Engine

ENGINE

EG-1

DESCRIPTIONThe 3E-E engine is an in-line 4-cylinder 1.5 liter OHC 12 valve engine.

ENGINE MECHANICAL

-ENGINE ENGINE MECHANICALEG-2

The 3E-E engine is an in-line 4-cylinder engine with the cylinders numbered 1-2-3-4 fromthe front. The crankshaft is supported by 5 bearings on the inside of the crankcase. Thesebearings are made of aluminum alloy.The crankshaft is integrated with 8 weights which are cast with it for balance. Oil holes are boredin the center of the crankshaft to supply oil to the connecting rods, bearings, pistons and othercomponents.The ignition order is 1-3-4-2. The cylinder head is made of aluminum alloy,with a cross flowtype intake and exhaust layout and with wedge type combustion chambers.Exhaust and intake valves are equipped with irregular pitch springs made of special valve springcarbon steel which are capable of following the valves even at high engine speeds.The camshaft is driven by a timing belt. The cam journal is supported at 4 locations between thevalve locker arms of each cylinder and on the front end of the cylinder head. Lubricationof the cam and cam journal is accomplished by oil being supplied through the oiler port in thecenter of the camshaft.Adjustment of the valve clearance is done by the valve adjusting screw.The resin timing belt cover is composed of 2 pieces. A service hole is provided in the No. 1 beltcover for adjusting the timing belt tension.Pistons are made of high temperature-resistant aluminum alloy, and a depression is made in thepiston head to prevent interference with the valves.Piston pins are the semi-floating type, with the pins fastened to the connecting rods by pressurefittings, allowing the pistons and pins to float.The No. 1 compression ring is made of steel and the No.2 compression ring is made of cast iron.The oil ring is made of a combination of steel and stainless steel. The outer diameter of eachpiston ring is slightly larger than the diameter of the piston and the flexibility of the rings allowsthem to hug the cylinder walls when they are mounted on the piston. Compression rings No. 1 andNo.2 work to prevent the leakage of gas from the cylinder and the oil ring works to scrape oil offthe cylinder walls to prevent it from entering the combustion chambers.The cylinder block is made of cast iron. It has 4 cylinders which are approximately twice thelength of the piston stroke. The top of each cylinder is shut off by the cylinder head and the lowerend of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, thecylinder block contains a water jacket through which coolant is pumped to cool the cylinders.The oil pan is bolted to the bottom of the cylinder block. The oil pan is an oil reservoir made ofpressed sheet steel.


(09221-00030) Spring

PREPARATIONSST (SPECIAL SERVICE TOOLS)

(09221-00150) Bushing “D”

(09221-00020) Body

(09221-00130) Guide “G”

(09221-00140) Guide ”H”

09201-70010 Valve Guide Bushing Remover &Replacer

09223-41020 Crankshaft Rear Oil SealReplacer

09221-25024 Piston Pin Remover & Replacer

09330-00021 Companion Flange Holding Tool

09213-14010 Crankshaft Pulley Holding Tool

09309-37010 Transmission Bearing Replacer

09202-70010 Valve Spring Compressor

09213-31021 Crankshaft Pulley Puller

Crankshaft front oil seal

Crankshaft pulley


09616-1201 1 Worm Bearing Adjusting ScrewWrench

Plug for the vacuum hose, fuelhose etc.

RECOMMENDED TOOLS09090-04010 Engine Sling Device

09200-00010 Engine Adjust Kit

09258-00030 Hose Plug Set

Connecting rod aligner

Engine tune-up tester

Precision straight edge

EQUIPMENT

Compression gauge

For suspending engine

Vernier calipers

Cylinder gauge

Torque wrench

Caliper gauge

Spring tester

CO/HC meter

Oil Pump pulley

Feeler gauge

Steel square

Dial indicator

Micrometer

Valve spring

Valve spring


08833-00080 Adhesive 1344,THREE BOND 1344,LOCTITE 242 or equivalent

SSM (SPECIAL SERVICE MATERIALS)

08826-00100 Seal Packing 1282B,THREE BOND 1282B or equivalent

08833-00070 Adhesive 1311,THREE BOND 1311 or equivalent

No. 1 engine hanger set boltFlywheel or drive plate mountingbolt

No.1 camshaft bearing capCylinder head coverRear oil seal retainer

08826-00080 Seal packing or equivalent

Water outlet housing

Oil pressure switch


TROUBLESHOOTINGWhen the malfunction code is not confirmed in the diagnostic code check and the problem stillcannot be confirmed in the basic inspection, then proceed to this step and perform troubleshoot-ing according to the numbers in the order given in the table below.

HINT: When inspecting a wire harness or circuit, the electrical wiring diagrams at the end ofrepair manual should be referred to and the circuits of related systems also should be checked.

After acceleration pedaldepressed

After acceleration pedalreleased

Starter runs - enginedoes not crank

Engine stalls soon after starting

Muffler explosion (after fire)

Igni

tion

Sig

nal

Circ

uit (

Spa

rk T

est)

Hesitatior/Poor acceleration

Excessive oil consumption

Difficult to start ordinarily

No complete combustion

Battery often discharges

Circ

uit O

peni

ngR

elay

Inta

ke A

ir Te

mp.

Sen

sor

Circ

uit

Thr

ottle

Pos

ition

Sen

sor

Circ

uit

High engine idle speed

Low engine idle speed

When shifting N to D

Fue

l Pre

ssur

eC

ontr

ol S

yste

m

During A/C operation

Engine does not crank

Difficult to start in cold

Vac

uum

Sen

sor

Circ

uit

Oxy

gen

Sen

sor

Circ

uit

Starter keeps running

Engine cranks slowly

Difficult to start in hot

No initial combustion

Wat

er T

emp.

Sen

sor

Circ

uit

Fue

l Pre

ssur

eR

egul

ator

Poor fuel economy

NS

W S

igna

lC

ircui

t

RP

M S

igna

lC

ircui

t

Nigh oil pressure

A/C

Sig

nal

Circ

uit

Low oil pressure

Incorrect first idle

Engine overcool

Fue

l Cut

Sys

tem

STA

Sig

nal

Circ

uit

Engine overheat

Diff

icul

t to

star

tP

oor

driv

abili

ty

EF

I Mai

nR

elay

Rough idling

Doe

s no

t sta

rtE

ngin

e st

alls

Suspect area

Fue

l Pum

p

Poo

r id

ling

Knocking

Symptom

See page

Fue

l Lin

es

Inje

ctor

sBack fire

Surging

EG

-188

EG

-148

EG

-184

EG

-204

EG

-185

EG

-150

EG

-170

EG

-147

EG

-146

EG

-153

EG

-145

EG

-199

EG

-162

EG

-141

EG

-164

Misfire

Oth

ers

IG-2

IG-3


Neutral Start SWor Clutch Start SW

Brakes drag evenwhen released

Dash Pot orThrottle Opener

Idle-Up ControlSystem

Theft DeterrentSystem

Engine ECU

Cooling FanSystem

AcceleratorPedal Link

Coolant Leakage

Compression

Starter Relay

Suspect area

Fuel Leakage

Fuel Quality

EGR System

Oil Leakage

Spark Plug

AT-14CL-7

Distributor

Sym

ptom

See pace

19

EG-190

EG-210

EG-224

EG-186

EG-123

EG-107

EG-201

EG-231

EG-14

BE-53

ST-27

Starter

IG-10

Clutch

IG-7

After acceleration pedal

depressed


released

Starter runs - engine

does not crank


Hesitatior/P

oor acceleration

Excessive oil consum

ption


No com

plete combustion




When shifting N

to D

During A

/C operation




Engine cranks slow

ly


No initial com

bustion

Poor fuel econom

y

Nigh oil pressure

Low oil pressure


Engine overcool

Engine overheat

Difficult to startPoor drivability

Rough idling

Does not startEngine stalls Poor idling

Knocking

Back fire

Surging

Misfire

Others


ST-4

ST-15

12

-E

NG

INE

EN

GIN

E M

EC

HA

NIC

AL

EG

-8

Connecting RodBearing

Water Temp.Sender Gauge

Radiator andRadiator Cap

Valve GuideBushing

Oil PressureSwitch

Flywheel orDrive Plate

CrankshaftBearing

Cylinder Block

Valve Clearance

Cylinder Head

Water Pump

Valve Timing

Suspect area

Timing Belt

Piston Ring

Thermostat

Oil Pump

Drive Belt

Sym

ptom

Alternator

See page

EG-234

EG-217

EG-215

EG-21 1

MA-1 1

EG-74

BE-40

EG-27

BE-39

EG-52

EG-36

MA-7

EG-23

EG-22

CH-5


depressed


released

Starter runs - engine

does not crank


Hesitatior/P

oor acceleration

Excessive oil consum

ption


No com

plete combustion




When shifting N

to D

During A

/C operation




Engine cranks slow

ly


No initial com

bustion

Poor fuel econom

y

Nigh oil pressure

Low oil pressure


Engine overcool

Engine overheat

Difficult to startPoor drivability

Rough idling

Does not startEngine stalls Poor idling

Knocking

Back fire

Surging

Misfire

Others


-E

NG

INE

EN

GIN

E M

EC

HA

NIC

AL

EG

-9

HIGH-TENSION CORDS INSPECTION(See page IG-6 )Maximum resistance:25 k� per cord

SPARK PLUGS INSPECTION ANDADJUSTMENT

BATTERY INSPECTION(See page CH-4 )Standard specific gravity:1.25-1.27 when fully charged at 20 °C (68°F)

(See page IG-7 )Correct electrode gap:1.1 mm (0.043 in.)Recommended spark plugs:ND W16EXR-U11NGK BPR5EY11

TUNE-UPENGINE COOLANT INSPECTION(See page EG-210 )

ENGINE OIL INSPECTION(See page EG-232 )

AIR FILTER INSPECTION(See page MA-8 )


DRIVE BELTS INSPECTION(See page MA-7 )Drive belt tension:GeneratorUsed belt 100 �20 lbfNew belt 160 �20 lbfPSUsed belt 100 �20 lbfNew belt 160 �20 lbfA/CUsed belt 110 �20 lbfNew belt 165 �15 lbfPS and A/CUsed belt 100 �20 lbfNew belt 160 �20 lbf

VALVE CLEARANCE INSPECTION ANDADJUSTMENT(See page MA-1 1)Valve clearance (Hot):0.20 mm (0.008 in.)

IGNITION TIMING INSPECTION ANDADJUSTMENT(See page IG-15 )Ignition timing:10° BTDC @ idle(w/ Terminals T and E1 connected)

IDLE SPEED INSPECTION ANDADJUSTMENT(See page MA-1 1)Idle speed (w/ Cooling fan OFF and at Neutral):M/T 750 rpmA/T 800 rpm

-ENGINE ENGINE MECHANICALEG-1 1

IDLE AND OR 2500 RPM CO HC CHECKHINT: This check is used only to determine whether ornot the idle CO/HC complies with regulations.1. INITIAL CONDITIONS(a) Engine at normal operating temperature(b) Air cleaner installed(c) All pipes and hoses of air induction system connected(d) All accessories switched OFF(e) All vacuum lines properly connected

HINT: All vacuum hoses for EGR system, etc. shouldbe properly connected.

(f) MFI system wiring connectors fully plugged(g) Ignition timing set correctly(h) Transmission in neutral position(i) Tachometer and CO/HC meter calibrated by hand

4. INSERT CO/HC METER TESTING PROBE AT LEAST40 cm (1.3 ft) INTO TAILPIPE DURING IDLING

5. IMMEDIATELY CHECK CO/HC CONCENTRATIONAT IDLE AND/OR 2,500 RPMHINT: When performing the 2 mode (2,500 rpm andidle) test, follow the measurement order prescribed bythe applicable local regulations.

2. START ENGINE3. RACE ENGINE AT 2,500 RPM FOR APPROX. 180

SECONDS


TroubleshootingIf the CO/HC concentration does not comply withregulations, perform troubleshooting in the ordergiven below.(a) Check oxygen sensor operation.

(See page EG-199 )(b) See the table below for possible causes, and then

inspect and correct the applicable causes if neces-sary.

1. Faulty ignition:• Incorrect timing• Fouled, shorted or improperly gapped plugs• Open or crossed high-tension cords• Cracked distributor cap2. incorrect valve clearance3. Leaky EGR valve4. Leaky intake and exhaust valves5. Leaky cylinder1. Vacuum leak:• Vacuum hose• EGR valve• Intake manifold (Air intake chamber)• Throttle body• Cylinder head gasket• Brake booster line2. Lean mixture causing misfire1. Restricted air filter2. Faulty EFI system:• Faulty pressure regulator• Clogged fuel return line• Defective water temp. sensor• Defective air temp. sensor• Faulty engine ECU• Faulty injector• Faulty throttle position sensor

Rough idle(Black smoke from exhaust)

Rough idle(Fluctuating HC reading)

Rough idle

Problem

NormalCause

High

High

High

High

Low

HC CO


5. CHECK CYLINDER COMPRESSION PRESSURE(a) Insert a compression gauge into the spark plug hole.(b) Fully open the throttle.(c) While cranking the engine, measure the compression

pressure.HINT: Always use a fully charged battery to obtain anengine speed of 250 rpm or more.

(d) Repeat steps (a) through (c) for each cylinder.Compression pressure:1.270 kPa (13.0 kgf/cm 2, 184 psi)Minimum pressure:981 kPa (10.0 kg f/cm 2, 142 psi)Difference between each cylinder:98 kPa (1.0 kg f/cm 2, 14 psi) or less(e) If compression of one or more cylinder is low, pour a

small amount of engine oil into that cylinder throughthe spark plug hole and repeat steps (a) through (c) forthe cylinder with low compression.

• If adding oil helps the compression, it is likely thatthe piston rings and/or cylinder bore are worn ordamaged.

• If pressure remains low, a valve may be stickingor seated improperly, or there may be leakagepast the gasket.

6. REINSTALL SPARK PLUGSTorque: 18 N �m (180 kgf �cm, 13 ft �lbf)

7. RECONNECT DISTRIBUTOR CONNECTORS8. REINSTALL AIR INTAKE CONNECTOR

COMPRESSION CHECKHINT: If there is lack of power, excessive oil consump-tion or poor fuel economy after engine tune-up, mea-sure the cylinder compression pressure.1. WARM UP ENGINE2. REMOVE AIR INTAKE CONNECTOR3. DISCONNECT DISTRIBUTOR CONNECTORS4. REMOVE SPARK PLUGS


TIMING BELT REMOVAL1. DISCONNECT NEGATIVE TERMINAL CABLE FROM

BATTERYCAUTION (w/ SRS): Work must be started after 90 sec-onds from the time the ignition switch is turned to the ”LOCK” position and the negative (-) terminal cable is

disconnected from the battery.2. REMOVE RH ENGINE UNDER COVER3. DISCONNECT ACCELERATOR CABLE4. A/T:

DISCONNECT THROTTLE CABLE5. DISCONNECT PCV HOSES6. w/ A/C and/or PS:

REMOVE PIPE CLAMP BOLTS7. w/ A/C and/or PS:

REMOVE DRIVE BELT8. REMOVE GENERATOR DRIVE BELT

TIMING BELTCOMPONENTS FOR REMOVAL ANDINSTALLATION


10. REMOVE RH ENGINE MOUNTING INSULATOR(a) Slightly raise the engine with a jack.

HINT: Place a wooden block between the jack andengine.

11. REMOVE CYLINDER HEAD COVERRemove the 2 nuts, seal washers and cylinder headcover with gasket.12. REMOVE SPARK PLUGS

(c) Using a 14 mm deep socket wrench, remove the nut.(d) Remove the 2 bolts and RH engine mounting insula-

tor.

9. REMOVE BOLT, GROUND STRAP AND VACUUMTRANSMITTING VALVES WITH BRACKET FROMRH ENGINE MOUNTING INSULATOR

(b) Remove the RH mounting insulator through bolt.


13. SET N0.1 CYLINDER TO TDC/COMPRESSIONTurn the crankshaft pulley and align its groove withthe ”0” mark on the No.1 timing belt cover.HINT: Check that the rocker arms on the No. 1 cylinderare loose. If not, turn the crankshaft pulley one com-plete revolution.

15. REMOVE TIMING BELT COVERSRemove the 7 bolts, No.1 and No.2 timing belt covers.

14. REMOVE CRANKSHAFT PULLEYS(a) w/ A/C and/or PS:Remove the 4 bolts and No.2 crankshaft pulley.

(b) Using SST, remove the pulley nut.SST 09213-14010,09330-00021

(c) Using SST, remove the pulley.SST 09213-31021


(b) Loosen the idler pulley bolt and push it left as far as itwill go and then temporarily tighten it.

(c) Remove the belt.(d) Remove the idler pulley bolt and pulley.18. REMOVE NO.2 IDLER PULLEY

17. REMOVE TIMING BELT AND NO.1 IDLER PULLEYHINT: If reusing the timing belt, draw a direction arrowon the belt (in direction of engine revolution), andplace matchmarks on the pulleys and belt as shown inthe illustration.

16. REMOVE TIMING BELT GUIDE

(a) Remove the tension spring.


20. REMOVE CAMSHAFT PULLEYHold the camshaft with wrench, and remove thepulley bolt and timing pulley.

NOTICE: Be careful not to damage the cylinder head withthe wrench.

19. REMOVE CRANKSHAFT TIMING PULLEYIf the timing pulley cannot be remove by hand,use 2screwdrivers.

NOTICE: Position shop rags as shown to prevent damage.

21. REMOVE OIL PUMP PULLEYUsing SST, remove the pulley nut and pulley.SST 09616-12011


COMPONENTS INSPECTION1. INSPECT TIMING BELTNOTICE:• Do not bend, twist or turn the belt inside out.• Do not allow the belt to come into contact with oil,

water or steam.• Do not utilize belt tension when installing or remov-

ing the set bolt of the camshaft timing pulley.

If there are defects as shown in the illustrations,check the following points and replace the timing beltif necessary.(a) Premature parting

• Check for proper installation.

• Check the timing cover gasket for damage andproper installation.

(c) If there are cracks or noticeable wear on the belt face,check to see is there are nicks on one side of the idlerpulley lock.

(d) If there is wear or damage on only one side of the belt,check the belt guide and the alignment of each pulley.

(b) If the belt teeth are cracked or damaged, check to seeif the camshaft is locked.


3. INSPECT TENSION SPRING(a) Measure the free length of the spring.

Free length:38.4 mm (1.512 in.)If the free length is not as specified, replace thetension spring.

(b) Measure the tension of the spring at the specifiedinstalled length.Installed tension:50 N (5.11 kgf, 11.3 lbf) at 51.5 mm (2.028 in.)If the installed tension is not as specified, replace thetension spring.

(e) If there is noticeable wear on the belt teeth, check thetiming belt cover for damage and check gasket hasbeen installed correctly and for foreign material on thepulley teeth.If necessary, replace the timing belt.

2. INSPECT IDLER PULLEYSCheck the turning smoothness of the timing belt idlerpulleys.If necessary, replace the idler pulley.


(c) Hold the camshaft with a wrench, and torque thepulley set bolt.Torque: 50 N �m (510 kgf �cm, 37 ft �lbf)HINT: Remove any oil or water on the camshaft timingpulley and keep it clean.

TIMING BELT INSTALLATION(See Components for Removal and Installation)1. INSTALL OIL PUMP PULLEY(a) Align the pulley and oil pump drive shaft.

(b) Align the knock pin hole on the 3E mark side with thecamshaft knock pin hole and install the camshaftpulley to the camshaft.

2. INSTALL CAMSHAFT TIMING PULLEY(a) Align the camshaft knock pin with the No.1 camshaft

bearing cap mark.

(b) Using SST to hold the pulley, torque the nut.SST 09616-12011

Torque: 36 N �m (370 kgf �cm, 27 ft �Ibf)


4. INSTALL NO.1 IDLER PULLEY(a) Install the No.1 idler pulley.(b) Pry the No. 1 idler pulley toward the left as far as it will

go and temporarily tighten it.HINT: Remove any oil or water on the idler pulled andkeep it clean.

5. INSTALL NO.2 IDLER PULLEYTorque: 27 N �m (280 kgf �cm, 20 ft �lbf)HINT: Remove any oil or water on the idler pulley andkeep it clean.

6. INSTALL TIMING BELTHINT: If reusing timing belt, align the points markedduring removal and install the belt with the arrowpointing in the direction of engine revolution.

3. INSTALL CRANKSHAFT TIMING PULLEYInstall the crankshaft timing pulley and align the TDCmarks on the oil pump body and crankshaft timingpulley.HINT: Remove any oil or water on the crankshafttiming pulley and keep it clean.

7. INSPECT VALVE TIMING AND BELT TENSION(a) Install the tension spring.


(f) Check that there is belt tension at the position in-dicated in the illustration.

(g) Remove the crankshaft pulley bolt.

(c) Temporarily install the crankshaft pulley bolt and turnthe crankshaft 2 revolutions from TDC to TDC.HINT: Always turn crankshaft clockwise.

(d) Check that each pulley aligns with the marks asshown in the illustration.

(e) Torque the No.1 idler pulley bolt.Torque: 18 N-m (185 kgf-cm, 13 ft-lbf)

(b) Loosen the No. 1 idler pulley set bolt.


10. INSTALL CRANKSHAFT PULLEYS(a) Align the pulley set key with the key groove of the

pulley.(b) Install the pulley bolt and SST to the crankshaft pulley.

SST 09213-14010(c) Using SST to hold the crankshaft pulley, torque the

pulley bolt.SST 09330-00021Torque: 152 N �m (1,550 kgf �cm, 112 ft �lbf)

(d) w/ A/C and/or PS:Install the No.2 crankshaft pulley with the 4 bolts.Torque: 19 N �m (195 kgf �cm, 14 ft �lbf)

11. INSTALL SPARK PLUGSTorque: 18 N �m (180 kgf �cm, 13 ft �lbf)

12. INSTALL CYLINDER HEAD COVER(a) Install the gasket to the cylinder head cover.(b) Apply seal packing to the cylinder head as shown in

the illustration.Seal packing:Parts No.08826-00080 or equivalentHINT: Install the head cover as soon as seal packing isapplied.

9. INSTALL TIMING BELT COVERSInstall the No. 1 and No.2 timing belt covers with the 7bolts.Torque: 7.5 N �m (75 kgf �cm, 65 in. �Ibf)

8. INSTALL TIMING BELT GUIDE


14. INSTALL VACUUM SWITCHING VALVES WITHBRACKET AND GROUND STRAP

15. INSTALL GENERATOR DRIVE BELT16. w/ A/C and/or PS:

INSTALL DRIVE BELT17. ADJUST DRIVE BELTS (See page MA-8 )18. w/ A/C and/or PS:

INSTALL PIPE CLAMP BOLTS19. INSTALL PCV HOSES20. A/T:

CONNECT THROTTLE CABLE, AND ADJUST IT21. CONNECT ACCELERATOR CABLE, AND ADJUST IT22. INSTALL RH ENGINE UNDER COVER23. CONNECT NEGATIVE TERMINAL CABLE TO

BATTERY

13. INSTALL RH ENGINE MOUNTING INSULATOR(a) Install the RH engine mounting insulator to the engine

with 2 bolts.Torque: 64 N �m (650 kgf �cm, 47 ft �lbf)

(b) Align the RH mounting insulator with the bracket andtemporarily install the mounting through bolt.

(c) Lower the engine and remove the jack.(d) Using a 14 mm deep socket wrench, install the nut.

Torque: 64 N�m (650 kgf �cm, 47 ft �lbf)

(c) Install the cylinder head cover with the 2 seal washersand nuts.Torque: 6.9 N �m (70 kgf �cm, 61 in. �lbf)

(e) Torque the through bolt.Torque: 73 N-m (740 kgf-cm, 54 ft-lbf)


CYLINDER HEADCOMPONENTS FOR REMOVAL ANDINSTALLATION


CYLINDER HEAD REMOVAL(See Components for Removal and Installation)1. DISCONNECT NEGATIVE TERMINAL CABLE FROM

BATTERYCAUTION(w/ SRS): Work must be started after 90 sec-onds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable isdisconnected from the battery.

2. REMOVE RH ENGINE UNDER COVER3. DRAIN ENGINE COOLANT4. DISCONNECT FRONT EXHAUST PIPE5. DISCONNECT ACCELERATOR CABLE6. A/T:

DISCONNECT THROTTLE CABLE7. REMOVE PCV HOSES8. REMOVE AIR CLEANER ASSEMBLY WITH AIR

INTAKE CONNECTOR

9. DISCONNECT FUEL HOSES(a) Remove the union bolt and gaskets, and disconnect

the fuel inlet hose.(b) Disconnect the fuel return hose.

NOTICE: Catch leaking fuel in a container.

10. DISCONNECT FOLLOWING HOSES:(a) MAP sensor hose from gas filter on intake chamber(b) Brake booster hose from union on intake chamber(c) Vacuum hose (s) from air pipe(d) Vacuum sensing hoses from fuel pressure regulator

and intake port on intake manifold(e) w/ A/C:

A/C idle-up hoses from union on intake chamber andthrottle body

11. w/ PS:REMOVE PS PUMP (See step 22 on page EG-56 )

12. w/ PS:REMOVE PS PUMP BRACKET

13. w/ A/C and w/o PS:REMOVE IDLER PULLEY BRACKET

14. REMOVE TIMING BELT AND CAMSHAFT TIMINGPULLEY(See steps 8 to 17 and 20 on pages EG-15 to EG-19 )

15. REMOVE DISTRIBUTOR


(b) Remove the 6 nuts, exhaust manifold, 2 gaskets andNo.2 heat insulator.

18. DISCONNECT ENGINE WIRE HARNESS(a) Disconnect the following connectors and wires:

• Front wiper motor connector

• California only: Throttle opener VSV and EGR gas temperaturesensor connectors

• Throttle position sensor connector

16. REMOVE WATER OUTLET HOUSING(a) Disconnect the following connectors:

(1) Engine coolant temperature sender gauge con-nector

(2) Engine coolant temperature sensor connector(3) Engine coolant temperature switch connector

(b) Disconnect the following hoses:(1) 2 radiator hoses(2) Water inlet hose(3) Heater outlet hose(4) No.1 water bypass hose(5) 2 TVV vacuum hoses

(c) Remove the bolt, 2 nuts and water outlet housing.(d) Using a soft-faced hammer, carefully tap off the

water outlet housing.

17. REMOVE EXHAUST MANIFOLD(a) Remove the 3 bolts and No.1 heat insulator.


20. REMOVE DELIVERY PIPE WITH INJECTORS(a) Remove the 2 bolts and delivery pipe together with

the 4 injectors.NOTICE: Be careful not to drop the injectors.

(b) Pull out the 4 injectors from the delivery pipe.(c) Remove the 2 spacers and 4 insulators from the cylin-

der head.

(b) w/o PS:Disconnect the No.4 air hoses from the 2-way.

(c) w/ PS:Disconnect the No.4 air hoses from the 3-way.

(d) Disconnect the No.1 water bypass hose from thewater inlet pipe.

• 4 injector connectors

• Ground strap from the cylinder head (Bolt)(b) Disconnect the wire clamps.(c) Remove the 2 bolts, and disconnect the engine wire

from the intake manifold.

(e) Remove the 5 bolts, 2 nuts and manifold with thegasket.

19. REMOVE INTAKE MANIFOLD(a) Remove the bolt, nut and intake manifold stay.


21. CHECK CAMSHAFT THRUST CLEARANCEUsing a dial gauge, measure the thrust clearancewhile moving the camshaft back and forth with ascrewdriver.Standard thrust clearance:0.08 - 0.18 mm (0.031 - 0.0071 in.)Maximum thrust clearance:0.25 mm (0.0098 in.)If the thrust clearance is greater than maximum, re-place the camshaft and/or cylinder head.22. LOOSEN ADJUSTING SCREW OF ROCKER ARMLoosen the adjusting screw lock nut and fully loosenthe adjusting screw.23. REMOVE CAMSHAFT(a) Uniformly loosen and remove bearing cap bolts in

several passes, in the sequence shown.(b) Remove the camshaft, oil seal and camshaft bearing

caps.NOTICE: Do not remove the distributor bearing cap.HINT: Arrange the camshaft bearing caps in correctorder.

24. REMOVE VALVE ROCKER ARMS(a) While lifting the top of the rocker arm spring, pry off

the spring with a screwdriver.

(b) Remove the rocker arm.HINT: Arrange the rocker arms in correct order.


(b) Lift the cylinder head from the dowels on the cylinderblock and place the head on wooden blocks on abench.HINT: If the cylinder head is difficult to lift off, prywith a screwdriver between the cylinder head andblock projections.NOTICE: Be careful not to damage the cylinder head andcylinder block surfaces of the cylinder head gasket.

(c) Remove the cylinder head gasket.

25. REMOVE CYLINDER HEAD(a) Uniformly loosen and remove the 10 cylinder head

bolts in several passes, in the sequence shown.NOTICE: Head warpage or cracking could result fromremoval in incorrect order.HINT: Some engines have head bolts with smoothlygrinded head surfaces.


2. REMOVE VALVES(a) Using SST, compress the valve spring and remove the

2 keepers.SST 09202-70010

(b) Remove the spring retainer, valve spring, valve andspring seat.

CYLINDER HEAD DISASSEMBLY(See Components for Removal and Installation)1. REMOVE NO.1 AND NO.2 ENGINE HANGERS

HINT: Arrange the valves, valve springs, spring seatsand spring retainers in correct order.

(c) Using pliers, pull out the oil seal.


CYLINDER HEAD COMPONENTSINSPECTION, CLEANING AND REPAIR1. CLEAN TOP OF PISTONS AND TOP OF BLOCK(a) Turn the crankshaft and bring each piston to top dead

center (TDC). Using a gasket scraper, remove all thecarbon from the piston top.

(b) Remove all the gasket material from the top of thecylinder block.NOTICE: Be careful not to scratch the surfaces.

(c) Using compressed air, blow carbon and oil from thebolt holes.CAUTION: Protect your eyes when using high pressureair.

2. REMOVE GASKET MATERIALUsing a gasket scraper, remove all the gasket materialfrom the manifold and cylinder head surface.NOTICE: Be careful not to scratch the surfaces.

4. CLEAN VALVE GUIDE BUSHINGSUsing a valve guide brush and solvent, clean all thevalve guide bushings.

NOTICE: Be careful not to damage the valve guide bush-ing interior.

3. CLEAN COMBUSTION CHAMBERSUsing a wire brush, remove all carbon from the com-bustion chambers.

NOTICE: Be careful not to scratch the head gasket con-tact surface.

5. CLEAN CYLINDER HEADUsing a soft brush and solvent, thoroughly clean thecylinder head.


6. INSPECT CYLINDER HEAD FOR FLATNESSUsing a precision straight edge and thickness gauge,measure the surface contacting the cylinder block andmanifold for warpage.Maximum warpage:Cylinder block side0.05 mm (0.0020 in.)Manifold side0.05 mm (0.0020 in.)If warpage is greater than maximum, replace the cylin-der head.

7. INSPECT CYLINDER HEAD FOR CRACKSUsing a dye penetrant, check the combustion cham-ber intake manifold and exhaust ports, head surfaceand top of the head for cracks.If cracked, replace the cylinder head.

9. INSPECT VALVE STEM AND GUIDE BUSHINGS(a) Using a caliper gauge, measure the inside diameter of

the guide bushing.Bushing inside diameter:6.01 - 6.03 mm (0.2366 - 0.2374 in.)

8. CLEAN VALVES(a) Using a gasket scraper, chip off any carbon from the

valve head.(b) Using a wire brush, thoroughly clean the valve head.

NOTICE: Be careful not to damage the seat valve surface.


(b) Using a micrometer, measure the diameter of thevalve stem.Valve stem diameter:Intake5.970 - 5.985 mm (0.2350 - 0.2356 in.)Exhaust5.965 - 5.880 mm (0.2348 - 0.2354 in.)

(c) Subtract the valve stem diameter measurement fromthe guide bushing inside diameter measurement.Standard oil clearance:Intake0.025 - 0.060 mm (0.0010 - 0.0024 in.)Exhaust0.030 - 0.065 mm (0.0012 - 0.0026 in.)Maximum oil clearance:Intake0.08 mm (0.0031 in.)Exhaust0.10 mm (0.0039 in.)If the clearance is greater than maximum, replace thevalve and guide bushing.

10. IF NECESSARY. REPLACE VALVE GUIDEBUSHINGS

(a) Using SST and a hammer, tap out the valve guidebushing.SST 09201- 70010

(b) Using a caliper gauge, measure the bushing bore di-ameter of the cylinder head.

(c) Select a new valve guide bushing (STD or O/S 0.05).If the bushing bore diameter of the cylinder head ismore than 11.027 mm (0.4341 in.), machine the boreto the following diameter:11.050 - 11.077 mm (0.4350 - 0.4361 in.)If the bushing bore diameter of the cylinder head isgreater than 11.077 mm (0.4361 in.), replace thecylinder head.

Bushing bore diametermm (in.)

11.050 - 11.077(0.4350 - 0.4361)

11.000 - 11.027(0.4331 - 0.4342)

Both intake and exhaust

Use O/S 0.05

Bushing size

Use STD


(c) Check the valve head margin thickness.Standard margin thickness:1.0 mm (0.039 in.)Minimum margin thickness:0.8 mm (0.031 in.)If the valve head margin thickness is less than mini-mum, replace the valve.

11. INSPECT AND GRIND VALVES(a) Grind the valve only enough to remove pits and

carbon.(b) Check that the valves are ground to the correct valve

face angle.Valve face angle:44.5�

(d) Check the valve overall length.Standard overall length:IntakeMain92.26 mm (3.6323 in.)Sub91.80 mm (3.6142 in.)Exhaust92.26 mm (3.6323 in.)

(d) Using SST and a hammer, drive in a new valve guide towhere there is 13.3-14.1 mm (0.5236-0.5551 in.)protruding from the cylinder head.SST 09201 - 70010

(e) Using a sharp 6 mm reamer, ream the valve guide toobtain the standard specified clearance between theguide bushing and valve stem.


(b) Check the valve seating position. Apply a light coat ofprussian blue (or white lead) to the valve face. Lightlypress the valve against the seat. Do not rotate thevalve.

(c) Check the valve face and seat for the following:

• If blue appears 360� around the face, the valve isconcentric. If not, replace the valve.

• If blue appears 360� around the valve seat, theguide and seat are concentric.If not, resurface the seat.

• Check that the seat contact is on the middle ofthe valve face with the following width.

CONTACT WIDTH:1.2 - 1.6 mm (0.047 - 0.063 in.)If not, correct the valve seat as follows:(1) If seating is too high on the valve face, use 30�

and 45� cutters to correct the seat.

Minimum overall length:IntakeMain91.76 mm(3.6126 in.)Sub91.30 mm(3.5945 in.)Exhaust91.76 mm(3.6126 in.)If the overall length is less than minimum, replace thevalve.(e) Check the surface of the valve stern tip for wear.

If the valve stem tip is worn, regrind it with grinder orreplace the valve is necessary.NOTICE: Do not grind off more than the minimum overalllength

12. INSPECT AND CLEAN VALVE SEATS(a) Using at 45� carbide cutter, resurface the valve seats.

Remove only enough metal to clean the seats.


(c) Using a spring tester, measure the tension of the valvespring at the specified installed length.Installed tension:156 N (15.91 kgf, 35.1 lbf) at 35.16 mm (1.3842 in.)If the installed tension is not as specified, replace thevalve spring.

13. INSPECT VALVE SPRINGS(a) Using a steel square, measure the squareness of the

valve springs.Maximum squareness:2.0 mm (0.079 in.)If squareness is greater than maximum, replace thevalve spring.

(b) Using vernier calipers, measure the free length of thevalve spring.Free length:41.52 mm (1.6346 in.)If the free length is not within specification, replacethe valve spring.

(d) Hand-lap the valve and valve seat with an abrasivecompound.

(e) After hand-lapping, clean the valve and valve seat.

(2) If seating is too low on the valve face, use 75�(IN), 60� (EX) and 45� cutters to correct the seat.


(b) Inspect cam lobesUsing a micrometer, measure the cam lobe height.Standard cam lobe height:IntakeMain35.35 - 35.45 mm (1.3917 - 1.3957 in.)Sub34.91 - 35.01 mm (1.3744 - 1.3783 in.)Exhaust35.83 - 35.93 mm (1.4106 - 1.4146 in.)Minimum cam lobe height:IntakeMain35.15 mm (1.3839 in.)Sub34.17 mm (1.3453 in.)Exhaust35.63 m m (1.4028 in.)If the cam lobe height is less than minimum, replacethe camshaft.

(c) Inspect camshaft journalsUsing a micrometer, measure the journal diameter.Standard diameter:26.979 - 26.995 mm (1.0622 - 1.0628 in.)If the journal diameter is less than specified, check theoil clearance.

14. INSPECT CAMSHAFT(a) Inspect camshaft for runout(1) Place the camshaft on V-blocks.

(2) Using a dial indicator, measure the circle runoutat the center journal.

Maximum circle runout:0.04 mm (0.0016 in.)

If the circle runout is greater than maximum, replacethe camshaft.

(d) Inspect camshaft journal oil clearance(1) Clean the bearing caps and camshaft journal.(2) Place the camshaft in the cylinder head.(3) Lay a strip of Plastigage across each of the cam-

shaft journals.


(6) Remove the bearing caps.(7) Measure the Plastigage at its widest point.

Standard oil clearance:0.037 - 0.073 mm (0.0015 - 0.0029 in.)Maximum oil clearance:0.10 mm (0.0039 in.)

If the oil clearance is greater than maximum, replacethe bearing the bearing caps and cylinder head.(8) Completely remove the Plastigage.

15. INSPECT ROCKER ARMSCheck the contact surface of the valve rocker arm andvalve stem end and/or camshaft lobe.If the contact surface of the valve stem end and/orcamshaft lobe is worn excessively, replace the rockerarm.

16. INSPECT INTAKE AND EXHAUST MANIFOLDSUsing a precision straight edge and thickness gauge,check the surface contacting the cylinder head forwarpage.

Maximum warpage:Intake0.05 mm (0.0020 in.)Exhaust0.20 mm (0.0118 in.)

If the warpage is greater than maximum, replace themanifold.

(4) Place the bearing cap with the top of the numberon the cap pointing toward the front and numer-ical order from the front side.

(5) Torque the cap bolts gradually from the inside inthe 3 passes.Torque: 14 N �m (140 kgf �cm. 10 ft �lbf)HINT: Do not turn the camshaft.


CYLINDER HEAD ASSEMBLY(See Components for Removal and Installation)HINT:• Thoroughly clean all parts to be assembled.

Before installing the parts, apply new engine oil• to all sliding and rotating and rotating surfaces.

Replace all gaskets and oil seals with new ones.

1. INSTALL VALVES(a) Install new oil seals on the valve guide bushings.

HINT: Pushing down on the places shown in the illus-tration.

(b) Rotate the oil seal to check that it is firmly installed.

(d) Install the seats, springs and spring retainers on thecylinder head.

(e) Using SST, compress the valve retainers and place 2keepers around the valve stem.SST 09202-70010

(c) Insert the valves in the valve guide bushing.Make sure the valves are installed in the correct order.

HINT: The intake valve oil seal is silver and the ex-haust valve oil seal is brown.


2. INSTALL AND TORQUE CYLINDER HEAD BOLTSHINT:

• The cylinder head bolts are tightened in 3 progressivesteps.

• If any of the bolts break or deform, replace them.(a) Apply a light coat of engine oil on the threads and

under the cylinder head bolts.(b) First, uniformly tighten the 10 cylinder head bolts in

several passes, in the sequence shown.

CYLINDER HEAD INSTALLATION(See Components for Removal and Installation)1. INSTALL CYLINDER HEAD(a) Place a new cylinder head gasket on the cylinder

block.NOTICE: Be careful of the installation direction.

(b) Place the cylinder head on the cylinder head gasket.

2. INSTALL NO.1 ENGINE HANGER(a) Clean the bolt threads and cylinder head bolt hole of

any sealer, oil or foreign material.Remove any oil with kerosene or gasoline.

(b) Apply sealant to 2 or 3 threads of the bolt end.Sealant:Part No.08833-00070, THREE BOND 1324 orequivalent

(c) Torque the bolt.Torque: 21 N �m(210 kgf �cm, 15 ft �lbf)

3. INSTALL NO.2 ENGINE HANGERTorque: 58 N �m (590 kgf �cm. 43 ft �lbf)

(f) Using a soft-faced hammer, lightly tap the valvestem tip to assure proper fit.


Torque: 29 N �m (300 kgf �cm, 22 ft �Ibf)

(c) Second, uniformly tighten the 10 cylinder head boltsin sequence shown.Torque: 49 N �m (500 kgf �cm, 36 ft �Ibf)

If any of the bolts do not meet the torque specifica-tion, replace the bolt.

3. (When replacing with a new cylinder head)INSTALL VALVE ROCKER ARM PIVOTS

Use a brass bar and hammer to install the arm pivotonto the cylinder head.HINT: When using a new cylinder head, and the pistonarm pivots must be installed

(c) Using a screwdriver, press the bottom lip of the rockerarm spring until it fits into the groove on the rockerarm pivot.HINT: Put the valve adjusting screw in the rocker armpivot.

4. INSTALL ROCKER ARMS(a) Before installing the rocker arm, check that the ad-

justing screw is as shown in the illustration.(b) Install a new rocker arm spring to the rocker arm.

(d) Third, retighten the cylinder head bolts an additional90� in the order as shown.


5. INSTALL CAMSHAFT AND OIL SEALHINT: To prevent the sub-intake valve and the pistonhead from damage, perform steps (a) and (c) below.

(a) Set No.1 cylinder to TDC/compression.(b) Coat all bearing journals with engine oil.(c) With the knock pin in the 12 o’clock position, place

the camshaft on the cylinder head.

(e) Pulling the rocker arm up and down, check that thereis spring tension on the rocker arm and that the rockerarm does not rattle.

(d) Place bearing caps on each journal with the arrowspointing toward the front.

(d) Using a screwdriver, pry the rocker arm spring ontothe rocker arm pivot.

(e) Apply MP grease to the lip of a new oil seal.


(g) Clean the installed surfaces of the No.1 bearing capand cylinder head with cleaner.

(h) Apply seal packing to the No. 1 bearing caps as shownin the illustration.Seal packing:Part No.08826-00080 or equivalentHINT: Install the No.1 bearing caps immediately afterapplying the sea) packing.

(i) Place the No.1 bearing caps on the cylinder head.

(j) Install and uniformly tighten the bearing cap bolts inseveral passes, in the sequence shown.Torque: 14 N �m (140 kgf �cm, 10 ft �lbf)

(k) Check the camshaft thrust clearance.(See step 21 on page EG-31 )Standard clearance:0.08 - 0.18 mm (0.0031 - 0.0071 in.)Maximum clearance:0.25 mm (0.0098 in.)

6. INSTALL INJECTORS AND DELIVERY PIPE(See step 1 on page EG-165 )Torque: 19 N �m (190 kgf �cm, 14 ft �lbf)

(f) install the oil seal as far as the deepest part of thecylinder head.


(f) Install the intake manifold stay with the bolt and nut.Torque: 17 N �m (175 kgf �cm, 13 ft �lbf )

8. CONNECT ENGINE WIRE HARNESS(a) Install the engine wire with the 2 bolts.(b) Connect the engine wire harness with the 2 clamps.(c) Connect the following connectors and wires:• Ground strap to the cylinder head (Bolt)• 4 injector connectors• Throttle position sensor connector• CALIF. only:

Throttle opener VSV and EGR gas temperaturesensor connectors

• Front wiper motor connector

(c) Connect the No. 1 water bypass hose to the water inletpipe.

(d) w/o PS:Connect the No.4 air hose to the 2-way.

(e) w/ PS:Connect the No.4 air hose to the 3-way.HINT: Connect the air hose on the atmospheric sidewhich is marked with white paint.

(b) Install the intake manifold with the 5 bolts and 2 nuts.Torque the bolts and nuts.Torque: 19 N �m (195 kgf �cm, 14 ft �Ibf)

7. INSTALL INTAKE MANIFOLD(a) Install a new gasket to the cylinder head.


10. INSTALL WATER OUTLET HOUSING(a) Remove any old packing (FIPG) material and be care-

ful not to drop any oil on the contacting surfaces ofthe water outlet housing and cylinder head.

• Using a razor blade and gasket scraper, removeall the packing (FIPG) material from the gasketsurfaces.

• Thoroughly clean all components to remove allthe loose material.

• Clean both sealing surfaces with a non-residuesolvent.

NOTICE: Do not use a solvent which will affect paintedsurfaces.

(b) Apply seal packing to the water outlet housing asshown in the illustration.Seal packing:Part No.08826-00100, THREE BOND 1282B orequivalent

9. INSTALL EXHAUST MANIFOLD(a) Install the No.2 heat insulator, 2 new gaskets and the

manifold with the 6 nuts.HINT: Install the exhaust manifold gasket with the ”E”mark facing outward.

(c) Install the No. 1 heat insulator with the 3 bolts.Torque: 7.8 N �m (80 kgf �cm, 69 in. �lbf)

(b) Torque the 6 nuts.Torque: 51 N �m (520 kgf �cm, 38 ft �lbf)


(d) Connect the following hoses:(1) 2 radiator hoses(2) Water inlet hose(3) Heater outlet hose(4) No.1 water bypass hose(5) TVV vacuum hose (from port P of throttle body)(6) TVV vacuum hose (from charcoal canister)(e) Connect the following connectors:(1) Engine coolant temperature sender gauge connector(2) Engine coolant temperature sensor connector(3) Engine coolant temperature switch connector11. INSTALL DISTRIBUTOR

Torque: 17 N �m (175 kgf �cm, 13 ft �lbf)

12. INSTALL CAMSHAFT TIMING PULLEY ANDTIMING BELT(See steps 2, 4, 6 to 10 and, 13 to 15 on pages EG-22 to 26)

Install a nozzle that has been cut to a 2 mm(0.08in.) opening.HINT: Avoid applying an excess amount to the sur-face. Be especially careful near oil passages.• Parts must be assembled within 15 minutes of

application. Otherwise, the material must be re-moved and reapplied.

• Immediately remove nozzle from the tube andreinstall cap.

• Do not pour in any coolant until at least 2 hoursafter installation is completed.

(c) Install the water outlet housing with the bolt and 2nuts.Torque: 17 N �m (175 kgf �cm, 13 ft �lbf)

13. ADJUST VALVE CLEARANCE(a) Turn the crankshaft pulley and align its groove with

the ”0” mark on the No. 1 timing belt cover.(b) Check that the rocker arm on No. 1 cylinder are loose

and the rockers on No.4 are tight.If not, turn the crankshaft one complete revolutionand align the marks as above.


(c) Measure only the valves indicated.Valve clearance (Hot):0.20 mm (0.008 in.)Reference:Valve clearance (Cold):0.18 mm (0.007 in.)HINT: After installing the cylinder head, warm up theengine and adjust the valve clearance.

(d) Using a thickness gauge, measure the gap betweenthe cam and rocker arm. Loosen the lock nut and turnthe adjusting screw to the specified clearance. Holdthe adjusting screw in position and tighten the locknut.

(e) Recheck clearance. The thickness gauge should movewith a very slight drag.

(f) Turn the crankshaft one revolution and adjust theother valves.

14. INSTALL SPARK PLUGS AND CYLINDER HEADCOVER(See steps 11 and 12 on pages EG-25 and EG-26 )

16. w/ PS:INSTALL PS PUMP BRACKET AND PS PUMP

(a) Install the PS pump bracket with the 3 bolts.Torque: 44 N �m (440 kgf �cm. 32 ft �lbf)

(b) Install the PS pump. (See step 8 on page EG-89 )

15. w/ A/C and/or PS:INSTALL IDLER PULLEY BRACKET12 mm head boltTorque: 27 N �m (275 kgf �cm, 20 ft �lbf)14 mm head boltTorque: 37 N �m (375 kgf �cm, 27 ft �lbf)


19. INSTALL AIR CLEANER ASSEMBLY WITH AIRINTAKE CONNECTOR

20. INSTALL PCV HOSES21. A/T:

CONNECT THROTTLE CABLE, AND ADJUST IT22. INSTALL ACCELERATOR CABLE, AND ADJUST IT23. CONNECT FRONT EXHAUST PIPE

(SEE STEP 6 ON PAGE EG-88 )24. INSTALL RH ENGINE UNDER COVER25. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY26. FILL WITH ENGINE COOLANT27. START ENGINE AND CHECK FOR LEAKS28. PERFORM ENGINE ADJUSTMENT(See page EG -10)29. PERFORM ROAD TESTCheck for abnormal noise, shock, slippage, correctshift points and smooth operation.30. RECHECK ENGINE COOLANT AND ENGINE OIL

LEVELS

17. CONNECT FOLLOWING HOSES:(a) MAP sensor hose to gas filter on intake chamber(b) Brake booster hose to union on intake chamber(c) Vacuum hose(s) to air pipe(d) Vacuum sensing hoses to fuel pressure regulator and

intake port on intake manifold(e) w/ A/C:

A/C idle-up hoses to union on intake chamber andthrottle body

18. CONNECT FUEL HOSES(a) Connect the fuel return hose.(b) Connect the fuel inlet hose with the union bolt and 2

new gaskets.Torque: 29 N �m (300 kgf �cm, 22 ft �lbf)


CYLINDER BLOCKCOMPONENTS FOR REMOVAL ANDINSTALLATION



ENGINE REMOVAL(See Components for Removal and Installation)1. REMOVE BATTERY AND RADIATOR RESERVOIR

TANK2. REMOVE HOOD3. REMOVE PCV HOSES4. REMOVE AIR CLEANER ASSEMBLY WITH AIR

INTAKE CONNECTOR5. REMOVE AIR CLEANER BRACKET6. REMOVE ENGINE UNDER COVERS7. DRAIN ENGINE COOLANT8. REMOVE RADIATOR (See page EG-217 )9. DISCONNECT ACCELERATOR CABLE10. A/T:

DISCONNECT THROTTLE CABLE

13. DISCONNECT FOLLOWING HOSES(a) Brake booster hose(b) MAP sensor hose(c) w/ A/C:

A/C idle-up hoses(d) Idle-up vacuum transmitting hoses(e) w/ PS:

PS idle-up air hoses

11. DISCONNECT FUEL HOSES(a) Remove the union bolt and gaskets, and disconnect

the fuel inlet hose.(b) Disconnect the fuel return hose.

NOTICE: Catch leaking fuel in a container.

12. REMOVE CHARCOAL CANISTER(a) Remove the vacuum hoses from TVV.(b) Disconnect the hoses from the canister.(c) Remove the charcoal canister from the bracket.


18. M/T:REMOVE CLUTCH RELEASE CYLINDER WITHOUTDISCONNECTING TUBE

Remove the 4 bolts, release cylinder and tube fromthe transaxle.19. REMOVE STARTER (See step 2 on page ST-15 )

14. DISCONNECT HEATER HOSES(a) Disconnect the heater inlet hose from the water outlet

housing.(b) Disconnect the heater outlet hose from the heater

radiator pipe.

17. DISCONNECT SPEEDOMETER CABLE FROMTRANSAXLE

15. DISCONNECT CONTROL CABLE(S) FROMTRANSAXLE

16. A/T:REMOVE CONTROL CABLE BRACKET


20. DISCONNECT ENGINE WIRE HARNESS(a) Disconnect the following connectors and wires:• Oxygen sensor connector• Oil pressure switch connector• Engine coolant temperature sender gauge con-

nector• Engine coolant temperature sensor connector• M /T:

Backup light switch connector• A/T:

Park/Neutral position switch connector• Distributor connectors• Engine coolant temperature switch connector• California only:

Throttle opener VSV connector• 3 VSV connectors• California only:

EGR gas temperature sensor connector• w/ A/C

A/C idle-up VSV connector• Wiper motor connector• MAP sensor connector• Igniter connector• 4 injector connectors• Throttle position sensor connector• Ground strap from the cylinder head (Bolt)• Starter connector and wire• Generator connector and wire(b) Disconnect the 8 clamps and engine wire harness.

21. REMOVE BOLT, GROUND STRAP AND VACUUMTRANSMITTING VALVES WITH BRACKET

22. w/PS:REMOVE PS PUMP WITHOUT DISCONNECTINGHOSES

(a) Remove the PS drive belt.(b) Remove the 2 bolts, and disconnect the PS pump from

the engine.HINT: Put aside the PS pump, and suspend it.


23. w/ A/C:REMOVE A/C COMPRESSOR AND MOUNTINGBRACKET

(a) Disconnect the compressor connector.(b) w/o PS:

Remove the compressor drive belt.(c) Remove the 4 compressor mounting bolts.

HINT: Put aside the compressor, and suspend it.

24. DISCONNECT FRONT EXHAUST PIPE(a) Remove the 2 bolts and disconnect the exhaust pipe

stay.

26. REMOVE ENGINE WITH TRANSAXLE FROMVEHICLE

(a) Attach the hoist chain to the engine hangers.

(b) Remove the 2 nuts and disconnect the exhaust pipe.25. REMOVE DRIVE SHAFTS (See page SA-20 )

(d) Remove the 4 bolts and compressor mounting brack-et.

-ENGINE ENGINE MECHANICAL .EG-57

(e) Using a 14 mm deep socket wrench, remove the nut.(f) Remove the 2 bolts and RH mounting insulator.

(g) Remove the bolt and disconnect the ground strap.

(b) Remove the rear mounting insulator through bolt.

(d) Remove the RH mounting insulator through bolt.

(c) Remove the 3 bolts and rear mounting insulator.


27. A/T:REMOVE6 TORQUE CONVERTER CLUTCHMOUNTING BOLTS

(a) Remove the engine rear end plate hole cover.(b) Turn the crankshaft to gain access to each bolt.(c) Hold the crankshaft pulley bolt with a wrench.(d) Remove the 6 bolts.28. SEPARATE ENGINE AND TRANSAXLE

(i) Lift the engine out of the vehicle slowly and carefully.HINT: Clear the battery carrier support while loweringthe transaxle.

(j) Place the engine with the transaxle onto the stand.

(h) Remove the 5 bolts and LH mounting bracket.


COMPONENTS FOR DISASSEMBLY ANASSEMBLY


5. w/ PS:REMOVE PS PUMP ADJUSTING STRUT

6. REMOVE TIMING BELT7. REMOVE CYLINDER HEAD8. REMOVE OIL DIPSTICK GUIDE AND GENERATOR

ADJUSTING BAR

PREPARATION FOR DISASSEMBLY(See Components for Disassembly and Assembly)1. M/T:

REMOVE CLUTCH COVER AND DISC2. REMOVE FLYWHEEL (M/T) OR DRIVE PLATE (A/T)

3. REMOVE REAR END PLATE4. INSTALL ENGINE TO ENGINE STAND FOR

DISASSEMBLY

9. REMOVE WATER PUMP WITH WATER INLET PIPE

10. REMOVE GENERATOR BRACKET


13. REMOVE OIL PRESSURE SWITCH14. REMOVE OIL PUMP AND PRESSURE REGULATOR

VALVE (See page EG-235 )

15. REMOVE OIL FILTER UNIONUsing a 12 mm hexagon wrench, remove the oil filterunion.

11. REMOVE RH ENGINE MOUNTING BRACKET12. REMOVE OIL FILTER


2. CHECK CONNECTING ROD THRUST CLEARANCEUsing a dial indicator, measure the thrust clearancewhile moving the rod back and forth.Standard thrust clearance:0.15 - 0.35 mm (0.0059 - 0.0138 in.)Maximum thrust clearance:0.45 mm (0.0177 in.)If the thrust clearance is greater than maximum, re-place the connecting rod assembly, If necessary, re-place the crankshaft.3. REMOVE CONNECTING ROD CAPS AND CHECK

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

marks on the rod cap to ensure correct reassembly.

CYLINDER BLOCK DISASSEMBLY(See Components for Disassembly and Assembly)1. REMOVE REAR OIL SEAL RETAINERRemove the 4 bolts and rear oil seal retainer.

(c) Using a soft-faced hammer, lightly tap the connect-ing rod bolt and lift the cap and lower bearing.HINT: Keep the lower bearing inserted with the con-necting rod cap.

(b) Remove the connecting rod cap nuts.


(h) Align the punched marks on the rod and cap.(i) Install and alternately tighten the nuts of the connect-

ing rod cap in several passes.Torque: 39 N �m (400 kgf �cm. 29 ft �lbf)HINT:

• Do not turn the crankshaft.• Apply a light coat of engine oil on the nut threads

and under the head of the nut before installation.(j) Remove the connecting rod cap.

(See procedure (b) and (c) above)

(e) Clean the crank pin and bearing.(f) Check the crank pin bearing for pitting and scratches.

If the crank pin or bearing damaged, replace the bear-ings. If necessary, grind or replace the crankshaft.

(d) Cover the connecting rod bolts with a short piece ofhose to protect the crankshaft from damage.

(g) Lay a strip of Plastigage across the crank pin.


(k) Measure the Plastigage at its widest point.Standard oil clearance:STD0.016 - 0.048 mm (0.0006 - 0.0019 in.)U/S 0.250.015 - 0.058 mm (0.0006 - 0.0023 in.)Maximum thrust clearance:0.08 mm (0.0031 in.)

If the oil clearance is greater than maximum, replacethe bearings. If necessary, grind or replace the crank-shaft.

HINT: If replacing the bearing, replace with one havingthe same number as marked on the bearing cap.There are 3 sizes of standard bearings supplied,marked 1, 2 or 3 respectively.(1) Completely remove the Plastigage.

4. PUSH OUT PISTON AND CONNECTING RODASSEMBLIES

(a) Using a ridge reamer, remove all the carbon from thetop of the cylinder.

46.007 - 46.014(1.8113 -1.8116)

1.487 - 1.491(0.0585 - 0.0587)

42.745 - 42.755(1.6829 - 1.6833)

1.609 - 1.615(0.0633 - 0.0636)

46.000 - 46.021(1.8110 - 1.8118)

46.01 4 - 46.021(1.8116 - 1.8118)

1.495 - 1.499(0.0589 - 0.0590)

42.985 - 43.000(1.6923 - 1.6929)

Bearing centerwall thickness

Big end innerdiameter

Crank pindiameter

Reference mm (in.)

U/S0.25

Size

46.000 - 46.007(1.8110 - 1.8113)

1.491 - 1.495(0.0587 - 0.0589)


5. CHECK CRANKSHAFT THRUST CLEARANCEUsing a dial indicator, measure the thrust clearancewhile prying the crankshaft back and forth with ascrewdriver.Standard thrust clearance:0.02 - 0.20 mm (0.0008 - 0.0079 in.)Maximum thrust clearance:0.3 mm (0.012 in.)If the clearance is greater than maximum, replace thethrust washers as a set.Oversize thrust washer:O/S 0.125Thrust washer thickness:STD2.43 - 2.48 mm (0.0957 - 0.0976 in.)O/S 0.1252.493 - 2.543 mm (0.0981 - 0.1001 in.)

(b) Cover the rod bolts with a short piece of hose toprotect the crankshaft from damage.

(c) Push out the piston and connecting rod assembly andthe upper bearing through the top of the cylinderblock.

HINT:• Keep the bearing, connecting rod and cap togeth-

er.• Arrange the piston and connecting rod assembl-

ies in the correct order.

6. REMOVE MAIN BEARING CAPS AND CHECK OILCLEARANCE

(a) Uniformly loosen and remove the main bearing capbolts in several passes, in the sequence shown.


(b) Using the removed main bearing cap bolts, pry themain bearing cap back and forth, and remove the mainbearing caps, lower bearings and thrust washers (No.3 main bearing cap only).HINT:

• Keep the lower bearing inserted together withcap.

• Arrange the main bearing caps and lower thrustwashers in correct order.

(c) Lift out the crankshaft.HINT: Keep the upper bearings and upper thrust washers together with the cylinder block.

(d) Clean each main journal and bearing.(e) Check each main journal and bearing for pitting and

scratches.If the journal or bearing is damaged, replace the bear-ing.If necessary, grind or replace the crankshaft.

(h) Install the main bearing cap.(See step 4 on page EG-81 )Torque: 57 N �m (580 kgf �cm, 42 ft �lbf)HINT: Do not turn the crankshaft.

(f) Place the crankshaft on the cylinder block.(g) Lay a strip of Plastigage across each journal.


(j) Measure the Plastigage at its widest point.Standard oil clearance:STD0.016 - 0.035 mm (0.0006 - 0.0014 in.)U/S 0.250.015 - 0.55 mm (0.0006 - 0.0022 in.)Maximum oil clearance:0.08 mm (0.0031 in.)HINT: If replacing the cylinder block subassembly, thebearing standard clearance will be: 0.018-0.045 mm(0.0007-0.0018 in.)HINT: If the oil clearance is greater than maximumreplace the bearings. If necessary, grind or replace thecrankshaft.

HINT: If replacing a standard size bearing with a sta-ndard oil clearance, replace with one having the samenumber. If the number of the bearing cannot be deter-mined, select a bearing from the table below accord-ing to the numbers imprinted on the cylinder blockand crankshaft.

(i) Remove the bearing caps with the lower bearing andlower thrust washers.(See procedure (a) and (b))

EXAMPLE: Cylinder block ”2” + Crankshaft ”1”=Total number (Use bearing ”3”)

Cylinder Block

Crankshaft

Bearing


7. REMOVE CRANKSHAFT(a) Lift out the crankshaft.(b) Remove the upper main bearings and upper thrust

washers from the cylinder block.

HINT: Arrange the main bearing caps, bearings andthrust washers in correct order.

(k) Completely remove the Plastigage.

1.997 - 2.000(0.0786 - 0.0787)

49.745 - 49.755(1.9585 - 1.9589)

2.118 - 2.124(0.0834 - 0.0836)

49.991 - 49.995(1.9681 - 1.9683)

49.996 - 50.000(1.9683 - 1.9685)

2.001 - 2.003(0.0788 - 0.0789)

54.018 - 54.024(2.1267 - 2.1269)

2.004 - 2.006(0.0789 - 0.0790)

49.985 - 49.990(1.9679 - 1.9681)

2.010 - 2.012(0.0791 - 0.0792)

54.030 - 54.036(2.1272 - 2.1274)

54.024 - 54.030(2.1269 - 2.1272)

2.007 - 2.009(0.0790 - 0.0791)

Cylinder blockmain journal bore

54.018 - 54.036(2.167 - 2.1274)

Bearing centerwall thickness

Main journaldiameter

(Reference) mm (in.)

U/S0.25

Size


3. INSPECT TOP OF CYLINDER BLOCK FORFLATNESS

Using a precision straight edge and thickness gauge,measure the surface contacting the cylinder headgasket for warpage.Maximum warpage:0.05 mm (0.0020 in.)If warpage is greater than maximum, replace the cylin-der block.

CYLINDER BLOCK INSPECTION1. REMOVE GASKET MATERIALUsing a gasket scraper, remove all gasket materialfrom the cylinder block surface.2. CLEAN CYLINDER BLOCKUsing a soft brush and solvent, clean the cylinderblock.

5. INSPECT CYLINDER BORE DIAMETERHINT: There are 3 sizes of the standard cylinder borediameter, marked ”1”, ”2” and ”3”, accordingly. Themark is stamped on the cylinder block.

4. INSPECT CYLINDER FOR VERTICAL SCRATCHESVisually inspect cylinders for vertical scratches.If deep scratches are present, rebore all 4 cylinders.If necessary, replace the cylinder block.


Using a cylinder gauge, measure the cylinder borediameter at position A, B and C in the thrust and axialdirections.Standard diameter:STDMark ’1’73.00 - 73.01 mm (2.8740 - 2.8744 in.)Mark ”2”73.01 - 73.02 mm (2.8744 - 2.8748 in.)Mark ”3’73.02 - 73.03 mm (2.8748 - 2.8752 in.)Maximum diameter:STD73.23 mm (2.8831 in.)O/S 0.5073.73 mm (2.9028 in.)If the diameter is greater than maximum, rebore all 4cylinders. If necessary, replace the cylinder block.

PISTON AND CONNECTING RODASSEMBLIES DISASSEMBLY(See Components for Disassembly and Assembly)1. CHECK FIT BETWEEN PISTON AND PIN

Try to move the piston back and forth on the pistonpin.If any movement is felt, replace the piston and pin asset.

6. REMOVE CYLINDER RIDGEIf the wear is less than 0.2 mm (0.008 in.), use a ridgereamer to machine the piston ring ridge at top of thecylinder.

2. REMOVE PISTON RINGS(a) Using a piston ring expander, remove the compression

rings.


PISTON AND CONNECTING RODASSEMBLIES INSPECTION1. CLEAN PISTON(a) Using a gasket scraper, remove the carbon from the

piston top.

3. DISCONNECT CONNECTING ROD FROM PISTONUsing SST, press out the piston pin from the piston.Remove the connecting rod.SST 09221- 25024 (09221 -00020, 09221 -00030,09221 -00130, 09221 -00140, 09221 -00150)

HINT:• The piston and pin are a matched set.• Arrange the pistons, pins, rings, connecting rods

and bearings in correct order.

(b) Remove the 2 side rails and oil ring expander by hand.HINT: Arrange the rings in the correct order only.

(b) Using a groove cleaning tool or broken ring, clean thering grooves.


HINT: There are 3 sizes of the standard piston diame-ter, marked ’1’, ”2”, and ”3”, accordingly. The mark isstamped on the top of the piston.Piston diameter:STDMark ’1’72.92 - 72.93 mm (2.8708 - 2.8712 in.)Mark ”2”72.93 - 72.94 mm (2.8712 - 2.8716 in.)Mark ”3”72.94 - 72.95 mm (2.8716 - 2.8710 in.)O/S 0.5073.42 - 73.45 mm (2.8905 - 2.8917 in.)(b) Measure the cylinder bore diameter in thrust direc-

tions. (See page EG-71 )(c) Subtract the piston diameter measurement from the

cylinder bore diameter measurement.Standard oil clearance:0.07 - 0.09 mm (0.0028 - 0.0035 in.)Maximum oil clearance:0.20 mm (0.0079 in.)

If the oil clearance is greater than maximum, replaceall 4 pistons and/or rebore all 4 cylinders.HINT: (Use cylinder block)When installing a standard piston, install one with thesame mark as the standard bore diameter marked onthe cylinder block.

2. INSPECT PISTON DIAMETER AND OIL CLEARANCE(a) Using a micrometer, measure the piston diameter at

right angles to the piston pin center line, 23 mm (0.91in.) from the piston head.

(c) Using a soft brush and solvent, thoroughly clean thepiston.NOTICE: Do not damage the piston.


4. INSPECT PISTON RING END GAP(a) Insert the piston ring into the cylinder bore.(b) Using a piston, push the piston ring a little beyond the

bottom of the ring travel, 110 mm (4.33 in.) from thetop of the cylinder block.

(c) Using a thickness gauge, measure the end gap.Maximum thrust clearance:No.10.26 - 0.48 mm (0.0102 - 0.0189 in.)No.20.30 - 0.57 mm (0.0118 - 0.224 in.)Oil (Side rail)0.15 - 0.52 mm (0.0059 - 0.0205 in.)Maximum end gap:No.11.08 mm (0.0425 in.)No.21.17 mm (0.0461 in.)

Oil (Side rail)1.12 mm (0.0441 in.)If the end gap is greater than maximum, replace thepiston ring. If the end gap is greater than maximum,even with a new piston ring, refore all 4 cylinders anduse 0/S piston ring. If necessary, replace the cylinderblock.

3. INSPECT CLEARANCE BETWEEN WALL OF RINGGROOVE AND NEW PISTON RING

Using a thickness gauge, measure the clearance be-tween new piston ring and the wall of the piston ringgroove.Piston ring groove clearance:No.10.04-0.08mm(0.0016-0.0031 in.)No.20.03 - 0.07 mm (0.0012 - 0.0028 in.)If the clearance is not within specification, replace thepiston.


CYLINDERS BORINGHINT:• Bore all 4 cylinder for the oversized piston out-

side diameter.• Replace the piston rings with ones to match the

oversized pistons.1. KEEP OVERSIZED PISTONS

Oversized piston diameter:O/S 0.5073.42 - 73.45 mm (2.8905 - 2.8917 in.)

2. CALCULATE AMOUNT TO BORE CYLINDERS(a) Using a micrometer, measure the piston diameter at a

right angle to the piston pin center line, 23 mm (0.91in.) from the piston head.

(b) Calculate the amount each cylinder is to be rebored asfollows.Size to be rebored = P + C - HP=piston diameterC=piston clearance0.07 - 0.09 mm (0.0028 - 0.0035 in.)H=allowance for honing0.02 mm (0.0008 in.) or less

3. BORE AND HONE CYLINDERS TO CALCULATEDDIMENSIONSAmount of honing:

0.02 mm (0.0008 in.) maximumNOTICE: Excess honing will destroy the finished round-ness.

5. INSPECT CONNECTING RODSUsing a rod aligner, check the connecting rod align-ment.• Check for bend.

Maximum bend:0.30 mm (0.0012 in.) per 100 mm (3.94 in.)

If bend is greater than maximum, replace the connect-ing rod assembly.

• Check for twistMaximum twist:0.05 mm (0.0020 in.) per 100 mm (3.94 in.)If twist is greater than maximum, replace the connect-ing rod assembly.HINT: If replacing the connection rods, replace thesame number of connecting rod bearings as that ofnew connecting rod caps.


CRANKSHAFT INSPECTION AND REPAIR1. INSPECT CRANKSHAFT FOR RUNOUT(a) Place the crankshaft on V-blocks.(b) Using a dial indicator, measure the circle runout at the

center journal.Maximum circle runout:0.06 mm (0.0024 in.)If the circle runout is greater than maximum, replacethe crankshaft.

2. INSPECT MAIN JOURNALS AND CRANK PINS(a) Using a micrometer, measure the diameter of each

main journal and crank pin.Main journal diameter:STD49.985 - 50.000 mm (1.9679 - 1.9685 in.)U/S 0.2549.745 - 49.755 mm (1.9585 - 1.9589 in.)Crank pin diameter:STD42.985 - 43.000 mm (1.6923 - 1.6929 in.)U/S 0.2542.745 - 42.755 mm (1.6829 - 1.6833 in.)If the diameter is not as specified, check the oil clear-ance (See pages EM-63 to EM-65). If necessary, grind orreplace the crankshaft.

(b) Check each main journal and crank pin for taper andout-of-round as shown.Maximum taper:0.08 mm (0.0031 in.)Maximum out-of-round:0.07 mm (0.0028 in.)If the taper and out-of-round is greater than maxi-mum, replace the crankshaft.

3. IF NECESSARY, GRIND AND HONE MAINJOURNALS AND/OR CRANK PINSGrind and hone the main journals and/or crank pins tothe finished undersized diameter (See procedure step2).Install new main journal and/or crank pin undersizedbearings.


B. If oil pump is installed to the cylinder block:(a) Using a knife, cut off the oil seal lip.(b) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft.Tape the screwdriver tip.

CRANKSHAFT OIL SEALS REPLACEMENTHINT: There are 2 methods (A and B) to replace the oilseal which are as follows:

(b) Using SST and a hammer, tap in a new oil seal until itssurface is flush with the oil pump case edge.SST 09309-37010

(c) Apply MP grease to the oil seal lip.

(c) Apply MP grease to a new oil seal lip.(d) Using SST and a hammer, tap in the oil seal until its

surface is flush with the oil pump case edge.SST 09309-37010

1. REPLACE CRANKSHAFT FRONT OIL SEALA. If oil pump is removed from cylinder block:

(a) Using a screwdriver, pry the oil seal.


B. If rear oil seal retainer is installed to cylinder block:(a) Using a knife, cut off the oil seal lip.(b) Using a screwdriver, pry out the oil seal.

NOTICE: Be careful not to damage the crankshaft.Tape the screwdriver tip.

(b) Using SST and a hammer, tap in a new oil seal until itssurface is flush with the rear oil seal edge.SST 09223-41020

(c) Apply MP grease to the oil seal lip.

(c) Apply MP grease to a new oil seal lip.(d) Using SST and a hammer, tap in tee oil seal until its

surface is flush with the rear oil seal retainer edge.SST 09223-41020

2. REPLACE CRANKSHAFT REAR OIL SEALA. If rear oil retainer is removed from cylinder block:

(a) Using a screwdriver and hammer, tap out the oil seal.


(d) After installing the piston pin, check that when theconnecting rod is aligned with the center of the pistonthe space between the piston and each end of thepiston pin are equal on the left and right sides.HINT: If the piston pin is off-center due to insuffi-cient insertion pressure on the piston pin, place awasher at the position indicated by � in the illustra-tion for (c). Then, while checking that the space isequal at the ends of the piston pin on the left and rightsides, press in the washer.

2. INSTALL PISTON RINGS(a) Install the oil ring expander and 2 side rails by hand.

PISTON AND CONNECTING ROD ASSYASSEMBLY1. ASSEMBLE PISTON AND CONNECTING ROD(a) Coat the piston pin and pin holes of the piston with

engine oil.(b) Align the cavity on the piston with the protrusion on

the connecting rod.

(b) Using a piston ring expander, install the 2 compres-sion rings with the code mark facing upward.Code mark:No.1T, 1N or 1RNo.22T, 2N or 2R

(c) Using SST, press in the piston pin.SST 09221- 25024 (09221 -00020, 09221 -00030,09221 -00130, 09221- 00140, 09221 -00150)


3. INSTALL BEARINGS(a) Align the bearing claw with the groove of the connect-

ing rod or connecting cap.(b) Install the bearings in the connecting rod and con-

necting rod cap.

(c) Position the piston rings so that the ring ends are asshown.NOTICE: Do not align the end gaps.


CYLINDER BLOCK ASSEMBLY(See Components for Disassembly and Assembly)HINT:• Thoroughly clean all parts to be assembled.• Before installing the parts, apply new engine oil

to all sliding and rotating surfaces.• Replace all gaskets, O-rings and oil seals with

new parts.

1. INSTALL MAIN BEARINGS(a) Align the bearing claw with the claw groove of the

main bearing cap or cylinder block.(b) Install the bearings in the cylinder block and main

bearing cap.NOTICE: Install the bearing with the oil hole in the cylin-der block.

4. INSTALL MAIN BEARING CAPS AND LOWERTHRUST WASHERS

(a) install the thrust washers on the No.3 bearing capwith the grooves facing outward.

2. INSTALL UPPER THRUST WASHERSInstall the thrust washers under the No.3 main bearingcap position of the block with the oil grooves facingoutward.

3. PLACE CRANKSHAFT ON CYLINDER BLOCK


(c) Apply a light coat of engine oil on the threads andunder the heads of the main bearing caps.

(d) Install and uniformly tighten the 10 bolts of the mainbearing caps in several passes, in the sequenceshown.Torque: 57 N �m (580 kgf �cm, 42 ft �lbf)

(e) Check that the crankshaft turns smoothly.(f) Check the crankshaft thrust clearance.

(See step 5 on page EG-66 )

6. INSTALL CONNECTING ROD CAPS(a) Match the numbered connecting rod cap with the

numbered connecting rod.(b) Install the connecting rod cap with the front mark

facing forward.

5. INSTALL PISTON AND CONNECTING RODASSEMBLIES

(a) Cover the connecting rod bolts with a short piece ofhose to protect the crankshaft from damage.

(b) Using a piston ring compressor, push the correctlynumbered piston and connecting rod assemblies intoeach cylinder with the front mark of the piston facingforward.

(b) Install the 5 main bearing caps in their proper loca-tions.HINT: Each bearing cap has a number and front mark.


(c) Apply a light coat of engine oil on the threads andunder the nuts of the connecting rod cap.

(d) Install and alternately tighten the nuts of the connect-ing rod cap in several passes.Torque: 39 N �m (400 kgf �cm, 29 ft �lbf)

(e) Check that the crankshaft turns smoothly.(f) Check the connecting rod thrust clearance.

(See step 2 on page EG-63 )7. INSTALL REAR OIL SEAL RETAINER(a) Remove any old packing (FIPG) material and be care-

ful not to drop any oil on the contact surfaces of therear oil seal retainer and cylinder block.

• Using a razor blade and gasket scraper, removeall the old packing (FIPG) material from thegasket surfaces and sealing groove.


• Using a non-residue solvent, clean both sealingsurfaces.

(b) Apply seal packing to the rear oil seal retainer asshown in the illustration.Seal packing:Part No.08826-00080 or equivalent• Install a nozzle that has been cut to a 2-3 mm

(0.08-0.12 in.) opening.

• Parts must be assembled within 5 minutes ofapplication. Otherwise the material must be re-moved and reapplied.


(c) Install the oil seal retainer with the 4 bolts.Torque: 7.4 N �m (75 kgf �cm, 65 in. �lbf)


3. INSTALL OIL PRESSURE SWITCH(a) Clean the switch threads and cylinder block switch

holes of any sealer, oil or foreign materials.Remove any oil with kerosene or gasoline.

(b) Apply adhesive to 2 or 3 threads of the switch end.Adhesive:Part No.08833-00080, THREE BOND 1344,LOCTITE 242 or equivalentHINT:

• This adhesive will not harden while exposed toair.

• It will act as a sealer or binding agent only whenapplied to threads, etc. and is cut off.

(c) Install the oil pressure switch.4. INSTALL OIL FILTER (See page EG-233 )

POST ASSEMBLY1. INSTALL OIL FILTER UNION

Using a 12 mm hexagon wrench, install the oil filterunion.Torque: 25 N �m (250 kgf �cm, 18 ft �lbf)

2. INSTALL OIL PUMP AND PRESSURE REGULATORVALVE (See page EG-235 )

5. INSTALL RN ENGINE MOUNTING BRACKETTorque: 58 N �m (590 kgf �cm, 43 ft �lbf)

6. INSTALL GENERATOR BRACKETTorque: 18 N �m (185 kgf �cm, 13 ft �lbf)


(b) Install the flywheel on the crankshaft.(c) Install and uniformly tighten the mounting bolts in

several passes, in the sequence shown.Torque: 88 N �m (900 kgf �cm, 65 ft �lbf)

15. A/T:INSTALL DRIVE PLATE (See procedure in step 14)

16. M/T:INSTALL CLUTCH DISC AND COVER (See page CL-19)

14. M/T:INSTALL FLYWHEEL

(a) Apply adhesive to 2 or 3 threads of new mounting boltend.Adhesive:Part No.08833-00070, THREE BOND 1324 orequivalent

7. INSTALL WATER PUMP WITH WATER INLET PIPE8. INSTALL OIL DIPSTICK GUIDE AND GENERATOR

ADJUSTING BAR9. INSTALL CYLINDER HEAD10. INSTALL TIMING BELT

11. w/PS:INSTALL PS PUMP ADJUSTING STRUTTorque: 21 N �m (210 kgf �cm, 15 ft �lbf)

12. REMOVE ENGINE STAND

13. INSTALL REAR END PLATETorque: 10 N �m (100 kgf �cm, 7 ft �lbf)


ENGINE INSTALLATION(See Components for Removal and Installation)1. A/T:

CHECK TORQUE CONVERTER CLUTCHINSTALLATIONUsing calipers and a straight edge, measure from theinstalled surface of the torque converter clutch to thefront surface of transmission housing.Standard correct distance:13.4 mm (0.528 in.) or moreIf the distance is less than standard, check for improp-er installation.

2. INSTALL TRANSAXLE TO ENGINETorque: 64 N �m (650 kgf �cm, 47 ft �lbf)

4. INSTALL ENGINE WITH TRANSAXLE IN VEHICLE(a) Attach the hoist chain to the engine hanger on the

engine.(b) Lower the engine into the engine compartment.

• Tilt the transaxle downwards, lower the engineand clear the battery carrier support.

NOTICE: Be careful not to hit to the park/neutral posi-tion switch (A/T) or power steering gear housing.

(c) Install the LH mounting bracket to the transaxle andmounting insulator with the 5 bolts.Bracket x Transaxle (Bolt head: NT)Torque: 49 NSm (500 kgfScm, 36 ftSIbf)Bracket x Insulator (Bolt head: 7T)Torque: 48 NSm (490 kgfScm, 35 ftSIbf)

3. A/T:INSTALL 6 TORQUE CONVERTER CLUTCHMOUNTING BOLTS

(a) First, install the gray bolt and then 5 bolts.(b) Tighten the bolts evenly.



(f) Install the RH mounting insulator to the engine mount-ing bracket with the 2 bolts.Torque: 64 N �m (650 kgf �cm. 47 ft �lbf)

(g) Using a 14 mm deep socket wrench, install the nut.Torque: 64 N �m (650 kgf �cm, 47 ft �lbf)

(i) Install the rear mounting insulator to the body withthe 3 bolts.Torque: 78 N �m (800 kgf �cm, 58 ft �lbf)

(h) Install the RH mounting insulator through bolt.Torque: 73 N �m (740 kgf �cm, 54 ft �lbf)

(e) Tighten the bolt as shown in the illustration.Torque: 48 N �m (490 kgf �cm, 35 ft �lbf)

(d) Connect the ground strap with the bolt.


(b) Install the A/C compressor to the bracket with the 4bolts.Torque: 25 N �m (250 kgf �cm, 18 ft �lbf)

(c) W/o PS:Install the drive belt. (See page MA-7 )

(d) Connect the A/C compressor connector.

7. w/ A/C:INSTALL A/C COMPRESSOR AND MOUNTINGBRACKET

(a) Install the compressor mounting bracket with the 4bolts.Torque: 27 N �m (280 kgf �cm, 20 ft �lbf)

6. CONNECT FRONT EXHAUST PIPE(a) Place a new gasket on the exhaust pipe.(b) Connect the exhaust pipe to exhaust manifold with 2

new nuts.Torque: 62 N �m (630 kgf �cm, 46 ft �lbf)

(j) Install the rear mounting insulator through bolt.Torque: 64 N �m (650 kgf �cm, 47 ft �lbf)

(k) Remove the hoist chain from the engine.5. CONNECT DRIVE SHAFTS (See page SA-23 )

(c) Install the exhaust pipe stay to the cylinder block withthe 2 bolts.Torque: 19 N �m (195 kgf �cm, 14 ft �lbf)


9. INSTALL VACUUM TRANSMITTING VALVES WITHBRACKET AND GROUND STRAP

10. CONNECT ENGINE WIRE HARNESS(a) Connect the engine wire harness with the 8 clamp.(b) Connect the following connectors and wires:

• Oxygen sensor connector

• Oil pressure switch connector

• Engine coolant temperature sender gauge con-nector

• Engine coolant temperature sensor connector

• M/T:Backup light switch connector

• A/T:Park/Neutral position switch connector

• Distributor connectors

• Engine coolant temperature switch connector

• California only:Throttle opener VSV connector

• 3 VSV connectors

• California only:EGR gas temperature sensor connector

• w/ A/C:A/C idle-up VSV connector

• Wiper motor connector

• MAP sensor connector

• Igniter connector

• 4 injector connectors

• Throttle position sensor connector

• Ground strap from the cylinder head (Bolt)

• Starter connector and wire

• Generator connector and wire11. INSTALL STARTER

(See step 1 on page ST-26 )

8. w/PS:INSTALL PS PUMP

(a) Install the PS pump and drive belt with the 2 bolts.A boltTorque: 43 N �m (440 kgf �cm, 32 ft �lbf)B boltTorque: 39 N �m (400 kgf �cm, 29 ft �lbf)


16. CONNECT HEATER HOSES(a) Connect the heater outlet hose to the heater radiator

pipe.(b) Connect the heater inlet hose to the water outlet

housing.

12. M/T:INSTALL CLUTCH RELEASE CYLINDER

Install the release cylinder and tube with the 4 bolts.Torque: 12 N �m (120 kgf �cm, 9 ft �lbf)

14. A/T:INSTALL CONTROL CABLE BRACKET

15. CONNECT CONTROL CABLE(S) TO TRANSAXLE

13. CONNECT SPEEDOMETER CABLE TO TRANSAXLE


19. CONNECT FUEL HOSES(a) Connect the fuel return hose.(b) Connect the fuel inlet with the union bolt and 2 gas-

kets.Torque: 29 N �m (300 kgf �cm, 22 ft �lbf)

20. A/T:CONNECT THROTTLE CABLE, AND ADJUST IT21. CONNECT ACCELERATOR CABLE, AND ADJUST IT

22. INSTALL RADIATOR(See page EG-219 )

23. FILL WITH ENGINE COOLANT24. INSTAL ENGINE UNDER COVERS25. INSTALL AIR CLEANER BRACKET26. INSTALL AIR CLEANER ASSEMBLY WITH AIR

INTAKE CONNECTOR27. INSTALL PCV HOSES28. INSTALL HOOD29. INSTALL BATTERY AND RADIATOR RESERVOIR

TANK

17. CONNECT FOLLOWING HOSES:(a) Brake booster hose(b) MAP sensor hose(c) w/ A/C:

A/C idle-up hoses(d) Idle-up vacuum transmitting hoses

HINT: When connecting the hoses to the VSV, con-nect the atmospheric-side hose (marked with whitepaint) on the inner side, as shown in the illustration.

(e) w/ PS:PS idle-up air hoses.

18. INSTALL CHARCOAL CANISTER(a) Install the charcoal canister to the bracket.(b) Connect the canister hoses.(c) Install the vacuum hoses to the TVV.


30. START ENGINE AND CHECK FOR LEAKS31. PERFORM ENGINE ADJUSTMENT

(See page EG -10)32. PERFORM ROAD TEST

Check for abnormal noise, shock, slippage, correctshift points and smooth operation.

33. RECHECK ENGINE COOLANT AND ENGINE OILLEVELS


EXHAUST SYSTEMCOMPONENTS


92.26 mm (3.6223 in.)91.80 mm (3.6142 in.)92.26 mm (3.6223 in.)91.76 mm (3.6126 in.)91.30 mm (3.5945 in.)91.76 mm (3.6126 in.)44.5°

5.970 - 5.985 mm (0.2350 - 0.2356 in.)5.965 - 5.980 mm (0.2348 - 0.2354 in.)0.025 - 0.060 mm (0.0010 - 0.0024 in.)0.030 - 0.065 mm (0.0012 - 0.0026 in.)0.08 mm (0.0031 in.)0.10 mm (0.0039 in.)0.8 mm (0.031 in.)

0.08 - 0.18 mm (0.0031 - 0.0071 in.)0.25 mm (0.0098 in.)0.037 - 0.073 mm (0.0015 - 0.0029 in.)0.10 mm (0.0039 in.)26.979 - 26.995 mm (1.0622 - 1.0628 in.)0.04 mm (0.0016 in.)35.35 - 35.45 mm (1.3917 - 1.3957 in.)35.15 mm (1.3839 in.)34.91 - 35.01 mm (1.3744 - 1.3783 in.)34.17 mm (1.3665 in.)35.83 - 35.93 mm (1.4106 - 1.4116 in.)35.63 mm (1.4028 in.)

STDLimitSTDLimitSTDLimit

STD Intake (Main)(Sub)

ExhaustLimit Intake (Main)

(Sub)Exhaust

0.05 mm0.05 mm30°, 45°, 75°

60°

45°

1.2 - 1.6 mm (0.047 - 0.063 in.)

6.01 - 6.03 mm (0.2366 - 0.2374 in.)11.048 - 11.059 mm (0.4350 - 0.4354 in.)11.098 - 11.109 mm (0.4369 - 0.4374 in.)20°C (68°F)

at 250 rpm STDLimit

Difference of pressure between each cylinder

STD0/S 0.05

Replacing Temperature (Cylinder head side)

SERVICE SPECIFICATIONSSERVICE DATA

STD (Intake Main)(intake Sub)

(Exhaust)Limit (Intake Main)

(Intake Sub)(Exhaust)

Free lengthInstalled load at 35.16 mm (1.3842 in.)Deviation

1,270 kPa (13.0 kgf/cm2, 184 psi)981 kPa (10.0 kgf/cm2, 142 psi)98 kPa (1.0 kgf/cm2, 14 psi) or less

IntakeExhaust

STD(Intake)Exhaust

Limit (Intake)(Exhaust)

Limit

41.52 mm (1.6346 in.)156 N (15.91 kgf, 35.1 lbf)2.0 mm (0.079 in.)

Warpage Cylinder block sideManifold sideValve seat

Journal diameterCircle runoutCam lobe height

0.05 mm (0.0020 in.)0.2 mm (0.0079 in.)

Contacting angleContacting width

LimitLimit

intakeExhaust

Inside diameterOutside diameter

Intake andexhaustmanifolds

Valve face angleStem diameter

Valve head margin thickness

Compressionpressure

Valve guidebushing

Journal oil clearance

Valve overall length

Stem oil clearance

Thrust clearance

IntakeExhaust

Refacing angle

Cylinder head

Valve spling

Warpage

Camshaft

Valve

Limit


Thrust clearance

Big end inner diameter STD No. 1

Connecting rod bearing center wallthickness

Bearing oil clearance STD

Rod bendRod twist

72.92 - 72.93 mm (2.8708 - 2.8712 in.)72.93 - 72.94 mm (2.8712 - 2.8716 in.)72.94 - 72.95 mm (2.8716 - 2.8720 in.)73.42 - 73.45 mm (2.8905 - 2.8917 in.)0.07 - 0.09 mm (0.0028 - 0.0035 in.)0.26 - 0.48 mm (0.0102 - 0.0189 in.)0.30 - 0.57 mm (0.0118 - 0.0224 in.)0.15 - 0.52 mm (0.0059 - 0.0205 in.)1.08 mm (0.0425 in.)1.17 mm (0.0461 in.)1.12 mm (0.0441 in.)0.04 - 0.08 mm (0.0016 - 0.0031 in.)0.03 - 0.07 mm (0.0012 - 0.0028 in.)20°C (68°F)

1.487 - 1.491 mm (0.0585 - 0.0587 in.)1.491 - 1.495 mm (0.0587 - 0.0589 in.)1.495 - 1.499 mm (0.0589 - 0.0590 in.)1.609 - 1.615 mm (0.0633 - 0.0636 in.)0.016 - 0.048 mm (0.0006 - 0.0019 in.)0.08 mm (0.0031 in.)0.03 mm (0.0012 in.)0.05 mm (0.0020 in.)

0.15 - 0.35 mm (0.0059 - 0.0138 in.)0.45 mm (0.0177 in.)46.000 - 46.007 mm (1.8110 - 1.8113 in.)46.007 - 46.014 mm (1.8113 - 1.8116 in.)46.014 - 46.021 mm (1.8116 - 1.8118 in.)46.000 - 46.021 mm (1.8110 - 1.8118 in.)

73.23 mm (2.8831 in.)73.37 mm (2.9028 in.)54.018 - 54.024 mm (2.1267 - 2.1269 in.)54.024 - 54.030 mm (2.1269 - 2.1272 in.)54.030 - 54.036 mm (2.1272 - 2.1274 in.)54.018 - 54.036 mm (2.1267 - 2.1274 in.)

0.05 mm (0.0020 in.)73.00 - 73.01 mm (2.8740 - 2.8744 in.)73.01 - 73.02 mm (2.8744 - 2.8748 in.)73.02 - 73.03 mm (2.8748 - 2.8752 in.)

Cylinder bore wearOn standard sized pistonOn oversized piston (O/S 0.50)Cylinder block main journal bore

STD No. 1No.2

OilLimit No.1

No.2Oil

Limit No.1No.2

Free lengthInstalled load at 51.5 mm (2.028 in.)

LimitLimit

STD No. 1No.2No.3

U/S 0.25

Cylinder head surface warpageCylinder bore

Piston to cylinder clearancePiston ring end gap

STD Mark”1”Mark”2”M ark”3”O/S 0.50

LimitSTD Mark“1”

Mark”2”Mark”3”

38.4 mm (1.512 in.)50 N (5.11 kgf, 11.3 lbf)

Piston pin installing temperature

Connectingrod andbearing

Ring to ring groove clearance

Idler pulleytension spring

Piston andpiston ring Piston diameter

Cylinder block

STDLimit

STD No.1No.2No.3

U/S 0.25

STD No.1No.2No.3

U/S 0.25STDLimitLimitLimit


0.02 - 0.20 mm (0.0008 - 0.0079 in.)0.3 mm (0.012 in.)2.43 - 2.48 mm (0.0957 - 0.0976 in.)2.493 - 2.543 mm (0.0981 - 0.1001 in.)0.016 - 0.035 mm (0.0006 - 0.0014 in.)0.08 mm (0.0031 in.)49.995 - 50.000 mm (1.9683 - 1.9685 in.)49.990 - 49.995 mm (1.9681 - 1.9683 in.)49.985 - 49.990 mm (1.9679 - 1.9681 in.)49.745 - 49.755 mm (1.9585 - 1.9589 in.)1.997 - 2.000 mm (0.0786 - 0.0787 in.)2.001 - 2.003 mm (0.0788 - 0.0789 in.)2.004 - 2.006 mm (0.0789 - 0.0790 in.)2.007 - 2.009 mm (0.0790 - 0.0791 in.)2.010 - 2.012 mm (0.0791 - 0.0792 in.)2.118 - 2.124 mm (0.0834 - 0.0836 in.)42.985 - 43.000 mm (1.6923 - 1.6929 in.)42.745 - 42.755 mm (1.6829 - 1.6833 in.)0.06 mm (0.0024 in.)

STDLimitSTD

O/S 0.125STDLimit

STD No.0No.1No.2

U/S 0.25 STD No. 1

No.2No.3No.4No.5

U/S 0.25STD

U/S 0.25Limit

Crank pin diameterCrank pin finished diameterCircle runout

Main journal finished diameterMain bearing center wall thickness

Tighten the boltan additional 90_after achievingspecified torque

TORQUE SPECIFICATIONS

Cylinder block x RH engine mounting bracket

Cylinder block x Crankshaft bearing cap

Cylinder head x Camshaft bearing cap

Cylinder head x Water outlet housing

Cylinder block x Intake manifold stay

Cylinder head x No. 1 engine hanger

Cylinder head x No.2 engine hanger

Cylinder head x Cylinder head cover

Cylinder block x No.2 idler pulley

Cylinder block x No.1 idler pulley

Cylinder head x Exhaust manifold

Cylinder head x Intake manifold

Cylinder block x Water pump

Cylinder head x Delivery pipe

Cylinder block x Oil regulator

Cylinder head bolt (Second)

Cylinder block x Drain plug

Cylinder head x Spark plug

Cylinder block x Oil strainer

Cylinder block x Oil pump

Cylinder head x Distributor

Cylinder head bolt (Third)

Main journal oil clearance

Cylinder head bolt (First)

Thrust washer thickness

Crankshaftand bearing

Main journal diameter

Thrust clearance

Part tightened

61 in.�lbf

65in.�lbf

kgf�cm ft�lbf

590

210

500

520

590

300

280

580

140

180

300

100

250

190

185

175

175

195

175

175

N�m

7.4

6.9


Rear engine mounting bracket x Transaxle case (A/T)

Cylinder block x Compressure mounting bracket

Rear engine mounting bracket x Insulator (M/T)

LH engine mounting bracket x Transaxle case

RH engine mounting insulator x RH member

Valve clearance adjusting nut x Rocker arm

Cylinder block x PS pump adjusting strut

Crankshaft pulley x No.2 crankshaft pulley

LH engine mounting bracket x Insulator

RH engine mounting bracket x Insulator

Exhaust manifold x Front exhaust pipe

Rear engine mounting insulator x Body

Connecting rod x Connecting rod cap

Intake manifold x Intake manifold stay

Exhaust manifold x No.1 heat insulator

Crankshaft x Flywheel (Drive plate)

Camshaft x Camshaft timing pulley

Cylinder block x Generator bracket

Cylinder block x Exhaust pipe stay

Cylinder block x Rear end plate

Crankshaft x Crankshaft pulley

Cylinder block x Oil filter union

Oil pump pulley x Drive rotor

Oil pan x Drain plug

280

69 in.�lbf

1,550

510

800

400

490

490

370

100

900

740

650

200

650

210

630

250

250

650

195

112

185

195

152

175

7.8


Reduces blow-by gas (HC)Reduces evaporative HCReduces NOxReduces HC, CO and NOxRegulates all engine conditions for reductionof exhaust emissions.

Positive crankcase ventilationFuel evaporative emission controlExhaust gas recirculation (CALIF. only)Three-way catalystElectronic fuel injection*

EMISSION CONTROL SYSTEMS

Remarks *For inspection and repair of the EFI system, refer to the EFI section.

SYSTEM PURPOSE

PCVEVAPEG RTWCEFI

Abbreviation PurposeSystem

-ENGINE EMISSION CONTROL SYSTEMSEG-98

PREPARATIONRECOMMENDED TOOLS

SSM (SPECIAL SERVICE MATERIALS)08833-00070 Adhesive 1311,THREE BOND 1311 or equivalent

09082-00050 TOYOTA Electrical Tester Set

EQUIPMENT

Torque wrench

Vacuum gauge

Thermometer

Tachometer

TVV

Heater

TVV

TVV


LAYOUT AND SCHEMATIC DRAWINGFor Federal and Canada Vehicles:


For California Vehicles:


To reduce HC emission, crankcase blow-by gas (HC) is routed through the PCV valve to the intake manifold forcombustion in the cylinders.

POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM

Engine not Running or Backfiring

Acceleration of High LoadIdling or Decelerating

Normal Operation


PCV VALVE INSPECTION1. REMOVE PCV VALVE2. ATTACH CLEAN HOSE TO PCV VALVE3. BLOW AIR FROM CYLINDER HEAD SIDE

Check that air passes through easily.NOTICE: Do not suck air through the valve.Petroleum substances inside the valve are harmful.

PCV HOSES AND CONNECTIONSINSPECTIONVISUALLY INSPECT HOSES, CONNECTIONS ANDGASKETSCheck for cracks, leaks or damage.

5. REINSTALL PCV VALVEApply oil to the PCV valve as shown and install it tothe cylinder head cover.

4. BLOW AIR FROM INTAKE MANIFOLD SIDECheck that air passes through with difficulty.If the PCV valve fails either of the checks, replace it.


To reduce HC emission, evaporated fuel from the fuel tank is routed through the charcoal canister to theintake manifold for combustion in the cylinders.

EVAPORATIVE EMISSION (EVAP)CONTROL SYSTEM

HC from canister is led intoair intake chamber.

HC from tank is absorbedinto the canister.

HC from tank is absorbedinto canister.

Canister Check Valve in CanisterThrottle ValveOpening

Positioned below

P port

Positioned aboveP port

Engine CoolantTemp.

Air is led into the fuel tank.

Evaporated Fuel (HC)

High pressurein tank

Above

54°C (129°F)

CheckValve inCAp

High vacuumin tank

Below

35°C (95°F)

CLOSED

CLOSEDCLOSED

CLOSED

CLOSED

OPEN

OPEN

OPEN

OPEN

OPEN

TVV


FUEL VAPOR LINES, FUEL TANK ANDTANK CAP INSPECTION1. VISUALLY INSPECT FUEL TANK

Look for lose connections, kinks or damage.2. VISUALLY INSPECT FUEL TANK

Look for deformation, cracks or fuel leakage.

4. INSPECT FOR CLOGGED FILTER AND STUCKCHECK VALVE

(a) Using low pressure compressed air, blow into port Aand check that air flows without resistance from theother ports.

CHARCOAL CANISTER INSPECTION1. REMOVE CHARCOAL CANISTER2. REMOVE CAP FROM CHARCOAL CANISTER3. VISUALLY INSPECT CHARCOAL CANISTER

Lock for cranks or damage.

(b) Blow into port Band check that air does not flow fromthe other ports.If operation is not as specified, replace the charcoalcanister.

3. VISUALLY INSPECT FUEL TANK CAPCheck if the cap and/or gasket are deformed or dam-aged.If necessary, repair or replace the cap.


(e) Heat the TVV to above 54�C (129�F) with hot water.(f) Blow air into a pipe and check that the TVV is open.

If a problem is found, replace the TVV.(g) Apply sealant to the thread of the TVV and reinstall it.

Sealant:Part No. 08833-00070, THREE BND 1324 orequivalentTorque: 27 N �m (280 kgf �cm, 20 ft �lbf)

(h) Fill the radiator with coolant.

TVV INSPECTIONCHECK TVV BY BLOWING AIR INTO PIPE(a) Drain the coolant from the radiator into a suitable

container.(b) Remove the TVV.(c) Cool the TVV to below 35�C (95�F) with cool water.(d) Blow air into a pipe and check that the TVV is closed.

5. CLEAN FILTER IN CANISTERClean the filter by blowing 294 kPa (3 kgf/cm2, 43 psi)of compressed air into port A while holding port Bclosed.NOTICE:

• Do not attempt to wash the canister.

• No activated carbon should come out.

6. REINSTALL CAP TO CHARCOAL CANISTER7. REINSTALL CHARCOAL CANISTER


EXHAUST GAS RECIRCULATION (EGR) SYSTEM(California only)


* Pressure increase→ Modulator closes→ EGR Valve opens→ Pressure drops EGR Valve closed← Modulator opens←** When the throttle valve is positioned above the port R, the EGR vacuum modulator will close the atmosphere passageand open the EGR valve to increase the EGR gas, even if the exhaust pressure is insufficiently low.

To reduce NOx emission, part of the exhaust gases is recirculated through the EGR valve to the intake manifold to lower themaximum combustion temperature.

* Pressure con-stantly alter-nating betweenlow and high

Pressure in the EGRValve PressureChamber

Positionedbetween port Eand port R

OPENS passageto atmosphere

Throttle ValveChamber

EGR VacuumModulator

Recirculated(increase)

EngineCoolantTemp.

Positionedbelow port E

Positionedabove port E

Below47�C(117�F)

Above53�C(127�F)

Notrecirculated

Notrecirculated

NotrecirculatedNotrecirculated

Notrecirculated

Intake AirVolume

Below4,000 rpm

Above4,000 rpm

Exhaust Gas

Recirculated

EngineRPM

EGRValve

(2)HIGH(3)HIGH

CLOSED

(4)ON

OPEN

OPEN

HIGH

LOW

OFF

CLOSED

CLOSED

CLOSED

CLOSED

OPENS passageto atmosphereOPENS passageto atmosphere

(1)HIGH


(d) Disconnect the vacuum hose from port R of the EGRvacuum modulator and connect port R directly to theintake manifold with another hose.

(e) Check that the vacuum gauge indicates high vacuumat 2,500 rpm.HINT: As exhaust gas is increasingly recirculated, theengine will start to misfire.

(f) Disconnect the vacuum gauge and reconnect thevacuum hoses to the proper locations.

2. PREPARATIONUsing a 3-way connector, connect a vacuum gaugeto the EGR valve vacuum hose as shown in the illus-tration.3. CHECK SEATING OF EGR VALVEStart the engine and check that the engine starts andruns at idle.

5. CHECK VSV AND EGR VACUUM MODULATORWITH HOT ENGINE

(a) Warm up the engine.(b) Check that the vacuum gauge indicates low vacuum

at 2,500 rpm.(c) Check that the vacuum gauge indicates zero at idle.

EGR SYSTEM INSPECTION1. CHECK AND CLEAN FILTER IN EGR VACUUM

MODULATOR(a) Check the filter for contamination or damage.(b) Using compressed air, clean the filter.

4. CHECK VSV WITH COLD ENGINE(a) The engine coolant temperature should be below 47�

C (117�F).(b) Check that the vacuum gauge indicates zero at 2,500

rpm.


6. CHECK EGR VALVE(a) Disconnect the vacuum hose from the EGR valve.(b) Apply vacuum directly to the EGR valve with the

engine idling.(c) Check that the engine runs rough or stops.(d) Reconnect the vacuum hoses to the proper locations.

IF NO PROBLEM IS FOUND DURING THISINSPECTION, THE SYSTEM IS OKAY OTHERWISEINSPECT PART

1M N-M

EGR VACUUM MODULATOR INSPECTION(a) Disconnect the vacuum hoses from ports P, Q and Rfrom the EGR vacuum modulator.(b) Block ports P and R with your finger.(c) Blow air into port Q. Check that the air passes through

to the air filter freely.

VSV INSPECTION1. CHECK VACUUM CIRCUIT CONTINUITY IN VSV BY

BLOWING AIR INTO PIPE(a) Connect the VSV terminals to the battery terminals as

illustrated.(b) Blow air into a pipe and check that the VSV is pen.

(d) Start the engine and maintain speed at 2,500 rpm.(e) Repeat the above test. check that there is a strong

resistance to air flow.It a problem is found, replace the EGR vacuum modu-lator.

(f) Reconnect the vacuum hoses to the proper locations.

(c) Disconnect the battery.(d) Blow air into a pipe and check that the VSV is closed.

If a problem is found, replace the VSV.

-ENGINE EMISSION CONTROL SYSTEMSEG-1 10

EGR VALVE INSPECTION1. REMOVE EGR VALVECheck the valve for sticking and heavy carbon depos-its.If a problem is found, replace it.2. INSTALL EGR VALVE WITH NEW GASKET


3. CHECK FOR OPEN CIRCUITUsing an ohmmeter, measure the resistance betweenthe terminals.Specified resistance:37 - 44� at 20�C (68�F)If the resistance is not within specification, replacethe VSV.

2. CHECK FOR SHORT CIRCUITUsing an ohmmeter, check that there is no continuitybetween the terminals and the VSV body.If there is continuity, replace the VSV.

ENGINE COOLANT TEMP. SENSORINSPECTION(See page EG-195 )


EXHAUST PIPE ASSEMBLY INSPECTION1. CHECK CONNECTION FOR LOOSENESS OR

DAMAGE2. CHECK CLAMPS FOR WEAKNESS. CRACKS OR

DAMAGE

TWC INSPECTIONCHECK FOR DENTS OR DAMAGEIf any part of the protector is damaged or dented tothe extent that it touches the TWC, repair or replaceit.

To reduce HC, CO and NOx emissions, they are oxidized, reduced and converted to nitrogen (N2), carbon dioxide(C02) and water (H20) by the three-way catalytic converter.

THREE-W AY CATALYTICCONVERTER (TWC) SYSTEM

OXIDATION ANDREDUCTIONHC, CO and NOx

Exhaust Port Exhaust Gas

CO2H2ON2

TWC


TWC REPLACEMENT1. REMOVE TWC(a) Jack up the vehicle.(b) Check that the TWC is cool.(c) Remove the 4 bolts and 2 nuts at the front and rear of

the TWC(d) Remove the TWC and 2 gaskets.2. INSTALL TWC(a) Place 2 new gaskets on the TWC front and rear pipes,

and connect the TWC to the exhaust pipes.(b) Tighten the bolts and nuts.


HEAT INSULATOR INSPECTION1. CHECK HEAT INSULATOR FOR DAMAGE2. CHECK FOR ADEQUATE CLEARANCE BETWEEN

TWC AND HEAT INSULATOR




TVV x Water outlet housing

EGR valve x Intake manifold

TWC x Exhaust pipe

at 20°C (68°F)

Part tightened

37 - 44 �ResistanceEGR VSV

kgf�cm ft�lbf

280

440

130

N�m


MFI SYSTEM

SYSTEM CIRCUIT

DESCRIPTION

Federal and Canada

-ENGINE MFI SYSTEMEG-1 15

California


The MFI system is composed of 3 basic subsystems: Fuel, Air Induction and Electronic ControlSystems.

FUEL SYSTEMFuel is supplied under constant pressure to the MFI injector by an electric fuel pump. Theinjectors injects a metered quantity of fuel into the intake manifold in accordance with signalsfrom the ECM (Engine Control Module).

AIR INDUCTION SYSTEMThe air induction system provides sufficient air for engine operation.

ELECTRONIC CONTROL SYSTEMThe 3E-E engine is equipped with a Toyota Computer Controlled System (TCCS) which centrallycontrols the MFI, ESA, Diagnosis systems, etc. by means of an Engine Control Module (ECMformerly MFI computer) employing a microcomputer.By means of the ECM, the TCCS controls the following functions:1. Multiport Fuel Injection (MFI)

The ECM receives signals from various sensors indicating changing engine operating conditionssuch as:Intake manifold absolute pressureIntake air temperatureEngine coolant temperatureEngine rpmThrottle valve opening angleExhaust oxygen content, etc.These signals are utilized by the ECM to determine the injection duration necessary for anoptimum air-fuel ratio.

2. Electronic Spark Advance (ESA)The ECM is programmed with data for optimum ignition timing under all operating conditions.Using data provided by sensors which monitor various engine functions (rpm, engine coolanttemperature, etc.) the microcomputer (ECM) triggers the spark at precisely the right instant. (SeeIG section.)

3. Idle- Up ControlThe ECM determines the appropriate idle speed according to engine condition and provides theelectric signal to the VSV which controls the bypass air.

4. Exhaust Gas Recirculation (EGR)The ECM controls the EGR system according to coolant temperature, engine rpm and intakemanifold absolute pressure. The electric signal from the ECM is transmitted to the VSV whichcontrols the EGR valve.

5. DiagnosisThe ECM detects any malfunctions or abnormalities in the sensor network and lights a malfunc-tion indicator lamp on the instrument panel. At the same time, the trouble is identified and adiagnostic code is recorded by the ECM. The diagnostic trouble code can be read by the numberof blinks of the malfunction indicator lamp when terminals T and E1 are connected. For thediagnostic trouble codes, refer to page EG-129 .

6. Fail-Safe FunctionIn the event of a sensor malfunction, a back-up circuit will take over to provide minimaldriveability, and the malfunction indicator lamp will light up.


PREPARATIONSST(SPECIAL SERVICE TOOLS)

(09268-41090) No.7 Union

(90405-09015) No.1 Union

(09268-41060) No.3 Union

(09268-41080) No.6 Union

09631-22020 Power Steering Hose Nut14 x 17 mm Wrench Set

Plug for the vacuum hose, fuelhose etc.

RECOMMENDED TOOLS

09268-41045 Injection Measuring Tool Set

09082-00050 TOYOTA Electrical Tester Set

09842-30070 Wiring ”F” EFI Inspection

09268-45012 EFI Fuel Pressure Gauge

09843-18020 Diagnosis Check Wire


09258-00030 Hose Plug set

Fuel line flare nut


Hexagon wrench(2.5mm)

EQUIPMENT

Carburetor cleaner

Torque wrench

Vacuum gauge

Sound scope

Thermometer

Throttle body

Tachometer

Soft brush

Dash pot

Injector


PRECAUTION1. Before working on the fuel system, disconnect the

cable from the negative terminal (-) of the battery.HINT: Any diagnostic trouble code retained by thecomputer will be erased when the battery terminal isremoved.Therefore, if necessary, read the diagnosis beforeremoving the battery terminal.

2. Do not smoke or work near an open flame whenworking on the fuel system.

3. Keep gasoline off rubber or leather parts.

3. IN THE EVENT OF ENGINE MISFIRE, THEFOLLOWING PRECAUTIONS SHOULD BE TAKEN

(a) Check proper connection of battery terminals, etc.(b) Handle high-tension cords carefully.(c) After repair work, check that the ignition coil terminals

and all other ignition system lines are reconnected securely.

(d) When cleaning the engine compartment, be especially care-ful to protect the electrical system from water.

4. PRECAUTIONS WHEN HANDLING OXYGENSENSOR

(a) Do not allow the oxygen sensor to drop or hit againstan object.

(b) Do not allow the sensor to come in contact withwater.

2. PRECAUTIONS WHEN CONNECTING GAUGE(a) Use the battery as the power source for the timing

light, tachometer, etc.(b) Connect the tester probe of a tachometer to terminal

IG� of the data link connector 1.

MAINTENANCE PRECAUTIONS1. CHECK FOR CORRECT ENGINE TUNE-UP

(See page EG-10 )

-ENGINE MFI SYSTEMEG-120

ELECTRONIC CONTROL SYSTEM1. Before removing MFI wiring connectors, terminals,

etc., first disconnect the power by either turning theignition switch OFF or disconnecting the battery ter-minals.

2. When installing the battery, be especially careful notto incorrectly connect the positive (+) and negative(-) cables.

3. Do not permit parts to receive a severe impact duringremoval or installation. Handle all MFI parts carefully,especially the ECM.

4. Do not be careless during troubleshooting as there arenumerous transistor circuits and contact with termi-nals can cause further trouble:

5. Do not open the ECM cover.6. When inspecting during rainy weather, take care to

prevent the entry of water. Also, when washing theengine compartment, prevent water from getting onthe MFI parts and wiring connectors.

7. Parts should be replaced as an assembly.

AIR INDUCTION SYSTEM1. Separation of the engine oil dipstick, oil filler cap, PCV

hose, etc. may cause the engine to run out of tune.2. Disconnection, looseness or cracks in the parts of the

air induction system between the throttle body andcylinder head will cause air suction and cause theengine to run out of tune.

IF VEHICLE IS EQUIPPED WITH MOBILERADIO SYSTEM (HAM, CB, ETC.)If the vehicle is equipped with a mobile communica-tion system, refer to the precaution in the IN section.


(b) Insert the tester probe into the connector from thewiring side when checking the continuity, amperageor voltage.

(c) Do not apply unnecessary force to the terminal.(d) After checking, install the water-proofing rubber se-

curely on the connector.

8. Take care when pulling out or inserting wiring connec-tors.

(a) Release the lock and pull out the connector. Pull onthe connectors, not the wires.

9. When inspecting a connector with a volt/ohmmeter:(a) Carefully take off the water-proofing rubber if it is a

water-proof type connector.

10. Use SST for inspecting or testing the injector or itswiring connector.SST 09842-30070

(b) Fully insert the connector and check that it is locked.


FUEL SYSTEM1. When disconnecting the high fuel pressure line, a

large amount of gasoline will spill out, so observe thefollowing procedure.

(a) Put a container under the connection.(b) Slowly loosen the connection.(c) Disconnect the connection.(d) Plug the connection with a rubber plug.

2. When connecting the flare nut or union bolt on thehigh pressure pipe union, observe the following proce-dure:Union bolt type:

(a) Always use a new gasket.(b) Tighten the union bolt by hand.(c) Tighten the bolt to the specified torque.


Flare nut type:(a) Apply a light coat of oil on the flare and tighten the

flare nut by hand.(b) Using SST, tighten the flare nut to the specified

torque.SST 09631- 22020Torque: 30 N �m (310 kgf �cm, 22 ft �lbf)HINT: Use a torque wrench with a fulcrum length of30 cm (11.81 in.).

3. Observe the following precautions when removingand installing the injectors.

(a) Never reuse an O-ring.(b) When placing a new O-ring on the injector, take care

not to damage it in any way.(c) Coat the new O-rings with spindle oil or gasoline

before installing never use engine, gear or brake oil.

4. Install the injector in the delivery pipe and cylinderhead as shown in the illustration.


(c) When the fuel return hose is pinched, the pressurewithin the high pressure line will rise to about 392 kPa(4 kgf/cm2, 57 psi). In this state, check to make surethat there are no leaks from any part of the fuelsystem.NOTICE: Always pinch the hose. Avoid bending it as itmay cause the hose to crack.

5. Check for fuel leaks after performing anywhere main-tenance on the fuel system.

(a) With engine stopped, turn the ignition switch ON.(b) Using SST, connect terminals +B and FP of the data

link connector 1.SST 09843-18020

(d) Remove the SST.SST 09843-18020


MALFUNCTION INDICATOR LAMP CHECK1. The malfunction indicator lamp will come on when the

ignition switch is placed at ON and the engine is notrunning.

2. When the engine is started, the malfunction indicatorlamp should go off.If the light remains on, the diagnosis system hasdetected a malfunction or abnormality in the system.

DIAGNOSTIC TROUBLE CODES OUTPUTTo obtain an output of diagnostic trouble codes, pro-ceed as follows:1. Initial conditions(a) Battery voltage 11 volts or more(b) Closed throttle position (throttle position sensor IDL

points closed)(c) Transmission in neutral position(d) Accessories switches OFF(e) Engine at normal operating temperature2. Turn the ignition switch ON. Do not start the engine.3. Using SST, connect terminals TE1 and E1 of the data


DIAGNOSIS SYSTEMDESCRIPTION

The ECM contains a built-in self-diagnosis systemwhich detects troubles within the engine signal net-work and a malfunction indicator lamp on the instru-ment panel.By analyzing various signals as shown in the latertable (See page EG-129 ) the ECM detects systemmalfunctions which are related to the various operat-ing parameter sensors or actuator. The ECM storesthe failure code associated with the detected failureuntil the diagnosis system is cleared by removing theEFI fuse with the ignition switch off.The malfunction indicator lamp on the instrumentpanel informs the driver that a malfunction has beendetected.The light goes off automatically when the malfunctionhas been cleared.


Diagnostic Trouble Code (See page EG-129 )(a) Normal System Operation (no malfunction)

• The light will blink once every 0.52 seconds.(b) Malfunction Code Indication

• In the event of a malfunction, the light will blinkevery 0.52 seconds. The first number of blinkswill equal the first digit of a 2-digit diagnostictrouble code, and after a 1.5 second pause, the 2nd number of blinks will equal the 2nd digit. Ifthere are 2 or more codes, there will be a 2.6second pause between each code.

• After all the codes have been output, there will bea 4.5 second pause and they will all be repeatedas long as the terminals TE1 and E1 of the datalink connector 1 are connected.

HINT: In the event of a number of trouble codes,indication will begin from the smaller value and con-tinue to the larger in order.

(c) 2 trip detection logic:Diagnostic trouble codes 21, 25, 26 and 71 use ”2 tripdetection logic”. With this logic, when a malfunction isfirst detected, the malfunction is temporarily stored inthe ECM memory. If the same case is detected againduring the second drive test, this second detectioncauses the malfunction indicator lamp to light up.

The 2 trip repeats the same mode a 2nd time.(However, the ignition switch must be turned OFFbetween the 1st time and 2nd time).

5. After the diagnosis check, remove the SST.SST 09843-18020

4. Read the diagnostic trouble code as indicated by thenumber of flashes of the malfunction indicator lamp.


Please refer to the TOYOTA hand - held testeroperator ’s manual for further details.

DIAGNOSTIC TROUBLE CODECANCELLATION1. After repairing the trouble, the diagnostic trouble

code retained in memory by the ECM must be cance-led out by removing the EFI fuse (15A) for 10 secondsor more, depending on ambient temperature (thelower the temperature, the longer the fuse must beleft out) with the ignition switch off.HINT:

• Cancellation can also be done by removing thebattery negative (-) terminal, but in this caseother memory systems (radio, clock etc.) will alsobe canceled out.

• If the diagnostic trouble code is not canceled out,it will be retained by the ECM and appear alongwith a new code in the event of future trouble.

• If it is necessary to work on engine componentsrequiring removal of the battery terminal, a checkmust first be made to see if a diagnostic troublecode has been recorded.

2. After cancellation, perform a road test to confirm thata ”normal” code is now displayed by the malfunctionindicator lamp.If the same diagnostic trouble code appears, it indi-cates that the trouble area has not been repairedthoroughly.

DIAGNOSIS INDICATION1. Including ”normal”, the ECM is programmed with the

following 15 diagnostic trouble codes.2. If 2 or more malfunctions are present at the same

time, the lowest-numbered diagnostic trouble codewill be displayed first.

DIAGNOSTIC TROUBLE CODE CHECK

BY USING TOYOTA HAND-HELD TESTER1. Hook up the TOYOTA hand-held tester to the DLC1.

2. Read the diagnostic trouble codes by following theprompts on the tester screen.


ECM TERMINAL VALUES MEASUREMENT

USING TOYOTA BREAK-OUT-BOX AND

TOYOTA HAND-HELD TESTER1. Hook up the TOYOTA break-out-box and TOYOTA

hand-held tester to the vehicle.2. Read the ECM input/output values by following the

prompts on the tester screen.HINT: TOYOTA hand-held tester has a ”Snapshot”function. This records the measured values and iseffective in the diagnosis of intermittent problems.

3. All detected diagnostic trouble codes, except codeNo.51, will be retained in memory by the ECM fromthe time of detection until canceled out.

4. Once the malfunction is corrected, the malfunctionindicator lamp on the instrument panel will go off butthe diagnostic trouble code(s) will remain stored inECM memory (except for code No.51).

Please refer to the TOYOTA hand - held tester/TOYOTA break-out-box operator’s manual for fur-ther details.


DIAGNOSTIC TROUBLE CODES

HINT:• If a malfunction is detected during the diagnostic trouble code check, refer to the circuit indicated

in the table, and turn to the corresponding page.• Your readings may vary from the parameters listed in the table, depending on the instruments

used.

(1) Oxygen sensor output is less than0.45 V for at least 100 secs. whenoxygen sensor is warmed up(racing at 2,000 rpm).(only for code 25)

*4(2) When the engine speed varies bymore than 40 rpm over thepreceding crank angle periodduring a period of 50 secs.during idling with the coolanttemp. 40 °C (104 °F) or more.*6 (2 trip detection logic) (1) and (2)

• Engine ground bolt loose• Open in E1 circuit• Open in injector circuit• Fuel line pressure (Injector

blockage, etc.)• Open or short in oxygen sensor

circuit• Oxygen sensor• Ignition system• Water temp. sensor• Vacuum sensor• Engine ECU• EGR system

• Engine ground bolt loose• Short in injector circuit• Fuel line pressure (Injector

leakage, etc.)• Open or short in oxygen

sensor circuit• Oxygen sensor• Water temp. sensor• Vacuum sensor• Compression pressure• Engine ECU

At normal driving speed (below 60 mphand engine speed above 1,900 rpm),amplitude of oxygen sensor signal (OX)is reduced to between 0.35 - 0.70 Vcontinuously for 60 secs. or more.*6 (2 trip detection logic)

• Open or short in water temp.

sensor circuit.

• Water temp. sensor

• Engine ECU

• Open or short in IGF or IGT

circuit from ignite to ECU.

• Ignite

• Engine ECU

• Open or short in distributor circuit

• Distributor

• Engine ECU

• Open or short in intake air

temp. circuit.

• Intake air temp. sensor

• Engine ECU

• Open or short in circuit of

oxygen sensor

• Oxygen sensor

• Engine ECU

NE signal is not input to engine ECUfor 0.3 sec. or more when enginespeed is 1,500 rpm or more.

• Open or short in NE circuit

• Distributor

• Engine ECU

Open or short in intake air temp. sensorcircuit for 0.5 sec. or more. (THA)

No NE signal is input to the engine ECUfor 2 secs. or more after STA turns ON.

IGF signal from ignite is not input toECU for 4 consecutive ignitions.

Open or short in water temp. sensorcircuit for 0.5 sec. or more. (THW)

Number ofblinks ”CHECK”Engine WarningLight

Output when no other code is recorded.

*1“CHECK”EngineWarningLight

Air-FuelRatioLeanMal-function

Air-FuelRatioRichMal-function

IntakeAirTemp.SensorSignal

WaterTemp.SensorSignal

OxygenSensorSignal

*2MemoryTrouble Area

IgnitionSignal

Diagnosis

RPMSignal

RPMSignal

SeePage

CodeNo. System

EG-146

EG-149

EG-147

’3ON

EG-151

EG-151

EG-151

Normal

IG-2

IG-2

-


REMARKS*1: ”ON’ displayed in the diagnosis mode column indicates that the Malfunction Indicator Lamp (MIL)

is lighted up when a malfunction is detected. ”OFF” indicates that the MIL does not light up duringmalfunction diagnosis, even if a malfunction is detected.

*2: ”O” in the memory column indicates that a diagnostic trouble code is recorded in the ECMmemory when a malfunction occurs. ”X” indicates that a diagnostic trouble code is not recordedin the ECM memory even if a malfunction occurs. Accordingly, output of diagnostic results isperformed with the ignition switch ON.

*3: The MIL comes on if a malfunction occurs only for California specifications.*4: No.(2) in the diagnostic contents of codes No.25 and 26 apply to California specification vehicles

only, while (1) applies to all models.*5: Code 26 and 71 is used only for California specifications.*6: ”2 trip detection logic” (See page EG-126 ).

With the coolant temp. at 70 °C (168 °F)or more, 50 secs. from start of EGRoperation. the EGR gas temp. is lessthan 70 °C (158 °F) and the EGR gastemp. has risen less than 10 °C (18 °F)during the 50 sacs.* (2 trip detection logic)

• Open in EGR temp. sensor circuit• Open in VSV circuit for EGR• EGR vacuum hose disconnected,

valve stuck• Clogged in EGR gas passage• Engine ECU

SPD signal is not input to the engineECU for at least 8 seconds during highload driving with engine speedbetween 2,500 rpm and 4,500 rpm(M/T), 2,500 rpm or more (A/T).

• A/C switch circuit• Throttle position sensor IDL circuit• Neutral start switch circuit• Accelerator pedal, cable• Engine ECU

Displayed when A/C is ON, IDL contactOFF or shift position in ”R”, ”D”, ”2”, or”1” ranges with the check terminals E1and T connected.

• Open or short in throttle position

sensor circuit

• Throttle position sensor

• Engine ECU

• Open or short in starter signal

circuit

• Open or short in IG SW circuit

• Engine ECU

Starter signal (STA) is not input toengine ECU even once until enginereaches 800 rpm or more when cranking.

• Open or short in vehicle speed

sensor circuit

• Vehicle speed sensor

• Engine ECU

Open or short detected continuously for0.5 sec. or more in vacuum sensorcircuit (PIM)

• Open or short in vacuum

sensor circuit

• Vacuum sensor

• Engine ECU

Open or short detected in throttleposition sensor signal (VTA)for 0.5 sec. or more.

Number orblinks ”CHECK”Engine WarningLight

*1”CHECK”EngineWarningLight

EGRSystemMal-function

ThrottlepositionSensorSignal

VehiclespeedSensorSignal

SwitchConditionSignal

VacuumSensorSignal

*2Memory

Trouble AreaDiagnosis

StarterSignal

CodeNo. See

Page

*3ON

System

EG-148

EG-145

EG-141

EG-152

EG-141

OFF

OFF

OFF


(1). Disconnect the fuse EFI (15 A) for 10 sec. or more, with IG switch OFF.(2). Start the engine and warm the engine up with all ACC switch off.(3). After the engine is warmed up, let it idle for 3 min.(4). After performing the idling in (3), perform gradual acceleration with in the range 1300

-1700 rpm (centered around 1500 rpm) with the A/C switch ON and ”D” range for A/Tor properly up shift for M /T.(Take care that the engine speed does not fall below 1200 rpm when shifting. Graduallydepress the accelerator pedal and kept it. Steady so that engine braking does not occur.)

(5). Maintain the vehicle speed at 40 - 50 mph.Keep the vehicle running for 1 - 2 min. after starting acceleration.

(6). After driving, stop at a safe place and turn the IG switch OFF for 3 sec. or more.(7). Start the engine and perform steps (3), (4), and (5) again.HINT: If a malfunction is detected the “CHECK” engine warning light will light up during step.

NOTICE: If the condition in this test are not strictly followed, detection of the malfunction willnot be possible.

DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN

Purpose of the driving pattern(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.(b) To check that the malfunction is corrected when the repair is completed confirming that

diagnostic trouble code is no longer detected.

Malfunction: Main Oxygen Sensor Deterioration

DTC NO. 21 Oxygen Sensor Circuit


(1). Disconnect the fuse EFI (15 A) for 10 sec. or more, with IG switch OFF.(2). Start the engine and warm the engine up.(3). After the engine is warmed up, let it idle for 2 min.(4). After performing the idling in (3), perform sudden racing to 4,000 rpm three times.(5). After performing the sudden racing in (4), perform racing at 2,000 rpm for 2 min.(6). After performing the racing in (5), Turn the IG switch OFF for 10 sec.(7). Start the engine and perform steps (2), (3), (4), and (5) again.HINT: If a malfunction is detected the “CHECK” engine warning light will light up during step (7).

NOTICE: If the conditions in this test are not strictly followed, detection of the malfunctionwill not be possible.

DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN

Purpose of the driving pattern(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.(b) To check that the malfunction is corrected when the repair is completed confirming that


Malfunction: Open or short in Oxygen Sensor

DTC NO. 25 Air-Fuel Ratio Lean Malfunction


DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERNPurpose of the driving pattern

(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.(b) To check that the malfunction is corrected when the repair is completed confirming that


Malfunction: Open or short in Injector Leak, Blockage

DTC NO. 25 Air-Fuel Ratio Lean Malfunction (CALIFORNIA)26 Air-Fuel Ratio Rich Malfunction (CALIFORNIA)

HINT: Before this test, check the feedback voltage for oxygen sensor.(1). Disconnect the fuse EFI (15A) for 10 sec. or more, with IG switch OFF.(2). Start the engine and warm the engine up, with all ACC switch OFF.(3). After the engine is warmed up, let it race at 2,000 rpm for 3 min.(4). After performing the racing in (3), perform idling for 2 min.

(”D” range for A/T)(5). After performing the idling in (4), Turn the IG switch OFF for 3 sec or more.(6). Start the engine and perform steps (3), (4) again.HINT: If a malfunction is detected the “CHECK” engine warning light will light up during step (6)

NOTICE: If the conditions in this test are not strictly followed, detection of the malfunctionwill not be possible.


HINT: A/C switch OFF in this test.(1) . Disconnect the EFI fuse (15A) for 10 sec. or more, with ignition switch OFF.(2) . Start the engine and warm the engine up with all ACC switch OFF.(3) . After the engine is warmed up, let it idle for 3 min.(4) . With the transmission in 5th gear (”D” range and 0/D ON for A/T), drive at 55 - 65 mph

for 4 min.(5) . After driving, stop at a safe place and turn the ignition switch OFF for 3 - 10 sec.(6) . Start the engine and perform steps 3 and 4 again.HINT: If a malfunction is detected the MIL will light up during step.

NOTICE: If the conditions in this test are not strictly followed, detection of the malfunction willnot be possible.

DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERNPurpose of the driving pattern(a) To simulate diagnostic trouble code detecting condition after diagnostic trouble code is recorded.(b) To check that the malfunction is corrected when the repair is completed confirming that


Malfunction: Short in VSV Circuit for EGR, Loose EGR Hose, Valve Stuck

DTC 71 EGR System Malfunction (California)


Check wiring between ECM terminal T and data linkconnector 1 terminal TE1, and ECM terminal E1 anddata link connector 1 terminal E1.

Is there diagnostic trouble code output when datalink connector 1 terminals TE1 and El areconnected?

Does malfunction indicator tamp go off after repairaccording to malfunction code?

Does malfunction indicator lamp go off when theengine is started?

Does malfunction indicator lamp come on whenECM terminal W is grounded to the body?

Check bulb, fuse and wiring between ECM andignition switch.

Does malfunction indicator lamp come on whenignition switch is at ON?

Check wiring between ECM and malfunctionindicator lamp.

DIAGNOSIS CIRCUIT INSPECTION

Check wiring betweenECM terminal El andbody ground.

Further repair required.

Cancel out diagnostic trouble code.

Repair or replace.

Repair or replace.

Try anotherECM.

Try anotherECM.

System Normal.

System Normal.

System 0 K

Repair.

BAD

BAD

BAD

YES

YES

YES

YES

YES


TROUBLESHOOTING w VOLT OHMMETERHINT: The following troubleshooting procedures are designed for inspection of each separatesystem, therefore the procedure may vary somewhat. However, troubleshooting should beperformed referring to the inspection methods described in this manual.Before beginning inspection, it is best to first make a simple check of the fuses, fusible links andcondition of the connectors.The following troubleshooting procedures are based on the supposition that the trouble lies ineither a short or open circuit in a component outside the computer or a short circuit within thecomputer.If engine trouble occurs even though proper operating voltage is detected in the computerconnector, then it can be assumed that the ECM is faulty and should be replaced.

FUSES AND FUSIBLE LINK LOCATION


MFI SYSTEM CHECK PROCEDUREPREPARATION(a) Disconnect the connectors from the ECM.(b) Remove the locks as shown in the illustration so that

the tester probe(s) can easily come in.NOTICE: Pay attention to sections “A” and “B“ in theillustration which can be easily broken.

(c) Reconnect the connectors to the ECM.HINT:

• Perform all voltage measurements with the con-nectors connected.

• Verify that the battery voltage is 11 V or abovewhen the ignition switch is ON.Using a voltmeter with high impedance (10 k�/Vminimum), measure that voltage at each terminal ofthe wiring connectors.

Terminals of ECM

THROTTLE POSITION SENSOR

THROTTLE POSITION SENSOR

INTAKE AIR TEMP. SENSOR

WATER TEMP. SENSOR CIRCUIT OPENING RELAY

NEUTRAL START SWITCH

FUEL PRESSURE-UP VSV

EGR GAS TEMP. SENSOR

THROTTLE OPENER VSV

DISTRIBUTOR GROUND

CHECK CONNECTOR

CHECK CONNECTOR

SENSOR GROUND

VACUUM SENSOR

SENSOR GROUND

VACUUM SENSOR

POWER GROUND

STARTER SWITCH

ENGINE GROUND

OXYGEN SENSOR

POWER GROUND

WARNING LIGHT

EFI MAIN RELAY

EFI MAIN RELAY

A/C AMPLIFIER

Terminal name Terminal name

A/C AMPLIFIER

Terminal name

SPEED SENSOR

DISTRIBUTOR IDLE-UP VSV

INJECTOR

INJECTOR

BATTERY

Symbol

EG R VSV

Symbol

IGNITER

IGNITER

Symbo l

No. 10

No. 20

NE�

BATT

*TOV

*THG

*EGR

THW

VISC

NSW

THA

ACT

A/C

+B1

SPDVTA

VCC

STA PIM

FPU

IDL

IGT

IGF

E02

E01


No trouble (”CHECK” engine warning light off) andengine running

Voltage at ECM Wiring Connectors

Coolant temperature 80�C (176�F)

Intake air temperature 20�C (68�F)

Throttle valve fully closed

Throttle valve fully open

No. 10 E01No. 20 E02

Alr conditioning ON

Throttle valve open

STD voltage (V)

+B+B1

THW - E2

Terminals Condition

IG SW ON

IG SW ON

IG SW ON

IG SW ON

IG SW ON

See page

IG SW ON

lG SW ON

BATT - E1

Cranking

A/C - E1

THA - E2

6 or more

6 or more

0.8-0.8

VCC - E2

PIM-E2

0.7-1.0

VCC - E2

STA - E1

VTA - E2

0.5-3.4

4.5-5.5

4.5-5.5

3.2-4.9

IGT - E1

IDL-E2

3.3-3.9

EG-148

EG-140

EG-150

EG-144

EG-146

EG-147

EG-149

EG-145

EG-143

EG-139

EG-141

W - E1

Idling

9-14

9-14

9-14

9-14

9-14

9-14

No.

- E1

-


Check that there is voltage between ECM terminal +B or +B1 andbody ground. (IG SW ON)

There is no voltage between ECM terminals +B or +B1 and E1.(IG SW ON)

Check wiring between ECM terminal E1 and bodyground.

Check wiring between EFI main relayand battery.

Check fuses, fusible links and ignitionswitch.

Check EFI main relay.

Repair or replace.

Repair or replace.

Repair or replace.

+B +B1

Try another ECM.

STD voltage

No voltage IG SW ON

ConditionTerminals

Replace.

Trouble

9-14V

BAD

BAD

BAD

BAD

No.

-E1

(1)

(2)

(3)


Check that there is voltage between ECM terminal BATT and bodyground.


There is no voltage between ECM terminal BATT and E1.

Check wiring between ECM terminaland battery.

Check fuse and fusible link.

Repair or replace.

Repair or replace.

Try another ECM.

STD voltage

No voltage

Terminals Condition

BATT - E1

Replace.

9-14 V

Trouble

BAD

BAD

BAD

No.

(1)

(2)



There is no voltage between ECM terminals IDL and E2.(IG SW ON) (Throttle valve open)

Check wiring between ECM terminal E1 and body ground.

Check wiring between ECM andthrottle position sensor.

Check throttle position sensor.(See page EG-172 )

Refer to +B - E1trouble section (No.1).(See page EG-139 )

Repair or replacethrottle position sensor.

Repair or replace.



Try another ECM.

Throttle valve open

IG SW ON

Repair or replace.

Try another ECM.

STD voltage

No voltage0.8 - 1.2 V

• IDL - E2

4.5 - 5.5 V

3.2 - 4.2 V

Terminals Condition

VCC - E2

9 - 14 V

VTA-E2

IDL - E2

Trouble

BAD

BAD

BAD

BAD

No.

(1)

(2)

(3)


Check that there is voltage between ECM terminals VCC and E2.(IG SW ON)

Check that there is voltage between ECM terminal + B or + B1 andbody ground. (IG SW ON)

There is no voltage between ECM terminals VCC and E2.(IG SW ON)

There is no specified voltage at ECM terminals VTA and E2.(IG SW ON)

Check wiring between ECM and throttleposition sensor.



Refer to + B - E1trouble section ( No.1),(See page EG-139 )

Check wiring between ECM andthrottle position sensor.

Refer to VCC - E2 troublesection.

Repair or replacewiring.

Repair or replace.

(1)

Try another ECM.

Repair or replace.

Try another ECM.

• VCC - E2

• VTA - E2

BAD

BAD

. NO

BAD

BAD

(2)

Repair or replace.

(1)

(2)

(3)


There is no voltage between ECM terminals No. 10 and/or No. 20and E01 and/or E02. (IG SW ON)

Check that there is voltage between ECM terminal No. 10 and/orNo. 20 and body ground.

Check resistance of each injector. (See page EG-164 )STD resistance (Cold): Approx. 13.8 �

Check wiring between ECM terminal E01 and/or E02 andbody ground.

Check wiring between ECMterminal No. 10 and/or No. 20and battery.

Check fusibie link, fuse and ignitionswitch.

No. 10 E01No. 20 E02

Repair or replace.

Repair or replace.

Repair or replace.

Try another ECM.

Replace injector.

. No voltage

STD voltageTerminals

IG SW ON

Condition

9-14 V

Trouble

BAD

BAD

BAD

BAD

No.

-

(1)

(2)

(3)


Check that there is voltage between ECM terminal W and bodyground.

There is no voltage between ECM terminals W and E1.(idling)


No trouble (malfunction Indicator lamp off) and enginerunning.

Check GAUGE (15 A) and malfunctionindicator lamp.

Check wiring between ECM terminalW and fuse. Repair or replace.

Repair or replace.

Repair or replace.

Fuse blows again

Try another ECM.

STD voltage

No voltage

ConditionTerminals

9- 14 V

Trouble

W - E1

BAD

BAD

BAD

No.

(1)

(2)


Check that there is voltage between ECM terminal + B or + B1and body ground. (IG SW ON)

There is no voltage between ECM terminal PIM or VCC and E2(IG SW ON)


Check wiring between ECM and manifoldabsolute pressure sensor.

Check manifold absolute pressuresensor. (See page EG-196 )

Refer to + B - E1trouble section (No. 1).(See page EG-139 )

Replace manifoldabsolute pressuresensor.

Repair or replace.

Repair or replace.Try another ECM.

STD voltage

No voltage4.5 - 5.5 V

3.3 - 3.9 VIG SW ON

Terminals Condition

P!M - E2

VCC - E2

Trouble

BAD

BAD

BAD

No.

(1)

(2)

(3)


Check that there is voltage between ECM terminal + B or + B1and body ground. (IG SW ON)

There is no voltage between ECM terminals THA and E2.(IG SW ON)


Check wiring between ECM and intakeIAT sensor.

Refer to + B - E1 troublesection (No. 1).(See page EG-139 )

Check IAT sensor.See page EG-195 )

Intake air temperature 20°C (68°F)

Repair or replace wiring.

Terminals

Replace IATsensor.

Repair or replace.

Try another ECM.

STD voltage

No voltage 0.5 - 3.4 VIG SW ON

ConditionNo. Trouble

BAD

BAD

BAD

7 THA - E2

(1)

(2)

(3)


Check that there is voltage between ECM terminal + B or + B1and body ground. IG SW ON)

There is no voltage between ECM terminals THW and E2.(IG SW ON)


Check wiring between ECM and ECTsensor.

Refer to + B - El troublesection (No. 1).(See page EG-139 )

Check ECT sensor.(See page EG-194 )

Coolant temperature 80°C (176°F)

Repair or replace.

Replace ECTSensor.

Repair or replace.Try another ECM.

No voltage

STD voltage

0.4 - 0.7 VIG SW ON

Terminals Condition

THW - E2

Trouble

BAD

BAD

BAD

No.

(1)

(2)

(3)


There is no voltage between ECM terminals STA and E1.(IG SW START)

Check that there is voltage at terminal 50 of starter.(IG SW START) STD voltage: 6 V or more


Check wiring between ECM terminal STAand ignition switch terminal ST2.

Check wiring between ignition switchterminal ST2.and starter terminal 50.

Check fusible link, H-fuse, battery,wiring and ignition switch.

Check starter.(See page ST-13or ST-25 )

Check starteroperation.

Repair or replace.

Repair or replace.

Repair or replace.

Try another ECM.

STD voltage

No voltage 6 V or moreCranking

ConditionTerminals

STA - E1

Trouble

BAD

BAD

BADBAD

No.

(1)

(2)

(3)


Check that there is voltage between ECM terminal IGT andbody ground. (Cranking or idling)

There is no voltage between ECM terminals IGT and El.(Cranking or idling)

Check fusible link, fuse and ignitionswitch.

Check wiring between ECMterminal E1 and body ground.

0.5 V or less (Fluctuate) 4.5 - 5.5 V

Check wiring between ECM and battery.

Check distributor. (See page IG-8 )

Check igniter. (See page IG-5 )

Cranking or Idling

Repair or replace.

Repair or replace.

Repair or replace.

Repair or replace.

Repair orreplace.

Try another ECM.

STD voltage

No voltage

Terminals Condition

IGT - E1

Trouble

BAD

BAD

BAD

BAD

BAD

No.

(1)

(3)

(2)


Check that there is voltage between ECM terminal A/C and bodyground.

There is no voltage between ECM terminals A/C and E1.(Air conditioning ON)

Check that there is voltage betweenamplifier terminal and body ground.

Check wiring between ECMterminal E1 and body ground.

Check wiring between amplifierand ECM.or A/C compressor.

Check wiring betweenECM terminal A/Cand amplifier.

Check compressor running.

Air conditioning ON

Repair or replace.

Repair or replace.

Repair or replace.

Repair orreplace.

Try another ECM

STD voltage

No voltage

ConditionTerminals

A/C - E1 8 -14 V

trouble

BAD

BAD

BADBAD

BAD

No.

(1)

(2)

(3)


Check that there is voltage between ECM terminal VF and body ground.

There is no voltage between ECM terminals VF and E1.

Check operation of oxygen sensor.(See page EG-199 )


Check wiring between oxygen sensorand ECU connector.

Check fuel pressure. (See page EG-153)

Check vacuum sensor.(See page EG-196)

Check spark plugs. (See page IG-7 )

Check distributor and ignition system.

Check injector. (See page EG-164 )

Is air leaking into air intake system?

Replace oxygen sensor.

Repair or replace.

Repair or replace.

Repair or replace.

Repair or replace.

Repair or replace.

Repair or replace.Try another ECM

System normal.

Repair air teak.

Repair wiring.

BAD

BAD

BAD

BAD

BAD

BAD

BAD

BAD

BAD

(1)

(2)



These is no voltage between ECM terininals THG and E2.(IG SW ON)

Check wiring between ECM terminaI E1 and body ground.

Refer to + B - E1 troublesection (No.1).(See page EG-139 )

Check EGR gas temp. sensor.(See page EG-198 )

Check wiring between ECM andEGR gas temp. sensor.

Check EGR system. (See page EG-109 )

Replace EGR gasternp. sensor.

Repair or replace.

Repair or replace.

California onIy

Try another ECM.

BADBAD

BAD

BAD

(1)

(2)

(3)


ON-VEHICLE INSPECTION1. CHECK FUEL PUMP OPERATION(a) Turn the ignition switch ON.

HINT: Do not start the engine.(b) Using SST, connect terminals +B and FP of the data


(c) Check that there is pressure in the fuel inlet hose fromthe fuel filter.HINT: At this time, you will hear fuel pressure noise.

FUEL PUMPFuel Pump


(d) Remove the SST.SST 09843-18020(e) Turn the ignition switch OFF.

If there is no pressure, check the following parts.

• Fusible link

• H - Fuses

• Fuses

• EFI main relay

• Circuit opening relay

• Fuel pump

• ECM

• Wiring connections2. INSPECT FUEL PRESSURE(a) Check that battery voltage is approx. 12 volts.(b) Disconnect the negative (-) terminal cable from bat-

teryCAUTION (w/ SRS): Work must be started after 90 sec-onds from the time the ignition switch is turned to the“LOCK” position and the negative (-) terminal cable isdisconnected from the battery.

(c) Put a suitable container or shop towel under the fuelfilter.

(d) Remove the union bolt and 2 gaskets, and disconnectthe fuel inlet hose from the fuel filter outlet.HINT: Slowly loosen the union bolt.

(e) Install the fuel inlet hose and SST (pressure gauge) tothe fuel filter outlet with 3 new gaskets and the unionbolt.SST 09268-45012Torque: 29 N �m (300 kgf �cm, 22 ft �lbf)

(f) Wipe off any splattered gasoline.(g) Reconnect the battery negative (-) cable.

(h) Using SST, connect terminals +B and FP of the datalink connector 1.SST 09843-18020


(i) Turn the ignition switch ON.Q) Measure the fuel pressure.

Fuel pressure:281 - 287 kPa(2.87 - 2.93 kg f/cm 2, 40.8 - 41.7 psi)If pressure is high, replace the fuel pressure regulator.If pressure is low, check the following parts:

• Fuel hoses and connection

• Fuel pump

• Fuel filter

• Fuel pressure regulator

(o) Reconnect the vacuum sensing hose to the fuel pres-sure regulator and plug the hose end.

(p) Measure the fuel pressure at idling.Fuel pressure:226 - 265 kPa (2.3 - 2.6 kg f/cm 2, 33 - 37 psi)

If pressure is not as specified, check the vacuumsensing hose and fuel pressure regulator.

(l) Start the engine.(m) Disconnect the vacuum sensing hose from the fuel

pressure regulator.(n) Measure the fuel pressure at idling.

Fuel pressure:281 - 287 kPa(2.87 - 2.93 kg f/cm 2, 40.8 - 41.7 psi)

(k) Remove the SST.SST 09843-18020


(q) Stop the engine. Check that the fuel pressure remains147 kPa (1.5 kg/cm2, 21 psi) or more for 5 minutesafter the engine is turned off.If pressure is not as specified, check the fuel pump,pressure regulator and/or injector.

(r) After checking fuel pressure, disconnect the batterynegative (-) cable and carefully remove the SST toprevent gasoline from splashing.SST 09268-45012

(s) Connect the fuel inlet hose with 2 new gaskets andthe union bolt.Torque: 29 N �m (300 kgf �cm, 22 ft �lbf)

(t) Reconnect the cable to the negative (-) terminal ofthe battery.

(u) Check for fuel leakage. (See page EG-1 1)


FUEL PUMP REMOVAL AND INSPECTIONCAUTION: Do not smoke or work near an open flamewhen working on the fuel pump.

1. DISCONNECT NEGATIVE TERMINAL CABLE FROMBATTERYCAUTION (w/ SRS): Work must be started after 90 sec-onds from the time the ignition switch is turned to the “LOCK” position and the negative (-) terminal cable isdisconnected from the battery.

2. REMOVE REAR SEAT CUSHION3. INSPECT FUEL PUMP RESISTANCE

Using an ohmmeter, measure the resistance betweenterminals 2 and 6.Resistance:0.2 - 3.0 W 20_ (68_F)If the resistance is not as specified, replace the fuelpump.

COMPONENTS FOR REMOVAL ANDINSTALLATION


4. INSPECT FUEL PUMP OPERATIONConnect the positive (+) lead from the battery toterminal 2 of the connector, and the negative (-) leadto terminal

6. Check that the fuel pump operates.NOTICE:

• These tests must be performed quickly (within 10seconds) to prevent the coil from burning out.

• Keep the fuel pump as far away from the battery aspossible.Always perform switching at the battery side.

• If operation is not as specified, replace the fuelpump.

5. REMOVE FLOOR SERVICE HOLE COVER(a) Disconnect the fuel pump (w/ fuel sender gauge)

connector.(b) Remove the 3 screws and service hole cover.

6. REMOVE FUEL PUMP BRACKET ASSEMBLY FROMFUEL TANKCAUTION: Remove the fuel filter cap to prevent the fuelfrom flowing out.

(a) Using SST, disconnect the outlet pipe from the pumpbracket.SST 09631-22020

(b) Remove the 8 bolts.(c) Disconnect the return hoses from the pump bracket.

(d) Pull out the pump bracket assembly.


3. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET(a) Pull out the lower side of the fuel pump from the pump

bracket.(b) Disconnect the connector from the fuel pump.(c) Disconnect the fuel hose from the fuel pump, and

remove the fuel pump.(d) Remove the rubber cushion from the fuel pump.

2. REMOVE FUEL SENDER GAUGE FROM FUEL PUMPBRACKET

(a) Remove the nut and spring washer, and disconnectthe lead wire from the pump bracket. Disconnect the3 lead wires.

(b) Remove the 2 screws and sender gauge.

FUEL PUMP DISASSEMBLY1. REMOVE FUEL CUTOFF VALVE FROM FUEL PUMP

BRACKETRemove the 2 screws, retainer, fuel cut-off valve andgasket.

COMPONENTS FOR DISASSEMBLY ANDASSEMBLY

-ENGINE M FI SYSTEMEG-159

FUEL PUMP ASSEMBLY(See Components for Disassembly and Assembly)1. INSTALL FUEL PUMP FILTER TO FUEL PUMP

Install the pump filter with a new clip.2. INSTALL FUEL PUMP TO FUEL PUMP BRACKET(a) Install the rubber cushion to the fuel pump.(b) Connect the fuel hose to the outlet port of the fuel

pump.(c) Connect the connector to the fuel pump.(d) Install the fuel pump by pushing the lower side of the

fuel pump.3. INSTALL FUEL SENDER GAUGE TO FUEL PUMP

BRACKET(a) Install the sender gauge with the 2 screws.(b) Connect the lead wire to the pump bracket with the

spring, washer and nut. Connect the 3 lead wires asshown.

FUEL PUMP INSTALLATION(See Components for Removal and Installation)1. INSTALL FUEL PUMP BRACKET ASSEMBLY TO

FUEL TANK(a) Insert the pump bracket assembly into the fuel tank.(b) Connect the return hoses to the pump bracket.

4. INSTALL FUEL CUTOFF VALVE TO FUEL PUMPBRACKET

Install a new gasket, fuel cut-off valve and retainerwith the 2 screws.

Torque: 1.5 N �m (15 kgf �cm, 13 in. �lbf)

4. REMOVE FUEL PUMP FILTER FROM FUEL PUMP(a) Using a small screwdriver, remove the clip.(b) Pull out the pump filter.


3. INSTALL FLOOR SERVICE HOLE COVER(a) Install the service hole cover with the 3 screws.(b) Connect the fuel pump (w/ fuel sender gauge) con-

nector.4. INSTALL REAR SEAT CUSHION5. CONNECT NEGATIVE TERMINAL CABLE TO

BATTERY

(d) Using SST,connect the outlet pipe to the pump brack-et.SST 09631-22020Torque: 30 N �m (310 kgf �cm, 22 ft �lbf) Use SST

2. CHECK FOR FUEL LEAKAGE (Seepage EG-122 )

(c) Install the pump bracket with the 8 bolts.Torque: 3.4 N �m (35 kgf �cm, 30 in. �lbf)


2. DISCONNECT FUEL RETURN PIPE FROM FUELPRESSURE REGULATOR

(a) Put a suitable container or shop towel under thepressure regulator.

(b) Remove the union bolt and 2 gaskets, and disconnectthe return pipe from the pressure regulator.HINT: Slowly loosen the union bolt.

(c) Remove the bolt and fuel return pipe from the deliverypipe.

FUEL PRESSURE REGULATOR REMOVAL1. DISCONNECT VACUUM SENSING HOSE FROM

FUEL PRESSURE REGULATOR

3. REMOVE FUEL PRESSURE REGULATOR(a) Remove the 2 bolts, and pull out the pressure regula-

tor.(b) Remove the O-ring from the pressure regulator.

ON-VEHICLE INSPECTIONINSPECT FUEL PRESSURE (See page EG-122 )

FUEL PRESSURE REGULATOR


2. CONNECT FUEL RETURN PIPE TO FUEL PRESSUREREGULATOR

(a) Install the bolt and connect the fuel return pipe to thedelivery pipe.Torque: 7.8 N �m (80 kgf �cm, 69 in. �lbf)

(b) Install the fuel return pipe to pressure regulator withnew gaskets and union bolt.Torque: 20 N �m (200 kgf �cm, 14 ft �Ibf)

3. CONNECT VACUUM SENSING HOSE TO FUELPRESSURE REGULATOR

4. CHECK FOR FUEL LEAKS (See page EG-122 )

FUEL PRESSURE REGULATORINSTALLATION1. INSTALL FUEL PRESSURE REGULATOR(a) Apply a light coat of gasoline to a new O-ring, and

install it to the pressure regulator.

(b) Rotate the pressure regulator to the left and rightwhile installing it into the delivery pipe.

(c) Check that the pressure regulator rotates smoothly.NOTICE: If it does not rotate smoothly, the O-ring maybe pinched, so remove the pressure regulator and per-form again steps (b) and (e) above.

(d) Install the pressure regulator and torque the 2 bolts.Torque: 7.8 N-m (80 kgf-cm, 69 in.-lbf)


2. INSPECT INJECTOR RESISTANCE(a) Disconnect the injector connector.(b) Using an ohmmeter, measure the resistance between

the terminals.Resistance:Approx. 13.8 � at 20�C (68�F)If the resistance is not as specified, replace the injec-tor.

(c) Reconnect the injector connector.

ON-VEHICLE INSPECTION1. INSPECT INJECTOR OPERATIONCheck the operating sound from each injector.(a) With the engine running or cranking, use a sound

scope to check that there is normal operating noise inproportion to engine rpm.

(b) If you have no sound scope, you can check the injec-tor transmission operating with your finger.If no sound or an unusual sound is heard, check thewiring connector, injector, or injection signal from theECM.

INJECTOR


INJECTORS REMOVAL1. DISCONNECT NEGATIVE TERMINAL CABLE FROM

BATTERYCAUTION (w/ SRS): Work must be started after 90 sec-onds from the time the ignition switch is turned to the“LOCK” position and the negative (-) terminal cable isdisconnected from the battery.

2. REMOVE AIR CLEANER CAP AND HOSE3. DISCONNECT ACCELERATOR CABLE4. A/T:

DISCONNECT THROTTLE CABLE5. DISCONNECT VACUUM SENSING HOSE FROM

FUEL PRESSURE REGULATOR6. DISCONNECT FUEL RETURN HOSE FROM FUEL

RETURN PIPENOTICE: Catch leaking in a container.

10. REMOVE DELIVERY PIPE WITH INJECTORS(a) Remove the 2 bolts and delivery pipe together with

the 4 injectors.NOTICE: Be careful not to drop the injectors when rem-oving the delivery pipe.

(b) Pull out the 4 injectors from the delivery pipe.(c) Remove the 2 spacers and 4 insulators from the cylin-

der head.

8. DISCONNECT FUEL INLET PIPE FROM DELIVERYPIPERemove the union bolt, 2 gaskets and inlet pipe.9. DISCONNECT INJECTOR CONNECTORS

7. DISCONNECT FUEL RETURN PIPE FROM FUELPRESSURE REGULATOR(See step 2 on page EG-162 )


(e) Connect SST (union and hose) to the injector, and holdand injector and union with SST (clamp).SST 09268-41045

(f) Put the injector into a graduated cylinder.HINT: Install a suitable vinyl tube on the injector toprevent gasoline from splashing out.

(g) Reconnect the battery negative (-) cable.(h) Turn the ignition switch ON.

NOTICE: Do not start the engine.

(c) Remove the fuel pressure regulator.(See page EG-162 )

(d) Connect the fuel return hose and SST (hose) to thepressure regulator with SST (union), new gaskets andunion bolt.SST 09268-41045 (09268-41080, 09268-41090)

(a) Disconnect the fuel hose from the fuel filter outlet.(b) Connect the SST (union and hose) to the fuel filter

outlet.SST 09268-41045 (90405-09015)HINT: Use the vehicle’s fuel filter.

INJECTORS INSPECTION1. INSPECT INJECTOR INJECTION

CAUTION: Keep injector clear of sparks during the test.

(i) Using SST, connect terminals +B and FP of the datalink connecter 1.SST 09843-18020


(j) Connect SST (wire) to the injector and battery for 15seconds and measure the injection volume with thegraduated cylinder. Test each injector 2 or 3 times.SST 09842-30070Injection volume:34 - 44 cm3 (2.1 - 2.7 cu in.)/ 15 sec.Difference between each injector:5 cm3 (0.3 cu in.) or less

If the injection volume is not as specified, replace theinjector.2. INSPECT LEAKAGE(a) In the condition above, disconnect test probes of SST

(wire) from the battery and check for fuel leakagefrom the injector.SST 09842-30070Fuel drop:One drop or less per 3 minutes

(b) Disconnect the battery negative (-) cable.(c) Remove SST.

SST 09268-41045 and 09843-18020

INJECTORS INSTALLATION1. INSTALL INJECTORS AND DELIVERY PIPE(a) Install a new grommet to the injector.(b) Apply a light coat of gasoline to an O-ring and install

it to the injector.

(c) While turning the injector to the left and right, installit to the delivery pipe. Install the 4 injectors.HINT: Alternately install the No.1 injectors with darkblue connectors and No.2 injectors with brown con-nectors as shown in the illustration.


4. CONNECT FUEL RETURN PIPE TO FUEL PRESSUREREGULATOR(See step 2 on page EG-163 )

5. CONNECT FUEL RETURN HOSE TO FUEL RETURNPIPE6. CONNECT VACUUM SENSING HOSE TO FUEL

PRESSURE REGULATOR7. A/T:

CONNECT THROTTLE CABLE, AND ADJUST IT

(g) Check that the injectors rotate smoothly.HINT: If the injectors do not rotate smoothly, theprobable cause is incorrect installation of O-rings.Replace the O-rings.

2. CONNECT INJECTOR CONNECTORSConnect the gray connectors to the No. 1 injectors andthe brown connectors to No.2 injectors.

(d) Place the 2 spacers and 4 insulators in position on thecylinder head.

(e) Place the injectors together with the delivery pipe onthe cylinder head.

3. CONNECT FUEL INLET PIPE TO DELIVERY PIPEInstall 2 new gaskets, the inlet pipe and union bolt.Torque: 29 N �m (300 kgf �cm, 22 ft �lbf)

(f) Install the 2 bolts. Torque the bolts.Torque: 19 N �m (190 kgf �cm, 14 ft �lbf)


8. CONNECT ACCELERATOR CABLE, AND ADJUST IT9. INSTALL AIR CLEANER CAP AND HOSE10. INSTALL PCV HOSES11. CONNECT NEGATIVE TERMINAL CABLE TO

BATTERY12. CHECK FOR FUEL LEAKS (See page EG-122 )


FUEL TANK AND LINECOMPONENTS


FUEL LINES AND CONNECTIONSINSPECTION(a) Check the fuel lines for cracks or leakage, and all

connections for deformation.(b) Check the fuel tank vapor vent system hoses and

connections for looseness, sharp bends or damage.(c) Check the fuel tank for deformation, cracks, fuel leak-

age or tank band looseness.(d) Check the filler neck for damage or fuel leakage.(e) Hose and the tube connections are as shown in the

illustration.(f) Make sure the hose clamps do not interfere with the

tank, tubes, hoses and other parts.If a problem is found, repair or replace the parts asnecessary.

PRECAUTIONS1. Always use new gaskets when replacing the fuel

tank or components parts.2. Apply the proper torque to all parts tightened.


ON-VEHICLE INSPECTION1. INSPECT THROTTLE BODY(a) Check that the throttle linkage moves smoothly.

THROTTLE BODY

Federal and Canada California


2. INSPECT THROTTLE POSITION SENSOR(a) California only:

Apply vacuum to the throttle opener.(b) Disconnect the sensor connector.(c) Insert a thickness gauge between the throttle stop

screw and stop lever.(d) Using an ohmmeter, measure the resistance between

each terminal.

3. FEDERAL AND CANADA:INSPECT DASHPOT (DP)

(a) Warm up engineAllow the engine to warm up to normal operatingtemperature.

(b) Check the vacuum at each port.

• Start the engine.

• Check the vacuum with your finger.

(b) Disconnect VSV for idle-up connector.

(e) Reconnect the sensor connector.

Clearance betweenlever and stop screw

throttle valvefully opened

*California only

0.70 mm (0.028 in.)

0.50 mm (0.020 in.)

Other than idling

Betweenterminals

3.3 - 10 k�

2.3 k� or less

IDL - E2

0.2 - 0.8 k�0 mm (0 in.)

Resistance

No vacuum No vacuum

Port name

No vacuum

No vacuum

VTA - E2

VTA - E2

IDL-E2

3 -7k�

At idling

VC - E2

Infinity

Vacuum

Vacuum

-ENGINE M FI SYSTEMEG-173

(c) Check idle speed (See page MA-1 1)Idle speed (w/ Cooling fan OFF and at Neutral):M/T750±50 rpmA/T800±50 rpm

If not at specified speed, adjust with the DP adjustingscrew.(6) Reinstall the DP separator, filter and cap.

(4) Release the throttle valve.(5) Check the DP setting speed.DP setting speed (w/ Cooling fan OFF):

1,500 ± 100 rpm

(d) Check and adjust DP setting speed(1) Remove the cap, filter and separator from DP.

(2) Race the engine at 2,500 rpm for a few seconds.(3) Plug the VTV hole.


(e) Check VTV operationRace the engine at 2,500 rpm for a few seconds,release the throttle valve and check that the enginereturns to idle in approx. 0.5 seconds.

(f) Reconnect idle-up VSV connector4. CALIFORNIA:

INSPECT THROTTLE OPENER(a) Warm up engine

Allow the engine to warm up to normal operatingtemperature.

(b) Disconnect idle-up VSV connector

(c) Check idle speed (See page MA-1 1)Idle speed (w/Cooling fan OFF and at Neutral):M/T750 ± 50 rpmA/T800 ± 50 rpm

(3) Release the throttle valve.(4) Check the DP setting speed.

Throttle opener setting speed (w/ Cooling fan OFF):1,500 ± 300 rpm

If the throttle opener setting is not as specified, re-place the throttle body.

(d) Check throttle opener setting speed(1) Disconnect the vacuum hose from the throttleopener and plug the hose end.

(2) Maintain the engine speed at 2,500 rpm.


THROTTLE BODY REMOVAL1. DISCONNECT NEGATIVE TERMINAL CABLE FROM

BATTERYCAUTION (w/SRS) : Work must be started after 90 sec.onds from the time the ignition switch is turned to the’LOCK’ position and the negative (-) terminal cable isdisconnected from the battery.

2. REMOVE ENGINE UNDER COVER2. REMOVE ENGINE UNDER COVER2. DRAIN ENGINE COOLANT3. DISCONNECT ACCELERATOR CABLE FROM

THROTTLE LINKAGE4. A/T:

DISCONNECT THROTTLE CABLE FROMTHROTTLE LINKAGE

5. DISCONNECT EMISSION VACUUM HOSE(S)6. REMOVE PCV HOSES7. DISCONNECT THROTTLE POSITION SENSOR

CONNECTOR8. REMOVE DELIVERY PIPE WITH INJECTORS


5. California only:CHECK VTV BY BLOWING AIR INTO EACH SIDE

(a) Check that air flows without resistance from partsB to A.

(b) Check that air flows with difficulty from parts A to B.

(5) Reconnect the vacuum hose to the throttleopener.(e) Reconnect VSV for idle-up connector.

If the operation is not as specified, replace the VTV.HINT: Reinstall the VTV with side A toward the shutoff va Ive.


THROTTLE BODY INSPECTION1. CLEAN THROTTLE BODY BEFORE INSPECTION(a) Wash and clean the cast parts with a soft brush and

carburetor cleaner.(b) Using compressed air, blow all passages and aper-

tures in the throttle body.NOTICE: To prevent deterioration, do not clean the throt-tle position sensor and dash pot or throttle opener.

2. INSPECT THROTTLE VALVE(a) California only:

Apply vacuum to the throttle opener.(b) Check that there is no clearance between the throttle

stop screw and throttle lever when the throttle valveis fully closed.

3. INSPECT THROTTLE POSITION SENSOR(See step 2 on page EG-173 )

9. REMOVE THROTTLE BODY(a) Remove the 2 bolts, 2 nuts and throttle body with the

gasket.

(b) Disconnect the water hose, No.1 water bypass hoseand 2 No.4 air hoses.

4. IF NECESSARY, ADJUST THROTTLE POSITIONSENSOR

(a) Loosen the 2 screws of the sensor.


(b) California only:Apply vacuum to the throttle opener.

(c) Insert a 0.60 mm (0.024 in.) thickness gauge betweenthe throttle stop screw and stop lever.

(d) Connect the test probe of an ohmmeter to terminalsIDL and E2 of the sensor.

(e) Gradually turn the sensor clockwise until the ohmme-ter deflects, and secure it with the 2 set screws.

THROTTLE BODY DISASSEMBLY1. REMOVE AUXILIARY AIR VALVERemove the 4 screws, air valve, gasket and O-ring.

2. FEDERAL AND CANADA only:REMOVE DASHPOT

Remove the 2 bolts, dash pot and spring.

3. REMOVE THROTTLE POSITION SENSORRemove the 2 screws and throttle position sensor.

(f) Recheck the continuity between terminals IDL and E2.

Clearance betweenlever and stop screw

Continuity(IDL -E2)

0.70 mm (0.028 in.)

0.50 mm (0.020 in.)

No continuity

Continuity


THROTTLE BODY ASSEMBLY1. INSTALL THROTTLE POSITION SENSOR(a) Check that the throttle valve is fully closed.(b) Place the sensor on the throttle body as shown.(c) Turn the sensor clockwise, and temporarily install the

2 screws.2. ADJUST THROTTLE POSITION SENSOR


3. FEDERAL AND CANADA only:INSTALL DASH POTInstall the spring and dash pot with the 2 bolts.

THROTTLE BODY INSTALLATION1. INSTALL THROTTLE BODY(a) Connect the following hoses to the auxiliary air valve.

(1) Water hose(2) No.1 water bypass hose(3) 2 No.4 air hoses

4. INSTALL AUXILIARY AIR VALVE(a) Place a new gasket and O-ring on the throttle body.

(b) Install the air valve with the 4 screws.


2. INSTALL DELIVERY PIPE WITH INJECTORS(See step 1 on page EG-167 )Torque: 19 N �m (190 kgf �cm, 14 ft �lbf)

3. CONNECT THROTTLE POSITION SENSORCONNECTOR

4. INSTALL AIR CLEANER CAP AND HOSE5. INSTALL PCV HOSES6. CONNECT EMISSION VACUUM HOSE(S)7. A/T:

CONNECT THROTTLE CABLE, AND ADJUST IT8. CONNECT ACCELERATOR CABLE, AND ADJUST IT9. FILL WITH ENGINE COOLANT10. CONNECT NEGATIVE TERMINAL CABLE TO rtn)

BATTERY

(b) Install a new gasket and the throttle body with the 2bolts and 2 nuts.Torque: 13 N �m (130 kgf �cm, 9 ft �lbf)


ON-VEHICLE INSPECTIONINSPECT AUXILIARY AIR VALVE OPERATIONCheck the engine rpm by closing the air valve port onthe throttle body.At low temp. (Engine coolant temp.: Below 80� C(176� F))• When the port is closed, the engine rpm should

drop.After warm-up• When the port is closed, check that the engine

rpm does not drop more than 100 rpm.If operation is not as specified, replace the air valve.

AUXILIARY AIR VALVE REMOVAL1. REMOVE THROTTLE BODY (See page EG-175 )2. REMOVE AUXILIARY AIR VALVE FROM THROTTLE

BODYRemove the 4 screws, air valve, gasket and O-ring.

AUXILIARY AIR VALVE


AUXILIARY AIR VALVE INSTALLATION1. INSTALL AUXILIARY AIR VALVE TO THROTTLE

BODY(See step 3 on page EG-179 )

2. INSTALL THROTTLE BODY (Seepage EG-179 )


ELECTRONIC PARTS LOCATION


2. INSPECT EFI MAIN RELAYA. Inspect relay continuity(a) Using an ohmmeter, check that there is continuity

between terminals 1 and 2.(b) Check that there is no continuity between terminals 3

and 5.If continuity is not as specified, replace the relay.

B. Inspect relay operation(a) Apply battery voltage across terminals 1 and 2.(b) Using an ohmmeter, check that there is continuity

between terminals 3 and 5.If operation is not as specified, replace the relay.

3. REINSTALL EFI MAIN RELAY

EFI MAIN RELAY INSPECTION1. REMOVE EFI MAIN RELAY

EFI MAIN RELAY


CIRCUIT OPENING RELAY INSPECTION1. REMOVE CIRCUIT OPENING RELAY2. INSPECT CIRCUIT OPENING RELAYA. Inspect relay continuity(a) Using and ohmmeter, check that there is continuity

between terminals STA and E1.(b) Check that there is continuity between terminals +B

and FC.(c) Check that there is no continuity between terminals +

B and FP.If continuity is not as specified, replace the relay.

B. Inspect relay operation(a) Apply battery voltage across terminals STA and E1.(b) Using an ohmmeter, check that there is continuity

between terminals +B and FP.

(c) Apply- battery voltage across terminals +B and FC.(d) Check that there is continuity between terminals +B

and FP.If operation is not as specified, replace the relay.

3. REINSTALL CIRCUIT OPENING RELAY

CIRCUIT OPENING RELAY


2. INSPECT VSVA. Inspect VSV for open circuit

Using an ohmmeter, check that there is continuitybetween the terminals.Resistance:37 - 44 � at 20� C 68� FIf there is no continuity, replace the VSV.

B. Inspect VSV for groundUsing an ohmmeter, check that there is no continuitybetween each terminal and body.If there is continuity, replace the VSV.

VSV INSPECTION7. REMOVE VSV

VSV FOR IDLE-UP


(b) Apply battery voltage across the terminals.(c) Check that air flows from ports E to F.

If operation is not as specified, replace the VSV.

C. Inspect VSV operation(a) Check that air does not flow from ports E to F.

3. REMOVE VSV


2. INSPECT VSVA. Inspect VSV for open circuit

Using an ohmmeter, check that there is continuitybetween the terminals.Resistance:33 - 39 � at 20°C (68°F)If there is no continuity, replace the VSV.

B. Inspect VSV for groundUsing an ohmmeter, check that there is no continuitybetween each terminal and the body.If there is continuity, replace the VSV.

VSV FOR FUEL PRESSURE CONTROL



(b) Apply battery voltage across the terminals.(c) Check that the air flows from ports E to F.


C. Inspect VSV operation(a) Check that the air flows from ports E to P.

3. REINSTALL VSV


2. INSPECT VSVA. Inspect VSV for open circuitUsing an ohmmeter, check that there is continuitybetween the terminals.Resistance:33 - 39 � at 20°C (68°F)If there is no continuity, replace the VSV.


VSV FOR THROTTLE OPENER(California only)





C. Inspect VSV operation(a) Check that the air flows from ports E to P.

3. REINSTALL VSV


2. INSPECT VSVA. Inspect VSV for open circuitUsing an ohmmeter, check that there is continuitybetween the terminals.Resistance:37 - 44 � at 20°C (68°F)If there is no continuity, replace the VSV.



VSV FOR EGR(California only)




C. Inspect VSV operation(a) Check that the air does not flows from ports E to F.

3. REINSTALL VSV


ECT SENSOR INSPECTION1. DRAIN ENGINE COOLANT2. REMOVE ECT SENSOR3. INSPECT ECT SENSOR

Using an ohmmeter, measure the resistance betweenthe terminals.Resistance:Refer to the graphIf the resistance is not as specified, replace the ECTsensor.

4. REINSTALL ECT SENSOR5. REFILL WITH ENGINE COOLANT

ENGINE COOLANT TEMPERATURE(ECT) SENSOR


IAT SENSOR INSPECTION1. REMOVE IAT SENSOR2. INSPECT IAT SENSORUsing an ohmmeter, measure the resistance betweenthe terminals.Resistance:Refer to the graphIf the resistance is not as specified, replace the IATsensor.3. REINSTALL IAT SENSOR

INTAKE AIR TEMPERATURE (IAT)SENSOR


MAP SENSOR INSPECTION1. REMOVE MAP SENSOR2. INSPECT POWER SOURCE VOLTAGE OF MAP

SENSOR(a) Disconnect the MAP sensor connector.(b) Turn the ignition switch ON.(c) Using a voltmeter, measure the voltage between ter-

minals VCC and E2 of the MAP sensor connector.Voltage:4-6V

(d) Reconnect the MAP sensor connector.3. INSPECT POWER OUTPUT OF MAP SENSOR(a) Turn the ignition switch ON.(b) Disconnect the vacuum hose on the air intake cham-

ber side.(c) Connect a voltmeter to terminals PIM and E2 of the

ECM, and measure the output voltage under ambientatmospheric pressure.

(d) Apply vacuum to the MAP sensor in 13.3 kPa (100mmHg, 3.94 in.Hg) segments to 66.7 kPa (500 mmHg,19.69 in.Hg).

(e) Measure the voltage drop from step (c) above for eachsegment.

MANIFOLD ABSOLUTE PRESSURE (MAP)SENSOR


(f) Reconnect the vacuum hose to the air intake cham-ber.

AppliedVacuum

kPa(mmHgin.Hg)

66.7

( 500 19.69)

53.5

(400 15.75)

40.0

( 30011.81)

13.3

(1003.94)

26.7

(2007.87)

Voltagedrop V

Voltage:

0.3-0.5 0.7-0.9 1.9 - 2.11.5 - 1.71.1 -1.3


EGR GAS TEMPERATURE SENSORINSPECTION1. REMOVE EGR GAS TEMPERATURE SENSOR2. INSPECT EGR GAS TEMPERATURE SENSOR

Using an ohmmeter, measure the resistance betweenthe terminals.Resistance:69 - 89 k� at 50�C (122�F)11 - 15 k� at 100�C (212�F)2 - 4 k� at 150�C (302�F)If the resistance is not as specified, replace thesensor.

3. REINSTALL EGR GAS TEMPERATURE SENSOR

EGR GAS TEMPERATURE SENSOR(California only)


OXYGEN SENSOROXYGEN SENSOR INSPECTION1. WARM UP ENGINE

Allow the engine to reach normal operating tempera-ture.

2. INSPECT FEEDBACK VOLTAGEConnect the positive (+) probe of a voltmeter toterminal VF of the data link connector 1, and negative(-) probe to terminal E1. Perform the test as follows:

Using SST, connect terminals T and E1 of the checkconnector.SST 09843- 18020And maintain engine speed at 2,500 rpm.

Warm up the oxygen sensor with the engine at 2,500rpm for approx. 120 seconds. And maintain enginespeed at 2,500 rpm.

Disconnect terminals T and E1 of the check connector.And maintain engine speed at 2,500 rpm.

Warm up the oxygen sensor with the engine at 2,500rpm for approx. 120 seconds.

Check the number of times the voltmeter needle fluc-tuates in 10 seconds.

After replacingthe oxygen sensor

Check the number of times the voltmeter needle fluctuates in 10 seconds.

Read and record diagnostic codes. (See page EG-129 )

Measure voltage between terminals VF and E1.

Malfunction code(s)(Ex. code Nos. 21, 25 and 26)

Repair the relevant diagnostic codes.

CONTINUED ON PAGE EG-200

Normal code, codeNos. 21, 25 and 26

Replace the ECU.

Less than 8 times

Less than 8 times

8 times or more

More than 0 V

8 timesor more

Normal

Zero

Zero

Zero again


Disconnect the water temp. sensor connector and connectresistor with a resistance of 4 - 8 k� or send an equivalentsimulation signal.

Warm up the oxygen sensor with the engine at 2,500 rpmfor approx. 120 seconds. And maintain engine speedat 2,500 rpm.

Disconnect terminals T and E1 of the check connector.And maintain engine speed at 2,500 rpm.

CONTINUED FROM PAGE FI-78

(1) (2)

Read and record diagnostic codes. (See page EG-129 )

Malfunction code(s)(Ex. code Nos. 21, 25 and 26)

Connect terminals T and E1 of the check connector.




Normal code, code Nos.21, 25 and 26

Repair the relevant diagnostic code.

Replace the oxygen sensor.

Disconnect the PCV hose.

Repair (Over lean)

Repair (Over rich)

More than 0 V


2. INSPECT VOLTAGE OF ECMCheck the voltage between each terminal of thewiring connectors.• Turn the ignition switch ON.• Measure the voltage at each terminal.HINT• Perform all voltage measurements with the con-

nectors connected.• Verify that the battery voltage is 11 V or more

when the ignition switch is ON.

ENGINE CONTROL MODULE (ECM)ECM INSPECTION

HINT: The MFI circuit can be checked by measuringthe resistance and voltage at the wiring connectors ofthe ECM.1. PREPARATION (See page EG-137 )


No trouble (”CHECK” engine warning light off) and engine running.

ECM Wiring Connectors Voltage

Check connector T - E1 not connected



Ex. neutral start switch P or N range

Check connector T - E1 connected

Neutral start switch P or N range



No. 10 E01No. 20 E02

Air conditioning ON

Throttle valve open

VTA - E2

ECM Terminals

STD Voltage ConditionTerminals

IG SW ON

IG SW ON

!G SW ON

IG SW ON

!G SW ON

IG SW ON

NSW - E1

BATT - E1

Cranking

+ B1 - E1

A/C - E1

0.5-3.4

6 or more

0.2-1.0

ACT - E1

THW-E2

PIM - E2

0.7-1.0

STA - E1

0.3-0.8

VCC - E2

THA - E2

IGT - E1

IDL - E2

4.5-5.5

3.2-4.2

9-14

3.3-3.9

+B - E1

1 or less

W - E1

9-14

9-14

9-14

9-14

9-14

9-14

Idling

9-14

T - El

Idling

0-2

-


3. INSPECT RESISTANCE OF ECMNOTICE:

• Do no touch the ECM terminals.• The tester probe should be inserted in the wiring

connector from the wiring side.Check the resistance between each of the termi-nals ofthe wiring connector.

• Disconnect the connectors from the ECM.• Measure the resistance at each terminal.

ECM Wiring Connectors Resistance

(HOT) 50�C (122F�) to 100�C (212�F)

(Cold) -10�C (14�F) to 50�C (122�F)






Throttle valve open

2.3 k� or less

475 - 650 �

0.2 - 0.4 k�

370 - 550 �

0.2 - 0.8 k�

Resistance

3.3 - 10 k�

ConditionTerminals

NE- NE�

THW - E2

VCC - E2

THA - E2

IDL - E2

VTA - E2

3-7 k�

2-3 k�

Infinity


2. CONNECT TACHOMETERConnect the test probe of a tachometer to terminal IG� of the data link connector 1.NOTICE• Never allow the tachometer terminal to touch

ground as it could result in damage to the igniterand/or ignition coil.

• As some tachometers are not compatible with thisignition system, we recommend that you confirmthe compatibility of yours before use.

3. INSPECT FUEL CUT OPERATION(a) Increase the engine speed to at least 2,500 rpm.(b) Check for injector operating sound.(c) Check that when the throttle lever is released,

injector operation sound stops momentarily andthen resumes.

HINT:• The vehicle should be stopped.• Accessories switched OFF.

Fuel return rpm:1.300 rpm

4. REMOVE TACHOMETER

FUEL CUT RPMFUEL CUT RPM INSPECTION1. WARM UP ENGINEAllow the engine to warm up to normal operatingtemperature.


+ B - E1 IG SW ON+B1- El IG SW ONBATT - E1IDL - E1 IG SW ON (Throttle valve open)VTA - E2 IG SW ON (Throttle valve fully closed)VTA - E2 IG SW ON (Throttle valve fully open)No.10 - E01, No.20 - E02 IG SW ONW - E1 No trouble (Malfunction Indicator Lamp off) and engine runningPIM - E2 IG SW ONVCC - E2 IG SW ON

10 - 1410 - 1410 - 144.5 - 5.50.8 - 1.23.2 - 4.210 - 1410 -143.3 - 3.94.5 - 5.5

0 mm (0 in.)0.50 mm (0.020 in.)0.70 mm (0.028 in.)Positioned with throttle valve fully opened

Throttle valve fully closed angleDash pot (DP) setting speed (Federal and Canada)Throttle opener setting speed (California)


at -20 � C (-4 �F)at 0 � C (32 �F)

at 20 � C (68 �F)at 40 � C (104 �F)at 60 �C (140 �F)at 80�C (176 �F)

Approx. 13.8 �34 - 44 cc(2.1 - 2.7 cu in.)/15 sec5 cc (0.3 cu in.) or less1 drop or less/ 3 min.

10 - 20 k�4 - 7 k�2 - 3 k�0.9 - 1.3 k�0.4 - 0.7 k�0.2 - 0.4 k�

0.2 - 0.8 k�2.3 k� or lessInfinity3.3 - 10 k�3 - 7 k�

281 - 287 kPa(2.87 - 2.93 kgf/cm2,40.8 - 41.7 psi)

EGR gas temp. sensor(California only)

69.40 - 88.50 k�11.89 - 14.37 k�2.79 - 3.59 k�

at 50 �C (122 �F)at 100 � C (212 �F)at 150 � C (302 �F)

6�1,500 � 100 rpm1,500� 300 rpm

VTA - E2IDL - E2IDL - E2

VTA - E2VC - E2

VSV for throttle opener(California only)

VSV for Fuel controlcontrol

Clearance between stop screw and lever

Difference volumeLeakage

ResistanceInjection volume

Fuel pressure regulator

Throttle Position sensor

33 - 39�

Resistance

ECT sensorIAT sensor

at 20�C (68�F)

Throttle body

33 - 39 �

at 20�C (68�F)

at 20�C (68�F)VSV for idle up

Fuel pressure

ECM Voltage

20°C (68°F)

at No vacuum

Voltage (V)

0.2 - 3.0�

VSV for EGR

Resistance

37 - 44 �

Fuel pump

37 -44�

Resistance

Resistance

Resistance

Resistance

Resistance

Resistance

at Cold

Terminals Condition

terminals

Injector at 20°C (68°F)


THW - E2 IG SW ON (intake air temp. 20 °C (68° F))THW - E2 IG SW ON (Engine coolant temp. 80 °C (176 °F))STA - E 1 CrankingIGT - E1 IG SW ONA/C - E 1 IG SW ON (Air conditioning ON)ACT - E1 IG SW ON (Idling)T - E1 IG SW ON (Data link connector 1 T - E1 not connected)T - E1 IG SW ON (Data link connector 1 T - E1 connected)NSW - E1 IG SW ON (Park/Neutral position switch P or N position)NSW - E1 IG SW ON (Ex.Park/Neutral position switch P or N position)

w/ Vehicle speed 0 km/h and engine coolant temp.80 °C (176 °F)Fuel cut rpmFuel return rpm

Infinity2.3 or less3.3 - 100.2-0.83-72-30.2-0.4370 - 5300

2.0 - 2.80.4 - 0.76 - 140.7 - 1.08 - 148 - 1410 - 141 or less0 - 26 - 14

Throttle valve openThrottle valve closed

Throttle valve fully openThrottle valve fully closed

IDL - E2IDL - E2VTA - E2VTA - E2VCC - E2THA - E2TH W - E2NE - NE�

Intake air temp. 20°C (68°F)Engine coolant temp. 80°C (176°F)


Fuel return pipe x Fuel pressure regulator

Fuel pump bracket x Fuel cut-off valve

Fuel pressure regulator x Delivery pipe

Fuel outlet pipe x Fuel pump bracket

Fuel return pipe x Delivery pipe

Throttle body x Intake manifold

Fuel tank x Fuel tank filler pipe

Fuel tank x Fuel pump set bolt

Delivery pipe x Cylinder head

Fuel line (Union bolt type)

ECM Voltage(cont’d)

Fuel inlet hose x Fuel filter

Fuel line (Flare nut type)

1,900 rpm1,300 rpm

Resistance ( k� )

Fuel tank x Body

ECM Resistance

Part tightened

Fuel cut rpm

Terminals Condition

30 in.�lbf

69 in.�lbf

69 in.�lbf

30 in.�lbf

kgf�cm ft�lbf

300

310

300

200

340

130

150

300

190

N�m

7.8

7.8

3.4

3.4


The cooling system is composed of the water jacket (inside the cylinder block and cylinder head),radiator, water pump, thermostat, electric fan, hoses and other components.Coolant which is heated in the water jacket is pumped to the radiator, through which an electricfan flows air cool the coolant as is passes through. Coolant which has been cooled is then sentback to the engine by the water pump, where it cools the engine.The water jacket is a network of channels in the shell of the cylinder block and cylinder headthrough which coolant passes. It is designed to provide adequate cooling of the cylinders andcombustion chambers which become the hottest part during engine operation.

DESCRIPTIONThis engine utilizes a pressurized water forced circulation cooling system which includes athermostat equipped with a bypass valve mounted on the inlet side.

COOLING SYSTEM

-ENGINE COOLING SYSTEMEG-207

RADIATORThe radiator performs the function of cooling the coolant which has passes through the waterjacket and become hot, and is mounted in the front of the vehicle. The radiator consists of anupper tank and lower tank, and a core which connects the two tanks. The upper tank contains theinlet for coolant from the water jacket and the filter inlet. It also has a hose attached throughwhich excess coolant or steam can flow. The lower tank contains the outlet for coolant and thedrain cock. The core contains many tubes through which coolant flows from the upper tank to thelower tank as well as cooling fins which radiate heat away from the coolant in the tubes. The airsucked through the radiator by the electric fan, as well as the wind generated by the vehicle’stravel, passes through the radiator, cooling it. Models with automatic transmissions include anautomatic transmission fluid cooler built into the lower tank of the radiator. A fan with an electricmotor is mounted behind the radiator to assist the flow of air through the radiator. The fan operateswhen the coolant temperature becomes high in order to prevent it from becoming too high.RADIATOR CAPThe radiator cap is pressure type cap which seals the radiator and the resulting pressurization ofthe radiator as the coolant expands. The pressurization prevents the coolant from boiling evenwhen the coolant temperature exceeds 100°C (212°F). A relief valve (pressurization valve) and a

vacuum valve (negative pressure valve) and built into the radiator cap. The relief valve opens and

lets steam escape through the overflow pipe when the pressure generated inside the cooling system

exceeds the limit (coolant temperature: 110−120°C (230−248°F), pressure; 58.8−103.0 kPa

(060−1.05 kg/cm2, 8.5-14.9 psi)). The vacuum valve opens to alleviate the vacuum which develops

in the coolant system after the engine is stopped and the coolant temperature drops. The valve’sopening allows the pressure in the cooling system to return to the coolant in the reservoir tank.RESERVOIR TANKThe reservoir tank is used to catch coolant which overflows the cooling system as a result ofvolumetric expansion when the coolant is heated. The coolant in the reservoir tank returns to theradiator when the coolant temperature drops, thus keeping the radiator full at all times andavoiding needless coolant loss. Check the reservoir tank level to find out if the coolant needs tobe replenished.WATER PUMPThe water pump is used for forced circulation of coolant through the cooling system. It ismounted on the front of the cylinder block and driven by a V-ribbed belt.THERMOSTATThe thermostat has a wax type bypass valve and is mounted in the water inlet housing. Thethermostat includes a type of automatic valve operated by fluctuations in the coolant tempera-ture. This valve closes when the coolant temperature drops, preventing the circulation of coolantthrough the engine and thus permitting the engine to warm up rapidly. The valve opens when thecoolant temperature has risen, allowing the circulation of coolant. Wax inside the thermostatexpands when heated and contracts when cooled. Heating the wax thus generates pressurewhich overpowers the force of the spring which keeps the valve closed, thus opening the valve.When the wax cools, its contraction causes the force of the spring to take effect once more,closing the valve. The thermostat in this engine operates at a temperature of 82�C (180�F).



08826-00100 Seal Packing 1282B,THREE BOND 1282B or equivalent


4.9 liters(5.2 US qts, 4.3 Imp. qts)5.4 liters (5.7 US qts, 4.8 Imp. qts)

Ethylene-glycol base

RECOMMENDED TOOLS09082-00050 TOYOTA Electrical Tester Set

09230-01010 Radiator Service Tool Set

09258-00030 Hose Plug Set

Engine coolant(w/Heater)

EQUIPMENTRadiator cap tester

COOLANT

Torque wrench

Capacity . Classification

Water pump

M/TA/T

Item


3. REPLACE ENGINE COOLANT(a) Remove the radiator cap.

CAUTION: To avoid the danger of being burned, do notremove it while the engine and radiator are still hot, asfluid and steam can be blown out under pressure.

(b) Drain the coolant from the radiator and engine draincocks. (The engine drain cock is near the oil filter.)

(c) Close the drain cocks.Torque (Engine drain cock):25 N�m (250 kgf �cm, 18 ft �lbf)

(d) Fill the system with coolant.Use a good brand of ethylene-glycol base coolant,mixed according to the manufacturer’s direction.Using coolant which includes more than 50% ethylene-glycol (but not more than 70%) is recommended.NOTICE:

• Do not use alcohol type coolant.• The coolant should be mixed with demineralized

water or distilled water.Coolant capacity (w/Heater or A/C):M/T4.9 liters (5.2 US qts, 4.3 Imp.qts)A/T5.4 liters (5.7 US qts, 4.8 Imp.qts)

(e) Install the radiator cap.(f) Start the engine and check for leaks.(g) Recheck the coolant level and refill as necessary.

COOLANT CHECK AND REPLACEMENT1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR

TANKThe coolant level should be between the ”LOW” and”FULL” lines at low temperature.If flow, check for leaks and add coolant up to the”FULL” line.

2. CHECK ENGINE COOLANT QUALITYThere should be no excessive deposits of rust orscales around the radiator cap or radiator filler hole,and the coolant should be free from oil.If excessively dirty, replace the coolant.


4. REMOVE INTAKE MANIFOLD STAYRemove the bolt, nut and intake manifold stay.

WATER PUMP REMOVAL1. REMOVE RH ENGINE UNDER COVER2. DRAIN ENGINE COOLANT3. REMOVE GENERATOR (See page CH-8 )

WATER PUMPCOMPONENTS FOR REMOVAL ANDINSTALLATION

-ENGINE COOLING SYSTEMEG-21 1

6. REMOVE OIL DIPSTICK GUIDE AND GENERATORADJUSTING BAR

(a) Remove the oil dipstick.(b) Remove the mounting bolt of the dipstick guide clamp

and generator adjusting bar.(c) Pull out the dipstick guide. Plug the guide installation

hole of the oil pump.(d) Remove the O-ring from the dipstick guide.

INSPECT WATER PUMP BEARINGCheck that the water pump bearing operation is no1rough or noisy.If necessary, replace the water pump assembly.

5. REMOVE WATER INLET PIPE(a) Disconnect the following hoses:

(1) Water inlet hose(2) Heater inlet hose(3) Water bypass hose

7. REMOVE WATER PUMPRemove the bolt, 2 nuts and water pump.

(b) Remove the bolt, water inlet pipe and O- ring.

WATER PUMP INSPECTION


WATER PUMP INSTALLATION(See Components for Removal and Installation)1. INSTALL WATER PUMP(a) Remove any old packing (FIPG) material and be care-

ful not to drop any oil on the contact surfaces of thewater pump and cylinder block.

• Using a razor blade and gasket scraper, removeall the old packing (FIPG) material from the con-tact surfaces and sealing groove.



(b) Apply seal packing to the water pump groove.Seal packing:Part No.08826-00100, THREE BOND 1282B orequivalent• Install a nozzle that has been cut to a 2-3 mm

(0.08-0.12 in.) opening.HINT:Avoid applying an excessive amount to the sur-face.

• Parts must be assembled within 5 minutes ofapplication. Otherwise the material must be re-moved and reapplied.


• Do not pour in any coolant until at least 2 hoursafter installation is completed.

2. INSTALL OIL DIPSTICK GUIDE AND GENERATORADJUSTING BAR

(a) Install a new O-ring to the dipstick guide.(b) Apply soapy water to the O-ring.(c) Push in the dipstick guide, and install it with the

mounting bolt of the generator adjusting bar and dip-stick guide clamp.Torque: 18 N �m (185 kgf �cm, 13 ft �lbf)

(d) Install the oil dipstick.

(c) Install the water pump with the bolt and 2 nuts.Torque: 17 N �m (175 kgf �cm, 13 ft �lbf)


3. INSTALL WATER INLET PIPE(a) Install a new O-ring to the water inlet pipe.(b) Apply a little soap and water to the O-ring.(c) Insert the water inlet pipe to the water pump.

NOTICE: Installing the water inlet pipe at an angle ortwisting it during installation will cause pinching ortearing of the O-ring.

4. INSTALL INTAKE MANIFOLD STAYInstall the intake manifold stay with the bolt and nut.


5. INSTALL GENERATOR (See page CH-21 )6. INSTALL RH ENGINE UNDER COVER7. REFILL WITH ENGINE COOLANT8. START ENGINE AND CHECK FOR LEAKS

(e) Connect the following hoses:(1) Water inlet hose(2) Heater inlet hose(3) Water hose

(d) Install the water inlet pipe with the bolt.Torque: 6.4 N �m (75 kgf �cm, 54 in. �lbf)


(c) Check the valve lift.Valve lift:8 mm (0.31 in.) or more at 95 �C (203�F)If the valve lift is not as specified, replace the thermo-stat.

(d) Check that the valve spring is tight when the thermo-stat is fully closed.If not closed, replace the thermostat.

THERMOSTATTHERMOSTAT REMOVALNOTICE: Do not remove the thermostat unless absolutelynecessary.HINT: Removal of the thermostat would have an ad-verse effect, causing a lowering of cooling efficiency.

1. DRAIN ENGINE COOLANT

(a) Immerse the thermostat in water and gradually heatthe water.

(b) Check the valve opening temperature.Valve opening temperature:80 - 84°C (176 - 183°F)If the valve opening temperature is not as specified,replace the thermostat.

THERMOSTAT INSPECTIONHINT: The thermostat is numbered with the valveopening temperature.

2. REMOVE WATER INLET AND THERMOSTAT(a) Remove the 2 nuts, water inlet and thermostat from

the water inlet housing.(b) Remove the gasket from the thermostat.


2. INSPECT RADIATOR CAPNOTICE: When performing steps (a) and (b) below, keepthe radiator pump tester at an angle of over 30 � abovethe horizontal.

(a) Using a radiator cap tester, slowly pump the testerand check that air is coming from the relief valve.Pump speed:1 push/3 seconds or moreNOTICE: Push the pump at a constant speed.If air is not coming from the relief valve, replace theradiator cap.

(b) Pump the tester several times and measure the reliefvalve opening pressure.Pump speed:1st time1 push/1 second or less2nd time or moreAny speedStandard opening pressure:74 - 103 kPa(0.75 - 1.05 kgf/cm 2, 10.7 - 14.9 psi)Minimum opening pressure:59 kPa (O.6 kgf/em 2, 8.5 psi)If the opening pressure is less than minimum, replacethe radiator cap.

RADIATOR CLEANINGUsing water or a steam cleaner, remove any mud anddirt from the radiator core.NOTICE: If using a high pressure type cleaner, be carefulnot to deform the fins of the radiator core. If the cleanernozzle pressure is 2,942 - 3,432 kPa (30 - 35 kg f/cm 2.427 - 498 psi), keep a distance of at least 40 cm (15.75in.) between the radiator core and cleaner nozzle.

RADIATOR INSPECTION1. REMOVE RADIATOR CAP

CAUTION: To avoid the danger of being burned, do notremove it while the engine and radiator are still hot, asfluid and steam can be blown out under pressure.


RADIATOR REMOVAL1. DISCONNECT CABLE FROM NEGATIVE TERMINAL

OF BATTERYCAUTION (w/ SRS): Work must be started after 90 sec-onds from the time the ignition switch is turned to the ’LOCK’ position and the negative (-) terminal cable isdisconnected from the battery.

2. REMOVE ENGINE UNDER COVERS3. DRAIN ENGINE COOLANT4. REMOVE AIR INTAKE CONNECTOR5. DISCONNECT COOLANT RESERVOIR HOSE

RADIATORRADIATOR INSPECTION1. CHECK COOLING SYSTEM FOR LEAKS(a) Fill the radiator with coolant and attach a radiator cap

tester.(b) Warm up the engine.(c) Pump it to 118 kPa (1.2 kgf/cm2, 17.1 psi)

If the pressure drops, check for leaks from the hoses,radiator or water pump. If no external leaks are found,check the heater core, block and head.

6. DISCONNECT RADIATOR HOSES7. A/T:

DISCONNECT OIL COOLER HOSESHINT:• Be careful as some oil will leak out. Catch it in a

suitable container.

• Plug the hose to prevent oil from escaping.8. DISCONNECT ELECTRIC COOLING FAN

CONNECTOR

9. REMOVE RADIATOR AND ELECTRIC COOLINGFAN

(a) Remove the 2 bolts and 2 upper supports.(b) Lift out the radiator.(c) Remove the 2 lower supports.


RADIATOR DISASSEMBLY1. ASSEMBLE SST

SST 09230-01010(a) Install the claw to the overhaul handle, inserting it in

the hole in part ”A” as shown in the diagram.(b) While gripping the handle, adjust the stopper bolt so

that dimension ”B” shown in the diagram is 0.2 - 0.5mm (0.008 - 0.0020 in.).

COMPONENTS FOR DISASSEMBLYAND ASSEMBLY

10. REMOVE ELECTRIC COOLING FAN FROMRADIATOR


RADIATOR ASSEMBLY(See Components for Disassembly and Assembly)1. A/T:

INSTALL OIL COOLER TO LOWER TANK(a) Clean the O-ring contact surface of the lower tank

and oil cooler.(b) Install new O-ring to the oil cooler.

4. A/T:REMOVE OIL COOLER FROM LOWER TANK

(a) Remove the 2 nuts, spring washers, plate washers andoil cooler.

(b) Remove the O-ring from the oil cooler.

3. REMOVE TANKS AND O-RINGS(a) Lightly tap the radiator hose inlet (or outlet) with soft

-faced hammer and remove the tank.(b) Remove the O-ring.

2. UNCAULK LOCK PLATESUsing SST to release the caulking, squeeze the handleuntil stopped by the stopper bolt.SST 09230 - 01010

NOTICE: If this adjustment is not performed, the clawmay be damaged.


2. INSPECT LOCK PLATEInspect the lock plate for damage.HINT:• If the sides of the lock plate groove are deformed,

reassembly of the tank will be impossible.• Therefore, first correct any deformation with

pliers or like object. Water leakage will result ifthe bottom of the lock plate groove is damagedor dented. Therefore, repair or replace if neces-sary.

3. INSTALL NEW O-RINGS AND TANKS(a) After checking that there are no foreign objects in the

lock plate groove, install the new O-ring withouttwisting it.HINT:When cleaning the lock plate groove, lightly rubit with sand paper without scratching it.

4. ASSEMBLE SSTSST 09230 - 01010(a) Install the punch assembly to the overhaul handle

inserting it in the hole in part ”A” as shown in theillustration.

(b) While gripping the handle, adjust the stopper bolt sothat dimension “B” shown in the diagram is 7.7 mm (0.30 in.).

(b) Install the tank without damaging the O-ring.(c) Tap the lock plate with a soft-faced hammer so that there is

no gap between it and the tank.

(c) Install the oil cooler with the O-rings to the lowertank.

(d) Install the plate washers, spring washers and nuts.Torque: 8.3 N �m (85 kgf �cm, 74 in. �lbf)


(b) Check the lock plate height (H) after completing thecaulking.Plate height:7.75 - 8.25 mm (0.305 - 0.325 in.)If not within the specified height, adjust the stopperbolt of the handle again and perform the caulkingagain.

5. CAULK LOCK PLATE(a) Lightly press SST against the lock plate in the order

shown in the illustration. After repeating this a fewtimes, fully caulk the lock plate by squeezing thehandle until stopped by the stopper plate.SST 09230-01010

• The points shown in the illustration and oil coolernear here (A/T) cannot be staked with the SST.Use pliers or like object and be careful not todamage the core plates.

HINT:• Do not stake the areas protruding around the

pipes, brackets or tank ribs.


6. INSPECT FOR WATER LEAKS(a) Tighten the drain plug.(b) Plug the inlet and outlet pipes of the radiator with

SST.SST 09230 - 01010

(c) Using a radiator cap tester, apply pressure to theradiator.Test pressure:177 kPa (1.8 kgf/cm 2, 26 psi)

(d) Inspect for water leaks.HINT: On radiators with resin tanks, there is a clear-ance between the tank and lock plate where a minuteamount of air will remain, giving the appearance of aleak when the radiator is submerged in water. There-fore, before performing the water leak test, first movethe radiator around in the water until a air bubblesdisappear.

7. PAINT LOCK PLATESHINT: If the water leak test checks out okay, allow theradiator to completely dry and then paint the lockplates.


3. CONNECT ELECTRIC COOLING FAN CONNECTOR4. A/T:

CONNECT OIL COOLER HOSES5. CONNECT RADIATOR HOSES6. CONNECT COOLANT RESERVOIR HOSE7. INSTALL AIR INTAKE CONNECTOR8. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY9. FILL WITH ENGINE COOLANT10. START ENGINE AND CHECK FOR LEAKS

11. A/T:CHECK AUTOMATIC TRANSMISSION (A/T) FLUIDLEVEL (See page MA - 17)NOTICE: Do not overfill.

12. INSTALL ENGINE UNDER COVERS

2. INSTALL RADIATOR(a) Place the 2 lower supports in position on the body.(b) Place the radiator in position, and install the 2 upper

supports with the 2 bolts.Torque: 12 N �m (120 kgf �cm, 9 ft �lbf)HINT:After installation, check that the rubber cushion(A) of the supports are not depressed.

RADIATOR INSTALLATION1. INSTALL ELECTRIC COOLING FAN TO RADIATOR

Torque: 4.9 N �m (50 kgf �cm, 43 in. �lbf)


ON-VEHICLE INSPECTIONLow Temperature (Below 83 °C (181°F))1. TURN IGNITION SWITCH ”ON”

Check that the cooling fan stops.If not, check that cooling fan relays and engine cool-ant temperature switch, and check for a separatedconnector or severed wire between the cooling farrelay and engine coolant temperature switch.

2. DISCONNECT ENGINE COOLANT TEMPERATURESWITCH CONNECTORCheck that the cooling fan rotates.If not, check the cooling fan relays, cooling fan, enginemain relay and fuse, and check for a short circuit betweenthe cooling fan relay and engine coolant temperatureswitch.

3. CONNECT ENGINE COOLANT TEMPERATURESWITCH CONNECTOR

ELECTRIC COOLING FANSYSTEM CIRCUIT


177fA-11

ELECTRIC COOLING FAN COMPONENTSINSPECTION1. INSPECT ENGINE COOLANT TEMPERATURE

SWITCHHINT: On the water inlet.

(a) Using an ohmmeter, check that there is continuitywhen the engine coolant temperature is below 83�C(181�F).

High Temperature (Above 94 �C (201�F))4. START ENGINE(a) Raise engine coolant temperature to above 94�C

(201�F).(b) Check that the cooling fan rotates.

If not, replace the engine coolant temperature switch.

A. Inspect relay continuity(a) Using an ohmmeter, check that there is continuity

between terminals 1 and 2.(b) Check that there is continuity between terminals 3


(b) Check that there is no continuity when the enginecoolant temperature is above 94�C (201�F).If continuity is not as specified, replace the switch.

2. INSPECT COOLING FAN MOTOR RELAY


B. Inspect relay operation(a) Apply battery voltage across terminals 1 and 3.(b) Using an ohmmeter, check that there is continuity

between terminals 4 and 5.(c) Check that there is no continuity between terminals 2

and 4.If operation is not as specified, replace the relay.

4. INSPECT COOLING FAN MOTOR(a) Connect battery and ammeter to the fan motor con-

nector.(b) Check to see that the motor rotates smoothly, and

check the reading on the ammeter.Standard amperage:A/T 5.7-7.7AM/T 8.6 - 11.6 AIf the amperage is not as specified, replace the coolingfan motor.

A. Inspect relay continuity(a) Using an ohmmeter, check that there is continuity

between terminals 1 and 3.(b) Check that there is no continuity between terminals 2

and 4.(c) Check that there is no continuity between terminals 4


B. Inspect relay operation(a) Apply battery voltage across terminals 1 and 2.(b) Using an ohmmeter, check that there is no continuity

between terminals 3 and 4.If operation is not as specified, replace the relay.

3. INSPECT ENGINE MAIN RELAY



Valve opening temperatureValve lift at 95�C (203�F)


Oil dipstick guide x RH engine mounting bracket

Intake manifold stay x Cylinder block

Water inlet x Water outlet housing

Water inlet pipe x Cylinder block

Radiator upper support x Body

Oil cooler x Radiator lower tank

Electric cooling fan x Radiator

Relief valve opening pressure

Water pump x Cylinder block

Drain plug x Cylinder block

Part tightened

Thermostat

Radiator

kgf�cm ft�lbfN�m


DESCRIPTIONA fully pressurized, fully filtered lubrication system has been adopted for this engine.

LUBRICATION SYSTEM

-ENGINE LUBRICATION SYSTEMEG-228

A pressure feeding lubrication system has been adopted to supply oil to the moving of thisengine. The lubrication system consists of an oil pan, oil pump, oil filter and other external partswhich supply oil to the moving parts in the engine block. The oil circuit is shown in the illustrationat the top of the previous page. Oil from the oil pan is pumped up by the oil pump. After it passesthrough the oil filter, it is fed through the various oil holes in the crankshaft and cylinder block.After passing through the cylinder block and performing its lubricating function, the oil isreturned by gravity to the oil pan. A dipstick on the side of the oil pump body is provided to checkthe oil level.OIL PUMPThe oil pump pumps up oil from the oil pan and sends it under pressure to the various parts of theengine. An oil strainer is mounted in front of the inlet to the oil pump. The oil pump itself is atrochoid type pump, inside of which is a drive rotor and a driven rotor. When the drive rotorrotates, the driven rotor rotates in the same direction, and since the axis of the drive rotor shaftis different from the center of the driven rotor, the space between the 2 rotors is changed as theyrotate. Oil is drawn when the space widens and is discharged when the space becomes narrow.OIL PRESSURE REGULATORAt high engine speeds, the engine oil supplied by the oil pump exceeds the capacity of the engineto utilize it. For that reason, the oil pressure regulator works to prevent an oversupply of oil.During normal oil supply, a coil spring and valve keep the bypass closed, but when too much oilis being fed, the pressure becomes extremely high, overpowering the force of the spring andopening the relief valves. This allows the excess oil to flow through the valve and return to the oilpan.OIL FILTERThe oil filter is a full flow type filter with a relief valve built into the paper filter element. Particlesof metal from wear, airborne dirt, carbon and other impurities can get in the oil during use andcould cause accelerated wear or seizing if allowed to circulate through the engine. The oil filter,integrated into the oil line, removes these impurities as the oil passes through it. The filter ismounted outside the engine to simplify replacement of the filter element. A relief valve is alsoincluded ahead of the filter element to relieve the high oil pressure in case the filter elementbecomes clogged with impurities. The relief valve opens when the oil pressure overpowers theforce of the spring. Oil passing through the relief valve bypasses the oil filter and flows directlyinto the main oil hole in the engine.



API grade SG or SH, Energy -Conserving llmultigrade engine oil or ILSAC multigradeengine oil and recommended viscosity oil

08833-00080 Adhesive 1344,THREE BOND 1344,LOCTITE 242 or equivalent

Engine oil Drain and refill w/ Oil filter change w/o Oil filter change


2.7 liters (2.9 US qts, 2.4 Imp. qts)2.5 liters (2.6 US qts, 2.2 Imp. qts)

RECOMMENDED TOOLS

08826-00080 Seal packing or equivalent


09090-04000 Engine Sling Device

09032-00100 Oil Pan Seal Cutter

09228-06500 Oil Filter Wrench

09905-00013 Snap Ring Pliers

EQUIPMENT

LUBRICANT

For suspending engine

Oil pressure gauge

Oil pressure switch

Torque wrench

Oil pump, Oil pan

Straight edge

Classification

Oil pump

CapacityItem


OIL PRESSURE CHECK1. ENGINE OIL QUALITY CHECK

Check the oil for deterioration, entry of water, dis-coloring or thinning.If the oil quality is poor, replace it.Oil grade:API grads SG or SH, Energy-Conserving IImultigrade engine oil or ILSAC multigrade engineoil.Recommended viscosity is as shown in theillustration.

2. CHECK ENGINE OIL LEVELThe oil level should be between the ”L” and ”F” markson the dipstick.If low, check for leakage and add oil up to the ”F”mark.

3. REMOVE OIL PRESSURE SWITCH AND INSTALLOIL PRESSURE GAUGE

4. WARM UP ENGINEAllow the engine to warm up to normal operatingtemperature.

6. MEASURE OIL PRESSUREOil pressure:At idle speedMore than 29 kPa (0.3 kgf/cm 2, 4.3 psi)At 3,000 rpm245 - 490 kPa (2.5 - 5.0 kgf/cm 2. 36 - 71 psi)HINT: Check for oil leakage after reinstalling the pres-sure switch.

6. REMOVE OIL PRESSURE GAUGE AND REINSTALLOIL PRESSURE SWITCH

(a) Remove the oil pressure gauge.(b) Apply adhesive to 2 or 3 threads of the oil pressure

switch.Adhesive:Part No. 08833-00080. THREE BOND 1344,NOCTITE 242 or equivalent LOCTITE 242 or equiva-lent

(c) Reinstall the oil pressure switch.7. START ENGINE AND CHECK FOR LEAKS


OIL AND FILTER REPLACEMENTCAUTION:• Prolonged and repeated contact with mineral oil will

result in the removal of natural fats from the skin,leading to dryness, irritation and dermatitis. In addi-tion, used engine oil contains potentially harmfulcontaminants which may cause skin cancer. Ade-quate means of skin protection end washing facilit-ies should be provided.

• Care should be taken, therefore, when changing engine oil, to minimize the frequency and length oftime your skin is exposed to used engine oil. Protec-tive clothing and gloves, that cannot be penetratedby oil, should be worn, The skin should be thorough-ly washed with soap and water, or use waterlesshand cleaner, to remove any used engine oil. Do notuse gasoline, thinners, or solvents.

• In order to preserve the environment, used oil mustbe disposed of only at designated disposal sites.

1. DRAIN ENGINE OIL(a) Remove the oil filler cap.(b) Remove the oil drain plug and drain the oil into a

container.

2. REPLACE OIL FILTER(a) Using SST, remove the oil filter.

SST 09228-06500

(b) Clean the filter contact surface on the filter mounting


(d) Tighten filter until the gasket contacts seat of thefilter mounting. Then using SST, give it an additional3/4 turn to seat the filter.SST 09228-06500

3. FILL WITH ENGINE OIL(a) Clean and install the oil drain plug with a new gasket.


(b) Fill the engine with new oil.Oil grade:See page EG-234Oil capacity:Drain and refillw/o Oil filter change2.9 liters (3.1 US qts, 2.6 Imp.qts)w/ Oil filter change3.2 liters (3.4 US qts, 2.8 Imp. qts)Dry fill3.4 liters (3.6 US qts, 3.0 Imp.qts)

4. START ENGINE AND CHECK FOR LEAKS5. RECHECK ENGINE OIL LEVEL

(c) Lubricate the filter rubber gasket with engine oil.


OIL PUMP AND PRESSURE REGULATORVALVE REMOVALHINT: When repairing the oil pump, the oil pan andstrainer should be removed and cleaned.1. REMOVE HOOD2. REMOVE TIMING BELT

(See steps 1 to 17 on pages EG-15 to EG-18 )HINT: When removing the RH engine mounting,attach the engine hoist chain to the lifting bracket orthe engine and lift the engine slightly.

3. REMOVE CRANKSHAFT TIMING PULLEY AND OILPUMP PULLEY(See steps 19 and 21 on page EG-19 )

4. REMOVE OIL DIPSTICK5. DRAIN ENGINE OIL (See step 1 on page EG-235 )

6. DISCONNECT FRONT EXHAUST PIPE(See step 24 on page EG-57 )

OIL PUMP AND PRESSUREREGULATOR VALVECOMPONENTS FOR REMOVAL ANDINSTALLATION


7. REMOVE OIL PAN(a) Remove the 2 nuts and 8 bolts.(b) Insert the SST blade between the cylinder block and

oil pan, cut off applied sealer and then remove the oilpan.SST 09032-00100NOTICE:

• Do not use SST for the oil pump body side and rearoil seal retainer.

• Be careful not to damage the oil pan flange.

8. REMOVE OIL STRAINERRemove the 3 bolts and oil strainer with the O-ring.

(b) Using a soft-faced hammer, carefully tap off the oilpump.

(c) Remove the oil pump body and the O-ring.

10. REMOVE OIL PUMP(a) Remove the 9 bolts and tension spring bracket.

9. REMOVE PRESSURE REGULATOR VALVE


OIL PUMP INSPECTION1. INSPECT BODY CLEARANCE

Using a thickness gauge, measure the clearance be-tween the driven rotor and pump body.Standard clearance:0.10 - 0.16 mm (0.0039 - 0.0063 in.)Maximum clearance:0.20 mm (0.0079 in.)If the clearance is greater than maximum, replace theoil pump rotor set and/or pump body.

2. INSPECT TIP CLEARANCEUsing a thickness gauge, measure the clearance be-tween both rotor trips.Standard clearance:0.06 - 0.15 mm (0.024 - 0.059 in.)Maximum clearance:0.20 mm (0.0079 in.)

If the clearance is greater than maximum, replace theoil pump rotor set.

2. INSPECT PRESSURE REGULATOR VALVECoat the valve piston with engine oil and check that itfalls smoothly into the valve hole by its own weight.If necessary, replace the valve.

3. ASSEMBLE PRESSURE REGULATOR VALVE(a) Insert the pressure regulator valve piston, spring andretainer.(b) Using snap ring pliers, install the snap ring.

PRESSURE REGULATOR INSPECTION1. DISASSEMBLE PRESSURE REGULATOR VALVE(a) Using snap ring pliers, remove the snap ring.(b) Remove the retainer, spring and pressure regulator

valve piston.


3. INSPECT SIDE CLEARANCEUsing a thickness gauge and flat block, measure theside clearance as shown.Standard clearance:0.03 - 0.09 mm (0.0012 - 0.0035 in.)Maximum clearance:0.10 mm (0.0039 in.)If the clearance is greater than maximum, replace theoil pump rotor set and/or pump body.

2. INSTALL OIL SEAL(a) Using socket wrench and a hammer, tap in a new oil

seal until the seal is flush with the outside face of oilpump.

(b) Apply MP grease to the oil seal lip.

OIL PUMP OIL SEAL REPLACEMENT1. REMOVE OIL SEAL

Using a screwdriver, pry out the oil seal.

CRANKSHAFT FRONT OIL SEALREPLACEMENT

(See page EG-77 )


OIL PUMP AND PRESSURE REGULATORVALVE INSTALLATION(See Components for Removal and Installation)1. INSTALL OIL PUMP(a) Remove any old packing (FIPG) material and be care-

ful not to drop any oil on the contact surfaces of theoil pump and cylinder block.• Using a razor blade and gasket scraper, remove

all the old packing (FIPG) material from the con-tact surfaces and sealing grooves.



(b) Apply seal packing to the oil pump as shown in theillustration.Seal packing:Part No.08826-00080 or equivalent• Install a nozzle that has been cut to a 2-3 mm

(0.08-0.12 in.) opening.HINT: Avoid applying an excessive amount to thesurface.• Parts must be assembled within 5 minutes of

application. Otherwise the material must be re-moved and reapplied.


(c) Place a new O-ring into the groove.

(d) Install the oil pump and the tension spring bracketwith the 9 bolts.Torque: 7.4 N �m (75 kgf �cm, 65 ft �lbf)

2. INSTALL PRESSURE REGULATOR VALVETorque: 29 N �m (300 kgf �cm, 22 in. �lbf)


NOTICE: Do not use a solvent which will affect the paint-ed surfaces.

(b) Apply seal packing to the oil pan as shown in theillustration.Seal packing:Part No.08826-00080 or equivalentSeal diameter:a 6 - 7mm(0.24 - 0.28 in.)b 3 - 4 mm(0.12 - 0.16 in.)• Install a nozzle that has been cut to a 3-4mm

(0.12 - 0.16 in.) or 6-7 mm (0.24-0.28 in.) opening.

HINT: Avoid applying an excess amount to the sur-face.

• Parts must be assembled within 15 minutes of applica-tion. Otherwise, the seal packing black willbe of no effect.

• Immediately remove nozzle from tube and reins-tall cap after use.

(c) Install the oil pan with the 2 nuts and 8 bolts.Torque: 8.3 N �m (85 kgf �cm, 74 in. �lbf)

5. CONNECT FRONT EXHAUST PIPE(See step 6 on page EG-89 )

6. INSTALL OIL PUMP PULLEY AND CRANKSHAFTTIMING PULLEY(See steps 1 and 3 on pages EG-22 and 23)

7. INSTALL TIMING BELT(See steps6 to 23 on pages EG-23 to 26)

8. INSTALL OIL DIPSTICK

3. INSTALL OIL STRAINER(a) Apply a little engine oil to a new O-ring.(b) Install the O-ring to the oil strainer.(c) Install the oil strainer with the 3 bolts.

Torque: 10 N �m (100 kgf �cm. 7 ft �lbf)

4. INSTALL OIL PAN(a) Remove any old packing material and be careful not to

drop any oil on the contact surfaces of the oil pan andcylinder block.

• Using a razor blade and gasket scraper, remove all thepacking (FIPG) material from the contactsurfaces.


• Clean both sealing surfaces with a non-residuesolvent.


9. FILL WITH ENGINE OIL(See step 3 on page EG-231 )

10. START ENGINE AND CHECK FOR LEAKS11. RECHECK ENGINE OIL LEVEL

(See step 2 on page EG-229 )12. INSTALL HOOD


0.10 - 0.1 6 mm (0.0039 - 0.0063 in.)0.20 mm (0.0079 in.)O.O6 - 0.15 mm (0.0024 - 0.0059 in.)0.20 mm (0.0079 in.)0.03 - 0.09 mm (0.0012 - 0.0035 in.)0.10 mm (0.0039 in.)

Body clearance (STD)Body clearance (Maximum)Tip clearance (STD)Tip clearance (Maximum)Side clearance (STD)Side clearance (Maximum)


29 kPa (0.3 kgf/cm2, 43 psi) or more245 - 490 kPa (2.5 - 5.0 kgf/cm2, 36 - 71 psi)

At idle speed (normal operating temperature)At 3,000 rpm (normal operating temperature)


Pressure regulator valve x Cylinder block

Oil strainer x Cylinder block

Oil pump x Cylinder block

Oil pan x Cylinder block

Oil pan x Drain plug

Oil pan x Oil pump

Part tightened

Oil presuure

Oil pump

74 in.�lbf

74 in.�lbf

65 in.�lbf

kgf�cm ft�lbf

300

250

100

7.4

8.3

N�m

8.3


Engine

Business

idleengine

startpoor

special service

special service

precision

runningengine

engine mfi

engine lubrication