrench
Needle bearing puller
Bearing installer
49 S033 107
49 S033 106
49 F027 007
Oil seal installer
Oil seal installer
Attachment ∅72
49 F027 005
49 S120 645A
49 0603 635A
Attachment ∅62
Rear shaft holder
Rear shaft nut wrench
49 S 120 748
49 F027 004
49 U027 003
Attachment
Attachment ∅80
Oil seal installer
CONTINUED
ST-3
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SPECIAL TOOLS 49 H025 001
49 M005 561
49 0727 570
Bearing installer
Differential hanger carrier
Pinion height gauge body
49 8531 565
49 0305 555
49 0259 720
Drive model pinion
Gauge block
Differential side bearing adjust nut wrench
49 0839 425C
49 F027 005
49 S120 710
Bearing puller set
Attachment ∅62 (Part of 49 F027 0A1)
Coupling flange holder
49 H027 002
49 G030 795
49 G030 338
Bearing remover
Oil seal installer
Attachment E
49 F401 331
49 S026 2A1
49 S026 204
Body (Part of 49 F401 330B)
Rear shaft bearing puller
Plate (Part of 49 S026 2A1)
49 S026 205
49 S026 208
Rod (Part of 49 S026 2A1)
Attachment (Part of 49 S026 2A1)
49 W027 0A0
49 W027 001
49 U027 004
Oil seal installer set
Body (Part of 49 W027 0A0)
Oil seal remover
49 M005 795
49 U027 005
49 U027 006
Oil seal installer
Bearing installer
Bearing installer
49 0710 520 Bearing puller
CONTINUED ST-4
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SPECIAL TOOLS 49 U027 007
49 F028 204
Oil seal installer
49 0813 215A Tubular dowel puller
49 M005 796
49 U027 0A0
49 UN27 003
Body (Part of 49 M005 795)
L.S.D. replacer set
Bushing installer
Collar A
49 UN27 004
49 U027 008
49 F027 009
Collar B
Gauge block
Attachment ∅68 & ∅77
49 U027 009
49 UB71525
49 U027 010
Oil seal installer
Bearing installer
Bearing installer
49 0107 680A
49 U027 011
49 U027 012
Engine stand
Shaft (Part of 49 U027 0A0)
Attachment A (Part of 49 U027 0A0)
49 U027 013
49 U027 014
Attachment B (Part of 49 U027 0A0)
Bolt (Part of 49 U027 0A0)
—
CONTINUED
ST-5
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SPECIAL TOOLS STEERING SYSTEM 49 T028 3A0
49 T028 303
49 T028 304
Ball joint puller set
Body (Part of 49 T028 3A0)
Attachment (Part of 49 T028 3A0)
491232670A
49 1232 672
49 1232 673
Power steering gauge set
Gauge (Part of 49 1232 670A)
Valve body (Part of 49 1232 670A)
49 H002 671
49 0180 510B
49 U032 3A0
Adapter
Preload measuring attachment
Pitman arm puller
49 B032 304
491243785A
49 U034 209
Adapter
Dust boot installer
Clip guide
49 U032 201
49 G032 354
49 G032 3A4
Locknut wrench
Adjust wrench
Power steering gauge adapter set
CONTINUED
ST-6
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SPECIAL TOOLS BRAKING SYSTEM 49 U043 0A0
49 U043 004
49 U043 005
Oil pressure gauge set
Oil pressure gauge (Part of 49 U043 0A0)
Joint (Part of 49 U043 0A0)
49 U043 006
49 0259 770B
49 B043 001
Hose (Part of 49 U043 0A0)
Flare nut wrench
Adjust gauge
49 0221 600C
49 E043 003A
49 0208 701 A
Disc brake expand tool
Turning lock tool
Boot air out tool
49 B043 004 Socket wrench
—
—
SUSPENSION 49 T028 3A0
49 0180 510B
49 U034 208
Ball joint puller set
Preload measuring attachment
Clip guide
49 UB39 615
49 U034 2A0
49 U034 209
Bushing puller & installer set
Lower arm bushing puller & installer set
Clip guide
BODY 49 0305 870A
49 0259 866A
Window tool set
Window inserting tool
—
CONTINUED
ST-7
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SPECIAL TOOLS BODY ELECTRICAL SYSTEM 49 H066 002
49 D066 002
49 0839 285
Deployment tool
Adapter harness
Fuel And Thermometer checker (OLD)
49 N088 0A0
49 D066 801 A
49 T088 0A3* 49 T088 0A5*2
Fuel And Thermometer checker (NEW)
Removing tool
Program card
1
NGS set
SST No. for Program card varies with language • 49 T088 030E (English & French) • 49 T088 031E (English & German) • 49 T088 032E (English & Dutch) • 49 T088 033E (English & Swedish) • 49 T088 034C (English & Spanish) • 49 T088 035C (English & Portuguese) • 49 T088 036C (English & Italian)
• • • • • • • •
49 T088 037B (English & Danish) 49 T088 038B (English & Norwegian) 49 T088 039B (English & Czech) 49 T088 041 B (English & Greek) 49 T088 042B (English & Hungarian) 49 T088 043B (English & Polish) 49 T088 044B (English & Spanish) 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only HEATER AND AIR CONDITIONER SYSTEMS 49 C061 0A0A
49 C061 012
49 C061 013
Manifold gauge set (R-134a)
Anti-back flow valve (R-134a)
Gas leak tester (R-134a)
49 D066 801A
49 H061 005
Removing tool
Attachment
—
ST-8
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