Terracan Engine

Fuel System
[Diesel 2.5]
GENERAL ................................................................. FLB -2
INJECTION PUMP-MECHANICAL ...................................... FLB -11
FUEL DELIVERY SySTEM-DIESEL .................................... FLB -22

FLB -2 FUEL SYSTEM [DIESEL 2.5]
GENERAL
SPECIFICATIONS EFMB3010
Fuel injection pump

Injection pump
Type Distribution type
Turning direction Clockwise as viewed trom drive side
Injection sequence 1 - 3 - 4 - 2
Governor type Centritugal type
Timer type Hydraulic
Feed pump type Vane type
Control equipment
Fast idle mechanism Manual type
Injection nozzle and holder

Type Screw-on type
Nozzle
Type Throttle type
Engine control system Pedal-operated cable type, incorporating electric engine

stop mechanism interlocked with starter switch
Th rottle button type
Fuel tank
Capacity lit. (U.S. gals., Imp.gals.) 75 (19.8, 16.6)
SERVICE SPECIFICATIONS EFMB3030
Standard Limit
Fuel injection pump /
Injection timing (when plunger lift 1 mm) 9° ATDC

Cam lift mm 2.2
Plunger diameter mm 10
Delivery valve opening pressure (bar) 25.8 bar
Fuel cut solenoid Rated voltage : 12V;
Resistance : 8n
Injection nozzle
Injection oritice (Number-diameter) mm 1-1.02
Breaking pressure (bar) 150 bar 132 bar
Idle speed rpm 750 ± 30
Engine control system

Cable length
Accelerator control cable mm L : 2725-2735
A + B : 125-129
Throttle cable mm L : 642-648
C : 60-62
Throttle knob stroke mm 25 or more
GENERAL FlB-3
TORQUE SPECIFICATIONS EFLBOO50
Nm Kg·m Ib·tt
Injection pipe clamp bolts 4 -6 0.4 - 0.6 3 -4
Injection pipe union nuts 23 - 37 2.3 - 3.7 17 - 27
Pump bracket-to-cylinder block bolts 18 - 25 1.8 - 2.5 13 - 18
Injection pump-to-pump bracket bolts 20 - 27 2.0 - 2.7 14 - 19
Injection pump mounting nuts 15 - 22 1.5 - 2.2 11 - 16
Fuel return pipe nuts 30 - 40 3.0 - 4.0 22 - 29
Injection nozzle 50 - 60 5.0 - 6.0 36 - 43
Retaining nut-to-nozzle body 35 - 40 3.5 - 4.0 25 - 29
Pump sprocket nut 80 - 90 8.0 - 9.0 58 - 65
Fuel tank mounting bolts 15 - 22 1.5 - 2.2 11 - 16
SPECIAL TOOlS EFLBOO70
Tool (Number and name) Illustration Use

09310-43000 Injection timing adjustment
Prestroke measuring adapter
Cl043000
09314-43000 Removal of injection pump sprocket

Injection pump sprocket puller
C1443000
GENERAL INFORMATION EFLB0080 and the highly pressurized tuel is injected trom the nozzle
in accordance with the injection sequence. The excess
A distribution-type tue I injection pump is installed in the tuel in the pump housing chamber is returned through the
tront upper case and is driven by the timing belt. The tuel overflow valve and the overflow pipe to the tuel tank. The
is drawn trom the tue I tank by a pump inside the tue I injec- injection pump is cooled and lubricated by means ot tuel
tion pump and sent to the injection pump through a tilter circulation. The excess tuel at the nozzle holder is also
which contains a water separator. The tue I under pres- returned through the overflow pipe with unions on the in-
sure enters the pump chamber, where the tue I pressure jection pump to the tuel tank. Since the injection pump is
is regulated by a regulating valve. From the pump cham- lubricated by tuel, water in the tuel will shorten the pump
ber, the tue I is sent through the distributor head passage lite to a great degree. Theretore, special care must be
and then the inlet port in the barrel to the high pressure taken to prevent the entry ot water, dust, etc. into the sys-
chamber above the plunger. The plunger pumps the tuel tem.
Overflow pipe Feed pump (for air vent)
Water level warning lamp
Fuel injection pump
Fuel tank
AU012
GENERAL FLB-5
TROUBLESHOOTING EFLB0090
FUEL INJECTION SYSTEM
Symptom Probable cause Remedy

Engine does not start Cranking speed too low Repair starting system or charge or
replace battery so that engine cranks at
a minimum of 150 rpm.
No voltage at fuel cut-off solenoid Check for voltage with test light. If necessary,
on injection pump replace fuse or faulty wires.
Fuel cut-off solenoid on injection Tighten solenoid. Check that solenoid clicks
pump loose or faulty when key is turned off and on.
Replace faulty solenoid.
No voltage at glow plug bus If test light shows no voltage at bus with key
at "ON" position, test relay and wiring.
Glow plug faulty Test and, if necessary, replace glow plug.
Air in fuel system Bleed fuel system.
Injection pump not delivering fuel If no fuel emerges from a looseness injection
pipe during cranking, check timing belt
and fuel supply from filter.
Injection pipes misconnected Connect pipes in correct location
Injection timing incorrect Adjust injection timing.
Faulty injection nozzles Check and, if necessary, repair or
replace nozzles.
Engine mechanical faults, as described Test compression and, if necessary,
earlier under this heading repair engine.
Faulty injection pump Try to start engine with new pump installed. If
necessary, replace pump permanently.
Idle speed incorrect Idle speed incorrectly adjusted Check and, if necessary, adjust the idle speed.
or idle rough irregular
Accelerator control binding Check that accelerator lever on pump is not
loose, then adjust accelerator cable.
Loose fuel hose between filter and Replace hose or secure with clamps,
injection pump bleed air from system.
Inadequate fuel supply owing to clogged Inspect and, if necessary, replace lines and
fuel filter, or fuel return line and hoses or replace fuel filter.
injection pipes leaking, dirty, kinked, or
squeezed at connections
Faulty injection nozzles Check and, if necessary, repair or replace
injection nozzles.
Faulty injection pump Try engine at idle with new pump installed. If
Engine lugging in too high a gear Observe correct shift speeds.
FLB-6 FUEL SYSTEM [DIESEL 2.5]

Smoky exhaust Engine not reaching correct operating Check and, if necessary, replace cooling
(black, blue or white) temperature system thermostat.
Maximum rpm incorrect Check and if necessary, replace injection pump.
injection nozzles.
Restricted exhaust system Check exhaust system for dents and
obstructions.
Engine mechanical faulty, as described Test compression and, if necessary,
Faulty injection pump Observe exhaust with new pump installed if
Poor power output, Injection pump accelerator lever loose or Tighten lever, check that accelerator pedal travel
slow acceleration not reaching maximum rpm adjusting screw is not restricted, then adjust accelerator cable.
(speedometer
Maximum rpm incorrect Check and, if necessary, replace injection pump.
accurate, clutch
not slipping) Air cleaner filter dirty Clean or replace air cleaner filter.
Inadequate fuel supply owing to clogged Inspect and, if necessary, replace lines and
fuel filter, or fuel return li ne and hoses, replaced fuel filter.
injection pipes leaking, dirty, kinked, or
squeezed at connections
Ice or solidified wax in fuel lines. Move car to a warm garage until ice or wax has
(winter time only) become liquid, then bleed fuel system.
/ injection nozzles.
Faulty injection pump Check acceleration and speed with new
pump installed. If necessary, replace
pump permanently.
GENERAL FLB -7

Excessive fuel Air cleaner filter dirty Clean or replace air cleaner filter.
consumption
Fuelleaks Check and, if necessary, replace or tighten
all pipes, hoses and connections.
Return pipe and hose blocked Check return line for kinks and dents.
Replace faulty lines. If line is clogged, blow it out
with compressed air, then bleed fuel system.
Idle speed too fast or maximum rpm too high Check and, if necessary, adjust idle speed
or replace injection pump.
injection nozzles.
Engine mechanical fault, as described Test compression and, if necessary,
Faulty injection pump Check fuel consumption with new pump installed,
if unnecessary, replace pump permanently.
Excessive Rusty pedal arm Clean and lubricate.
accelerator pedal
Incorrect routing Ensure bending radius of 150 mm or more
eftort required
and correct excessively bent portion.
(Incomplete pedal
return included) Rusty cable Replace
Shift throttle cable Lubricate link and shaft.
Broken accelerator Binding cable end Remove rust and burrs from cable end.
control cable
Incorrect perpendicularity of cable Correct ends on the lever side.
end mounting point
Incorrect perpendicularity between Correct or replace parts.
cable end and cable
Engine does not stop Faulty starting switch operation Correct or replace part.
Broken harness between starting switch Replace harness
and fuel cut solenoid
FLB-8 FUEL SYSTEM [DIESEL 2.5]
INSPECTION AND ADJUSTMENT EFLB0150 ADJUSTMENT EFLB0160
ACCELERATOR CABLE EVACUATION OF AIR FROM FUEL LlNE
1. Warm engine until stabilized at idle. Evacuate air after following services.
• When fuel is drained and re-filled tor service.

2. Confirm idle rpm is at prescribed rpm.
• When tue I tilter is replaced.
• When main fuel line is removed.
3. Stop engine.
1. Loosen fuel filter air plug.
4. Confirm there are no sharp bends in accelerator ca-
ble. 2. Place rags around air plug hole. Operate hand pump
repeatedly until no bubbles come from plug hole.
5. Check inner cable for correct slack. Tighten air plug.
3. Repeat until hand pump operation becomes stift.
/
Lock nut
AUOO3
6. If there is too much slack, adjust slack by the following AUOO5

procedures.
1) Loosen adjusting nut. Fully elose throttle lever. ADJUSTMENT EFLB0170
2) Tighten adjusting nut until throttle lever just starts EVACUATION OF WATER FROM FUEL FILTER
moving.
Water is in the filter when tuel filter indicator lights. Evac-
Return 1 turn and lock with lock nut. This adjusts
uate water by the tollowing procedures.
accelerator cable play to standard value.
1. Loosen drain plug.
Standard value : approx. 1 mm (0.04 in.)
2. Drain water with hand pump. Finger-tighten drain
plug.
3) Adjust so that accelerator pedal stopper touch es
pedal arm when throttle lever is fully opened.
4) After adjusting, confirm that throttle level fully

opens and closes by operating pedal.
V Drain plug
AUOO6
- Return spring
AU004
GENERAL FLB-9
INSPECTION AND ADJUSTMENT EFMB3180 5. If the injection start pressure can not be adjusted by
changing the shim thickness, replace nozzle assem-
INJECTION NOZZLE bly.
INJECTION START PRESSURE
1.
2.
Set injection nozzle in nozzle tester and check the
following.
Move nozzle tester handle at about one stroke per

~
Shim~
second.
3. The pressure gauge pointer rises slowly and swings

when injection is made. Read the position at which
the pointer started to swing. Check the injection start
pressure is the standard value. EFLB018B
Standard value: 150 bar INJECTION STATUS

Limit: 132 bar or less 1. Move nozzle tester handle at about 1 stroke per sec-
ond.
[NEEDLE VALVE VIBRATION]
Inject on is normal if the characteristic intermittent

sound is heard as the handle is operated, and vibra-
tion of the needle valve is feit at the handle.
[SPRAY]
Check that the spray is good, as illustrated in the fig-

ure, in the test, the spray may be bolt shaped with a
course mist and fuel may remain. This is phenome-
AUOO7
non common in this type of inspection, and the nozzle
function is normal.
4. If the nozzle is faulty, disassemble and adjust injec-
tion start pressure to the standard value by changing
the shim thickness. Injection pressure increases by Not good
approx. 12 bar as shim thickness is increased by 0.1 / ~------~~~------~~
Large
mm (0.0039 in.). Injection Direction Split Intermittent
Good angle im balance injection injection
& CAUTION
When disassembling nozzle holder, be careful not
to al/ow entry of dirt or water. !'.),' •. I!li~L l~t.\~.!i'I,I \I\ ~
EFLB018C
2. Move nozzle tester handle at 4 to 6 strakes per sec-

ond.
3. Confirm the spray is cone shaped with an angle of

about 15°. This indicates a good condition.
4. If the injection is not good, disassemble nozzle and

replace nozzle tip or entire assembly.
5. Confirm fuel does not drip after injection.

6. It dripping, disassemble injection nozzle and replace

nozzle tip or entire assembly.
EFLB018D
NOZZLE OlL-SEAL
1. Maintain internal nozzle pressure (press ure gauge in-

dication value) with the nozzle tester at 120 - 132 bar.
Check tor tuelleaking trom nozzle tip in this condition.
2. It there is leakage, disassemble injection nozzle and

replace nozzle tip or entire assembly.
I I
I 1
~j
/
EFLB018E
INJECTION PUMP-MECHANICAL FLB -11
INJECTION
PUMP-MECHANICAL
INSPECTION EFLB10l0
FUEL INJECTION PUMP AND INJECTION

NOZZLE ON VEHICLE
If found defective, replace the injection pump as assembly.
[QjJ NOTE
Limit the injection pump adjustment to the idle adjustment.
Description Check procedure Criteria

Idling run Measure rpm 702-780 rpm
Color of exhaust gas Give fast acceleration under no load and check Voluminous black smoke is unacceptable.
color of exhaust gas. (Measure smoke value). (Smoke ref. value : within 50%)
Timer Operate accelerator lever to maintain an Engine noise changes.
engine speed of approx. 1,500 rpm. In this
condition, manually operate accelerator switch
knob to see how engine speed changes.
Fuel cut solenoid Turn on and off ignition switch Actuating sound (click) is heard.
COMPONENTS EFLB1030
13~
o
14---0 B
9
15----0
1. Injection pipe No.1

5. Injection pump sprocket
6. Injection pump bracket
7. Injection pump harness assembly
8. Fuel injection pump
Nm kg·m Ib·tt
9. Fuelhose
10. Fuel return pipe nut A 30-40 3.0-4.0 21-29
11. Fuel return pipe B 50-60 5.0-6.0 36-43
12. Gasket C 4-6 0.4-0.6 3-4
13. Injection nozzle D 23-37 2.3-3.7 16-27
14. Holder gasket E 80-90 8.0-9.0 58-65
15. Nozzle gasket F 20-27 2.0-2.7 14-19
G 15-22 1.5-2.2 10-16
NOTE
H 18-25 1.8-2.5 13-18
Reverse the removal procedures to reinstall
EFLB103A
REMOVAL EFLB1050 So you must remove the hexagon nut with holding
return pipe.
INJECTION PIPE
FUEL RETURN PIPE NUT
When loosening the union nuts, hold delivery valve holder
on fuel injection pump head or hexagon nut ot tue I return When removing the tuel return pipe nut,. hold the fuel return
pipe with a wrench to prevent it trom rotating along with pipe by the hexagon nut with a wrench.
the union nut.
& CAUTION
& CAUTION If you remove the hexagon nut without holding the
Beeause VE type injeetion pipe is different from fuel return pipe nut, the pipe might b, damaged.
DPC type Injeetion pipe, be eareful when you in- So you must remove the hexagon nut with holding
stall. (VE type injeetion pipe is eoated yellow) return pipe.
EFLB105A EFLB105C
INJECTION PUMP SPROCKET INJECTION NOZZLE
Use the special tool to remove the injection pump sprocket. Using a deep socket wrench, loosen the injection nozzle
and remove.
& CAUTION
& CAUTION
Jarring the sproeket may eause injeetion pump
malfunetion. Write the number of the eylinder on the injeetion
nozzle that has been removed.
Cover the opening with an appropriate eap to pre-
vent entry of dust, water and foreign material into
the fuel passage land eombustion ehamber.
EFLB105B
FUEL INJECTION PUMP
When removing the tue I return pipe nut, hold the tuel return EFLB105D
pipe by the hexagon nut with a wrench.
& CAUTION
If you remove the hexagon nut without holding the
fuel return pipe nut, the pipe might be damaged.
FLB -14 FU EL SYSTEM [DIESEL 2.5]
INSPECTION EFMB3070 CHECKING OF SPRAY CHARACTERISTICS
INJECTION NOZZLE 1. Operate tester handle at a rate of approximately on

stroke/sec. When the tester handle is moved, the noz-
Make the following checks and, if defects are found, cor- zle should inject fuel producing a characteristic inter-
rect or replace. mittent noise, and vibration of needle valve should be
palpable at the tester handle.
[mJ NOTE
Fuel may remain at the nozzle tip after injection. This
sometimes occurs when checking the nozzle but it
does not mean that the nozzle is malfunctioning.
2. Spray condition
Only one shows the good spray condition, others be-
ing poor. Spray may be shaped like a rod with coarse
fuel particles and the gas oil may be present at the
AU007 orifice after injection. This is a symptom that occurs
uniquely du ring this inspection and does note repre-
CHECKING OF INJECTION PRESSURE
sent any abnormal condition of the nozzle.
1. Mount nozzle on nozzle tester and operate tester han-
3. Operate the tester handle 4 to 6 strokes per second.
dle to bleed the nozzle.
The shape of spray is conical with an angle of about
2. Operate tester handle at a rate of approximately one 30 degree.
stroke/sec and read the pressure gauge."
If the pressure reading is below the service limit, dis- Notgood
assemble nozzle and adjust it by replacing the interior I ~------~~~------~~
shim so that the pressure reading will be within the Large
Injection Direction Split Intermittent
standard value range. Good angle imbalance injection injection
Standard value :
Service limit:
150 bar
132 bar
!'.' !!l~1. m,\~~(ilf,l l \ ~
I,'
EFLB018C
NOZZLE OlL TIGHTENESS

~NOTE
1. Increase of O. 1 mm shim thickness will result in Operate the nozzle tester so that the interior pressure of
increase of press ure to 12 bar. the nozzle is maintained at apressure gauge reading of
2. 20 different shims available ranging in thickness 120 - 132 bar and check nozzle tip for fuel leakage.
from 1.00-1.95 mm.
~
Shim-i d
e EFLB018B
INSTALLATION EFLB1090 INJECTION PIPE
NOZZLE GASKET AND HOLDER GASKET When tightening the injection pipe nuts, hold the delivery
valve holder or the fuel return pipe by the hexagon nut with
a wrench in order to prevent it from rotating along with the
1. Clean nozzle holder installation area of the cylinder
nut.
head.
2. Fit a new nozzle gasket and holder gasket into the

nozzle holder hole in the cylinder head.
Holder gasket
Nozzle gasket
EFLB109B
ADJUSTMENT EFLB1110
EFLB109A
1. Loosen (but do not remove) two nuts and two bolts
INJECTION NOZZLE holding the injection pump.
2. Loosen (but do not remove) the 4 nuts on the injection

Install the injection nozzle in the cylinder head and tighten
pump side which hold the injection pipes.
to the specified torque, using a deep socket wrench.
& CAUTION
When loosening the nuts, hold the delivery valve
holder with a wrench to prevent it from turning
along with the nut.
3. Remove the plug from the rear of injection pump, and

attach the special tool and dial indicator.
~ & CAUTION
Before installing the adapter, make sure that the
EFLB105D
push rod projects 10mm. Push rod projection can
be adjusted by means of the interior nut.
FUEL RETURN PIPE NUT
While holding the fuel return pipe by the hexagon nut with
a wrench, tighten the fuel return pipe nut to the specified
torque.
EFLB111A
EFLB105C
4. Set the notch on the crank pulley at approximately 30° 9. Tighten the bolts and nuts to the specified torque.
BTDC of the compression stroke of the NO.1 cylinder.
With the notch in this position, set the dial indicator at When higher than
zero. Turn the crank pulley slightly in both directions - = standard value
to make sure that the dial indicator pointer does not i~ )~- JJ~-"~'--_ ~
l \~ I ""~
deviate trom the zero position.
It the pointer deviates, the notch position is not cor-
,,_.Y ': :: "X)-
! .-'~ -'
rect. Readjust it to 30° BTDC. \..-, -J When lower than
:) - standard value
Approx.30·
------.;
~ /)
~:"
PO-:b Set the dial indicator
U
,
---~
EFLB111D
:,~
EFLB111B
5. Turn the crankshaft clockwise to bring the notch on the

pulley to 4° ATDC, and check to be sure that the dial
indicator reading is within the standard value range.
Standard value : 0.97-1.03 mm
ATDC4'
I
," 0.97-1.03 mm
--~:'1
/
EFLB111C
6. It dial indicator reading is not within the standard value

range, tilt the injection pump body to the right or left
until the reading is within the standard value range.
Then, temporarily tighten the injection pump nuts and
bolts.
7. Repeat Steps 4 and 6 to make sure that the adjust-

ment has been correctly performed.
8. Remove the dial indicator and the special tool.

INJECTION NOZZLE HOLDER EFLB1130
COMPONENTS
0- 6
1
............ ' " - - - 5
~4
L J
1. Retaining nut
2. Nozzle tip
3. Spacer
4. Retaining pin
5. Pressure spring
6. Shim
7. Nozzle holder body
Nm kg'm Ib·tt
NOTE
A 35-40 3.5-4.0 25-29
Reverse the disassembly procedures to reassembly.
EFLB113A
DISASSEMBLY EFLB1150 DISTANCE PIECE
RETAINING NUT Check the surface in contact with the nozzle holder body
by using minimum.
1. Lightly clamp the retaining nut with a cushion bracket
PRESSURE SPRING
2. Hold the retaining nut with a box wrench, and loosen
the nozzle holder body using a deep socket wrench. Check spring for weakness and breakage.
REASSEMBLY EFLB1190
RETAINING NUT
1. Finger-tighten the nozzle holder body.
2. Lightly clamp the retaining nut in a vise with cushion

plates.
3. While holding the retaining nut with a box wrench,

tighten the nozzle holder body to the specified torque
EFLB115A
with a deep socket wrench.
INSPECTION EFLB1170 Tightening torque : 35-40 Nm (3.5-4.0 kgm)
NOZZLE TIP
1. Check the nozzle tip for carbon deposits: Scrape off

carbon deposits with a piece of wood land clean each
part with patrol. After cleaning, keep parts submerged
in diesel fuel. Take particular care to protect the noz-
zle tip needle valve from damage.
2. While the nozzle tip is submerged in diesel fuel, check

that the needle valve slides smoothly. If the needle
valve does not slide smoothly, replace the nozzle tip.
When replacing the nozzle tip, completely wash off EFLB115A
the anticorrosive oil from the new nozzle tip with clean
diesel fuel before using it.
3. Check plunger tip "An for deformation and breakage.

If "An is damaged or broken replace it.
EFLB117A
LUCAS INJECTION PUMP EFLB1210
COMPONENTS
Fuel cut solenoid valve
Tacho-pick up
96SI0078196SIOO79196SIOOBO
EFLB121A
INSPECTION AND ADJUSTMENT EFLB1230
INJECTION TIMING
• Preparation
Turn off the engine.
Set the timing belt in normal mounting condition.
Set the transmission in neutral position
1. Untighten the upper installation nut and bolt of injec-

tion pump and also untighten the injection pump and
EFLB123C
also untighten the injection pipe halfway.
4. With the V-groove of crankshaft pulley being posi-
& CAUTION tioned at ATDC 4°by turning the crankshaft clockwise
When untightening injection pipe nut, hold the of 1 rotation, check to sure that the dial indicator read-
valve holder with spanner so that the delivery ing is within the value indicated on throttle lever.
valve holder shall not be turned together. • If dial indicator reading is not within the standard
value range, tilt the injection pump body to the
right or left until the reading is within the standard
value range.
Example 7.43
Throttle lever
EFLB123A
2. Using box wrench, turn the crankshaft pulley to mate

the V-groove at ATDC 4°. EFLB123D
Disconnect the timing check plug of injection pump,
then insert the SST (Timing Measurement Guide 5. Tighten the injection pump nut and bolt and injection
Shaft). pipe nut. Turn the crankshaft pulley counterclockwise
more than 90° and then match to ATDC 4°by turning
the crankshaft clockwise. And, check the dial gauge
indicating value and adjusting value.
Limited Value : ± 0.05 mm
EFLB123B
3. Set the dial gauge to zero (0) after dial gauge installa-
tion special tool and dial gauge are installed to timing
check guide shaft.
EFLB123E
6. Remove the timing adjusting data and SST and Guide

Shaft, then assemble the check plug using hexagon
wrench.
INSPECTION AND ADJUSTMENT EFLB1240 7. After adjustment, completely tighten the lock nut.
IDLE RPM
1. Set the vehicle in the following conditions before in-
spection and adjustment.
Engine coolant temperature : 80-90
Lights, accessories : OFF
Transmission position: Neutral
2. Check that the valve clearance is within standard

value.
EFLB123H
3. Check that the injection timing within standard value
EFLB123F
4. Set the tachometer to injection nozzle or injection

pipe.
~NOTE
When setting tachometer to injection pipe, fully loosen
the assembly clamp of pipe prior to set.
Tachometer
EFLB123G
5. Check that the idle rpm is with standard value.
Standard Value : 750 ± 50 rpm
6. If the idle rpm is over the standard value, loosen the

lock nut of idle adjusting screw to the standard value.
FUEL DELIVERY
SYSTEM-DIESEL
COMPONENTS EFLB2010
~--- O.9-1.4kg·m
1----5
1-....- \ ; - - - - - 7 9
11\-----4 11
;---3
1. Fuel hose (main) 7. Water level sensor

2. Water level sensor connector 8. Fuel return hose (main)
3. Fuel filter 9. Fuel hose (connection)
4. Drain plug 10. Fuel return hose (connection)
5. Fuel filter cartridge 11. Fuel main pipe
6. Fuel filter pump 12. Fuel return pipe
EFLB201A
FUEL DELIVERY SYSTEM-DIESEL FLB -23
REMOVAL EFLB2030
1. Fuel filter cartridge

With holding fuel filter pump in vice, remove the fuel
filter cartridge using fuel filter wrench.
EFLB205A
REPLACEMENT EFLB2070
Fuel filter
EFLB203A
1. Lower the fuel tank press ure by removing fuel filler
2. Water level sensor cap.
With holding water level sensor in vice, turn and re-
2. Disconnect the connector of water level sensor.
move the fuel filter cartridge with both hands.
3. Remove fuel filter cartridge from fuel filter pump body
with hand.
4. Disconnect fuellose(main) from fuel filter pump.
5. Remove fuel filter pump.
6. Replace fuel filter.
EFLB203B
INSPECTION EFLB2050
1. Normal inspection
1) Check hose and pipe for crack, cooking, blaze

and clog.
EFLB207A
2) Check fuel filter for clog and damage.
2. Operation of water level sensor

Connect circuit tester to water level sensor connector.
If the circuit is discontinuity or continuity when the float
is moved up or down, the water level sensor is good.
ENGINE CONTROL EFLB2090
ACCELERATOR PEDAL
1.
2.
Accelerator pedal assembly
Bracket assembly ,
~
3. Return spring
4. Snap ring
5. Plain washer
NOTE
Reverse the disassembly procedures to reassemble.
EFLB209A
THROTTLE CONTROL EFLB2110
Broken cable,
worn covering,
damaged bolt
Adjusting lever section
EFLB211A
REASSEMBLY EFLB2130
ACCELERATOR PEDAL
Apply grease to accelerator pedal slide-contacting sur-

face.
RETURN SPRING
Apply grease to inner surface.
_Apply grease
EFLB213A
CABLE INSTALLATION AND

ADJUSTMENT EFLB2150
THROTTLE CABLE
Turn the throttle button fully in the opposite direction to that

of arrow indicated on the button. With the inner cable most
protruded, install the accelerator pedal arm or accelerator
lever. At that time, make sure that when the engine speed
reaches the lowest speed, the inner cable is in the most
protruded state.
~NOTE
1. Make this adjustment with the cab titt and titt han-
dle down.
2. Route each cable so that it may not come in con-
tact with the edge of sheet metal.
3. The routing radius of each cable shal/150 mm or
more.
Turn fully
EFLB215A
ACCELERATOR CONTROL CABLE
Turn the throttle button in the opposite direction to that

of arraw indicated on the button and make sure that the
accelerator pedal does not move. Install the accelerator
contral cable to the adjusting lever and secure the engine
side of the cable by tightening the nut.
[QJ) NOTE
Do not move the engine side adjusting lever when the
accelerator control cable is installed.
Full
EFLB215B
ACCELERATOR PEDAL STOPPER
Make adjustment so that when the engine side adjusting

lever is in contact with the fuel stopper, clearance between
accelerator pedal and adjusting bolt is equal to dimension
A.
Dimension A : 0 - 5 mm
- Return spring
AU004
COMPONENTS EFLB2170
7 0'
flA
2 4
1. Fuel gauge unit

2. Breather hose
3. Fuel tank
4. Drain plug
5. Filler and breather pipe assembly
6. Filler hose Nm kg·m Ib·tt
7. Breather hose A 15-22 1.5-2.2 11-16
8. Filler neck
9. Filler neck cover
EFLB217A
REMOVAL EFLB2190 5. Remove the tuel tank.

Remove the tue I gauge unit it necessary.
1. Discharge tue I with the drain plug removed.
EFLB219D
EFLB219A
6. Remove the filler neck and tiller pipe by the tollowing
2. Disconnect the tue I teed hose and return hose. procedure.
1) Disconnect the tiller and breather hose tram filler

and breather pipes.
EFLB219B
3. Disconnect the tuel gauge unit connector.

EFLB219E
2) Pull out the tiller neck cover and then remove the
filler neck.
EFLB219C
4. Disconnect the breather hose and tiller hose.
EFLB219F
EFLB219D
3) Remove the filler and breather pipe assembly.
EFlB219G
INSTALLATION EFLB2210
When hose are connected to pipes, make that specitied

overlap length are observed. Tighten hose clamps as po-
sition shown in the illustration to prevent the hoses trom
interfering with other parts.
tmJ
30-40 mm (1.2 to 1.6 in.)
p l
20-30 mm (0.8 to 1.2 in.)
EFLB221A
Fuel System
[Covec-F 2.5]
GENERAL ................................................................. FLA-2
DIAGNOSIS ...........................•................................... FLA -15

FLA-2 FUEL SYSTEM [COVEC-F 2.5]
GENERAL (Computed VE pump Control system-Full). This supple-

ment is intended for use by vehicle maintenance techni-
cians or persons with an adequate knowledge of injection
DESCRIPTION EFMB6010 pumps.
This Supplement shop manual consists of two parts, ser- CONSTRUCTION & OPERATION
vice manual for construction & operation and self-diagno-
sis system. The first part, service manual for construc- OUTLINE
tion & operation, describes construction and operation of
the micro-computor controlled fuel injection quantity and The COVEC-F fuel injection system (Computed VE pump
injection timing control system COVEC-F (Computed VE Control system-Full) is a distributor type fuel injection sys-
pump Control system Full). And the second part, service tem that uses a micro-computor to control fuel injection
manual for self-diagnosis system, describes the self-diag- quantity and injection timing. COVEC-F was developed to
nosis system of the microcomputer controlled fuel injec- improve the power performance of small diesel engines, to
tion quantity and injection timing control system COVEC-F improve driving comfort, as weil as to decrease pollution.
SPECIFICATIONS
Item Specification
No of cylinders 4, 6
Direction of rotation Clockwise and counter clockwise
Maximum speed Approx 3,000 r/min
Plunger diameters 8,9, 10, 11, 12mm
Injection timing adjustment TCV duty ratio control
Injection quantity control Electronic control of control sleeve position
Weight Approx 6.5kg
Prevention of reverse rotation Constructed so that fuel injection is not performed at reverse rotation
Additional devices Not necessary
GENERAL FLA-3
FEATURES EFMB6030 DECREASED SMOKE AT ACCELERATION
IMPROVED POWER PERFORMANCE Injection quantity is increased at acceleration to increase

engine output. With conventional injection pumps, this
The left hand figure shows the relationship between accel- excess fuel results in the generation of smoke. With
erator position and output torque. Compared to conven- COVEC-F, however, fuel injection quantity is precisely
tional injection pumps, COVEC-F provides the most suit- controlled, even at acceleration, to prevent the generation
able injection quantity corresponding to accelerator posi- of smoke without adversely affecting engine response.
tion. This enables increased torque at a lower accelerator
position, wh ich improves power performance.
Conventional injection pump
COVEC-F ~_--
"'''''-
Excess fuel at acceleration
//\ Conventional injection pump:

Accelerator position
50 100
EFMB603C
Accelerator position (0/0)
EFMB603A ADDITIONAL DEVICES UNNECESSARY
INCREASED COMFORT Additional devices such as aboost compensator, aneroid

compensator, or injection timing compensation devices
On conventional injection pumps, minute variations of con- are unnecessary as compensation is performed electron-
trol sleeve position are not performed. COVEC-F, however, ically in response to signals from the various sensors.
detects variations in speed at each engine combustion at Because of this, the exterior of the injection pump is
idling, and in response to this controls the control sleeve greatly simplified, enabling better utilization of space
position to increase or decrease the fuel injection quan- around the injection pump.
tity. In this way, each cylinder's injection quantity is con-
trolled for each injection to decrease engine vibration and
improve comfort.
Conventional type COVEC-F

c c
0 0
""
0ijj
0
""
0ijj
0
Co Co
CI) Fixed CI) Individual control
>
CI) / >
CI) /
/
CI) CI)
"iii "iii
1! 1!
"E "E
0 0
Ü ü KFMB503D
Time Time
EFMB603B
FLA -4 FUEL SYSTEM [COVEC-F 2.5]
SYSTEM OUTLINE EFMB6060
The figure below shows an outline of the COVEC-F-II sys-

tem.
Battery voltage
COVEC-F
CD c/u
® Np sensor
@ Fuel temperature
GE actuator
CD C/U: Control unit

® Np sensor: Pump speed sensor
® CSP sensor: Control sleeve position sensor
@ TCV : Timing control valve
(j) TPS: Timing position sensor
EFMB606A
No Part name Function

1 Control unit Running condition comparison, processing
2 Np sensor Detects pump speed
3 CSP sensor Detects control sleeve position
4 Fuel temperature sensor Detects fuel temperature
5 Compensation resistor Compensation
6 TCV Adjusts injection timing
7 TPS Detects timer piston position
GENERAL FLA -5
SYSTEM CONTROL EFMB6090
COVEC-F detects physical signals as electrical signals

from each sensor and switch. The control unit processes
this information to electronically control injection timing
and injection quantity.
Input signal Control section Output signal Control item
Injection system
Injection pump
Np sensor
I ,'" I Fuel injection quantity I
CSP sensor
Fuel temperature sensor

[
- GE actuator
TCV
,'" Injection timing
Compensation resistor
Control
TPS unit
Vehicle Additional vehicle side

control devices
Sensors
I • EGR valve • EGR control
SIW
Battery voltage
I
- - • Glowplugs
• Diagnostic
lamps
- • Glow control
• Self-diagnosis
system
CSP : Control sleeve position sensor

TPS : Timing position sensor
EFMB609A
FLA -6 FU EL SYSTEM [COVEC-F 2.5]
CONSTRUCTION EFMB6120
EXTERIOR AND CROSS-SECTIONAL VIEWS
TPS TCV
GE actuator
EFMB612A
m G')
><
'tI
m m
r-
"Tl
;:: z
o ~ m
C ~ :D
m »
C r-
:S
m
=E
50411
~ Al
136
5~
40
58
27
515 515
"TI
~
.....
I
FLA-8 FUEL SYSTEM [COVEC-F 2.5]
CONSTRUCTION EFMB6160
COVEC-F BODY
GE actuator
EFMB616A
Refer to the VE type injection pump service manual for is sometimes equipped with acheck valve inside the over-
conventional injection pump construction and parts with flow valve. With COVEC-F, however, the overflow valve
common construction. is always equipped with acheck valve to prevent overflow
Fuel intake and pressure delivery by COVEC-F is identical until a fixed pressure is reached. COVEC-F-II is provided
to that of the conventional injection pump. The inside of with a TPS (timing position sensor) at the lower part of the
the pump is separated into a governor chamber, where injection pump to detect timer piston position.
fuel injection quantity control is performed, and a pump
chamber, where fuel intake and delivery are performed.
The conventional injection pump is controlled by a centrifu-
gal governor. COVEC-F, however, utilizes a GE actuator
(ie, an electronic governor). Flyweights are not utilized.
Therefore, there is no control lever at the upper cover.
Instead, the control unit cable is connected to the upper
part of the injection pump. Also, the conventional injec-
tion pump utilizes a flyweight holder gear (with 23 teeth) to
detect pump speed. COVEC-F, however, utilizes a sens-
ing gear plate provided on the drive shaft to detect pump
speed. The number of projections on the gear plate cor-
responds to the number of engine cylinders.
A TCV (timing control valve) is provided at the lower part
of the pump body between the timer's high press ure and
low pressure chambers to adjust pressure to that neces-
sary for advance timing. The conventional injection pump
GENERAL FLA-9
GE ACTUATOR (ELECTRONIC GOVERNOR) DECREASED SMOKE AT ACCELERATION
The GE actuator is attached to the governor chamber at The TCV has a fuel inlet located in the center of the side of
the upper part of the injection pump. the TCV body. The fuel inlet is equipped with a filter. This
inlet connects through the inside of the TCV to a hole in
the end of the TCV body. A needle valve inside the TCV
seats inside this end hole. When current is applied to the
TCV, the needle valve is pulled to the left (see right hand
figure) by a magnet to open the end seat. Injection tim-
ing is varied by timer piston movement transferred to the
roller holder, as with conventional injection pumps. Pre-
viously, though, the pressure inside the timer's high pres-
sure chamber controlling the timer piston varied in accor-
dance with pump speed. With COVEC-F, however, the
TCV controls pressure inside the high pressure chamber.
EFMB616B
Fuel inlet Tip hole
The governor chamber and the pump chamber are con-

nected through a magnet filter, and the fuel oil flowing into
the governor chamber cools the coi!.
The magnet filter also prevents iron fHings from entering
the inside of the GE actuator. The tip of the shaft pressfit-
ted to the rotor is equipped with a ball pin which is eccen-
tric to the shaft. This ball pin is inserted into a hole in the
control sleeve.
Needle
Fuel inlet Tip hole
EFMB616C
Needle
EFMB616D
NP SENSOR (PUMP SPEED SENSOR) OVERFLOW VALVE (WITH CHECK VALVE)
The Np sensor detects pump speed necessary for the var- The overflow valve is installed on the end face of the GE
ious controls, and outputs signals to the control unit. The actuator cover (ie, on the distributor head side). The check
Np sensor is constructed of a permanent magnet and an valve is constructed with a ball and spring to prevent over-
iron pole, and a coil. The magnetic field is varied by sens- flow until the pump chamber pressure reaches a specified
ing gear movement, and the voltage generated is detected value.
as a speed signal.
Spring
Ball
Magnet Coi!
EFMB616G
EFMB616E
CONTROL UNIT
TPS SENSOR (TIMING POSITION SENSOR)
The control unit is installed on the vehicle. The control
The TPS is installed on the timer's low pressure side. The unit receives information signals detected by each sensor.
TPS is constructed of acore rod and a bobbin, and detects Based on this information, the control unit then performs
timer piston position electrically. comparative calculations using programmed set values,
and then instantaneously outputs optimum control signals
Core rod to each control section. The control unit also includes a
fault diagnosis system.
Timing position Bobbin
EFMB616F
EFMB616H
GENERAL FLA -11
OPERATION EFMB6180
GE ACTUATOR (ELECTRONIC GOVERNOR)
Return spring
Control sleeve
EFMB618A
Unlike the conventional injection pump, COVEC-F adjusts Magnetic flux Core
fuel injection quantity electromagnetically. Control sleeve
position is detected by the control sleeve position sensor
and fed back to the control unit.
When the coil is energized, the core gene rates magnetic
flux to rotate the rotor within a specific range. The intensity
of the magnetic flux generated by the coil is determined
by the input current. The rotor is rotated until the intensity
of the core's magnetic flux equals the force of the rotor's
return spring. Rotor Coil
EFMB618B
The control sleeve position sensor detects rotational an-

gle. It is installed at the top of the GE actuator to detect
whether the control sleeve position (ie, the rotor's angle
of rotation) specified by the current is in fact the correct
position. The control sleeve position sensor consists of a Accompanying this, the roller holder rotates to vary the in-
sensor yoke, a sensor coil, a movable plate and a fixed jection timing. Injection timing can therefore be varied by
plate. The movable plate is connected directly to and ro- utilizing the ON-OFF duty ratio of the current flowing to the
tates with the shaft. TCV. Injection timing is controlled by duty. All characteris-
The fixed plate compensates for temperature induced in- tics and control signals are processed with TCV drive sig-
ductance variations. nal duty ratios. Also, the frequency of the TCV drive signal
can be varied to correspond to the frequency of injection
Sensoryoke pump speed.
Timing position
Movable plate Sensor coil High Low

pressure , pressure
EFMB618C
side
hL,--"'::~~~~ side
The control sleeve position sensor converts differences
in the inductances of the upper and lower coils into an-
gles, and feeds this back to the control unit. The control
unit compares the target angle with the actual angle mea-
sured, and compensates the current so that the angle cor-
responds to the target angle.
TCV
EFMB618E
Duty ratio is the ratio of the time that the timing control
valve is closed per unit of time (ie, per cycle).
Rotor's rotational angle (')
EFMB618D
Duty ratio = tofT x 100(%)
TCV (TIMING CONTROL VALVE)

[QJ] NOTE
The TCV is located at the lower part of the injection pump. Injection timing is retarded when the duty ratio de-
Two holes (A and B) in the pump housing connect to the creases tram 100%.
TCV. Hole A connects the timer piston's high pressure
chamber to the fuel inlet side of the TCV. A filter is installed
Open Open
at this inlet to exclude foreign matter.
Hole B connects the timer piston's low pressure chamber Drive signal Time
to the fuel outlet at the tip of the TCV. Installed between the
timer piston's high and low pressure chambers, the TCV
adjusts high pressure chamber pressure by opening and Closed Closed
closing the needle.
to
When current is not flowing to the TCV, the tip of the
needle completely separates the high and low pressure T
chambers. When current is applied, the needle tip seat
is opened, the high and low pressure chambers are EFMB618F
connected, and the high pressure chamber pressure
decreases. The timer piston is then moved by the timer
spring to a position that balances the high pressure
chamber pressure.
GENERAL FLA -13
NP SENSOR (PUMP SPEED SENSOR) CHECK VALVE
When the drive shaft rotates, the sensing gear plate pro- The right hand figure shows the advance characteristics
jections pass through the pump speed sensor's magnetic of the conventional injection pump and the possible range
field to generate AC voltage at the coil. This voltage is of advance control of COVEC-F.
input to the control unit, converted to a pulse signal, and With the conventional VE type injection pump, fuel pres-
used as a pump speed signal. sure is increased in accordance with increases in speed
to obtain advance characteristics.
Permanent magnet
With COVEC-F, the overflow valve is equipped with a
check valve so that even at starting rotation, there is
sufficient pressure to control advance. Therefore, as
shown at left, the possible control range is much wider.
Sensing gear plate Goil Pole

EFMB618G
TPS (TIMING POSITION SENSOR)
The TPS detects variations in the core rod inductance to Pump speed (r/min)
measure timer piston position.
EFMB618J
• Reference (standard point)
TA = Omm
Gore rod
Timing position
EFMB618H
• Reference (Operation)
TA = advance angle direction

Gore rod
Timing position Bobbin

EFMB6181
CONTROL UNIT The control signals output by the micr-computor are then
converted to drive signals. These are then input to the GE
Information signals detected by each sensor and switch actuator and the TCV to control fuel injection quantity and
are input to the control unit's micro-computor. Based on injection timing.
these information signals, characteristic data as weil as In addition to this, COVEC-F also has a function that con-
compensation data recorded in the ROM (read only mem- tinually compensates real values to target values (feed-
ory) are read into the CPU (central processing unit). Com- back control) to perform optimum control of the diesel en-
parative calculations are then performed utilizing this data gine and ensure precision and endurance.
and information signals are output.
Input section Control section Output section
11 Control unit ~
I sensors:
~
I
CPU
ROM I
.. Drive circuit
/
I V
Switches :
""
EFMB618K
an
,... «
:3u..- Abnormal symptom II Check point II Remedy

i
::;:
u.
w
Malfunction of both I - - - - - - - - - - - - j / Measure the resistance Replace the sensor

Engine will not start
*Np & TDC sensor of the sensor coil coil
due to the fail safe
Malfunction of *CSP 1-_ _ _ _ _ _ _ _ _--1/ Measure the resistance

Replace the pump
sensor of the sensor coil
1'-_________-1/ Measure the resistance

Short circuit of FCV Replace the FCV
of the FCV coil
Malfunction of *GE
servo
Engine will not Engine stall due to

Engine will not start
start due to the the fail safe
*FCV stuck
Measure the resistance Repair the open or

J: Low supply voltage Open or short circuit
of the wire short circuit
t-
~
W Low voltage Check the battery
Z Repalce the battery
supplied to ECM voltage
"a:
Z
w
No fuel suppling to High flow resistance
1---------------11 Check the fuel filter
Replace the fuel
the pump in the fuel line filter
0
u.. CD
~
'"u.
::;: a:
"O-
Z
i=u..
w
~
Cf)
Air incoming from the I I Check the fuel tank Refuel
-
fuel tank
CI)
CI) 0 0 b
Z
J:W No complete combustion
CI) 0 CI) > ..J occurs due to the bad glow
u; Z wO
..JO
..J
i system
0
-~
Z al..J w
:lw z Improper injection timing
~ 0><
a:w
(;
z
at starting
iS C t-N w
..... In
~
C\I i
::;;
LLI
Abnormal symptom [-CheCk point 1 Remedy I LI.
W
oW
~ Engine stall due to Malfunction of both 1 - - - - - - - - - - - - 1 1 Measure the resistance Replace the sensor
o
...... the fail safe Np &TOC sensor of the sensor coil coil
:E
w
l- Malfunction of CSP 1-_ _ _ _ _ _ _ _ _--11 Measure the resistance
m sensor of the sensor coil Replace the pump
>
m
.J
W Malfunction of GE
:::J servo
LL
Sudden engine stall Engine stall due to Engine stall due to

in driving the FCV elose the tail safe
Measure the resistance

Low supply voltage Open or short circuit
of the wire
Low voltage
supplied to ECM H Repalce the battery
Engine stall due to

the no fuel suppling
High flow resistance
in the fuelline
H Replace the fuel
filter
to the pump
I
Air incoming from the I
fuel tank
I Check the fuel tank H Refuel
..J
..J
r!
UJ
~I
w
i::;; z
LI.
W
(;
Z
W
...,.... u
CheC~point
I 18Ol
«
..J
LL
Abnormal symptom [
I I Remedy ::>
lL
LU
r
Incorrect voltage
ofGE
m Incorrect output of
CSP sensor
m Looseness of
sensor plagte
r---l Tighten the nut
Looseness of
moving plate
r---l Tighten the nut
Loosenes~ of CSP r---l Ti hten

sensor co11 9
I
Malfunction of the CSP sensor stuck Repair the open

CSP sensor to the LO side circuit of CSP(-)
Sudden rise of ~ Sudden rise of engine Repair the open

engine rpm rpm without changing circuit of CSP(MDL)
of fuel quantity
Repair the short

circuit of CSP(+),
CSP(MDL)
Repair the bad

continuity
:E
0..
H Malfunction of the
GE motor
GE motor stuck to
the FULL side
Open circuit 01 GE
ground
Repair the open
circuit of GE ground
a:
W
Z
(3
Z
Y 0'p~n circuit of
wlnng
H Repair the open
circuit of wiring
W
LL
~
0
w
U) \A/ y Incorrect signal 01
*TI
H Incorrect signal of
*TI
f--rl Bad Tf ~~m r---l Replace the sensor
tn 0:
0 Z Continued on next page
Z
~
«
W
C
C Y Bad continuity
H Repair the bad
continuity
::l
Ci t/)
-
11)
N ,. Abnormal symptom [ Check point , Remedy
o
i~
u.I w
o
W
~ Bad reference
Bad circuit of ECM Replace the ECM
o
...... From previous page
voltage
:!:
w Repair the bad
I- Bad continuity
continuity
cn
>
cn
..J Incorrect signal of Bad accelerator Measure the output
W Replace the sensor
::l *APS sensor voltage of the sensor
U.
Noise at the sensor
Sudden rise of engine 1 - - - - - - - - - - - - - - 1 1 Repair the bad

Bad continuity
rpm with changing of continuity
fuel quantity
Bad return of Bad return of the

1 - - - - - - - - - - - - - - 1 1 Replace the sensor
accelerator pedal sensor
Bad return of
1 - - - - - - - - - - - - - - 1 1 Replace the pedal
accelerator pedal
Malfunction of com- Malfunction of Replace the compen-

pensation resistor compensation resistor sation resistor
Incorrect adjustment Repair the bad

Bad continuity
of fuel quantity continuity
Bad tolerance among Malfunction of the 'Tw

Replace the sensor
the component sensor
Repair the bad

,..
CIO
I
Bad continuity
continuity
es:
..J
U.
-
0)
I
oe(
..J
o :Effect much
.. -- .. __.-
w
~
:::;:
LL
W
~
Lackof Bad
lL
Hardto Rough powerl return of Englne Much Much Knockln g Poor Impossible Sudden
ITEM black whlte and rlse of Checkpoint
start Idling poor stop fuel to stopthe
Maln cause accelera overrun smoke smoke vlbrtlon economy englne engine
tlon rpm rpm
Poor connection or Tightening torque :

Fuel cut looseness of terminal 0 0 b. 2.0-2.5kg·m
solenoid
valve Valve fail Check the resistance or
(Open or being stuck) 0 0 0 output signal
Inspect the part after removal
Poor connection or Check the installation

looseness of connector 0 0 0 b. b. 0 0 0 0 condition
Malfunction of TCV
TCV 0 0 0 b. b. 0 0 0 0
(Open or being stuck)
Check the resistance or
output signal
TCV filter clogged
(O-ring tom) 0 0 0 b. b. 0 0 0 0
Bad output of CSP

sensor 0 0 0 0 0 0 0 0 0 0
CSP sensor Check the resistance or
output signal
Malfunction of CSP
sensor(open or short) 0 0 0 0 0 0 0 0 0
Bad output of GE coil 0 0 0 0 0 0 0 0 0 b. b.

GE Check the resistance or
actuator output signal
Malfunction of GE coil
(open or short)
0 0 0 0 0 0 0 0 0 b.
Check the resistance or

Malfunction of tuel 0 0 0 0 0 output signal
Fuel tempo tempo sensor
== sensor
f2
c. Bad output of sensor 0 0 b. 0 0 0
Check the characteristic 01
resistance lor tempo range
==
>
cn Compensation resistor
cn poor connection
0 0 0 b. b. 0 0 b. 0 Check the open or short
Ci) Compensation
0 resistor
~ Z Wrong resistor 0 0 0 b. b. 0 0 b. 0
Check the compensation
Cf)
~
resistor
0
z 18'"Ol C Np sensor Tightening torque :
~ 0
:::;: LI. (TDC sensor Bad installation noise 2.0-2.5kg·m
LL
w ...I is good) Compensation resistor
W
Ci cn
.....
~
C\I
U.I
~
oW Hard to Rough
Lackof Bad
powert return of Englne Much Much Knocklng Poor Impossible Sudden
ITEM black white and rise of Checkpoint
poor overrun fuel to stopthe
~
start Idling stop engine
Main cause accelera- smoke smoke vibrtlon economy englne
rpm rpm
o..... Np sensor
tion
(TDC sensor Malfunction of sensor Check the resistance and

:E (open or short) 0 !::.. output signal
w is good)
~
Cf)
Tightening torque:2.0-2.5kg·m
>
Cf)
Np sensor
Bad installation, noise 0 0 Check the output signal
(with faulty
..J TDC sensor)
W Malfunction of sensor Check the resistance and
::J (open or short) 0 output signal
U.
Bad installation and Tightening torque:O.7-0.9kg·m
output signal 0 0 0 !::.. !::.. 0 0 0 0 Check the output signal
TPS
Malfunction of sensor
0 0 0 !::.. !::.. 0 0 0 0 Check the resistance
(open or short)
Bad installation and Inspect the installation

output signal 0 !::.. !::.. !::.. condition
Boost sensor
Malfunction of sensor Check the output signal's
(open or short) 0 !::.. !::.. !::.. characteristic
TDC sensor Bad installation, noise

(with good Np Malfunction of sensor 0 0 0 0 0 0 0 Inspect the installation
sensor) (open or short) condition and fly wheel
TDC sensor Bad installation, noise Check the output signal's
(with faulty Np Malfunction of sensor 0 0 0 0 0 0 0 0 characterstic
sensor) (open or short)
Bad installation and Inspect the installation

output signal
0 0 !::.. 0 0 !::.. 0 !::.. condition
'ECTsensor
Malfunction of sensor Check the output signal's
(open or short) !::.. 0 !::.. 0 0 !::.. 0 !::.. characteristic
Bad installation and Check the output signal's

output signal
0 0 characteristic
VSP
Malfunction of sensor
(open or short) 0 0 Check the wiring harness
o
~ Malfunction of sensor Check the output signal's
APS sensor !::.. 0 0 0 0 0 0 0
<
..J
(open or short) characteristic
U.
.....
~
~
~
Lackof
u. Hard to Rough
Bad
powerl return of Engine Much Much Knocking Poor Impossible
Sudelen
ITEM rise of Checkpoint
IdUng poor black white and fuel to stopthe
start overrun stop engine
Main cause accelel'& smoke smoke vlbrtlon economy engine
Ilon rpm rpm
IDLE switch Check the resistance and

Open or short 0 0 b. 0 output signal
Bad installation and Tightening torque:2.0-2.5kg·m

Neutral switch output signal b. Check the output signal
(open and short)
Power system Check the resistance and

(open or short)
0 output signal
ECU
Bad output signal of
Tightening torque:O.7-0.9kg·m
PWM signal for TCM 0 0 Check the output signal
(open or short)
Bad output signal of
barometrie pressure 0 0 0 0 Check the resistance
sensor
ECU
Bad communication for Inspect the installation
IMMOB (open or short) 0 0 condition
T/C waste gate Check the output signal's

Malfunction (stuck) 0 0 0
(boost hose) characteristic
Glow relay Open or short 0 0 0 Inspect the installation

condition and fly wheel
Check the output signal's
EGR solenoid Being stuck,
valve bad operation 0 0 0 characterstic
NOTE
Abbreviation marked * are listed below.
Np : Injection pump speed sensor

CSP : Control sleeve position
FCV : Fuel cut valve
GE : Electronic governor
Tf : Fuel temperature sensor
APS : Acceleration position sensor
~ Tw : Water temperature sensor
CI)
o TCV : Timing control valve
z ECT : Engine coolant temperature
~
IMMOBI : Immobilizer
C
SELF-DIAGNOSIS PRECAUTIONS EFMB6815 CIRCUIT TESTER USE
. , WARNING • Turn the engine's key switch OFF when checking con-
tinuity or resistance.
The following definitions and warming signs are
used in this service manual. These are extremely
important to safe operation. Important points are & CAUTION
described to prevent bodily injury and property If the key switch is on when checking continuity
damage. They must be fully understood before or resistance, electrical components may be dam-
beginning COVEC-F self diagnosis system opera- aged.
tion.
& CAUTION
Improper maintenance can result in injury or Key switch
property damage.
MEANINGS OF MARKS
The tollowing marks are used in this service manual to ta-

cilitate correct COVEC-F self diagnosis system operation.
ADVICE
PCOVTOO2
Procedures that must be performed to enable the best pos-

• 00 not damage connector terminals when checking
sible COVEC-F seit diagnosis system operation.
continuity or resistance. 00 not push the tester pins
into the female terminals.
~NOTE
Information assisting in the best possible COVEC-F & CAUTION
seit diagnosis system operation.
New faults may arise if the connector terminals
PREPARATION are damaged.
Prepare the tollowing.
• Circuit tester
~NOTE
The eireuit tester is used during inspeetion proeedures
to eheek the eontinuity and resistanees of eaeh elee-
trieal eomponent.
Connector
terminals
PCOVTOO3
• Always reconnect connectors in their original posi-

tions after checking continuity or resistance.
Circuit tester
PCOVT001
DIAGNOSIS FLA -23
& CAUTION
New faults or improper operation may arise if con-
nectors are not remstalled in their original posi-
tions.
PCOVT004
SELF-DIAGNOSIS FROM FAllURE

MODE EFMB6820
The COVEC-F system includes a self-diagnosis system

wh ich alerts the operator to system malfunctions. The
control unit continually monitors the signals input fram
each sensor and the GE actuator for abnormal values.
FAllURE MODE TABLE
No. DTC No. CONTENTS - MIL

1 P0105 BAROMETRIC SENSOR-MAL. X
2 P0110 INT. AIR TEMP. CIRCUIT-MAL. X
3 P0115 ENG. COOLANT TEMP-MAL. 0
4 P0120 ACCEL P. SNSR-MAL. X
5 P0121 APS. RANGE/PERFORMANCE-MAL. 0
6 P0180 FUEL TEMP. SNSR. CIRCUIT-MAL. X
7 P0320 ENGINE SPEED INPUT CIRCUIT-MAL. X
8 P0335 CRANKSHAFT P. SN SR-MAL. X
9 P0500 VEHICLE SPEED SNSR-MAL. X
10 P0600 IMMOBILIZER COMMUNICATION-MAL. 0
11 P0605 CONTROL MODULE(EEPROM) ROM-MAL. X
12 P0613 ECU-MALFUNCTION X
13 P1116 BOOST PRESSURE SENSOR-MAL. 0
14 P1120 ELECTRIC GOVERNOR-MAL. 0
15 P1122 BOOST PRESSURE CONTROL VALVE-MAL. 0
16 P1123 TIMER POSITION SENSOR-MAL. X
17 P1127 CONTROL SLEEVE POSITION SNSR.-MAL. 0
18 P1131 INJECTION QUANTITY ADJUST-MAL. X
19 P1135 INJECTION TIMING SERVO-MAL. X
20 P1324 GLOW RELAY -MALFUNCTION 0
21 P1522 BATTERY VOLTAGE ERROR 0
22 P1525 5V SOURCE VOLTAGE X
23 P1621 FUEL CUT VALVE-MAL. 0
DIAGNOSIS FLA -25
Use the follwing chart to check the system when malfunc-

tions occur.
Advice
When the key switch In ON, leave each electrical component's connector connected.
USER COMPLAINT
Key switch ON
NO
Check the lamp.
YES NO
Determine the location of Determine the cause

the fault from the self- from the phenomenon
diagnosis table on page 2. table on page 3.
Check and correct in

Check and correct. accordance with phe-
nomen on.
EFMB682A
FLA -26 FU EL SYSTEM [COVEC-F 2.5]
INSPECTION OF PARTS EFMB6860
GE ACTUATOR
Advice
Turn the key switch OFF.
GE INSPECTION
Resistance incorrect
Resistance correct.
Replace with identical part No control unit. t-----------J~ System faulty.
System operating normal.
Faulty vehicle harness

Re-install original control unit Mechanical pump fault
EFMB686A
1. GE actuator terminals
Termi- Compo- 23456

Remarks
nal nent
7 8 9 101112
1 GE (-) GE (-)
2 TCV (+) Timing control valve (+)
3 CSP (+) Oscillate (+)
4 Adj (+) Adjustment resistor (+)
5 Adj (-) Adjustment resistor (-)
6 FCV Fuel Cut Valve
7 CSP (-) Oscillate (-) EFMB686B
8 TF (-) Fuel Temperature (-)

9 GE (+) GE (+)
10 TCV (-) Timing control valve (-)
11 CSP Neutral
12 TF (+) Fuel temperature (+)
DIAGNOSIS FLA -27
2. Check the GE actuator resistances.

• Reference values
Temperature
Terminal Resistance (0C)
1- 9 0.71 ±0.130 23
3 - 7 11.8 ± 0.60 23
3 - 11 5.9 ± 0.30 23
7 - 11 5.9 ± 0.30 23
345 6
9 101112
EFMB686C
EFMB6880
Advice
MgN INSPECTION
Check MgN tightness
Resistance correcl. Replace MgN
EFMB688A
1. Check MgN resistance.

• Reference Values
Temperature
Resistance (0) (OC) Remarks
8.6 ± 1.1 23 ± 10
EFMB688C
EFMB688B
2. Confirm that there is continuity between the MgN

body's earth (-) and the GE actuator connector ter-
minal no 6.
DIAGNOSIS FLA -29
EFMB6900
TCV (TIMING CONTROL VALVE)
Advice
TCV INSPECTION
Check TCV tightness
Resistance correct. ReplaceTCV
EFMB690A
1. Check MgN resistance. 3.Confirm that there is continuity between the GE actu-
ator connector terminal no 2 and no 10.
2. Check TCV resistance.
• Reference Values
Temperature
Resistance (0) (0C) Remarks
11.0 ± 0.7 20 ± 10
EFMB690C
EFMB690B
EFMB6920
NP SENSOR
Advice
Np SENSOR INSPECTION
Check Np sensor tightness
Resistance correct. Replace Np sensor
EFMB692A
1. Np sensor terminals. • Reference Values
Component Resistance Temperature

Terminal No Remarks Terminal No (OC)
wiring (kO)
1 SIGNAL Output 1- -2 1.65 ± 0.15 25 ± 5
2 GND
3 Blind plug 2.6V
EFMB692C
EFMB692B
2. Check Np sensor resistance.

DIAGNOSIS FLA -31
EFMB6940
TPS (TIMING POSITION SENSOR)
Advice
TPS INSPECTION
Check TPS tightness
Resistance correct. ReplaceTPS
EFMB694A
1. TPS terminals. • Reference Values
Component Resistance Temperature

Terminal No Remarks Terminal No (OC)
wiring (kSl)
1 OSC (+) Oscillate (+) 1 - - 3 82 ± 5.7 25 ± 10
2 - - 3 82 ± 5.7 25 ± 10
2 OSC (-) Oscillate (-)
3 MDL
EFMB694C
EFMB694B
2. Check TPS resistance.

EFMB6960
COMPENSATION RESISTOR
Advice
COMPENSATION RESISTOR
INSPECTION
Check compensation resistor

I tightness
I
Resistance correct. Replace compensation

resistor
EFMB696A
1. GE actuator terminals Compensation

Distinguishing
resistor (No, Part No.
No.
Compensation kO)
Distinguishing
resistor (No, Part No.
No. No12,8.20 956 146649-5600
kO)
No13, 15.0 957 146649-5700
N01,0.18 945 146649-4500
No2,0.30 946 146649-4600
N03,0.43 947 146649-4700
No4,0.62 948 146649-4800
N05,0.82 949 146649-4900
No6, 1.10 950 146649-5000
Compensation
No7, 1.50 951 146649-51 00 resistor
N08,2.00 952 146649-5200

No9,2.70 953 146649-5300
EFMB696B
No10, 3.90 954 146649-5400
No11, 5.60 955 146649-5500
DIA~NOSIS FLA -33
2. Measure the compensation resistance, referring to

the above table.
Resistance tolerance : ± 5%
EFMB696C
SCHEMATIC DIAGRAM EFMB6970
ENGINE CONTROL SYSTEM (1)
IGNITION
SWITCH
ENGINE
COMPARTMENT
FUSE&
RELAY
BOX
0.858/0
1.25BIW See Starting

System
------------------~
To Fuellnjection pump
2.0BIW on page SD-6
0.5BIW
2.0BIW 0.5BIW
To ECM on page SD-4

5
0.5BIW 0.5BIW
1 C45 2 C46
2.0R 2.0l./W 0.5UY 0.5Gr 0.5Y 0.5R 0.5BIW 2.0BIY
EFMB697A
DIAGNOSIS FLA -35
0.85B/0 - - - - - - - - - - - - TRANSMISSION 0.85B/0

I I RANGE
l~" I I
0.85B/0
0.85B/0
S"F~e
Box Details
I
--
1o
0.5GIY
1
r -----
---------
-JE62
:.L 0.5G
'SwrrCH
I
4 M20-1
- - - - - - - - - - - -. INSTRU-
IMENT
1 EE07 7 - - - - - - 5 EE 01 ,CLUSTER
0.5 G 0.5G/B I·
See Back-Up
I
Lamps
7 M20-2
0.5GIY 0.5Br
O.5Br/O 0.5Br
,,, Tachometer
I ... 'IDIODE
J
"
~
ZOg
0.5Br
See Indicato rs&
MC04
Gauges - - - -- 3 - - - -- 2
MIT
4rlEco4 IVT
0.5W 0.5Br 0.5BIY
0.5Br
6 C40-4 10 C40-3 9 _____ .§ C40-1
, - -
- - - - - - - - - - - - - - - - - -.~.~ -: - - - - - - .... - - - - - - - - -,7. -:.-:'" -:',- -7 ECM
~
I~tart ," " l l ; l C h o ! l l e t e r..•. ".GlOW IND. .' MILlNQ",.,.I
\ ~., ' .
...
" With IMMO: ICM .... . . . . . . '.,. '. . , ' ,
, WI01MMO: Diagnosis (K4ine) . .... . " Di,i!\gnosili{l:~fle) . " . J " · T C M .. ....,
-- - - - - - -o~~~I-;4~-1- - - - - - - ---- -:::;~fC~O~2-- - - - - -0-5~~1~4~-;"~ ...... ~
12 - - - - - - - - - - - - - - - 11 l MC04 4 1 MC04-1
With IMMO W/O IMMO

0.5G/0 0.5Gr/B 0.50
0.5UB
0.5UB 0.5Br 5 8 M51
DATA LINK CONNECTOR

See Ground
6 M51 Distribution
0.5B
8 9 M61 19 __ 1J M50
- - - - - IIMMOBILIZER
ICONTROL
0.85B
,
-'TCM
, , ,MODULE
• ,
'- - - - - - --' G01 --------,
EFMB697B
I HOT AT ALL TIMES I

, - - - .. ENGINE . . . . . . , - - - -...... ACCELERATOR
•.,".ikIlMI!!JI~' i;il.~' COMPARTMENT
1 0 4 · FUSE&
ccCi!
SENSOR
RELAY BOX
2 C42 0.5Y 0.5Gr 0.58 0.5G

5.0G
2.0Gr 0.5G
0.5GIL 0.5G/8
From Fuse (20A)

2.08 2.08 on page SD-2
0.58 0.58 0.581W 0.5G/B
A
AlC COMPRESSOR AlC

RELAY SWITCH
4 E17 E51
,- CONDENSER AlC ,', "' THERMO-
FAN PRESSURE ," STATIC
MAIN SWITCH SWITCH
RELAY
G20
EFMB697C
DIAGNOSIS FLA -37
4 C54 C53
~---------------~---------------~800STER ENGINE ,..-------------------------------..., TIMING
800ster Air PRESSURE COOLANT POSITION
pressure,,--_....____,temperature SENSOR TEMPERATURE SENSOR
sensor sensor SENSOR
,--- --'1 I----~
I
2 C53
1- 3 C51
0.58 0.58
2
-- - --
3 C54
0.5W 0.58 0.58 0.5W 0.5Lg
-T ----...,
I I
I I
"-----~~B ~ ~-------
See Vehicle
-- -----
0.5W 0.58 0.5W speed sensor
0.58 0.5W/Y ~ ~ ~ ~~;~-.- :~:r ~~B-I_-_-___-___~·.5~.~

... . - - - - O~:: CC04 0.58
l- I , ------ I
I
I
I I I
I
~
J. J.
0.5W/Y 0.5B/Y 0.58 0.58 0.5W/L 0.5G
1 _____ g ______ 3 C50 3 _____ .1 '<- _____ 2 C55

INJECTION :, ENGINE
- - - - - - - +e--..,.----'
I
PUMP
SPEED
SENSOR
'---------.. .-.+ -...; - - - - SPEED
f- SENSOR
I
G20
• 1////1 B @ 1\\\\1
,,'
•
G20
EFMB697D
>'OB"""""""'; FUEL
" INJECTION
PUMP
1.25W 1.25R 0.58r 0.58 0.58 0.5GNI
1.25W 1.25W 1.25R 1.25R 0.58
ECM
I I
I I From Fuse 11(10A)
- _. I I
L
on page SD-2
0.5R 0.5W 0.58 2.08
1.258N1
0.5R 0.5W 0.58

G20
"~'0·!Zl!l%_I8:l! FUEL
INJECTION
PUMP
EFMB697E
ACCELERATOR EGR2 TIMING EGRl
SENSOR SOLENOID POSITION SOLENOID
ENGINE 1- - - - -
TCM
- - - I
ICM
:iil-~-:
(SPEED) SENSOR (DUTY)
li1J
II!2I InII
rv rvfl'-
1~
- --- IMSO ')
CONTROL '-1i1161
SYSTEM '---
~II
IC'~ I C46 ;öl I ....
(COVEC-F)
C40-1
GLOW RELAY CONTROL
I",
0-
t-1--2-
AlC COMPRESSOR RELAY 0-
--L bw
EGR #1 SOLENOID
TCM
CONDENSER FAN MAIN RELAY
::::: IBIL~=
~~~~~~~l~~~~ ~
RELAY c~~t~&"
v-
GLQWIND.
IMI
POWEASOU
GODL
\
/ IL
C40-2
-~
,--~
r?
BATIERY VOLTAGEIGROj:
lI!lI
DIAGNOSIS(L-Line)
0-- --fß ~
C40-3
~
...nn
TACHOMETER <>- [--U.J ...f1Ol-
ENGINE SPEE~~~~~6 0 - -
INJECTION PUMP SPEED SIGNAL
GROUND
VEHICLE SPEED SENSOR 0- --.;
SEN~mS~~U~~~~r~ ~ HIf-<IT
ACCELERATOR SENSOR SIGNAL
-
SENSOR SOURCE
GROUND
BOOSTER SIGNAL 0- --fR
SENSOR GROUND
C40-4
GOVERNOR
BATTERY VOLTAGE{~ L...nf ri6

fENGINE COOlANT TEMPERATURE ~J~~JRSJ~~~ ~
AlC SWITCH
FUEL TEMPERATURE SENSOR
START SIGNAL
AIR TEMPERATURE SENSOR SIGNAL
0-- 7~
,-
FUEL QUANTITY ADJUST RESISTOR
IDLESWITCH
POWER SOURCE r:>f
0---
t-U-J
GLOW ~g~~RO~~~~~
AiC' POWERJ~JACE.
TIME CONTROL
FUELCUT u
,--
C40-1
111110 9 8 7 6 5 4 3 2 1 1
122121120119181716151413121
C4.Q.:2
n
6 543 2 11 1C46 1 Ic
'L
1211 10 9 8 7
C40-3 -j>:; -j> if; ;-
~ <;,. <;> 5\~~1 ~~
L1
n n
~I ___ [~~
8 7 6 5 432 1 -:.- '---
116115114113112111110191 G20 '------
~
GLOW DATA LINK POWERRELAY ENGINE 8001
PLUG CONNECTOR COOLANT PREll
TEMPERATURE SENIl
SENSOR
FLA-41
Rl INJECTION PUMP ENGINE SPEED

LENOID SPEED SENSOR SENSOR START TACHO
ITY) RELAY INSTRUMENT CLUSTER FILTER
-l :~~:
~-----------------.
:1];
'I
E09 M55
GLOW
FUSIBLE
( LINK l iGNITION
FUSIBLE
LINK
~II
VEHICLE
SPEED 80A 40A
SENSOR
2 C50 1 C55 ------ --- --- --~
:l1J: 11 M20-1 4 M20-1 7 M20-2 1 M20-1
ES7
---- :
:
~ ----
+-
I
T G20
)FUSE 11 BATTERY
=~==-~==t==+==~--_t--t_--t__t----.~ <1, 10A GROUND
J!\~l --+--l---t+=j~==j==t==;-II---I-:':--~:5J -~~:~2-

-r------t-
-----
TRANSMISSION:
j
E13
RANGE S/W ' r - - - - - -. Ale
L---.--4-------------------------'+-_4--+-4-~~-----------_4--~3~~---,
I
__ ____ iRELAY
, ,
5,
,_ _ _ _ _ _ J'
----r-1--~-r1-~----1---~-+--++-------------,
- CONDENSER
=-~=t==i=L!=-----~--~~==================1==f================~====i=====i=~--_+----t_t_-------.--------
+_1- -
f--
__________~E~'7~@]~FANMAIN '--'RELAY
-----·-----------------'cf------,~~~:v
4
C42
---
10 11 12 5 C57
M22
~
4 C54
:~@J:
lliD
AlC
SWITCH
GOVERNOR FUEL QUANTITY FUEL ro",,, """ I
POSITION SENSOR FUEL CUT
I
CONTROL
I M25 •
ELECTRIC ADJUST RESISTOR TEMPERATURE
SENSOR VALVE VALVE :~: -:-
L--- THERMOSTATIC G20
BOOS~~~: NETURAL FUEllNJECTION PUMP SWITCH
PRESSURE S/W
SENSOR
EFMB697F
Fuel System
[Gasoline 3.5]
GENERAL ................................................................. FL - 2
MFI CONTROL SYSTEM .•.•....•.•...••....•••....•••...••••....•••••.•• FL -20
FUEL DELIVERY SYSTEM ••..••••..••••...••••...••••...•••.•.•••.•..••• FL -78
TROUBLESHOOTING FOR DTC ..•••.•.••.....•••....•••.••.••••..•••••. FL ·88

FL-2 FUEL SYSTEM [GASOLINE 3.5]
GENERAL
SPECIFICATION EFMBOO10
Fuel tank
Capacity 75 lit.
Fuel filter
Type High pressure type
Fuel pump
Type Electrical, in-tank type
Driven by Electric motor
Throttle body
Throttle position sensor (TP Sensor)
Type Variable resistor type
Output voltage at curb idle 0.3 - 0.9V
Output voltage at WOT 4.5 - 5.0V
Idle speed control (ISC) motor

Type Step motor type
Resistance 28 - 320 at 20°C (68°F)
Idle position switch
Type Contact type (Built in TPS)
Input sensor
Mass air flow sensor
Type Hot film type -
Intake air temperature (IAT) sensor
Type Thermistor type
Resistance 2.33 - 2.97kO or 2.5 - 2.7V at 20°C (68°F)
0.31 - 0.43kO or 0.6 - 0.8V at 80°C (176°F)
Engine coolant temperature (ECT) sensor
Type. Thermistor type
Resistance 2.4kO or 2.5 - 2.7V at 20°C (68°F)
0.3kO or 0.5 - 0.7V at 80°C (176°F)
Heated oxygen sensor (H02S)
Type Zirconia sensor
Vehicle speed sensor
Type Hall IC type
Camshaft position (CMP) sensor
Type Hall effect sensor
Crankshaft position (CKP) sensor
Type Hall effect sensor
Output actuator
Injector
Type Electromagnetic type
Number 6
Coil resistance 13 - 160 at 20°C (68°F)
Fuel press ure regulator
Fuel pressure 320 - 340kPa (3.26 - 3.47kg/cm2 , 46 - 49 psi)
GENERAL FL -3
SEALANT EFBB0020
Engine coolant temperature sensor LOCTITE 962T or equivalent
SERVICE STANDARD EFMB0030
Actual ignition timing BTDC 5° ± 2°

Curb idle speed N-range AlCON: OFF 800 ± 100
AlCON:ON 800 ± 100
D-range AlCON: OFF 800 ± 100
AlCON:ON 800 ± 100
TIGHTENING TORQUE EFBB0040
Item Nm Kg.cm Ib.tt

Delivery pipe installation bolt 10 - 13 100 - 130 7-9
Engine coolant temperature sensor 20 - 40 200 - 400 14 - 29
Heated oxygen sensor 40 - 50 400 - 500 29 - 36
Heated oxygen sensor connector bracket bolt 8 - 12 80 - 120 5.8 - 8.7
Fuel pressure regulator installation bolt 7 - 11 70 - 110 5-8
High pressure hose and fuel main pipe 30 - 40 300 - 400 22 - 29
High pressure hose and fuel filter 25 - 35 250 - 350 18 - 25
High pressure hose to delivery pipe 3-4 30 - 40 2.2 - 3
Fuel pump assembly to fuel tank 2 - 3 20 - 30 1.4 - 2.2
High pressure hose at fuel tank 30 - 40 300 - 400 22 - 29
Throttle body to surge tank 10 - 13 100 - 130 7.2 - 9
Fuel tank drain plug 15 - 25 150 - 250 11 - 18
Fuel filter mounting bolts 9 - 14 90 - 140 6.5 - 10
Accelerator arm bracket bolts 8 - 12 80 - 120 5.8 - 8.7
ISC motor (stepper motor) 2.5 - 4.5 25 - 45 1.8 - 3.3
Fuel sender to fuel tank 2-3 20 - 30 1.4 - 2.2
Fl -4 FUEl SYSTEM [GASOLINE 3.5]
SPECIAL TOOlS EFA90050

09353-38000 Connection ot tuel pressure gauge
Fuel pressure gauge adapter to delivery pipe tor measurement
ot tuel pressure.
EFA9005A
09353-24100
Fuel pressure gauge & hose
EFA9005B
GENERAL FL -5
TROUBLESHOOTING EFA90060
When checking engine trouble, it is important to start with

an inspection of the basic systems. If one of the follow-
ing conditions exists, (A) engine start failure, (B) unstable
idling or (C) poor acceleration, begin by checking the fol-
lowing basic systems.
1. Power supply
• Battery
• Fusible link
• Fuse
2. Body ground
3. Fuel supply
• Fuelline
• Fuel filter
• Fuel pump
4. Ignition system
• Spark plug
• High-tension cable
• Ignition coil
5. Emission control system

• PCV system
• Vacuum leak
6. Others
• Ignition timing
• Idle speed
Trouble with the MFI system is often caused by poor con-

tact of the harness connectors. It is important to check all
harness connectors and verify that they are securely con-
nected.
FL -6 FUEL SYSTEM [GASOLINE 3.5]
TROUBLESHOOTING GUIDE CHART EFDA0070
~
STARTING Poor
Poor Idling
Unable to start Difficult to start Driving
Sub-Symptoms "Sc
.oC
CD
c
CD
c
CD
:g "'0
Q) "'0
Q)
fI)
CD
....
(/)
Q)Q) (/)(/)
(/) ·Öl ·Öl
ü)
Q) Q) 0)
N~
cQ) Q)C E c c 0. 0. .~ oe;,; cu
0> _0 CD CD ~ (/)
(/)
"'0 0 2-8 Ci> Q):.;::: Q) :§ CD~ 0)
._-
2 CD CD Q)
-(/) .c:~ C
Q)E .... Q» 0.:::1 Q) (/) .c: .sc_ ti :§ :2 .c:
0)
C :i2
C:::I Q)cO
1:::.- E.o C
.0, Ci> ~ ~:!2 CDO ~ .c:
0) CD2l>.
.50-':::: .~ 0
!: :::I
0)_ m 0) C oE
0 0 !: ~8 .c:.c: 0
c.> 0)
0 0)<110
:::I
0
C
Check points co
Wc
- C ....
Cf)Q)2 .so C>
Wo « :5: .!!l :5:.!!l E I 0
...J a: c~o
WOCl. Cf) ~
Starter relay 1
Starter 2 2 1
Park/Neutral SW [Aff] or
3
Clutch start SW [MIT]
Flywheel [MIT] or 4
Drive plate [Aff]
Mass air flow sensor circuit 3 3 10 7
Idle speed control actuator 4 3 3 3 3 3 2 7 2
Fuel pressure regulator 5 5 5 5 4 11 1
ECT sensor circuit 6 4 1 1 2 2 1 2 8 6
Compression 7 8 8 5
Piston rings 8 9 9
Ignition timing 10 11 14
Timing mark 9 12
Injectors 10 13 8 8 7 4 13 15 4
PCM 11 14 9 9 4 8 5 14 16 5
NC circuit 2 6
Connecting rod bearing 3
Crankshaft bearing 4
Fuel quality 1 2 2 1 3 3
Spark plugs 2 3 4 2
Fuel pump 6 6 6 5 12
Fuellines 7 7 7 6 13
Ignition circuit 2 11 3
Intake air tempo sensor circuit 12 4 4 4 9 1
Accelerator pedal link 1 1
TP Sensor circuit 5 6
Cylinder head 15
Clutch [MfT] 1
Brakes not releasing properly 2
Oxygen sensor circuit 10
Crankshaft position sensor 3
Battery voltage 1 1
EFDA007A
GENERAL FL -7
_ _-,Maln Symptoms
Engine Stalls Others Refuellng
Cl
c: z ~Q)
'E o äi
Sub-Symptoms
~ 2§ -E §
~
(1)+=0
>0. ~ ß
~c: Cl
C
0iij
Ul
Q)
E
::J
Ul
Q)
c Q)
c:
°C o c °Cl °Öl
Check points 8
cn
::J
Cl ~g W
c c:
w
Fuel quality
Fuel pressure regulator 2 4 2
Fuel pump 3
Fuellines 4 5
ISC actuator 5 2
MAF sensor circuit 6 2 13
ECT sensor circuit 7 11
Injectors 8 6 10
ECM 9 7 3 3 17
TP Sensor circuit 2 12
Sparkplug 3 6 8
AlC circuit 14
Fuelleakage
Accelerator pedal link 3
Clutch [MfT] 4
Brakes drag when pedal released 5
Compression 7
Piston ring 8
Ignition timing 9
Oxygen sensor circuit 15
Intake air tempo sensor circuit 16
Coolant leakage
Cooling fan 2
Thermo switch 3
Radiator and radiator cap 4 2
Thermostat 5
Timing belt 6
Engine coolant pump 7
Oilpump 9
Cylinder head 10
Cylinder block 11
ECTsender 12 3
Crankshaft position sensor 11 8 4 4
Fill vent valve hose-clogging
Canister fillter-Contamination 2
Fuel shut off valve-operation 3
EFDAOO7B
@)NOTE
The number herein means the check order.
MFI TROUBLESHOOTING
PROCEDURES EFA900BO
PROBLEM
Communieatlon with sean tool is not possible.

(Cannot eommunieate with any system)
Measure battery voltage at the data link Check the harness between the power
connector
NG ,
/
supply and data link connector, and
(Voltage between pin 9 and ground) repair if necessary.
OK
,1/
Measure at the data link connector Check the harness wire between the
• Continuity between pin 4 and ground
NG , data link connector and ground, and
/
• Continuity between pin 5 and ground repair if necessary
OK
'I'
NG
Use another the scan tool "
/ Faulty data link connector or wiring
OK
'I'
Repair Scan tool
EFA9008A
GENERAL Fl-9
SCAN TOOl COMMUNICATION WITH PCM

IS NOT POSSIBlE EFA90090
Comment Probable cause

One of the following causes may be suspected • Malfunction of PCM power supply circuit.
• No power supply to PCM • Malfunction of the PCM.
• Defective ground circuit of PCM • Open circuit between PCM and DLC.
• Defective PCM
• Improper communication line between
PCM and scan tool
ENGINE Will NOT START EFA90100
I NG ,
I Check electrical supply
I "
0 Battery
1. Connection
2. Specific gravity, charging system
3. Drive belt
4. Voltage
OK Fusible link
0
,/
I NG ,
I Check starting system
I "
0
0
Ignition switch
Starter relay
0 Starter
o Wiring
EFA9010A
DIFFICULT TO START (ENGINE

CRANKS) EFMBOll0
Check trouble codes

, Diagnostic trouble codes
/
Diagnostic
0 Using H I-SCAN PRO
trouble code
Normal codes
,/
Check tor vacuum leaks
, 0 Oil tiller cap
/
NG 0 Oil dipstic
0 Vacuum hose connections
0 PCV hose
OK 0 Hose between throttle body and
intake manitold
,/
Check ignition
, 0 High tension cables
/
0 Unplug injector connectors

NG 0 Ignition coil, ignition power
0 Check tor a strong spark by transistor
holding spark plug wire 8-10 mm 0 Spark plug
(0.30-0.39 in.) away trom the
engine block while cranking the
engine.
OK
'v
Continued on the
next page
EFA9011A
GENERAL FL -11
Check ignition timing

,
/ Diagnostic trouble codes
Diagnostic
800 ± 100 : (at N-range, AlC OFF) o Using HI-SCAN PRO
trouble code
OK
Check fuel supply to injector I----N-G---~ > 0 Oil filler cap

o Fuel in tank o Oil dipstick
o Fuel pressure o Vacuum hose connections
o PCV hose
OK
Check spark plugs

,
/ o High tension cables
NG
Standard: 1.0-1.1 mm o Ignition coil, ignition power
(0.039-0.043in.) transistor
o Check compression if necessary o Spark plug
OK
Check MFI electronic circuit

,
/ o Wiring connections
I NG o Power to PCM
1. Fusible links
2. Fuses
3. MFI control relay
o Engine coolant temperature sensor
o Intake air temperature sensor
o Injection signal circuit
1. Injector
2. PCM
o TP Sensor
o Air flow sensor
EFMB011B
ROUGH IDLE OR ENGINE STALLS EFMB0120
Check diagnostic trouble codes

, Read the diagnostic trouble codes
/
NG
0 Using HI-SCAN
OK
,/
Check for vacuum leaks

,
/ 0 Oil fillercap
NG
0 Oil dipstick
o Vacuum hose connections
0 PCV hose
0 Hose between throttle body and
OK intake manifold
,1/
Check fuel supply to injector
, 0 Fuel !ine (Ieakage, deformation)
/
NG
0 Fuel in tank 0 Fuses
0 Fuel pressure 0 Fuel pump
0 Fuel filter
OK 0 Fuel pressure regulator
,1/
Check air cleaner filter
, Clean or replace
I /1
NG
lOK
Check idle speed

,
NG /1 Adjust idle speed
800 ± 100 : (at N-range, AlC OFF)
OK
Check ignition timing: ,I Adjust idle timing

/
BTDC 5' ± 2' (at curb idle) NG
lOK
Check spark plugs

, 0 Check compression
NG '1
Standard: 1.0-1.1 mm (0.039-0.043 in.)
0 Check compression if necessary
o Compression
Limit: 12 kg/cm 2 (1.18 MPa, 171 psi)
[250-400 rpm]
lOK
Continued on the
next page
EFMB012A
GENERAL FL -13
From the previous page
1 I
I Check tuel pressure
I NG
,
.....
0
0
Fuel pump
Fuel filter
0 Fuel pressure regulator
OK
c-
'v
I
I Check injectors
I NG
,..... Injector condition
OK
,,,
I
I Check MFI electronic circuit
I NG
,.... 0
0
Wiring connections
Powerto PCM
1. Fusible links
2. Fuses
0 Engine coolant temperature sensor
0 Injection signal circuit
1. Injector wiring
2. PCM
EFA9012B
ENGINE HESITATES OR ACCELERATES

POORLY EFBB0130
I Check clutch or brakes I ,, o Slipping clutch

I NG 0 Dragging brakes
OK
'I'
I Check for vacuum leaks in intake air line ~
,, o Oil filler cap
NG o Oil dipstic
o Hose connections
OK 0 PCV hose
'I'
I Check air cleaner filter I
I NG
,
. '\1 Clean the filter or replace
OK
I
'I'
Check air cleaner filter I ,, Check for diagnostic trouble codes
I NG
o Using HI-SCAN
OK
'v
Continued on the
next page
EFA9013A
GENERAL FL -15
From the previous page
1 ,,
Check ignition 0 High tension cables
0 Unplug injector connectors
NG 0 Ignition coil
0 Check for a strong spark by holding
spark plug wire 8-10 mm
(0.31-0.39 in.) away from enging
block while cranking engine
lOK
Check ignition timing :
, Adjust idle timing
NG '1
BTDC 5° ± 2° (at curb idle)
OK
-J
Check fuel pressure
, 0 Fuel pump
/
NG 0 Fuel filter
OK 0 Fuel pressure regulator
Check injectors
'" ~
0 Injector condition
/1
NG
OK
Check spark plugs

'" , Check compression
/
Standard: 1.0-1.1 mm (0.039-0.043 in.)
NG
0 Check compression if necessary
o Compression
Limit: 12.0 kg/cm2 (1.18 MPa, 171 psi)
[250-400 rpm]
OK
w
Check MFI electronic circuit
I
,, 0 Wiring connections
NG 0 Powerto PCM
1. Fusible links
2. Fuses
0 Engine coolant temperature sensor
0 Injection signal circuit
1. Injector wiring
2. PCM
EFBB013B
TROUBLESHOOTING EFA90140
Trouble symptom Probable cause Remedy

Engine will not crank. Battery charge low Charge or replace battery
"
Battery cables loose, corroded or worn Repair or replace cables
Transaxle range switch taulty Adjust or replace switch
(Vehicle with automatic transaxle only)
Fusible link blown Replace fusible link
Starter motor taulty Repair starter motor
Ignition switch taulty Replace ignition switch
Engine cranks slowly Battery charge low Charge or replace battery
Starter motor taulty Repair starter motor
Starter keeps running Starter motor taulty Repair starter motor
Ignition switch taulty Replace ignition switch
Starter spins but engine Pinion gear teeth broken or starter Repair starter motor
will not crank motor taulty
Ring gear teeth broken Replace tlywheel ring gear or
torque converter
FUEL TANK AND FUEL L1NE EFA90150

Engine malfunctions due to Bent or kinked fuel pipe or hose Repair or replace
insufficient fuel supply
Clogged tuel pipe or hose Clean or replace.
Clogged fuel filter of in-tank fuel filter Replace
Water in tuel filter Replace the fuel filter or clean the
tuel tank and fuel lines
Dirty or rusted fuel tank interior Clean or replace
Maltunctioning tuel pump Replace
(clogged tilter in the pump)
Evaporative emission system Incorrect routing of a vapor line Correct
malfunction (when fuel filler cap
Disconnected vapor line Correct
is removed, pressure is released)
Folded, bent, cracked or clogged vapor line Replace
Faulty fuel tank cap Replace
Maltunctioning overfill limiter Replace
(two-way valve)
GENERAL FL -17
MULTIPORT FUEL INJECTION (MFI) EFBB0160 IGNITION TIMING CONTROL
GENERAL INFORMATION The ignition power transistor located in the ignition primary
circuit turns ON and OFF to control the primary current
The Multiport Fuel Injection System consists ot sensors tlow to the ignition coi!. This controls the ignition timing in
which detect the engine conditions, the POWERTRAIN order to provide the optimum ignition timing with respect to
CONTROL MODULE (PCM) which controls the system the engine operating conditions. The ignition timing is de-
based on signals trom these sensors, and actuators which termined by the PCM trom the engine speed, intake air vol-
operate under the control ot the PCM. The PCM carries urne, engine coolant temperature and atmospheric pres-
out activities such as tue I injection control, idle air con- sure.
trol and ignition timing contro!. In addition, the PCM is
Tp
equipped with several diagnostic test modes which sim- (msec)
plify troubleshooting when a problem occurs. .....-+--+-
1.75 ~.-....-.......-
.r:
~
A
1.50 t----._-+-.....- .....- ....
FUEL INJECTION CONTROL
3l
~ 1.25 ~---.-.......- .....-+--+-
The injector drive times and injector timing are controlled c:
so that the optimum air/tuel mixture is supplied to the en- ~ 1.00 f---'---+--+-+--+-
gine to correspond to the continually-changing engine op- :E' 0.75 ~---._-+- .....- .....- ....
eration conditions. A single injector is mounted at the in- L--.l._--'-_-L.._-'-_.L.....;_ N
take port ot each cylinder. Fuel is sent under pressure 600 1,000 1,400 1,800 2,200
trom the tuel tank by the tuel pump. with the pressure be- Engine speed (rpm)
ing regulated by the tuel pressure regulator. The tuel thus EFJB016C
regulated is distributed to each ot the injectors. This is
called multiport. Fuel injection is normally carried out on ce
tor each cylinder for every two rotations ot the crankshaft. OTHER CONTROL FUNCTIONS EFA90170
The PCM provides a richer air/tuel mixture by carrying out

"open-Ioop" control when the engine is cold or operating 1. Fuel Pump Control :
under high load conditions in order to maintain engine per- Turns the fuel pump relay ON so that current is sup-
tormance. In addition, when the engine is warm or operat- plied to the tue I pump while the engine is cranking or
ing under normal conditions, the PCM controls the air/tuel running.
mixture by using the heated oxygen sensor signal to carry 2. AlC Compressor Clutch Relay Control :
out "closed-Ioop" control in order to obtain the theoretical Turns the compressor clutch of the AlC ON and OFF.
air/tuel mixture ratio that provides the maximum cleaning 3. Fan Relay Control :
performance trom the three way catalyst. The radiator tan and condenser tan speeds are con-
trolled in response to the engine coolant temperature
IDLE SPEED CONTROL and vehicle speed.
4. Evaporative Emission Purge Control (Reter to
The idle speed is kept at the optimum speed by controlling GROUP EC).
the amount ot air that bypasses the throttle valve in accor-
dance with changes in idling conditions and engine load
du ring idling. The PCM drives the idle speed control (ISC) DIAGNOSTIC TEST MODE EFA90180
motor to keep the engine running at the pre-set idle target

speed in accordance with the engine coolant temperature • When an abnormality is detected in one ot the sensors
and air conditioning load. In addition, when the air condi- or actuators related to emission control, the CHECK
tioning switch is turned off and on while the engine is idling, ENGINE/MALFUNCTION INDICATOR LAMP iIIumi-
the ISC motor operates to adjust the throttle valve bypass nates as a warning to the driver.
air amount in accordance with the engine load conditions • When an abnormality is detected in one of the sensors
in order to avoid tluctuations in the engine speed. or actuators, a diagnostic trouble code corresponding
to the abnormality is output.
• The RAM data inside the ECM that is related to the
sensors and actuators can be read by means ot the
scan too!. In addition, the actuators can be controlled
under certain circumstances.
HOW TO COPE WITH INTERMITTENT the present time, but a momentary shortage has probably
caused the fuse to blow.
MALFUNCTIONS EFA90190
The main causes of a short circuit are the following.
Most intermittent malfunctions occur under certain condi-
tions. If those conditions can be identified, the cause will • Harness being crushed by the vehicle body.
be easier to find. • Damage to the outer casing of the harness due to
TO COPE WITH INTERMITTENT MALFUNCTION: wear or heat.
• Water getting into the connector or circuitry.
1. Ask the customer about the malfunction. • Human error (mistakenly shorting a circuit, etc.).
Ask what it feels like, what it sounds like, etc. Then
ask about driving conditions, weather, frequency of INSPECTING THE MFI SYSTEM EFBB0210
occurrence, and so on.
2. Determine the conditions from the customer's re- If the MFI system components (sensors, PCM, injector,
sponses. etc.) faU, the interruption or failure to supply the proper
Typically, almost all intermittent malfunctions occur amount of fuel for various engine operating eonditions will
from conditions like vibration, temperature and/or result. The following situations may be eneountered:
moisture change, poor connections. From the cus-
tomer's replies, it should be deduced which condition 1. Engine is hard to start or does not start at all
exists. . 2. Unstable idle
3. Use the simulation test 3. Poor driveability
In the cases of vibration or poor connections, use the
simulation tests below to attempt to duplicate the cus-
If any of the above conditions is noted, first check for trou-
tomer's complaint. Determine the most likely circuit(s)
ble codes and make basic engine checks (ignition system
and perform the simulation tests on the connectors
malfunction, incorrect engine adjustment, ete.). Then, in-
and parts of that circuit(s). Be sure to use the inspec-
speet the MFI system components.
tion procedures provided for diagnostic trouble codes
and trouble symptoms. For temperature andlor mois- ON-BOARD DIAGNOSTICS
ture conditions related intermittent malfunctions, us-
ing common sense, try to change the conditions of • Diagnostic trouble codes are set as folIows:
the suspected circuit components, then use the sim- After the PCM first detects a malfunetion, a diagnostie
ulation tests below. trouble code is recorded when the engine is restarted
4. Verify that the intermittent malfunction is eliminated. and the same malfunction is re-detected. (The mal-
Repair the malfunctioning part and try to duplicate function is detected in driving cycle). However, forfuel
the condition(s) again to verify that the intermittent system rich/lean misfiring, a diagnostic trouble code
malfunction has been eliminated. is recorded on the first detection of the malfunction.
• Erasing diagnostic trouble codes:
SIMULATION TESTS After recording the diagnostic trouble code, if the PCM
does not re-detect the malfunction for 40 driving ey-
For these simulation tests, shake, then gently bend, pull eies, the diagnostic trouble code will be erased from
and twist the wiring of each of these examples to duplicate the PCM memory. However, for fuel system richllean
the intermittent malfunction. or misfiring, the diagnostic trouble code will be erased
if both of the following conditions are met:
• Shake the connector up-and-down, right-and-Ieft. When driving conditions (engine speed, engine
• Shake the wiring harness up-and-down, right-and- coolant temperature, etc.) are identical to those
left. when the malfunction was first recorded.
• Vibrate the part or sensor. When the PCM does not re-detect the malfune-
tion tor 80 driving cycles.
SERVICE POINTS IN INSPECTING A
BLOWN FUSE EFAA0200 ~NOTE
A "driving eyele" is eomplete as soon as the vehiele
Remove the fuse and measure the resistance between the goes into elosed-Ioop operation.
load side of the fuse and ground. Set the switches of all
circuits which are connected to this fuse to a condition MALFUNCTION INDICATOR LIGHT (MIL)
of continuity. If the resistance is almost on at this time,
there is a short somewhere between these switches and The MIL lights up to notity the driver that there is a problem
the load. If the resistance is not on, there is no short at with the vehicle.
GENERAL FL-19
However the MIL will go off automatically after 3 subse- SELF-DIAGNOSIS

quent sequential driving cycles that do not redetected the
same malfunctions. The PCM monitors the inpuVoutput signals (some signals
at all times and others under specified conditions). When
Immediately afterthe ignition switch is turned on, the MIL is the PCM detects an irregularity, it memorizes the diagnos-
lit for 5 seconds to indicate that the light operates normally. tic trouble code, and outputs the signal to the self-diagno-
sis output terminal. The diagnosis results can be read by
The following Items can be indicated by the MIL: a Generic Scan Tool (GST) or Hi-Scan Pro. A diagnostic
trouble code (DTC) will remain in the PCM as long as bat-
• Catalyst tery power is maintained. The diagnostic trouble code will
• Fuel system however be erased when the battery terminal or the pow-
• Air flow sensor (MAF sensor) ertrain control module (PCM) connector is disconnected
• Intake Air Temperature Sensor (IAT sensor) or erased using the Generic Scan Tool.
• Engine Coolant Temperature Sensor (ECT sensor)
• Throttle Position Sensor (TPS) CHECKING PROCEDURE (SELF-DIAGNOSIS)
• Front Oxygen Sensor
• Rear Oxygen Sensor Heater ~NOTE
• Rear Oxygen Sensor
• Front Oxygen Sensor Heater 1. When battery va/tage is excessively low, diag-
• Injector nostic trouble codes can not be read. Be sure
• Misfire
to check the battery for valtage and the charging
• Crankshaft Position Sensor (CKP sensor) system before starting the test.
• Camshaft Position Sensor (CMP sensor) 2. Codes are erased If the battery or the PCM con-
• Evaporative Emission Control System nector is disconnected. Do not disconnect the
• Vehicle Speed Sensor (VSS) battery betore the diagnostic trouble codes are
• Idle Speed Control completely read and recorded.
• PCM
• Manifold Absolute Pressure (MAP) Sensor Inspectlon Procedure (Uslng Generle Scan Tool)
• Idle Switch
1. Turn OFF the ignition switch.
• EGR System
2. Connect the scan tool to the data link connector on
the lower crash pad.
3. Turn ON the ignition switch.
4. Use the Hi-Scan Pro to check the diagnostic trouble
code.
5. Repair the taulty part trom the diagnosis chart.
6. Erase the diagnostic trouble code.
7. Disconnect the Hi-Scan Pro.
Malfunction indicator light
EFA9021A
INSPECTING THE MALFUNCTION INDICATOR

LAMP (MIL)
1. After turning the ignition key on, check that the light
illuminates for 5 seconds without the engine running. Cruise AirBag L-line.
2. If the light does not iIIuminate, check for an open cir-
cuit in the harness, blown fuse and blown bulb. EFHA021B
MFI CONTROL SYSTEM

TROUBLESHOOTING EFMB0220
DIAGNOSTIC TROUBLESHOOTING FLOW
I Gather information from customer.

I
.... /
l Verify complaint
J
Several reoccurances One time only
.. v .... /
Check for diagnostic trouble codes. Check for diagnostic trouble codes.
Diagnostic trouble code Diagnostic trouble code No code
No code or .. v .. v
communication Record the diagnostic trouble code,
with scan tool then erase the code.
not possible
,I.- .. v
Refer to the MFI TROU- Try to reproduce the symptom. I No symptom
I I
BLESHOOTING PROCE-
DURES
Reproduced
.. v .... /
Read the diagnostic trouble codes. OK
Diagnostic trouble Diagnostic trouble

code displayed code displayed
.... / "I.- 'v

Refer to the INSPECTION CHART INTERM ITTENT MALFUNCTIONS
FOR DIAGNOSTIC TROUBLE CODES (Refer to FL-18 How to Co pe with
(FL-21) Intermittent Malfunctions)
EFMB022A
MFI CONTROL SYSTEM FL-21
INSPECTION CHART FOR DIAGNOSTIC

TROUBLE CODES EFMB0240
DTC NO. CONTENT EOBD NON-EOBD

P0101 Mass or Volume Air Flow Circuit Range/Performance Problem 0 -
P0100 Mass or Volume Air Flow Sensor Malfunction - 0
P0102 Mass or Volume Air Flow Circuit Low Voltage 0 -
P0103 Mass or Volume Air Flow Circuit High Voltage 0 -
P0110 Intake Air Temp. Sensor Malfunction - ~
P0112 Intake Air Temp. Circuit Low Voltage 0 -

P0113 Intake Air Temp. Circuit High Voltage 0 -
P0115 Engine Coolant Temp. Circuit Malfunction (open/short) 0 0
P0116 Engine Coolant Temp. Circuit Drift 0 -
P0120 Throttle Position Sensor Malfunction - ~
P0122 Throttle Position Sensor Circuit Low Voltage 0 -

P0123 Throttle Position Sensor Circuit High Voltage 0 -
P0125 Excessive Time to Enter Closed Loop Control (ECT sensor) 0 -
P0130 Oxygen Sensor Malfunction (Bank 1) - 0
P0132 Oxygen Sensor Circuit Malfunction - Open (Bank 1, Sensor 1) 0 -
Oxygen Sensor Circuit Malfunction - Response
P0133
rate (Bank 1, Sensor 1)
0 - ,~
P0134 Oxygen Sensor Circuit Malfunction - No Activity (Bank 1 , Sensor 1) 0 -

P0135 Oxygen Sensor Heater Circuit Malfunction (Bank 1, Sensor 1) 0 -
P0140 Oxygen Sensor Circuit Malfunction - Short (Bank 1, Sensor 2) 0 -
P0141 Oxygen Sensor Heater Circuit Malfunction (Bank 1, Sensor 2) 0 -
Oxygen Sensor Circuit Malfunction - Response
P0150
rate (Bank 2, Sensor 1)
0 0

P0154 Oxygen Sensor Circuit Malfunction - No Activity (Bank 2, Sensor 1) 0 -
Oxygen Sensor Circuit Malfunction - Heater open/short
P0155
(Bank 2, Sensor 1)
0 -
P0160 Oxygen Sensor Circuit Malfunction - Short (Bank 2, Sensor 2) 0 -
Oxygen Sensor Circuit Malfunction - Heater open/short
P0161
(Bank 2, Sensor 2)
0 -
P0171 Fuel System Too Lean - (Bank 1) 0 -
PO 172 Fuel System Too Rich - (Bank 1) 0 -
P0174 Fuel System Too Lean - (Bank 2) 0 -
P0175 Fuel System Too Rich - (Bank 2) 0 -
P0201 Injector Circuit Malfunction (Injector -1) 0 ~
DTC NO. CONTENT EOBD NON-EOBD

P0300 Random Misfire Detected 0 -

P0301 Misfire Detected (Cylinder -1) 0 -
P0325 Knock Sensor Circuit Malfunction ~ ~
P0335 Crankshaft Position Sensor Circuit Malfunction 0 ~
P0340 Camshaft Position Sensor Circuit Malfunction 0 ~
P0350 Ignition Coil Malfunction 0 ~
P0320 Ignition Failure Sensor Malfunction ~ -

P0421 Warm-up Catalyst Efficiency Below Threshold - (Bank 1) 0 -
P0431 Warm-up Catalyst Efficiency Below Threshold - (Bank 2) 0 0
P0443 Purge Control Solenoid Valve Malfunction 0 0
P0500 Vehicle Speed Sensor Malfunction 0 ~
P0506 Idle Speed Control RPM Lower Than Expected 0 -

P050? Idle Speed Contra I RPM Higher Than Expected 0 -
P0510 Idle Switch Malfunction 0 -
P1330 Spark Timing Adjust Malfunction 0 ~
~NOTE
"0" means DTC and MIL-ON.
"Ll" means only DTC-ON.
"-" means not applicable.
MFI CONTROL SYSTEM FL -23
TROUBLE AREA RELATED TO DTC EFMB0250
~NOTE
Check items tor each diagnostic items do not list a/l possible causes.
DTC No. Diagnostic items Check items (Remedy) Memory MIL*

P0100 Mass Air Flow Circuit • Open or short in mass air flow sensor circuit
Malfunction • Mass air flow sensor 0 0
• PCM
P0110 Intake Air Temperature • Harness and connector
Circuit Malfunction • Intake air temperature sensor
• Open or short in intake air temp. sensor circuit 0 -
• Intake air temp. sensor
• PCM
P0115 Engine Coolant Temperature • Harness and connector
Circuit Malfunction • Engine coolant temperature sensor
• Open or short in engine coolant temp. 0 0
sensor circuit
• PCM
P0120 Throttle Position Circuit • Harness and connector
Malfunction • Throttle position sensor
• Idle switch 0 -
• Open or short in throttle position sensor circuit
• PCM
P0130 Oxygen Sensor Circuit • Harness and connector
Malfunction (Bank 1 • Oxygen sensor 0 0
Sensor 1)
P0136 Oxygen Sensor Circuit • Harness and connector
Malfunction (Bank 1 • Oxygen sensor (rear) 0 0
Sensor 2)
P0201 Injector Circuit Malfunction • Harness and connector
- Cylinder 1
0 0
• Injector
P0202 Injector Circuit Malfunction
- Cylinder 2
0 0

- Cylinder 3
0 0

- Cylinder 4
0 0

- Cylinder 5
0 0

0 0
- Cylinder 6
P0220 TPS 2 (Sub) tor ETS • Harness and connector
Malfunction • Throttle position sensor
0 0
• Open or short in TPS circuit
• PCM
P0325 Knock Sensor 1 Circuit • Open or short between knock sensor
Maltunetion and PCM
0 0
• Harness and connector
• Knock sensor
DTC No. Diagnostic items Check items (Remedy) Memory MIL*

P0335 Crankshaft Position Sensor • Harness and connector
Circuit Malfunction • Open or short in crankshaft position sensor
0 0
I • Crankshaft position sensor
• PCM
P0340 Camshaft Position Sensor • Harness and connector (lf harness and
Circuit Malfunction connector are normal replace camshaft 0 0
position sensor)
P0350 Ignition Primary/Secondary • Harness and connector
Circuit Maltunction • Bad connection between PCM and
0 0
spark plugs
• Bad ignition system
P0500 Vehicle Speed Sensor • Harness and connector
0 0
Maltunction • Vehicle speed sensor
P1330 Spark Timing Adjust Signal • PCM maltunction
0 0
• Harness and connector
~NOTE
.. 0 : MIL(Malfunction Indication Lamp) lights up.
Inspec- Refer-
Inspection Normal
Inspection contents tion pro- ence
Item condition
cedure page
Heated Engine: Warm When at 4,000 r/min, 200m V or less P0130 -
oxygen (Air/tuel mixture is made engine is suddenly
sensor leaner when decelerating, decelerated
(tront) and is made richer when
When engine is 600-1,000mV
racing.)
suddenly raced
Engine: Warm Engine is idling 400mV or less
(The heated oxygen sensor
2,500 r/min
<=> 600-1,000mV
signal is used to check the (Changes)
air/tuel mixture ratio, and
control condition is also
checked by the PCM.)
Mass airtlow • Engine coolant Engine is idling 0-2V - -
sensor *1 temperature: 80-90°C
3,000 r/min 2-4V
(176-203°F)
• Lights, electric cooling Engine is idling Voltage increases
tan and all accessories: in respones to
OFF racing
• Transaxle:
Neutral (AlT: Prange)
MFICONTROLSYSTEM FL-25
Inspec- Refer-
Inspection Normal
item condition
cedure page
Intake air Ignition switch: ON or with When intake air -20oe (-4°F) P0110 -
temperature engine running temperature is -20oe
sensor (-4°F)
When intake air ooe (32°F)
temperature is ooe 3.4-3.6V
(32°F)
When intake air 200 e (68°F)
temperature is 200 e 2.5-2.7V
(68°F)
(104°F)
(176°F)
Throttle Ignition switch: ON Set to idle position 300-900mV P0120 -
position (6-20%)
sensor
Gradually open Increases in
proportion to
throttle opening
angle
Open fully 4500-5000mV
(80-100%)
Power Ignition switch: ON Battery positive - -
supply voltage
voltage
eranking Ignition switch: ON Engine: Stopped OFF - -
signal
Engine: eranking ON
(Ignition
switch-ST)
Engine Ignition switch: When engine coolant -20 oe (-4°F) P0115 -
coolant ON or with engine running temperature is -20oe
temperature (-4°F)
sensor
When engine coolant ooe (32°F)
temperature is ooe 3.4-3.6V
(32°F)
When engine coolant 200 e (68°F)
(68°F)
When engine coolant 400 e (104°F)
(104°F)
When engine coolant 80 0 e (176°F)
(176°F)
Inspec- Refer-
Inspection Normal
item condition
cedure page
Crankshaft • Engine: Cranking Compare the rpm of the Identical P0335 -
position • Tachometer: Connected tachometer with the one
sensor of the scan tool.
• Engine: Idling When engine coolant 1300-1500r/min
• Idle position switch: ON temperature is -20°C
(-4°F)
When engine coolant 1300-1500r/min
temperature is O°C
(32°F)
temperature is 20°C
(68°F)
(104°F)
(176°F)
Vehicle Drive at 40 km/h (25 miles/h) Approx. 40 km/h P050 -
speed
sensor
Idle position Ignition switch: ON Check Throttle valve: Set to ON P051 0 -
switch by operating accelerator idle position
pedal repeatedly
Throttle valve: Slightly OFF *4
open
AlC switch Engine: Idling (When AlC switch: OFF OFF - -
AlC switch is ON, AlC
AlC switch: ON ON
compressor should be
operating.)
Park/Neutral Ignition switch: ON P or N P or N - -
position
D, 2, L or R D,2, L or R
switch <AT>
Injectors *2 Engine: Cranking When engine coolant 13.8-20.6ms - -
temperature is O°C
(32°F) (Injection
is carried out
for all cylinders
simultaneously)
When engine coolant 34-51ms
(68°F)
When engine coolant 8.8-13.2ms
(176°F)
Inspec- Refer-
Inspection Normal
Item condltlon
cedure page
Injectors *3 • Engine coolant Engine is idling 2.6-3.8ms
temperature: 80-95°C
2,500 r/min 2.3-3.5ms
(176-203°F)
• Lights, electric cooling When engine is Increases
fan and all accessories: suddenly raced
OFF
• Transaxle: Neutral
(AlT : Prange)
Ignition coils • Engine: After having Engine is idling 7-23° BTDC - -
and ignition warmed up
2,500 r/min 27-47° BTDC
power • Timing light is set.
transistors (The timing light is set
in order to check actual
ignition timing.)
AlC Engine: After having warmed AlC switch: OFF OFF (Compressor - -
compressor up/Engine is idling clutch is not
clutch relay operating)
AlC switch: ON ON (Compressor
clutch is
operating)
Heated • Transaxle: 3,500 r/min 600-1 ,000mV P0136 -
oxygen 2nd gear <MIT>
sensor (rear) L range <AlT>
• Drive with wide open
throttle
~NOTE
1. In a new vehicle [driven approximately 500km
(300mile) or less], the mass air f10w sensor out-
put voltage is sometimes 10% higher than the
standard voltage.
2. The injector drive time represents the time when
the cranking speed is at 250 rlmin or below when
the power supply voltage is 11 V.
3. In a new vehicle [driven approximately 500km
(300mile) or less], the injector drive time is some-
times 10% longer than the standard time.
4. The idle position switch normally turns off when
the voltage of the throttle position sensor is
50-100mV higher than the voltage at the idle
position. If the idle position switch turns back
on after the throttle position sensor voltage
has risen by 100m V and the throttle valve has
opened, the idle position switch and the throttle
position sensor need to be adjusted.
ACTUATOR TEST REFERENCE

TABLE EFBB0260
Inspec-
Drive Reference
Inspection item Inspection contents Normal condition ti on pro-
contents page
cedure
Injectors Cut fuel to NO.1 Engine: Warm, idle Idle speed drops Code No. -
injector (Cut the fuel supply to equally for each P0201,
each injector in turn and injector P0202,
Cut fuel to NO.2
check cylinders wh ich don't P0203,
injector
affect idling.) P0204,
Cut fuel to NO.3 P0205,
injector P0206,
Cut fuel to NO.4
injector
Cut fuel to NO.5
injector
Cut fuel to NO.6
injector
Fuel pump Fuel pump • Engine: Pinch the Pulse is feit. - -
operates and fuel Cranking return hose
is recirculated. • Fuel pump: with fingers
Activated to feel the
pulse of the
Inspect fuel being
according to recirculated.
both the above
Listen near Sound of operation
conditions
the fuel tank is heard
for the sound
of fuel pump
operation.
Evaporative Solenoid valve Ignition switch: ON Clicks when P0443 -
emission turns trom OFF solenoid valve
purge to ON. is driven.
solenoid
Radiator fan Drive the fan Ignition switch: ON Fan motor - -
(Hi) motors (radiator AlC switch: ON operates at high
Condenser and condenser). speed.
fan (Hi)
Radiator fan Drive the fan Ignition switch: ON Fan motor - -
(Hi) motors (radiator AlC switch: ON operates at low
Condenser and condenser). speed.
fan (Low)
CHECK AT THE POWER-TRAIN CONTROL • Checks don't have to be carried out in the order
given in the chart.
MODULE (PCM) EFMB0270
TERMINAL VOLTAGE CHECK CHART & CAUTION
1. Connect a needle-nosed wire probe (paper clip etc.) Short-eireuiting the positive(+) probe between s
to a voltmeter probe. eonneetor terminal and ground eould dsmsge the
2. Insert the needle-nosed wire probe into each ot the vehiele wiring, the sensor, PCM, or sll three. Use
PCM connector terminals trom the wire side, and esre to prevent this!
measure the voltage while reterring to the check
4. It voltmeter shows any deviation trom standard value,
chart.
check the corresponding sensor, actuator and related
electrical wiring, then repair or replace.
~NOTE 5. After repair or replacement, rech eck with the volt-
• Measure voltage with the PCM connectors con- meter to contirm that the repair has corrected the
nected. problem.
• You may find it convenient to pull out the PCM to
make it easier to reach the connector terminals.
POWER-TRAIN CONTROL MODULE (PCM) CONNECTOR TERMINAL ARRANGEMENT
r-r-
1 2
r-r-
3 4
- r- -r-
5 6
-r-
7 8
r-r--
1 2 3
r- r- r--r-
456 1 2 3 4
r- r- r-r--
567
r-r-
1 2
r--
3 4
r- r- r-r-r-
5 6 7
9 1~ 11 1213 141E 1617 1e 19 ~ 121 22 123 7 8 9 1~ 1112 1314 1516 17 8 9 1~ 11 l;o!13 1415 lE 17 1815 8 9 1011 1213 1415 1617 1819 ~
[24 25 ~ 3132 ~ 35
34 1 181~ ~ 121 fl2~ 2425 rze ~~1 22~3 24 12s25 2725 21 ~ 23 24~ 25~7 ~ ~~
~- -'-- '--'-- --'-- -'-- '-- -- '-'-- -'- '-'-
I+-!.- - - E200-1----l.! I-!.- - E200-2 ----1.!I-!-- - E2OO-3 --1·111--- - E200-4 ---t.!
EFMB027A
Terminal
Check item Check condition (Engine condition) Normal conditlon
No.
E200-1 (1) No. 1 injector • Engine: Warm, idle From 11-14V,
• Suddenly depress the accelerator pedal momentarily drops
E200-1 (9) No. 2 injector
slightly
E200-1 No. 3 injector
(24)
E200-1 (2) No. 4 injector
(10)
(25)
E200-1 (6) EGR solenoid Ignition switch: ON B+
• Engine: Idle From B+, momentarily
• Suddenly depress the accelerator pedal. drops
E200-1 Fuel pump relay Ignition switch: ON B+
(20)
Engine: Idle 0-0.5V
E200-1 Evaporative Engine: Warm, 3000 r/min Low: 0-1V
(34) emission purge High: B+
solenoid
Terminal
Check item Check condition (Engine condition) Normal condition
No.
E200-1 IG COll 1/4 Engine: 3000 r/min Lew: 0-0.1V
(11 ) High: 0.5-3V
E200-1 IG COll 2/5
(12)
E200-1 IG COll 3/6
(13)
E200-2 (1) Power supply Ignition switch: ON B+
E200-2 (7)
E200-1 Fan motor relay Radiator fan is not operating [Engine coolant B+
(17) (High) temperature is 90°C (194°F) or less]
Radiator fan is not operating at high speed [Engine 0-1V
coolant temperature is 105°C (221°F) or more]
E200-1 Fan motor relay Radiator fan is not operating [Engine coolant B+
(18) (low) temperature is 90°C (194°F) or less]
Radiator fan is not operating at low speed [Engine 0-1V
coolant temperature is 90-105°C (194-221°F) or more]
E200-1 AlC compressor • Engine: Idle B+ or momentarily
(21) clutch relay • AlC switch: OFF -? ON 6V or more-? 0-3V as
(AiC compressor is operating) AlC clutch cycles
E200-2 (3) Engine ignition Engine: Idle Lew: O-O.5V
detect signal High: 4.5-5V
E200-1 (8) Generator G • Engine: Warm, idle (radiator fan: OFF) Lew: 0-1V
terminal • Headlight: OFF -? ON High: 2-3V
• Rear defogger switch: OFF -? ON
• Stop light: OFF -? ON
E200-2 Generator FR • Engine: Warm, idle (radiator fan: OFF) Voltage falls by
(14) terminal • Headlight: OFF -? ON O.2-3.5V
• Rear defogger switch: OFF -? ON
• Stop light: OFF -? ON
E200-1 Check engine/ Ignition switch: OFF -? ON 0-3V -? 9-13V
(22) Malfunction indicator (After several seconds
lamp have elapsed)
E200-2 Power steering Engine: Warm, idle When steering wheel B+
(12) pressure switch is stationary
When steering wheel 0-3V
is turned
E200-2 (9) MFI relay Ignition switch: OFF B+
(Power supply)
Ignition switch: ON 0-3V
E200-2 AlC pressure switch Engine: Idle Turn the AlC switch OFF 0-3V
(22)
Turn the AlC switch ON B+
(AiC compressor is
operating)
E200-2 Ignition switch-ST Engine: Cranking 8V or more
(18)
MFICONTROLSYSTEM FL -31
Terminal
Check item Check condition (Engine condition) Normal condltlon
No.
E200-2 Intake air Ignition switch: ON When intake air 3.4-3.6V
(24) temperature sensor temperature is O°C (32°F)
When intake air 2.5-2.7V
(68°F)
(104°F)
(176°F)
E200-3 (3) Heated oxygen • Transaxle: 2nd <M!T>, L range <ArT> 0.6-1.0V
sensor (Rear, Left) • Driving with the throttle widely open
• Engine: 3500 r/min or more
E200-3 (4) Heated oxygen
sensor (Rear, Right)
E200-3 (1) Heated oxygen Engine: Warm, 2500 r/min o <=> 0.8V
sensor (Front, Left) (Check using a digital type voltmeter) (Change repeatedly)
E200-3 (2) Heated oxygen
sensor (Front, Right)
E200-2 Backup power Ignition switch: OFF B+
(26) supply
E200-2 (4) Engine coolant Ignition switch: ON When engine coolant 3.4-3.6V
temperature sensor temperature is O°C (32°F)
When engine coolant 2.5-2.7V
(68°F)
(104°F)
(176°F)
E200-3 (8) Throttle position Ignition switch: ON Idle 0.3-0.9V
sensor (Check for smooth voltage
Wide open throttle valve 4.5-5.0V
increase as throttle is
moved from idle position
to wide open throttle)
E200-3 Vehicle speed • Ignition switch: ON o <=> 5V
(10) sensor • Move the vehicle slowly forward (Change repeatedly)
E200-3 (9) Closed throttle Ignition switch: ON Set throttle valve to 0-1V
position switch idle position
Slightly open throttle valve 4V or more
E200-2 Camshaft position Engine: Cranking 0.4-3.0V
(16) sensor
Engine: Idle 0.5-2.0V
Terminal
Check item Check condition (Englne condition) Normal condition
No.
E200-2 (5) Crankshaft position Engine: Cranking 0.4-4.0V
sensor
Engine: Idle 1.5-2.5V
E200-2 Mass air flow sensor Engine: Idle 0-2V
(15)
Engine: 3000 r/min 2-4V
E200-4 Park/Neutral position Ignition switch: ON Set selector lever to P or N 0-3V
(21) switch <Afr>
Set selector lever to 8-14V
D,2,L or R
E200-1 Heated oxygen Engine: Warm, idle 0-3V
(26) sensor heater
Engine: 5000 r/min B+
(Rear, Left)
E200-1 Heated oxygen Engine: Warm, idle 0-3V
(27) sensor heater (Rear,
Right)
E200-1 (3) Heated oxygen Engine: Warm, idle 0-3V
sensor heater
(Front, Left)
E200-1 (4) Heated oxygen Engine: Warm, idle 0-3V
sensor heater (Front,
Right)
TERMINAL RESISTANCE AND

& CAUTION
CONTINUITY CHECK EFMB0280 If resistance or continuity checks are performed
on the wrong terminals, damage to the vehicle
1. Turn the ignition switch to OFF.
wiring, sensors, PCM, and/or ohmmeter may oe-
2. Disconnect the PCM connector.
cur. Use care to prevent th/s!
3. Measure the resistance and check tor continuity be-
tween the terminals of the PCM harness-side connec- 3. It the ohmmeter shows any deviation trom the nor-
tor while reterring to the check chart. mal condition, check the corresponding sensor, actu-
ator and related electrical wiring, and then repair or
~NOTE replace.
• When measuring resistance and checking conti- 4. After repair or replacement, recheck with the ohmme-
nuity, a harness tor checking connect pin pres- ter to contirm that the repair or replacement has cor-
sure should be used instead ot inserting a test rected the problem.
probe.
• Checks do not have to be carried out in the order
given in this chart.
,-r-
766
r- - r-r-
4 3
-r-
2 1
-r-r-
7 6 5
r-
- 4 3 21 664 3218766 4 3 2 1
l2cl 1918 1116 1514 1~ 12 111( 9 8 1918 1716 1514 1312 111~ 9 8
~ 29 2524 ~
2322 21 2827 26:25 ~1
'- - --
'- - L..- _ L . . - _L..- L..-L..-
1-1·- -E200-4---t·111-·- -E2OO-3---.f·1 1-1·--E2OO-2---t·1 1-1·- - - E2OO-1---t·1

EFMB028A
Terminal No. Inspection item Normal condltlon (Check conditlon)

E200-1 (1) - E200-2 (1) NO.1 injector 13-16n [At 20°C (68°F)]
E200-1 (9) - E200-2 (1) NO.2 injector
E200-1 (24) - E200-2 (1) NO.3 injector
E200-1 (2) - E200-2 (1) No.4 injector
E200-1 (10) - E200-2 (1) NO.5 injector
E200-1 (25) - E200-2 (1) NO.6 injector
E200-1 (6) - E200-2 (1) EGR solenoid 62-74n [At 20°C (68°F)]
E200-1 (34) - E200-2 (1) Evaporative emission purge solenoid 24.5-27.5n [At 20°C (68°F)]
E200-2 (2) - Body ground PCM ground Continuity (On)
E200-1 (3) - E200-2 (1) Heated oxygen sensor heater 7-40n [At 20°C (68°F)]
(Front, Left)
E200-1 (4) - E200-2 (1) Heated oxygen sensor heater
(Front, Right)
E200-1 (26) - E200-2 (1) Heated oxygen sensor (Rear, Left) 7-40n [At 20°C (68°F)]
E200-1 (27) - E200-2 (1) Heated oxygen sensor (Rear, Right)
Terminal No. Inspection item Normal condition (Check condition)

E200-2 (24) - E200-2 Intake air temperature sensor 5.3-6.70 [When intake air temperature
(17) is O°C (32°F)]
2.3-3.00 [When intake air temperature
is 20°C (6S0F)]
1.0-1 .50 [When intake air temperature
is 40°C (104°F)]
0.30-0.420 [When intake air temperature
is SO°C (176°F)]
E200-2 (4) - E200-2 (17) Engine eoolant temperature sensor 5.1-6.50 [When eoolant temperature is O°C (32°F)]
2.1-2.70 [When eoolant temperature is 20°C (6S0F)]
0.9-1 .30 [When eoolant temperature is
40°C (104°F)]
0.26-0.360 [When eoolant temperature
is SO°C (176°F)]
E200-3 (9) - E200-2 (17) Closed throttle position switeh Continuity (When throttle valve is at idle position)
No eontinuity (When throttle valve is slightly open)
E200-4 (21) - Body Park/Neutral position switeh <AlT> Continuity (When seleet lever is at P or N)
ground
No eontinuity (When seleet lever is at D,2,L or R)
COMPONENT INSPECTION EFMB0290
LOCATION OF MFI COMPONENTS
[KJ AFS & IAT-sensor [ [ ] PCSV

00 Engine coolant temperature sensor DJ Control relay
@] TPS (including idle switch) QJ Injector
W Knock sensor [K] Ignition coil
[I] 02 sensor [g Ignition failure sensor
m Crankshaft position sensor [}!] DLC connector
~ Camshaft position sensor
EFMB029A
A AFS & IAT-sensor B Engine Coolant tempo sensor
EFB9009A EFB9010A
C D Knock sensor
EFMBOOSA KFW5014A
E F
KFW3244A KFW5202A
G H
KFW5203A EFB9007A
J Injector
KFW5221A KFW5018A
K Ignition coil L
KFW5222A EFB9OO6A
V/
I
EFB900BA
PCM CONFIGURATION
r-r- r-r- r- - r-r- r-- r-r-~ r- r- r-r-r- r- - r-~r- -r- r-r- - r- r-r-r-
1 2 3 4 5 6 7 8 123 456 1 2 3 4 567 1 2 3 4 567
91Cl 1112 ~3 1415 11l1/ 1819 ~ 21 122 23 7 8 91Cl 1112 1314 15161/ 8 9 1Cl 11 1~ 13 141! 11l~7 1819 8 9 1Cl 11 1213 1~ 15 16 1/18 ~9 2Cl
~~~ ~ ro" f'C f"l:t 3C~1 ~~ 133 I~ 35 18U ~ ~1 ~~ ~4 ~5 ~ ~ 21 ~ 23~4 2!~ 27 ~ 21~23 ~4 ~ r- ~ 3(]
'-'- '-- '-'- '-'- '- '- ~ '- ~'- -'- ~'- ~'-- '-'- '--
1-1·- - - E2OO-1---I'I 1-1·- - E200-2 --1·11-1·- - E200-3 --tl11-1·- - E2OO-4 ---1·1
EFMB029C
PCM HARNESS CONFIGURATION
765 43 21765 4321654 321 87 65 4 3 2 1
11-'- - E200-4 - - - I '11+-1·- - E200-3 --t·II-I·--E200-2 -----I.I 1-1·- - - E200-1-----+l·I
EFMB029D
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR EFMB10l0
The engine coolant temperature sensor installed in the

engine coolant passage of the cylinder head detects
the engine coolant temperature and emits signals to the
PCM. This part employs a thermistor which is sensitive
to changes in temperature. The electric resistance of the
thermistor decreases in response to a temperature rise
(NTC). The PCM determines engine coolant temperature
by the sensor output voltage and provides optimum fuel EFB9010A
enrichment when the engine is cold.
CIRCUIT DIAGRAM
E2DO-2 (17)
Part side , - - - - - - - - - - - - + - - Sensor GND
E2DO-2 (4)
Harness side '------+--ECT signal
PCM harness connector

r-r-r- r- r-r-.-- r- r- r-
'"
765 "4 3 2 1 76 5 4 3 2 1 654 321 87 6 5 4 3 2 1
~19 1817 1E 11 1~ 1 1211 1( 9 8 1~ 1e1 1115 141~ 1211 ~o 9 8 17 ~6~5 1413 1 ~1 ~o 9 87 ~~ ~1~ 98 1711 54 ~3~2 110 9
~o~ 28212E 25[24 ~22 21 2E 21 2E 25 124 2 122 ~1~ 2E25~ ~122 21~ 15 18 35~ 3332 3130 2524
'-'-- - '-'-- '--'--'-- '-'-- '-- '-
....
\. --E2Q0.4,---l·\I--I·--E200-3i- --l'!I-!.--E200-2!----!.! I-!'---E200-1,----l.!
EFMB101A
SENSOR CHECKING
USING HI-SCAN (PRO)
Check
Check item Oata display Intake air temperature Test specification
conditions
Engine coolant Sensor temperature Ignition switch When -20°C (-4°F) -20°C
temperature sensor : ON or engine
When O°C (32°F) O°C
running
When 20°C (68°F) 20°C
When 40°C (104°F) 40°C
When 80°C (176°F) 80°C
USING MULTI-METER 20
1. Remove the engine coolant temperature sensor from

li
the intake manifold. .,.,c 4
g 2
2. With the temperature sensing portion of the engine .~ ~:g
coolant temperature sensor immersed in hot engine ~ 0.4
coolant, check the resistance. 0.2
0.1 -20 0 20 40 60 80 100

Temperature [OC (OF)] Resistance (kO) (4) (32) (68)(104)(140)(178)(212)
Temperature ·e CF)
o (32) 5.9
EFJB703D
20 (68) 2.5
40 (104) 1.1
80 (176) 0.3
EFA9028A
3. If the resistance deviates from the standard value

greatly, replace the sensor.
HARNESS INSPECTION PROCEDURES
~ E1
Check for continuity of the ground circuit.
0 Connector: Disconnected OK =C> [TI
®
(31 2 1 1) Repair the
Harness side
'----' ( NG =C> harness.
connector -
EFMB101B
~ E1
Measure the power supply voltage.
o Connector: Disconnected
OK=C> END!
0 Ignition switch: ON
~@
o Voltage (V): 4.5-4.9V
1(31':'1 1) ) .........J.pCM Repairthe

Har;;'ess~side
~200-2(4)
NG =C> harness.
connector
EFMB101C
TROUBLESHOOTING PROCEDURES
0 Engine : Running
0 DTC : P0115
YES
.... 1/
Check the wiring connection. NO
0
0 Is the connection OK?
.... 1
/1 0 Repair the wiring.
J
YES
""V
0 Check the ECT Sensor. NO ,I
0 Is the ECT Sensor OK? /1 0 Repair the ECT sensor.
I
o Check the cooling system including NO

THERMOSTAT opening state.
(Reter to EM Group)
"I
"I 0 Replace the THERMOSTAT.
I
0 Is it OK?
YES
'v
0 Erase diagnostic trouble code trom memeory.
0 Is same code No. present after rechecking?
o Replace PCM.
DTC : Diagnosis Trouble Code

PCM : Powertrain Control Module
ECT : Engine coolant Temperature
EFA9030A
USING VOLTMETER
Check item Coolant temperature Test specification

Engine coolant temperature sensor output voltage When ooe 4.05V
When 200 e 3.44V
0
When 40 e 2.72V
When BOoe 1.25V
TROUBLEHSOOTING HINTS
If the fast idle speed is not adequate or the engine gives

off dark smoke du ring warm-up, the engine coolant tem-
perature sensor might be the cause.
INSTALLATION
1. Apply sealant LOeTITE 962T or the equivalent to the

threaded portion.
2. Install the engine coolant temperature sensor and

tighten it to the specified torque.
Tightening torque
Engine coolant temperature sensor:
20-40 Nm (200-400 kg·cm, 14-29 Ib·tt)
3. Securely connect the harness connector.

MASS AIR FLOW(MAF) SENSOR & to the air flow. The air flow sensor generates a pulse so it
repeatedly opens and closes between the SV vo/tage sup-
INTAKE AIR TEMP.(IAT) SENSOR EFMB1030
plied from the powertrain control module.
The intake air temperature sensor (/AT Sensor). /ocated in
This hot film type air flow sensor is composed of a hot
the intake air hose. is a resistor-based sensor for detect-
film sensor. housing and metering duct (hybrid sensor ele-
ing the intake air temperature. The intake air temperature
ment). Mass air flow rate is measured because the change
information from the sensor he/ps the peM provide the
of the mass air flow rate causes a change in the amount
necessary fuel injection.
of heat being transferred from the hot film probe surface
CIRCUIT DIAGRAM
PCM
E200-2 (22)
I-f-+-- IAT signal
E200-3 (2)
Hamess side
Sensor source (SV)
E200-2 (9)
H - 4 - - - Sensor GND
E200-2 (19)
Power supply
E200-2 (11)
Part side AFS signal
PCM hamess connector
1 - - - E20Q.4--....j. 11-1- - E200·3--I·11- E200-2-1 ""'.

"I - - - E2OO-1---I·1
EFMB103A
1 Measure the power supply voltage for the

IAT sensor.
o Connector: Disconnected.
OK=>~
o Ignition switch : ON.
o Voltage (V) : 4.8-5.2 V.
Repairthe
Hamessside
connector
NG=> hamess.
EFJB705B
~ [8
Check for an open circuit, or a short circuit to
@
ground between the powertrain control module
and the IAT sensor.
OK=> 0
o Connector : Disconnected
o PCM connector : Disconnected
~
{sI4I31211) Repairthe
Hamess side '-----' NG=> hamess.
connector =
EFMB705C
l!J ~
o Connector: Disconnected. OK=> 0
j~
@
Q
M
{sI413I 11} 2
Repairthe
NG=>
~ ~ ~
Hamessside '-----" hamess.

connector 0
-!".
EFJB705D
4 Check the power supply(Bat) voltage for

MAF sensor.
OK=>~
o PCM connector : Connected
o Voltage: Battery voltage
Repairthe
Hamessside
connector
NG=> hamess.
EFJB705E
Fl-46 FUEl SYSTEM [GASOLINE 3.5]
~ [8
Check for an open-circuit, or a short-circuit
to ground between the PCM and MAF sensor. OKs:> END!
,--.., o Connector: Disconnected
)
@ o PCM connector : Disconnected
~
P
{s14131211
~
Hamessside
~
'---'
, NGs:> Repairthe
hamess.
connector ~
EFMB705F
0 Engine : Running
YES
,:"
0 Check the wiring harness and connections. NO ,I

0 Is it normal? /1 0 Repair or replace
I
YES
0 Check the MAF & IAT sensor output NO ,I

voltage.
0 Is it normal?
/1 0 Repair the MAF & IAT sensor.
I
o Erase diagnostic trouble codes trom NO_ _~"II

I--_ _ 0 OK I
memeory. /I~------------------------~
o Is same code present after rechecking?
o Replace PCM.

EFJB705G
TROUBLESHOOTING HINTS • Disturbed air flow in the MAF sensor, discon-

nected air duct, and clogged air cleaner filter.
1. If the engine stalls occasionally, start the engine and • Poor combustion in the cylinder, faulty ignition
shake the MAF sensor harness. If the engine stalls, plug, ignition coil, injector, and incorrect compar-
check for poor contact at the MAF sensor connector. ison.
2. If the MAF sensor output voltage is other than 0 when
the ignition switch is turned on (do not start the en- 4. Even if no AFS malfunction occurs, check the mount-
gine), check for a faulty MAF sensor or peM. ing direction of the AFS.
3. If the engine can idle even if the MAF sensor output
voltage is out of specification, check for the following
conditions;
Check item Check condition Test speclficatlon

Mass air flow sensor output voltage Idle rpm 0.5V
2000 rpm 1.0V
~NOTE
• When the vehicle is new [within initial operation
of about 500 km (300 mi/es)], the mass air flow
sensor air quantity will be about 10% higher.
• Use an accurate digital voltmeter.
• Before checking, warm up the engine until the
engine coolant temperature reaches 80 to 9(1 C
(176 to 19ffF).
THROTTLE POSITION SENSOR

(TPS) EFMB1050
The TPS is a variable resistor type that rotates with the

throttle shaft to sense the throttle valve angle. As the throt-
tle shaft rotates, the output voltage of the TPS changes.
The peM detects the throttle valve opening based on this
voltage change.
EFMBOO5A
CIRCUIT DIAGRAM
Part side
Harness side

..- ..-
765 43 21765 4321 654 321 87 65 43 21
11 6 514 1312 11 0 987
~2!24 23 122 2Ü2( IS 18
1 - - - E2OO-4 ,11, E2OQ-3 11- E200-2 - I 1 E2OQ-l---l
EFMB105A
l!J EJ
Measure the power supply voltage of the
throttle position sensor.
0 Connector : Disconnected
OK=C> 0
0 Ignition switch : ON
0 Voltage (V) : 4.25 - 4.7
r
_11
13 12 11 Repair the
NG =C> harness.
EFBB105B
~ Check for continuity of the ground circuit.

0 Connector : Disconnected
OK =C> 0
(41 3 12 1
Harne';s side
~~ )
NG =C>
Repair the
harness.
connector =
EFBB105C
~ Check for an open-circuit, or a short-circuit to

[TI
n:
PCM
EJ ground between the powertrain control module

and the throttle position sensor.
OK =C>
@ (8) 0 Throttle position sensor connector :
Disconnected
~
L
(41 3 12 11
0 Powertrain Control Module connector :
Disconnected
Repairthe
Harness side
'-----' ( NG =C> harness.
connector - =
EFMB105D
~ Measure the power supply voltage of the TPS.

OK=C> END!
'\
EJ 0 Connector: Disconnected
0 Ignition switch: ON
0 o Voltage (V): 4V or more
4131 11
Harne;s side
L NG =C>
Repair the
harness.
connector
=
EFBB105E
TROUBLESHOOTING HINTS
The TPS signal is important in the control of the automatic

transaxle. Shift shock and other trouble will occur if the
sensor is faulty.
SENSOR CHECKING
USING HI-SCAN (PRO)
Check item Data display Check conditions Throttle valve Test specification
Crankshaft position Sensor voltage Ignition switch : ON At idle position 300-900 mV
sensor
Open slowly Increases with valve
opening
Open wide 4,250-4,700 mV
Using voltmeter
1. Disconnect the throttle position sensor connector.
2. Measure resistance between terminal 1 (sensor

ground) and terminal 4 (sensor power).
Standard value : 3.5 - 6.5 kfl
3. Connect a pointer type ohmmeter between terminal 1

(sensor ground) and terminal 3 (sensor output).
4. Operate the throttle valve slowly from the idle position

to the full open position and check that the resistance
changes smoothly in proportion with the throttle valve
opening angle.
5. If the resistance is out of specification, or fails to

change smoothly, replace the throttle position sensor.
Tightening torque
TP Sensor: 1.5-2.5 Nm (15-25 kg·cm, 1.1-1.8 Ib·tt)
53
@
EFBB105F
SENSOR CHECKING (IOLE SWITCH)
USING HI-SCAN (PRO)
Check item Oata display Check conditions Throttle valve Normal indlcation
Idle position switch Switch state Ignition switch : ON (check At idle position ON
• Service data by operating accelerator
Open a little OFF
item pedal repeatedly)
Uslng voltmeter
1. Disconnect the throttle position sensor connector.

2. Check the continuity between terminal 3 and sensor
ground.
TPS voltage Contlnuity

Higher than 300-900mV Non-conductive (oon)
300-900mV Conductive (On)
3. If out of specification, replace the throttle position sen-

sor.
EFBB105G
HEATED OXYGEN SENSOR (H02S) EFMB1090 than the theoretical ratio, and outputs about OV when the
ratio is leaner (higher oxygen concentration in exhaust
The heated oxygen sensor senses the oxygen concentra- gas.). The PCM controls the tuel injection ratio based on
tion in exhaust gas and converts it into a voltage which is this signal so that the air tue I ratio is maintained at the
sent to the PCM. For Zirconium type sensors, the oxygen stoichiometric ratio. The oxygen sensor has a heating ele-
sensor outputs about 1V when the air tuel ratio is richer ment which ensures sensor performance during all driving
conditions.
CIRCUIT DIAGRAM
ENGINE
COMPARTMENT
JUNCTION
BLOCK
VARIABLE
RESISTOR
G13
26 E200-1 3 E200-3 27 E200-1 4 4 E200-1 2 E200-3 3 E200-1
EFMB109A
1. If the H02S is defective, abnormally high emissions • Defective injector

may occur. • Air leaks in the intake manifold
2. If the H02S check results are normal, but the sensor • Defective volume air flow sensor, intake air tem-
output voltage is out of specification, check for the fol- perature sensor, barometrie pressure sensor and
lowing items (related to air fuel ratio control system): engine coolant temperature sensor.
Check item Check conditions Engine state Test specification (14)

Oxygen sensor Engine: Warm-up (make the mixture When sudden deceleration 200mV or lower
lean by engine speed reduction, from 4,000 rpm
and rich by racing)
When engine is suddenly 600-1,000 mV
raced
Engine: Warm-up (using the heated Idle 400 mV or lower - (oscilate)
oxygen sensor signal, check the 600-1,000 mV
air/fuel mixture ratio, and also check
2,000 rpm
the condition of control by the PCM)
INSPECTION 4. Connect a high-impedance digital-type volmeter 00-

tween terminal 1 and terminal 2.
~NOTE
Sensor Sensor Sensor Sensor
• Before checking, warm up the engine until the
1.
engine coolant temperature reaches 80 to 9S'C
(176 to 20S'F).
• Use an accurate digital voltmeter.
Disconnect the oxygen sensor connector, and mea-

gl:!:f' gJ:I:f
Heater (-) Heater (+) Heater (-) Heater (+)
sure the resistance between terminal 3 and terminal
Front Rear
4.
Standard value Heated oxygen sensor harness side connector
EFAA719F
Temperature °c (OF) Resistance (0)

5. While repeatedly racing the engine, measure the oxy-
400 (752) 30 or more gen sensor output voltage.
Oxygen sensor
Engine Resistance (0)
output vOltage
Race Min. 0.6V 30 or more
128
...•, ..,"
0::: Maximum (rich)
0
(f)
:.
."
,.'
z >
w
~
0 • • I •
.: .. . . .
(f) ci 64 • • I •
C\I x
EFAA719E 0 •
'..;· ....., '.;
I
0:::
2. Replace the oxygen sensor if there is a malfunction.
LI. ~ I
oJ
V -,
Minimum (Iean)
0
3. Apply battery voltage directly between terminal 3 and
terminal 4. EFJB719H
~NOTE
Be careful when applying the voltage. Damage will
result if terminals 1 and 2 are connected to any volt-
age.
Tightening torque
Heated oxygen sensor :
40-50 Nm (400-500 kg·cm, 29-36 Ib·tt)
Sensor Sensor
OL-..........~I~~==~=-_ '~~""'
Rich - Ideal ratio - Lean
Mixture ratio
6. If there is a problem, there may be an oxygen sensor

EFJB7191
~
Heater (+) Heater (_)
malfunction. Heated oxygen sensor side connector (FRONT, REAR)
EFAA719G
Measure the power supply voltage of the heated

amessside
connector
oxygen sensor.
OK=>0
o Ignition switch: ON
o Voltage (V): Battery voltage
NG =>.Repairthe
harness.
EFHA719B
2 Check for open circuit, or a short circuit to ground r-;;J

between the PCM and the oxygen sensor. 0K => ~
o Oxygen sensor connector : Disconnected
Repairthe
Hamessside
NG=> harness.
connector
EFHA719C
3 Check for continuity of the ground circuit.

o Connector : Disconnected OK=> END!
Repair the
NG=> harness.
EFHA719D
CAMSHAFT POSITION SENSOR EFMB1110
The CMP is a Hall-effeet sensor that deteets the eamshaft

position on the eompression stroke ot the No.1 eylinders,
eonverts it into a pulse signal, and inputs it to the PCM.
The PCM then eomputes the tuel injeetion sequenee, ete.
based on the input signal.
KFW5203A
CIRCUIT DIAGRAM
Camshaft position (CMP) sensor side connector
Crankshaft position (CMP)

sensor side connector
Harness side connector (H)

r-r-r- r- r- r-r- r-r- r- r-r-r- r- r- r-r- r-
7 6 5 4 3 2 1 7 6 5 4 3 2 1 654 321 8 7 6 5 4 3 2 1
~019 111 161! 141 1211 109 8 1918 1716 1514 1312 1110 9 8 1716 ~514 131 11~O 9·8 7 2322 2120 9 8 111E 5 4 ~31~ 110 9
30[29 282721 2!24 2* ~1 ~8~i 2i: 2! ~42 ~ ~*O 2E2!~ 2~ 2120 1111 3534 3332 3130 2928 ~~ 2524
'-'- -- '-'- '-'-'- - '- '-'-'- -- '-'-
1-1·- - E200-4 ---+1·1 t-I'- - E200-3 ----I. 11- E200-2 --111-'--- E2CJO-1---I'1
EFMB111A
~ !8
Measure the power supply voltage.
OK~ 0
J)1vt
® o Voltage (V): Batlery voltage
(31211
Hamessside
Repairthe
NG~
connector '------'
) hamess.
"::"
EFHA723B
~ ~
o Connector : Disconnected OK~ 0
®
•
Hamess side
connector
-=-
NG~
Repairthe
hamess.
EFHA723C
3 Check the signal voltage.

o Ignition switch : ON
OK ~ END!
o Voltage: 4.8-5.2 V
Repairthe
NG~ hamess.
EFMB111D
It the CMP Sensor does not operate correctly, sequential

injection is may not occur and the engine may stall or run
irregularly at idle or tail to accelerate normally.
CRANKSHAFT POSITION SENSOR EFMB1130
The crankshaft position sensor is a Hall-effeet sensor that

senses the crank angle (piston position) ot each cylinder
and converts it into a pulse signal. Based on the input
signal, the PCM computes the engine speed and controls
the tuel injection timing and ignition timing.
KFW5202A
CIRCUIT DIAGRAM
Crankshaft position sensor side connector
Crankshaft position
sensor side connector
Output characteristic
5V~- - -
OV_ ~
Time
One rotation of crank angle sensor

, , '-" r- r-r- r-r- r r- r-r-
"765 "4 3 "2 1 "7 6 5 4 3 2 1 654 321 8 7 6 5 4 3 2 1
~19 1E1 1615 1413 1211 1D 9 8, 19 1817 1615 1413 1211 lC 9 8 ~7 6 1514 312 1110 98 7 2322 21~ ~9 8 1716 54 31~ 11D 9
3D~ 2S 2121 25~ ~3~ 21 ~827 2E 25 ~2322 212C ~12524 23 122 21~ H1E 3534 j3* 31j30 ~28 272S ~~
'--'-- '-'- '-'- '-'- '- ,-,-c- '- '-'-
1 +-,- - E200-4 ---111 f+-'- - E200-3 --111- E200·2 - I 1+-1,--- E2OQ-1-----l
EFMB113A
TROUBLESHOOTING HINTS • Faulty engine coolant temperature sensor

• Faulty idle speed control motor
1. If unexpected shocks are feit du ring driving or the en- • Poorly adjusted reference idle speed
gine stalls suddenly, shake the crankshaft position
sensor harness. If this causes the engine to stall, 4. The engine will run without a crank angle sensor sig-
check for poor sensor connector contact. nal, but will not start. Once the sensor detects TOC,
2. If the tachometer reads 0 rpm when the engine is the data is stored until the next re-start.
cranked, check for faulty crank angle sensor, broken
timing belt or ignition system problems.
3. If the engine can be run at idle even if the crarik an-
gle sensor reading is out of specification, check the
following:
USING HI-SCAN (PRO)
Check Item Check conditions Check content Normal state

Crankshaft position • Engine cranking Compare cranking speed Indicated speed agrees
sensor • Tachometer connected and multi-tester reading
(check on and off ignition
coil by tachometer)
Check Item Check conditions Coolant temperature Test speclflcatlon

Crankshaft position • Engine: Running at idle When -20°C (-4°F) 1,500-1 ,700 rpm
sensor • Idle position switch: ON
When O°C (-32°F) 1,350-1 ,550 rpm
When 20°C (-68°F) 1,200-1 ,400 rpm
When 40°C (-104°F) 1,000-1 ,200 rpm
When 80°C (-176°F) Idle rpm
W Hamessside
bJ Measure the power supply voltage.
OK=> [!]
connector
~
® ()
(21<:1
~ () NG=> harness.
Repair the
EFAA725C

OK=>0
NG => Repair the

harness.
EFAA725D

o Ignition switch : ON
OK => END!
o Voltage: 4.8-5.2 V
E200-2
Repairthe
harne55.
Hamessside NG=>
connector
EFMBll3E
FUEL INJECTOR EFMBl150
The injectors inject fuel according to a signal coming from

the PCM. The amount of fuel injected by the injectors is
determined by the time during which the solenoid valve
is energized. The amount of time the solenoid value is
energized is determined by the pulse width of the signal
from the PCM.
KFW5018A
CIRCUIT DIAGRAM
Injector side connector
Hamessside
connector (ABCDEF)
PCM

, r-, r-" r- ,r-r- r- r- ,r- , r- r-
765 4 3 2 1 765 43 2 1 654 321 8 7 65 4 3 2 1
~716 1514 131 11 0 987

~*
2C 1S 1e 11 1615 1~ 13 U 11 H98 1918 1716 1514 13 2 1110 9 8 ~120 9 8 ~716 ~5~4 ~31~ 110 9
!JC 29 ~812712e
~~~
2~24 23~ 21 2e~7
~~~ '-~
2625
~-
242 ~
~
212C
~
262524
'-'-'-
23r. 212C 1S1e
~
35fw
'-'-
3n2 31~0 ~~8 fz72e 2524
1-1-- - E200-4 - - - + I -11-1- - E200-3 ----1-11-- E200-2 - I 1-1- - - E200-1-----l
EFMBl15A
1 Measure the power supply voltage.

OK=>~
Hamessside NG => Repair the

connector harness.
EFHA729B
2 Check for an open circuit, or a short circuit to

~ ground between the powertrain control module OK => END!
o and the injector.
o Injector connector : Disconnected
Repairthe
Hamess side
connector NG=> harness.
EFBBl15C
INJECTOR CHECKING
USING HI-SCAN
Check Item Data display Check conditions Check content Test specification
Injector Drive time Engine: eranking ooe (32°F) Approx. 17 ms
200 e (68°F) Approx. 35 ms
0
80 e (176°F) Approx. 8.5 ms
Check Item Data display Check conditions Engine state Test specification
Injector Drive time • Engine coolant Idle rpm 2.2-2.9 ms
temperature: 80 to
2,000 rpm 1.8-2.6 ms
95°e (176 to 205°F)
• Lamps, electric Rapid racing To increase
cooling fan, accessory
modules: All OFF
• Transaxle: Neutral
(P range for vehicle
with AlT)
• Steering wheel: Neutral
• When the vehiele is new (within initial operation

~NOTE of about 500 km [300 miles)), the injeetor drive
• The injeetor drive time is when the supply voltage time may be about 10% longer.
is 11 V and the eran king speed is less than 250
rpm.
• When engine eoolant temperature is lower than
(J'C (3ZF), the PCM fires all four eyfinders simul-
taneously.
Check Item Item No. Drive content Check condition Normal state
Injector 01 No. 1 injector shut off Engine: Idling after Idle should become
• Actuator test warm-up (Shut off unstable as injector
02 No. 2 injector shut off
the injectors in shuts off.
03 No. 3 injector shut off sequence du ring
04 No. 4 injector shut off and after engine
warm-up; checkthe
05 No. 5 injector shut off idle condition)
06 No. 6 injector shut off
USING STETHOSCOPE AND VOLTMETER 4. Measure the resistance between terminals.
Operation Sound Check Standard value : 13-16n [at20°C (68°F)]

1. Using a stethoscope, check the injectors for a clicking
sound at idle. Check that the sound is produced at 5. Re-connect the connector to the injector.
shorter intervals as the engine speed increases.
~NOTE
Ensure that the sound (rom an adjacent injector is
not being transmitted along the delivery pipe to an
inoperative injector.
KFW5021A
1. If the engine is hard to start when hot, check for tuel

pressure and injector leaks.
KFW5019A 2. If the injectors do not operate when the engine is
cranked, then check the followings:
2. If a stethoscope is not available, check the injector • Defective power supply circuit to the PCM, faulty
operation with your finger. If no vibration is feit, check ground circuit
the wiring connector, injector or injection signal from • Defective control relay
the PCM. • Defective crankshaft position (CKP) sensor or
camshaft position (CMP) sensor
3. If there is any cylinder whose idle state remains un-

changed when the fuel injectors are cut one after an-
other during idling, check for the following items about
that a cylinder.
• Injector and harness
• Ignition plug and high tension cable
• Compression pressure
KFW5020A
4. If the injection system is OK but the injector drive time
is out of specification, check for the following items.
Resistance Measurement Between Terminals • Poor combustion in the cylinder (faulty ignition
plug, ignition coil, compression pressure, etc.)
3. Disconnect the connector at the injector. • Loose EGR valve seating
EVAPORATIVE EMISSION CANISTER

PURGE CONTROL SOLENOID
VALVE EFMBl170
The evaporative emission canister purge control solenoid

valve is a duty control type, which controls purge air from
the evaporative emission canister.
EFB9007A
CIRCUIT DIAGRAM
Engine compartment junction block
2
Harness side connector (H) EVAP Canister Purge
Solenoid Valve
Control relay harness side
/4T3I2r1l
l:illITm
PCM

--
7 6 5
r- r- -4 3
r-r- r-r-r-
2 1 7 6 5
r- r-
4 3 2 1
r-
654
r- r- ---
321
--
8 7
r-
6 5
r- e- r-
4 3
e-r-
2 1
201! 181 1615 1413 1211 1C 9 8 1918 1716 1514 1312 1110 9 8 ~7 6 1514 1312 1110 987 2*2 2120 ~9~8 1716 ~514 1312 11109
302E 2B2726 2524 232221 2B27 2625 ~42322 2120 262! 24 2 22 2120 1918 3534 33p2 3130 2928 2726 2*4
~ '-'-'- -- '-'- '- '-'- '-'-'- - '- -- -- '-'-
f--/'- - E200-4 ----1./1-/.-- E200·3 - - - J ./ I - E200-2 --l /f----- E200-1----.!
EFMBl17A
o Engine: Running
VES
,1/
0 Check wiring harness and connection. NO ,I
/ 0 Repair the wiring.
0 Is the connection OK?
VES
0 Check the electrical part ot EVAP Ca- NO , 0 Replace the EVAP Canister Purge
/
nister Purge Control Solenoid Valve. Control Solenoid Valve
0 Is the electrical part OK?
o Erase any diagnostic trouble codes trom

memeory.
NO ,loOK I
/IL...-_ _ _....J
o Is same code present after rechecking?
lVES
Replace PCM.

EFAA731B
USING HI-SCAN (PRO)
Check Item Check conditions HI-SCAN display Type

Evaporative emission IG. S/w ON (00 not start) PCSV Activate
canister purge solenoid
valve
• Actuator test
5
4.5
~ 4
Q) 3.5
Cl 3
!9 2.5
~ 2
'5 1.5
Co 1
'5
o 0.5
0~-7~-----~~--
-9.3 +4.0
(-70, -2.76, -1.35) (+30, +1.18, +0.58)
Pressure kPa (mmHg, inHg, psi)
(Relative to atmospheric pressure)
EFJB731E
1 Measure the power supply voltage.

OK=t>0
Hamessside
connector
N G =t> Repair the
harness.
EFBBl17B
2 ~~~c~~~~~~~r Check for an open circuit, or a short circuit to ground

""""0=""'""· between the evaporative emission canister purge 0 K =t> END!
solenoid valve and the powertrain control module.
o
~
E200·1
(16)
0 PCM connector : Disconnected
0 Evaporative emission canister purge solenoid
valve connector : Disconnected
Hamessside
NG=t> Repairthe
harness.
connector (H)
EFMB117C
KNOCK SENSOR EFMBl190
The knock sensor is a piezoelectric device attached to the

cylinder block that senses pressure trom engine knocking
conditions. This vibrational pressure is then converted into
a voltage signal which is delivered as output. It engine
knock occurs, ignition timing is retarded to suppress it.
EFA9094A
CIRCUIT DIAGRAM
,,-
peM harness connector

r- r-r- r- r-r-r- r- r- r- r- r- r- r- ,-, r- r- r-r-
765 4 3 2 1 7 6 5 4 3 2 1 654 321 8 7 6 5 4 3 2 1
2C 1S 161 1615 1413 1211 1( 9 ·8 19U 17~6 1514 1312 lllC 9 8 ~7 6 1514 1312 11 0 9 8 7 2322 21~ ~9~8 1716 5 4 312 ~110 9
3~ 2!1 ~el27l2E 25~4 2322 121 2e~7 12E25 ~23122 212C 126 2124 123122 212C 191E 3534 33~2 131~O ~92E 2726 ~5~
L-L-L- -'- L- L- '-L- '--'- - '- '-
1+-1·--E200-4 ---1·11-1·--E200-3 -----111- E200-2 - l 1+-1--- E2CJO.1---l
EFMBl19A
I 0 Engine: Running
1
o Check the wiring connection between NO ,I
knock sensor and PCM. /1 0 Repair the sensor.
I
0 Is the connection OK ?
lYES
o Check the torque of the knock sensor. NO ,I

o With the specification ? (20 ± 5Nm) /1 0 Retorque the knock sensor bolt.
I
NO J
o Is the knock sensor OK?
(test by substution)
I----~>I 0 Replace the knock sensor.
I
o Erase any diagnostic trouble codes from NO

memo~.
o Is same code present after rechecking ?
~---~)~I 0 OK
'-------'
I
YES
'v
I 0 Replace PCM.

EFAA733B
1. The MIL is ON or the DTC is displayed on the

HI-SCAN PRO under the following condition:
• When the knock sensor signal is not detected,
even though the engine is in an overload condi-
tion.
• When the knock sensor signal is abnormally low.
1
EJ PCM
Check tor an open circuit, or a short circuit to
ground between the PCM and the knock sensor
0 K =C> 0
@ o Knock sensor connector : Disconnected
~ Repairthe
Harness side NG ~ harness.
connector (A) A1-E200-3:21
EFMB119C
2J EJ
Check for continuity of the ground circuit
o Continuity OK =C> END!
r.....
[211]
~
Harness side
~
( NG =c> Repairthe
harness.
connector ~
EFBB119D
SENSOR INSPECTION
1. Disconnect the knock sensor connector.
2. Measure the resistance between terminals 2 and 3.
Standard value : about 5Mfl [at 20°C (68°F)]
3. If the resistance is zero, replace the knock sensor.
Knock sensor :
16-28Nm (160-250 kg·cm, 11.8-18.4 Ib·tt)
4. Measure the capacitance between the terminal 2 and

3.
Standard value : 800-1600 pF
EJ
@
EFBB119E
POWER STEERING PRESSURE

SWITCH EFMB1210
The power steering oil pressure switch senses the power

steering load and inputs it to PCM, which then adjusts the
idle speed control motor to maintain idle speed when the
power steering pump puts a load on the engine.
EFA9103A
CIRCUIT DIAGRAM
~--~--------~--~PCM

E200·2 (14)
Power steering
switch

r-r-r-
765
r- r-r-
4 3
-- -r-r-
765
- - 4 3 2 1
r-r-r-
6 5 4
r- r-r--r- r-r-- --
6 5
r- r- r- r-
2 1
2 1 321 8 7 43
2019 1e 17 1615 141 1;; 11 109 e 1918 1716 1514 1312 1110 9 8 r716 1514 1312 1110 9 8 7 r
2*2 21~0 19 8 1716 514 131. 1110 9
3029 28272E 2524 232221 2827 2625 242322 2120 262524 2 22 2120 1918 35G4 3332 31FlO ~9~8 2726 2*4
~~
-- ~'- --- -- -- '-'- '-~- '-'- -'- '-'-
1 - - - - E200-4 ---+1'I 1-1,- - E200-3 - - - I '1 f--- E200-2 - I It--·- - - E200-1----l'1
EFMB121A
USING HI-SCAN (PRO)
Check item Data display Check conditions Steering wheel Normal indication
Power steering oil Switch state Engine: Idling Steering wheel neutral OFF
pressure switch position (wheels
straightahead direction)
Steering wheel half turn ON
~ Measure the power supply voltage.

0 Connector: Disconnect OK=C> END!
B 0 Ignition switch: ON
@) (
1
Harness side Repair the
connector ( NG=c> harness.
~
EFAA735B
CONTROL RELAY EFMB1230
When the ignition switch is turned on, battery voltage is

applied trom the ignition switch to the PCM, turning ON
the ignition power transistor and energizing the MFI control
relay coil. This turns ON the MFI control relay switch, and
supplies power trom the battery to the PCM through the
MFI control relay switch.
KFW5221A
CIRCUIT DIAGRAM
Control relay
Control relay harness side
rn3F2m
cmrmJ
G17 L-.f-----.--..,~ CKP, CMP, 02 sensor, Injectors

E200-2 (7)
Power
E200-2 (17)
'---------'----'-1- Control relay
E200-2 (19) Battery
E200-1 (20)
Fuel pump relay
PCM

,-,-,- ,- ,- ,-,- , - , - - - ,- ,- ,- ,-,- ,-,- ,- - r-- ,-,-
765 4 3 2 1 7 6 5 4 3 2 1 6 5 4 321 8 7 6 5 4 3 2 1
2~19 1817 161! 1413 1211 1e 9 8 1918 1716 1514 1312 111~ 9 8 716 1514 1312 1110 987 p* 21~0 9 8 1716 5 4 131 1110 9
In 21 28~7 35~4
~*
3~29 282721 2124 2 2E 21 242 22 212~ 2E 21 24 2 2 212C 191B 31~0 2928 2*6 2*4
L-'--- -- '---'---'--- '---'--- - '---'--- '--- '---'--- '-'---
1 - - - E200-4 - - - l ' 11-+1- - E200-3 ---111--- E200-2 - I 1-1,--- E200-1 ----1·1
EFMB123A
IGNITION COIL EFMB1250
The ignition power transistor functions to control the igni-

tion timing by controlling the ignition coil primary current
through signals from the PCM.
KFW5222A
CIRCUIT DIAGRAM
Igcoil3 Ig coil1 Ig coil2

(No. 3 & 6) (No. 2 & 5) (No. 1 & 4)
-.L I -.L 1 I -.L I I
Harness side
'--r----III
Ig failure sensor harness side
L - - - - t - - - - - - t - - - - IG failure sensor (3)
.------....,
E200-1 (11)
L---------t-- Ig. coil1, 4
'--_ _ _ _ _ _ _ _ _ _E_20_0_-1_{:...-1-'2)--r- Ig. coil 2, 5
'--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _E_20_0_-1_{:...-1-'3)_+__ Ig. coil3, 6
PCM

-r-
765
r-r-
4 3
r-r- ,-r-
2 1 7 65 4 3 2 1
r-r-
654
r-
321
r- r-r-
8 7
,-;-
6 5
- r-
4 3
r-;-
2 1
2120 19 8 1716 5 4 312 11~0 9

~*
2019 111 1E 1! 1413 1211 109 8 1918 1 16 1514 1312 1110 9 8 716 1514 1312 110 987
23~21 ~42 22 2928 27~6

3029
'----
282 21 2524
'-'- '-'--
2827
-
2125
'-'-'-
2120
-'-
2E 25 24
'-"-
222 212C 1918
"-"-
35f34
-"-
3332 3130
~*4
"-
1--- E200-4 ---1·11-1- - E200-3 ---111- E200-2 - l 11--- E200-1 - - - - - - - - I
EFMB125A
THROTTLE POSITION SENSOij(TPS)

INSPECTION EFMB2060
1. Connect a HI-SCAN (PRO) to the data link connector.
[QJJ NOTE
Betore inspecting the TPS, verity the basic idle speed
is as specitied.
EFMB206B
5. Turn the ignition switch to the OFF position.
THROTTLE BODY CLEANING EFBB2120
[QJJ NOTE
Disconnect the intake air hose trom the throttle body,
and check the throttle valve surface tor dirt. Spray
EFA9100A
cleaning solvent on the tace ot the valve to remove
dirt.
2. If a HI-SCAN (PRO) is not used, connect a digital type
voltmeter between ground and TPS output terminal.
1. Warm up the engine, then stop it.
2. Remove the intake air hose fram the throttle body.
3. Plug the bypass passage inlet of the throttle body.
[QJJ NOTE
Make sure the solvent does not enter the by-pass pas-
sage.
4. Spray cleaning solvent into the valve thraugh the throt-

EFMB206A tle body intake port and let it soak for about 5 minutes.
After 5 minutes open the valve and wipe it clean with
3. Turn the ignition switch to the ON position(do not start a soft rag.
engine) and check that TPS output voltage is as spec-
ified. If a HI-SCAN (PRO) is used, read the TPS volt-
age. & CAUTION
Keep the throttle valve closed while spraying to
Standard value (ETS vehicle) : 300-900mV avoid charging the intake path with solvent.
4. If it is out of specification, loosen TPS mounting 5. Start the engine, race it several times and allow the
screws and adjust by turning the TPS. engine to run near idle for 1 minute.
6. Repeat Steps 4 and 5.

[QJJ NOTE
• Turning the TP Sensor c10ckwise increases the 7. Unplug the bypass passage inlet.
output voltage.
• Tighten the screws securely after adjustment. 8. Attach the intake air hose.
9. Disconnect the battery ground cable for more than 10 FUEL PUMP OPERATION CHECK EFBB2oeo
seconds.
2. Apply battery voltage to the fuel pump drive connector

to check that the pump operates.
EFA9112B
FUEL FILTER REPLACEMENT EFBB2070
1. Lift up the vehicle. KFW5022A
2. Reduce the internal pressure of the fuel lines and ~NOTE

hoses and make the following operations.
• Disconnect the fuel pump harness connector at The tuel pump is an in-tank type and its operating
the fuel tank rear side. sound is hard to hear without removing the tuel tank
• Start the engine and after it stops, turn the igni- cap.
tion switch to OFF.
3. Pinch the hose to check that fuel pressure is feit.
• Disconnect the battery negative (-) terminal.
• Connect the fuel pump harness connector.
3. Remove the two fitting nuts while holding the fuel filter
nuts securely.
4. Remove the fuel filter mounting bolts, and then re-

move the fuel filter from the fuel filter clamp.
Tightenging torque
Fuel filter fitting nut :
30-40 Nm (300-400 kg·ch, 22.1-29.5 Ib·tt)
HEW31 006
EFA9157A
EVAP CANISTER PURGE PORT VACUUM

CHECK EFBB2090
CHECKING CONDITION
Engine coolant temperature : 80-95°C (176-205°F)
1. Disconnect the vacuum hose trom the throttle body

EVAP Canister purge hose titting and connect a vac-
uum pump.
KFW5023A
2. Remove the bolt connecting the tuel line to the tuel

delivery pipe.
w./
EEB9015A
2. Start the engine and check to see that, after increas- ~

Ir--.\ ~
ing the engine speed, vacuum rises tairly constantly. EFA9141A
~NOTE & CAUTION

If there is no vacuum, it is possible that the throttle Cover the hose connection with a shop towel to
body port may be restricted and may require cleaning. prevent splashing of fuel caused by residual pres-
sure in the fuel line.
3. Using the tuel pressure gauge adapter, install the tuel

pressure gauge to the tuel pressure gauge adaptor.
Tighten the bolt to the specitied torque.
Fuel pressure gauge to tuel delivery pipe:

25-35 Nm (250-350 kg·cm, 18-26 Ib·ft)
Engine speed (rpm)
EFA9109B
FUEL PRESSURE TEST EFBB2100
1. Reduce the internal pressure ot the tue I lines and

hoses:
• Disconnect the tue I pump harness connector
• Start the engine and after it stalls, turn the ignition
switch to the OFF position EFA9141B
• Disconnect the battery negative (-) terminal
• Connect the tuel pump harness connector 4. Connect the battery's negative (-) terminal.
5. Apply battery voltage to the terminal tor the pump 8. Measure the tuel pressure when the vacuum hose is
drive and activate the tuel pump. With tuel pressure connected to the pressure regulator.
applied, check that there is no tue I leakage trom the
pressure gauge or connection part. Standard value :
Approx.255 kPa (2.57 kg/cm 2 , 37 psi)
6. Start and run the engine at curb idle speed.
7. Disconnect the vacuum hose trom the pressure regu- 9. It the results ot the measurements made in steps (7)
lator, and plug the hose end. Measure the tuel pres- and (8) are not within the standard value, use the table
sure at idle. below to determine the probable cause, and make the
necessary repairs.
Standard value :
320-340 kPa (3.26-3.47 kg/cm2 , 46-49 psi)
EFBB210A
III
EFBB21oe
Condition Probable cause Remedy

Fuel pressure is too low • Clogged tuel tilter • Replace fuel filter
• Fuel leakage to the return side, caused by • Replace fuel pressure
poor seating ot the fuel-pressure regulator regulator
• Low discharge pressure of the fuel pump • Check the in-tank fuel hose for
large or replace the fuel pump
Fuel pressure is too high • Sticking tuel pressure regulator • Replace fuel pressure
• Clogged or bent fuel return hose or pipe regulator
• Repair or replace hose or pipe
There is no difference in • Clogged, or damaged vacuum • Repair or replace the vacuum
fuel pressure when the hose or nipple hose or the nipple
vacuum hose is connected • Sticking or poor seating ot the tue I • Repair or replace hose or pipe
and when it is not. pressure regulator
10. Stop the engine and check tor a change in the fuel
pressure gauge reading, which should hold tor ap-
proximately 5 minutes. It the gauge indication drops,
observe the rate at which it drops. Determine and re-
move the causes according to the following table.
Condition Probable cause Remedy

Fuel pressure drops slowly • Injector leakage • Replace injector
after engine is stopped
Fuel pressure drops • The check valve within the tuel • Replace tuel pump
immediately after engine pump is open
is stopped
11. Reduce the pressure in the fuel line.
12. Disconnect the hose and the gauge.
& CAUTION
Cover the hose connection with a shop towel to
prevent splashing of fuel caused by fuel residual
pressure in the fuelline.
13. Replace the O-ring at the end of the hose.
14. Connect the fuel hose to the delivery pipe and tighten
to the specified torque.
15. Check for fuel leakage.

• Apply battery voltage to the fuel pump drive ter-
minal to operate the fuel pump.
• With pressure, check the fuelline for leaks.
KFW5022A
FUEL DELIVERY SYSTEM

ACCELERATOR PEDAL EFBB2190
COMPONENTS
I:lr--- Adjusting bolt
Throttle body side inner cable
4-6 (40-60, 3-4) v===================~~----
Bushing--~
Accelerator side inner cable
Accelerator arm bracket
Accelerator arm -----+
TORQUE : Nm (Kg·cm, Ib·ft)
EFBB219A
FUEL DELIVERY SYSTEM FL -79
REMOVAL EFA91220 INSTALLATION EFA91240
1. Remove the bushing and inner cable of the accelera- 1. When installing the return spring and accelerator arm,
tor arm. apply multi-purpose grease around each moving point
of the accelerator arm.
2. Pull the left side of the accelerator pedal toward you,
and then remove the accelerator pedal from the ac-
celerator arm.
EFA9124A
2. Apply sealant to the bolt mounting hole and tighten

EFA9122A
the accelerator arm bracket.
3. Loosen the bolts of the accelerator arm bracket and Tightening torque
remove. Accelerator arm bracket bolts :
8-12 Nm(8CH20 kg·cm, 6-7 Ib·ft)
Bushing
Accelerator arm---->.,;~-tt
Apply grease
EFA9122B
EFA9124B
INSPECTION EFA91230
3. Securely install the resin bushing of the accelerator
1. Check the inner and outer cable for damage. cable on the end of the accelerator arm.
2. Check the cable for smooth movement.

Accelerator cable
3. Check the accelerator arm for deformation.
4. Check the return spring for deterioration.
5. Check the connection of the bushing to the inner ca-

ble.
6. Check the accelerator for proper operation.
EFA9124C
FUEL INJECTOR EFA91260
INSPECTION
1. Measure the resistance of the injectors between the

terminals using an ohmmeter.
Resistance: 13-16!l[at 20°C (68°F)]
2. If the resistance is not within specification, replace the

injector.
EFA9126A
FUEL LlNE EFBB2280
COMPONENTS
:1----- Air intake surge tank
Pressure regulator-\-'r-~O{-..s:~::?
,----Intake manifold
15-20 (150-200, 11-14)-...""....,:~18J
~,.........."....---Gasket
TORQUE : Nm (kg'cm, Ib·ft)
EFBB228A
REMOVAL EFA91290 FUEL LlNE AND VAPOR LlNE EFBB2320
1. Release residual pressure from the fuelline to prevent REMOVAL

fuel from spilling.
1. Remove the fuel tank cap to lower the fuel tank's in-
& CAUTION ternal pressure. Raise the vehicle and disconnect the
fuel pump connector.
Cover the hose connection with rags to prevent
splashing ot tuel trom residual pressure in the tuel
line.
& CAUTION
• Reduce the tuel pressure betore disconnect-
2. Remove the delivery pipe with the fuel injector and ing the tuelline and hose. or tuel will spill out.
pressure regulator. • Cover the pipe connection with a shop towel
to prevent splashing ot tuel trom residual
pressure in the tuelline.
INSTALLATION EFA91300
2. Remove the fuel pump installation screws, then re-

1. Install a new grommet and O-ring to the injector.
move the fuel pump assembly from the fuel tank
2. Apply a coating of solvent, spin die oil or gasoline to
the injector O-ring.
L
EFHAOO6A
EFA9130A
3. Remove the fuel return hose and line.
3. While turning the injector left and right, install it onto 4. Remove the fuel vapor hose and line
the delivery pipe.
INSPECTION EFJB1330
4. Be sure the injector turns smoothly.
1. Check the hoses and pipes for cracking, bending, de-
[QJ) NOTE formation or restrictions.
If injector does not turn smoothly, the O-ring may be
jammed. Remove the injector and re-insert it into the 2. Check the EVAP Canister for restrictions.
delivery pipe and re-check.
3. Check the fuel pump assembly for restrictions and
damage.
Injector
Delivery pipe
EFA9130B
INSTALLATION EFBB2340
1. Install the fuel vapor hose and return hoses.

• If the fuelline has a stepped section, connect the
fuel hose to the line securely, as shown in the
illustration.
• If the fuel line does not have a stepped section,
connect the fuel hose to the line securely.
EFA9134A
2. Install the fuel filter and tighten the fuel filter bracket.
3~ Tighten the two fitting nuts while holding the fuel filter
nuts.
Tightening torque
Fuel filter fitting nuts :
20-40 Nm (300-400 kg·cm, 22.1-29.5 Ib·tt)
4. Install the clips and make sure that they do not inter-
fere with other components.
FUEL TANK EFMB2350
COMPONENTS
Electrical fuel pump and fuel sender connector
Canister
Vapor Tube Hose --~~
~t--~'------ Canister Vent Tube
Vapor Hose
EFMB235A
FUEL DELIVERY SYSTEM FL-85
REMOVAL EFJB1360 7. Loosen the two self-locking nuts that hold the tank in
position and remove the two tank bands.
1. To reduce the internal press ure of the fuel main pipes
and hose, first start the engine and then disconnect
the electrical fuel pump connector located near the
tuel tank.
& CAUTION
Be sure to reduce the fuel pressure before discon-
necting the tuel main pipe and hose, otherwise
tuel will spill out.
2. Disconnect the battery cable from the negative termi-

EFA9136D
nal of the battery.
8. Detach the fuel filler hose and leveling hose.
9. Remove the tuel vapor hose and the tuel tank.
EFA9136A
3. Remove the tue I tank cap.

EFA9136E
4. Disconnect the return hose and vapor hose.
INSPECTION EFA91370
1. Check the hoses and the pipes tor cracks or damage.
2. Check the fuel tank cap tor proper operation.
3. Check the tuel tank tor detormation, corrosion or

cracking.
4. Check the tue I tank inside tor dirt or contamination.

EFHA136C
5. Check the in-tank tuel tilter tor damage or restriction.
5. Disconnect the tuel pump connector.
6. Test the two-way valve tor proper operation.
6. Disconnect the high pressure hose from the fuel tank.
7. Using a vacuum hand pump, check the operation ot
the two-way valve.
EFHA136C
Guide lines for

Valve pump
acceptance or rejection
When connected to Negative pressure
inlet side generated and vacuum
maintained
When connected to No negative pressure
outlet side generated
EFA9138B
o",et'~.t'ld. 4. Connect the vapor hose and return hose. Attach the
[- J~
fuel hose to the line as shown in the illustration.
ZI Zlei 11I, 1 : : : : ' : t

nl';;;;)tthI22~
t
EFA9137A
INSTALLATION EFJB1380
1. Connect the leveling hose to the tank at approximately

40 mm (1.6 in.) of the filler neck. EFA9138C
2. When connecting the filler hose, connect the end with 5. To connect the high pressure hose to the fuel pump,
the shorter straight pipe to the tank side. temporarily tighten the flare nut by hand, and then
tighten it to the specified torque. Be careful that the
Tankside . tuel hose does not twist.
[J1A
Filter hose
Leveling hose
Tightening torque
~
(1.6 in.)
40mm
Filler pipe side

U
Fillerhose
B
High pressure hose flare nut:
~NOTE
30-40 Nm(300-400 kg·cm, 22-29 Ib·tt)
When tightening the tlare nut, be careful not to bend

A<B or twist the fine to prevent damage to the fuel pump
EFA9138A connection.
3. Confirm that the pad is fully bonded to the fuel tank. Flare nut
Install the fuel tank by tightening the self-Iocking nuts
to the tank bands until the rear end of the tank band
contacts the body.
Secure side
EFA9138D
FUEL DELIVERY SYSTEM FL-87
6. Connect the electrical tue I pump assembly connector.
EFHA006A
TROUBLESHOOTING FOR
DTC
DIAGNOSTIC ITEM EFMB5000
DTC Diagnostic item

P0100 Mass Air Flow Sensor Malfunction
P0101 Mass Air Flow Circuit Rang/Performance Problem
P0102 Mass Air Flow Circuit Low Voltage
P0103 Mass Air Flow Circuit High Voltage
DESCRIPTION the sensor and uses the signal to set fuel injector base
pulse width and ignition timing.
The Mass Air Flow (MAF} sensor is located near the air The resistance of the sensor decreases as mass air flow
cleaner. increases. Voltage and current flow is increased to main-
The setlsor measures the mass of air passing through the tain the film's temperature and resistivity.
air intake and gene rates a voltage signal. The Powertrain
Control Module(PCM) receives the voltage generated by
TROUBLESHOOTING GUIDE
DTC detection condition Probable cause

Background • Mass air flow sensor failed
• While the engine is running, the mass air flow sensor outputs a • Open or shorted mass air flow
voltage signal which corresponds to the mass of air flow. sensor circuit, or loose connector
• The Powertrain Control Module checks whether the voltage of • Powertrain control module failed
this signal is at or above the set value.
Check Area
• At idle rpm
• Or engine speed is 3000 r/min or more
Judgment Criteria
• Sensor output voltage has continued to be 0.5V or lower for 4 sec.
Check Area
• Throttle position sensor voltage is 12V or lower.
• Engine speed is 2000 rpm or less.
Judgment Criteria
• Sensor output voltage has continued to be 4.5V or higher for 4 seconds.
TROUBLESHOOTING FOR DTC FL-89
CIRCUIT DIAGRAM
JOINT
CONNECTOR
EFMB705A
TEST PROCEDURE
• Turn the ignition switch on.

• Connect scan tool to data link connector.
• Verify DTC P0100, P01 01, P0102 or P0103 is set.
Is DTC P0112 or P0113 also set?
~
11" ..
&--{ ~
.)
•
9
Start engine.
YES
• Using scan tool, monitor MAF sensor signal.

Is signal within normal parameters? CONTINUED ON
NEXTPAGE
I
No, signal is always below Yes, signal is within normal No, signal varies, but some-
normal. parameters. times falls below normal
• Disconnect MAF sensor. Problem is intermittent or was re-

I
Check MAF sensor for restrictions
• Ignition on, engine off. paired and Powertrain Control such as leaves or other debris. Also,
• Measure voltage between ground Module (PCM) memory was not check sensor terminals for corrosion
and MAF sensor harness cleared. Check terminal connections or loose connections. If OK, replace
connector terminal 4. at PCM and MAF sensor. Clear code MAF sensor. Clear code and verify
Battery voltage should be present, and verify MAF is within normal MAF is within normal parameters.
is it? parameters.
~
Check sensor for restrictions such as leaves or other
$
Repair open in wire supplying battery voltage to MAF
debris. If OK, replace MAF sensor. Clear code and sensor. Clear code and verify MAF sensor is within
verify MAF is within normal parameters. normal parameters.
CONTINUED ON
NEXTPAGE
MP0100B
TROUBLESHOOTING FOR DTC FL -91
CONTINUED FRO"'!
PREVIOUS PAGE
• Turn the ignition off.

• Disconnect MAF sensor.
• Measure resistance between ECM connector E200-2 terminal
22 and MAF sensor harness connector terminal 5.
Resistance should be approximately 1 ohm or less, is it?
Replace MAF sensor. Clear code and verify MAF is Repair open in wire between MAF sensor harness
within normal parameters. connector terminal 5 and ECM connector E200-2
terminal 22. Clear code and verify MAF is within normal
parameters.
CONTINUED FROM
PREVIOUS PAGE
• Ignition off, PCM and MAF sensor still disconnected.

• Ground MAF sensor harness connector terminal 3.
• Measure resistance between ground and ECM connector
E200-2 terminal 9.
Resistance should be approximately 1 ohm or less, is it?
Verify PCM connectors are secure. If OK, replace MAF Repair open in wire between MAF sensor harness
sensor with a known good component. connector terminal 3 and PCM. Clear code and verify
Clear code and verify MAF sensor is within normal MAF is within normal parameters.
parameters. If problem persists, replace ECM.
MP0100c
EFMB5020
DTC Diagnostic item

P0110 Intake Air Temperature Sensor Malfunction
P0112 Intake Air Temperature Circuit Low Voltage
P0113 Intake Air Temperature Circuit High Voltage
DESCRIPTION When the temperature sensed is cold, the PCM enriches

fuel mixture by increasing injector pulse width; as the air
The Intake Air Temperature (IAT) sensor is in the MAF sen- warms, the injector pulse width time is shortened.
sor. The IAT sensor is a variable resistor whose resistance
changes as the temperature of the air flowing through the
air intake changes. The Powertrain Control Module (PCM)
uses the IAT sensor input to adjust fuel injector pulse width.

Background • IAT sensor failed
• The intake air temperature sensor converts the intake air • Open or shorted mass air flow
temperature to a voltage and outputs it. sensor circuit, or loose connector
• The powertrain control module checks whether the voltage • powertrain control module failed
is within a specified range.
Check Area
• Sixty seconds or more have passed since the engine was started.
Judgment Criteria
• Sensor output voltage has continued to be 4.6V or higher [corresponding
to an intake air temperature of -45°C (-49°F) or lower] for 4 sec.
• Sensor output voltage has continued to be O.2V or lower [corresponding
to an intake air temperature of 125°C (257°F) or higher] for 4 sec.
CIRCUIT DIAGRAM
JOINT
CONNECTOR
EFMB705A
TEST PROCEDURE

• Verify DTC P011 0, P0112 or P0113 is set.
Is other DTC also set?
YES
• Engine at ambient temperature (overnight cool

down in shop recommended).
• Measure air temperature of shop.
CONTINUED ON
• Turn the ignition on. NEXT PAGE
• Connect scan tool and observe intake air
temperature (lAT) sensor reading.
Scanned temperature should be very close to shop
air temperature, is it?
I
No, scanned temperature No, scanned temperature Yes, scanned temperature
is above air temperature is below air temperature is very close to measured
of shop. of shop. air temperature of shop.
I
• Turn the ignition off. • Turn the ignition off. No problem found at this time.
• Disconnect MAF & IAT sensor. • Disconnect MAF & IAT sensor. Fault is intermittent or was
• Turn the ignition on. • Turn the ignition on. repaired and PCM memory was
• Observe IAT sensor reading on • Measure voltage between not cleared. Clear code and verify
scan tool. ground and MAF & IAT harness IAT sensor is within normal
Scanned temperature should now connector terminal 2. parameters.
be -40°F (-4.4°C), is it? Voltage measured should be 4.5
to 5.0 volts, is it?
I I
NO Yes, 4.5 to 5.0 volts No, 0 volts is No, 12 volts is
is present. present. present.
I I
Repair short to battery voltage in
Replace MAF & IAT sensors.
Clear code and verify IAT sensor wire between MAF & IAT sensor
is within normal parameters. and PCM.
Clear code and verify IAT sensor
is within normal parameters.
B C
CONTINUED ON CONTINUED ON
NEXTPAGE NEXTPAGE
MPOll0B
CONTINUED FROM
PREVIOUS PAGE
A

• Disconnect MAF & IAT sensor.
• Measure resistance between ground and MAF &
IAT sensor harness connector terminal 3.
Resistance should be approximately 1 ohm or less,
is it?
Replace MAF & IAT sensor. Repair open in wire between MAF
Clear codes and verify IAT sensor & IAT sensor harness connector
is within normal parameters. terminal 3 and PCM. Clear codes
and verify IAT sensor is within
normal parameters.
CONTINUED FROM CONTINUED FROM

PREVIOUS PAGE PREVIOUS PAGE
B
•MAF & JAT sensor disconnected. • MAF & IAT sensor disconnected.
•Turn the ignition off. • Turn the ignition off.
•Disconnect PCM connector. • Disconnect PCM connector C44-2.
•Measure resistance between ground and MAF & • Ground MAF & IAT sensor harness connector
IAT sensor harness connector terminal 5. terminal 1.
Resistance should indicate an open circuit, does it? • Measure resistance between ground and PCM
connector C44-2 terminal 9.
Resistance should be approximately 1 ohm or less,
is it?
Repair short to ground in wire Verify PCM connectors are secure Repair open in wire between MAF
between MAF & IAT sensor If OK, replace MAF & JAT sensor. & IAT sensor harness connector
harness connector terminal 5 and Clear code and verify IAT sensor terminal 5 and PCM. Clear code
PCM. Clear code and verify IAT is within normal parameters. and verify IAT sensor is within
sensor is within normal If problem persists, replace ECM. normal parameters.
parameters.
MP0110C
EFMB5030
DTC Diagnostic item

P0115 Engine Coolant Temperature Circuit Malfunction (Open/Short)
P0116 Engine Coolant Temperature Circuit Drift
P0125 Insufficient Coolant Temperature For Feed-Back Control
DESCRIPTION the sensor resistance is low. The Powertrain Control Mod-

ule (PCM) checks ECT voltage fifty times per second and
The Engine Coolant Temperature (ECT) sensor is located uses the information to help adjust the fuel injector pulse
in a coolant passage of the cylinder head. The ECT sen- width and ignition timing. When the temperature sensed
sor is a variable resistor whose resistance changes as the is very cold, the PCM enriches the fuel mixture.
temperature of the engine coolant flowing past the sensor
changes. When the coolant temperature is low, the sensor
resistance is high; when the coolant temperature is high,

Background • Engine Coolant Temperature
• The engine coolant temperature sensor converts the engine sensor failed.
coolant temperature to a voltage and outputs it. • Open or shorted Engine Coolant
• The Powertrain Control Module checks whether the voltage is within Temperature sensor circuit, or
a specified range. In addition, it checks that the engine coolant loose connector.
temperature (signal) does not drop while the engine is warming up. • Powertrain Control Module failed.
Malfunction; out-of-range
• Sensor output voltage has continued to be 4.6V or higher [corresponding
to a coolant temperature of -45°C (-49°F) or lower] for 4 sec.
• Sensor output voltage has continued to be 0.1 V or lower [corresponding
to a coolant temperature of 140°C (284°F) or higher] for 4 sec.
Malfunction; out-of-range
• Sensor output voltage increased from a value lower than 1.6V to a value
high er than 1.6V [Coolant temperature decreases from higher than 40°C
(104°F) temperature to lower than 40°C (104°F) temperature.].
• Sensor output voltage has continued to be 1.6V or higher for 5 min.
Judgment Criteria, Proper Performance

• The Engine Coolant Temperature is approx. 40°C (104°F) or
less after starting sequence is completed.
• Approx. 60 - 300 seconds have passed for the engine
coolant temperature to rise to about 40°C (104°F) after
starting sequence was completed.
CIRCUIT DIAGRAM
Engine coolant temperature sensor
PCM
MP0115A
TEST PROCEDURE

• Verify DTC P0115, P0116 or P0125 is set.
Is DTC P0112, P0113 also set?
I
$
• Engine cold.
$J
Refer to section P0112, P0113 and
• Connect scan tool and observe Engine Coolant Temperature follow those test procedures.
(ECT) sensor and IAT sensor readings.
Scanned temperatures should agree with air temperature of shop.
Dothey?
I
~
I I
No, IAT temperature reading No, ECT temperature
disagrees. reading disagrees.
I I
• Turn ignitition off. Refer to DTC P0112, P0113 and Replace ECT sensor. Clear code
• Disconnect ECT sensor. follow procedure to test IAT sensor. and verify ECT sensor is within
• Turn the ignition on. normal parameters.
• Measure voltage across ECT
sensor harness connector
terminals 1 and 3.
Voltage measured should be 4.5 to
5.0 volts. Is it?
I
I I
Yes, 4.5 to 5.0 volts is No, less than 4.5 volts is
present present
I I
Replace ECT sensor. Clear any •Turn the ignition off.
codes and verify ECT sensor is •Disconnect the ECT sensor.
within normal parameters. •Disconnect PCM connector E200-2.
•Ground ECT harness connector terminal 3.
•Measure resistance between ground and PCM harness
connector E200-2 terminal 9.
Resistance should be approximately 1 ohm or less. Is it?
§ [$
Repair open circuit between ECT sensor harness connector
terminal 3 and PCM harness connector E200-2 terminal 9.
A
Clear all codes and verify ECT sensor is within normal parameters.
CONTINUED ON
NEXTPAGE
MP0115B
CONTINUED FROM
PREVIOUS PAGE
•Turn the ignition off.

•Disconnect the ECT sensor.
•Disconnect PCM connector E200-2.
•Measure resistance between ground and PCM harness
Resistance should indicate an open circuit. Does it?
Repair short to ground between ECT sensor harness connector

terminal 3 and PCM harness connector E200-2 terminal 9.
Clear all codes and verify ECT sensor is within normal parameters.

• Disconnect the ECT sensor.
• Disconnect PCM connector E200-2.
Measure resistance between ground and ECT sensor harness
connector terminal 1.
YES
Verify PCM connector is secure. Repair open circuit between ECT sensor harness connector
Replace ECT sensor with a known terminal 1 and PCM harness connector E200-2 terminal 4.
good component. If problem per- Clear any codes and verify ECT sensor is within normal parameters.
sists, replace PCM. Clear code and
verify ECT sensor is within normal
parameters.
MPOll5C
EFMB5040
DTC Diagnostic item

P0120 Throttle Position Circuit Malfunction
P0122 Throttle Position Circuit Low Voltage
P0123 Throttle Position Circuit High Voltage
DESCRIPTION Control Module (PCM) applies a reference voltage to the

TPS and then measures the voltage that is present on
The throttle position sensor (TPS) mounts on the side of the TPS signal circuit. The PCM uses the TPS signal to
the throttle body and is connected to the throttle blade adjust the timing and injector pulse width. The TPS signal
shaft. The TPS is a variable resistor (potentiometer) along with the MAP sensor signal is used by the PCM to
whose resistance changes according to the throttle blade calculate the engine load.
shaft position. During acceleration, the TPS resistance
decreases; during deceleration, the TPS resistance
increases. The TPS also includes an idle position switch.
The switch is closed in the idle position. The Powertrain

Background • Throttle Position sensor failed
• The Throttle Position sensor outputs a voltage which is proportional or maladjusted.
to the throttle valve opening angle. • Open or shorted Throttle Position
• The Powertrain Control Module checks whether the voltage output sensor circuit, or loose connector.
by the throttle position sensor is within a specified range. • Closed Throttle Position switch
In addition, it checks that the voltage output does not become ON malfunction.
too large while the engine is idling. • Closed Throttle Position switch
signal wire shorted.
Malfunction; out-of-range • Powertrain control module failed.
• With the close Throttle Position switch set to ON, the sensor output
voltage has continued to be 2V or higher for 4 sec.
• Sensor output voltage has continued to be 0.2V or lower for 4 sec.
Operating parameters
• Engine speed is between 500 and 3,000 rpm.
• Engine load is lower than 30%.
Proper Performance
• Sensor output voltage has continued to be 4.6V or higher for 4 sec.
CIRCUIT DIAGRAM
MP0120A
TEST PROCEDURE

• Verity DTC P0120, P0122 or P0123 is set.
Are any other codes also set?
$
• Turn the ignition on with the
engine idling.
• Using scan tool, observe throttle
position sensor output.
Throttle position output should be
between 0.3V and 0.9V, is it?
I
No, output is above 0.9V or
belowO.3V.
I No, output is above 0.9V I Yes, output is between 0.3V
and 0.9V.
I
• Turn the ignition on, with the • Turn the ignition off. Problem is intermittent or was
engine off. • Disconnect TP sensor. repaired, and PCM memory was not
• Throttle should be fully released. • Turn the ignition on (engine off). cleared. Check terminal connec-
• Attempt to adjust TP sensor • Using scantool, measure voltage. tions at PCM and TP sensors. Clear
output voltage to between 0.4 Voltage should be 0 volts. Is it? any codes and verity TP sensor is
and 0.5 volts. within normal parameters.
Can TP sensor voltage be adjusted
as specified?
Replace TP sensor. Clear any codes Repair short to voltage in wire

and verity TP sensor is within normal between TP sensor harness con-
parameters. nector terminal 4 and PCM harness
Clear any codes and verify TP
sensor is within normal parameters.
NO
• Ignition on, engine off.

• Hold throttle in wide open
position.
• Measure TP sensor voltage.
Voltage should be about 4.8 volts,
is it?
CONTINUED ON CONTINUED ON
NEXT PAGE NEXT PAGE
MP0120C
CONTINUED FROM
PREVIOUS PAGE

• Disconnect TP sensor.
• Turn the ignition on.
• Using a voltmeter, measure voltage between
ground and TP sensor harness connector
terminal 4.
5 volts should be present. Is it?
• Turn the ignition on with the engine off. Repair open in wire between TP sensor harness
• Disconnect the TP sensor. connector terminal 4 and PCM harness connector
• Measure resistance between ground and TP E200- terminal 2.
sensor harness connector terminal 1. Clear any codes and verify TP sensor is within
Resistance should be approximately 1 ohm or less. normal parameters.
Is it?
• Connect a fused jumper ac ross TP sensor Repair poor ground or open in wire between TP
harness connector terminal 1 and terminals 4. sensor harness connector terminal 1 and PCM
• Using scan tool, observe TP sensor's output harness connector E200-2 terminal 2.
voltage. Clear code and verify TP sensor is within normal
Voltage should be above 4.8 volts. Is it? parameters.
• Turn the ignition off. Replace TP sensor.

• Fused jumper in place. Clear code and verify TP sensor is within normal
• Measure voltage (backprobe) between PCM parameters.
connector E200-3 terminal 2 and ETS connector
E200-2 terminal 4.
5 volts should be present. Is it?
CONTINUED ON
NEXT PAGE
MP0120D
CONTINUED FROM CONTINUED

PREVIOUS PAGE FROM PAGE 3
D C
Fault repaired. Problem was Replace TP sensor. Clear any

misadjusted TP sensor. Clear codes and verify TP sensor is
any codes and verify TP sensor within normal parameters.
• Turn the ignition on with the engine idling. Repair open or short to ground.
• Using scan tool, observe idle output. Clear any codes and verify TP sensor
Idle switch should be closed. Is it? is within normal parameters.
• Turn the ignition oft. Replace throttle position sensor.

• Disconnect the TP sensor. Clear code and verify TP sensor is
• Measure resistance between TP sensor connector terminal within normal parameters.
2 and TP sensor terminal 3 while moving the throttle valve
from idle to open position.
Resistance should indicate a short circuit in the idle position,
and an open circuit with the throttle valve in an open position.
Are resistance measurements OK?
Verify PCM connector is secure. If OK, replace the TP sensor. Replace the TP sensor.
If problem persists, replace PCM. Clear any codes and verify Clear any codes and verify TP sensor
TP sensor is within normal parameters. is within normal parameters.
MP0120E
EFMB5060
DTC Diagnostic item

P0132 Oxygen Sensor Circuit Malfunction -Open (Bank 1, Sensor 1)
P0133 Oxygen Sensor Circuit Malfunction (Bank 1, Sensor 1)
P0150 Oxygen Sensor Circuit Malfunction (Bank 2, Sensor 1)
P0152 Oxygen Sensor Circuit Malfunction Open (Bank 2, Sensor 1)
DESCRIPTION
To obtain a high purification rate for the CO, HC and NOx

components of the exhaust gas, a three way catalytic
converter is used, but for the most efficient use of the
three-way catalytic converter, the ratio of the air must
be precisely controlled so that it is always Glose to the
stoichiometric air-fuel ratio. The oxygen sensor has the
characteristic whereby its output voltage changes sud-
denly in the vicinity of the stoichiometric air-fuel ratio. This
characteristic is used to detect the oxygen concentration
in the exhaust gas and provide feedback to the computer
for control of the air-fuel ratio. When the air-fuel ratio
becomes LEAN, the oxygen concentration in the exhaust
increases and the oxygen sensor informs the PCM of the
LEAN condition. When the air-fuel ratio is RICHER than
the stoichiometric air-fuel ratio the oxygen concentration
in the exhaust gas is reduced and the oxygen sensor
informs the PCM of the RICH condition.
The PCM determines by the electromotive force from the
oxygen sensor whether the air-fuel ratio is RICH or LEAN
and controls the injection time accordingly. However, if
malfunction of the oxygen sensor causes output of abnor-
mal electromotive force, the PCM is unable to perform an
accurate air-fuel ratio contro!. The heated oxygen sensors
include a heater which heats the sensing element. The
heater is controlled by the PCM. When the intake air vol-
ume is low (the temperature of the exhaust gas is low),
current flows to the heater to heat the sensor for accurate
oxygen concentration detection.

Background • Heated oxygen sensor
• When the heated oxygen sensor beg ins to deteriorate, the oxygen deteriorated
sensor signal response becomes poor. • Open circuit in heated oxygen
• The Powertrain Control Module torcibly varies the air/tuel sensor output line
mixture to make it leaner and richer and checks the response • Powertrain control module tailed
speed ot the heated oxygen sensor.
In addition, the Powertrain Control Module also checks tor an open
circuit in the heated oxygen sensor output line.
Maltunction; out-ot-range
• Coolant temperature sensor: Normal.
• Heated oxygen sensor signal voltage has continued to be 0.1 V or lower
tor 3 min. or more after the staring sequence was completed.
• Engine Coolant Temperature is higher than 80°C (176°F).
• Engine speed is higher than 1,200 r/min.
• Engine load is 25% or more. Judgment Criteria
• Input voltage supplied to the Powertrain Control Module interface
circuit is 4.5V or more when 5V is applied to the heated
oxygen sensor output fine via a resistor.
Proper Operation
• Engine Coolant Temperature is 50°C (122°F) or more.
• Engine speed is between 1,500 and 3,000 r/min or 1,100 and 3,000 r/min.
• Engine load is 25 - 60%.
• Intake air temperature is -10°C (14°F) or more.
• Under the closed loop air-tuel control.
• Monitoring Time: 8sec.
Failure Criteria
• When the air-tuel ratio is torcibly changed (Iean to rich
and rich to lean), the heated oxygen sensor signal doesn't
provide response within 1.28 sec.
• Monitored only once per trip.
CIRCUIT DIAGRAM
ENGINE
COMPARTMENT
JUNCTION
BLOCK
VARIABLE
RESISTOR
G13
26 E200-1 3 E200-3 27 E200-1 4 4 E200-1 2 E200-3 3 E200-1
EFMB109A
TEST PROCEDURE

• Verify DTC P0132, P0133, P0150 or P0152 is set.
Are other DTCs also set?
I ~
IVESI
~ I
• Start engine and warm it to normal operating temperature. First, repair conditions that caused
• Turn on air conditioning (if equipped). other DTCs to be set. Refer to DTC
• Increase engine speed to 4000 RPM and, using scan tool, monitor test procedures.
oxygen sensor voltage.
Voltage should vary between 0 and 900mV. Does it?
[
No, voltage is No, voltage is No, 0 volts No, voltage No, voltage Yes, voltage
constant and the constant and present. va ries but stays varies but stays varies between
reading is approximately 5 below500mV above 500mV ·100 and 900mV.
between 19 and or 12 volts. (Iean). (rich).
58mV. I
Repair short to
W ~
voltage in wiring
D
harness. Clear
code and verify v CONTINUED ON
oxygen sensor CONTINUED ON NEXTPAGE
is within normal NEXT PAGE
parameters.
• While running the engine, measure • Disconnect oxygen sensor connector.

voltage (backprobe) between front Does voltage now read between 19 and 58mV on
oxygen sensor connector terminals scan tool?
1 and 2.
Does voltage read above and below
500mV?
I-r-_
NO I ~
Repair short to ground in wire between oxygen Replace oxygen
sensor harness connector terminal 1 and ground. sensor. Clear
CONTINUED ON Clear code and verify oxygen sensor is within code and verify
NEXT PAGE normal parameters. oxygen sensor
is within normal
parameters.
MP01328
CONTINUED FROM
PREVIOUS PAGE
~.
~ ~
• Turn the ignition off. Replace oxygen sensor. Clear code
• Disconnect front oxygen sensor. and verify oxygen sensor is within
• Disconnect PCM connector. normal parameters.
• Ground front oxygen sensor harness connector terminal 1.
• Measure resistance between ground and the related PCM
harness connector E200-3 terminal.
Resistance measured should be approximately 1 ohm or less. Is it?
IVESI @
Verity PCM connectors are secure. If OK, replace Front Oxygen Repair open wire or cause of high
sensor with a known component of good quality. Clear code and resistance. Clear code and verify
verity oxygen sensor is within normal parameters. oxygen sensor is within normal
If problem persists, replace PCM. parameters.

T
Voltage varies but stays below
'f
Voltage va ries but stays above
500mV (Iean). 500mV (rich).
I
• Inspect air inlet downstream of air flow sensor for leaks or
damage.
• Inspect exhaust manifold for cracks.
Are any leaks or damage found?
I
~
I VEsl
I
Repair leaks or replace exhaust
$
• Perform a fuel pressure test
manifold. Clear code and verify Is fuel pressure within specification and no pressure leak down
oxygen sensor is within normal is observed?
parameters.
CONTINUED ON
NEXT PAGE
MP0133C
r
E
Voltage varies between 0 and

900mV.
.L
lVESJ l NO [
I 1
• Turn the ignition off. Follow diagnostic procedures.
• Disconnect the connector at the ignition coil. Clear code and verify oxygen
• Measure voltage drop across negative battery cable by sensor is within normal parameters.
connecting voltmeter between negative battery post and cable
attachment point on engine while cranking the engine.
Measured voltage drop should be less than 0.5 volts, is it?
IVESI I NO I
I I
• Disconnect negative battery terminal. Replace negative battery cable.
• Measure resistance between generator case and an engine Clear code and verify oxygen
ground point. sensor is within normal parameters.
IVESI
I
• If Malfunction Indicator Lamp (MIL) is turned on intermittently
$
Clean mating surfaces of generator
and DTC P0133 is set, the problem is most likely a poor ground housing and engine block. Clear
circuit. Clean negative battery terminal and engine ground. Also code and verify oxygen sensor is
clean mating surfaces of generator housing and engine block. within normal parameters.
• If Malfunction Indicator Lamp (MIL) was on and DTC P0133 is
set, replace oxygen sensor.
• Clear code and verify oxygen sensor is within normal parameters.
HPOl33D
EFMB5070
DTC Diagnostic item

P0135 Oxygen Sensor Heater Circuit Malfunction (Bank 1, Sensor 1)
P0155 Oxygen Sensor Heater Circuit Malfunction (Bank 2, Sensor 1)
DESCRIPTION in the exhaust gas is reduced and the oxygen sensor

To obtain a high purification rate for the CO, HC and NOx The PCM determines by the electromotive force from the
components of the exhaust gas, a three way catalytic oxygen sensor whether the air-fuel ratio is RICH or LEAN
converter is used, but for the most efficient use of the and controls the injection time accordingly. However, if
three-way catalytic converter, the ratio of the air must malfunction of the oxygen sensor causes output of abnor-
be precisely controlled so that it is always close to the mal electromotive force, the PCM is unable to perform an
stoichiometric air-fuel ratio. The oxygen sensor has the accurate air-fuel ratio control. The heated oxygen sensors
characteristic whereby its output voltage changes sud- include a heater which heats the sensing element. The
denly in the vicinity of the stoichiometric air-fuel ratio. This heater is controlled by the PCM. When the intake air vol-
characteristic is used to detect the oxygen concentration ume is low (the temperature of the exhaust gas is low) ,
in the exhaust gas and provide feedback to the computer current flows to the heater to heat the sensor for accurate
for control of the air-fuel ratio. When the air-fuel ratio oxygen concentration detection.
DTC detection conditlon Probable cause

Background • Open or shorted oxygen sensor
• The Powertrain Control Module checks whether the heater current heater circuit
is within a specified range when the heater is energized. • Open circuit in oxygen sensor
heater
Check Area • Powertrain control module failed
• Battery voltage is between 12 and 16V.
Judgment Criteria
• The heater current ofthe front heated oxygen sensor heater
(Bank 1 Sensor 1 and Bank 2 Sensor 1) has continued to be
0.2 A or less, or 3.5 A or higher for 6 sec.
CIRCUIT DIAGRAM
ENGINE
COMPARTMENT
JUNCTION
BLOCK
VARIABLE
RESISTOR
G13
26 E200·1 3 E200-3 27 E200-1 4 4 E200-1 2 ____________ j E200-3 3 E200-1
EFMB109A
TEST PROCEDURE

• Verify DTC P0135 or P0155 is set.
• Disconnect front oxygen sensor.

• Start engine.
• Measure voltage between oxygen sensor
harness connector terminal 3 and ground.
Voltage should between 12 and 16 volts. Is it?
•Turn the ignition switch off. Repair open or short to ground in wire between
• Disconnect the front oxygen sensor. engine compartment junction block terminal and
• Disconnect the related PCM connector. oxygen sensor harness connector terminal 3.
•Ground front oxygen sensor harness terminal 4. Clear code and verify oxygen sensor is within
• Measure resistance between ground and PCM normal parameters.
harness connector E200-1 terminal 4 or E200-3
terminal 1.
Resistance should be 1 ohm or less. Is it?
•Turn the ignition switch off. Repair open in wire between oxygen sensor
•Disconnect the front oxygen sensor. harness connector terminal 4 and the related PCM
•Disconnect the related PCM connector. harness connector terminal.
•Measure resistance between ground and oxygen Clear code and verify oxygen sensor is within
sensor harness connector terminal 4. normal parameters.
CONTINUED ON
NEXTPAGE
MP0135B
CONTINUED FROM
PREVIOUS PAGE
A
• Turn the ignition switch off. Repair short to ground or another circuit in
• Disconnect the front oxygen sensor. wire between oxygen sensor harness connector
• Measure resistance between terminals 3 and 4 terminal 4 and the related PCM harness connector
of oxygen sensor connector. terminal.
Is resistance within normal parameters Clear code and verify oxygen sensor is within
(11 - 14 ohms)? normal parameters.
Verify PCM connector is secure. If OK, replace Front Replace oxygen sensor. Clear code and verify
Oxygen Sensor with a known good component. oxygen sensor is within normal parameters.
Clear code and verify oxygen sensor is within
normal parameters. If problem persists, replace
PCM.
MP0135C
EFMB5080
DTC Diagnostic item

P0136 Oxygen Sensor Circuit Malfunction - Open (Bank 1, Sensor 2)
P0156 Oxygen Sensor Circuit Malfunction - Open (Bank 2, Sensor 2)
P0140 Oxygen Sensor Circuit Malfunction - Short (Bank 1, Sensor 2)
P0160 Oxygen Sensor Circuit Malfunction - Short (Bank 2, Sensor 2)

To obtain a high purification rate for the CO, HC and NOx The PCM determines by the electromotive force from the
components of the exhaust gas, a three way catalytic oxygen sensor whether the air-fuel ratio is RICH or LEAN
converter is used, but for the most efficient use of the and controls the injection time accordingly. However, if
three-way catalytic converter, the ratio of the air must malfunction of the oxygen sensor causes output of abnor-
be precisely contra lied so that it is always close to the mal electromotive force, the PCM is unable to perform an
stoichiometric air-fuel ratio. The oxygen sensor has the accurate air-fuel ratio control. The heated oxygen sensors
characteristic whereby its output voltage changes sud- include a heater wh ich heats the sensing element. The
denly in the vicinity of the stoichiometric air-tuel ratio. This heater is controlled by the PCM. When the intake air vol-
characteristic is used to detect the oxygen concentration urne is low (the temperature of the exhaust gas is low),

Background • Heated oxygen sensor failed
• The Powertrain Control Module checks for an open circuit in • Open circuit in heated oxygen
the heated oxygen sensor output line. sensor output line
• Powertrain control module failed
Normal values
• Heated oxygen sensor signal voltage has continued to be 0.1 V or lower
for 3 min. or more after the staring sequence was completed.
• Engine coolant temperature is 80°C (176°F) or more.
• Engine speed is higher than 1,200 r/min.
• Engine load is 25% or more.
• Monitoring Time: 7 - 10 sec.
Items to Check
• Input voltage supplied to the Powertrain Contral Module interface
circuit is 4.5V or more when 5V is applied to the heated
oxygen sensor output line via a resistor.
• Making the air-fuel ratio 15% richer doesn't result in raising the
heated oxygen sensor output voltage beyond 0.1 V.
CIRCUIT DIAGRAM
ENGINE
COMPARTMENT
JUNCTION
BLOCK
VARIABLE
RESISTOR
G13
26 E200-1 3 E200-3 27 E200-1 4 4 E200-1 2 1 E200-3 3 E200-1
EFMB109A
TEST PROCEDURE

• Verify DTC P0136, P0156, P0140 or P0160 is set.
Are other DTCs also set?
J.
$
• Start engine and warm it to normal operating temperature.
IY~SI
Repair conditions that caused other
• Turn on air conditioning (if equipped). DTCs to set. Refer to the appropriate
• Increase engine speed to 4000 RPM and, using scan tool, monitor DTC test procedures.
oxygen sensor is voltage.
Voltage should vary between 0 and 900mV. Does it?
I
No, voltage is No, voltage is No, 0 volts· No, voltage No, voltage Yes, voltage
constant approximately 5 present. va ries but stays varies but stays varies between
between or 12 volts and below500mV above 500mV 100 and 900mV.
19 and 58mV. constant. (Iean). (rich).
I
Repair short to
voltage in wiring
harness. Clear
code and verify
oxygen sensor
, v
CONTINUED ON
W D
CONTINUED ON
NEXT PAGE
is within normal NEXTPAGE
parameters.
• While running the engine, measure • Disconnect oxygen sensor connector.

voltage (backprobe) between rear Does voltage now read between 19 and 58mV on
oxygen sensor connector terminals scan tool?
1 and 2.
Does voltage very above and below
500mV?
I NO I
I
rvisl
I
A Repair short to ground in wire between oxygen Replace oxygen

sensor harness connector terminal 1 and ground. sensor. Clear
CONTINUED ON Clear code and verify oxygen sensor is within code and verify
NEXTPAGE normal parameters. oxygen sensor
is within normal
parameters.
MP0136B
CONTINUED FROM
PREVIOUS PAGE
'f
IVESI
~
•Turn the ignition off. Replace oxygen sensor.
•Disconnect the related PCM connector. Clear code and verity oxygen sensor
•Disconnect rear oxygen sensor. is within normal parameters.
•Ground rear oxygen sensor harness connector terminal 1.
•Measure resistance of wire between oxygen sensor harness
connector terminal 1 and the related PCM connector terminal.
lVESJ I NO I
Verity PCM connectors are secure. If OK, replace Rear Oxygen Repair open wire or cause of high
sensor. resistance. Clear code and verity
Clear code and verity oxygen sensor is within normal oxygen sensor is within normal
parameters. If problem persists, replace PCM. parameters.

f
Voltage varies but stays below
f
Voltage va ries but stays above
500mV (Iean). 500mV (rich).
I
• Inspect air inlet downstream of air flow sensor for leaks or
damage.
• Inspect exhaust manifold for cracks.
Are any leaks or damage found?
I
I I
I
~ NO
I
Repair leaks or replace exhaust • Perform a fuel pressure test.
manifold. Is fuel pressure within specification and no pressure leak
Clear code and verify oxygen sensor is observed?
CONTINUED ON
NEXT PAGE
MP0136C

'f
E
Voltage varies between 0 and

900mV. 1
I
IVESI I NO I
'T
• Turn the ignition off. Follow diagnostic procedures
• Disconnect ignition coil connector. outlined in shop manual. Clear code
• Measure voltage drop across negative battery cable by and verify oxygen sensor is within
connecting voltmeter between negative battery post and cable normal parameters.
attachment point on engine while cranking the engine.
Voltage drop measured should be less than 0.5 volts, is it?
/vES] I NO I
T
• Disconnect negative battery terminal. Replace negative battery cable.
• Measure resistance between generator case and engine ground Clear code and verity oxygen sensor
point. is within normal parameters.
Resistance measured should be approximately 1 ohm or less, is it?
lVESI
~
• If Malfunction Indicator Lamp (MIL) is turning on intermittently Clean mating surfaces of generator
and DTC P0136 is set, problem is most likely a poor ground housing and engine block. Clear
circuit. Clean negative battery terminal and engine ground. Also code and verify oxygen sensor is
clean mating surfaces of generator housing and engine block. within normal parameters.
• If Malfunction Indicator Lamp (MIL) was on and DTC P0139 is
set, replace oxygen sensor.
• Clear code and verity oxygen sensor is within normal parameters.
BP0136D
EFMB5090
DTC Diagnostic item

P0141 Oxygen Sensor Heater Circuit Maltunction (Bank 1, Sensor 2)
P0161 Oxygen Sensor Heater Circuit Maltunction (Bank 2, Sensor 2)

, informs the PCM of the RICH condition.
To obtain a high puritication rate tor the CO, HC and NOx The PCM determines by the electromotive force trom the
components ot the exhaust gas, a three way catalytic oxygen sensor whether the air-fuel ratio is RICH or LEAN
converter is used, but tor the most efficient use ot the and controls the injection time accordingly. However, if
three-way catalytic converter, the ratio ot the air must malfunction of the oxygen sensor causes output of abnor-
be precisely controlled so that it is always elose to the mal electromotive force, the PCM is unable to perform an
stoichiometric air-tuel ratio. The oxygen sensor has the accurate air-fuel ratio control. The heated oxygen sensors
characteristic whereby its output voltage changes sud- include a heater which heats the sensing element. The
denly in the vicinity ot the stoichiometric air-fuel ratio. This heater is controlled by the PCM. When the intake air vol-
characteristic is used to detect the oxygen concentration ume is low (the temperature of the exhaust gas is low),
the stoichiometric air-tuel ratio the oxygen concentration

Background • Open or shorted oxygen sensor
• The Powertrain Control Module checks whether the heater current heater circuit
is within a specified range when the heater is energized. • Open circuit in oxygen sensor
heater
Check Area • Powertrain control module failed
• Battery voltage is between 12 and 16V.
Judgment Criteria
• The heater current ot the front heated oxygen sensor heater
(Bank 1 Sensor 1 and Bank 2 Sensor 1) has continued to be
0.2 A or less, or 3.5 A or higher for 6 sec.
CIRCUIT DIAGRAM
ENGINE
COMPARTMENT
JUNCTION
BLOCK
VARIABLE OXYGEN
RESISTOR SENSOR
(B2I51)
G13
26 E200-1 3 E200-3 27 E200-1 4 4 E200-1 2 E200-3 3 E20o-1
EFMB109A
TEST PROCEDURE

I
• Disconnect rear oxygen sensor.
• Start engine.
• Measure voltage between oxygen sensor harness
connector terminal 3 and ground.
Voltage should be between 12 and 16 volts. Is it?
I
S
• Turn the ignition switch off.
S
Repair open in wire between engine comportment
• Disconnect the rear oxygen sensor disconnected. junction block terminal and oxygen sensor harness
• Disconnect the related PCM connector. Ground rear connector terminal 3.
oxygen sensor harness connector terminal 4. Clear code and verify oxygen sensor is within
• Measure resistance between ground and the related normal parameters.
PCM connector terminal.
Resistance measured should be approximately 1 ohm
or less. Is it?
I
S
• Turn the ignition switch off.
S
Repair open in wire between the related PCM harness
• Disconnect the rear oxygen sensor disconnected. connector terminal and oxygen sensor harness
• Disconnect PCM connector C44-1. Measure connector terminal 4.
resistance between ground and oxygen sensor Clear code and verify oxygen sensor is within normal
harness connector terminal 4. parameters.
I
~
• Ignition switch off.
~
Repair short to ground or another circuit in wire
• Rear oxygen sensor disconnected. between the related PCM harness connector terminal
• Measure resistance between terminals 3 and 4 of and oxygen sensor harness connector terminal 4.
oxygen sensor connector. Clear code and verify oxygen sensor is within normal
Is resistance within normal parameters (7-9 ohms)? parameters.
I
S
Verify PCM connector is secure. If OK, replace Rear
~
Replace oxygen sensor. Clear code and verify oxygen
Oxygen sensor. Clear code and verify oxygen sensor sensor is within normal parameters.
is within normal parameters. If problem persists,
replace PCM.
MP0141B
EFMB5100
DTC Diagnostic item

P0201, P0202
Injector Circuit Maltunetion (Cylinder-1, Cylinder-2, Cylinder-3, Cylin-
P0203, P0204
der-4, Cylinder-5, Cylinder-6)
P0205, P0206
DESCRIPTION when to pulse the injectors. Engine coolant temperature,

intake air temperature, air tlow and throttle position data
The tuel injectors are solenoid operated valves that are are all used by the PCM to calculate injector pulse width.
normally closed. When a tuel injector solenoid is ener- The PCM also uses its network ot sensors to determine
gized (pulsed) the injector needle valve moves, allowing whether all injectors should be pulsed at the same time
pressurized tuel to pass through the injector and mix with (simultaneous injection) or each injector should be pulsed
the air entering the engine. Each tue I injector (there is one individually (sequential injection). Sequential injection is
tor each engine cylinder) is mounted in the intake manitold almost always used during normal engine operation and
and is positioned to spray tue I into a cylinder head intake simultaneous injection may be used when the engine is
port. being cranked.
The Powertrain Control Module (PCM) controls injector
timing and pulse width (how long the tuel injectors are
turned on). The PCM pulses the tuel injectors based on in-
formation provided by its network ot engine sensors. The
PCM uses the crankshaft position sensor to determine

Background • Failed injector
• A surge voltage is generated when the injectors are driven and • Open or shorted injector circuit,
the current tlowing to the injector coil is shut off. or loose connector
• The Powertrain Control Module checks this surge voltage. • Failed powertrain control module
Normal Operation
• The engine speed is between 50 and 1,000 r/min
• Throttle position sensor output voltage is 1.16V or less.
• Monitoring Time: 4 sec.
Malfunction
• Injector coil surge voltage (system voltage +2V) has not
been detected tor 4 sec.
CIRCUIT DIAGRAM
Injector side connector
Harness side
connector (ABCDEF)
PCM

r-r-r- r-r- r- r-r- r-r-r- r-r- r-r- r-
7 6 5 4 3 2 1 765 4 3 2 1 654 321 8 7 6 5 4 3 2 1
~C19 181 16U 1413 1211 1C 9 8 1S 1S17 1615 1413 1211 1C 9 8 1716 1514 1312 11~0 9 8 7 ~~ ~1~ 9 8 716 5 4 31~ ~11C 9
~CI29 2~ 27 21 2524 123~ 21 2E 27 2625 ~12C

~2* L-L- 2625~ 2lZi 21~C 1918 35~ ~3~2 3130 2524
'-'-- '-'- '- '-'- '-'-L- L-L- L-L- _L-
1+-1·- - E200-4 ---1·11-1·- - E2OO-3 --1·11- E200-2 ----l 11+-'--- E2OQ-1---l
EFMB115A
TEST PROCEDURE

• Verify DTC P0201, P0202, P0203, P0204, P0205
or P0206 is set.
1
• Engine idling at normal operating temperature,
Disconnect the fuel injectors, one at a time, and
note the drop in engine speed for each one.
Engine speed should drop the same amount for
each fuel injector, does it?
I
•
S
Turn the ignition off.
S
Problem is intermittent or was repaired and
•Disconnect fuel injector connector. Powertrain Control Module (PCM) memory was
•Turn the ignition on. not cleared.
•Measure voltage between ground and fuel Clear code and verify fuel injector functions.
injector harness connector terminal 2.
Battery voltage should be present. Is it?
I
L$J
• Disconnect the fuel inector.
S
Repair open in wire between engine compartment
• Turn the ignition off. junction block and fuel injector's harness connector
• Disconnect the related PCM connector. Ground terminal 2.
fuel injector harness connector terminal 1. Clear code and verify fuel injector functions.
• Measure resistance between ground and the
related PCM connector.
Resistance measured should be approximately 1
ohm or less. Is it?
l
•
S
S
Repair open in wire between the related PCM
•Disconnect the fuel injector. harness connector terminal and fuel injector
•PCM connector disconnected. harness connector terminal 1.
•Measure resistance between ground and fuel Clear code and verify fuel injector functions.
injector harness connector terminal 1.
t
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MP0201B
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• Turn the ignition off. Repair short to ground or another circuit in

• Disconnect the tuel injector. wire between the related PCM harness connector
• Measure resistance between tuel injector terminal and tuel injector harness connector
connector terminals 1 and 2. terminal 1.
Resistance should be approximately 14.5 ohms at Clear code and verity tuel injector tunctions.
6S'F (20'C). Is it?
Verify PCM connector is secure. It OK, replace Replace tuel injector.

tuel injector with a known good component. Clear Clear code and verify tuel injector operates.
code and verity tuel injector operates.
It problem persists, replace PCM.
MP0201C
EFMB5110
DTC Diagnostic item

P0300 Random Misfire Detected
DESCRIPTION graund for energizing the primary ignition coils. When a

primary ignition coil is energized and deenergized, the
With the ignition switch ON or START, voltage is applied secondary coil produces a high voltage spike ac ross the
to the ignition coil. High tension leads go to each cylinder attached spark plugs. At the same time, the tachometer
from the ignition coil. The ignition coil fires two spark plugs interface (part of the ignition power transistor) provides
every power stroke (the cylinder under compression and the PCM and Transaxle Contral Module (TCM) with an
the cylinder on the exhaust stroke). Coil number one fires RPM signal.
cylinders 1 and 4. Coil number two fires cylinders 2 and 5.
And coil number three fires cylinders 3 and 6.
The ignition power transistor, contra lied by the Powertrain
Contra I Module (PCM), provides a switching circuit to

Background • Failed ignition system part(s)
• If a misfire occurs while the engine is running, the engine • Poor crankshaft position
speed suddenly changes. sensor signal
• The Powertrain Control Module checks for changes in the engine • Incorrect air/fuel ratio
speed by monitoring the CKP signal. • Low compression
• Failed engine coolant temperature
Normal Operation sensor
• Five seconds or more have passed after the engine has started. • Timing belt missing teeth
• The engine speed is between 500 and 6,000 r/min. • Failed injector
• The engine Coolant Temperature is higher than -10°C(14°F). • Failed powertrain contra I module
• The intake air temperature is higher than -10°C (14°F).
• There is no sudden acceleration/deceleration such as
during a shift change.
Abnormal Operation (a change in the rate of angular acceleration by

the crankshaft is monitored for misfire detection.)
• A misfire has occurred more frequently than allowed during
the last 200 revolutions [when the catalyst temperature is
higher than 950°C (1,742°F)].
• A misfire has occurred more frequently than the allowed number
of times (2%) during 1,000 motor revolutions.
CIRCUIT DIAGRAM
Ig coil 3 Ig coil1 Igcoil2

(No. 3 & 6) (No. 2 & 5) (No. 1 & 4)
-L I -L I I -L I I
Hamessside
Ig failure sensor hamess side

'-f----il'
1.-_ _ _ +-____-+___ IG failure sensor (3)
.---------,
E200-1 (11)
L---------'--'-t- Ig. coil 1, 4
L -_ _ _ _ _ _ _ _ _ _E_20_0_-1--'-(1~2}'_f_ Ig. coil 2, 5
L -_ _ _ _ _ _ _ _ _ _ _ _ _ _E2_0_0_-1-'(_13..:..}+_ Ig. coil3, 6
PCM

.- .-
765 43 21765 4 3 2 1 6 5 4 321 8 7 6 5 4 3 2 1
1/16 1514 1312 11 0 9 8 7
2E 2!i 24 23 12:1 212C 1S18
1 - - - - E200-4 ---1·11-1·- - E2OO-3 ---+l·1 f--- E200-2 ---I 1-1--- E2OO-1----l
EFMB125A
TEST PROCEDURE
• Check the fuel quality.

• Turn ignition switch on.
• Verify DTC P0300 is set.
Is DTC P0300 the only code set and fuel at least 87
octane?
• Ignition on. Refer to the appropriate section and follow test

• Disconnect ignition coil connector. Measure procedures for the other set codes. Refuel vehicle
voltage between ground and ignition coil with 87 or higher octane fue!. Clear codes and
connector terminal 1. verify DTC P0300 is no longer set.
Battery voltage should be present, is it?
• Turn ignition off. Repair wire between engine compartment junction

• Disconnect ECM connector. block and ignition coil connector terminal 1.
• Ground ignition coil harness connector terminals Clear code and verity code does not reappear.
2. Measure resistance between ground and
PCM connector E200-1 terminals 11, 12 and 13.
ohm or less, is it?
• Ignition off. Repair open in wire(s) between ignition coil

• Measure resistance of wire between ignition connector terminal 2 and ECM connector E200-1
failure sensor harness connector terminal 3 and terminal 11, 12 and 13.
ignition coil harness connector terminal 1. Clear code and verity code does not reappear.
ohm or less, is it?
t
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MP0300B
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A
• Turn the ignition off. Repair open in wire(s) between ignition failure
• Measure resistance between ground and ignition sensor harness connector terminal 3 and ignition
failure sensor harness connector terminal 3. coil connector terminal 1.
Resistance measured should be approximately 1 Clear code and verify code does not reappear.
ohm or less. Is it?
•Disconnect the ignition coil. Repair open in wire between engine compartment
•Reconnect PCM connectors. junction block and ignition coil connector terminal
•Put the ignition switch in the start position. 3. Clear code and verify code does not reappear.
•Measure voltage between ground and ignition
coil harness connector terminal 3.
Voltage should vary between 5 and 4 volts. Does it?
Verify PCM connector is secure. If OK, replace • Turn the ignition off.
power transistor with a known good component. • Disconnect the ignition coil.
Clear code and verify code does not reappear. • Measure resistance across ignition coil connector
If problem persists, replace PCM. terminals 1 and 2. Note results for primary coil
resistance.
• Measure resistance across ignition coil spark
plug wire terminals 1 and 4. Measure resistance
across ignition coil spark plug wire terminals 2
and 5. And measure resistance across ignition
coil spark plug wire terminal 3 and 6.
Note results tor secondary coil resistance.
Primary coil resistance should be approximately
1.3 ohms. Secondary coil resistance should be
between 1O.3K ohms and 13.9K ohms.
Are resistances within specification?
CONTINUED ON
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MP0300c
CONTINUED FROM
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B
• Tum the ignition off. Replace ignition coil. Clear code and verity code
• Inspect spark plugs, cables, tuel injectors and does not reappear.
vacuum hoses.
Are components all undamaged and within
specitication?
Repair or replace damaged or out ot specitication Replace power transistor. Clear code and verity
components. Clear code and verity code does not code does not reappear.
reappear.
P0300D
EFMB5120
DTC Diagnostic item

P0301, P0302,
P0303, P0304, Misfire detected (Cylinder-1, Cylinder-2, Cylinder-3, Cylinder-4, Cylinder-5, Cylinder-6)
P0305, P0306
DESCRIPTION ground for energizing the primary ignition coils. When a

primary ignition coil is energized and deenergized, the
With the ignition switch ON or START, voltage is applied secondary coil produces a high voltage spike ac ross the
to the ignition coil. High tension leads go to each cylinder attached spark plugs. At the same time, the tachometer
from the ignition coil. The ignition coil fires two spark plugs interface (part of the ignition power transistor) provides
every power stroke (the cylinder under compression and the PCM and Transaxle Control Module (TCM) with an
the cylinder on the exhaust stroke). Coil number one fires RPM signal.
cylinders 1 and 4. Coil number two fires cylinders 2 and 5.
And coil number three fires cylinders 3 and 6.
The ignition power transistor, controlled by the Powertrain
Control Module (PCM), provides a switching circuit to

Background • Failed ignition system related
• If a misfire occurs while the engine is running, the engine part(s)
speed suddenly changes. • Poor crankshaft position
• The Powertrain Control Module checks for changes in the engine speed. sensor signal
• Incorrect air/fuel ratio
Normal Operation • Low compression
• Five seconds or more have passed after the engine was started. • Failed engine coolant temperature
• The engine speed is between 500 and 6,000 rpm. sensor
• The engine Coolant Temperature is higher than -10°C (14°F). • Timing belt missing teeth
• The intake air temperature is higher than -10°C (14°F). • Failed injector
• The engine is not making sudden acceleration/decelera- • Failed EGR valve
tion such as during a shift. • Failed powertrain control module
Malfunction Criteria (a change in the angular acceleration of the

crankshaft is used for misfire detection.)
• A misfire has occurred more frequently than allowed for
during the last 200 revolutions [when the catalyst temperature
is higher than 950°C (1 ,742°F)).
• A misfire has occurred more frequently than the allowed number
of times (2%) during 1,000 motor revolutions.
CIRCUIT DIAGRAM
Igcoil3 Ig coil1 Igcoil2

(No. 3 & 6) (No. 2 & 5) (No. 1 & 4)
--L 1 --L 1 I --L 1 I
Hamess side
'---+------1 11
Ig failure sensor hamess side
L----t------+--- IG failure sensor (3)
.-------,
L -_ _ _ _ _ _-'--'_+_
E200-1 (11) Ig. coil1, 4
L -_ _ _ _ _ _ _ _ _E_2_00_-_1.:...(1~2}-+- Ig. coil2, 5
L -_ _ _ _ _ _ _ _ _ _ _ _ _ _E2_OO
_-1-'(_13...:.}+_ Ig. coil3, 6
PCM

r- r- r-, r- , , r-, r- , r- r- ,
765 4 3 2 1 765 4 3 2 1 654 321 87 65 4 3 2 1
~1S 1S 11 1615 1413 1211 1( 9 8 lS 1S11 1615 14~3 1211 H9 8 ~7 6U 14 3 1211 ~o 9 8 7 2322 2120 98 1716 ~5~4 1312 110 9
3Ias 12e127 126 25~ ~22 21 2e~7 12625 24~22 2121 ~62524 ~~ 21~ 151S ~534 ~3~ 31~ 25~
'-'-'- '-'- '- '-'- '-- '-- '-
1-1·- - E2OO-4 ----111--1- - E200-3---l-11- E200-2 --I 1-1·- - E2OO-1---+/·1
EFMB125A
TEST PROCEDURE
• Verify vehicle tuel is 87 octane or higher.

• Turn ignition switch on.
• Verify DTC P0301, P0302, P0303, P0304, P0305 or P0306.
Is DTC P0201, P0202, P0203, P0204, P0205 or P0206 also set or
is tuel less than 87 octane?
II
I NO
I
I ~
• Turn the ignition off. Perform related test procedures.
• Disconnect the ignition coi!. It needed, retuel with 87 octane or
• Measure resistance across ignition coil connector terminals 1 higher, clear code and verify code
and 2. Note results tor primary coil resistance. does not reappear.
• Measure resistance ac ross ignition coi! spark plug wire terminals
1 and 4. Measure resistance ac ross igntion coi! spark plug wire
terminals 2 and 5. And measure resistance across ignition coi!
spark plug wire terminal 3 and 6.
Note results tor secondary coi! resistance.
Primary coil resistance should be approximately 1.3 ohms.
Secondary coil resistance should be between 10.3 Kohms ohms
and 13.9 Kohms ohms. Are resistances within specitication?
I I
IVES I I NO I
I I
• Turn the ignition off. Replace ignition coi!. Clear code
• Inspect spark plugs, cables, vacuum hoses and connections. and verify code does not reappear.
Are components undamaged?
I ~
~ ~ I
• Turn the ignition off. Repair or replace parts.
• Check tuel injector tor clogging. Clear code and verity code does not
Is tuel injector OK? reappear.
I
c$J
Verify PCM connector is secure. It OK, replace PCM.
I NO I
I
Clean or replace tuel injector.
Clear code and verify code does not reappear. Clear code and verity code does not
reappear.
BP0301B
EFMB5130
DTC Diagnostic item

P0335 Crankshaft Position Sensor Circuit Malfunction
DESCRIPTION voltage signal from the CKP sensor allows the Powertrain
Control Module (PCM) to determine the engine of the RPM
The Hall-effect Crankshaft Position (CKP) sensor consists and Crankshaft Position.
of a magnet and coil located next to the flywheel. The
DTCdetection condition Probable cause

Background • Failed crankshaft position sensor
• When the engine is running, the Crankshaft Position • Open or shorted crankshaft
sensor outputs a pulse signal. position sensor circuit
• The Powertrain Control Module checks whether the pulse signal • Failed powertrain control module
is input while the engine is cranking.
Normal Operating condition

• Engine is being cranked.
Normal Operation
• Sensor output voltage has not changed (no pulse signal is input) for 4 sec.
Malfunction
• Normal signal pattern has not been input for cylinder identification
from the crankshaft position sensor signal and camshaft
position sensor signal for 4 sec.
CIRCUIT DIAGRAM
MP0335A
TEST PROCEDURE


• Disconnect Crankshaft Position (CKP) sensor.
• Measure voltage between ground and CKP
sensor harness connector terminal 3.
• Turn the ignition off. Repair open in wire between CKP sensor harness
• Disconnect the CKP sensor. connector terminal 3 and Joint connector teminal.
• Disconnect PCM connector E200-2. Clear code and verify CKP sensor is within normal
• Ground CKP sensor harness connector terminal parameters.
2. Measure resistance between ground and PCM
harness connector E200-2 terminal 3.
ohm or less. Is it?
• Turn the ignition off. Repair open in wire between CKP sensor harness
• Disconnect the CKP sensor. connector terminal 2 and PCM harness connector
• Disconnect PCM connector E200-2. Measure E200-2 terminal 3.
resistance between ground and CKP sensor Clear code and verify CKP sensor is within normal
harness connector terminal 2. parameters.
YES
Repair short to ground or another circuit in wire

between CKP sensor harness connector terminal
2 and PCM harness connector E200-2 terminal 3.
Clear code and verify CKP sensor is within normal
parameters.
A
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MP0335B
CONTINUED FROM
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A
• Turn the ignition off. ~
• Disconnect the CKP sensor.

• Measure resistance between ground and CKP
ohm or less. Is it?
~
• Inspect CKP sensor for damage or debris.
$
Repair open or poor ground connection in ground
Is CKP sensor OK? wire. Clear code and verify CKP sensor is within
normal parameters.
•
~
Turn the ignition on.
$
Repair or replace CKP sensor.
•Disconnect the CKP sensor. Clear code and verify CKP sensor is within normal
•PCM connector connected. parameters.
•Measure voltage between ground and CKP
Sensor harness connector terminal 3.
Voltage should be approximately 5 volts. Is it?
~
Verify PCM connector is secure. If OK, replace
$
Repair or replace CKP sensor.
CKP sensor with a known good component. Clear Clear code and verify CKP sensor is within normal
code and verify CKP sensor is within normal parameters.
parameters. If problem persists, replace PCM.
MP0335C
EFMB5140
DTC Diagnostic item

P0340 Camshaft Position Sensor Circuit Malfunction
DESCRIPTION
The Camshaft Position (CMP) sensor senses the Top

Dead Center (TDC) point of the #1 cylinder in the com-
pression stroke. The CMP sensor signal allows the PCM
to determine when to operate the fuel injectors.

Normal Operation • Camshaft Position sensor
• When the engine is running, the Camshaft Position malfunction
sensor outputs a pulse signal. • Open or shorted camshaft position
• The Powertrain Control Module checks whether the pulse signal is input. sensor circuit or loose connector
• Powertrain control module failed
Malfunction
• Normal signal pattern has not been input for cylinder identification
from the camshaft position sensor signal for 4 sec.
CIRCUIT DIAGRAM
10 3 E200-2
MP0335A
TEST PROCEDURE


• Disconnect Camshaft Position (CMP) sensor.
• Measure voltage between ground and CMP
es
I
•
S
Turn the ignition off. Repair open in wire between CMP sensor harness
• Disconnect the CMP sensor. connector terminal 3 and Engine compartment
• Disconnect PCM connector E200-2. junction block.
• Ground CMP sensor harness connector terminal Clear code and verify CMP sensor signal is within
2. normal parameters.
• Measure resistance between ground and PCM
ohm or less. Is it?
•
•
S
Disconnect the CMP sensor.
es
Repair open in wire between CMP sensor harness
connector terminal 2 and PCM harness connector
•Disconnect PCM connector E200-2. terminal. Clear code and verify CMP sensor signal
•Measure resistance between ground and CMP is within normal parameters.
I
S
• Disconnect the CMP sensor.
es
Repair short to ground in wire between CMP
sensor harness connector terminal 2 and PCM
• Measure resistance between ground and CMP harness connector terminal. Clear code and verify
sensor harness connector terminal 1. CMP sensor signal is within normal parameters.
ohm or less. Is it?
L
S
• Inspect CMP sensor tor debris or misadjustment.
~
Repair open in wire between CMP sensor harness
Also verify timing is adjusted properly. connector terminal 1 and ground. Clear code and
Is CMP sensor and timing OK? verify CMP sensor signal is within normal
parameters.
l
~
Verify PCM connector is secure. It OK, replace
~
Repair or replace CMP sensor as needed. Clear
PCM. Clear code and verity CMP sensor signal is code and verify CMP sensor signal is within normal
within normal parameters. parameters.
MP0340B
EFBB5170
DTC Diagnostic item

P0421 Warm Up Catalyst Efficiency Below Threshold (Bank 1)
P0431 Warm Up Catalyst Efficiency Below Threshold (Bank 2)
DESCRIPTION If the catalyst is functioning normally, the waveform of the

rear oxygen sensor switches back and forth between rich
The PCM compares the waveform of the front oxygen sen- and lean much more slowly than the waveform of the front
sor with the waveform of the rear oxygen sensor to de- oxygen sensor. When both waveforms change at a similar
termine whether or not catalyst performance has deteri- rate, catalyst performance has deteriorated.
orated. Air-fuel ratio feedback compensation keeps the
waveform of the front oxygen sensor repeatedly changing
back and forth from rich to lean.

Normal Operation • Catalytic converter deteriorated
• The signal from the rear Oxygen sensor differs from the front Oxygen • Heated oxygen sensor failed
sensor. This is because the catalytic converter purifies, the exhaust • Powertrain control module failed
gas. When the catalytic converter has deteriorated, the signal
from the rear becomes similar to that of the front.
• The Powertrain Control Module checks the outputs of
both oxygen sensor signals.
Normal Operation
• Engine speed is 3,000 rpm or higher.
• Closed throttle position switch: OFF
• Closed loop operation
• Monitoring Time: 140 sec.
Malfunction
• The front and rear Oxygen sensor signals are similar.
TEST PROCEDURE

• Connect scan too!.
Is DTC P0133, P0135, P0136 ancl/or P0141 also set?
$
• Turn the ignition on with the engine running.
IVESI
I
Check DTC P0133, P0135, P0136
• Inspect for leakage before and after catalyst. ancl/or P0141 first by following the
• Inspect for leakage around the front and rear oxygen sensors. code test procedures.
Is exhaust system around the catalyst and oxygen sensors OK?
~
• Check rear oxygen sensor by following DTC P0136 test
$
Tighten the parts where leaks are
procedure. found. Clear code and verity oxygen
Is rear oxygen sensor OK? sensor signals are within normal
parameters.
~ I NO I
I
• Turn the ignition off. Repair or replace the rear oxygen
• Replace the catalyst. sensor. Clear code and verity oxygen
• Erase DTC P0421 from memory. sensor signals are within normal
• Road test the vehicle and verity DTC P0421 does not reset. parameters.
Does DTC P0421 reset?
I NO I
~ T
Verity PCM connector is secure. If OK, replace PCM. Clear code Problem has been corrected.
and verify oxygen sensor signals are within normal parameters. No additional testing required.
BP0421B
EFMB5190
DTC Diagnostic item

P0443 Purge Control Solenoid Valve Malfunction
DESCRIPTION a charcoal canister until it can be flushed into the intake

manifold.
The evaporative system reduces hydrocarbon emission by
trapping fuel tank vapors until they can be burned as part
of the incoming fuel charge. Evaporating tuel is stored in

Normal Operation • Evaporative emission purge
• The Powertrain Control Module checks current flows in the evaporative control solenoid valve failed
emission purge solenoid drive circuit when the solenoid is ON and OFF. • Open or shorted evaporative
emission purge solenoid circuit,
Normal Operation or loose connector
• Battery voltage is 10V or higher. • Powertrain control module failed
Maltunction
• The solenoid coil surge vOltage (system vOltage +2V) is not detected
when the EVAP emission vent solenoid is turned on/off.
CIRCUIT DIAGRAM
16 E200·1
MP0443A
TEST PROCEDURE

• Verity DTC P0443 is set.
• Turn the ignition off

• Disconnect PCSV(Purge Contra I Solenoid Valve)
connector.
• Measure voltage between ground and PCSV
harness connector terminal 2.
Battery voltage should be present. is it?
• Turn the ignition off. Repair open or short to ground in wire between
• Disconnect the PCSV. Engine compartment junction block terminal
• Disconnect PCM connector E200-1. Ground and PCSV connector terminal 2.
PCSV harness connector terminal 1. Clear codes and verity PCSV is within normal
• Measure resistance between ground and PCM parameters.
ohm or less. is it?
•Turn the ignition off. Repair open in wire between PCM connector
•Disconnect the PCM. E200-1 terminal 16 and PCSV harness connector
•Disconnect the PCSV solenoidvalve. terminal 1.
•Measure resistance between graund and purge Clear code and verity PCSV is within normal
contra I solenoid valve harness connector parameters.
terminal 1.
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MP0443B
CONTINUED FROM
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A
• Turn the ignition off. Repair short to ground or another circuit in wire
• Disconnect the PCSV. between PCM connector terminal 16 and purge
• Measure resistance between the purge control control solenoid valve connector terminal 1.
solenoid valve connector terminals 1 and 2.
Resistance should be approximately 27 ohms. Is it?
Verify PCM connector is secure. If OK, replace Replace purge control solenoid valve.
purge control solenoid valve with a known good Clear code and verify purge control solenoid valve
component. Clear code and verify purge control is within normal parameters.
solenoid valve is within normal parameters.
If problem persists, replace PCM.
MP0443C
EFMB5220
DTC Diagnostic item

P0500 Vehicle Speed Sensor Malfunction
DESCRIPTION
The vehicle speed sensor outputs a pulse signal while the

vehicle is driven.
The powertrain contral module checks whether the pulse
signal is present.

Normal Operation • Failed vehicle speed sensor
• The vehicle speed sensor outputs a pulse signal while • Open or shorted vehicle-speed
the vehicle is driven. sensor circuit, or loose connector
• The Powertrain Contra I Module checks whether the • Failed powertrain control module
pulse signal is present.
Normal Operation
• Closed thrattle position switch: OFF
• Engine speed is 3,000 rpm or more.
• Engine load is 70% or more.
Malfunction
• Sensor output voltage has not changed (no pulse signal is input) for 4 sec.
CIRCUIT DIAGRAM
Vehicle
speed
sensor
10 E200-3
MP0500A
TEST PROCEDURE

• Drive vehicle.
Does speedometer operate OK?
S
~
Repair defective speedometer cable andl
• Inspect between VSS and transaxle gear. or drive gear parts. Clear code and verify
Is the VSSltransaxle gear interface OK? VSS signal is within normal parameters.
•
e
Ignition off.
[$
Repair interface between VSS and
• Disconnect the VSS. transaxle gear. Clear code and verify
• Disconnect PCM connector E200-3. VSS signal is within normal parameters.
• Ground VSS connector harness terminal 3.
• Measure resistance between ground and PCM harness
Resistance measure should be approximately 1 ohm or
less. Is it?
CONTINUED ON
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MP0500B
CONTINUED FROM
PREVIOUS PAGE
• Turn the ignition off. Repair wire between VSS harness connector
• Disconnect the VSS. terminal 3 and PCM harness connector E200-3
• Disconnect the PCM. terminal 10.
• Measure resistance between VSS harness con- Clear code and verify VSS signal is within normal
nector terminal 3 and ground. parameters.
Resistance should indicate an open circuit. Does
it?
Verify PCM connector is secure. If OK, replace Repair short to ground or another circuit in wire
VSS with a known component of good quality. between VSS harness connector terminal 3 and
Clear code and verify VSS signal is within normal PCM harness connector E200-3 terminal 10.
parameters. If problem persists, replace PCM. Clear code and verify VSS signal is within normal
parameters.
MPQ500C
Engine Mechanical
System [3.5 V6]
GENERAL ......................................•......................... EMA-2
ENGINE BLOCK ......................................................... EMA -19
MAIN MOVING SYSTEM ..................•.............................. EMA -24
COOLING SYSTEM ......................•......................•...•..• EMA -38
LUBRICATION SySTEM ................................................ EMA-49
INTAKE AND EXHAUST SYSTEM ..................................... EMA -53
CYLINDER HEAD ASSEMBLY .•....•.....................•............ EMA -63
TIMING SYSTEM ........................................................ EMA -69

EMA-:2 ENGINE MECHANICAL SYSTEM [3.5 V6]
GENERAL
SPECIFICATIONS EDMBOO10
Description Specification Limit

General
Type V-type, DOHC
Number of Cylinders 6
Bore 93 mm (3.661 in.)
5troke 85.8 mm (3.3779 in.)
Total displacement 3497 ce
Compression ratio 10.0
Firing order 1-2-3-4-5-6
Idle R.P.M 800 ± 100
Ignition timing at idling speed BTDC 5° ± 2°
Valve timing
Intake valve
Opens (BTDC) 11S
Closes (ABDC) 60S
Exhaust valve
Opens (BBDC) 43S
Closes (ATDC) 20S
Camshaft
Drive mechanism Cogged type belt
Cam height intake 35.098 - 35.298 mm (1.3818 - 1.3897 in.)
Cam height exhaust 34.81 - 35.01 mm (1.3705 - 1.3783 in.)
Journal diameter 25.951 - 25.970 mm (1.0220 - 1.0224 in.)
Bearing oil clearance 0.05 - 0.09 mm (0.0007 - 0.0024 in.)
End play 0.1 - 0.15 mm (0.0039 - 0.0059 in.)
Cylinder head
Flatness of gasket surface Max. 0.03 mm (0.0012 in.) 0.05 mm
Flatness of maunting
5urface
Intake Max. 0.10 mm (0.0039 in.) 0.10 mm
Exhaust Max. 0.15 mm (0.0059 in.) 0.15 mm
Valve guide hole diameter
0.05 (0.002).0.5. 12.05 - 12.068 mm (0.474 - 0.475 in.)
0.25 (0.010) 0.5. 12.25 - 12.268 mm (0.482 - 0.483 in.)
0.50 (0.20) 0.5. 12.50 - 12.518 mm (0.492 - 0.493 in.)
Intake valve seat ring hole diameter
0.3 (0.012) 0.5. 36.30 - 36.325 mm (1.429 - 1.430 in.)
0.6 (0.024) 0.5. 36.60 - 36.625 mm (1.441 - 1.442 in.)
Exhaust valve seat ring hole diameter
0.3 (0.012) 0.5. 33.30 - 33.325 mm (1.311 - 1.312 in.)
0.6 (0.024) 0.5. 33.60 - 33.625 mm (1.323 - 1.324 in.)
GENERAL EMA-3

Valve
Overall length
Intake 106.28 mm (4.184 in.)
Exhaust 105.4 mm (4.150 in.)
Stem diameter
Intake 6.565 - 6.580 mm (0.258 - 0.259 in.)
Exhaust 6.530 - 6.550 mm (0.257 - 0.258 in.)
Face angle 45° - 45S
Margln
Intake 1.0 mm (0.0394 in.)
Exhaust 1.5 mm (0.059 in.)
Clearance (stem - to - guide)
Intake 0.02 - 0.05 mm (0.0009 - 0.0020 in.)
Exhaust 0.05 - 0.085 mm (0.0020 - 0.0033 in.)
Valve spring
Free height 46.4 mm (1.8268 in.) 41.5 mm (1.6339 in.)
Lode 24.0 kg / 37.9 mm (53 Ib / 1.492 in.) 55.8 kg / 28.9 mm
Out of squareness Max 2° (123 Ib / 1.378 in.)
Valve guide
Length
Intake 45.5 mm (1.7913 in.)
Exhaust 50.5 mm (1.9882 in.)
Service oversize 0.05, 0.25, 0.50
Valve seat contact width
Intake 0.9 - 1.3 mm (0.035 - 0.051 in.)
Exhaust 0.9 - 1.3 mm (0.035 - 0.051 in.)
Service oversize 0.30, 0.60
Seat angle
Intake 20°
Exhaust 45°
Piston
Diameter (Standard) 92.96 - 92.99 mm (3.659 - 3.661 in.)
Clearance (Piston-to-cylinder) 0.03 - 0.05 mm (0.0012 - 0.0020 in.)
Ring froove width
No. 1 1.503 - 1.505 mm (0.0592 - 0.05925 in.)
No. 2 1.501 - 1.503 mm (0.0591 - 0.0592 in.)
Oil 3.010 - 3.030 mm (0.1185 - 0.1193 in.)
Piston for service 0.25 mm (0.010 in.), 0.50 mm ( 0.020 in.)
0.75 mm (0.030 in.), 1.00 mm ( 0.040 in.)
Oversize
EMA-4 ENGINE MECHANICAL SYSTEM [3.5 V6]

Piston ring
Number of rings per piston 3
Compression ring type 2
Oil ring 1
Compression ring type
No. 1 Barrel type, steel
No. 2 Taper type, special cast iron
Oil ring type 3-piece type
Ring end gap
No. 1 0.30 - 0.45 mm (0.0118 - 0.0177 in.)
No. 2 0.45 - 0.60 mm (0.0177 - 0.0236 in.)
Oil ring side rail 0.2 - 0.7 mm (0.0079 - 0.0276 in.)
Ring side clearance
No. 1 0.04 - 0.08 mm (0.0008 - 0.0031 in.)
No. 2 0.02 - 0.06 mm (0.0016 - 0.0024 in.)
Ring for service 0.25mm (0.010 in.), 0.50 mm (0.020 in.)
0.75 mm (0.030 in.), 1.00 (0.039 in.), Oversize
Connecting rod
Piston pin press - in load 7500 - 17,500 N
(750 - 1,750 kg, 1,653 - 3,858 Ib)
Side clearance (Big end) 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Bend 0.05 mm or less/100 mm
(0.0020 in. or less/3.937 in.)
Twist 0.1 mm or less/100 mm
(0.0039 in. or less/3.937 in.)
Bearing
Oil clearance 0.022 - 0.040 mm (0.0009 - 0.0016 in.) 0.1 mm (0.004 in.)
Pin diameter 21.974 - 21.985 mm (0.8651 - 0.8655 in.)
Crankshaft
Journal O.D. 63.982 - 64.00 mm (2.519 - 2.5197 in.)
Pin O.D. 54.982 - 55.00 mm (2.165 - 2.1653 in.)
Out - of - roundness of journal and pin Max. 0.03 mm (0.0012 in.)
Taper of journal and pin Max. 0.005 mm (0.0002 in.)
End play 0.05 - 0.25 mm (0.002 - 0.0098 in.)
Main bearing 0.3 mm (0.012 in.)
Oil clearance 0.018 - 0.036 mm (0.0007 - 0.0014 in.)
Cylinder block
Cylinder bore 93 mm (3.661 in.)
Flatness of gasket surface Max. 0.05 mm (0.002 in.)
Out - of - roundness and taper Max. 0.02 mm (0.0008 in.) 0.05 mm (0.002 in.)
Oil pump
Side clearance
Body clearance 0.100 - 0.181 mm (0.0039 - 0.0071 in.)
Side clearance 0.040 - 0.095 mm (0.0016 - 0.0037 in.)
Tip clearance 0.06 - 0.018 mm (0.0024 - 0.0071 in.)
Relief spring
Free length 46.3 mm (1.823 in.)
Load 3.4 kg / 39.1 mm (7.5 Ib. /1.54 in.)
Oil filter
Type Cartridge, full flow
GENERAL EMA-5

Engine oil pressure 80 kPa (11.4 psi) or more
[Conditions : Oil temperature is 75 to
90°C (167 to 194°F)]
Cooling method Engine coolant cooling,
forced circulation with electric fan
Cooling system
Quantity 11 lit (11.62 U.S.qts., 9.7 Imp.qts)
Thermostat
Type Wax pellet type with jiggle valve
Normal opening temperature 82°C (179.6°F)
Opening temperature range 80°C - 84°C (176 - 183.2°F)
Wide open temperature 95°C (203°F)
Radiator cap
Main valve opening pressure 86.1 - 124.5 kPa
(0.98 - 1.27 kg/cmk, 13.94 - 18.06 psi)
Main valve closing pressure 83.4 kPa (0.85 kg/cmk, 12.1 psi)
Vacuum valve opening pressure - 6.86 kPa (- 0.07 kg/cm2 , - 1.00 psi)
Air cleaner
Type Dry type
Element Unwoven cloth type
Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
SERVICE STANDARD
Stanard value
Coolant concentration
Tropical area: 40%
Other area: 50%
LUBRICANT
Engine coolant: Ethylene glycol base for aluminum radiator
SEALANT
Engine coolant temperature sensor Three bond No.2310 or equivalent

LOCTITE 962T or equivalent
EMA -6 ENGINE MECHANICAL SYSTEM [3.5 V6]
TIGHTENING TORQUE EDMBOO20
Nm kg.cm Ib.ft
Crankshaft bolt 180 - 190 1,800 - 1,900 130 - 138
Timing belt tensioner 20 - 27 200 - 1,100 15 - 20
Comshaft sprocket bolt 90 - 110 900 - 1000 65 - 80
Cylinder head cover bolts 5 - 6 50 - 60 4-5
Main bearing cap bolts 90 - 100 900 - 1000 65 - 72
Connecting rod nuts 35 + 92° 350 + 92° 26 + 92°
Cylinder head bolts
Cold engine 105 - 115 1050 - 1150 75 - 82
Oil pan drain plug 35 - 45 350 - 450 26 - 32
Lower oil pan bolt 10 - 12 100 - 120 7.2 - 9
Upper oil pan bolt
[10 x 380 mm (0.937 x 1.4961 in.)] 30 - 42 300 - 420 22 - 30
[8 x 22 mm (0.3150 x 0.8661 in.)] 19 - 28 190 - 280 14 - 20
[171.5 mm (6.7519 in.)] 5 - 7 50 - 07 3.7 - 5
[152.5 mm (6.7520 in.)] 5-7 50 - 07 3.7 - 5
Oil screen bolt 15 • 22 150 - 220 11 - 15
Oil pump case bolts 12 - 15 120 - 150 9 - 10
Oil relief valve plug 40 - 50 400 - 500 29 - 36
Oil pressure switch 8 - 12 80 - 120 5.8 - 8.7
Oil pump cover screw 8 - 15 80 - 150 5.8 - 11
Oil filter 17 - 25 170 - 250 12 - 18
Drive plate and adaptor plate bolt 73 - 77 730 - 770 53 - 55
Air cleaner body installation bolt 8 - 12 80 - 120 6-9
Surge tank stay 15 - 20 150 - 150 11 - 14
Air intake surge tank to intake manifold (bolt) 15 - 20 150 - 200 11 - 14
Air intake surge tank to intake manifold (nut) 15 - 20 150 - 200 11 - 14
Intake manifold to engine 12 - 15 120 - 150 9 - 10
Heat protector to exhaust manifold 12 - 15 120 - 150 14
Exhaust manifold to engine 27 - 33 270 - 330 20 - 40
Oil level gauge guide to engine 12 - 15 120 - 150 9 - 11
Water outlet fitting bolt 17 - 20 170 - 200 12.3 - 14.5
Power steering oil pump bracket to front cylin- 17 - 26 170 - 260 12 - 19
der head assembly
Power steering oil pump to bracket 17 - 26 170 - 260 12 - 19
Crank position sensor wheel screw 5 - 6 50 - 60 4 - 5
Engine mounting insulator bolt. 30 - 40 300 - 400 22 - 30
Engine mounting bracket bolt and nut. 65 - 85 650 - 850 48 - 63
33 - 50 330 - 500 24 - 37
Transaxle mounting bracket bolts. 30 - 42 300 - 400 22 - 31
Transaxle mounting insulator bolt. 30 - 42 300 - 420 22 - 31
Starter to engine bolt. 27 - 34 270 - 340 20 - 25
Generator inlet pipe to front cylinder head assembly 12 - 15 120 - 150 9 - 11
Fuel hose clamp to rtear cylinder head assembly 12 - 15 120 - 150 9 - 11
Transaxle mounting plate 10 - 12 100 - 120 7 - 9
GENERAL EMA-7
Nm kg.cm Ib.tt
Rear plate 10 - 12 100 - 120 7.3 - 8.6
Oil seal case 10 - 12 100 - 120 7.3 - 8.6
Crankshaft pulley bolt 180 - 190 1,800 - 1,900 130 - 138
Timing belt cover bolt 10 - 12 100 - 120 7 - 9
Engine hanger bracket to engine 20 - 27 200 - 270 14 - 20
Generator mount bracket to engine 20 - 30 200 - 300 14 - 22
Generator mount nut (Engine front case side) 20 - 30 200 - 300 14 - 22
Generator mount bolt (Generator mount bracket side) 20 - 30 200 - 300 14 - 22
Startor to engine (Nut) 20 - 30 200 - 300 14 - 22
Drive belt pulley bolt 35 - 55 350 - 550 26 - 40
Drive belt tensioner bolt 45 - 50 450 - 500 33 - 36
Engine coolant pump to cylinder block bolt head mark "7" bolt 15 - 22 150 - 2200 11 - 15
Engine coolant temperature sensor 20 - 40 200 - 400 14 - 29
Engine coolant inlet fitting attaching bolt 17 - 20 170 - 200 12 - 14
Air cleaner mounting bolts 8 - 12 80 - 120 6-9
Intake manifold to cylinder head nuts 12 - 15 120 150 9 - 11
Throttle body to surge tank bolts 10 - 13 100 - 130 7 - 9.5
Exhaust manifold to cylinder head nuts 25 - 30 250 - 300 18 - 22
Exhaust manifold heat protector to exhaust manifold bolts 12 - 15 120 - 150 9 - 11
Oxygen sensor to exhaust manifold 40 - 50 400 - 500 29 - 36
Front exhaust pipe to exhaust manifold nuts 30 - 40 300 - 400 22 - 29
Front exhaust pipe to catalytic converter bolts 40 - 60 400 - 600 29 - 43
Catalytic converter to center exhaust pipe nuts 30 - 40 300 - 400 22 - 29
Center exhaust pipe to main muffler nuts 30 - 40 300 - 400 22 - 29
Main muffler hanger support bracket bolts 10 - 15 100 - 150 7 - 11
Delivery pipe installation bolts 10 - 15 100 - 150 7 - 11
Timing belt tensioner pulley bolt 43 - 55 430 - 550 31 - 40
Timing belt idler pulley bolt 50 - 60 500600 36 - 43
Timing belt tensioner arm FIXED BOLT 35 - 55 350550 26 - 40
Auto tensioner fixed bolt 20 - 27 200 - 270 14 - 20
Startor to engine (Bolt) 27 - 34 270 - 340 20 - 25
Camshaft bearing cap
Outer 19 - 21 190 - 210 14 - 15
Inner 10 - 12 110-120 7 - 9
EMA -8 ENGINE MECHANICAl SYSTEM [3.5 V6]
SPECIAL TOOlS ECBB0300

Crankshaft front oil seal installer Installation of the crankshaft front oil seal
~
(09214-33000)
OD
HFR20A01
Camshaft oil seal installer Installation of the camshaft oil seal
QD
(09221-21000)
HFR20A02
Valve guide installer Removal and installation of the valve guide

(09222-22000 (8))
~
(09221-29000 (A))
(A)
KFW3003A
Valve stem oil seal installer Installation of the valve stem oil seal
(09222-22001 )
, )
KFW3002A
Valve spring compressor Removal and installation of the intake

(09222-28000) or exhaust valve
c::ID Ö
J20008F
Valve stem oil seal remover Removal of the valve stem oil seal
(09222-29000) ",
.. ",
" , ="
.z:::
- - -- ..
~
.. ' -
KFW3009A
GENERAL EMA-9

Crankshaft rear oil seal installer Installation of the erankshaft rear oil seal
(09231-33000)
KFW3004A
Crankshaftwreneh Used if the erankshaft needs to be rotated

(09231-33100) to attach the timing belt, ete.
KFW3008A
Piston pin remover and installer Removal and installation of the piston pin
(09234-33001 )
Fork insert
(09234-33003)
HFR20A10
TROUBLESHOOTING ECBB0400

Knocking of crankshaft Worn main bearing Replace
and bearing Seized bearing Replace
Bent crankshaft Replace
Excessive crankshaft end play Replace thrust bearing
Piston and connecting Worn bearing Replace
rod knock Seized bearing Replace
Worn piston pin Replace piston and pin or
connecting rod
Worn piston in cylinder Recondition cylinder
Broken piston ring Repair or replace
Improper connecting rod alignment Replace
Noisy valves Faulty auto-Iash adjuster Replace
Thin or diluted engine oil (Iow oil pressure) Change
Worn or damaged valve stern or valve guide Replace
Excessively worn Shortage of engine oil Add or replace
cylinder and piston Check oil level on daily basis
Dirty engine oil Replace
Poor quality of engine oil Use proper oil
Improperly assembled piston and connecting rod Repair or replace
Improper piston ring end clearance Replace
Dirty air cleaner Clean air cleaner assembly and
replace the air filter
Connecting rod and Insufficient oil supply Check engine oil level
main beaing noise Thin or diluted engine oil Change and determine cause
Excessive bearing clearance Replace
Damaged crankshaft Shortage of engine oil Add or replace
bearing Check oil level on daily basis
Low oil pressure Adjust or repair
Poor quality of engine oil Use proper engine oil
Worn or out-of -round of crankshaft journal Replace
Restricted oil passage in crankshaft Clean
Worn bearing Replace bearing and check
engine oil and lubrication system
Bearing improperly installed Replace
Non-concentric crankshaft or bearing Replace
Timing belt noise Incorrect belt tension Replace
Low compression Blown cylinder head gasket Replace gasket
Worn or damaged piston rings Replace rings
Worn piston or cylinder Repair or replace piston and/or
cylinder block
Worn or damaged valve seat Repair or replace valve
and/or seat ring
Oil pressure drop Low engine oil level Check engine oil level
. Faulty oil pressure switch Replace
Clogged oil filter Replace
Worn oil pump gears or cover Replace
Thin or diluted engine oil Change and determine cause
Oil relief valve stuck (open) Repair
Excessive bearing clearance Replace
GENERAL EMA -11

High oil pressure Oll relief valve stuck (closed) Repair
Excessive engine rolling Loose engine roll stopper (front, rear) Re-tighten
and vibration Loose transaxle mount bracket Re-tighten
Loose engine mount bracket Re-tighten
Loose center member Re-tighten
Broken transaxle mount insulator Replace
Broken engine mount insulator Replace
Broken engine roll stopper insulator Replace
Low coolant level Leakage of coolant
Damaged radiator core joint Replace
Corroded or cracked hoses Replace
(Radiator hose, heater hose, etc)
Faulty radiator cap valve or setting of spring Replace
Faulty thermostat Replace
Faulty engine coolant pump Replace
Clogged radiator Foreign material in coolant Replace
Abnormally high coolant Faulty thermostat Replace parts
temperature Faulty radiator cap Replace
Restrietion of flow in cooling system Replace
Loose or missing drive belt Adjust or replace
Faulty engine coolant pump Replace
Faulty temperature gauge or wiring Repair or replace
Faulty electric fan Repair or replace
Faulty thermo-sensor on radiator Replace
Insufficient coolant Refill coolant
Abnormally low coolant Faulty thermostat Replace
temperature Faulty temperature gauge or wiring Repair or replace
Leakage from oil cooling Loose hose and pipe connection Replace
system Blocked or collapsed hose and pipe Repair or replace
Inoperative electrical Damaged Replace or repair
cooling fan
Exhaustgasleakage Loose connections Re-tighten
Broken pipe or muffler Repair or replace
Abnormal noise Detached baffle plate in muffler Replace
Broken rubber hanger Replace
Pipe or muffler contacting vehicle body Correct
Broken pipe or muffler Repair or replace
CHECKING ENGINE OlL EDHA0500
1. Position a vehicle on a level surface.
2. Turn off the engine.
~NOTE
In the case of a vehicle that has not been used for a
prolonged period, run the engine for several minutes.
Turn off the engine and wait for 5 minutes at least,
then check the oillevel.
3. Check that the engine oillevel is within the level range

indicated on the oil dipstick. If the oillevel is found to
have fallen to the lower limit (the "L" mark), refill to the
"F" mark.
~NOTE
When refilling, use the proper grade of engine oil.
4. Check that the oil is not dirty or mixed with coolant or

gasoline, and that it has the proper viscosity.
EDA9000A
GENERAL EMA -13
SELECTION OF ENGINE OlL ECBB0600
Recommended API classification: SO OR ABOVE SE OR ABOVE [For EC.]

Recommended SAE viscosity grades:
Temperature range
anticipated before Recommended SAE viscosity number
next oil change
oe °F
40 104 20W 15W 10W
10W
-50 -50 -50
-30
20 68 -40 -40 -40
10 50 5W
-10 14 -40.1 5W"1
-15 5 -30 5W"1
-25 -13 -20"2
*1 Restricted by driving condition and environment.

*2 Not recommended for sustained high speed vehicle operation
EDA9990B
~NOTE
For best performance and maximum protection of all
types of operation, select only those lubricants which:
1. Satisfy the requirements of the API classification.

2. Have the proper SAE grade number for expected
ambient temperature range.
Lubricants which do not have both an SAE grade

number and an API service classification on the con-
tainer should not be used.
CHANGE ENGINE OlL EDMB0030 REPLACEMENT OlL FILTER ECBB0800
1. Run the engine until it reaches normal operating tem- FILTER SELECTION
perature.
All Hyundai Motor Company engines are equipped with
a high quality, disposable oil filter. This filter is recom-
3. Remove the oil filler cap and oil filter and then drain mended as areplacement filter for all vehicles. The quality
plug. of after market replacement filters is various considerably.
Drain the engine oil.
High quality of replacement filters should be used to as-
4. Tighten the drain plug to the specified torque. sure the most efficient service. Make sure that the rubber
gasket fram the old oil filter is completely removed from
Tightening torque the contact surface on the engine block before installing a
new filter.
Oil pan drain plug : 35-45 Nm (350-450
kg.cm, 25-33 Ib.ft)
Part number
~NOTE
Whenever tightening the oil drain plug, use a new
drain plug gasket.
ECA9970A
PROCEDURE FOR REPLACING OlL FILTER
1. Use a filter wrench to remove the oil filter.
EDB900.1A 2. Before installing a new oil filter on the engine, apply

clean engine oil to the surface of the rubber gasket.
5. Fill the new engine oil through the oil filler cap.
3. Tighten the oil filter of the specified torque.
Drain and Refill
Oil quantity : 4.4 lit (5 U.S. qts., 4.2 Imp. qts.) Tightening torque
Cil filter: 17 - 25 Nm (170 - 250 kg.cm, 12 - 18 Ib.ft)
~NOTE
00 not over fill. This will cause oil aeration and loss 4. Start and run the engine and check engine oilleaks.
of oil pressure.
5. After stopping the engine, check the oil level and add
6. Install the oil filler cap. oil as necessary.
7. Start and run the engine.
8. Turn off the engine and then check the oil level. Add
-~
oil if necessary.
Apply engine oil
ECA9970B
GENERAL EMA -15
CHECKING COOLANT LEAK RADIATOR CAP PRESSURE TEST EDHA1000
CHECK EDMBOO4O
1. Use an adapter to attach the cap to the tester.
1. Loosen the radiator cap.
2. Increase the pressure until the indicator of the gauge
2. Confirm that the coolant level is up to the filler neck. stops moving.
3. Install aradiator cap tester to the radiator filler neck Main valve opening pressure :
and apply 150 KPa (21 psi, 1.53 kg/cm2 ) press ure. 107.9 ± 14.7 kPa (1.1 ± 0.15 kg/cm2 , 15.64 ± 2.13 psi)
Hold for two minutes, then check for leakage from the
radiator, hoses or connections. Main valve closing pressure :
83.4 kPa (0.85 kg/cm2 , 12.1 psi)
& CAUTION
1. Radiator coolant may be extremely hot. Do 3. Check that the pressure level is maintained at or
not open the system while hot, or scalding above the limit.
engine coolant could gush out, causing per-
sonal injury. Allow the vehicle to cool betore 4. Replace the radiator cap if the reading does not re-
servicing this system. main at or above the limit.
2. When the tester is removed, be caretul not to
spill any coolant trom it. ~NOTE
3. Be sure to clean away completely any coolant Be sure that the cap is clean before testing, since rust
trom the area. or other foreign material on the cap seal will cause an
4. Be c;aretul, when installing and removing the incorrect reading.
tester and when testing, not to detorm the
tiller neck ot the radiator.
4. If there is leakage, repair or replace with the apropri-

ate part.
ECA9090A
KDMB002A
SPECIFIC GRAVITY TEST EDMBOO50
1. Measure the specific gravity of the coolant with a hy-

drometer.
2. Measure the coolant temperature and calculate the

concentration from the relation between the specific
gravity and temperature. Use the following table for
reference.
KDMBOO2B
RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY
Coolant temperature °C CF) and specific gravity Safe Coolant

Freezing
operating concentration
temperature
10 (50) 20 (68) 30 (86) 40 (104) 50 (122) temperature (Specific
°C (OF)
°C (OF) volume)
1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30%
1.063 1.058 1.054 1.049 1.044 -20 (-4) -15(5) 35%
1.071 1.067 1.062 1.057 1.052 -25 (-13) -20 (-4) 40%
1.079 1.074 1.069 1.064 1.058 -30 (-22) -25 (-13) 45%
1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50%
1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55%
1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) 60%
Example • /f the concentration is above 60%, the engine

cooling property will decrease, affecting the
The safe operating temperature is -15°C (5°F) when the engine adversely. For these reasons, be sure
measured specific gravity is 1.058 at coolant temperature to maintain the concentration level withln the
of 20°C (68°F) specified range.
• Do not mix types of anti - freeze.
& CAUTION
• /fthe concentration of the coolant is below
30%, its anti-corrosion property will be ad-
versely affected.
RECOMMENDED COOLANT
Antifreeze Mixture ratio of antifreeze in coolant

ETHYLENE GLYCOL BASE FOR ALUMINUM 50% [Except tropical areas]
40% [Tropical areas]
GENERAL EMA -17
CHECKING COMPRESSION 2) If the compression remains the same, valve

seizure, poor valve seating or a compression
PRESSURE EDHA1200
leak in the cylinder head gasket are all possible
causes.
1. Before checking the engine compression, check the
engine oil level. Also check that the starter motor and Tightening torque
battery are all in normal operating condition.
Spark plug : 20-30 Nm (200-300 kg.cm, 14-22 Ib.tt)
2. Start the engine and wait until the engine coolant tem-
perature reaches 80 - 95°C (176 - 205°F).
TIGHTENING CYLINDER HEAD
3. Stop the engine and disconnect the spark plug cables. BOLTS ECBB1300
4. Remove the spark plugs. 1. First loosen slightly and then tighten to the specified
torque.
5. Crank the engine to remove any foreign material in
the cylinders. Tightening torque
6. Insert the compression gauge into the spark plug Cylinder head bolts cold [Engine temperature
hole. approximately 20°C (68°F)] :
105 - 115 Nm (1050 - 1150 kg.cm, 75 - 82 Ib tt.)
7. Depress the accelerator pedal to open the throttle
fully.
8. Crank the engine and read the gauge.
Standard value : 1,200kpa(12.2 kg/cm2 , 170psi)

Limit: 1,050kpa(1 0.7kg/cm2 , 149psi)
EDA9010A
2. Be sure to follow the specific torque sequence as

shown in the illustration.
m NOTE
Run the engine to normal operating temperature and
let it cool, then re-torque the bolts to specifications.
EDHA015A
9. Repeat steps 6 to 8 for all cylinders, making sure that

the pressure difference for each of the cylinders is
within the specified limit.
Q
Limit Max. 100kpa (1.0 kg/cm 2 , 14psi) Timing belt side
between cylinders ~o
10. If a cylinder's compression or pressure differential is EDA9060B
outside the specification, add a small amount of oil

through the spark plug hole, and repeat steps 6 to 9.
1) If the addition of oil causes the compression to

rise, it is possible that the piston ring is be worn.
ADJUSTING VALVE CLEARANCE EDHA1400 3. Adjust the drive belt tension to specitication by tu ring
the adjusting bolt clockwise or counterclockwise.
As the intake and exhaust valves are equipped with hy-
draulic lash adjusters, there is no need to adjust the valve Standard Value
clearance. The proper tunction ot the hydraulic lash mech-
Air - conditioner compressor
anism may be determined by checking tor tappet noise.
When there is a tappet noise or any unusual noise, check : 7 - 10 mm (0.28 - 0.039 in.)
the hydraulic lash adjuster by removing and bleeding or
Alternator : 10 - 13 mm (0.39 - 0.51 in.)
replacing it.
Power steering: 8 - 11 mm (0.31 - 0.43 in.)
ADJUSTING DRIVE BELT AND

4. When installing the belt on the pulley, make sure it is
TENSION ER EDMBOO6O
centered on the pulley.
1. Hang the belt on the pulley ot the tensioner and install

Pulley
the tensioner.
~~~
(It the tensioner is al ready installed, loosen its mount-
ing bolts to allow belt installation.)
Tightening torque
Tensioner assembly bolt : Wrong V-riböed belt Wrong
Right
45 - 50 Nm (450 - 500 kg.cm, 33 - 36 Ib.tt)
EOYROO2O
Power steering pully
Idlerpully
Tension pully
Crankshaft pully Air conditioner

pully
Tension pully
EDMBOOSA
2. Install drive belt.

ENGINE BLOCK EMA -19
ENGINE BLOCK
ENGINE BLOCK
COMPONENTS EDMB0100
Cylinder Block
--+t----- Main bearing cap
90 -100 (900 - 1000,65 - 72)
TORQUE : Nm (kg.cm, Ib.ft)
EDMB010A
REMOVAL EDMBOll0 5. Oversize pistons are available in four sizes.
Remove the timing belt, cylinder head assembly, drive Piston service size and mark mm (in.)
plate, transrude mounting plate, oil pan and oil pump case. 0.25 (0.010) 0.8 : 0.25
0.50 (0.020) 0.8 : 0.50
For further details, refer to the appropriate section. 0.75 (0.030) 0.8 : 0.75
1.00 (0.040) 0.8 : 1.00
INSPECTION EDMB0120
CYLINDER BLOCK 6. To rebore the cylinder bore to the oversize, maintain

the specified clearance between the oversize piston
1. Check the cylinder block for scores, rust and corro- and the bore and make sure that all used pistons are
sion. Also check for cracks or any other defects. Re- the same oversize. The standard measurement of the
place the block if defective. piston outside diameter is taken at a level of 12mm
(0.47 in.) above the bottom of the piston skirt and
2. Measure the cylinder bore with a cylinder gauge at the ac ross the thrust faces.
three levels indicated, in the directions A and S.
Piston-to-cylinder clearance :
Level 1 : No.1 piston ring position at TDC
0.03 - 0.05 mm (0.0012 - 0.0020 in.)
Level 2: Center of cylinder
Level 3 : Sottom of cylinder

I J
[
EDA9460A
ECBB444A
3. If the cylinder bores show more than the specified
out-of-round or taper, or if the cylidner walls are badly
scuffed or scored, the cylinder block should be re- 7. Check for damage or cracks in the cylinders.
bored and honed. New oversize pistons and rings
should be installed. 8. Check the top surface of the cylinder block for flat-
ness. If the top surface exceeds the limit, grind to the
Standard value minimum limit or replace.
Cylinder bore: 93 - 93.03 mm (3.661 - 3.6625 in.) Standard value

Out-of-round and taper of cylinder bore: Flatness of gasket surface :
Max. 0.02 mm (0.0008 in.) Max. 0.03 mm (0.0012 in.)
Service limit
4. If a ridge exists at the top of the cylinder, cut it off with
a ridge reamer. Flatness of gasket surface : 0.05 mm (0.0020 in.)
ENGINE BLOCK EMA -21
& CAUTION
6. Check the clearance between the piston and cylinder.
When the cylinder head is assembled, grinding Standard: 0.03 - 0.05 mm (0.0012 - 0.0020 in.)
less than O.2mm (O.OOBin.) is permissible.
~NOTE
~"'\0\~OO When boring the eyfinders, finish all of the eyfinders
/~\\ (j0 ()~___~ to the same oversize. 00 not bore only one eyfinder
to the oversize.
~\ ~
REASSEMBLY EDHA2500
Install the following parts by referring to their respective

sections.
EDA9460B
1. Crankshaft
2. Drive plate
BORING CYLINDER EDMB0130 3. Piston
4. Cylinder head
1. Oversize pistons should be selected according to the 5. Timing belt
largest bore cylinder. 6. Oil pump case
Identification Mark Size

0.25 0.25 mm (0.010 in.)
0.50 0.50 mm (0.020 in.)
0.75 0.75 mm (0.030 in.)
1.00 1.00 mm (0.040 in.)
~NOTE
The size of piston is stamped on top of the piston.
2. Measure the outside diameter of the piston to be

used.
3. According to the measured 0.0., calculate the new

bore size.
New bore size = Piston 0.0 + 0.03 to 0.05 mm (0.0012
to 0.002 in.) (clearance between piston and cylinder)
- 0.01 mm (0.0004 in.) (honing margin.)
4. Bore each of the cylinders to the calculated size.
& CAUTION
To prevent distortion that may result 'rom temper-
ature rise during honing, bore the cylinder holes
in the firing order.
5. Hone the cylinders, finishing them to the proper di-

mension (piston outside diameter + gap with cylinder).
ENGINE MOUNTS
COMPONENTS EDMB0150
FRONT ENGINE MOUNTING

12 - 20 (120 - 200, 9 -15)
r----.. J~-
I' (
\yL )~ ~ ___-~- __ ~
(\J f.>® \. ~/
'- ,----.,~'
\ ~,
61
@
('
,
~.;---
"--.J - -/ ~ L-~
\1 _---- /'
\ --.
~ ~-
y
~-t:::-/\
Engine mounting insulator I
, . - - - - - - 30 - 40 (300 - 400, 22 - 30)
TORQUE : Nm (kg.cm, Ib/.ft)
EDMB015A
"
ENGINE BLOCK EMA-23
TIM MOUNTING EDMBOl60
~
A 1---- 30 _ 42 (300 - 420, 22 - 31)
30 - 42 (300 - 420, 22 - 31)
Transru<le mounting insulator
EDMB016A
INSPECTION EDMB0170
1. Check the insulator for damage, crack and deforma-

tion.
2. Check the insulator stopper plate for damage, crack

and defor mation.
~NOTE
Be careful not to apply oil to the insulator.
MAIN MOVING SYSTEM

CAM SHAFT
COMPONENTS ECBB3000
Cylinder head cover bolt
Cyl;nde, head cove: - 6 (50 ISO' 4 - 5 )
,~-- PCV hose
Oil filter cap
,-l\,.I--'------ Camshaft (EX)
Camshaft oil seal

Cylinder head (LH) .
90 -110 (900 -1100, 65 -79) Camshaft sprocket
TORQUE : Nm (kg.cm, Ib.tt)
EDB9029A
MAIN MOVING SYSTEM EMA-25
DISASSEMBLY EDMB0200
1. Remove intake manitold.
2. Disconnect the breather hose and the engine har-

ness.
3. Remove the power steering pulley, air conditioner pul-

ley, crankshaft pulley, idler pulley and tensioner pulley.
4. Remove the timing belt cover.

ED89030C
5. Loosen the auto tension er.
6. Remove the timing belt tram the camshaft sprocket. INSPECTION EDMB0210
7. Remove the spark plug cables. CAMSHAFTS
8. Loosen the cylinder head cover bolts and then remove 1. Check the camshaft journals tor wear. If the journals
it. are badly worn out, replace the camshaft.
2. Check the cam lobes for damage. If the lobe is dam-

"'9 ... ,
aged or excessively worn out, replace the camshaft.
(00 00 00 C
u. ....1
-y-
Cam height
[Standard]
Intake : 35.098 - 35.298 mm (1.3818 - 1.3897 in.)
Exhaust : 34.81 - 35.01 mm (1.3705 - 1.3783 in.)
EDB9030A
9. Remove the camshaft sprackets.
10. Remove the camshaft bearing caps.
EDA9260A
3. Check the cam surface for abnormal wear or damage,

and replace if necessary.
Front bearing cap Bearing cap Rear bearing cap
4. Check each bearing for damage. If the bearing
surface is excessively damaged, replace the cylinder
EDB9030B
head assembly or camshaft bearing cap, as neces-
11. Remove the camshafts. sary.
Camshaft end play : 0.1-0.15mm(0.0039-0.0059 in.)
OlL SEAL (CAMSHAFT FRONT)
1. Check the lips for wear. If lip threads are worn out,
replace the oil seal with new one.
2. Check a contact surface ot oil seallip on camshaft. If

there stratified wear, replace the camshaft.
HLA (HYDRAULIC LASH ADJUSTER) A
With the HLA filled with engine oil, hold A and press B by
hand. If B moves, replace the HLA.
EDA9260B
Problem Possible cause Action

1. Temporary noise when starting Normal This noise will disappear after the oil in the
a cold engine engine reaches the normal pressure.
2. Continuous noise when the Oil leakage of the high pressure Noise will disappear within 15 minutes
engine is started after parking chamber on the HLA,allowing when engine runs at 2000-3000 rpm.
more than 48 hours. air to get in. If it doesn't disappear,refer to step 7 below.
3. Continuous noise when the Insufficient oil in cylinder
engine is first started after head oil gallery.
rebuilding cylinder head.
4. Continuous noise when the Oil leakage of the high-pressure
engine is started after excessivly chamber in the HLA, allowing
craking the engine by the air to get in.
starter motor or band. Insufficient oil in the HLA.
5. Continuous noise when the
engine is running after & CAUTION
changing the HLA. 00 not run engine at a speed higher
than 3000 rpm, as this may damage
the HLA.
6. Continuous noise during idle Engine oil level too high Check oil level.
after high engine speed. or too low. Drain or add oil as necessary.
Excessive amount of air in the Check oil supply system.
oil at high engine speed.
Deteriorated oil. Check oil quality.
If deteriorated, replace with specitied type.
7. Noise cotinues for more Low oil pressure. Check oil pressure and oil supply system
than 15 minutes. of each part of engine.
Faulty HLA. Remove the cylinder head cover and
press HLA down by hand.
If it moves, replace the HLA.
L . , WARNING
Be careful with the hot HLAS.
AUTO LASH ADJUSTER 4. The left and right banks of the camshafts are different
and you should be careful not to confuse them.
1. Check auto - lash adjusters for free play by inserting
a small wire through the air bleed hole in the rocker Identification signal
arm and push the autolash adjuster check ball down Left bank
very lightly. Intake (IN) : F
Exhaust (Ex) : E
2. While lightly holding the check ball down move the Right bank
rocker arm up and down to check for free play. If there Intake (IN) : G
is no play replace the auto - lash adjuster. Exhaust (Ex) : H
ITJrr1lD1JBO []]J 0 [JO[] oll
LUIIllILLII 0nD C1BOOO C[J

EDB9030E
EDB90348
REASSEMBLY ECBB3250 5. Confirm the identification mark and the number.

Bearing caps of No.3. No.4. and No.5 have the front
CAMSHAFT AND BEARING CAP mark and arrange the front mark upon the cyJinder
head while installing the bearing caps.
1. Rotate the crankshaft and No. 1 cylinder is in TDC
(Compression stroke) Identification mark
Intake: I
2. Check the position of the rocker arm whether it is ex-
Exhaust: E
actly installed on the lash adjuster and valve or not.
3. Install the camshaft dowel pin as illustration.
Cylinder head (RH)
EDB9034C
Cylinder head (RH)
EDB9034A
6. Tighten the bearing cap by 2 or 3 steps
Tightening Torque
Outer (*) 16 EA : 1.9 - 2.1 kg.m
Inner 24 EA : 1.0 - 1.2 kg.m
EDB9034D
CONNECTING ROD
COMPONENTS EDMB0230
No. 1 Pistion rign--,e~
/.\./I-- Connecting
rod bolt
Connecting rod~connecting rod bearing
Piston and connecting rod assembly - - - -
"*"---- Connecting rod upper bearing
/
Connecting rOd~/
lower bearing "
C,." Connecting rod cap
~ 35 + 92" (350 + 92")
EDMB023A
DISASSEMBLY ECBB3400 4. To remove the pin from the piston, place the piston
in the support fixture with the rod resting on the fork
CONNECTING ROD CAP inserts. Pass the remover tool through the top of the
support fixture and use it to press out the pin.
& CAUTION
Keep the bearings in order with their correspond-
ing connecting rods (according to cylinder num-
bers) tor proper reassembly.
Support fixture
1. Remove the connecting rod cap bolts, then remove
the caps and the big end lower bearing mark for re-
assembly.
2. Push each piston connecting rod assembly toward the

top of the cylinder. EDA9048A
5. To install a new pin, the proper fork inserts must be in

place to support the rod.
6. Position the rod inside the piston. Insert the proper pin
guide through one side of the piston and through the
rod. Hand tap the pin guide so it is held by the piston.
Insert the new pin into the piston from the other side
and set the assembly into the support fixture with the
pin guide facing down.
ECBB444D
~NOTE
The pin guide should be centered on the connecting
DISASSEMBLY AND REASSEMLY OF THE PISTON rod through the piston. If assembled correctly, the pin
PIN guide will sit exactly under the center of the hole in the
tool's arch, and rest evenly on the fork inserts. If the
1. Using the special tools 09234 - 33001 and 09234 - wrang size pin guide is used, the piston and pin will
3002, disassemble and reassemble the piston and not up with the support fixture.
connecting rod.
Fork insert (09234-33002)

09234-
33001
ECA9361C
ECA9361A
7. Insert the installer tool through the hole in the arch of
the support fixture and use an hydraulic press to force
2. The piston pin is a press fit in the rod little end, and
the piston pin through the rod little end. Continue
the piston floats on the pin.
pressing until the pin guide falls free and the installer
tool seats against the top of the arch.
3. The tool consists of a support fixture with fork inserts,
guides, adapters, an installer and a remover. The
piston is supported in the support fixture while the pin
is being installed or removed. Guides help position
the pin as it is installed or removed, while the rod is
supported by fork inserts.
MAIN MOVING SYSTEM EMA -31
& CAUTION PISTON RING SERVICE SIZE AND MARK
Do not exeeed 750:t 1,750 kg (1,653:t 3,8581b) of Standard None

foree when the installing tool seats angainst the 0.25 mm (0.010 in.) O.S 25
top of the areh. 0.50 mm (0.020 in.) O.S 50
0.75 mm (0.030 in.) O.S 75
INSPECTION ECBB3500 1.00 mm (0.040 in.) O.S 100
PISTONS AND PISTON PINS

~NOTE
1. Check each piston for scuffing, scoring, wear and
other defects. Replace any piston that is defective.
The mark can be found on the upper side
next to the end.
0' the ring
2. Check each piston ring for breakage, damage and

abnormal wear. Replace the defective rings. When
the piston requires replacement, its rings should also
be replaced.
3. Check that the piston pin fits in the piston pin hole.
Replace any piston and pin assembly that is defective.
The piston pin must be pressed smoothly by hand into
the pin hole (at room temperature).
PISTON RINGS
KFW3037C
1. Measure the piston ring side clearance. If the mea-

sured value exceeds the service limit, insert a new CONNECTING RODS
ring in the ring groove to measure the side clearance.
1. When the connecting rod cap is installed, make sure
If the clearance still exceeds the service limit, replace
that the cylinder numbers, marked on rod end cap
the piston and rings together. If it is less than the ser-
at disassembly, match. When a new connecting rod
vice limit, replace only the piston rings.
is installed, make sure that the notches holding the
bearing in place are on the same side.
Piston ring side clearance
No.1 : 0.04 - 0.08 mm (0.0016 - 0.0031 in.) 2. Replace the connecting rod if it is damaged at either
No.2 : 0.02 - 0.06 mm (0.0008 - 0.0024 in.) end of the thrust faces. If it has a stratified wear, or if
the surface of the inside diameter of the small end is
2. To measure the piston ring end gap, insert a piston severely rough, replace the rod.
ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down
with a piston. Measure the gap with a feeler gauge. If
the gap exceeds the service limit, replace the piston
ring.
Piston ring end gap

[Standard dimensions]
No.1 : 0.30 - 0.45 mm (0.012 - 0.018 in.) Notches
No.2 : 0.45 - 0.60 mm (0.018 - 0.024 in.)
Oil ring side rail : 0.2-0.7 mm (0.0079 - 0.0276)
EDA9047A
When replacing the ring without correcting the cylinder

bore, check the gap with the ring situated at the lower part
of cylinder that is less worn out.
REASSEMBLY ECBB3600 6. Install the No. 1 piston ring.
1. Install the spacer.
rr:~=::::~r--7Side rail
~;;;;;;;;;;::3o:;f--Spacer
öl 0 ill'1 )
Piston lower
KFW3055A
ECA9082A 7. Position each piston ring end gap as far away from
its neighboring gaps as possible. Make sure that the
gaps are not positioned in the thrust and pin direc-
tions.
90· Position Irom
the gap 01 No. 2 ring
8. Hold the piston rings firmly with a piston ring compres-
sor as they are inserted into cylinder.
Gap of upper No.1 ring

side rail 11& ~ ~Jlgap
fI ~
Gap position 01 spacer
Fro~t of -""'- .
EDJA490A
englne .........
'\
2. Install the upper side rail. To install the side rail, first
.put one end of the side rail between the piston ring
groove and spacer, hold it firmly, and press down with
No.2 ring gap . . ~
andspacer ~
expander gap
~{ Gap of lower
finger on the portion to be inserted into the groove (as side rail
iIIustrated). ECA9380D
& CAUTION 9. Install the upper main bearings in the cylinder block.
Do not use a piston ring expander when installing 10. Install the lower main bearings in the main bearing
the side rail. caps.
3. Install the lower side rail by the same procedure de-

scribed in Step 2.
& CAUTION
Install the bearing so it matches the oil hole In the
block.
ECA9380B
4. Apply engine oil around the piston and piston grooves. EDA9390E
5. Using a piston ring expander, install the No.2 piston

ring.
MAIN MOVING SYSTEM EMA -33
11. Install the thrust washers in the No. 3 main bearing 16. Check the connecting rod side clearance.
cap with the oil grooves facing outward.
Connecting rod side clearance
Standard: 0.10-0.25 mm (0.0039-0.0098 in.)
Limit: 0.4 mm (0.0157 in.)
EDA9390F
12. Make sure that the front mark of the piston and the
front mark (identification mark) of the connecting rod
EDA9051A
are directed toward the front of the engine.
13. When the connecting rod cap is installed, make sure

that any cylinder numbers placed on the rod and cap
at disassembly match.
14. When a new connecting rod is installed, make sure

that the notches for holding the bearing in place are
on the same side.
15. When assembling, bolts should be fastened using the

plastic angle technique as folIows.
1} Apply oil to the threads and matching areas.
2} Tighten the connecting rod bolt.
Tightening torque
Connecting rod bolt :
50 - 55 Nm (500 - 550 kg.cm, 36 - 37 Ib.ft)
& CAUTION
After removing the connecting rod bolt, do not
use it again.
When using a new bott, do not tighten the bott
more than 3 times.
Notches
EDA9047A
CRANK SHAFT
COMPONENTS ECBB3700
Cylinder block
Drive plate
Crankshaft bush
- " + - - - Crankshaft
Lower bearing
~-- Main bearing cap
/'
t
,
Ma;n bearing cap boU
90 -100 (900 -1000, 65 -72)
ECBBOO1B
DISASSEMBLY ECBB3800 MEASURING OlL CLEARANCE
Check for oil clearance by measuring the outside diameter

1. Remove the timing belt train, front case, cylinder head
of the crankshaft journal and the inside diameter of the
assembly and oil pan. For details, refer to the respec-
bearing. The clearance can be obtained by calculating the
tive chapters.
difference between the measured outside diameters.
2. Remove the rear plate and the rear oil seal. Standard value
Oil clearance
3. Remove the connecting rod caps.
Crankshaft main bearing :
~NOTE 0.018 - 0.036 mm (0.0007 - 0.0014 in.)
Mark the main bearing caps to be able to reassemble Connecting rod bearing :
in the original position and direction.
0.022 - 0.048 mm (0.0009 - 0.002 in.)
4. Remove the main bearing ca ps and remove the crank-
shaft. Keep the bearings in order according to the cap
number.
INSPECTION EDMB0250
CRANKSHAFT
1. Check the crankshaft journals and pins for damage,

uneven wear and cracks. Also check the oil holes for
restrictions. Repair or replace any defective parts. KFW3058A
PLASTIGAUGE METHOD
2. Inspect the crankshaft journal and pin for out-of-round
and taper. Plastigauge may be used to measure the clearance.
Standard value 1. Remove oil, grease and any other dirt from the bear-
ings and journals.
Crankshaft journal 0.0 :
63.982 - 64.00 mm (2.519 - 2.5197 in.) 2. Cut the plastigauge the same length as the width of
the bearing and place it in parallel with the journal,
Crankshaft pin 0.0 :
avoiding the oil holes.
54.982 - 55.00 mm (2.165 - 2.1653 in.)
3. Install the crankshaft, bearings and caps and tighten
them to the specified torques. Ouring this operation,
do not turn the crankshaft. Remove the caps. Mea-
sure the width of the plastigauge at the widest part by
using the scale printed on the gauge package.
If the clearance exceeds the service limit, the bearing
should be replaced or an undersize bearing should
be used. When installing a new crankshaft, be sure
to use standard size bearings.
If the standard clearance can not be obtained even
after replacing the bearing, the journal and pin should
be ground to the undersize and a bearing of the cor-
responding size should be installed.
ECA9410A
MAIN BEARINGS AND CONNECTING ROD

BEARINGS
Visually inspect each bearing for peeling, melting, seizure

and improper contact. Replace any defective bearings.
Main bearing cap bolt

Main bearing cap \
EDA9420C BOY183D
OlL SEAL 6. Cap bolts should be tightened evenly in stages 4 to 5

increments before they are tightened to the specified
Check the front and rear oil seals for damage or worn sur- torque.
faces. Replace any seat that is defective.
7. Make certain that crankshatt turns freely and check
DRIVE PLATE (AlT) the end play of the crankshatt.
Replace distorted, damaged, or cracked drive plates. Crankshaft end play

Standard: 0.070 - 0.250mm (0.0028 - 0.0098 in.)
Limit: 0.35 mm (0.014 in.)
REASSEMBLY ECBB4000
MAIN BEARING
1. Install a grooved main bearing (upper bearing) on the

cylinder block side.
2. Install a grooveless main bearing (Iower bearing) on

the main bearing cap side.
3. Install the crankshatt. Apply engine oil to journal and

pin. EDA9051A
4. Install the bearing caps with the arrow mark directed 8. Using special tool(09231-33000), install the rear oil
toward the front of the engine. Cap number must be seal in oil seal case.
correct.
9. Apply sealant to the area shown in the illustration.
5. Tighten the cap bolts to the specified torque. Install the oil seal case in the cylinder block.
Tightening torque Tightening torque

Main bearing cap bolts : Oil seal case bolt :
90 - 100 Nm (900 - 1000 kg.cm, 65 - 72 Ib.tt)
10-12Nm (100 - 120 kg.cm, 7 - 9 Ib.tt)
.
Grooveless - I - - 09231-33000
J L
Lower bearing Upper bearing
I'
EDA9420D EDA9430C
EDA9430D
10. Tighten the rear plate to the specified torque.
Tightening torque
Rear plate : 10 -12 Nm (100 - 120 kg.cm, 7 - 9 Ib.tt)
11. Tighten the drive plate and the adapter plate (AlT).
Tightenlng torque
Drive plate and adapter plate bolt :
73 - 77 Nm (730 - 770 kg.cm, 53 - 56 Ib.tt)
~ Drive plate
(AlT)
_~AdaPter plate
,f1
fD~~t.~
EDJA530A
COOLING SYSTEM
ENGINE COOLANT HOSE/PIPES
COMPONENTS EDMB0270
Water outlet pipe
Water outlet fitting
Water inlet fitting
Water pump
EDMB027A
COOLING SYSTEM EMA-39
INSPECTION EDHA6100 3. Remove the engine coolant sensor.
Check the engine coolant pipe and hose for cracks, dam-
age and restrictions. Replace if necessary.
REASSEMBLY EDJA4700
Fit the O-ring in the groove of the engine coolant inlet pipe
end. Wet the periphery of the O-ring with water and insert
the engine coolant inlet pipe.
~NOTE KDMBOO3E
1. 00 not apply oil or grease to the engine coolant

pipe O-ring.
INSTALLATION ECBB5400
2. Keep the engine coolant pipe connections free of
sand, dust, etc.
1. Apply sealant to the sensor's threads. Tighten it to
3. Insert the engine coolant pipe into the end of the
the specified torque.
engine coolant pump inlet.
4. Whenever installing the engine coo/ant in/et pipe,
Recommended sealant :
a/ways replace the O-ring with a new one.
Three bond NO. 2310 or LOCTITE 962T
Tightening torque
The coolant sensor :
20-40Nm(200-400 kg.cm, 14-29 Ib.tt}
2. Connect the coolant sensor to the harness.
Waterpump 3. Connect the ground cable of battery.
HEW2513B 4. Refill the coolant.
COOLANT TEMPERATURE
SENSOR EDMB0280
REMOVAL
1. Drain the engine coolant.
2. Remove the engine harness after disconnecting the

ground cable of the battery.
SCHEMATIC DIAGRAM ECBB5500
INLET CONTROL
Radiator
Coolant suction hose
Thermostat
1
Thermostat housing Heater hose
1
Coolant pipe Water hose
1
Water pump
1
Cylinder block Heater core
1
Cylinder head Throttle body
Coolant outlet
EDHA650A
FLOW CHART
- - - 1 - - 1 - - - - Cylinder head
--1--- Cylinder block
--+--- Heater
--+~I---+-~- Throttle body
Radiator
--
Thermostat
Thermostat closed
KFW3201A
COOLING SYSTEM EMA -41
ENGINE COOLANT PUMP
COMPONENTS ECBB5600
Carn shaft sprocket
Gasket
Waterpurnp
M:b~~~ ~ ~
~ /' \gIJ'---- Crank shaft sprocket
~ , fi!'
Tension bearing ~~
Idl.rb•• ""g ~~~~,......,
Q~ \
ECBBOO1E
REMOVAL ECBB5700 2. Install the new engine coolant pump gasket and pump
assembly. Tighten the bolts to the specitied torque.
1. Using the drain plug, drain the coolant.
Tightening torque
2. Remove the drive belt and the engine coolant pump
pulley. Engine coolant pump bolt :
Head mark "7" : 15-22 (150-220, 11-16)
3. Remove the timing belt cover, the auto tensioner and
idler pulley.
4. Remove the engine coolant pump mounting bolts.
5. Remove the engine coolant pump assembly trom the

cylinder block.
ECB9500L
3. Install the auto tensioner and timing belt. Adjust the

timing belt tension, then install the timing belt cover.
4. Install the drive belt, coolant pump pulley and then

ECB9500L
adjust the auto tensioner.
5. Retill the coolant.

INSPECTION EDHA7300
6. Run the engine and check tor leaks.
1. Check the engine coolant pump tor cracks,.damage or
wear, and replace the pump assembly it necessary.
2. Check the bearing tor damage, abnormal noise and

sluggish rotation and replace the pump assembly it
necessary.
3. Check the seal it tor leaks and replace the pump as-
sembly it necessary.
INSTALLATION ECBB5900
1. Clean the gasket surfaces ot the engine coolant pump

body and the cylinder block.
O-ring
Waterpump
HEW2513B
RADIATOR
COMPONENTS EDMB0300
Radiator hose
Coolant reservoir tank
. , . . . - - - Radiator
Radiator fan
EDMB030A
REMOVAL ECBB6100 INSPECTION EDHA8000
1. Disconnect the ground cable from the battery termi- 1. Check for foreign material between the radiator fins.
nal.
2. Check the radiator fins for damage and straighten it
2. Disconnect the fan motor connector. necessary.
3. Loosen the radiator drain plug to drain the coolant. 3. Check the radiator tor corrosion, damage, rust or
scale.
4. Disconnect the upper and lower hoses and overflow
tube after marking the radiator hose and the hose 4. Check the radiator hoses tor cracks, damage or dete-
clamp the ease reassembly. rioration.
5. Check the reservoir tank tor damage.
6. Check the automatie transaxle oil cooler hoses tor

cracking, damage or deterioration (only AlT).
INSTALLATION EDJA6300
1. Fill the radiator and reservoir tank with a clean coolant

mixture.
ECB9500B 2. Run the engine until the coolant warms up enough so

that the thermostat valve opens and then turn off the
5. For vehicles with automatie transaxles, disconnect the engine.
oil cooler hoses from the automatie transaxle.
3. Remove the radiator cap and pour the coolant up to
& CAUT/ON the fil/er neck ot the radiator. Fil/ the reservoir tank to
the upper level.
Cover or plug the hose and inlets of the radiator
so that dust and other foreign material etc. can 4. Check that there are no leaks trom the radiator, hoses
not enter after the hose is disconnected from the or connections.
radiator.
6. Remove the radiator mounting bolt.
ECB9500C
7. Remove the radiator and the fan motor.
8. Remove the radiator fan motor and condenser fan mo-

tor from the radiator.
COOLING SYSTEM EMA -45
RADIATOR PAN MOTOR
COMPONENTS ECBB6400
- - + - - - - Radiator
Fan Shroud
ECB9500D
REMOVAL ECBB6500 7. Remove the three screws and detach the tan motor.
1. Disconnect the ground cable trom the battery cable.
2. Disconnect the connectors trom the tan motor and the

harness trom the shroud.
3. For vehicles with automatie transaxies, remove the oil

cooler hose trom the shroud.
4. Remove the tour bolts holding the shroud.

ECB9500E
5. Remove the shroud with the tan motor.
6. Remove the tan mounting clip and detach the tan trom
the tan motor.
INSPECTION
~
ECBB6600
2 MOTOR
1 3 4
Item SPEED
RADIATOR FAN MOTOR AND CONDENSER
FAN MOTOR
RADIATOR EI) e LOW
FAN EI) EI) e MIDDLE
1. Check that the radiator fan rotates when battery volt-
MOTOR EI) EI) e e HIGH
age is applied between the terminals. CONDENSER EI) e LOW
FAN EI) EI) e MIDDLE
2. Check that there are no abnormal noises while the
motor is running.
MOTOR EI) EI) e e HIGH
ECBB444B
INSTALLATION EDMB0350
Installation is the reverse of removal.
~NOTE
1. Make sure the cooling fan does not come info
contact with the shroud when installed.
2. After installation, make sure there is no unusual
ECB9500F
noise or vibration when the fan is rotating.
RADIATOR FAN MOTOR RELAY
1. Remove the radiator fan motor relay (High and Low)

trom the relay box in the engine room.
ECA9061A
EDA9094A
2. Check to be sure that the radiator fan rotates when

battery vOltage is applied between the terminals (as
shown table below).
3. Check to see that adnormal nioses are not produced

while the motor is turning.
4 3
EDA9097A
RADIATOR CAP
COMPONENTS ECBB6BOO
Radiator cap Spring
Bent valve Vacuum spring
Pressure : 107.9±14.7 (1.1±0.15, 15.64±2.13) Pressure : 83.4 (0.85, 12.1)
PRESSURE : Kpa (kg/cm2 , psi)

HCT25012 '
INSPECTION EDHAB300 3. Increase the pressure until the indicator of the gauge
stops moving.
1. Check the radiator cap for damage, cracks or weak-
ening. 4. Replace the radiator cap if the reading does not hold
steady for about 10 seconds.
Weakening
HCT25013
KFW3203A
2. Connect the tester to the radiator cap.

THERMOSTAT INSTALLATION ECBB7300
1. Check that the flange of the thermostat is correctly

REMOVAL EDHA9100
placed in the socket of the thermostat housing.
1. Drain the coolant to thermostat level or below. 2. Install the in let fitting.
2. Remove the inlet fitting and gasket. Tightening torque
3. Remove the thermostat. Engine coolant inlet fitting bolt :
17-20 Nm (170-200 kg.cm, 12-14 Ib.tt)
INSPECTION . EDHA9200
3. Refill the coolant.
1. Heat the thermostat as shown in the illustration.
2. Check that the valve operates properly.
3. Verify the temperature at which the valve begins to

open.
Valve opening temperature : 80 - 84°C (176 - 183.2°F)

Full opening temperature : 95°C (203°C)
ECB95000
Water
ECA9600A
LUBRICATION SYSTEM EMA-49
LUBRICATION SYSTEM
OlL PUMP
COMPONENTS EDMB0400
Oil pump outer rotor
Oil pump inner rotor
Oil pump case

12 -15 (120 -150, 9 - 10)
~ Oil pressure switch
\......-J--- Oil pump
.~-- Upper baffle plate
Relif valve planger

__- - Relif valve spring
J---- Relif valve plug
Crankshaft sprocket
Upper oil pan - - - - t ~~~~
35 - 45 (350 - 450, 26 - 32)

-~
Lower oil pan
10 - 12 (100 - 120, 7 - 9)
TORQUE : Nm (kg·cm, Ib.ft)
EDMB040A
DISASSEMBLY EDH~9500
1. Remove the oil pressure switch, using 24 mm deep

socket. Side clearance
~NOTE
Since asealant is used on the threaded area, be care-
Body clearance
ful not to damage the oil pressure switch.
2. Remove the oil filter and the oil pan.

EDA9041A
3. Remove the oil screen and gasket.
4. Remove the three bracket securing bolts and remove

the oil filter bracket and gasket.
5. Remove the oil relief valve plug from the oil pump
case.
6. Remove the oil pump case.
24mm socket
EDA9340B
RELIEF PLUNGER AND SPRING
1. Check the relief plunger for smooth operation.
2. Check the relief spring for deformation or breaks.

OlL FILTER BRACKET
HFR20A33 1. Make sure that there is no damage on the surface that

mates with the oil filter.
INSPECTION ECBB8200
2. Check the oil filter bracket for oil leaks or cracks.
OlL PUMP OlL PRESSURE SWITCH
1. Visually check the parts of the oil pump case for 1. Check the continuity between the terminal and the
cracks and damage. body with an ohmmeter.
If there is no continuity, replace the oil pressure
2. Assemble the rotor on the oil pump and then check switch.
the clearance with a thickness gauge.
Oll pump side clearance

Standard value
Body clearance:0.1 00-0.181 mm (0.0039-0.0071 in.)
Side clearance:0.040-0.095mm (0.0016-0.0037 in.)
Oil pump Tip clearance :
0.06 - 0.18 mm (0.0024 - 0.0071 in.)
ECA9320D
2. Check the continuity between the terminal and the

body when the fine wire is pushed. If there is con-
tinuity even when the fine wire is pushed, replace the
switch.
LUBRICATION SYSTEM EMA -51
3. .If there is no continuity when a 50 kpa (7 psi) vacuum 2. Install the oil seal into the oil pump case as tightly as
is applied through the oil hole, the switch is operating possible, using the sp.ecial tool (09214-33000).
properly.
Check for air leakage. If air leaks, the diaphragm is (
broken Replace it.
Oil pumpcase
EDA9350B
3. Install the relief plunger and spring, and tighten the oil
ECA9320E
relief valve plug to the specified torque.
Operation Pressure
Tightening torque
Oil pressure switch :
Oil relief valve plug :
80 kpa (0.8 kg/cm 2 • 11.4 psi)or more
40-50 Nm (400-500 kg.cm, 29-36 Ib.tt)
REASSEMBLY ECBBB300
1. Install the oil pump case with the gasket.
Tightening torque
Oil pump case bolt :
12-15 Nm (120-150 kg.cm, 9-11 Ib.ft)
Oil pump cover screw :
8-12 Nm (80-120 kg.cm, 6-9 Ib.ft)
EDA9044A
<Front view> <Rearview>

4. Install the oil screen and a new gasket.
Tightening torque
Oil screen bolt :
15-22 Nm (150-220 kg.cm, 11-15Ib.ft)
5. Clean the gasket surfaces of the cylinder block and

EDA9042A
the oil pan.
6. Apply sealant to the groove of the oil pan flange.
[Q:J) NOTE
1. Make the first cut approx. 4 mm from the end of
the nozzle furnished with the sealant. After appli-
cation of the sealant, do not exceed 15 minutes
before installing the oil pan.
2. Make sure that the sealant doesn't enter the in-
side of the oil pan.
7. Install the oil pan and tighten the bolts to the specified 9. Using a 24 mm deep socket, install the oil pressure
torque. switch atter applying sealant to the threadedarea.
Tightening torque Sealant : Three bond No.11 04E or equivalent

Oil pan bolt :
*: 19-28 Nm (190-280 kg.cm, 14-20 Ib.tt) ~NOTE
** : 5-7 Nm (50-70 kg.cm, 4-5 Ib.ft) 00 not torque the oil pressure switch too much.
*** : 30-42 Nm (300-420 kg.cm, 22-30 Ib.tt) Tightening torque

Oil pressure switch :
8 - 12 Nm (80 - 120 kg.cm, 6 - 9 Ib.tt)
24mmsocket
HFR20A33
10. Tighten the lower oil pan bolts as shown in figure.
EDA9045A
8. Tighten the oil pan bolts as shown in the illustration.
8 7
EDJA970A
**15
**16
*6 *10 *17
EDA9045B
INTAKE AND EXHAUST SYSTEM EMA -53
INTAKE AND EXHAUST

SYSTEM
EXHAUST MANIFOLD
COMPONENTS EDMB0450
Heat protector Exhaust manifole Gasket
--1---- Heat protector
-1---- Exhaust manifold
Front muffler -----~-
EDMB045A
REMOVAL ECBB9100 INSTALLATION ECBB9300
1. Remove the heat protector. 1. Install the exhaust manifold with gasket.
Tightening torque
Exhaust manifold : 25-30N.m (250-300
kg.cm, 18-22 Ib.tt)
[QJ] NOTE
00 not re - use an exhaust manifold gasket.
ECB951OB
2. Remove the exhaust manifold.
ECB9510C
2. Install the heat protector.
ECB9510C
3. Remove the exhaust manifold gasket.
INSPECTION ECBB9200
1. Check for damage or cracks.
2. Using a straight edge and feeler gauge, check for dis-

ECB951 OB
tortion on the cylinder head matching surface.
Standard value : 0.15 mm (0.006 in.) or less

Service limit: 0.3 mm (0.012 in.) or less
ECB9510D
3. Check the exhaust manifold for damage and cracks.

INTAKE AND EXHAUST SYSTEM EMA-55
INTAKE MANIFOLD
COMPONENTS EDMB0500
- + + - - - - - - - Surge tank
.....- : : : ; , 1 \ \ - - - - - - Delivery pipe
- + - - - - - - - Gasket
~::::".'~ ~~~r-- Intake manifold
EDMB050A
REMOVAL EDMB0510 6. Remove the surge tank stay.
1. Remove the air intake hose connected to the throttle

body.
KDMBOO3C
KDMB003B
2. Remove the accelerator and cruise control cables.
3. Remove the engine coolant hose and throttle body.
KDMBOO3D
7. Bleed off the pressure in the tuel pipe li ne to prevent

the tuel trom spilling.
8. Disconnect the connector trom high pressure hose.
KFW3231A
4. Remove the P.C.V. hose and brake booster vacuum

hoses.
5. Disconnect the vacuum hose connections.
ECBB444F
9. Remove the surge tank and gasket.
KDMBOO3B
KFW3236A
10. Disconnect the fuel injector harness connector. INSPECTION EDMB0520
SURGE TANK AND INTAKE MANIFOLD
1. Check the surge tank and intake manifold for damage,

cracking or restriction of the vacuum outlet port, water
or gas passages.
2. Check for distortion on the surface using a straight

edge and feeler gauge.
Standard value: 0.15 mm (0.006 in.) or less

KFW3237A Service limit: 0.2 mm (0.0078 in.)
11. Remove the delivery pipe with the fuel injector and the
pressure regulator.
[QJ] NOTE
When the delivery pipe is removed, be careful not to
drop an injector.
KDMB087A
KFW3238A
12. Disconnect the wiring harness of the coolant sensor

assembly.
13. Remove the surge tank.
KDMB009B
INSTALLATION EDMB0530
1. Install the intake manifold and delivery pipe reversing

the order of the removal procedure.
Tightening torque
Intake manifold :
12 -15 N.m (120 - 150 kg.cm, 9 -11 Ib.tt)
Surge tankstay :
15-20 N.m (150-200 kg.cm, 11-14Ib.tt)
KFW3241A
KDMBOO3C
KDMB003D
INTAKE AND EXHAUST SYSTEM EMA-59
MUFFLER
COMPONENTS EDMB0600
Rear muffler ------,.t€~~
Catalytic converter
~ 30-40(300-400,22-29) ~
Front exhaust pipe ~
30 - 40 (300 - 400, 22 - 29) Gasket
Main muffler
Gasket
EDMB060A
REMOVAL EDMB0610 3. Remove the front exhaust pipe from the rubber
hanger.
REAR MUFFLER
',i
& CAUTION
Before removing or inspecting the exhaust sys-
tem, ensure that the exhaust system is cool.
1. Disconnect the rear muff/er from the center exhaust

pipe. @ C
KDMB001E
KDMB001B
2. Remove the rubber hangers and the rear muffler.
ECA9078A
INSPECTION EDHAB200
1. Check the mufflers and pipes for leaks, corrosion and

damage.
2. Check the rubber hangers for deterioration and

cracks.
KDMB001C
INSTALLATION EDHAB300
FRONT EXHAUST PIPE (INCLUDING CATALYTIC
CONVERTER) 1. Temporarily install the front exhaust pipe, the catalytic
converter assembly, the center exhaust pipe and the
1. Remove the front exhaust pipe from the center ex- main muff/er, in this order.
haust pipe.
2. Install the rubber hangers so that they hang equally
2. Remove the front exhaust pipe bolt and the exhaust left and right.
manifold pipe mounting nuts.
3. Tighten the parts securely and then confirm that there
is no interference with any components.
KDMBOO1D
AIR CLEANER (ACL)
COMPONENTS EDMB0650
Air cleaner cover Air flow sensor
Air intake hose
~---- Air cleaner filter
+ - - - Air cleaner body
EDMB065A
REMOVAL ECBBA300 INSPECTION ECBBA400
1. Disconnect the air flow sensor connector. 1. Check the air intake hose, air cleaner cover for dam-
age.
2. Remove the air intake hose and air duct connected to
the air cleaner. 2. Check the air duct for damage.
3. Remove the three bolts attaching the air cleaner

mounting brackets.
4. Detach the air cleaner.
ECB9505D
3. Check the air cleaner element for restriction, contam-

ination or damage.
If the element is slightly restricted, remove dust and
ECB9505C
debris by blowing compressed air from the inside of
5. Remove the air flow sensor fram the air intake hose. the element. Replace the element if it cannot be
cleaned.
& CAUTION
Do not pult on the air flow sensor wires.
ECA9066A
INSTALLATION EDHAB800
1. Install the air cleaner assembly following the reverse

order of removal.
CYLINDER HEAD ASSEMBLY EMA -63
CYLINDER HEAD
ASSEMBLY
CYLINDER HEAD
COMPONENTS ECBBBOOO
~Rockerarm
; ~ Lash adjuster
e VIve spring
t:==:Prin sh••'
g
Cylinder head (LH)
Cylinder block

EDB9031A
DISASSEMBLY ECBBB100 12. Remave the cylinder head assembly. The cylinder
head bolts should be removed using the 12 mm
1. Drain the coolant and disconnect the upper radiator socket, in two or three steps.
hose.
2. Remove the breather hose and air-intake hose.
3. Remove the vacuum hose, fuel hose and coolant

hose.
4. Remove the intake manlfold.
5. Remove the cables fram the spark plugs. The cables

should be removed by holding the boot portion.
6. Remove the ignition coil. EDB9032C
7. Remove the upper and lower timing belt cover.
1 5 8 4
o o o o
2 6 7 3
o o o o
EDB9035B
EDB9025C 13. Clean the gasket pieces fram the cylinder block top
surface and cylinder head boUom surface.
8. Remove the timing belt and camshaft sprockets.
~NOTE
Make sure that fragments from the gasket da not fall
in the engine.
RETAINER LOCK
1. Compress the valve spring using special tool. (09222

- 28000, 09222 - 28100)
2. Remove the retainer lock.
EDB9027G
9. Remove the heat protector and exhaust manifold as-

sembly.
10. Remove the coolant pump pulley and head cover.
11. Remove the intake and exhaust camshaft.
EDB9032D
CYUNDERHEADASSEMB~ EMA -65
INSPECTION EDMB0700 VALVE
CYLINDER HEAD 1. Replace the valve if its stem is bent, worn or dam-
aged. Also replace it if the stem end (the surface con-
tacting the hydraulic-Iash adjuster) is hollowed out.
1. Remove scale, sealing compound and carbon
deposits. After cleaning oil passages, apply com- 2. Check the valve face contact area, and recondition or
pressed air to make certain that the passages are replace as necessary.
not clogged.
A
2. Visually check the cylinder head for cracks, damage
or water leakage.
3. Check the cylinder head surface for flatness with a

straight edge and feeler gauge as shown in the illus-
tration.
Cylinder head flatness:

Standard dimensions: Max. 0.03mm(0.0059 in.)
Service limit: 0.05mm(0.0020 in.) ECA9281B
3. Replace the valve if the width of the margin (thickness

of the valve head) is less than the minimum specified.
Valve margin
Standard value
Intake: 1.0mm (0.0394 in.)
Exhaust: 1.3mm (0.0512 in.)
KFW3047A
Contact area
(It must be at the
VALVE GUIDES center of the face
Check the valve stem-to-guide clearance. If the clearance

exceeds the service limit, replace the valve guide with a
new oversize guide.
EDA9300D
Valve stem-to-guide clearance VALVE SPRING

Standard value
Intake : 0.02 - 0.05 mm (0.0009 - 0.0020 in.) 1. Check the free height of each valve spring and replace
Exhaust : 0.050 - 0.085 mm (0.0020 - 0.0033 in.) if necessary.
2. Using a square, test the squareness of each valve
o
spring. If the spring is excessively out-of-square, re-
place it.
Valve spring
Valve Standard value
guide
Free height : 46.4 mm (1.8268 in.)
Load: 24 kg / 37.9 mm (53 Ib / 1.492 in.)
Out - of - square : Max. 2°
Service limit
Guide inside diameter Free height: .41.5 mm (1.6339 in.)
Load: 55.8 kg / 28.9 mm (123 Ib /1.1378 in.)
ECA9281D
Removal 0
• Press .•
0
Installation
09222-22000
Free
height
ECA9281C EDA9300G
RECONDITIONING VALVE SEAT 3. Using the special tool (09221-29000, 09222-22000)

press-fit the valve guide. The valve guide must be
1. Before reconditioning, check the valve guide for wear. press-fitted from the upper side of the cylinder head.
Replace worn guides if necessary and then recondi- Keep in mind that the intake and exhaust valve guides
tion the valve seats. are different in length.
2. Recondition the valve seat using the Valve Seat Cutter 4. After the valve guide is press-fitted, insert a new valve
and Pilot. and check for proper clearance.
3. After reconditioning, the valve and valve seat should 5. After the valve guide is replaced, check that the valve
be lapped lightly with a lapping compound. is fully seated. Recondition the valve seats as neces-
sary.
~NOTE
Da not instal/ a valve guide unless it is oversize.
Intake Exhaust
45.5mm 50.5mm
(1.79 in.) (1.99 in.)
KFW3048A
REPLACING VALVE GUIDE
1. Using the special tool (09222 - 22000 B), withdraw the

old valve guide out the bottom of the cylinder head. EOY168A
2. Recondition the valve guide hole so that it can receive REPLACING VALVE SEAT RING
the newly press-fitted oversize valve guide.
1. Cut away the inner face of the valve seat to reduce
VALVE GUIDE OVERSIZES the wall thickness.
Oversize valve
Size mm (in.) Size Mark guide hole size
mm (in.)
12.05 - 12.068
0.05 (0.002) O.S. 5
(0.474 - 0.475)
0.25 (0.010) O.S. 25

12.25 - 12.268 %
-++-,0.5-1.0mm
(0.482 - 0.483) (0.020-0.039 in.)
0.50 (0.020) O.S. 50

12.50 - 12.518 ---~..... ~
(0.492 - 0.493)
EOYR3940
CYUNDERHEADASSEMB~ EMA-67
2. Enlarge the diameter of the valve seat so that it

matches the specified hole diameter of the new valve
seat ring.
Heightof I
valve seat
ring
EOY167A
VALVE SEAT RING OVERSIZES
Description Size mm (in.) Size Seat ring height H mm (in.) Oversize hole diameter
Mark 1.0. mm (in.)
Intake valve 0.3 (0.012) 0.8. 30 7.9 - 8.1 (0.311 - 0.319) 36.300 - 36.325 (1.429 - 1.430)
seat ring
0.6 (0.024) 0.8. 60 8.2 - 8.4 (0.323 - 0.331) 36.600 - 36.625 (1.441 - 1.442)
Exhaust valve 0.3 (0.012) 0.8. 30 7.9 - 8.1 (0.311 - 0.319) 33.30 - 33.325 (1.311 - 1.312)
seat ring
0.6 (0.024) 0.8. 60 8.2 - 8.4 (0.323 - 0.331) 33.600 - 33.625 (1.323 - 1.324)
3. Heat the cylinder head to about 250°C (480°F) and

press-fit an oversize seat ring for the bore in the cylin- --+1--- 09222 - 28200
der head.
4. Using lapping compound, lap the valve to the new

seat. Valve stern seal
Valve seat contact width

Intake : 0.9 - 1.3 mm (0.035 - 0.051 in.)
Exhaust : 0.9 - 1.3 mm(0.035 - 0.051 in.)
EDB9037A
REASSEMBLY ECBBB300
.. 1. Install the spring seats.
2. Using special tool (09222 - 28200), lightly tap the seal

in position.
~NOTE
• 00 not reuse old valve stern seals.
• Incorrect installation of the seal could result in oi!
EDB9037B
leakage of from the valve guides.
3. Apply engine oil to each valve. Insert the valve into
their guides. Avoid pushing the valve into the seal by
force. After installing the valve, check that it moves
smoothly.
4. Place valve springs so that the side coated with 8. Install the gasket so that the surface with the identifi-
enamel faces toward the valve spring retainer. cation mark faces toward the cylinder head.
€:iF~~~~:!t--Spring ~NOTE
Retainer 00 not app/y sea/ant to these surfaces.
side
'J:.t-==-- Stern seal
Spring seat
ECA9290B
5. Using the special tool (09222 - 28000, 09222 -

28100), compress the spring and install the retainer
locks. After installing the valves, ensure that the EDB9032B
retainer locks are correctly in place before releasing

the valve spring compressor. 9. Tighten the cylinder head bolts in the sequence
shown in the illustration with a torque wrench.
~NOTE
When the spring is compressed, check that the va/ve
stern seal is not pressed against the bottom of the
retainer.
EDA9010A
10. Tighten the cylinder head bolts using the torque - an-
gle method. Starting at top center, tighten all cylinder
head bolts in sequence as shown in the illustration,
EDAA040B using the 12 mm socket.
6. Clean both gasket surfaces of the cylinder head and Tightening procedure
cylinder block.
Cylinder head bolt :
7. Verity the identification marks on the cylinder head 105 - 115 Nm (1050 - 1150 kg.cm, 75 - 82 Ib.ft)
gasket.
8 4 1 5
o o o o
7 3 2 6
o o o o
ECBBOO3A
TIMING SYSTEM EMA -69
TIMING· SYSTEM
TIMING BELT
COMPONENTS EDMB0800
Timing belt
Camshaft sprocket
Auto
Sensing blade
•
Crankshaft
pully
1
~~
43-55/' • •
(430 - 550, 31 - 39) ~ Crankshaft
~ sprocket
r
~ ~
180 -190
(1800 -1900,130 -138)
~~
«If~
Eog;o. support
lower bracket
Timing belt upper cover
50 - 60 (500 - 550, 31 - 39)

Timing biet lower cover
EDMB080A
REMOVAL EDMB0810
1. Using a [16 mm), rotate the tensioner arm clockwise

(about 14° )and remove the belt trom the pulley.
2. Remove the power steering pump pulley, idler pulley,

tensioner pulley and crankshaft pulley.
EDB9025E
5. Unbolt the tensioner to remove the timing belt.
~NOTE
If you plan to use the timing belt again, mark the rota-
tion direetion on the belt so you reinstall it eorrectly.
EDB9025B
3. Remove the upper and lower timing belt covers. INSPECTION EDHAD200
1. Inspect the belt closely. If the following problems are

evident, replace the belt with a new one.
1) Hardened back surface of rubber

Back surface is glossn, non-elastic and so hard
that when the nail of your finger is pressed into it,
no mark is produced.
EDB9025C
4. Remove the auto tensioner.
ECA9200B
2) Cracked back surface of rubber.
~NOTE
EDB9025D
~~m~ ~c,~
Rotate the erankshaft eloekwise and afign the timing Separation
mark to set the No. 1 eyfinders piston to TDC (eom-
pression stroke).
At this time, the timing marks of the eamshaft sproeket
and eyfinder head cover should eoineide with eaeh
other. EDA9220B
3) Side of belt is badly worn.
~NOTE
A belt in good condition should have clear-cut sides
as if it were cut with a sharp knife.
~
Separation
~ ,~' ..
Abnormal wear
(Fluffy canvas fiber)
EDA9220C
4) Teeth are badly worn out.
Initial stage : Canvas on load side of the tooth

flank worn (fluffy canvas fibers, rubber gone,
color changed to white, and unclear canvas
texture)
Last stage: Canvas on the load side of the tooth

flank worn down and rubber exposed (tooth width
reduced).
5) Missing tooth
Flankwom ~
(On load side) , ..~
,,::... ~,
0,:"
Tooth missing and

canvas fiber exposed
EDA9220D
2. If backlash or an irregular noise is observed when

rotating the pulley, replace the timing belt tensioner
and idler pulley.
EDA9025A
TIMING BELT ECBBC300
Water pump pulley

Timing mark
Cam Position Sensor(CPS)
'" _=--.'';;,H-t;=;:-I---- Idler pulley

Tensioner arm
Tensioner pulley ----------=~Ml Engine support
lower bracket
Crank Angle Sensor(CAS)

Auto tensioner
Crankshaft sprocket
EDB9026A
INSTALLATION EDMB0820 2. Install tensioner arm, shaft and plane washer to cylin-
der block.
The methed of installing timing belt and auto ten-
sioner. Tightening torque : 35 - 55 Nm (350 - 550 kg.cm)
1. Install idler pulley to engine support lower bracket.
Cylinder block
Shaft
Tensioner arm
Oil pumpcase
EDB9027B
EDB9027A
3. Install crankshaft sprocket and align the timing mark.
@~~~::::::::,,",Timing mark
~-+--Crankshaft
EDB9027F
sprocket
EDB9027C 6. Aligh the timing marks of each sprocket and install the
timing belt in this order.
Ln CAUTION Crankshaft sprocket ~ Idler pulley ~ Exhaust
camshaft sprocket (LH) ~ Intake camshaft sprocket
Be careful not to bend crankshaft sensing blade. (LH) ~ Water pump pulley ~ Intake camshaft
sprocket (RH) ~ Exhauft camshaft sprocket (RH) ~
Tensioner pulley
Crankshaft sprocket
EDB9027D
4. Install camshaft sprocket and adjust initial installation

EDB9027G
state as illustration.
~NOTE
Coin cidence • In this step, No. 1 is in TDC (Compression stroke)
• Do not insert fingers.
EDB9027E
5. Install auto tensioner to oil pump case.
[Qj1 NOTE EDB9027H
At this time auto tensioner's set pin should be assem-

bled completely. 7. After installating the timing belt, recontirm the timing
mark.
8. Install the tensioner pulley.
9. Pull out the set pin of auto tensioner.

THE METHOD TO ADJUST THE TENJSION OF

TIMING BELT.
1. Rotate the crankshaft 2 rotation clockwise and mea-

sure the projected load of auto tensioner in the TDC
W1 Compression stroke) after 5 minutes.
2. Check the projectde length is 3.8 - 4.5 mm.
3. Check again if the timing marks of each sprocket is

with in specified position.
~NOTE
If not within specified position, do again from proce-
dure 6 in the method of installing timing belt and auto
tensioner.
EDB9028A
Engine Mechanical
System [2.5 TCI]
GENERAL ................................................................. EM - 2
I
ENGINE BLOCK ........................................................... EM -24
MAIN MOVING SySTEM .................................................. EM -35
COOllNG SYSTEM ....................................................... EM -42
lUBRICATION SySTEM .................................................. EM -51
INTAKE AND EXHAUST SYSTEM ....................................... EM -56
CYLINDER HEAD ASSEMBlY ........................................... EM -70
TIMING SYSTEM .......................................................... EM -78

EM -2 ENGINE MECHANICAL SYSTEM [2.5 TCI]
GENERAL
GENERAL ELCB0010
[2.5 TCI]
Boost compensator
Turbo charger
Dil level gauge
Dil filter - - - - +
Generator - - - - \ - _~~ ~~~~~~~~~
EGR valve
11\l~r.:~,-lI--+l+- Waste gahe valve
......!JI.1:I---- Auto idle up actuator

Injection pump
ECLA001B
GENERAL EM-3
SPECIFICATIONS ELCBOO20
Standard Limit
Engine model D4BH (2.5 TCI)
Type Diesel engine
No. of cylinders 4 in - line
Valve mechanism OHC
Total displacement 2,467 ce
Bor x stroke 91.1 x 95 mm
Compression ratio 21
Valve timing
Intake valve
Opens (BTDC) 20°
Closes (ABDC) 48°
Exhaust valve
Opens (BBDC) 54°
Closes (ATDC) 22°
Firing order 1 - 3 - 4 - 2
Cyllnder head
Flatness of gasket surface 0.05 mm (0.002 in.) 0.2 mm (0.0079 in.)
Flatness of maunting mounting surface 0.15 mm (0.006 in.) 0.3 mm (0.0118 in.)
Overall height 94.0 - 94.1 mm (3.701 - 3.705in.)
Oversize rework dimensions of valve guide
hole (both intake and exhaust)
0.05 13.050 - 13.068 mm (0.5138 - 0.5145)
0.25 13.250 - 13.268 mm (0.5127 - 0.5224)
0.50 13.500 - 13.518 mm (0.5315 - 0.5322)
Oversize rework dimensions of intake
valve seat ring hole
0.30 43.300 - 43.325 mm (1.7047 - 1.7057 in.)
0.60 43.600 - 43.625 mm (1.7165 - 1.7175 in.)
Oversize rework dimensions of intake
valve seat ring hole
0.30 37.300 - 37.325 mm (1.4685 - 1.4695 in.)
0.60 37.600 - 37.625 mm (1.4803 - 1.4813 in.)
Camshaft
Cam height
Intake and Exhaust 37.05 mm (1.4587 in.) 36.55 mm (1.4389)
Journal diameter 29.94 - 29.95 mm (1.1787 - 1.1791 in.)
Oil clearance 0.05 - 0.08 mm (0.002 - 0.0031 in.) 0.13 mm (0.005 in.)
End play 0.1 - 0.2 mm (0.0039 - 0.0079 in.) 0.4 mm (0.0157 in.)
"
Rocker arm
ioD. 18.910 - 18.928 mm (0.7445 - 0.7452 in.) 0.08 mm (0.0031 in.)
Rocker arm - to - shaft clearance 0.012 - 0.050 mm (0.0005 - 0.0020 in.)
Rocker shaft
O.D. 18.878 - 18.898 mm (0.7432 - 0.7440 in.)
EM-4 ENGINE MECHANICAL SYSTEM [2.5 TCI]
Standard Limit
Valve
Overall length
Intake and Exhaust 136.5 mm (5.3740 in.)
Stem diameter
Intake 7.96 - 7.975 mm (0.3133 - 0.3140 in.)
Exhaust 7.93 - 7.950 mm (0.3122 - 0.3130 in.)
Face angle 45° - 45°30'
Thickness of valve head (margin)
Intake and Exhaust 2.0 mm (0.0787 in.) 1.0 mm (0.0394 in.)
Stem-to - guide clearance
Intake 0.03 - 0.06 mm (0.0012 - 0.0024 in.) 0.10 mm (0.0039 in.)
Exhaust 0.05 - 0.09 mm (0.0020 - 0.0035 in.) 0.15 mm (0.0059 in.)
Valve spring
Free height 49.1 mm (1.9331 in.) 48.1 mm (1.8937 in.)
Lode / Installed height 276 N (27.6 kg) / 40.4
Out - of squareness Max 2° 4°
Valve guide
Overall lenght
Intake 71 mm (2.7953 in.)
Exhaust 74 mm (2.9134 in.)
1.0. 8.0 - 8.02 mm (0.3150 - 0.3157 in.)
0.0. 13.06 - 13.07 mm (0.5142 - 0.5146 in.)
Valve stat
Seat angle 45°
Valve contack width 0.9 - 1.3 mm (0.0354 - 0.0512 in.)
Sinkage 0.2 mm (0.0079 in.)
Silent shaft
Journal diameter
Right
(front) 18.300 - 18.467 mm (0.7205 - 0.7270 in.)
(rear) 42.975 - 42.991 mm (1.6920 - 1.6926 in.)
Left
(front) 18.959 - 18.980 mm (0.7464 - 0.7472 in.)
(rear) 42.975 - 42.991 mm (1.6919 - 1.6926 in.)
Oil clearance
Front 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
Rear 0.05 - 0.09 mm (0.0020 - 0.0035 in.)
Piston
0.0. 79.0 - 79.2 mm (3.1102 - 3.1181 in.)
Piston - to cylinder clearance 0.04 - 0.08 mm (0.0016 - 0.0031 in.)
Ring groove width
No. 1 ring 2.601 - 2.603 mm (0.1024 - 0.1025 in.)
No. 2 ring 2.100 - 2.102 mm (0.0827 - 0.0828 in.)
Oil ring 4.010 - 4.035 mm (0.1579 - 0.1589 in.)
I Service size 0.25, 0.50, 0.75, 1.00'oversize
GENERAL EM -5
Standard Limit
Piston ring
End gap
No. 1 ring 0.35 - 0.50 mm (0.0138 - 0.0197 in.) 0.8 mm (0.0315 in.)
No. 2 ring 0.25 - 0.40 mm (0.0098 - 0.0157 in.) 0.8 mm (0.0315 in.)
Oil ring 0.25 - 0.45 mm (0.0098 - 0.0177 in.) 0.8 mm (0.0315 in.)
Ring - to - ring froove clearance
No. 1 ring 0.056 - 0.076 mm (0.0022 - 0.0030 in.) 0.15 mm (0.0059)
No. 2 ring 0.046 - 0.066 mm (0.0018 - 0.0026 in.) 0.15 mm (0.0059)
Oil ring 0.02 - 0.065 mm (0.0008 - 0.0026 in.) 0.1 mm (0.0039)
Service size 0.25, 0.05, 0.75, 1.00
Piston pin
0.0. 28.994 - 29.0 mm (1.1415 -1.1417 in.)
Coonecting rod
Brg end center - to - small end center lenght 157.95 -158.05 mm (6.2185 - 6.2224 in.)
Bend Max. 0.05 (0.0020)
Twist Max. 0.1 (0.0039)
Big end side clearance 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Crankshaft
End play 0.05 - 0.18 mm (0.0020 - 0.0071 in.) 0.25 mm (0.0098 in.)
Journal 0.0. 66 mm (2.5984 in.)
Pin 0.0. 53 mm (2.0866 in.)
Out - of roundness and taper of journal and pin 0.05 mm (0.0020 in.)
Oil clearance of journal 0.02 - 0.05 mm (0.0008 - 0.0020 in.)
Oil clearance of pin 0.02 - 0.05 mm (0.0008 - 0.0020 in.) 0.1 mm (0.0039 in.)
Journal 0.1 mm (0.0039 in.)
0.25 U.S. 65.735 - 65.750 mm (2.5879 - 2.5886 in.)
0.50 U.S. 65.485 - 65.500 mm (2.5781 - 2.5787 in.)
0.75 U.S. 65.235 - 65.250 mm (2.5683 - 2.5689 in.)
Pin
0.25 U.S. 52.735 - 52.750 mm (2.0716 - 2.0768 in.)
0.50 U.S. 52.485 - 52.500 mm (2.0663 - 2.0669 in.)
0.75 U.S. 52.235 - 52.250 mm (2.0565 - 2.0571 in.)
Cylinder block
1.0. 91.10 - 91.13 mm (3.5866 - 3.5878 in.)
Flatness of gasket surface 0.05 mm (0.0020 in.) 0.1 mm (0.0039 in.)
Overall height 318.45 - 318.55 mm (12.537 - 12.541 in.)
Flywheel
Flatness 0.13 mm (0.0051 in.) 0.13 mm (0.0051 in.)
Oil pump
Tip clearance
Inner gear 0.22 - 0.35 mm (0.0087 - 0.0138in.) 0.5 mm (0.0197 in.)
Outer gear 0.12 - 0.22 mm (0.0047 - 0.0087 in.) 0.4 mm (0.0157 in.)
Side clearance
Inner gear, Outer gear 0.04 - 0.10 mm (0.0016 - 0.0039 in.) 0.15 mm (0.0059 in.)
Body clearance
Outer gear 0.12 - 0.22 mm (0.0047 - 0.0087 in.)
Inner gear, 0.03 - 0.09 mm (0.0012 - 0.0035 in.)
Oil press ure at engine idle speed 80 Kpa (0.8 kg/cm2 ) or more
Cooling system Water - cooled forced circulation system
Drive belt V - type
Water pump type Centrifugal impeller
Fan clutch type Thermo type with plate type bimetal
Standard Limit
Thermostat type
Type Wax type with by - pass valve
Coolant temperature gauge unit
Type Thermister type (2 elements)
Thermostat
Valve opening temperature (0C) 82
Fully opening temperature (0C) 95
Coolant temperature gauge unit
Resistance
Coolant temperature gauge element (OfC) 90.5 - 117.5/70,21.3 - 26.3 /115
Glow control element (OfC) 22.3 - 27.3 / -20,2.92 - 3.58 / 20
Air cleaner Paper filter type
Muffler Expansion resonance type
~NOTE
• O. D. : Outer Diameter
• I. D. : Inner Diameter
• V.S.: Vndersize Diameter
• O.S.: Oversize Diameter
GENERAL EM-7
TORQUE SPECIFICATIONSSS ELCB0030
Nm kg.cm Ib.ft
Crankshaft pulley bolt 170 - 190 1700 - 1900 125 - 140
Camshaft sprocket bolt 65 - 75 650 - 750 48 - 55
Timing belt tensioner bolt 22 - 30 220 - 300 16 - 22
Injection pump sprocket nut 80 - 90 800 - 900 59 - 66
Silent shaft sprocket nut 34 - 40 340 - 400 25 - 30
Timing belt tensuioner "8" nut 22 - 30 220 - 300 16 - 22
Rocker cover bolt 5 - 7 50- 70 4-5
Rocker arm shaft bolt 35 - 40 350 - 400 25 - 29
Camshaft bearing cap bolt 19 - 21 190 - 210 13 - 15
Cylinder head bolt
Cold engine 105-115 1050 - 1150 77 - 85
Hot engine 115-125 1150 - 1250 85 - 92
Oil pan bolt 6-8 60 - 80 4-6
Oil pan drain plug 35 - 45 350 - 450 26 - 33
Front case bolt (upper, lower) 12 - 15 120 - 150 9 - 11
Silent shaft driven gear bolt 34 - 40 340 - 400 25 - 30
Silent shaft plug cap 30 - 45 300 - 450 22 - 33
Silent shaft gear cover bolt 15 - 18 150 - 180 11 - 13
Connecting rod cap nut 45 - 48 450 - 480 33 - 35
Flywheel bolt 130 - 140 1300 - 1400 96 - 103
Crankshaft bearing cap bolt 75 - 85 750 - 850 55 - 63
Oil relief valve plug 30 - 45 300 - 450 22 - 33
Oil pump cover screw 9 - 14 90 - 140 7 - 10
Oil pressure switch 8 - 12 80 - 120 6 - 9
Oil filter bracket 12 - 15 120 - 150 9 - 11
Oil jet check valve 30 - 35 300 - 350 22 - 26
Ouil cooller by - pass valve 50 - 60 500 - 600 37 - 44
Cooling fan attaching bolt 10 - 12 100 - 120 7-8
Fan clutch attaching bolt 10 - 12 100 - 120 7-8
Water outlet fitting attaching bolt 10 - 13 100 - 130 7-9
Water pump attaching bolt 12 - 15 120 - 150 8 - 11
Coolant temperature gauge unit 30 - 40 300 - 400 22 - 30
Intake and exhaust manifold nuts and bolts 15 - 20 150 - 200 11 - 15
Heat protector to exhaust manifold 12 - 15 120 - 150 9 - 11
Exhaust pipe to exhaust manifold stud nuts 30 - 40 300 - 400 22 - 30
Exhaust pipe to muffler 30 - 40 300 - 400 22 - 30
EM-8 ENGINE MECHANICAl SYSTEM [2.5 TCI]
SPECIAL TOOlS ELCB0040

Silent shaft bearing puller Removal of silent shaft rear bearing
/
(09212 - 43100)
ECLAOO2L
Silent shaft bearing installer Installation of silent shaft rear bearing

(09212 - 43200)
ECLAOO2M
Bearing installer stopper Removal of Right silent shaft rear bearing

(09212 - 43300)
@)
ECLAOO2N
Crank shaft front oil seal installer Installation of crankshaft front oil seal
(09214 - 32000)
cf)
ECLAOO20
Crankshaft front oil seal guide Guide for installation of crank shaft front oil seal
cO
(09214 - 32100)
ECLAOO2P
Connecting - rod small - end Replacement of connecting - rod small

busing replacement tool - end bushing
(09214 - 43000)
ECLAOO2J
Camshaft oil seal installer Installation of the camshaft oil seal

(09221 - 21000)
G)
ECLAOO21
GENERAL EM-9

Cylinder head bolt wrench Loosening and tightening of cylinder head bolt.
(09221 - 32000)
ECLAOO2A
Valve seat cutter pilot Correction of valve seat
/
(09221 - 43200)
ECLAOO2B
Valve seat cutter 45° Correction of valve seat

(09221 - 43300)
@
ECLAOO2C
~
(09221 - 43400)
ECLAOO2D
~
(09221 - 43500)
ECLAOO2E
Valve spring compressor Compression of valve spring
t=l
(09222 - 21000)
ECLAOO2G
Valve stem seal installer Installation of valve stem seal
~
(09222 - 32100)
ECLAOO2H

Valve guide installer Removal and Installation of valve guide
~/
(09222 - 32200)
ECLAOO2F
Silent shaft drive gear oil Installation of silent shaft drive oil seal
c0
seal guide
(09222 - 43200)
ECLAOO2K
Crankshaft rear oil seal installer Installation of crankshaft rear oil seal
®
(09231 - 32000)
ECLAOO2Q
Oil pressure switch wrench
oru
Removal and Installation of oil pressure switch
(09260 - 32000)
ECLAOO2S
Injection pump sprocket puller Removal of injection pump sprocket

(09314- 43000)
ECLAOO2R
GENERAL EM -11
TROUBLESHOOTING ELCB0050

Low compression Blown cylinder head gasket Install new head gasket
Worn or broken piston rings Hone cylinder bores and
install new rings
Warped or pitted valves Install new valve
Excessive run - out of valve seats on valve faces Reconditioning valve
seats and valves
Incorrect valve clearance Adjust to specifications
Noisy valves Worn valve guides Install new valves land
/ or new valve guides
with O.S.
Excessive run - out of valve seats on valve faces Reconditioning valve
seats and valve
Excessive camshaft end play Correct end play
Connecting rod noise Insufficient oil supply Check engine oil level
Low oil pressure Check engine oil level,
Inspect oil relief valve
and spring
Thin or diluted oil Change oil to correct
viscosity
Excessive bearing clearance Measure bearings for
correct clearance
Connecting rod journals out - of - roundness Replace crankshaft or
regrind journals
Misaligned connecting rods Replace bent connecting
rods
Crankshaft bearing noise Insufficient oil supply Check engine oil level
Lower oil pressure Check engine oil level.
Inspect oil relief valve
and spring
viscos8ity
correct clearances
Excessive end play Check No. 3 main
bearing for wear on
flanges
Replace crankshaft or
regrind journals
Crankshaft journal out - of - roundness worn Tighten to correct torque
Loose flywheel Correct cylinder wear

Piston noise Execssive clearance due to cylinder wear Replace piston
Piston or piston pin worn Install new piston
Burnt piston Install new rings
Piston ring damaged
Oilleak Oil pan drain plug loose Tighten to torque
Oil pan mounting bolt loose Tighten to correct torque
Oil pan gasket broken Install new gasket
Crankshaft front oil seal defective Install new oil seal
Crankshaft rear oil seal dective Install new oil seal
Rocker cover gasket broken Install new gasket
Oil filter loose Tighten to correct torque
Oil filter gasket broken Install new gasket
Oil consumption Wo rn , scuffed, or broken rings Hone cylinder bores and
install new rings
Carbon in oil ring slot Install new rings
Rings fitted too tight in grooves Remove the rings. Check
grooves. If groove
is not proper width,
replace pistion
Worn valve guides Install new valve and
/ or new valve guides
with O.S.
Faulty valve stem seals Install new valve stem
seals
Oil pressure drop Low oil level Check engine oil level
Siow idle speed Set idle speed to
specification
Faulty oil pressure switch Install new switch
Colgged oil filter Install new oil filter
Worn parts in oil pump Replace worn parts
or pump
viscosity
correct clearance
Oil relief valve stuck Remove valve and
inspect, clean and
reinstall
Oil pump cover be nt or cracked Install new oil pump
Oil screen loose or clogged Clean or replace screen
GENERAL EM -13

Oil pressure drop Hole in oil pickup tube Replace or repair tube
Cracked, porous or plugged gallery Repair or replace
cylinder block
Gallery plugs missing or misinstalled Install plugs or repair
Overheat Insufficient coolant Replenish
Antifreeze concentration too great Correct
Loose or broken drive belt Correct or replace
Inoperative fan clutch Replace
Damaged or blocked (insufficiently venti- Correct
lated) radiator fins
Water leaks
Damaged radiator core joint Replace
Corroded or cracked hoses Replace
(Radiator hose, heater hose, etc)
Loose bolt or defective gasket in water outlet Correct or replace
fitting (thermostat)
Faulty radiator cap valve or setting of spring Replace
Loose cylinder head bolt Correct
Damaged cylinder head gasket Replace parts
Cracked cylinder block Replace
Cracked cylinder head Replace
Faulty thermostat operation Replace
Faulty water pump operation Replace
Water passage clogged with slime or rust Clean
deposit or foreign substance
No rise in temperature Faulty thermostat Repair
Loss of power Intake system
a. Clogged air cleaner a. Clean or replace
element
b. Air leaks from intake system connection b. Repair
Exhaust system
a. Deformed muffler and exhaust pipe or a. Repair or replace
deposited carbon
b. Gas leak from system b. Retighten joints
Repair or replace broken
pipe or muffler

Unusual noise and vibration Intake system
a. Loose clamping bolts and nuts of the intake system a. Tighten
Exhaust system
a. Loose clamping bolts and nuts oef the exhaust system a. Tighten
b. Damaged muffler and exhaust pipe b. Replace
c. Broken rubber hangers c. Replace
d. Interference of pipe or muffler with vehicle body d. Correct
GENERAL EM -15
CHECKING ENGINE OlL ECJA0500
1. Position a vehicle on a level surface.
~NOTE
If a vehicle that has not been used tor a prolonged
period, run the engine tor several minutes.
Turn off the engine and wait tor 5 minutes at least, and
then check the oi/level.
3. Check that the engine oillevel is within the level range

indicated on the oil dipstick. If the oil level is found to
have fallen to the lower limit (the "L" mark), refill to the
"F" mark.
~NOTE
When retilling, use the proper grade ot engine oi/.
4. Check that the oil is not dirty or mixed with coolant or

gasoline and it has the proper viscosity.
EDA9000A
SELECTION OF ENGINE OlL ELCBOO70
Recommended API classification: ABOVE CD

Recommended SAE viscosity grades:
Temperature range
anticipated betore Recommended SAE viscosity number
next oil change
oe °F
40 104 20W 15W 10W
10W
-50 -50 -50
-30
20 68 -40 -40 -40
10 50 5W
-10 14 -40'1 5W'1
-15 5 -30 5W'1
-25 -13 -20'2
*1 Restricted by driving condition and environment.

*2 Not recommended for sustained high speed vehicle operation
EDA9990B
~NOTE
For best performance and maximum protection of all
types of operation, select only those lubricants which:
1. Satisfy the requirements of the API classification.

2. Have the proper SAE grade number for expected
ambient temperature range.
Lubricants which do not have both an SAE grade

numberand an API service classification on the con-
tainer should not be used.
GENERAL EM -17
CHANGING ENGINE OlL ECMB0100

Part numbar
1. Run the engine until it reaches normal operating tem-

perature.
3. Remove the oil filler cap and the drain plug. Drain the
engine oil.
4. Tighten the drain plug to the specified torque.

ECA9970A
Tightening torque
PROCEDURE FOR REPLACING THE OlL FILTER
Oil pan drain plug :
1. Use a filter wrench to remove the oil filter.
35 - 45 Nm (350 - 450 kg.cm, 25 - 33 Ib.tt)
2. Before installing a new oil filter on the engine, apply
clean engine oil to the surface of the rubber gasket.
~NOTE
Whenever tightening the oil drain plug, use a new 3. Tighten the oil filter to the specified torque.
drain plug gasket.
Oil filter: 12-16 Nm (120-160 kg.cm, 9-12Ib.ft)
5. Fill new engine oil through the oil filler cap opening.
4. Start and run the engine and check for engine oilleak.
Capacity :
Drain and refill : 6.5 lit (6.87 U.S.qts., 5.72 Imp.qts.) 5. After turning off the engine, check the oillevel and add
oil as necessary.
~NOTE
00 not overfill. This will cause oil aeration and 1055 0'
~1rt'\·.---~
oil pressure.
6. Install the oil filler cap.
7. Start and run the engine. Apply angina oil
8. Turn off the engine and then check the oil level. Add
oil if necessary.
ECA9970B
REPLACING THE OlL FILTER ECJA0800
All Hyundai Motor Company engines are equipped with

a high quality, disposable oil filter. This filter is recom-
mended as areplacement filter for all vehicles. The quality
of attermarket replacement filters is considerably diverse.
High quality replacement filters should be used to assure

the most efficient service. Make sure that the rubber gas-
ket from the old oil filter is completely removed from the
contact surface on the engine block before installing a new
filter.
CHECKING COOLANT LEAK ECMB0110 RADIATOR CAP PRESSURE TEST ELCB0110
1. Loosen the radiator cap. 1. Use an adapter to attach the cap to the tester.
2. Confirm that the coolant level is up to the filler neck. 2. Increase the pressure until the gauge stops moving.
3. Install aradiator cap tester to the radiator filler neck Main valve opening pressure :
and apply 150 KPa (21 psi, 1.53 kg/cm2 ) pressure.
107.9kPa±14.7kPa (1.1±0.15 kg/cm 2 , 15.64±2.13)
Hold it for two minutes in that condition while checking
for leakage from the radiator, hoses or connections. Main valve closing press ure :
83.4 kPa (0.85 kg/cm2 , 12.1 psi)
~NOTE
1. Radiator coolant may be extremely hot. Do not 3. Check that the pressure level is maintained at or
open the system because hot, or scalding water above the limit.
could gush out causing personal injury. Allow the
vehicle to cool before servicing this system. 4. Replace the radiator cap if the reading does not re-
2. When the tester is removed, be careful not to spill main at or above the limit.
any coolant trom it.
3. Be sure to clean away completely any coolant ~NOTE
from the area.
Be sure that the cap is clean before testing, since rust
4. Be careful when installing and removing the
or other foreign material on the cap seal will cause an
tester and when testing, not to deform the filler
incorrect reading.
neck of the radiator.
4. If there is leakage, repair or replace with the appropri-

ate part.
ECA9090A
KDMBOO2A
GENERAL EM -19
SPECIFIC GRAVITY TEST ECMB0120
1. Measure the specific gravity of the coolant with a hy-

drometer.
2. Measure the coolant temperature and calculate the

concentration from the relation between the specific
gravity and temperature, using the following table for
reference.
KDMB002B
RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY
Coolant temperature °C (OF) and specific gravity Safe Coolant

Freezing
operating concentration
temperature
10 (50) 20 (68) 30 (86 40 (104) 50 (122) temperature (Specific
°C rF)
°C (OF) volume)
1.054 1.050 1.046 1.042 1.036 -16 (3.2) -11 (12.2) 30%
1.063 1.058 1.054 1.049 1.044 -20 (-4) -15 (5) 35%
1.071 1.067 1.062 1.057 1.052 -25 (-13) -20 (-4) 40%
1.079 1.074 1.069 1.064 1.058 -30 (-22) -25 (-13) 45%
1.087 1.082 1.076 1.070 1.064 -36 (-32.8) -31 (-23.8) 50%
1.095 1.090 1.084 1.077 1.070 -42 (-44) -37 (-35) 55%
. 1.103 1.098 1.092 1.084 1.076 -50 (-58) -45 (-49) 60%
Example • If the concentratlon Is above 60%, both the

ant/-freeze and englne coollng property will
The safe operating temperature is -15°C (5°F) when the decrease, affectlng the eng/ne adversely. For
measured specific gravity is 1.058 at coolant temperature these reasons, be sure to maintain the con-
of 20°C (68°F) centration level wlthln the speclfled range.
• Do not rn/x types of anti-freeze.
& CAUTION
• If the concentratlon of the coolant Is below
30%, Its antl-corroslon propertles will be ad-
versely affected.
RECOMMENDED COOLANT
Antifreeze Mixture ratio of anti freeze in coolant

ETHYLENE GLYCOL BASE FOR ALUMINUM 50% [Except tropical areas]
40% [Tropical areas]
CHECKING ENGINE COMPRESSION 9. If, after oil is added, the compression rises, the cause
PRESSURE ELCB0130 of the malfunction is a worn or damaged pistion ring
and / or cylinder inner surface. If however, the com-
pression does not rise, the cause is a bad valve or a
1. Be sure that the engine oil, starting motor and battery bad gasket.
are in the normal condition.
2. Start the engine and allow it to warm up until the tem- CHECKING AND ADJUSTMENT OF VALVE
perature of the coolant reaches 80°C to 90°C (176°F CLEARANCE ELCB0140
to 194°F)
1. Start the engine and allow it to warm up until the tem-
3. Loosen the nuts at the nozzle side of the infecdtion perature of the coolant reaches 80°C to 90°C (176°F
pipes, and disconnect the pipes from the nozzle hold- to 194°F)
ers.
2. Check the infection timing and the idling speed, and
adjust if necessary.
& CAUTION
Caps must be used to prevent entry of foreign ma- 3. Remove the upper timing belt cover.
terials Into the nozzles.
4. Remove the rocker cover.
4. Remove the glow plug plate and all 4 glow plugs. 5. Turn the crankshaft clockwise and align the timing
mark on the camshaft sprocket with the timing mark
5. Set an engine tachometer in place. on the top of the front upper case.
6. Place a compression gauge adaptor and compres-

Timing mark
sion gauge in the glow plug hole.
Compression gauge
(O"l'P-'~
ECLA019H
6. Check that valve clearance indicated in the diagram

ECLA005A
(A) is at the standard value.
[A]
7. Crank the engine with the throttle valve fully open,
and measure the compression at the place where the No. 1 No. 1 No. 1 No. 1
compression gauge indicator shows a stabilized read- Exh. Int. Exh. Int. Exh. Int. Exh. Int.
ing.
Standard value (at engine speed of 250 rpm) :

1920 kPa (19.2 kg/cm 2 , 278 psi)
Difference between each cylinder :
300 kPa (3.0 kg/cm 2 , 43 psi) or less ECLA0191
Standard value : Hot engine

8. If, after the measurement, the compression is below Intake : 0.25 mm (0.0098 in.)
the limit, put a small amount of engine oil through Exhaust : 0.25 mm (0.0098 in.)
the glow plug hole into the cylinder, then measure the Cold engine
compression once again and determine the cause of Intake : 0.15 mm (0.0059 in.)
the malfunction Exhaust : 0.15 mm (0.0059 in.)
GENERAL EM -21
7. 11 not within the standard value, loosen the adjust- 12. When installing the rocker cover assembly to the cylin-
ing screw locking nut and, while turning the adjust- der head, apply a coating of the specified sealant to
ing screw, use a thickness gauge to adjust the valve the semicircular packing and cylinder head top sur-
clearance to the standard value. faces, and then tighten at the specified torque
Specified sealant :
3M ART Part No. 8660 or equivalent
Tightening torque :
5 - 7 Nm (50 - 70 kg.cm, 4- 5 Ib.ft)
& CAUTION
ECLA003E
If they are overtorqued. a deformed rocker cover
or oilleakage could result.
8. Block the adjusting screw with a screwdriver, so that
it cannot move and tighten the locknut to the specified
torque.
Apply sealant
Tightening torque :
12 - 18 Nm (120 - 180 kg.cm, 9 - 13 Ib,.ft)
9. Rotate clockwise the crankshaft one complete turn Serni - circular

(360 degree).
10. Check that valve clearance indicated in the diagram

ECLAOO3F
(B) is at the standard value.
[B] ADJUSTMENT OF THE TIMING BELT

No. 1 No. 2 No. 3 No. 4 TENSION ELCB0150
Exh. Int. Exh. Int. Exh. Int. Exh. Int.
1. Remove the timing beklt upper cover and bring the

pistion in No. 1 cylinder to top dead center on corn-
pression strocke. Check that the timing marks of
sprockets are aligned.
ECLA019K
Standard value : Hot engine

Intake : 0.25 mm (0.0098 in.)
Exhaust : 0.25 mm (0.0098 in.)
Cold engine
Intake : 0.15 mm (0.0059 in.)
Exhaust : 0.15 mm (0.0059 in.) Piston in No. 1 cylinder
at top dead center
11. If not within the standard value, repeat steps 7 to 8 to ECLAOO5B
adjust the valve clearance of remaining valves.

2. Loosen the timing belt tensioner mounting bolts.
& CAUT/ON
Do not loosen the belts more than necessary.
They could drop in the lower cover.
Direction of ADJUSTMENT OF THE TIMING BELT "B" TENSION
1. Remove the timing belt upper cover and bring the pis-
tion in No. 1 cylinder to top dead center on compres-
sion stroke. Check that the timing marks of sprockets
are aligned.
ECLA005C
3. Turn the crankshaft in normal direction (clockwise)

through two camshaft sprocket teeth and hold it.
4. Tighten the tensioner mounting bolts.
~NOTE ECLAOO5B
Tighten the upper bolts first and then the lower ones.
2. Remove the access cover.
Camshaft sprocket
~~teeth
------ -$J
ECLAOO5D
ECLAOO5F
5. Reverse the crankshaft to aligh the timing marks, and

push down belt at a point halfway with forefinger to 3. Loosen the timing belt "B" tensioner mounting nut and
~~ .
check that tension of belt is up to standard value.
Standard value : 4 - 5 mm (0.16 - 0.20 in.) ~NOTE

00 not loosen the bolts (upper) more than necessary.
Tyey could drop in the lower cover.
4. Tighten the tensioner mounting nut and bolt.
~NOTE
Tighten the nut (Iower) first and then the bolt (upper).
ECLA005E
6. Mount the timing belt upper cover.
ECLAOOSG
GENERAL EM-23
5. Mount the access cover.
6. Mount the timing belt upper cover.
INSPECTION AND ADJUSTMENT OF THE

BELT FLEX ECMB0140
1. Check the belt for damage or wear. Confirm that the

belt is set correctly in pulley groove.
~NOTE
If the belt "squeals" or slips, check belt for friction,
damage or breaks and check pully contact surface for
damage.
2. Press at 100N (10 kg,22Ibs.) center of belt between

pulleys as indicated in the diagram. Measure belt flex.
Standard value
Air - conditioner compressor :
7 - 10 mm (0.28 - 0.39 in.)
Alternator : 10 - 13 mm (0.39 - 0.51 in.)
Power steering : 8 - 11 mm (0.31 - 0.43 in.)
& CAUTION
Measure the biet flex between specified pulleys
(~).
Water pump puller
Power steering Air conditioner pulley
Air conditioner
compressor belt
Alternator Crankshaft Air conditioner

pulley pu!!ey compressorpu!!ey
ECLA003A
ENGINE BLOCK
ENGINE BLOCK
COMPONENTS ELCB0200
Cylinder sleeve
40 - 50 (400 - 500, 30 - 37)
Packing
Cover
,
5 • 7 (50 - 70, 4 • 5)
Cylinder block
50 - 60 (500 - 600, 37 - 44 )
ECLAOO7A
ENGINE BLOCK EM-25
INSPECTION ELCB0210 4. Using cylinder gauge, measure the cylinder bore.

If it wears out excessively, bore the cylinder to over-
~NOTE size and replace the piston and piston rings.
Measurement points are as shown.
1. Before inspection and repair, clean parts to re-
move dirt, oil, carbon, deposits, and scale.
2. Before c/eaning the cyfinder block, be sure to
3.
check for evidences of water leaks and damage.
Romove contaminants from oil holes with com-
pressed air and, at the same time, make sure that
EB
E
they are not blocked.
CYLINDER BLOCK
1. Check for scratches, rust, and corrosion. Use also

a flaw - detecting agent for the check. If defects are
evident, correct or replace. ECLAOO7C
2. Using a straightedge and thickness gauge, check Standard value : 91.1 mm (3.5866 in.)
the cylinder block top surface for flatness. Lay the
straightedge longways and crossways as indicated BORING OF CYLINDER
by A, B, ... in illustration. If flatness is not within the
limit, replace the cylinder block. At measurement, 1. Using the maximum cylinder bore as a basis, deter-
ensure that the cylinder block top surface is free from mine the oversize piston to be used.
any traces of gasket material.
2. There are four oversize pistons available :
0.25 mm (0.010 in.), 0.50 mm (0.020 in.), 0.75 mm
(0.030 in.), and 1.00 mm (0.039 in.). bore the cylin-
der to obtain the specified clearance according to the
piston 0.0.
3. Based on the piston O. O. measured, calculate the bor-

ing dimension.
Boring dimension = Piston 0.0. + 0.04 to 0.08 mm

(0.0016 to 0.0031 in.) (piston to cylinder clearance)
- 0.02 mm (0.0008 in.) (haning margin).
ECLA007B
Standard value : 0.05 mm (0.002 in.) 4. Bore cylinders to obtain the calculated boring dimen-
Limit: 0.1 mm (0.004 in.) sion.
3. Check cylinder wall for scratches and seizure.

If defects are evident, correct (to oversize) or replace.
I
"'"
.--======--..-1 Thrust
direction
ECLAOO7D
~NOTE
1. To prevent thermal distortion due to temperature
rise during boring operation, bore eyfinders in the
sequenee of No. 2, 4, 1 and 3.
2. The eyfinders must be honed to finish dimension.
3. Check e/earanee between piston and ey/inder.
Piston to cylinder clearance :

0.04 - 0.08 mm (0.0016 - 0.0031 in.)
~NOTE
1. When boring eyfinders, finish all of four eyfinders
to the same oversize.
2. Don't bore on/y one eyfinder to oversize.
ENGINE BLOCK EM-27
ENGINE MOUNTS
ENGINE MOUNTING ECMB0150
COMPONENTS
FRONT ENGINE MOUNTING
12 - 20 (120 - 200, 9 -15)
+-----
~:-- Engine mounting
, - - - - 30 - 40 (300 - 400,22 - 30)

30 - 40 (300 - 400, 22 - 30)
TORQUE : Nm (kg.cm, Ib/.ft)
ECMB015A
TIM MOUNTING ECMB0160
Transaxle mounting insulator
30 - 42 (300 - 420,22 - 31)
P!Wl---- 30 - 42 (300 - 420, 22 - 31)
TORQUE : Nm(kg.cm, Ib.tt)
ECMB004A
INSPECTION ELCB0240
1. Check the insulator for damage, crack and deforma-

tion.
2. Check the insulator stopper plate for damage, crack

and deformation.
[Q] NOTE
Be careful not to apply oil to the insulator.
ENGINE BLOCK EM -29
FRONT CASE
COMPONENTS ELCB0250
Silent shaft (R~.9ht) Bearing

34 - 40 (340 - 400, 25 - 30)
15-18 (150-180,11-13) /-1

Driven gear I
I
I
/
20-27 (200~'5-20)
&\\ Silent shaft (Ieft)
~
Front oil seal
Oil screen I
12-15 (120-150,9-11)
Front upper case
Drain plug gasket
Oil pan
i
6 - 8 (60 - 80, 4 - 6)
ECLA007G
REMOVAL ELCB0260 OlL PUMP
SILENT SHAFT 1. Remove the oil pump cover from the front lower case.
1. Remove the oil pan.
2. Remove the oil pump outer gear. Put matching mark
2. Remove the oil screen. on the outer gear to insure correct reassembly.
3. Remove the spacer from the forward end of the left 3. Remove the silent shaft drive gear cover and then
silent shaft. remove the drive gear and driven gear.
4. Remove the front upper case. CAMSHAFT
5. Remove the left silent shaft. 1. Turn the crankshaft to bring the piston in No. 1 cylin-
der to the top dead center on the compression stroke.
6. Remove the plug cap from the top of the right silent (The piston in cylinder is at the top dead center on the
shaft drive gear. compression stroke when the dowel pin is at the top-
most.)
Cylinder block (Right)
2. Remove the timing belt upper cover. With the timing
belt as installed, remove the camshaft sprocket, and
place on the timing belt lower cover.
Plug -+---+--e 3. Remove the rocker shaft assembly.
4. Remove the camshaft bearing cap and take out the

camshaft.
ECLAOO71
INSPECTION ELCB0270
7. Slightly loosen the flange bolt at the forward end of the

right silent shaft. When loosening the bolt, remove the SILENT SHAFT
plug on the right side of the cylinder block and insert
a screwdriver to prevent rotation. 1. The oil holes must be free from clogging.
2. Check journal for seizure, damage, and contact with

the bearing. If defects are evident, replace the silent
Driver shaft, bearing, or front case assembly.
3. Check the silent shaft for oil clearance. If wear is ex-

cessive, replace the silent shaft bearing, silent shaft,
or front case assembly.
Silentshaft
(Right)
Oil clearance standard value
Front: 0.02 - 0.06 mm (0.0008 - 0.0024 in.)
ECLA007J Rear : 0.05 - 0.09 mm (0.0020 - 0.0035 in.)
8. Remove the front lower case and the silent shaft as

an assembly.
9. Remove the left silent shaft from the front lower case.
ECLAOO7K
ENGINE BLOCK EM ..31
CAMSHAFT REPLACEMENT ELCB0280
1. Check the camshaft journal surfaces and, if damage SILENT SHAFT

or seizure is evident, replace the camshaft. If the
camshaft journals are seized, check the cylinder head [QJ) NOTE
for damage. Check also the cylinder head oil holes for
Use Bearing Installer Stopper (special tool) only tor
clogging.
removal and reinstallation ot the right bearing.
ECLA019B
ECLAOO8A
2. Check cam surfaces for abnormal wear and damage.

1. Using Bearing Installer Stopper and Silent Shaft Bear-
If defects are evident, replace the camshaft, measure
ing Puller (09212 - 43300, 09212 - 43100), remove
the lobe height and, if the limit is exceeded, replace
two rear bearings from the cylinder block.
the camshaft.
o
09212 - 43100
• Bearing
t
,
Applyoil
09212 - 43300
ECLAOOSB
EDA9260A
Standard value : 2. Using Bearing Installer Stopper and Silent Shaft Bear-
ing Installer (09212 - 43300, 09212 - 43200), press-fit
Intake and exhaust : 37.05 mm (1.4587 in.) bearing into cylinder block.
Limit:
Intake and exhaust : 36.55 mm (1.4389 in.)
&
09212 - 43200 B a "ng
I
Applyoil
09212 - 43300
ECLAOOSC
INSTALLATION ELCB0290
Back of si/ent shaft gear
Mating marks
;--\ 15 -18 (150 -180,11 -13)

<0 Relief plunger Driven gear
\
~
~
~
Relief spring /
, d!fI Gasket
Plug ~
H - I - - - - Gear cover
30 - 4S (300 - 450,22 - 33) \ _
* Replace the gasket with new ones after removal.
H7EM062A
ENGINE BLOCK EM -33
Oll SEAL FRONT lOWER CASE
When mounting the oi! seal from the rear, too, fit the Oil Tighten seven flange bolts to specification.
Seal Guide to the drive gear shaft first to prevent the oil
seal lips from being caught in steps in shaft during instal- Front lower case
lation.
L=75
[YJi] NOTE
Apply oil to outer surfaces of Oi! Seal Guide. L =65 L=25
L = 65
L = Bolt thread length
ECLAOO8H
FlANGE BOlT
When tightening the bolts, be sure to secure the silent

shaft in position.
ECLA008E
SllENT SHAFT DRIVE GEAR
When mounting the drive gear from the rear because of

the drive gear oil seal press-fitted in front lower case, first
fit Oil Seal Guide (09222 - 43200) to the drive gear shaft
before insertion. Silentshaft
(Right)
[YJi] NOTE
Apply oi! to outer surfaces of Oil Seal Guide. ECLA007J
Cylinder block (Right)
. Plug -t----t---\9l
ECLA008G ECLA0071
CRANKSHAFT FRONT OlL SEAL CAMSHAFT OlL SEAL
Using Oil Seallnstaller and Guide (09214 - 32000,09214 1. Apply oil to the oil seal lips.
- 32100), install the crankshaft front oil seal.
2. Using Camshaft Oil Seal installer (09221 - 21000),
press-fit a new camshaft oil seal into the front bearing
~NOTE
cap.
The oil pump drive shaft must be installed before in-
stalling the front oil seal.
& CAUTION
Crankshaft seal Front lower case Drive in the shaft after the camshaft bearing cap
;s installed.
Apply oil to the oil seallip.
0iI pump
drive shaft 09221 - 2100::.0_ _- - - -
Apply DU to outer surfaces
ECLAOOBI
CAMSHAFT
1. To obtain the end play, measure A and B. Replace ECLA019E

parts if the limit is exceeded.
End play = B - A
Standard value : 0.1 - 0.2 mm (0.0039 - 0.0079 in.)

Limit: 0.4 mm (0.0157 in.)
ECLA019C
2. Install the camshaft to the cylinder head with the

dowel pin at the highest position.
-+--,,"""- Dowel pin
Camshaft
ECLA019D
MAIN MOVING SYSTEM EM-35
MAIN MOVING SYSTEM

CRANK SHAFT
ELCB0300
130 -140 (1300 -1400, 96 -103)
Rear oil seal Fly wheel-~~~::-..
[MIT]
Adapter plate
[ArT]
~~----- Upper bearing

~\:) Drive adapter
~~ + - - - - - Crankshaft
Crankshaft adapter
~~L-.-_ _ _ Lower bearing
~~
~ ~~ Cmnkshaft bo,,;ng cap
~~
~~ ~I+--- 75 - 85 (750 - 850, 55 - 63)
ECLAOO9A
INSPECTION ELCB0310 2. If the use of a new bearing still results in an oil clear-
ance larger than the standard value, grind the crank-
CRANKSHAFT shaft to the undersize and use a bearing of corre-
sponding undersize.
1. Measure the journal and pin dimensions in directions
3. When grinding the crankshaft to undersize, ensure
A and B at front and rear (1 and 2) positions.
correct fillet radius dimensions in journals and pins.
2. If worn excessively, grind to an undersize. If the ser-

vice limit is exceeded, replace the crankshaft.
2.5mm R
1--+-1-- (0.0098 in.)
2.5mmR
(0.0098 in.)
ECLAOO9D
CRANKSHAFT OlL CLEARANCE (PLASTIGAGE

ECLAOO9B
METHOD)
A Plastigage can be used to simplify the measurement of

Standard value oil clearance. use the following procedure to check the oil
Journal 0.0. : 66 mm (2.598 in.) clearance with a Plastigage (for journals).
Pin 0.0. : 53 mm (2.087 in.)
1. Wipe crankshaft 0.0. and bearing 1.0. clean of oil.
CRANKSHAFT OlL CLEARANCE 2. Install the crankshaft.
3. Put a strip of Plastigage lengthwise in the center of

1. Oetermine the clearance from the diference between
the journal.
the 0.0. of journal as weil as pin 0.0. and the 1.0. of
each bearing as assembled to the crankshaft. Mea-
sure the bearing 1.0. in directions A and Bat front and
rear (1 and 2) positions.
Standard value
Oil clearance of journal :
0.02 - 0.05 mm (0.0008 - 0.002 in.)
Oil clearance of pin :
0.02 - 0.05 mm (0.0008 - 0.002 in.)
ECLAOO9E
Limit: 0.1 mm (0.0039 in.)
4. Replace the main bearing cap carefully and tighten
bolts to specification.
75 - 85 Nm (750 - 850
kg.cm, 54 -62 Ib.ft)
5. Remove bolts and carefully remove the main bearing
cap.
6. Using the scale printed on the bag of plastigage, mea-

sure the amount the Plastigage has been flattened
(the widest point).
ECLA009C
MAIN MOVING SYSTEM EM -37
CRANKSHAFT BEARING
The upper main bearing is provided with an oil hole,

whereas the lower bearing has no oil hole, There is no
difference in center bearing (with flange) between upper
and lower.
ECLA009F f::g0ll hol, ~ho/'

CRANKSHAFT FRONT AND REAR OlL SEALS Upper bearing
Lower bearing (No. 1 .2.4.5)
1. Wear and damage in oil seal lips. (No. 1.2.4.5)
2. Deteriorated or hardened rubber.
3. Cracks or damage on oil seal case.

ECLAOO9H
RING GEAR (MANUAL TRANSAXEL)

BEARING CAP
1. If the ring gear teeth are worn, damaged, or broken,
replace the ring gear. If the teeth are damaged or bro- 1. Install the main bearing to the cylinder block. Ensure
ken, check the starting motor pinion. To remove the the correct cap number and arrow mark direction.
ring gear for replacement, tap its outer rim one place
after another. Heating the gear makes it impossible Main bearing cap direction
to remove. To install the ring gear onto the flywheel,
heat it up to 260-280°C (500-536°C) : it is a shrink fit o
in the flywheel. Arrow mark
Front of engine <;:J (Shows front of engine)
2. Check the ball bearing for rotating condition and un-

usual noise. Ensure also that the packed grease is C'J Cap No.
not leaking.
o
_--,.~~~~~ Flywhyeel ECLAOO9I
Ring gear
2. Check to ensure that the crankshaft turns smoothly

and there is an adequate end play.
ECLA009G
FLVWHEEL
1. Check the flywheel clutch disc surface visually.
2. If ridge wear, streak, or seizure is evident, replace. ECLAOO9J
3. If the clutch disc surface runs out exceeding the limit, Standard value :
replace.
0.05 - 0.18 mm (0.0020 - 0.0071 in.)
Limit: 0.13 mm (0.0051 in.) Limit: 0.25 mm (0.010 in.)
OlL SEAL CASE
Using special tool, press-fit a new crankshaft rear oil seal

into the oil seal case.
09231 - 32000
ECLAOO9K
OlL SEPARATOR
1. Push oil separator into the oil seal case.
2. Make sure that the oil hole in the separator comes at

the bottom (indicated by an arrow in illustration.)
ECLAOO9L
MAIN MOVING SYSTEM EM-39
PISTON
COMPONENTS ELCB0330
Piston ring No. 1 ~
Piston ring No. 2 ~

Oil ring C
~Piston
Piston Pin~ ~~
- - Piston and connecting rod assembly
snapring~~
Bushing - - -...... ~ Upper bearing
Connecting rod ----f~'"
Cylinder bolck
~ Lower bearing
~
-.
Connecting rod cap
•
e--.. 45 - 48 (450 - 480, 33 - 35)
•
B
TORQUE: Nm (kg.cm, Ib.ft)
ECLA010A
INSPECTION ELCB0340
PISTON
1. Check each piston for scuffing, scoring, wear and

other defects. Replace any piston that is defective.
2. Check that the piston pin fits in the piston pin hole.
Replace any piston and pin assembly that is defective.
The piston pin must be smoothly pressed by hand into Piston ring End gap
the pin hole (at room temperature)
ECLA010D
PISTON RING
Standard Value: End gap
1. Check each piston ring for breakage, damage and No. 1 : 0.35 - 0.50 mm (0.0138 - 0.0197 in.)
abnormal wear. No. 2 : 0.25 - 0.40 mm (0.0098 - 0.0157 in.)
Replace the defective rings. Oil ring: 0.25 - 0.45 mm (0.0098 - 0.0177 in.)
Limit: 0.8 mm (0.0315 in.)
2. When the piston requires replacement, its ring should
also be replaced.
CONNECTING ROD BEARING
3. Measure the clearance between piston ring and ring
home. 1. Check the bearing surfaces for uneven contact pat-
tern, streaks, scratches, and seizure. If defects are
evident, replace. If the surfaces are seriously nicked
and seized, check also the crankshaft. If the crank-
shaft is also damaged, replace the crankshaft or grind
to undersize for reuse.
ECLA010B
]
Standard Value : Ring - to - ring groove clearance
No. 1 : 0.056 - 0.076 mm (0.0022 - 0.0030 in.)
No. 2: 0.046 - 0.066 mm (0.0018 - 0.0026 in.)
Oil ring: 0.02 - 0.065 mm (0.0008 - 0.0026 in.)
ECLA010E
[Limit]
No. 1 : 0.15 mm (0.0059 in.)
2. Measure the connecting rod bearing I.D. and crank-
No. 1 : 0.15 mm (0.0059 in.)
shaft pin O.D. If the clearance (oil clearance) exceeds
Oil ring: 0.1 mm (0.0039 in.)
the limit, replace the bearing and, if necessary, the
crankshaft. Or, grind the crankshaft to an undersize
4. Place a piston ring in the cylinder bore and set it and, at the same time, replace the bearing with an un-
square by pushing it down with piston. dersize.
5. Measure the end clearance using a thickness gauge.
ECLA010F
MAIN MOVING SYSTEM EM -41
Standard value : 0.02 - 0.05 mm (0.0008 - 0.0020 in.) 3. Position ends of piston and oil (side rail, spacer) rings
Limit: 0.10 mm (0.0039 in.) as iIIustrated.
CONNECTING ROD, PISTION PIN AND PISTON
1. Match the piston with the connecting rod.
2. Line up the front marks and insert the piston pin. The
piston pin must be smoothly pressed by hand into po-
sition. Replace the piston pin if there is excessive play.
ECLA010M
4. Insert the piston and connecting rod assembly from

above the top of cylinder. Ensure that the front mark
on piston crown and that (ID mark) on the connecting
rod face toward the front of engine (to the crank pulley
side).
5. Clamp firm the piston rings with the ring band and in-
stall the piston assembly into cylinder. Do not strike
it hard into the piston, as broken piston ring or dam-
ECLA010J aged crank pin could result.
PISTON RING
1. Install the oil ring expander and oil ring to the piston.
_ _ _N_o_.1D 0
~~: \"0.2 0 Cl
) Oil~ cfb
L-- ECLA010N
6. Make sure the clearance of connecting rod big end

side.
ECLA010L
Standard Value : 0.10 - 0.25 mm (0.0039 - 0.0098 in.)

2. 2. Then, install No.2 piston ring and No.1 piston ring, Limit: 004 mm (0.0157 in.)
in that order. Make sure that the ring side, on which
manufacturer and size marks are stamped, faces to
the piston crown.
ECLA0100
COOLING SYSTEM
ENGINE COOLANT PUMP
COMPONENTS ELCB0400
Power steering pump
W
Power steering pump bracket
~.~ . .
<---. -~?:: .:: ...
~ ~ ~~-'~
0
Thermostat housing 0 _ ring tP .....
~ .ctJl)()!~
1~'I
12-15(120-150,9-11)
Therbmostat G k t Radiator lower hose
1 -.
I
~
'6"0
~ as e
I
.
\~
. Gasket
Water inlet fitting ~

12 -15 (120 -150, 9 -11)
12 -15 (120 -150, 9 -11)

* Replace the gasket and 0 - ring
with new ones after removal
ECLAOllF
COOLING SYSTEM EM-43
INSPECTION ELCB0410
THERMOSTAT
1. Check that valve closes tightly at room temperature.
2. Check for defects or damage.
3. Check for rust on valve. Remove if any.
4. Immerse thermostat in container of water. Stir to raise

water temperature and check that thermostat opening ECLA011B
valve temperature and the temperature with valve fully
. open [valve liftover 8.5 mm (0.33 in.)] are at the stan-
dard value. INSTALLATION ELCB0420
WATER PIPE 0 - RING
Fit water pipe O-ring in the groove provided at water pipe

end, wet the periphery of water pipe O-ring and insert wa-
ter pipe.
0- ring
Standard value :
Opening valve temperature 82° C (180° F)
Full - open temperature 95° C (203° F)
ECLA011C
=l ECLAOllE
~NOTE
Measure va/ve heifht when fully e/ose. Ca/eu/ate litt & CAUTION
by measuring the height when fully open. 1. Do not apply oll and grease to water pipe
O-ring.
BELT
2. Keep the water pipe connections free of sand,
1. Check the surface for damage, peeling or cracks. dust, etc.
3. Insert water pipe untillts end bottoms.
2. Check the surface for presence of oil or grease.
3. Check the rubber for wear or hardening.
WATER PUMP
1. Check each part for cracks, damage or wear, and re-

place the water pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and

sluggish rotation, and replace the water pump assem-
bly if necessary.
3. Check the seal unit for leaks, and replace the water
pump assembly if necessary.
4. Check for water leakage. If water leaks from hole "A"

seal unit is defective. Replace as an assembly.
WATER PUMP
Water pump installation bolt size are different and caution

must be paid to ensure that they are properly installed.
Hardness
d x I Torque Nm
No category
mm (in.) (kg.cm, Ib.tt)
(Head mark)
8 x 25 (0.31
1 4T
x 0.98) 12 - 15 (120 -
8 x 40 (0.31 150, 9 - 11)
2 4T
x 1.57)
8 x 70 (0.31 20 - 27 (200 -
3 7T
x 2.76) 270,15 - 20)
Indication for
hardness category
ECLA011D
COOLING SYSTEM EM -45
RADIATOR
ELCB0430
Radiator cap
Radiator upper hose
Radiator lower hose
Shroud
Reserve tank
ECLA012A
REMOVAL ELCB0440 6. Tilt radiator and take out obliquely upward.
RADIATOR
1. Loosen the radiator drain plug to drain the coolant.
2. Disconnect the radiator hoses trom the tollowing

parts.
Upper hose ... trom the radiator
Lower hose ... trom the engine.
3. Disconnect the overflow tube tram the radiator.
H7EMOO3A
[QJ] NOTE
When the radiator is removed, make sure that the ra-
diator core is not bent or crushed by other parts.
7. Remove the radiator shroud.

CORRECTION OF RADIATOR FIN
H7EM913A
A be nt or crushed portion shoude be corrected as shown.
4. Remove the radiator shroud bolts trom the radiator.
~NOTE
Shroud should be hung on the cooling fan, because it
cannot be removed unless the radiator is taken out.
H7EMOO3B
H7EM913B
5. Remove the radiator mounting bolts.
H7EM914A
eOOLING SYSTEM EM -47
RADIATOR PAN MOTOR
eOMPONENTS ELCB0450
3 - 7 (30 - 70, 2 - 5)
10 -12 (100 -120, 7 - 9)
Shroud
Cooling fan
TORQUE : Nm (kg.cm,lb.ft)
ECLA012B
INSPECTION ELCB0460
COOLING FAN
1. Check the blades for damage and cracks.
2. Check for cracks and damage araund bolt holes in

fan hub.
3. If any portion of fan is damaged or cracked, replace

cooling fan.
FAN CLUTCH
1. Check to ensure that fluid in fan clutch is not leaking

at case joint and seals. If fluid quantity decreases
due to leakage, fan speed will decrease and engine
overheating might result.
2. When fan attached to engine is turned by hand, it

should give a sense of some resistance. If fan turns
lightly, it is defective.
3. In case of thermostatic contral type, check for a bro-

ken bimetal.
Bimetal --11'''
ECLA012C
BELT
A belt which has following defects should be replaced.
1. Damaged, peeled or cracked surface.
2. Oil or greasy surface.
3. A belt worn to such an extent that it is in contact with

bottom of V groove in pulley.
4. Worn or hardened rubber.

COOLING SYSTEM EM-49
WATER TEMPERATURE GAUGE UNIT,

THERMO SWITCH ELCB0470
TORQUE: Nm (kg.cm,lb.ft)
ECLA012D
INSPECTION ELCB0480
WATER TEMPERATURE GAUGE UNIT
1. Put the sensor in water and increase the water tem-

perature to measure the nesistance.
ECLA012E
2. If the measurement radically deviates from specifica-

tion, replace.
3. Measure the resistance across terminal (A) and body

for water temperature gauge element and across ter-
minal (6) and body for glow control element.
0.4 n / 70° C
Terminal (A)
23.8 n / 115° C
24.8 n / - 20° C
Terminal (6)
3.25 n / 20° C
Terminal(A)
Terminal(B)
ECLA012F
LUBRICATION SYSTEM EM -51
LUBRICATION SYSTEM
OlL FILTER
ELCB0500
Oil filter
30 - 45 (300 - 450, 22 - 33)
~
12-15 (120-150,9 -11) r ~JOlm
Oil filter bracket
50 - 60 (500 - 600, 37 - 44)

Oil cooler by - pass valve
8-12(80-120,6-9)
Oil pressure switch
Gasket -<3 0;< jet
Check valve ft
Y- 30 - 50 (300 - 350, 22 - 26)

ECLAOl3A
REMOVAL ELCB0510 2. Insert a thin rod in the oil hole of the switch and push
it in lightly. The switch is normal it no continuity is
OlL PRESSURE SWITCH detected (infinite resistance on the tester). If there is
continuity, replace the switch.
To remove the oil pressure switch, use Oil Pressure Switch
Wrench (09260 - 32000).
~NOTE
During removal, use care to prevent damage to the
sealant applied to threads.
ECLA013D
3. Apply a 0.5 kg/cm 2 pressure to the oil hole.

The switch is normal if there is no continuity.
Also check for air leaks. If any air leaks are detected,
the cause may be a broken diaphragm. Replace the
switch if it leaks.
ECLA013B
OlL JET, CHECK VALVE

INSPECTION ELCB0520
1. Check the oil jet and check valve tor clogging.
OlL FILTER BRACKET 2. Check the oil jet tor damage and deformation.
1. The oil filter mounting surface must be tree from dam-
age. Engine oil
2. Check for cracks and oil leaks.
3. Make sure that the relief plunger slides smoothly and

the relief spring is not damaged.
OlL PRESSURE SWITCH Oiljet
1. Connect a tester (ohm range) between the terminal Check valve assembly
and the body of the switch to check for continuity. The
ECLA013E
switch is normal if there is continuity. If there is no
continuity, replace the switch. OlL COOLER BYPASS VALVE
1. Make sure that the valve moves smoothly.
2. Ensure that the dimension L measures the standard

value under normal temperature and humidity.
Dimension L : 34.5 mm (1.36 in.)
ECLA013C
LUBRICATION SYSTEM EM-53
3. The dimension must be the standard value when OlL FILTER

measured after the valve has been dipped in 100° C
(212° F) oil. Wipe clean the mounting surface on the filter bracket.
Then, apply a thin coat of engine oil to filter O-ring and
Dimension L : 40 mm (1.57 in.) or more tighten oil filter hand-tight.
L
& CAUTION
Never use a wrench to tighten the oil filter.
Valve -~
Apply engine oil
ECLA013F
ECA99708
OlL JET
There are two types of oil jets installed: one for No. 1 and
3, and the other for No. 2 and 4. Make sure that the correct
one is installed with correct direction as shown.
Cylinder
~a Knock pin
Oiljet
ECLA013G
OlL PRESSURE SWITCH
Before installation, apply sealant to the switch threads.
@lNOTE
The sealant must not get into the thread top surface.
Use care not to torque excessively.
OlL PUMP
COMPONENTS ELCB0540
'0.-. . -
,/"\.
...
Relief plunger
~ Relief spring
'\. -, Gasket
'\. ~ Plug
.~Qt? 30 - 45 (300 - 450, 22 - 33)
.. Oil pump inner gear
- Oil pump cover
Oil pump outer gear
Oil pump case
ECLA014A
LUBRICATION SYSTEM EM -55
DISASSEMBLY ELCB0550 INSTALLATION ELCB0570
OlL PUMP OlL PUMP
Before removing the oil pump outer and inner gears, mark Install the outer gear, ensuring it is in position with correct
the outer gear to make sure that it goes back to the position direction according to the alignment mark made during dis-
with correct direction. assembly.
~NOTE
Innergear ~ :J."~
o ~ Marking
When instalfing the gears, be sure to apply engine oil
to the entire surfaces of the gears.
" [/
o 00,#
6ut9'r gear
y
/ ~~~
" Marking
ECLA014B o~ar
INSPECTION ELCB0560
y
/
OlL PUMP ECLA014B
1. Install the outer and inner gear into the front case and
make sure that they turn smoothly with no excessive
play between them.
2. Check the side clearance (the front case and oil pump
cover surface)
EDA9340B
Standard: 0.04 - 0.10 mm (0.0016 - 0.0039 in.)

Limit: 0.15 mm (0.0059 in.)
3. Check the body clearance.
[Standard]
Drive gear : 0.03 - 0.09 mm (0.0012 - 0.0035 in.)
Driven gear: 0.12 - 0.22 mm (0.0047 - 0.0087 in.)
[Limit]
Drive gear : 0.5 mm (0.0197 in.)
Driven gear: 0.4 mm (0.0157 in.)
INTAKE AND EXHAUST

SYSTEM
EXHAUST MANIFOLD
COMPONENTS ELCB0600
Intake manifole
18(180,13)
EGR
9 - - - - - 1 9 (190,14)
I i = - - - - Waste gate actuator
9 (90,7)
Front exhaust pipe
Exhaust manifold 30 - 40 (300 - 400, 22 - 30)

18 (180,13) and turbo charger
·,®1
Gasket--l7
Heat protector
*Replace the gasket with new ones after removal.

ECLA015A
INTAKE AND EXHAUST SYSTEM EM -57
COMPONENTS ELC80610
[TCI]
Turbo charger assembly
- M - - Exhaust fitting
-f-h''''rt-- Exhaust manifold
60 (600,44) Gasket
TORQUE: Nm (kg.cm,lb.ft)
ECLA0158
EM -58 ENGINE MECHANICAL SYSTEM [2.5 TCll
INSPECTION ELCB0620
Check the following and replace if faulty.
INTAKE AND EXHAUST MANIFOLDS
1. Check the parts for cracks and damage.
2. Check the vacuum port, water passages and gas pas-

sages for clogging.
3. Using a straightedge and a thickness gauge, check

distortion of the cylinder head mounting surface.
Standard value: 0.15 mm max.

Limit : 0.3 mm
EXHAUST MANIFOLD GASKET
The gasket may be reused if they are free from peeled or

damaged surface.
INTAKE AND EXHAUST SYSTEM EM-59
MUFFLER
COMPONENTS ECMB0250
Front exhaust pipe Center exhaust pipe
30 - 40 ( 300 - 400, 22 - 30)

30 - 40 ( 300 - 400, 22 - 30)
Rear muffler - - - t -
Gasket
30 - 40 ( 300 - 400, 22 - 30)
Gasket
Main muffler
Gasket
ECMBOO1A
INSPECTION ELCB0640
1. Check the mufflers and pipes tor corrosion and dam-

age.
2. Check the rubber hangers for deterioration and

cracks.
TURBO CHARGER (TC)
COMPONENTS ELCB0650
INTAKE AIR OUTLET PISTON RING
EXHAUST
INTAKE '------../ . - . GAS OUTLET
AIR INLET
PISTON RING
t
EXHAUST GAS INLET
ECLBOO2A
COMPONENTS ELCB0660
0- ring
Snap ring
Turbine housing
Compressor cover
Cartridge assembly
Coupling

ECLA016A
DISASSEMBLY ELCB0670 4. Remove by tapping the compressor cover of cartridge

assembly with plastic hammer.
1. Before removal, make the matching mark on com-
pressor cover bearing housing and turbine housing.
& CAUTION
Be sure not to damage the compressor and tur-
bine wheel blade.
ECLA0160
~~~ Matching
~:::::::::$~;:;~ mark CLEANING
1. Use a heavy duty carbon solvent to loosen the carbon

from the parts.
ECLA016B & CAUTION

2. Loosen the assembly and tap the housing by plastic Do not use caustic solutlons, wlre brushes, or
hammer when removing the housing. wire wheels to remove carbon deposlts from any
turbo charger part.
2. A smalI, closed, agitated cleaning tank and solvent

will give the best results.
Coupling Assembly
Turbine housing
H7ET008B
3. Remove the snap ring using snap ring filler.
H7ETOO9A
3. After the carbon is loosened, use a hard, bristle type

brush and remove all dirt particles.
ECLA016C
H7ETOO9B
4. Clean all drilled pass ag es with air under pressure and 5. Check if there are foreign materials disturbing the oil
put oil on cleaned parts to prevent corrosion. flow in the oil passage of cartridge assembly.
WASTE GATE INSPECTION
1. Check the waste gate rod operation under the pres-

sure below.
Nominal Value : 77.5 kPa (0.79 kgf / cm 2 )
H7ET009C
INSPECTION ELCB0680
1. Check the inner housing contacting turbine wheel for

crack, pitching and other damages caused by over-
heat.
ECLA016J
2. Make sure that the waste gate valve lever operates
freely by hands.
REASSEMBLY ELCB0690
3. Make sure there are no damages on the inner housing
surface contacting compressor wheel.
1. Apply engine oil to new O-ring and insert the O-ring
to the groove of cartridge assembly.
Contacting surface
ECLA016E
4. Turbine wheel and shaft assemblies with cracks in the ECLA016G
blades or broken bl ades can not be used again. If

the bl ades are slightly bent, it can be used again but 2. Assemble cartridge assembly and compressor cover
severely bent blades can not be reused. matching the mark.
Oil passage Turbine wheel
ECLA016F ECLA016H
3. Install the snap ring as shown in the figure.
Snap Ring
ECLA0161
4. Before reassembly, make sure that the turbine hous-

ing matching mark is matched with compressor cover
and cartridge assembly.
H7ET010D
INTERCOOLER
COMPONENTS ELCB0700
Air hose
~~~~~~~iL~~---- Intercooler
Intercooler covler---~~
Fan motor assembly
ECMB700A
REMOVAL ELCB0710
1. Remove the intercooler cover.
2. Disconnect the fan motor and air temperature switch

connector.
3. Remove the air hoses.
4. Remove the intercooler assembly.
5. Remove the fan motor assembly.
6. Remove the intercooler bracket.
INSPECTION ELCB0720
AIR TEMPERATURE SWITCH
1. Place the sensing part of sensor into the water.
2. Check the continnity according as the temperature in-

crease.
ECLA017B
Temperature Normal Condition

50°C or less No - Continuity
60°C or more Continuity
INTERCOOLER FAN MOTER
Check the working of fan when the vehicle speed is 60

km/h or less and intake air temperature is 50°C or more.
(Revolution: 3500 rpm)
AIR CLEANER (ACL)
COMPONENTS ECMB0400
Air cleaner cover Clamp Air intakek hose
~------- Air cleaner filter
+--~- Air cleaner body
ECMB005A
INSPECTION ECMB0410
1. Check the air cleaner body, cover, or filter for distor-

tion, corrosion or damage.
2. Check the air duct for damage.
ECKA060B
3. Check the air cleaner filter for restriction, contami-

nation or damage. If the filter is slightly restricted,
remove the dust and other contaminants by blowing
compressed air from the upper side through the filter.
EDDA080B
4. Check the air cleaner housing for restrictions, contam-

ination or damage.
CYLINDER HEAD
ASSEMBLY
CVLINDER HEAD
COMPONENTS ELCB0800
Retainer lock----_&
weolg---- Retainer
Spring-----~e3
~
Cylinder head bolt
G Valve spring seat Cold engine: 105 -115 (1050 -1150, n - 85)
Valve stern seal-----1ellll Hot engine: 115 -125 (1150 -1250, 85 - 92)
8
Exhaust valve guide --n n- Intake valve guide

I
!
I
/ .I
~~~':tiI~~~1:__- Cylinder head
;..\----- Gasket
Exhaust valve seat ring
TORQUE : Nm (kg.cm, Ib.ft) * Replace the gasket with new ones after removal
ECLAOl8A
CYLINDER HEAD ASSEMBLY EM-71
DISASSEMBLY ELCB0810
CYLINDER HEAD
o o 0 o
1. Remove the injection pipe assembly. When loosening o 6 o 14 0 16 o 8 o
1 10 18 12 4
the injection pipe nut, hold the nozzle holder and the
delivery valve holder with a spanner to prevent them
from turning with the nut.
~NOTE
After the injection pipe is removed, put a cap on the ECLA018C
nozzle holder and the delivery valve holder to prevent

ingress of dust and foreign matter. 9. Remove the cylinder head.
2. Remove the timing belt upper cover. 10. Remove the cylinder head gasket. Clean the cylinder
head and cylinder block gasket surfaces.
3. Loosen the camshaft sprocket bolt to such an extent
that it can be further loosened with fingers. VALVE AND VALVE SPRING
4. Bring the piston in No.1 cylinder to the top dead center 1. Remove the cylinder head assembly.
on the compression stroke. Align the timing mark on
2. Remove the parts as iIIustrated below and store them
the camshaft sprocket with that made on the upper
separately for each cylinder.
case.
Using· Valve Spring Compressor (09222-21000), re-
5. Manually remove the camshaft sprocket bolt. move the valve spring retainer lock.
Keep the disassembled parts arranged according to
6. With the timing belt engaged, remove the sprocket the cylinder number and intake and exhaust.
. from the camshaft and place the assembly on the tim-
ing belt lower cover.
& CAUTION
Do not turn the crankshaft once the sprocket is
removed. Keep the timing belt tense.
7. Remove the rocker cover, rocker arm shaft assembly

and camshaft.
8. Using the special tool, Cylinder Head bolt Wrench

ECLA018D
(09221-32000), loosen 18 Cylinder head bolts and re-
move them. Loosen the bolts in the sequence shown
and in two to three steps.
ECLA018B
INSPECTION ELCB0820
INTAKE VALVE, EXHAUST VALVE
1. If the valve stem develops wear (taper wear) or dam-

aged, replace. If there is a dent in the stem end Free heighty
face (the surface in contact with the rocker arm ad-
just screw), replace.
JA
BOY041D
Standard value : 2° or less

Limit: 4°
VALVE GUIDE
45·t;-......... Margin Measure the valve guide to stem clearance and, if the
ECA9281B
measurement exceeds the limit, replace the valve guide
or valve, or both ..
2. Check the valve face for contact. If the contact is
not proper, correct with a valve refacer. The contact Standard value
pattern with the valve seat must be even at the center Intake: 0.03-0.06 mm (0.0012-0.0024 in.)
of valve face. Exhaust : 0.05-0.09 mm (0.0012-0.0024 in.)
Limit .
3. Replace if the margin (valve head thickness) exceeds Intake : 0.10 mm (0.0394 in.)
the limit. Exhaust: 0.15 mm (0.0394 in.)
Standard value
Intake and exhaust : 2.0 mm (0.0394 in.)
Limit
Intake and exhaust: 1.0 mm (0.0394 in.)
StemO.D.
Guide 1.0.
Contact area
(It must be at the
BOY105D
center of the face
CYLINDER HEAD
1. Before cleaning the cylinder head, check for water and

oil leaks, damage, or cracks.
EDA9300D
2. Remove oil, scale, sealant, and carbon deposits

VALVE SPRING
completely. After cleaning the oil passages, apply
compressed air to ensure that the passages are not
1. Measure the free height of spring and replace if the
clogged.
limit is exceeded.
3. If there is gas leak from the cylinder head gasket sur-
Standard value : 49.1 mm (91.933 in.)
face, measure the surface flatness. If distortion ex-
Limit: 48.1 mm (1.894 in.)
ceeds the limit, replace the cylinder head.
Standard value : 0.05 mm (0.002 in.)

2. Measure the squareness of the spring and, if the limit
is exceeded, replace. Limit: 0.2 mm (0.008 in.)
CYLINDER HEAD ASSEMBLY EM-73
4. Visually check the camshaft bearing internal surfaces VALVE SEAT REPLACEMENT PROCEDURE
for damage or seizure. If defects are evident, replace
the bearing. 1. Cut the valve seat to be replaced from the inside to
thin the wall thickness. Then, replace the valve seat.
RECONDITIONING VALVE SEAT
0.5 -1 mm (0.0197 - 0.0394 In.)
Check the valve seat for overheating and improper con-
tact with the valve face. Recondition or replace the seat if
necessary. Bofore reconditioning the seat, check the valve
guide for wear. If the valve guide is worn, replace if and
then recondition the seat. Recondition the valve seat with Cut away --+--+-
0.5 -1 mm
a valve seat grinder or cutter. The valve seat contact widty --I~""" (0.0197 -
should be within specificatons and centered on the valve 0.0394 In.)
face. After reconditioning, the valve and valve seat should
be lapped lightly with a lapping compound.
BOYR3940
2. Rebore the valve seat hole in cylinder head to the

oversize valve seat diameter.
Intake valve seat ring hole diameter

0.300.5. : 43.300 - 43.325 mm (1.7047 - 1.7057 in.)
0.60 0.5. : 43.600 - 43.625 mm (1.7165 - 1.7175 in.)
Exhaust valve seat" ring hole diameter
0.300.5. : 37.300 - 37.325 mm (1.4685 - 1.4695 in.)
0.600.5.: 37.600 - 37.625 mm (1.4803 -1.4813 in.)
3. Before fitting the valve seat, either heat the cylinder

head up to approximately 250°C (482°F) or cool the
valve seat in liquid nitrogen to prevent the cylinder
head bore from abrasion.
4. After installation, recondition the valve seat.
Intake
45"
ECHA920B
Height of
valve seat
Angle No.
45° 09221-43300
65° 09221-43400 Over size I.D.
30° 09221-43500
BOYR167A
VALVE GUIDE REPLACEMENT PROCEDURE INSTALLATION ELCB0830
1. Using the push rod of Valve Guide installer (09222 - VALVE STEM SEAL
32200) and apress, remove the valve guide forward
cylinder block. 1. Using Valve Stem Seal Installer (09222 - 32100), in-
stall the valve stem seal into the valve guide.
~NOTE
Push rod
1. The valve stem seal must be not reused.
09222 - 32200 2. The special tool must be used for the installa-
Valve guide tion of the valve stem seal. Improper installa-
Cylinder head tion could result in oil consumption through valve
guide.
ECLA018F
2. Rebore valve guide hole to the new oversize valve

guide outside diameter. 09222 - 32100
3. Using Valve Guide Installer (09222 - 32200), press-fit

the valve guide, working from. the the cylinder head
top surface.
09222 - 32200
Valve guide ~
ECLA018G ECLA0181
~NOTE VALVE SPRING
When valve guides have been replaced, check for Direct the valve spring end with identification color to the
valve contact and correct valve seats as necessary. rocker arm.
4. After installing valve guides, insert new valves in them

to check for sliding condition. ~~~~~-Spring
Identification retainer
color
Valve guide hole diameter
0.050.S.: 13.050-13.068 mm (0.0012-0.0024 in.)
0.25 O.S.: 13.250-13.268 mm (0.5216-0.5223 in.) 'II-=--Stem seal
0.500.S.: 13.500-13.518 mm (0.5315-0.5322 in.)
Spring
_f:=::::=~_.1.&===-- seat
BOY0448
CYUNDERHEADASSEMB~ EM-75
VALVE SPRING RETAINER LOCK
Using a valve spring compressor (09222 - 21000), com-

press the spring and fit the retainer lock in position.
~NOTE
The valve spring, if compressed excessively, causes
the bottom end of retainer to be in contact with, and
damages, the stem seal.
ECLA018D
CYLINDER HEAD
1. Scrape off gasket adhered to cylinder head assembly.
& CAUTION
Be careful that foreign material does not fall into
coolant and oil passage ways.
2. Tighten in the numericalorder indicated in the dia-

gram in two or three groups with special too!.
. . Forward of engine
000 0
o 13 0 5" 0 3 70 "11 0
17 9 1 f5
ECLA018J
Specified torque
Cold engine :
105 - 115 Nm (1050 - 1150 kg.cm, 77 - 85 Ib.ft)
Hot engine :
115 - 125 Nm (1150 - 1250 kg.cm, 85 - 92 Ib.ft)
ROCKER ARM
COMPONENTS ELCB0840
Breather hose 5 - 7 (50 - 70, 4 - 5)
~--+-I---~
Oi! filler ca[)-----I't!l!!lilli
Rockercover----+_
a 3 5 - 40 (350 - 400, 25 - 29)

Rocker cover aaSil<et-----,~
7 ' - - - - - - - Rocker shaft
~;~"\------ Rocker arm (Intake)

Rocker shaft spring ----------:"....~..;
Rocker arm(Exhaust) ----F:...:
~~
Camshaft bearing cap
19-21(190-210,13-15>-1 ~-tl
~~
. . o t " ' 4 i T - - - - - - Camshaft
o - - - - - Packing
Camshaft oil seal
~/A_
*Replace the gasket with new ones after removal.
ECLA019A
CYLINDER HEAD ASSEMBLY EM -77
INSPECTION ELCBoa45 ROCKER SHAFT
ROCKER SHAFT 1. Keep the oil hole side down.
1. Check oil holes for clogging and clean as necessary. 2. Install the rocker shaft with its side having one oil hole
facing to the front.
2. Replace the shaft if damage or seizure is evident on
the surfaces, to which rocker arms are installed.
. . . Engine front
. . Engine front
~~
10il hole 2 Oil holes
10i1 hole 2 Oil holes
ECLA019F
ECLA019F ROCKER ARM (EXHAUST AND INTAKE)
ROCKER ARM Install in correct position, confirming the identification

marks.
1. Check the slipper surface (the surface in contact with
the cams). Replace if damage or seizure is evident. SEMI - CRICULAR PACKING
2. Check bore for damage and seizure. Replace if de- Apply sealant to the portion indicated in illustration.
fects are evident.
Specified sealant : 3M part No 8660 or equivalent
3. Check the oil clearance
Standard: 0.01 - 0.04 mm (0.0004 -0.0016 in.)

Limit: 0.08 mm (0.0031 in.)
Apply sealant
CHECKING AND ADJUSTMENT OF VALVE
CLEARANCE
Refer to general part.
ECLA019G
ROCKER ARM AND ROCKER SHAFT
Turn the crackshaft to bring the pistion in No 1. cylinder

to the top dead center on the compression strake. This
reduces the cam lift to minimum and facilitates installation.
TIMING SYSTEM
TIMING BELT
COMPONENTS ELCB0900
Timing belt upper cover Camshaft sprocket 2.2 -3.0 kgm
65 - 75 (650 - 750, 48 - 55)
tII--~~&8~-80 - 90 (800 - 900, 59 - 66)
Timing belt
Crankshaft sprocket

ECLA020A
TIMING SYSTEM EM-79
REMOVAL ELCB0910 6. Remove the timing belt.
TIMING BELT
1. Remove the cooling fan, water pump, crankshaft pul-

ley and timing belt cover.
....
Slide toward water pump
2. Turn the crankshaft to bring the piston in No. 1 cylin-

der to the top dead center on the compression stroke.
3. Mark an arrow on the back of the timing belt and timing

belt B with achalk to indicate the direction of rotation.
This ensures that the belt is installed in the same di-
rection for reuse. ECLA020C
CAMSHAFT SPROCKET
1. Loosen the bolt securing the camshaft sprocket and

remove the camshaft sprocket.
2. Remove the sprocket nut.
~NOTE
Use care not to give shock to the tuel injection pump
shaft, as it could result in detective tuel injection pump.
ECLA020B Using Injection Pump Sprocket Puller (09314 - 43000)
or suitable tool, remove the sprocket trom injection
4. The piston in No. 1 cylinder is at the top dead center pump.
on the compression stroke when all timing marks at
the three places are aligned as shown. 3. Remove the tensioner and tensioner spring.
ECLA005B ECLA020D
5. Slightly loosen the two bolts securing the tension er.

Then, slide the tensioner toward the water pump and
tighten the bolts temporarily to secure the tensioner
in place.
INSPECTION ELCB0920
OlL
TIMING BELT
1. Check the belt for oil or dust deposits. Replace if

necessary. Small deposits should be wipe away with
a dry cloth or paper. 00 not clean with solvent. •
2. When the engine is overhauled or belt tension ad-
justed, check the belt in detail. If the following flaws
are evident, replace the belt with a one. ECA9200A
Description Flaw conditions

1. Hardened back surface of rubber Back surface is glossy, Non-elastic and so hard that, when
your fingernail is pressed into it, no mark is produced.
ECA9200B
2. Cracked back surface of rubber
ECA9200Y
3. Cracked or separating canvas
ECA92001
_,\~craCk
separati~
ECA9200J
~~
sepa~
ECA9200K
4. Badly worn out teeth (initial stage) Canvas on load side tooth flank worn (Fluffy canvas
fibers, rubber gone and color changed to white,
and unclear canvas texture)
TIMING SYSTEM EM -81
Description Flaw conditions
.~
Flank worn. . °0
(On load "de) , •.•• \
ECA9200c
5. Badly worn out teeth (last stage) Canvas on load side tooth flank worn down and rubber
exposed (tooth width reduced)
ECA9200D
6. Cracked tooth bottom
ECA9200E
7. Missing tooth Tooth missing and
~ ECA9200F
8. Side of belt bady worn
~.
Abnormal wear (Fluffy canvas fiber)
ECA9200G
9. Side of belt cracked

[QJ} NOtE
Normal belt should have precisely cut side as if produced
by a sharp knife.
ECA9200H
CRANKSHAFT SPROCKET
1. Mount the crankshaft sprocket to the crankshaft not-

ing the direction of the sprocket as weil as the flange.
2. Mount the camshaft sprocket and tighten the flange

bolts to specified torque. Piston in No. 1 cylinder
at top dead center
~c,ank'h.ft ECLAOO5B
3. Check if all timing marks are aligned correctly.

FrontW.
.-..- Oll pump gear
.....,....... drive shaft 4. Back off tensioner bolt A, that have previously been
secured to the water pump side, one to two turns to
give tension to the belt using tensioner spring tension.
Sprocket
Flange
ECLA020E
TIMING BELT TENSIONER
Install the tensioner, tensioner spring and tensioner spacer

and with the tensioner moved all the way to the water
pump, temporarily tighten bolt A. Tighten bolt B not fully
...
but finger - tight.
Slide toward water pump ECLA020F
5. Confirm that the timing belt is correctly engaged with

three sprockets.
6. Turn crankshaft clockwise by the two teeth of the

camshaft sprocket and keep the position.
& CAUTION
Never turn the crankshaft counterclockwise.
ECLA020C
TIMING BELT
1. Correctly line up timing marks on three spröckets.
2. While ensuring that the tension side of timing belt is

not slack, install belt onto the crankshaft sprocket,
injection pump sprocket, tensioner and camshaft
sprocket, in that order.
~NOTE ECLA020G
When installing the belt onto the injection pump
sprocket, keep the sprocket in position, as it tends to
turn by itself at the timing mark alignment position.
If the belt is to be reused, make sure that the arrow
mark made during disassembly taces to the correct
direction at reassembly.
TIMING SYSTEM EM-83
7. Tighten the bolt A.
8. Tighten the bolt B.

If the bolt B is tightened first, the tension er should
be turned together, causing an undue tension to be
applied to the timing belt.
ECLA020F
9. Turn the crankshaft in the direction of backward rota-

tion to line up timing marks. In this condition, ensure
that the deflection when the center of belt is pushed
by the index finger.
Standard: 4 - 5 mm (0.1575 - 0.1969 in.)
ECLA020H
FLANGE
Note that bolt holes in the flange and those in the injection
pump sprocket are offset positioned at one place. When
assembling, position the jlange and sprocket as shown.
Flange
ECLA0201
TIMING BELT ELCB0940
COMPONENT
Silent shaft sprocket - Right Spacier
Tensioner spacier
34 - 40 (340 . 400, 25 - 30)
SHentshaft s.,ocket -~ ~ ~
Tensioner spring
Timing belt tensioner B
22 - 30 (220 - 300,16 - 22)
Timing biet B
34 - 40 (340 - 400, 25 - 30) Crankshaft spricket B
Flange
ECLA021A
TIMING SYSTEM EM -85
REMOVAL ELCB0950
& CAUTION
TIMING BELT "B" Keep the removed parts free from oil and grease.
Do not use detergent to clean the timing belt "B",
1. Remove the timing belt. sprocket and tensioner. Wipe clean with rag if
found dirty.
2. Using chalk or the like, put an arrow on the back of
Replace if excessively contaminated with dirt,
the timing belt "B" to indicate the direction of drive.
grease or oil.
Wrench extension
bar or similar size rod
Screw driver
[shaft dia.
8 mm (0.31 in.)
Silent shaft,
right
ECLA021B
Rightside
~~~=-~~~~=n
3. Slightly loosen the bolts and nuts securing the ten-
sioner.
Then, slide the tensioner toward the water pump and
tighten the nuts to secure the tension er in place tem-
porarily.
4. Remove the timing belt " B"

Remove this plug and insert a screwdriver
5. Remove the crankshaft sprocket "B"
Remove cover and insert bar
6. Remove the two silent shaft sprockets.
7. When loosening the nut and bolt for two silent shaft
sprockets, be sure to lock the silent shaft as shown.
~NOTE
1. Water, oil, or grease on the bett shortens its life
drastically. Use special care to ensure that the
removed timing belt, sprockets, and tension er are
tree trom oil and grease. ECLA021C
2. Note also that these parts should not be cleaned.

Replace them it seriously contaminated.
3. If there is oil on parks, check tor oilleaks trom oil
seals in trom case and camshaft.
CRANKSHAFT SPROCKET "B"
1. Mount the crankshaft sprocket "B" to the crankshaft,

noting the direction of the sprocket "B".
~cm"""'ft
Front~
..-..- Oll pump gear
.......- .~ve shaft
Sp-"~~"B' Flange
Spacer
GaSket~
ECLA020E
. I Front lower case
Spring .
2. The spacer must be installed with its chamfered end Tensloner
facing toward the silent shaft. If the spacer is installed
in the wrong direction, damage to oil seal will result. ECLA021E
TIMING BELT "B"
~
~::_.
1. Une up timing marks on the crankshaft sprocket B,
and right and left silent shaft sprockets.
..
2. With the timing belt B installed, ensure that its tension
......... _-- ...... side is not slack.
Tapper
@)NOTE
If the belt is to be reused, make sure that the arrow
mark made during disassembly faces to the correct
ECLA021D
direction at reinstallation.
TIMING BELT "B" TENSIONER
Timing mark----;~
Install the tensioner spring and spacer, with the tensioner
moved all the way to the water pump, and tighten the nut. Tensioner----.~~~
Tighten the bolt not fully put finger - tight.
~~~~·Timing belt B
.""#--- sprocket b
ECLA021F
TIMING SYSTEM EM-87
3. With the tension side of timing belt B kept tight by 7. Ensure that the deflection is 4 to 5 mm (0.0394 to
pushing the slack side (indicated by A in illustration) 0.1969 in.) when the belt is pushed by the index finger
with a finger, make sure that the timing marks are at the position indicated by and arrow.
properly aligned with each other.
Belt deflection : 4 - 5 mm (0.157 - 0.197 in.)
Timing mark---..,;;.;::-.,
Silent shaft sprocket
Tensioner---:~~~
Crankshaft sprocket
ECLA021G
ECLA02l1
4. Back off tensioner B nut, that have previously been
secured to the water pump side, one to two turns to
give tension to the belt using tensioner spring tension.
5. Tighten the tensioner B attaching nut.
6. Tighten the tensioner B attaching bolt.
~NOTE
If the bolt is tightened first, the tension B should be
turned together, resulting in reduced timing belt B ten-
sion.
ECLA021H
Engine Electrical
System
GENERAL ................................................................. EE - 2
•
IGNITION SySTEM .............................................•.......... EE -10
IGNITION SYSTEM (V6) ..................•............•.............•..•. EE -11
CHARGING SYSTEM ......•....................••.•...........•••.••..... EE -14
STARTING SYSTEM .................••..........•.•......••.•••••••••.... EE -34
CRUISE CONTROL SYSTEM ....•...........•.••........••.•••••••..•... EE-45
PREHEATING SySTEM................................................... EE -50

EE -2 ENGINE ELECTRICAL SYSTEM
GENERAL
SPECIFICATIONS EBMB0010
IGNITION
3.5L V6 Engine
Type
Primary coil resistance 0.74 ± 10% (fl)
Secondary coil resistance 13.3 ± 15% (Kfl)
SPARK PLUG
3.5L V6
Type
Champion RC10PYP4
NGK PFR5N-11
Plug gap 1.0-1.1 mm (0.039-0.043 in.)
STARTER MOTOR
3.5L V6 Diesel
Type Reduction drive (with planetary gear) Reduction drive (with planetary gear)
Voltage 12V 12V
Output 1.2KW 200KW
No-load characteristics
Terminal voltage 11V 11V
Amperage 90A or below 90A or below
Speed 2,800 RPM 2,800 RPM
Number of pinion teeth 8 8
Pinion gap 0.5-2.0 mm (0.0197-0.079 in.) 0.5-2.0 mm (0.0197-0.079 in.)
GENERATOR
3.5L V6 Diesel
Type Battery voltage sensing Battery voltage sensing
Rated output 13.5V / 120A 12V / 75A
Voltage regulator type Electronic built-in type Electronic built-in type
Regulator setting voltage 14.4 ± 0.3 V 14.4 ± 0.3 V
Temperature compensated -10 ± 3 mV / °C -10±3mV/oC
BATTERY
All Engines
Type MF 68 AH, MF 90 AH, MF 100 AH
Ampere hours
5HR 55 AH or more
Cold cranking [at -17.8°C (O°F)] 540 AH or more
Reverse capacity 122 min.
Specific gravity [at 25°C (7rF)] 1.280 ± 0.01
GENERAL EE -3
[QJ] NOTE
COLD CRANKING AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal
voltage of 7.2 or greater at a specified temperature. REVERSE CAPACITY RATING is the amount of time a battery
can deliver 25A and maintain a minimum terminal voltage of 10.5 at 26.7'C (8(J'F).
CRUISE CONTROL SYSTEM
Speed contral module Operating voltage range

Operating temperature DC 10 - 16V
Voltage drap between unit and actuator -30 ± 75°C (-22 ± 16rF)
Operating speed range 0.4V
Low speed limit: 40 ± 3 km/h (25 ± 2 mph)
High speed limit: 145 ± 5 km/h (90 ± 3 mph)
Actuator Rated voltage
Operating temperature DC 12V
Operating consumption -30 ± 90°C (-22 ± 194°F)
Insulating resistance 3A or less (at 12V 20°C)
1Mn or less (at 500V megger)
Cruise main switch Rated voltage
Operating force DC 12V
Voltage drop 0.3 - 1.0 kg
0.15 V or less
Stop lamp switch Rated voltage
Rated load DC 12V
Stop lamp 27 x 5W (Iamp load)
Cruise control 0.1 - 0.5A (relay load)
Insulating resistance Min 3 Mn (by 500V megger)
TIGHTENING TORQUE
Items Nm Kg·cm Ib·tt

Generator terminal (B+) 5-7 50-70 3.6-5.1
Starter motor terminal (B+) 10-12 100-120 7.3-8.8
Battery terminal 4-6 40-60 2.9-4.3
Spark plug 20-30 200-300 15-22
EE-4 ENGINE ELECTRICAL SYSTEM
TROUBLESHOOTING EBMB0030
IGNITION SYSTEM

Engine will not start or is hard Ignition lock switch faulty Replace ignition lock switch
to start (Cranks OK)
Ignition coil faulty Inspect ignition coil
Power transistor faulty Inspect power transistor
Spark plugs faulty Replace plugs
Ignition wiring disconnected or broken Inspect wiring
Spark plugs faulty Replace plugs
Rough idle or stalls Ignition wiring faulty Inspect wiring
Ignition coil faulty Inspect ignition coil
Spark plug cable faulty Inspect spark plug cable
Engine hesitates/poor Spark plugs faulty Replace plugs
acceleration
Ignition wiring faulty Inspect ignition coil
Poor mileage Spark plugs faulty Replace plugs
CHARGING SYSTEM

Charging warning indicator does Fuse blown Check fuses
not light with ignition switch
Light burned out Replace light
"ON" and engine off
Wiring connection loose Tighten loose connections
Electronic voltage regulator faulty Replace voltage regulator
Charging warning indicator Drive belt loose or worn Adjust tension or replace drive belt
does not go out with engine
running (Battery requires
frequent recharging) Fuse blown Check fuses
Electronic voltage regulator or generator faulty Test generator
Wiring faulty Repair wiring
Engine hesitates/poor Drive belt loose or worn Adjust tension or replace drive belt
acceleration
Wiring connection loose or open circuit Tighten loose connection or
Overcharge
repair wiring
Poor grounding Repair
Electronic voltage regulator or generator faulty Test generator, if faulty, repair
or replace.
Worn battery Replace battery
Electronic voltage regulator faulty Replace voltage regulator
Voltage sensing wire faulty Repair wire
GENERAL EE-5
STARTING SYSTEM

Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded or worn out Repair or replace cables
Transaxle range switch faulty (Vehicle Adjust or replace switch
with automatic transaxle only)
Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Ignition lock switch faulty Replace ignition lock switch
Engine cranks slowly Battery charge low Charge or replace battery
Battery ca bl es loose, corroded or worn out Repair or replace cables
Starter motor faulty Repair starter motor
Starter keeps running Starter motor faulty Repair starter motor
Ignition switch faulty Replace ignition switch
Starter spins but engine Short in wiring Repair wiring
will not crank
Pinion gear teeth broken or starter motor faulty Repair starter motor
Ring gear teeth broken Replace flywheel ring gear or
torque converter
GLOW CONTROL SYSTEM (DIESEL)

Engine will not start below 50°C Wiring connection loose or bad wiring Repair or replace wiring
ECT sensor malfunction Replace ECT sensor
Glow plug malfunction Repair or replace glow plug
Glow plug control unit failed Replace glow control unit
After first combustion, engine Wiring connection loose or bad wiring Repair or replace wiring
stall or rough idle below 50°C
Glow plug malfunction Check the resistance of glow plug
and replace, if necessary
Glow plug relay malfunction Check the relay and replace,
if necessary
Glow plug control unit failed Check the control unit and
replace, if necessary
Yellow glow lamp will not turn-ON Open lamp Replace lamp
Wiring connection loose or bad wiring Repair or replace wiring
Shorted wiring Repair or replace wiring
Glow plug control unit failed Replace control unit, if necessary

PRE-TROUBLESHOOTING
PRE-TROUBLESHOOTING
Before starting troubleshooting, inspect each of the follow-

ing sections, and if there is an abnormality, carry out a re-
pair.
1. Check if the installation and connection routes of the

cables and vacuum hoses of the cruise vacuum pump
assembly, actuator and pulley assembly are all nor-
mal.
2. Check if the pulley assembly and the movement of

cables are working smoothly.
3. Check if there is no excessive play or tension in each

cable.
First, select the applicable malfunction symptom from the

''TROUBLE SYMPTOM CHARTS" shown on next pages.
Determine the condition of all function circuits.
1. Make the following preliminary inspections.

• Check that the installation of the actuator, accel-
erator cable are correct, and that the cables and
links are securely connected.
• Check that the accelerator pedal moves
smoothly.
• Adjust the cable so there is not excessive tension
or excessive play on the accelerator cable.
• Check that the actuator and unit assembly, cruise
main, control switch and the connector of each
cancel switch are connected securely.
2. Check in the sequence indicated in the ''TROUBLE

SYMPTOM CHARTS".
3. If anormal condition is indicated, replace the cruise

control module.
GENERAL EE-7
TROUBLE SYMPTOM CHARTS

TROUBLE SYMPTOM 1
CC system is canceled when cancellation is

not wanted.
Or, the CC system cannot be set after an
automatie cancellation.
After the occurrence of the problem, was the NO

ignition switch and cruise main switch left 1------11 Can the CC system be set? I
ON? ~-rY-E-S--------------------~N-O~
YES
Set the CC system and I Check for trouble codes.

conduct a road test.
Did the problem reoccur?

YES NO (now normal)
With the cruise main switch ON and the Check whether or not the vehicle was driven on a steep
engine running, check for trouble codes. slope, or the SET and RESUME control switches were
operated simultaneously. (The cause is not clear under
these circumstances.)
CC : Cruise Control
EBA9003A
TROUBLE SYMPTOM 2

The set vehicle speed varies greatly Malfunction of the vehicle speed Repair the vehicle speed sensor
upward or downward sensor circuit system, or replace the part
"Surging" (repeated alternating Malfunction of the speedometer cable
acceleration and deceleration) or speedometer drive gear
occurs after setting
Cruise vacuum pump circuit Repair the actuator system, or
poor contact replace the part
Malfunction of the acutator and unit Replace the actuator and unit
TROUBLE SYMPTOM 3

The CC system is not canceled when Damaged or disconnected wiring Repair the harness or replace
the brake pedal is depressed of the stop lamp switch the stop lamp switch
Cruise vacuum pump drive circuit Repair the harness or replace
short-circuit the vacuum pump
Malfunction of the actuator and unit Replace the actuator and unit
TROUBLE SYMPTOM 4

The CC system is not canceled Damaged or disconnected wiring of Repair the harness or repair or
when the shift lever is moved to the inhibitor switch input circuit replace the inhibitor switch
"N" position (It is canceled, however,
Improper adjustment of inhibitor switch
when the brake pedal is depressed
TROUBLE SYMPTOM 5

Cannot decelerate (coast) by Temporary damaged or disconnected Repair the harness or replace
using the SET switch wiring of SET switch input circuit the SET switch
Actuator circuit poor contact Repair the harness or replace
the actuator
Malfunction of the actuator
TROUBLE SYMPTOM 6

Cannot accelerate or resume speed Damaged or disconnected wiring, Repair the harness or replace
by using the RESUME switch or short circuit, or RESUME the RESUME switch
switch input circuit
Actuator circuit poor contact Repair the harness or replace
the actuator
Malfunction of the actuator
GENERAL EE-9
TROUBLE SYMPTOM 7

ce system can be set while driving Malfunction of the vehicle-speed Repair the vehicle speed sensor
at a vehicle speed of less than sensor circuit system, or replace the part
40kmlh (25mph), or there is no
Malfunction of the speedometer cable
automatic cancellation at that speed
or the speedometer drive gear
TROUBLE SYMPTOM 8

The cruise main switch indicator Damaged or disconnected bulb of Repair the harness or replace the part.
lamp does not illuminate (But cruise main switch indicator lamp
ce system is normal)
Harness damaged or disconnected
TROUBLE SYMPTOM 9

Malfunction of control function by Malfunction of circuit related to Repair the harness or replace the part
ON/OFF switching of idle switch idle switch function
Malfunction of the actuator and unit
TROUBLE SYMPTOM 10

Overdrive is not canceled during Malfunction of circuit related to Repair the harness or replace the part
fixed speed driving overdrive cancelation, or malfunction
of actuator and unit
No shift to overdrive during
manual driving
IGNITION SYSTEM
GENERAL INFORMATION EBBB0040
Ignition timing is eontro"ed by the eleetrie eontrol ignition

timing system. The ignition timing data tor the engine op-
erating eonditions are programmed in the memory ot the
power train eontrol module (peM).
The engine eonditions (speed, load, warm-up eondition,

ete.) are deteeted by the various sensors. Based upon
these sensor signals and the ignition timing data, signals
to interrupt the primary eurrent are se nt to the power tran-
sistor. The ignition eoil is aetivated and timing is eontro"ed
at the optimum point.
·CKP : Crankshaft Position Sensor
·CMP : Camshaft Position Sensor
EFA9401D
IGNITION SYSTEM (V6) EE -11
IGNITION SYSTEM (V6) Therefore, be careful to arrange the spark plug cables
properly as shown in the illustration.
INSTALLATION OF SPARK PLUG CABLE

EBBB0100
Improper arrangement of spark plug cables will induce

flashover between the cables, causing misfiring and surg-
ing at acceleration in high-speed operations.
o
'tt--tt+-- 2
~ 351
\\-t----t-4-- 1
o
4-+-+--++1
I-HI--++- 5
3
5
1
EBA901OE
IGNITION COIL EBBBOO60

~NOTE
1. Measurement of the primary coil resistance Puff on the spark plug cable boot when removing the
Measure the resistance between connector terminals spark plug cable, not the cable, as it may be damaged.
1 and 2 (the coils at the No. 3 and No. 6 cylinder
sides) of the ignition coil, and between terminals 2 and 2. Using the spark plug wrench, remove all of the spark
4 (the coils at the No. 1 and No. 4 cylinder sides), and plugs from the cylinder head.
between terminals 2 and 3 (the coils at the No.2 and
No.5 cylinder sides). ~NOTE
Take care not to affow contaminants to enter through
Standard value : 0.74:t 10% (0)
the spark plug holes.
EBHAOO6A
EBA9015A
2. Measurement of the secondary coil resistance 3. Check the spark plugs for the following:
Measure the resistance between the high-voltage ter-
minal for the No. 3 and No. 6 cylinders, between the 1) Broken insulator
high-voltage terminals for the No. 1 and No. 4 cylin-
ders and between the high-voltage terminals for the 2) Worn electrode
No.2 and No.5 cylinders.
3) Carbon deposits
Standard value : 13.3:t 15% (K!1)
4) Damaged or broken gasket
& CAUTION 5) Condition of the porcelain insulator at the tip of
When measuring the resistance of the secondary the spark plug (carbon tracking)
col/, be sure to disconnect the connector of the
Ignition coil.
2 1
3 4 5
EBA9015B
EBA9009B
4. Check the spark plug gap using a wire gap gauge,
and adjust if necessary.
INSPECTION AND CLEANING EBHAOll0 Standard value

Spark plug gap: 1.0-1.1 mm (0.039-0.043 in.)
1. Disconnect the spark plug cable from the spark plug.
IGNITION SYSTEM (V6) EE -13
EBA9015C
5. Re-insert the spark plug and tighten to the specified

torque. If it is overtorqued, damage to the threaded
portion of cylinder head may result.
Tightening torque
Spark plug : 20-30Nm (200-300kg·cm, 15-22 Ib·tt)
~NOTE
When replacing the spark plug, use resistance plugs.
CHARGING SYSTEM
The charging system included a battery, an generator with Generator

a built-in regulator, and the charging indicator light and
wire. The generator has six buHt-in diodes (three positive
and three negative), each rectifying AC current to OC cur-
rent. Therefore, OC current appears at generator "8" ter-
minal.
Ammeter
In addition, the charging voltage of this generator is regu-
lated by the battery voltage detection system. The gener-
CB 8
ator is regulated by the battery voltage detection system. ES:]
The main components of the generator are the rotor, sta-
tor, rectifier, capacitor brushes, bearings and V-ribbed belt
pulley. The brush holder contains a built-in electranic volt-
o
Voltmeter
CB
Battery
8
age regulator.
EBBBOl3A
Rotor
~ii1i.~- Stator
CONDITIONS FOR THE TEST
~~~B--Front
bearing
1. Start the engine.
2. Switch on the headlamps, blower motor and so on.

And then, read the voltmeter under this condition.
EBA9130A
RESULT
1. The voltmeter may indicate the standard value.

INSPECTIONA EBBB0130
Standard value : O.2V max.

VOLTAGE DROP TEST OF GENERATOR OUTPUT
WIRE 2. If the value of the voltmeter is higher than expected
(above O.2V max.), poor wiring is suspected. In this
This test determines whether or not the wiring between the case check the wiring fram the generator "8" terminal
generator "8" terminal and the battery (+) terminal is good to the fusible link to the battery (+) terminal. Check
by the voltage drap method. for loose connections, color change due to an over-
heated harness, etc. Correct them before testing
PREPARATION again.
1. Turn the ignition switch to "OFF". 3. Upon completion of the test, set the engine speed at
idle. Turn off the head lamps, blower motor and the
ignition switch.
[QJJ NOTE
To find abnormal conditions of the connection, actions OUTPUT CURRENT TEST
should not be taken on the two terminals and each
connection during the test. This test determines whether or not the generator gives an
output current that is equivalent to the nominal output.
2. Connect a digital voltmeter between the generator "8"
terminal and battery (+) lead wire to the battery (+) PREPARATION
terminal. Connect the (+) lead wire of the voltmeter to
the "8" terminal and the (-) lead wire to the battery (+) 1. Prior to the test, check the following items and correct
terminal. as necessary.
CHARGING SYSTEM EE -15
1) Check the battery installed in the vehicle to en-

sure that it is in good condition. The battery
checking method is de scribed in "BATTERY".
The battery that is used to test the output current Voltmeter Ammeter
should be one that has been partially discharged.
With a fully charged battery, the test may not be con-
ducted correctly due to an insufficient load.
2) Check the tension of the generator drive belt. Check engine _

The belt tension check method is described in the
section "COOLlNG". Crt!:J-
2. Turn off the ignition switch.
3. Oisconnect the battery ground cable.
4. Oisconnect the generator output wire fram the gener-

ator "B" terminal.
5. Connect a OC am meter (0 to 100A) in series between

the "B" terminal and the disconnected output wire. Be
sure to connect the (-) lead wire of the ammeter to the
EBBB013B
disconnected output wire.
TEST
~NOTE
1. Check to see that the voltmeter reads as the same
Tighten each connection securely, as a heavy current value as the battery voltage. If the voltmeter reads OV,
will flow. 00 not rely on clips. and the open circuit in the wire between the generator
"B" terminal and battery (-) terminal, a blown fusible
6. Connect a voltmeter (0 to 20V) between the "B" termi-
link or poor grounding is suspected.
nal and ground. Connect the (+) lead wire to the gen-
erator "B" terminal and (-) lead wire to a good ground. 2. Start the engine and turn on the headlights.
7. Attach an engine tachometer and connect the battery 3. Set the headlights to high beam afJd the heater blower
ground cable. switch to HIGH, quickly increase the engine speed
to 2,500 rpm and read the maximum output current
8. Leave the engine hood open.
value indicated by the am meter.
[ID] NOTE
After the engine starts up, the charging current quickly
drops. Therefore, the above operation must be done
quickly to read the maximum current value correctly.
RESULT
1. The ammeter reading must be higher than the limit

value. If it is lower but the generator output wire is in
good condition, remove the generator from the vehicle
and test it.
Limit value (95A generator) : 63A min.
[bQ) NOTE
• The nominal output current value is shown on the
nameplate affixed to the generator body.
• The output current value changes with the elec-
trical load and the temperature of the generator
itself. Therefore, the nominal output current may

not be obtained. If such is the case, keep the
headfights on the cause discharge of the battery,
or use the fights of another vehicle to increase
the electricalload.
The nominal output current may not be obtained if
the temperature of the generator itself or ambient
temperature is too high.
In such a case, reduce the temperature before
testing again.
2. Upon completion of the output current test, lower the

engine speed to idle and turn off the ignition switch.
3. Disconnect the battery ground cable.
4. Remove the ammeter and voltmeter and the engine

tachometer.
5. Connect the generator output wire to the generator

"B" terminal.
6. Connect the battery ground cable. EBBB013C
REGULATED VOLTAGE TEST TEST
The purpose of this test is to check that the electronic volt- 1. Turn on the ignition switch and check to see that the
age regulator controls voltage correctly. voltmeter indicates the following value.
PREPARATION
Voltage: Battery voltage
1. Prior to the test, check the following items and correct
if necessary. If it reads OV, there is an open circuit in the wire be-
tween the generator "S(L)" terminal and the battery
1) Check that the battery installed on the vehicle is
and the battery (+), or the fusible link is blown.
fully charged. For battery checking method, see
"BATTERY." 2. Start the engine. Keep all lights and accessories off.
2) Check the generator drive belt tension. For belt
3. Run the engine at a speed of about 2,500 rpm and
tension check, see "COOLlNG" section.
read the voltmeter when the generator output current
2. Turn ignition switch to "OFF." drops to 10A or less.
RESULT
4. Connect a digital voltmeter between the "S(L)" termi- 1. If the voltmeter reading agrees with the value listed in
nal of the generator and ground. Connect the (+) lead the Regulating Voltage Table below, the voltage reg-
of the voltmeter to the "S(L)" terminal of the generator. ulator is functioning correctly. If the reading is other
Connect the (-) lead to good ground or the battery (-) than the standard value, the voltage regulator or the
generator is faulty.
terminal.
REGULATING VOLTAGE TABLE
5. Disconnect the generator output wire from the gener-
ator "B" terminal. Voltage regulator ambient Regulating voltage (V)
temperature °C(°F)
6. Connect a DC am meter (0 to 100A) in series between
the "B" terminal and the disconnected output wire. -20 (-4) 14.2-15.4
Connect the (-) lead wire of the ammeter to the dis-
20 (68) 13.9-14.9
connected output wire.
60 (140) 13.4-14.6
7. Attach the engine tachometer and connect the battery
80 (176) 13.1-14.5
ground cable.
2. Upon completion of the test, reduce the engine speed 9. With the engine running at approx. 2500 r/min, turn
to idle, and turn off the ignition switch. the headlights and other lights on and off to adjust the
generator load on the ammeter slightly above 30A.
Limit: max. O.3V
4. Remove the voltmeter and ammeter and the engine
tachometer. [QJ] NOTE
5. Connect the generator output wire to the generator When the generator output is high and the value dis-
"B" terminal. played on the ammeter does not decrease to 30A, set
the value to 40A. Read the value displayed on the volt-
6. Connect the battery ground cable. meter. In this case the limit becomes max. OAV.
10. If the value displayed on the voltmeter is still above

GENERATOR OUTPUT LlNE VOLTAGE the limit, a malfunction in the generator output wire
DROP TEST EBBB0140 may exist. Check the wiring between the generator
"B" terminal and the battery (+) terminal (including
fusible link). If a terminal is not sufficiently tight or if the
This test determines the condition of the wiring from the
harness has become discolored due to overheating,
generator "B" terminal to the battery (+) terminal (including
repair, the test again.
the fusible link).
11. After the test, run the engine at idle.
1. Be sure to check the following before testing:
• Generator installation and wiring connections 12. Turn off all lights and turn the ignition switch to the
• Generator drive belt tension OFF position.
• Fusible link
• Abnormal noise from the generator while the en- 13. Disconnect the tachometer or the scan tool.
gine is running.
14. Disconnect the negative battery cable.
15. Disconnect the ammeter and voltmeter.
3. Disconnect the negative battery cable.
16. Connect the generator output wire to the generator
"B" terminal.
4. Disconnect the generator output wire from the gener-
ator "B" terminal. Connect a DC test ammeter with 17. Connect the negative battery cable.
a range of 0-100A in series between the "B" termi-
nal and the disconnected output wire. (Connect the
(+) lead of the ammeter to the "B" terminal. Connect
the (-) lead of the ammeter to the disconnected output
wire.)
[QJ) NOTE
An inductive-type ammeter which enables mea-
surements to be taken without disconnecting the
generator output wire is recommended. Using this
equipment willlessen the possibility of a voltage drop
caused by a loose "B" terminal connection.
5. Connect a digital-type voltmeter between the gener-

ator "B" terminal and the battery (+) terminal. (Con-
nect the (+) lead of the voltmeter to the "B" terminal.
Connect the (-) lead of the voltmeter to the battery (+)
cable.)
6. Reconnect the negative battery cable.
7. Connect a tachometer or the scan tool.
8. Start the engine.

Ammeter
----(OI;J::=~
Voltmeter
(Digtialtype)
•
Battery
EBA9020C
REMOVAL AND INSTALLATION EBBB0150
KFW2008A
DISASSEMBLY AND REASSEMBLY EBBB0160
Rear bearing
Front housing
Rotor assembly
Retainer
Screw (4EA) Front bearing
Pulley
Molded cap
- B terminal
Rectifier
Spacer
Flange
Cover
Regulator assembly
Rear housing
Stator assembly
EBA9030A
DISASSEMBLY EBBB0180
& CAUTION
1. Remove the four through bolts. Be eareful that the vise jaws do not damage the
rotor.
2. Insert a flat screwdriver between the front bracket and
stator core, and pry downward.
& CAUTION
1. Do not insert the screwdriver too deeply, as
there is a danger of damaging the stator eoil.
2. The rear cover may be hard to remove be-
cause a ring is used to lock the outer race of
the rear bearing. To facifitate removal of rear
cover, heat just the bearing box seetion with
a 200-watt soldering iron. Do not use a heat
KFW2020A
gun as it may damage the diode assembly.
4. Remove the pulley nut, spring washer, pulley, and
spacer.
5. Remove the front bracket and two seals.
6. Remove the rotor from the vise.
7. Remove the brush holder screws, rectifier screws,

and nut from the "8" terminal.
8. Remove the stator assembly from the rear bracket.

KFW2018A
9. Detach the slinger from the brush holder.
10. If the stator is to be removed, unsolder the three stator

leads to the main diodes on the rectifier.
& CAUTION
1. When soldering or unsoldering, make sure
that heat from soldering iron is not transmit-
\ 2.
ted to the diodes for a long period.
Do not exert excesslve force on the leads of
the diodes.
KFW2017A
11. When separating the rectifier from the brush holder,

unsolder the two plates soldered to the rectifier.
INSPECTION
ROTOR
1. Check the rotor coil for continuity. Make sure there is

continuity between the slip rings.
If resistance is extremely low, there is a short. If there

KFW2019A is no continuity or if there is a short circuit, replace the
rotor assembly.
3. Secure the rotor in a soft-jaw vise with the pulley side
up. Resistance value : Approx. 3.1 {l
KFW2021A KFW2024A
2. Check the rotor coil for a ground. Check that there RECTIFIERS
is no continuity between the slip ring and the core. If
there is continuity, replace the rotor assembly. Positive rectifier test
Check for continuity between the positive rectifier and sta-

tor coil lead connection terminal with an ohmmeter. The
ohmmeter should read continuity in only one direction. If
there is continuity in both directions, a diode is shorted.
Replace the rectifier assembly.
KFW2022A
STATOR
1. Make a continuity check on the stator coil. Check that

there is continuity between the coil leads. If there is
no continuity, replace stator assembly. KFW2025A
Negative rectifier test
Check for continuity between the negative rectifier and the

stator coillead connection terminal. The ohmmeter should
read continuity in only one direction. If there is continuity
in both directions, the diode is shorted, and the rectifier
assembly must be replaced.
[V6]
KFW2023A
2. Check the coil for grounding. Check that there is no

continuity between the coil and the core. If there is
continuity, replace the stator assembly.
KFW2026A
CHARGING SYSTEM EE-23
Diode trio test 3. When installing a new brush, insert the brush into the
holder, and then solder the lead wire.
Check the three diodes for continuity by connecting an
ohmmeter to both ends of each diode. Each diode should
have continuity in only one direction.
If continuity is present in both directions, the diode is de-

fective and the heatsink assembly must be replaced.
[V6]
A-
KFW2009A
REASSEMBLY EBBB0190
Reassembly is the reverse of disassembly. Pay attention

to the following:
KFW2027A
Before the rotor is attached to the rear bracket, insert a

BRUSH REPLACEMENT wire through the small hole in the rear bracket to hold the
brush. After the rotor has been installed, the wire can be
1. Measure the length of the brush protrusion shown in
removed.
the illustration, and replace the brush if the measured
value is below the limit value.
Limit: 2mm (0.8 in.) or less
[V6]
2mm
EBA9030E
2. The brush can be removed if the solder of the brush

lead wire is removed.
KFW2029A
GENERATOR (DIESEL) EBMB0200 that it sometimes causes battery under or overcharging

or causes flickering of meters and lamps due to ripples of
The conventional internal voltage detection type alterna- generated voltage resulting from load fluctuation.
tor controls the charging voltage regardless of the battery The figure below show the internal circuits of the alternator
condition and according to the external load change so and voltage regulator.
Diode trio
1--------
I
I
I
1 I ~
I I Battery :
I I
I ~
c I
I
o. I
I
I
I R I
Tr. I
lL-_
I
~----------------~
Voltage regulator
-=-
B7A07415
1. Stator
2. Rotor
3. Rear bracket
4. Brush
5. Electronic regulator
6. Rectifier
7. Fan
8. Pulley
9. Front bracket
10.Vacuum pump
B7AD7400
REMOVAL AND INSTALLATION

(DIESEL) EBMB0210
8 7
4
1. Eye bolt
2. Oil tube
3.0il hose
4. Lock bolt
5. Nut
6. Support bolt
7. Altenator assembly
8. Alternator brace
NOTE
Reverse the removal procedures to reinstall.
TORQUE : Nm (Kg.cm, Ib.ft)

B7AD7395
INSTALLATION EBMB0220
ALTERNATIOR ASSEMBLY
For belt tension, reter to Group EM Engine-Service adjust-

me nt procedures.
& CAUTION
• Install the oil hose to the alternator in ad-
vance.
When the alternator is installed, connect the
oil hose to the nipple on the oil pan side.
Clamp the hose clip at the straight portion of
the nipple.
• When the oil tube is installed, do not take a
sharp bend nor bring the tube in contact with
the cylinder block.
DISASSEMBLY AND REASSEMBLY EBMB0230
16
18 19
17
1. Check valve
2. Nipple
3. Vacuum pump housing
4. O-ring
5. Rotor
6. Vane
m~
7. Vacuum pump plate
8. O-ring
9. Pulleyfan
10.Spacer
11.Seal
12. Rotor assembly
8 7 6 5 4 3
13. Rear bearing
14.Bearing retainer
15.Front bearing
16. Front bracket
17.Stator assembly
18.Plate
19.Regulator & brush holder
20.Rectifier Assembly NOTE
21.0il seal Reverse the disassembly procedures to reassemble.
22. Rear bracket
B7AD7420
DISASSEMBLY EBMB0240 OlL SEAL
FRONT BRACKET Push out and remove the oil seal using a screwdriver.
1. With a screwdriver blade inserted between the front

bracket and stator core, pry it to separate the stator
and the front bracket.
2. If they are hard to separate, lightly strike the bracket

with a plastic hammer while prying with the screw-
driver.
& CAUTION
Do not insert the screwdriver too deep as the sta- B7AD7435
tor core could be damaged.
INSPECTION EBMB0250
VACUUM PUMP
Check the following and replace if defective.
1. Check the rotor ends for streaks and damage.
2. Check the housing surface in contact with the rotor for

streaks and damage.
EBMB024A
3. Check the vanes for damage and break.
STATOR ASSEMBLY, REGULATOR AND BRUSH Housing

HOLDER
& CAUTION
• When soldering or unsoldering, use care not
to expose the diode to soldering iron heat for
extended time.
Complete soldering or unsoldering in as 'e?
Vane
short a time as possible.
• Do not overstress the diode leads. B7AD744Q
ROTOR
1. When removing the stator, unsolder the three stator
leads from the main diodes. 1. Check the rotor coil coritinuity. Make sure that there
is continuity between slip rings.
2. When removing the rectifier from the brush holder, Measure the rotor resistance. If it is excessively smalI,
unsolder two soldered points. it indicates a shorted rotor, If without continuity or
shorted, replace the rotor assembly.
Standard value : 3 - 5 ohms
B7AD7430
B7ZN0440 B7ZN046O
2. Check the rotor coil grounding. Make sure that there RECTIFIER
is no continuity between the slip ring and core. Re-
place the rotor assembly if there is continuity. 1. Inspection of (+) Heat Sink Assembly
Using a circuit tester, check continuity between the
(+) heat sink and the stator coillead connection termi-
nals. If there is continuity in both directions, the diode
is shorted. Then, replace the rectifier assembly.
B7ZN0450
STATOR
1. Check the stator continuity. Make sure that there is B7ZN0480

continuity between coil leads. Replace the stator as-
sembly if there is no continuity 2. Inspection of (-) Heat Sink Assembly
Check continuity between the (-) heat sink and the sta-
tor coillead connection terminals. If there is continuity
in both directions the diode is shorted. Then, replace
the rectifier assembly.
B7ZN0470
2. Check the coil grounding. Make sure that there is

no continuity between the coil and core. Replace the
stator assembly if there is continuity. B7ZN0490
3. Inspection of Diode Trio

With a circuit tester connected to both ends of each
diode, check continuity of the three diodes. If there is
continuity or no continuity in both directions, the diode
is damaged. Then, replace the rectifier assembly.
REASSEMBLY EBMB0260
ROTOR ASSEMBLY
1. Betore installing the rotor on the rear bracket, thread a

steel wire through the small hole provided in the rear
bracket to lift up the brush. After rotor installation,
remove the steel wire.
B7ZN0500
BRUSH
1. The brush must be replaced it worn to the wear limit

line.
EBLB022A
o 2. When installing the rotor on the alternator rear

bracket, wind vinyl tape round the splined shaft to
prevent damage to the oil seal
Wear limit line
B7ZN0510
2. Unsolder the brush lead wires, and the brush and

spring will come out.
/
Wind vinyl tape
B7AD7500
ROTOR AND VANES
1. Check weil the housing, rotor, etc. tor chips and tor-
eign matter. Then, apply engine oil and install.
B7ZN0520
2. Install the vanes with round end tacing outward.
3. When installing a new brush, push the brush into the 3. Apply grease to the O-ring and tit in the housing
holder as iIIustrated and solder the leads. groove when the bolts are tightened.·
Round end
I
( r
EBMB025A B7AD7505
4. When tightening the housing, lightly push it in the di-

rection of arrow so as to minimize the clearance at "A"
and tighten the bolts uniformly.
[QJ) NOTE
After the assembly, be sure to conduct the perfor-
mance test to check to see that the ultima te vacuum
is as specified below.
Standard value of ultimate vacuum :

600 mmHg or better at 3,000 rpm
-J-tjl---_ Push housing in

this direction "A"
B7AD7510
BATTERY VISUAL INSPECTION (1) EBBB0200
1. CHECKING FLOW
Check for obvious damage such as a cracked or broken

case or cover that could permit loss of electrolyte.
Determine the cause of damage and correct as needed.
Clean any corrosion with as solution of baking soda
Not O.K
IReplace battery I
and water.
O.K Height difference is
Inspect the height of electrolyte

I above 10mm between cells
I IReplace battery I
O.K Shortage of electrolyte

IReplace battery I
Below 11.0V
Battery test
IReplace battery I
Above 12:SV
O.K (11.0-12 V) IStarting system inspectionl
Below 11.0V
IReplace battery I
L
Load test (Using battery tester) I
O.K
Battery is good
EBA9018B
2. CHECKING SHEET
Responsibility
Item Trouble Cause Remedy
User Manufacturer
1. Visual inspection * Battery terminal * Carelessness
damage
* Over tightening the Replace 0
battery cable
Cover Breakage * Carelessness Replace 0
* Electrolyte
leakage
- Cover breakage * Carelessness Replace I 0
- Cover leakage * Bad cover seal Replace 0
2. Electrolyte height * Electrolyte height * Cell shorted electrically Replace 0
inspection between cells is * Vaporization caused by Replace 0
over 10mm excessive temperature
* Shortage of * Electrolyte loss caused Replace 0
electrolyte by over-charge
Responsibility
Item Trouble Cause Remedy
User Manufacturer
3. Voltage inspection 1. Battery voltage 1. Over charge Replace 0
>13.2V * Check
, the electric
system
2. 12.5V < Battery 2. Normal
voltage< 12.9
3. 12.0V < Battery 1. Insufficient charge * Battery Load 0
voltage< 12.4V Test (Refer
(Simple discharge) to Load Test
below)
4. 11.0 V <Battery 2. Internal faiiure 0
voltage <12.0 (Over
discharge)
5. Battery voltage 1. Charge condition Replace 0
: 11 .OV or less failure
2. Battery discharged 0
for a long period
3. Internal circuit open 0
3. LOAD TEST
1. When discharging the battery during 15 seconds at

half currency of Cold Cranking Power (CCP), the volt-
age of the battery should be as shown below.
REGULATING VOLTAGE TABLE
Ambient Temperature Voltage

above 20°C 9.6V
- 18°C 9.5V
- 10°C 9.4V
_ 4°C 9.3V
_ -1°C 9.1V
_ -7°C 8.9V
- -12°C 8.7V
2. When the voltage is not within specification, repeat

the load test again, and re-charge.
3. If the battery is left alone for 2 hours after re-charging

and its output is over 12.5V, and the voltage after a
load test is over the standard value, the battery can
be used.
BATTERY VISUAL INSPECTION (2) EBBB0210

& CAUTION
1. Make sure the ignition switch and all accessories are When batteries are being charged, an explosive
in the OFF position. gas forms beneath the cover of each cell. Do
not smoke near batteries being charged or which
2. Disconnect the battery cables (negative first). have recently been charged. Do not break live cir-
cuits at the terminals of batteries being charged.
3. Remove the battery from the vehicle. A spark will occur when the circuit is broken.
Keep open flames away from the battery.
& CAUTION
Care should be taken in the event the battery case
is cracked or leaking, to protect your skin from the
electrolyte. Heavy rubber gloves (not the house-
hold type) should be worn when removing the bat-
tery.
EBA9018D
EBA9018C
4. Inspect the battery carrier for damage caused by the

loss of electrolyte. If acid damage is present, it will be
necessary to clean the area with a solution of clean
warm water and baking soda. Scrub the area with a
stiff brush and wipe off with a cloth moistened with
baking soda and water.
5. Clean the top of the battery with the same solution as

described in Step(4).
6. Inspect the battery ca se and cover for cracks. If

cracks are present, the battery must be replaced.
7. Clean the battery posts with a suitable battery post

tool.
8. Clean the inside surface of the terminal clamps with

a suitable battery cleaning tool. Replace damaged or
frayed cables and broken terminal clamps.
9. Install the battery in the vehicle.
10. Connect the cable terminals to the battery post, mak-

ing sure the tops of the terminals are flush with the
tops of the posts.
11. Tighten the terminal nuts securely.
12. Coat all connections with light mineral grease after

tightening.
STARTING SYSTEM 85 86 87 30
When de-energized
When energized
EBA9020E
The starting system includes the battery, starter motor, so-
lenoid switch, ignition switch, inhibitor switch (Aff only),
connection wires and the battery cables.
Relay
{1
When the ignition key is turned to the start position, cur-
rent flows and energizes the starter motor's solenoid coi!. ~~
The solenoid plunger and clutch shift lever are activated,
and the clutch pinion engages the ring gear. The contacts
close and the starter motor cranks.
-85 -87
85 30
In order to prevent damage caused by excessive rotation

of the starter armature when the engine starts, the clutch
pinion gear overruns. EBA9020F
CHECK IGNITION LOCK SWITCH
Remove the ignition lock switch and check continuity be-

tween the terminals. If the continuity is not as specified,
replace the switch.
~I
Condition 1 2
Pushed 0 -0
Free
EBA9020G
EBBB029A
EBHA0200
CHECK CLUTCH PEDAL (MIT)
Check that pedal height, pedal freeplay and clutch pedal

clevis pin play are correct. (Refer to clutch group)
EBHA020A
EBA9020D
CHECK STARTER RELAY
Remove the starter relay and check continuity between the

terminals. If the continuity is not as specified, replace the
relay.
STARTING SYSTEM EE -35
REMOVAL AND INSTALLATION EBHA0210
27-34 (275-346,20-25)
Start motor
27-34 (275-346, 20-25)

KFW2011A
1. Disconnect the battery ground cable. 5. Installation is the reverse of removal.
2. Remove the speedometer cable and the shift cable.
3. Disconnect the starter motor connector and terminal.
4. Remove the starter motor assembly.

COMPONENTS EBHA0220
Solenoid
Snap ring
Screw
Packing A
Ball
Planetary gear
Sun gear
Planetary gear holder screws
Ring gear
Overrun clutch
Stop ring
Front bracket
Rear bracket
Brush holder
Armature
Yoke assembly
EBHA306A
STARTING SYSTEM EE-37
CHECKING FOR OPERATION EBHA0230
SERVICE ADJUSTMENT PROCEDURES FOR

PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the M-terminal of

the solenoid.
2. Connect a 12V battery the S-terminal and the M-ter-

minal.
3. The pinion should move out. EBHA3060
& CAUTION MAGNETIC SWITCH PULL-IN TEST

This test must be performed quickly (in less than
10 seconds) to prevent the coil from overheating.
the magnetic switch.
2. Connect a 12V battery between the S-terminal and

the M- terminal.
& CAUTION
This test must be performed qulckly (in less than
Field coil wire 10 seconds) to prevent the col/ from burnlng.
3. If the pinion moves out, then the pu "-in coil is good. If

it doesn't move out, replace the magnetic switch.
EBA9023A
4. Check the pinion for stopper clearance (pinion gap)

with a feeler gauge.
Pinlon gap: 0.5-2.0 mm (0.02-0.079 in.)
12V battery
EBA9023D
MAGNETIC SWITCH HOLD-IN TEST

EBA9023B the magnetic switch.
5. If the pinion gap is out of specification, adjust by 2. Connect a 12V battery between the S-terminal and
adding or removing gaskets between the solenoid the body.
and the front bracket.
& CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. If the pinion moves out, everything is in order. If the

pinion moves back and forth repeatedly, the hold-in
circuit is open. If it is open, replace the magnetic
switch.
EE-38 ENGINE ELECTRICAl SYSTEM
~NOTE
This test must be performed quickly (in less than 10
seconds) to prevent the coil trom burning.
3. Pull the pinion out and release it. If the pinion returns
Field coil wire quickly to its original position, everything is in order. If
it doesn't, replace the magnetic switch.
EBA9023E
FREE RUNNING TEST
1. Place the starter motor in a vise equipped with soft

jaws and connect a fully-charged 12-volt battery to the Field coil wire
starter motor as folIows:
2. Connect a test ammeter (1 OO-ampere scale) and car-

bon pile rheostat as shown in the illustration. EBA9023G
INSPECTION EBHA0240
CHECKING THE COMMUTATOR
1. Place the armature on a pair of V-blocks, and check

I" Battery
the run - out by using a dial gauge.
--L12V
Standard value
Armature run - out: 0.05 mm (0.002 in.)
EBA9023F Limit
Armature run - out: 0.1 mm (0.0039 in.)
3. Connect a voltmeter (15-volt scale) acrass the starter
motor.
4. Rotate the carbon pile to the off position.
5. Connect the battery cable fram battery's negative post

to the starter motor body.
6. Adjust the carbon pile until battery voltage reads 11

volts.
7. Confirm that the maximum amperage is within

KFW2033A
the specifications and that the starter motor turns
smoothly and freely:
2. Check the outer diameter of the commutator.
Current : Max. 90 Amps
Standard value
Speed : Min. 3,000 rpm Outer diameter of the commutator : 29.4 mm (1.157 in.)
MAGNETIC SWITCH RETURN TEST Limit
Outer diameter of the commutator : 28.4 mm (1.118 in.)
1. Disconnect field coil wire fram the M-terminal of the
magnetic switch.
2. Connect a 12V battery between M-terminal and the

body.
OVERRUNNING CLUTCH
1. While holding the clutch housing, rotate the pinion.

The drive pinion should rotate smoothly in one direc-
tion, but should not rotate in the opposite direction.
If the clutch does not function properly, replace the
overrun clutch assembly.
2. Inspect the pinion for wear or burrs. If the pinion is

worn or burred, replace the overrun clutch assembly.
KFW2034A If the pinion is damaged, also inspect the ring gear for
wear or burrs.
3. Check the depth of the undercut between segments.
Standard value
Depth of the undercut between segments
: 0.5mm (0.020 in.)
Limit
Depth of the undercut between segments
: 0.2mm (0.079 in.)
EBA9024E
FRONT AND REAR BRACKET BUSHING
Inspect the bushing for wear or burrs. If the bushing is

worn or burred, replace the front bracket assembly or the
rear bracket assembly.
REASSEMBLY OF THE STOP RING AND

Miea
SNAP RING EBHA0250
KFW2035A
Using a suitable pulling tool, pull the overrunning clutch

BRUSH HOLDER
stop ring over the snap ring.
Check for continuity between the brush holder plate and
the brush holder.
The normal condition is no continuity.
KFW2043A
KFW2036A
CLEANING THE STARTER MOTOR

PARTS EBA90260
Soldered
1. 00 not immerse parts in cleaning solvent. Immersing
(Make sure that
the yoke and field coil assembly and/or armature will there is no excess
damage the insulation. Wipe these parts with a cloth solder on brush
only. surface)
2. 00 not immerse the drive unit in cleaning solvent. The

overrun clutch is pre-Iubricated at the factory and sol-
vent will wash lubrication fram the clutch. EBA9027B
3. The drive unit may be cleaned with a brush moistened

with cleaning solvent and wiped dry with a cloth. DISASSEMBLY EBHA0280
REMOVAL OF THE SNAP RING AND STOP RING

REPLACEMENT OF BRUSHES AND
1. Press the stop ring using a socket.
SPRINGS EBA90270
1. Brushes that are worn out, or oil-soaked, should be

replaced.
2. When replacing field coil brushes, crush worn out

brushes with pliers, taking care not to damage the pig-
tail.
KFW2031A
2. After removing the snap ring (using snap-ring pliers),

D 0 - + - - Limit line remove the stop ring and the overrunning clutch.
EBA9027A
3. Sand the pigtail end with sandpaper to ensure good

soldering.
4. Insert the pigtail into the hole provided in the new

brush and solder it. Make sure that the pigtail and ex-
KFW2032A
cess solder do not co me out onto the brush surface.
5. When replacing the ground brush, slide the brush

fram the brush holder by prying the retaining spring
back.
STARTING SYSTEM EE -41
REMOVAL AND INSTALLATLON

(DIESEL) EBMB0290
COMPONENTS
,
27-34 (270-340, 19.5-24.6)
/'
/'
1. Bolt
2. Starting motor assembly
TORQUE : Nm (Kg.cm, Ib.ft)

B7AD7520
EBMB0300
PINION GAP ADJUSTMENT
1. Disconnect the field coil wire from the terminal M of

the magnetic switch.
2. Connect a battery between the terminal Sand starting

motor body. (Connect the positive terminal of battery
to the terminal S.)
EBMB030A
~NOTE
3. When the battery is connected, the pinion moves out.
This test must be performed quickly within 10 seconds Now, push back the pinion with a finger and measure
to prevent the switch coil trom burning. the pinion stroke (the travel along which the pinion is
pushed back).
This is the pinion gap.
4. If the pinion gap is not up to specification, adjust by

adding or removing fiber washers between the mag-
netic switch and front bracket. Using more washers ® e
makes the gap smaller. Battery 12V
EBMB031B
RETURN TEST OF MAGNETIC SWITCH

Pinion With a battery connected between the terminal M and
B7ZN0700
body of the magnetic switch, manually pull the pinion out
to the pinion stopper. Body coils are fully operational if
the pinion returns immediately when releasing it.
EBMB0310
PULL-IN TEST OF MAGNETIC SWITCH ~NOTE

This test must be completed within 10 seconds.
The pull-in coil is in good condition if the plunger is pulled
in to cause the pinion to move out when a battery is con-
nected between the terminals Sand M of the magnetic
switch. If the pinion does not move out, replace the mag-
netic switch.
o 0
Battery 12V
~NOTE
The connector must be disconnected from terminal M
for this test.
The test must be finished within 10 seconds.
EBMB031C
NO-LOAD TEST
Battery 12V 1. Set up a circuit as shown wh ich connects a starter

motor, battery, ammeter, voltmeter, and variable re-
sistance.
2. The starting motor should be in good condition if it

turns smoothly and steadily when the switch is turned
ON with a maximum variable resistance value. Adjust
EBMB031A the variable resistor so that the voltmeter reads 11.5V.
If the current and rpm are out of specification after this
HOLD-IN TEST OF MAGNETIC SWITCH
adjustment, troubleshoot according to the table below
With a battery connected between the terminal Sand body and take remedial action as required.
of magnetic, manually pull the pinion up to the pinion stop-
per. The hold-in coil is in good condition if the pinion re-
mains out when releasing it.
~NOTE
This test must be completed with 10 seconds.
Variable resistor
B7AD7550
Symptom Possible cause

Large current with Contaminated bearing
low rpm (torque also Armature coil rubbing
being smalI) pole piece
Armature and field coil
grounding
Armature coil shorting
Large current with Solenoid switch grounding
no rotation Armature and field coil
grounding
Seized bearing
No current flowing Broken armature and field coils
with no rotation Broken brush and pigtail
Improper contact between
brush and commutator
Small current with Improper field coil connection
low rpm (torque also (Note, however, that open or
being smalI) improperly connected shunt
coil only will result in high rpm.)
Large current with Shorted field coil
high rpm (torque
being smalI)
DISASSEMBLY AND REASSEMBLY EBMB0320
4
,,
I
1
10 ,
9
I
1. Screw 17.Screw
2. Magnetic 18.Center bracket
3. Fiber 19.Packing
4. Screw 20.Lever spring
5. Screw 21.Washer
6. Rear bracket 22.Gear
7. Brush holder assembly 23. Lever
8. Yoke assembly 24.Snap ring
9. Armature 25.Stop ring
1O.Front bearing 26.Pinion gear
11.Rear bearing 27.Spring
12. Screw 28.Pinion shaft assembly
13.Cover 29.Front bracket
14.Snap ring
15.Washer NOTE
16.Plate Reverse the disassembly procedures to reassemble
B7AD7555
CRUISE CONTROL SYSTEM EE-45

SYSTEM BLOCK DIAGRAM EBA90290
Cruise control
switch
Throttle Accelerator Resume/Accel

pedal '1-------,
body
I Diagnosis
connector I
Set/Coast
I'1---------------------1
J
Actuator '"-_ _ _-I Cancel I
I Throttle
valve
& unit
assembly
.-
I
switches
ELC 4-speed Vehicle

Automatie transaxle speed
control module sensor
EBA9029A
COMPONENT PARTS AND FUNCTION OUTLINE
COMPONENT PART FUNCTION

Vehicle speed sensor Converts vehicle speed to pulses.
Cruise control module (CCM) Receives signals from sensor and control switch; CCM
controls all automatie speed control function.
Actuator Regulates the throttle valve to the set opening
by signals from the CCM.
Control switch
CRUISE main switch Switch for automatie speed control power supply.
SET/RESUME switch Controls automatie speed control functions by SET
(COAST) and RESUME (ACCEL).
CRUISE main switch indicator lIIuminates when CRUISE main switch is ON
(Built into cluster).
Cancel switch Sends cancel signals to the CCM
Stop lamp switch/Clutch switch (MIT) Cancels cruise
Controls the overdrive ON and OFF, based on
Transaxle range switch
signals from the CCM for the CC.
Data link connector By connecting the voltmeter or scan tool, control
module diagnostic codes may be read.
*CC : Cruise Control

COMPONENTS LOCATION EBBB0310
SSEE490E
EBBB031A
EBAA030B EBAA030C
EBA9030L EBA9030N
EBSB031B
COMPONENTS EBBB0320
1. Pulley protector
2. Accelerator cable and pulley assembly connection
3. Cruise control cable and pulley assembly connection
4. Throttle cable and pulley assembly connection
5. Vacuum pump connector
6. Pump assembly
7. Pulley assembly
8. Accelerator cable and pedal connection
9. Accelerator cable
10.Throttle cable
11 .Actuator
12. Vacuum hose
S6EE510A
REMOVAL AND INSTALLATION EBBB0330

Switch side
1. Remove the battery negative terminal.

connector
~
2 1
2. Disconnect the accelerator cable and cruise control
.-.
6 514 3 @
cable from throttle assembly by turing throttle lever to
full open position.
3. Disconnect the accelerator cable from accelerator

pedal connection.
EBAA032B
4. Remove the accelerator cable mounting bolts.
STOP LAMP SWITCH
After operating the stop lamp switch, check for continuity

between the terminals.
~ Position
1 2 3 4
Not pushed 0
Pushed 0 0
EBAA031B EBAA032C
5. Remove the actuator and unit assembly mounting

bolt.
....
Pushed
6. Installation is the reverse order of removal.
EBA9032C
INSPECTION EBAA0330
Y27-059C
CONDITION
PARTS INSPECTION EBAA0320
• Turn AlC and all lights OFF. Inspect and adjust at no
CRUISE CONTROL MAIN SWITCH load.
• Warm the engine until idle is stabilized. Confirm that
1. Operate the switch and check for continuity between the idle speed is at the specified RPM.
the terminals. • Turn the ignition switch OFF.
2. If continuity is not as specified, replace the switch.

1. Confirm there are no sharp bends in the cables.
~I
Position
1 2 3 4 5 6 2. Depress the accelerator pedal and check if the throttle
lever moves smoothly from fully closed to fully open.
0 0
ON
0 0 3. Check the inner cables for correct slack.
OFF
4. If there is too much slack or no slack, adjust the play
EBAA032A by the following procedures :
SERVICE HINT
1. If the cable is very loose, the loss of speed going uphill

will be large.
2. If the cable is too tight, idle RPM will be high.

CABLE ADJUSTMENT
1. Assemble the cable to actuator and unit assembly.
2. Tighten nut "b" after pulling the cable tightly.
3. Back nut "b" off one turn.
4. Tighten nut "a".
5. Cable should have approximately 1mm of slack with

the actuator and unit against the stop.
Nut "a"
Nut "b"
EBAA033A
PREHEATING SYSTEM
GLOW SYSTEM EBMB0330
SPECIFICATIONS
SERVICE SPECIFICATIONS
Items Auto glow system

Water temperature sensor resistance [at 20°C (68°F)] k 2.92 - 3.58
Glow plug resistance [at 20°C (68°C)] m 250
TORQUE SPECIFICATIONS
Items Nm kg·cm Ib·ft

Water temperature sensor 8 - 10 80 - 100 6 - 7
Glow plug 15 - 20 150 - 200 11 - 14
Glow plug plate attaching nut 1 - 1.5 10 - 15 0.7 - 1.1
SEALANTS AND ADHESIVES
Items Specified sealant and Adhesive

Water temperature sensor 3M Adhesive Nut Locking 4171 or equivalent
SERVICE ADJUSTMENT 5. The system is normal if battery voltage (about 9V or

PROCEDURES EBMB0340 over) is generated for about 6 seconds during engine
cranking and after start operation. [at cooling water
INSPECTION OF GLOW SYSTEM OPERATION temperature 20°C (68°F)J
Conditions before inspection : 6. When the voltage or continuity time is not normal,
Battery voltage : 12V check the terminal voltage in glow control unit, and
single parts.
1. Connect voltmeter between glow plug plate and plug
body (ground).
2. Check indicated value on voltmeter with ignition

switch ON.
3. Check that preheat indication lamp lights for about 6

seconds and indicates battery voltage (about 9V or
over) tor about 36 seconds immediately after ignition
switch is turned on. [At cooling water temperature
20°C (68°F)]
B7AD7645
~NOTE
Continuity time varies depending upon eooling water
temperature.
4. After checking 3, set ignition switch at START position.
\
PREHEATING SYSTEM EE -51
INSPECTION OF GLOW CONTROL UNIT
Check terminal voltage in glow control unit and continuity

on harness side.
H7EE020A
fil2lXl3l
~
COO7FOOl COO2F003
E8L8039A
1. Check with glow control unit connector connected.

(M14)
Tester
Measuring Check
Terminal Connect area or measuring part connec- Standard value
item conditions
tion
1 Glow plug relay Voltage 1 - ground Ignition Indicates battery
switch ON voltage for about 30
seconds after ON
2. Remove glow control unit connector. Check with har-

ness side connector. (M13)
Connect area or measuring Measuring Tester Check

Terminal Standard value
part item connection conditions
1 Ignition switch Voltage 1 - ground During engine Battery voltage
cranking
2 Preheat indication lamp Voltage 2 - ground Constantly Battery voltage
3 Ignition switch Voltage 3 - ground Ignition switch Battery voltage
(lG1 power source) ON
4 Water temperature sensor Resistance 4 - ground -20°C (-4°F) 24.8 ± 2.5 kfl
0°C(30°F) 8.62 kfl
20°C (68°F) 3.25 kfl
40°C (104°F) 1.05 kfl
5 Vacant terminal - - - -
6 Control unit earth Continuity 6 - ground Constantly Continuity
7 Generator L terminal Voltage 7 - ground Ignition 1- 4 V
Switch On
PREHEATING SYSTEM EE-53
INSPECTION OF ENGINE COOLANT INSPECTION OF STARTER RELAY EBMB0360
TEMPERATURE SENSOR EBMB0350

1. Remove starter relay trom relay bracket.
1. Remove ECT sensor trom intake manitold.
2. Connect battery power source to terminal 1.
2. Check that ECT sensor resistance is within the stan- Check continuity between terminals with termi-
dard value. nal 3 grounded.
Standard value : 3.25kO [at 20°C (68°F)] Between terminals

With power Continuity
4 and 5
Between terminals
Continuity
Without 1 and 3
power Between terminals
No Continuity
4 and 5
B7AD7655
3. After checking, apply specitied adhesive to coolant

temperature sensor screw area to install intake man-
itold.
Specified adhesive : 3M Adhesive Nut

Locklng 4171 or equivalent H7EEOO1A
1 3 1 2 1 1 1
5 I 4 I
(M41)
G6ClOOlT V5BE080A
EBlB041A
B7AD7660
REMOVAL AND INSTALLATION EBMB0370
COMPONENTS
15-20 (1511-220, 11-14) rJ-1

:.~
1
1-1.5 (10-15,0.7-1.1)
1. Glow plug plate

2. Glowplug
NOTE
Reverse the removal procedures to reinstall.
EMBM037A
PREHEATING SYSTEM EE-55
INSPECTION EBMB0380
GLOW PLUG
1. Check the continuity between the terminal and body

as iIIustrated. Replace if discontinuity or with large
resistance.
Standard value : O.2S!l
& CAUTION
Remove oil from plug before measuring as glow
plug resistance is very smalI.
2. Check for rust on glow plug plate.
3. Check glow plug for damage.
EBMB038A
Emissions Control
System
GENERAL ...................................................•.......•..... EC - 2
CRANKCASE EMISSION CONTROL SYSTEM ........•.•.....••......• EC - 7
EVAPORATIVE EMISSION CONTROL SySTEM .....•.......•.......••• EC -10
EXHAUST EMISSION CONTROL SYSTEM ...•....•...............••••. EC -14

EC -2 EMISSIONS CONTROL SYSTEM
GENERAL
SPECIFICATIONS EEMB0010
Components Function Remarks

Crankcase Emission System HC reduction
Positive crankcase ventilation (PCV) valve Variable flow rate type
Evaporatlve Emission System HC reduction
EVAP Canister
EVAP Canister Purge Solenoid Valve Duty control solenoid valve
Exhaust Emission System
MFI system (air-fuel mixture control device) CO, HC, NOx reduction Heated oxygen sensor feedback type
Three-way catalytic converter CO, HC, NOx reduction Monolithic type
EVAP : Evaporative Emission
SERVICE STANDARD
EVAP Canister Purge Solenoid Valve

Coil current 0.45A or below (at 12V)
Coil resistance 24.5 - 27.5 n [at 20°C (68°F)]
EVAP Canister Purge Solenoid Valve
Coil resistance 36 - 44 n [at 20°C (68°F)]
SEALANT
Engine coolant temperature sensor threaded portion THREE BOND 2403 or equivalent
TROUBLESHOOTING

Engine will not start or hard to start Vacuum hose disconnected or damaged Repair or replace
Malfunction of the EVAP Canister Purge Repair or replace
Solenoid Valve
Rough idle or engine stalls Vacuum hose disconnected or damaged Repair or replace
Malfunction of the PCV valve Replace
Malfunction of the EVAP Canister Check the system; if there
Purge System is a problem, check its
component parts
Excessive oil consumption Positive crankcase ventilation line clogged Check positive crankcase
ventilation system
GENERAL EC-3
EMISSION CONTROLS LOCATION EEMBOO30
AFS,IAT TPS ECT PCSV 02 sensor
02 sensor
CMP CKP Injector
EEMBOO3A
EC-4 EMISSIONS CONTROL SYSTEM
A. PCV valve B. EVAP Canister Purge Solenoid Valve
KFWS21SA
EFB9007A
C. Catalytic Converter (MCC) D. Catalytic Converter (UCC)
EEA900SG EEBB003B
E. EVAP. canister
_------
_-
. .
..
-.-
--
..
EEA900SE
GENERAL EC-5
SCHEMATIC DRAWING EEMB0050
*1. HEATED OXYGEN SENSOR (H02S) o IGNITION SWITCH **1. FUEL INJECTOR
*2. HOT FILM SENSOR o BATIERYVOLTAGE **2. IGNITION COIL
*3. INTAKE AIR TEMP. SENSOR o VEHICLE SPEED SENSOR **3. ISC MOTOR
(IAT SENSOR) o AlC LOAD SIGNAL (Linear Solenoid Type)
*4. ENGINE COOLANT TEMP. SENSOR o 'PNP' SWITCH (AlT ONLY) **4. EVAP Canister Purge Solenoid Valve
(ECT SENSOR) o FUEL PUMP RELAY SIGNAL o FUEL PUMP CONTROL
*5. THROTILE POSITION SENSOR o MFI CONTROL RELAY
(TPSENSOR) o AlC RELAY
*6. CAMSHAFT POSITION SENSOR o IGNITION TIMING CONTROL
(CMP SENSOR) o DIAGNOSIS
*7. CRANKSHAFT POSITION SENSOR
(CKP SENSOR)
*8. KNOCK SENSOR
*9. HEATED OXYGEN SENSOR (RR)
Fuel Relay
Main Relay
PCM
OUTPUT INPUT
UCC
PCM : Powertrain Contra I Module
EVAP : Evaporative Emission
UCC : Underbody Catalytic Converter
MCC : Manifold Catalytic Converter
EEMBOOSA
VACUUM HOSES LAYOUT EEMB0110
-i'<:-+----;I'~!fI'H-+--- Blow-by hose
i'\--I-----:t-1.~~bt+h,L~----- PCV valve
EEMB011A
CRANKCASE EMISSION CONTROL SYSTEM EC -7
CRANKCASE EMISSION
CONTROL SYSTEM
POSITIVE CRANKCASE VENTILATION
(PCV) VALVE EEBBOO70
COMPONENTS
~~~!f--- Breather hose

t-\'\lI-*-,
\1r'-'-I"'I-rT-P.C.V hose
Blow by hose--tHF~
Front
P.C.Vvalve
Blow by hose
Breather hose
Rear
.... During low load operation

+ ----- During high load operation
< Fresh air
EEHA013A
PCV VALVE OPERATING EEA90140
Intake manifold side (No vacuum) Intake manifold side (High vacuum)
EEA9014A EEA9014B
Rocker cover side Rocker cover side

Engine condition Not running Engine condition Idling or decelerating
PCV valve Not operating PCV valve Fully operating
Vacuum passage Restricted Vacuum passage Small
Intake manifold side (Moderate vacuum) Intake manifold side (Low vacuum)
EEA9014C EEA9014D
Rocker cover side Rocker cover side

Engine condition Normal operation Engine condition Accelerating and high load
PCV valve Properly operating PCV valve Slightly operating
Vacuum passage Large Vacuum passage Much large
CRANKCASE EMISSION CONTROL SYSTEM EC';9
DISASSEMBLY EEA90150 INSTALLATION
1. Disconnect the ventilation hose from the positive Install the positive crankcase ventilation valve and tighten
crankcase ventilation (PCV) valve. Remove the PCV to the specified torque.
valve from the rocker cover and reconnect it to the
ventilation hose. Tightening torque
PCV valve : 8-12 Nm (80-120 kg·cm, 6-8 Ib·ft)
2. Run the engine at idle and put a finger on the open
end of the PCV valve and make sure that intake man-
ifold vacuum is feit.
~NOTE
The plunger inside the PCV valve should move back
and forth.
3. If vacuum is not feit, clean the PCV valve and ventila-

tion hose in cleaning solvent, or replace if necessary.
EEA9015A
INSPECTION
1. Remove the positive crankcase ventilation valve.
2. Insert a thin stick into the positive crankcase venti-

lation valve from the threaded side to check that the
plunger moves.
3. If the plunger does not move, the positive crankcase

ventilation valve is clogged. Clean or replace it.
EEA9015B
EVAPORATIVE EMISSION
CONTROL SYSTEM
COMPONENTS EEMB0100
Fuel pump relay
Fuel filter
Pressure regulator --Io.IE::UJ::::'
Purge
/;;======.1 Control
Solenoid
Valve
(PCSV)
Delivery pipe
Canister
Fuel tank
EEMB010A
EVAPORATIVE EMISSION CONTROL SYSTEM EC -11
EVAPORATIVE (EVAP) CANISTER PURGE

SOLENOID VALVE EEBB0120
Canister
Coo'rol mlay 1 Engine coolant

temperature sensor
(
Intake air
temperature
(
I
Air flow sensor
(Hot Film)
(
EEBB012A
EVAP CANISTER PURGE SOLENOID VALVE
~NOTE
The EVAP Canister Purge Solenoid Valve is con-
trolled by the ECM; when the engine coolant
temperature is low, and also during idling, the valve
closes so that evaporated tuel is not drawn into the
surge tank. After the warm-up ot the engine during
ordinary driving, valve opens to let the stored vapors
f10w into the surge tank.
EEB9007A
1. Disconnect the vacuum hose (black with red stripe)

trom the solenoid valve.
2. Detach the harness connector.
3. Connect a vacuum pump to the nipple to which the
•.
red-striped vacuum hose was connected .
4. Apply vacuum and check when voltage is applied to

the EVAP Canister Purge Solenoid Valve and when
the voltage is discontinued.
EEBB012B
Battery voltage Normal condition

INSPECTION
When applied Vacuum is released
~NOTE When discontinued Vacuum is maintained
When disconnecting the vacuum hose, make an iden-
tification mark on it so that it can be reconnected to its
original position.
~NOTE
Ifthere is no vacuum created, the intake manifold port
may be clogged and require cleaning.
E
:J
:J
o
<Il
>
KFW4011A
5. Measure the current between the terminals of the so-

lenoid valve. Engine speed(rpm)
EVAP Canister Purge Solenoid Valve EEA9023B
Coil at 20°C (68°F) : O.45A or below (at 12V)

Coil resistance : 24.5 - 27.5 n [at 20°C (68°F)] EVAPORATIVE (EVAP) CANISTER EEJB0240
CANISTER
Inspect the Canisfer Close Valve (CCV) and its air filter as
shown in the illustration.
1. Look for loose connections, and sharp bends or dam-

age to the fuel vapor lines.
2. Look for distortion, cracks or fuel leakage.
3. After removing the EVAP Canister, inspect for cracks
or damage.
KFW4012A
VACUUM HOSE
Engine coolant temperature : 80-95°C (176-205°F)
1. Disconnect the vacuum hose from the intake manifold

purge hose nipple and connect a hand vacuum pump
to the nipple.
_----
--
--
. .
..
EEA9005E
TWO-WAY VALVE
1. Inspect that air flows as shown.

2. Check that the valve is connected correctly noting the
arrow mark on the valve.
EEA9023A
2. Start the engine and check that, after raising the en-
gine speed by racing the engine, vacuum remains
fairly constant.
EVAPORATIVE EMISSION CONTROL SYSTEM EC -13
Mark: _ . . .~
EVAP Canister Air side

side
VSEC201D
FUEL FILER CAP EEM0260
Check the gasket ot the tuel tiller cap, and the tiller cap
itself, for damage or deformation. Replace.the cap it nec-
essary.
Gasket
VSEC205A
EXHAUST EMISSION
CONTROL SYSTEM
VEHICLES WITH CATALYTIC
CONVERTER EEA90270
Exhaust emissions (CO, HC, NOx) are controlled by a

combination of engine modifications and the addition of
special control components in the fuel.
Modifications to the combustion chamber, intake manifold,

camshaft and ignition system form the basic control sys-
tem. Additional control devices include a catalytic con-
verter and the oxygen sensors which monitor mixture rich-
ness.
These systems have been integrated into a highly effective

system which controls exhaust emissions while maintain-
ing good driveability and fuel economy.
AIRlFUEL MIXTURE RATIO CONTROL

SYSTEM [MULTIPORT FUEL INJECTION
(MFI) SYSTEM] EEA90280
The MFI system employs the signals from the heated oxy-
gen sensor to activate and control the injector installed in
the manifold for each cylinder, precisely regulating the air/
fuel mixture ratio and reducing emissions.
This allows the engine to produce exhaust gases of the

proper composition to permit the use of a three-way cat-
alyst. The three-way catalyst is designed to convert the
three pOlIutants (1) hydrocarbons (HC), (2) carbon monox-
ide (CO), and (3) oxides of nitrogen (NOx) into harmless
substances. The two operating modes in the MFI system
are as folIows:
1. Open loop-air/fuel ratio is controlled by information

programmed into the PCM du ring the manufacturing
process.
2. Closed loop-air/fuel ratio varies by the PCM based on
information supplied by the heated oxygen sensor.

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Fuel System

INJECTION PUMP-MECHANICAL ...................................... FLB -11

FUEL DELIVERY SySTEM-DIESEL .................................... FLB -22

Fuel injection pump

Injection nozzle and holder

Engine control system Pedal-operated cable type, incorporating electric engine

SERVICE SPECIFICATIONS EFMB3030

Injection timing (when plunger lift 1 mm) 9° ATDC

Engine control system

TORQUE SPECIFICATIONS EFLBOO50

SPECIAL TOOlS EFLBOO70

Tool (Number and name) Illustration Use

09314-43000 Removal of injection pump sprocket

Overflow pipe Feed pump (for air vent)

Water level warning lamp

Fuel injection pump

FUEL INJECTION SYSTEM

Symptom Probable cause Remedy

Symptom Probable cause Remedy

Symptom Probable cause Remedy

INSPECTION AND ADJUSTMENT EFLB0150 ADJUSTMENT EFLB0160

ACCELERATOR CABLE EVACUATION OF AIR FROM FUEL LlNE

• When fuel is drained and re-filled tor service.

3. Repeat until hand pump operation becomes stift.

6. If there is too much slack, adjust slack by the following AUOO5

1) Loosen adjusting nut. Fully elose throttle lever. ADJUSTMENT EFLB0170

4) After adjusting, confirm that throttle level fully

INJECTION START PRESSURE

Move nozzle tester handle at about one stroke per

3. The pressure gauge pointer rises slowly and swings

Standard value: 150 bar INJECTION STATUS

Inject on is normal if the characteristic intermittent

Check that the spray is good, as illustrated in the fig-

2. Move nozzle tester handle at 4 to 6 strakes per sec-

3. Confirm the spray is cone shaped with an angle of

4. If the injection is not good, disassemble nozzle and

5. Confirm fuel does not drip after injection.

6. It dripping, disassemble injection nozzle and replace

1. Maintain internal nozzle pressure (press ure gauge in-

2. It there is leakage, disassemble injection nozzle and

FUEL INJECTION PUMP AND INJECTION

If found defective, replace the injection pump as assembly.

Description Check procedure Criteria

1. Injection pipe No.1

INJECTION PUMP SPROCKET INJECTION NOZZLE

FUEL INJECTION PUMP

INSPECTION EFMB3070 CHECKING OF SPRAY CHARACTERISTICS

INJECTION NOZZLE 1. Operate tester handle at a rate of approximately on

NOZZLE OlL TIGHTENESS

INSTALLATION EFLB1090 INJECTION PIPE

2. Fit a new nozzle gasket and holder gasket into the

2. Loosen (but do not remove) the 4 nuts on the injection

3. Remove the plug from the rear of injection pump, and

5. Turn the crankshaft clockwise to bring the notch on the

Standard value : 0.97-1.03 mm

6. It dial indicator reading is not within the standard value

7. Repeat Steps 4 and 6 to make sure that the adjust-

8. Remove the dial indicator and the special tool.

INJECTION NOZZLE HOLDER EFLB1130

DISASSEMBLY EFLB1150 DISTANCE PIECE