Hyundai Sonata 1991 Shop Manual

HYUnCRI

1991 Shop Manual

son

HYUnDRI

SOndTd Shop Manual FOREWORD

This shop manual is intended for use by service technicians of authorized Hyundai dealers to help them provide efficient and correct service and maintenance on Hyundai vehicle. All the contents of this manual. including drawings and specifications, are the latest available at the time of publication. However. specifications and procedures are subject to change without any notice. As for the modifications affecting service performance, dealers shall be provided technical service bulletins or supplementary volumes. This book may not be reproduced or copied, as a whole or as a part. without the wrinen permission of publisher.

APR. 1990. Printed in Korea

CONTENTS TITLE

SECTION

General Information

00

Lubrication and Maintenance

10

Engine

20

Cooling System

25

Engine Electrical System

27

Intake & Exhaust System

28

Emission Control System

29

Fuel System

31

Clutch

41

Manual Transaxle

43

Automatic Transaxle

45

Drive Shaft and Front Axle

49

Front Suspension

54

Rear Suspension

55

Steering System

56

·Brake System

58

Body (Interior and Exterior)

60

Body Electrical System

90

Air Conditioning SyStem

97

Appendix (Electrical wiring system)

-

HVUnOr:l1 MOTOR COMPr:lnV

• •• •• •• •• •• •• •• •• ••

HVunDR MOTOR COMPRnY

Printing: APR. 28. 1990

Seoul Korea

Publication No.: YS-900406 Printed in Korea

GENERAL INFORMATION-

GENERAL INFORMATION GENERAL INFORMATION HOW TO USE THIS MANUAL

YOOCAOA

This manual is divided into 19 sections. This first page of each section is marked with a black tab at the edge of the page. You can quickly find the first page of each section without looking through a full table of contents. Each

section

includes

the

essential

removal,

installation,

adjustment and maintenance procedures for servicing all body styles. This information is current as of time of publication. An INDEX is provided on the first page of each section to guide you to the item to be replaced.

TROUBLESHOOTING tabills are included for each system to help you diagnose the system problem and find the cause. The repair for each possible cause is referenced in the remedy column to quickly lead you to the solution.

DEFINITION OF TERMS Standard Value (Service standard)

YOOCBOA

Indicates the value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by a tolerance.

Service limit Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part or assembly must be kept functionally or in

strength. It is a value established outside the range of standard value.

NOTE, WARNING AND CAUTION

YOOCCOA

NOTE A point of information. WARNING Information about an activity that could cause damage to the vehicle. CAUTION Information about an activity that could cause injury or damage to the driver, occupants or repair personnel.

00-2

GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER LOCATION YOOCDOA The vehicle identification number (V.I.N) is on the top of the instrument panel, on the radiator support panel, and the driver's door post.

VEHICLE IDENTIFICATION NUMBER

YOOCEOA

Vehicle identification number consists of 17 digit.

®~®®®G)@®®©@ @@@@@(D

~TTTTTTTT 1)

2)

3)

4)

5)

6)

7)

8)

I

10)

9)

1)

W.I.C. (World manufacturer's identifier) KMH : Hyundai Motor Company's Passenger car 2HM : Bromont Assembly Plant, Canada

2)

Line and drive type B : Sonata LHD drive vehicle A : Sonata RHO drive vehicle

3)

Body type F : 4 Door sedan

4)

Series (Body style and version) 1 : Standard 2 : Deluxe (GL)

5)

Restraint system (Front seat) None seat belt 2 1 : Active system

o:

6)

Engine type o : 1795 cc F : 1997 cc

7)

Check digit

8)

Product year L-1990 M-1991

9)

10)

3

Supper deluxe (GLS)

Passive system

S : 2351 cc T : 2972 cc V6

N-1992 P-1993

Plant code U Ulsan plant B : Bromont plant Vehicle production sequence number 000001-999999 00-3

GENERAL INFORMATION ENGINE IDENTIFICATION NUMBER LOCATION VOOCfOA

The engine identification number is stamped at the right front side on the top edge of the cylinder block.

ENGINE IDENTIFICATION NUMBER Engine identification number consists of 10 digits.

@®®®®

@@@@@G)

TTTTT 1)

1)

2)

3)

4)

I 6)

5)

Engine fuel G : Gasoline

2)

Engine range

4 : In line 4 cycle 4 cylinder 3)

Engine development order

A-Z: 4)

Engine capacity

M 1795 cc P : 1997 cc

S : 2351 cc T : 2972 cc V6

5)

Product year

6)

Engine production sequence number 0‫סס‬oo1-999999

00-4

YOOCGOA

GENERAL INFORMA, ;O~~ PROTECTION OF THE VEHICLE

YOOCHOA

Always be sure to cover fenders, seats, and floor areas before starting work. CAUTION The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to prevent the hood from falling and possibly injuring you. Assure that the support rod has been released prior to closing the hood. Always double check to be sure the hood is firmly latched before driving away.

A WORD ABOUT SAFETY

YOOCJOA

The following precautions must be followed when jacking up the vehicle. 1. 2.

Block wheels. Use only specified jacking positions.

3.

Support vehicle with safety stands (rigid jacks)

4.

Refer to the page 00-9. Start the engine only after making certain the engine compartment is clear of tools and people.

PREPARATION OF TOOLS AND MEASURING EQUIPMENT YOOCKOA Be sure that all necessary tools and measuring equipment are available before starting work activity..

SPECIAL TOOLS

YOOCLOA

Use special tools when they are required.

00-5

GENERAL INFORMATION

REMOVAL OF PARTS

YOOCMOA

First find the cause of trouble prior to removing or disassembling any components.

DISASSEMBLY

YOOCNOA

If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance. 1. Inspection of parts Each part when removed should be carefully inspected for malfunction, deformation, damage, and other problems.

2. Arrangement of parts All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.

3. Cleaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned by the appropriate method.

I J

~,

-U

00-6

GENERAL INFORMATION

PARTS

YOOCPOA

HYUnCRI

When replacing parts, use HYUNDAI genuine parts.

Genuine Parts

Made

REASSEMBLY

In

YOOCOOA

Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones. 1.

Oil seals

2.

Gaskets

3.

a-rings

4. 5.

Lock washers Coller pins (split pins)

6.

Plastic nuts

Q

o

Depending on where they are; 1.

Sealant should be applied to gaskets.

2. 3.

Oil should be applied to moving components of parts. Specified oil or grease should be applied at the prescribed locations (oil seals, etc.) before assembly.

ADJUSTMENTS

VOOCROA

Use gauges and testers to correct adjustments to the standard values.

00-7

GENERAL INFORMATION

ELECTRICAL SYSTEM 1.

YOOCSOA

Be sure to disconnect the battery cable from the negative (-) terminal of the battery first.

2. 3.

Never pull on the wiring when removing connectors. Locking connectors must be heard to click if the connector

4.

is secure. Handle sensors and relays carefully. Be careful not to drop them' or hi: them against other parts.

RUBBER PARTS AND TUBING

YOOCTOA

Always prevent gasoline or oil from touching rubber parts or tubing.

PRECAUTIONS FOR A CATALYTIC CONVERTER YOQCUOA

CAUTION If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard.To prevent this, observe the following precautions and explain them to your customer.

1.

Use only unleaded gasoline.

2.

Avoid prolonged idling. Avoid running the engine at fast idle speed for more than 10 minutes and at idle speed for more than 20 minutes.

3.

Avoid spark jump test. Spark jump only when absolutely necessary. Perform this test as rapidly as possible and, while testing, never race the engine.

4.

Avoid prolonged engine compression measurement. Engine compression tests must be made as rapidly as possible.

5.

Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter.

6.

Avoid coasting with

7.

braking. Do not

dispose

of

ignition turned off and prolonged used

catalyst

contaminated with gasoline or oil.

00-8

along

with

parts

GENERAL INFORMATION VEHICLE LIFT AND SUPPORT LOCATiONS

YOOCVOA

.. . -.

Jack provided with the vehicle Rigid jack, single or double post lift Garage jack H bar lift

The jack provided with the vehicle (for reference)

Rigid rack (Safety stand)

Garage jack (floor jack)

Single-post lift

Double-post lift

Free wheel type auto lift

(H bar lift) CAUTION 1) Never use a jack at the lateral rod or rear suspension assembly. 2) In order to prevent scarring the centermember, place a piece of cloth on the jack's contact surface (to prevent corrosion caused by damage to the coating). 3) Never attempt to position a floor jack on any part of the vehicle underbody. 4) Do not attempt to raise one entire side of the vehicle by placing a jack midway between the front and rear wheels. To do so could result in permanent damage to the body. >

00-9

LUBRICATION AND II MAINTENANCE SCHEDULED MAINTENANCE TABLE

2

RECOMMENDED LUBRICANTS AND CAPACiTIES

6

MAINTENANCE SERViCE

7

SCHEDULED MAINTENANCE TABLE

SCHEDULED MAINTENANCE TABLE RECOMMENDED CUSTOMER MAINTENANCE (FOR U.S.A.) The following maintenance services must be performed to assure good emission control and performance. Keep receipts for all vehicle emission services to protect your emission warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first. R : REPLACE I : INSPECT, AFTER INSPECTION, CLEAN, LUBRICATE, ADJUST, REPAIR OR REPLACE IF NECESSARY

NO

DESCRIPTION

MILES X 1000

7.5

15

22.5

30

37.5

45

52.5

60

KILOMETER X 1000

12

24

36

48

60

72

84

96

MONTHS

5

10

20

30

40

50

60

70

R

R

R

R

R

R

R

R

EMISSION CONTROL ITEMS

1

ENGINE OIL AND FILTER

2

VALVE CLEARANCE (JET VALVE ONLY)

3

FUEL FILTER

R

4

FUEL LINES AND CONNECTIONS

I

5

VACUUM, CRANKCASE VENTILATION HOSES

I

6

FUEL HOSE, VAPOR HOSE & FUEL FILLER CAP

I

7

AIR CLEANER FILTER

R

R

8

SPARK PLUGS

R

R

I

I

I

I

GENERAL ITEMS 1

DRIVE BELT (WATER PUMP AND ALTERNATOR)

I

I

2

ENGINE COOLANT

R

R

3

TIMING BELT

4

MANUAL TRANSAXLE OIL

5

AUTO TRANSAXLE OIL

6

BRAKE FLUID

7

BRAKE HOSES, LINES

8

REAR BRAKE DRUMS/LININGS/PARKING BRAKE

9

BRAKE PADS, CALIPERS, ROTORS

R I I

R

I I

R I

I

R I

I

I

I

I I

I

R

I I

10

EXHAUST PIPE CONNECTIONS, MUFFLER & SUSPENSION BOLTS

I

11

STEERING GEAR RACK, LINKAGE & BOOTS

I

I

12

WHEEL BEARING GREASE

I

I

13

DRIVESHAFTS & BOOTS

10-2

I

I

I

I

SCHEDULED MAINTENANCE TABLE MAINTENANCE UNDER SEVERE USAGE CONDITIONS The following items must be serviced more frequently on vehicles normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals. I : INSPECT. CORRECT OR REPLACE IF NECESSARY R: REPLACE

MAINTENANCE ITEM

MAINTENANCE OPERATION

MAINTENANCE INTERVALS Every 3.000 miles (4,800 km)

DRIVING CONDITION A. B. C. F. H

ENGINE OIL AND FILTER

R

AIR CLEANER FILTER

R

SPARK PLUGS

R

BRAKE PADS. CALIPERS. ROTORS

I

More frequently

C. D. G. H

REAR BRAKE DRUMS/LININGS

I

More frequently

C. D. G. H

STEERING GEAR RACK LINKAGE & BOOTS

I

DRIVESHAFT & BOOTS

I

or 3 months

More frequently Every 24,000 miles (40.000 km) or 18 months

Every 7.500 miles (12.000 kml or 6 months

Every 7.500 miles (12,000 km) or 6 months

C. E B. H

C. D. E. F C. E. F

SEVERE DRIVING CONDITIONS A-Repeated short distance driving B-Extensive idling C-Driving in dusty conditions D-Driving in areas using salt or other corrosive materials or in very cold weather E-Driving in sandy areas F-More than 50% driving in heavy city traffic during hot weather above 90°F (32°C) G-Driving in mountainous areas H-Towing a trailer

10-3

SCHEDULED MAINTENANCE TABLE

SCHEDULED MAINTENANCE TABLE RECOMMENDED CUSTOMER MAINTENANCE (FOR CANADA) The following maintenance services must be performed to assure good emission control and performance. Keep receipts for all vehicle emission services to protect your emission warranty. Where both mileage and time are shown, the frequency of service is determined by whichever occurs first. R : REPLACE I : INSPECT AND, AFTER INSPECTION, CLEAN, ADJUST, REPAIR OR REPLACE IF NECESSARY

DESCRIPTION

NO

I KILOMETER

I MILES

X 1DOD

X 1DOD

I

12

I

I

75

15

R

R

24

I I

36 22.5

I I

72

84

96

30

I 60 I I 37.5 I

45

52.5

60

R

R

R

R

R

48

EMISSION CONTROL ITEMS (or every 6 months)

1

ENGINE OIL AND FILTER

2

JET VALVE CLEARANCE

3

FUEL FILTER

4

FUEL LINES AND CONNECTIONS

I

5

VACUUM, CRANKCASE VENTILATION HOSES

R

6

FUEL HOSE, VAPOR HOSE & FUEL FILLER CAP

R

7

AIR CLEANER FILTER

R

R

8

SPARK PLUGS

R

R

I

I

I

R

I

I

I R

GENERAL ITEMS

1

DRIVE BELT (FOR WATER PUMP, ALTERNATOR AND PIS)

2

ENGINE COOLANT

3

TIMING BELT

(or every 2 years)

R

R R I

4

MANUAL TRANSAXLE OIL

5

AUTO TRANSAXLE FLUID

I

R

I I

6

BRAKE HOSES, LINES

I

I

I

7

BRAKE FLUID

8

REAR BRAKE DRUMS/LININGS/PARKING BRAKE

9

BRAKE PADS, CALIPERS, ROTORS

(or every 2 years)

R I

I R

I I

R

I I

I

10

EXHAUST PIPE CONNECTIONS, MUFFLER & SUSPENSION BOLTS

I

I

11

STEERING GEAR RACK, LINKAGE & BOOTS

I

I

12

WHEEL BEARING GREASE

I

13

DRIVESHAFTS & BOOTS

10-4

I

I

J I

J

SCHEDULED MAINTENANCE TABLE MAINTENANCE UNDER SEVERE USAGE CONDITIONS The following items must be serviced more frequently on cars normally used under severe driving conditions. Refer to the chart below for the appropriate maintenance intervals. I : INSPECT. CORRECT OR REPLACE IF NECESSARY R: REPLACE

MAINTENANCE ITEM

MAINTENANCE OPERATION

MAINTENANCE INTERVALS Every 3.000 miles (4.800 km)

DRIVING CONDITION

ENGINE OIL & FILTER

R

CLEANER FILTER

R

More frequently

C. E

SPARK PLUGS

R

Every 24,000 miles (40,000 kml or 18 months

B. H

BRAKE PADS. CALIPERS. ROTORS

I

More frequently

C. D. G. H

REAR BRAKE DRUMS/LININGS

I

More frequently

C. D. G. H

STEERING GEAR RACK LINKAGE & BOOTS

I

Every 7,500 miles (12,000 km) or 6 months

C. D. E. F

DRIVESHAFT & BOOTS

I

or 3 months

Every 7.500 miles (12,000 km) or 6 months

A, B. C. F. H

C. E. F

SEVERE DRIVING CONDITIONS A-Repeated short distance driving B-Extensive idling C-Oriving in dusty conditions D-Driying in areas using salt or other corrosive materials or in very cold weather E-Driving in sandy areas F-More than 50% driving in heavy city traffic during hot weather above 90°F 132°q G-Driving in mountainous areas H-Towing a trailer

10-5

RECOMMENDED LUBRICANTS AND CAPACITIES

RECOMMENDED LUBRICANTS AND CAPACITIES RECOMMENDED LUBRICANTS Parts

Specifications

Remarks

Engine oil

API classification SF, SF/CC or SG

For further details, refer to SAE viscosity number

Manual transaxle

Hypoid gear oil, SAE 75W-85W

Automatic transaxle

GENUINE HYUNDAI ATF AUTOMATIC TRANSMISSION FLUID, MOPAR ATF PLUS TYPE 7176, OR DIAMOND ATF SP

Brake

Brake fluid DOT 3 or equivalent

Power steering

ATF DEXRON@II

Wheel bearing

SAE J310a Multipurpose grease NLGI grade #2 or equivalent

Coolant

Ethylene glycol base for AI radiator

Transaxle linkage, parking brake cable mechanism, hood lock and hook, door latch, seat adjuster, tailgate latch

SAE J310a Multipurpose grease NLGI grade #2 or equivalent

Door hinges

Engine oil

Pedal bearing, strut insulator bearing

SAE J310a Chassis grease NLGI grade #0 or equivalent

MOPAR ATF PLUS TYPE 7176 is recommended lubricant

LUBRICANTS CAPACITIES Description

Capacities

Engine oil Oil pan Oil filter Total Cooling system Manual transaxle Automatic transaxle Power steering

3.5 0.4 3.9 7.0 2.5 5.8 0.9

10-6

lit lit lit lit lit lit lit

(3.698 U.S. qts., 3.081 Imp.qts.) (0.423 U.S. qts., 0.352 Imp.qts.) (4.121 U.S. qts., 3.433 Imp.qts.) (7.4 U.S. qts., 6.2 Imp.qts.) (2.642 U.S. qts., 2.201 Imp.qts.) (6.129 U.S. qts., 5.106 Imp.qts.) (0.951 U.S. qts., 0.792 Imp.qts.)

Remarks

MAINTENANCE SERVICE

MAINTENANCE SERVICE CHANGING THE ENGINE OIL 1. 2. 3.

Y10EAOA

Warm up the engine. Remove the filler cap (on the rocker cover), and drain the engine oil (with the drain plug removed). Tighten the drain plug. Tightening torque Drain plug .... 34-44 Nm (350-450 kg.cm, 25-33 Ib.lt)

4.

Fill the crankcase with fresh oil through the filler port. 3.90 lit. (4.12 U.S.qts., 3.43 Imp,qts) Dry fill Drain and refill Without oil filter: 2.9 lit (3.06 U.S.qts., 2.55 Imp.qts.) With oil filter: 3.3 lit (3.49 U.S.qts., 2.90 Imp.qts.)

5. 6. 7.

Pull the dipstick out in order to check the oil level. Install the filler plug. Recheck the level of the engine oil alter a road test.

Recommended engine oil API SF, SF/CC or SG SAE 20W-20, 20W-40, 20W-50 (ABOVE 32°F OR O°C) 10W-30, 10W-40, lOW-50 (ABOVE -10°F OR -23°C) 5W-20, 5W-30, 5W-40 (BELOW 60°F OR 16°C)

REPLACEMENT OF THE ENGINE OIL FILTER 1. 2. 3.

Y10E8OA

Replace the oil filter at the time of every oil change. Use a filter wrench (available commercially) to remove the oil filter. Drain the oil in the filter.

10-7

MAINTENANCE SERVICE 4.

Lightly coat the O-ring (1) of the new oil filter with engine oil, and install the filter by completely turning it by hand.

VALVE CLEARANCE (Check and adjust as required)

Y10ECOA

As the intake and exhaust valves are equipped with auto-lash adjustment mechanisms, there is no need for valve clearance adjustment. The proper functioning of the auto-lash mechanism may be determined by checking for tappet noise. When there is tappet noise or any unusual noise, check the auto-lash by removing it.

'J::::j~~_AutO-laSh adjuster

Valve Clearance Adjustment Intake and Exhaust Valves The auto-lash adjuster is installed to the rocker arm so that the valve clearance adjustment is maintenance-free. For additional information regarding the auto-lash adjuster, refer to "ENGINE" section.

Jet Valve CAUTION 1. The cylinder head bolts should be retightened before attempting this adjustment. 2. If the jet valve clearance is not good, this will affect not only the exhaust gas level, but also be the cause of engine trouble. It is, therefore, important that the correct adjustment procedures be followed, as described here. 1.

3. 4. 5. 6.

Start the engine and allow it to warm up until the temperature of the coolant reaches BOoC to 95°C (176°F to 203°F). Check the ignition timing and idling speed, and adjust if necessary. Remove the rocker cover. Remove timing belt front upper cover. Turn crankshaft clockwise and align with camshaft sprocket timing mark.

10-8

/p/,* Timing mark (on cylinder head)

Timing mark / (on camshaft sprocket) ~ ... _

MAINTENANCE SERVICE 7.

Check that valve clearance indicated in the diagram is at the standard value. Jet valve clearance Hot engine Cold engine

Exhaust

0.25 mm (O.OO98 in.) 0.17 mm (O.OO67 in.)

No.1

No.2 No.3

No.4

Intake

8.

9.

If valve clearance is off the standard value, loosen rocker arm adjusting screw locking nut. Use feeler gauge and adjust valve clearance by turning adjusting screw. Secure rocker arm adjusting screw with screw driver so that it will not rotate and tighten locking nut.

10. Rotate the crankshaft one complete turn clockwise (360 degree). 11. Check that valve clearance indicated in the diagram is at the standard value. 12. Repeat steps. 8. and 9. to adjust the valve clearance of remaining valves.

.Exhaust

• No. 1

No.2

No.3

No.4

Intake

13. Apply a coating of the sealant to the places on the semi-circular packing shown by arrows in the figure. 14. Install the timing belt front upper cover. 15. Install the rocker cover. 16. Install the air intake hose and air intake pipe.

Apply a coating of specified sealant

Cylinder head

10-9

MAINTENANCE SERVICE

CHECKING TENSION

AND

ADJUSTMENT

OF

V-BELT Vl0EDOA

Measure the deflection of the V-belt at the point shown in the illustration. V-belt deflection [under a tension of 10 kg (22 lb)) . 9.0-10.4 mm (0.35-0.41 in.)

REPLACEMENT OF THE AIR FILTER

Y10EEOA

The air filter will become dirty and loaded with dust during use and the filtering effect will be substantially reduced. Replace with a new one. 1. Remove the air intake hose and air duct. 2. Remove the connector for the air-flow sensor from the air fi Iter cover. 3. Disconnect the air filter cover clip. 4. Remove the air filter cover.

CAUTION The air filter cover should be removed carefully because it includes the air-flow sensor. 5. 6.

Remove the air filter element. Set a new air filter element and clamp the' air filter cover.

COOLING SYSTEM

Y10EFOA

Check the cooling system for damaged hoses, loose or seeping connections, or other possible causes of coolant leaks. Antifreeze The engine cooling system is provided with a mixture of 50% ethylene glycol anti-freeze and 50% water at the time of manufacture. Since the cylinder head and water pump body are made of aluminum alloy casting, be sure to use a 30 to 60% ethylene glycol antifreeze coolant to provide corrosion protection and freezing prevention.

CAUTION If the concentration of the antifreeze is below 30%. the anticorrosion property will be adversely affected. In addition. if the concentration is above 60%. both the antifreezing and engine cooling properties will decrease, adversely affecting the engine. For these reasons. be sure to maintain the concentration level within the specified range.

10-10

MAINTENANCE SERVICE Measurement of Antifreeze Concentration Run the engine until coolant is fully mixed. Drain some coolant (antifreeze), and measure temperature and specific gravity of the coolant. Determine concentration and safe working temperature. If the coolant is short of antifreeze, add antifreeze up to a concentration of 50%.

Replacement the Coolant 1. Set the temperature control level to the hot position. 2. Remove the radiator cap. CAUTION Remove cap slowly as the system is pressurized and the coolant may be hot. 3. 4. 5. 6.

Loosen the drain plug to drain the coolant. Drain the coolant from the reserve tank. After draining the coolant, tighten the drain plug securely. Supply the coolant into the radiator until it is filled up to its filler neck. 7. Supply the coolant into the reserve tank. a. After warming the engine until the thermostat opens, remove the radiator cap and check the coolant level. 9. Supply the coolant into the radiator until it is filled up to its filler neck, and install the radiator cap securely. 10. Fill the reserve tank with coolant up to the "FULL" line.

REPLACEMENT OF IGNITION CABLES

Y10EHOA

The ignition cables should be replaced periodically with new ones. After replacing, make sure that the ignition cables and terminals are properly connected and fully seated.

Correct

Incorrect

NOTE When disconnecting an ignition cable be sure to hold cable cap. If the cable is disconnected by pulling on the cable alone an open circuit might result.

10-11

MAINTENANCE SERVICE

REPLACEMENT OXYGEN SENSOR

Yl0EJOA

The oxygen sensor is a device which controls the fuel mixture. If the oxygen sensor is damaged, the exhaust emissions as well as driveability deteriorates. Therefore, it should be replaced periodically with a new one.

Hexagon nut

Housing

'-~'~

.

""'

ij)'~"".7 ....

....................: z n e c l o r .•............... ~

FUEL SYSTEM Tank, Lines And Connections 1.

Check for damage or leakage in the fuel

Y10EKOA

lines and

connections.

2.

3.

Inspect the surface or fuel hoses for heat and mechanical damage. Hard and brittle rubber, cracking, checking, tears, cuts, abrasions and excessive swelling indicate deter.ioration of the rubber. If the fabric casing of the rubber hose is cracked or worn, the hoses should be changed.

Fuel Filter The fuel filter should be replaced regularly because its performance is reduced by dirt and water collected over an extended period of use. Replace as required.

10-12

MAINTENANCE SERVICE CRANKCASE EMISSION CONTROL SYSTEM (PCV valve) Y'OELOA The crankcase ventilation system must be kept clean to maintain good engine performance. Periodic servicing is required to remove combustion products from the PCV valve.

Air cleaner

Air intake hose

Throttle body

Surge tank

Ventilation hose PCVvalve

-

_..

~

Injector

4 - - Intake manifold

Blow-by gas _ Fresh air

--~

1.

DisConnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Then, remove PCV valve from the rocker cover and reconnect it to the ventilation hose. 2. Idle the engine and put a finger to the open end of PCV valve to make sure that intake manifold vacuum is felt on the finger.

NOTE At this time, the plunger inside the PCV valve moves back and forth. 3.

If no vacuum is felt replace the PCV valve and ventilation hose in cleaning solvent or replace if necessary.

10-13

MAINTENANCE SERVICE EVAPORATIVE EMISSION CONTROL SYSTEM Y10EMQA.

1.

If the fuel-vapor vent line is clogged or damaged, a fuel-vapor mixture excapes into the atmosphere causing excessive emissions. Disconnect the line at both ends, and blow it clean with compressed air. Remove the filler cap from the filler pipe and check to see that the filler cap is seating properly on the fuel filler pipe. 2. The overfill limiter (2-way valve) installed on the vapor line between the canister inlet and fuel tank outlet should be checked for correct operation.

Air filter

\

Fuel check valve

Filter Fuel pump Fuel filler cap (Vacuum relief)

Fuel injector

Overfill limiter (Leveling pipe)

Purge-control solenoid valve :

I Thermal expansion volume

t

--

Engine Canister Charcoal-i+--l_

...Jr~-- Fuel

._. . . ,

-

Fuel pump

Filter ... - -

CANISTER (Replace)

Yl0ENQA

If or when the canister filter becomes clogged, the purge air volume will decrease and consequently, the canister capacity will be replaced.

10-14

Purge air

__

Fuel vapo(

MAINTENANCE SERVICE

MANUAL TRANSMISSION (Inspect oil level)

Y10€POA

mm (in.)

Inspect each component for evidence of leakage. and check the oil level by remaining the filler plug. If the oil is contaminated. it is necessary to replace it with new oil. 1. With the vehicle parked at a level place. remove the filler plug and make sure that oil level is the same level as the plug hole. 2. Check to be sure that the transaxle oil is not dirty.

TRANSAXLE OIL (Replace) 1. 2. 3.

Y10EQOA

With the vehicle parked at a level place. remove the magnet plug to drain transaxle oil. Replace packing with a new one and install the magnet plug. Supply transaxle oil (through the filler plug part) until the oil level is the same level as the plug hole. Transaxle oil total capacity : 2.5 liters (2.6 U.S. qts., 2.2 Imp. qts.)

AUTOMATIC TRANSAXLE (Change fluid)

Y1QEROA

Drain the fluid and check whether there is any evidence of contamination.

Replenish with new fluid after the cause of any contamination has been corrected. 1. Remove drain plug at differential bottom to let fluid drain. 2. Place a drain container with large opening under the transaxle oil pan. 3. Loosen oil pan bolts and tap pan at one corner to break it loose allowing fluid to drain. then remove oil pan. 4. Check the oil filter for clogging and damage and replace if necessary. 5. Clean drain plug and tighten drain plug with gasket to 30-35 Nm (300-350 kg.cm. 22-25 Ib.ft). 6. Clean both gasket surfaces of transaxle case and oil pan. 7. Install oil pan with new gasket and tighten oil pan bolts to 10-12 Nm (100-120 kg.cm. 7.5-8.5 Ib.ft). 8. Pour 4 liters (4.2 U.S.qts.• 3.5 Imp.qts.) of ATF into case through dipstick hole. [Total quantity of ATF required is approx. 5.8 liters (6.1 U.S.qts.. 5.1 Imp.qts.). Actually however, approx. 4.5 liters (4.8 U.S.qts.. 4.0 Imp.qts.) of fluid can be replaced because rest of fluid remains in torque converter.]

10-15

MAINTENANCE SERVICE Recheck fluid level after transaxle is at normal operating temperature. 9. Start engine and allow to idle for at least two minutes. Then, with parking brake on, move selector lever momentarily to each position., ending in "N" Neutral position. 10. Add sufficient ATF to bring fluid level to lower mark. Recheck fluid level after transaxle is at normal operating temperature. Fluid level should be shown upper and lower marks of "HOT" range. Insert dipstick fully to prevent dirt from entering transaxle.

INSPECT STEERING LINKAGE 1.

Y10£SOA

Check steering wheel freeplay. Maximum steering wheel freeplay ..... 30 mm (1.181 in.)

2.

Check steering linkage for looseness and damage as follows. 1) Tie rod ends do not have excessive play. 2) Dust seals and boots are not damaged. 3) Boot clamps are not loose.

POWER STEERING OIL PUMP BELT (Check and service as required) 1. 2.

Yl0ETOA

Inspect the belt for evidence of cuts and cracks. Replace, if necessary. Check belt for proper tension. If necessary, adjust the belt tension as follows. 1) Push the belt with a force of 98 N (22 Ib) at a point halfway between the power steering oil pump pulley and water pump pulley. The belt deflection should be 7 to 10 mm (0.28-0.39 in.) 2) If belt deflection is not within specified limits, loosen oil pump mounting bolt, and move the oil pump to obtain proper belt deflection at 98 N (22 Ib) force.

POWER STEERING FLUID LEVEL (Inspect fluid level)

Y10EUOA

1.

Park the vehicle on a flat, level surface, start the engine, and then turn the steering wheel several times to raise the temperature of the fluid to approximately 50°C (122°F). 2. With the vehicle still idling, turn the wheel all the way to the left and right several times. Check the fluid in the oil reservoir for foaming, check the fluid level. and replenish the fluid in the oil reservoir through the oil filter if necessary.

10-16

MAINTENANCE SERVICE POWER STEERING HOSES (Check for deterioration or leaks) 1. 2.

Yl0EVQA

Check the hose connections for fluid leaks. The power steering hoses should be replaced if there are severe surface cracking. pulling. scuffing or worn steps. Deterioration of the hoses could cause premature failure.

BALL JOINT AND STEERING LINKAGE SEALS, STEERING AND DRIVE SHAFT BOOTS Y10EWQA 1.

These components, which are permanently lubricated at the factory, do not require periodic lubrication. Damaged seals and boots should be replaced to prevent leakage or contamination of the grease. 2. Inspect the dust cover and boots for proper sealing leakage and damage. Replace them if defective.

I J

REAR WHEEL BEARINGS (Inspect for grease leaks)

YlOEXOA

Inspect for evidence of grease leakage around the hub cap and the back of the hub. If there is leakage of grease, remove the hub and inspect its oil seal for damage. Clean the grea~e off the hub and bearing and repack with specified new grease. Specified grease : Multipurpose grease SAE J310a, NLGI No.2

INSPECT BRAKE LINE 1. 2. 3.

Y10EVOA

Check all brake pipes and hoses for damage. wear, cracks, corrosion, leaks. bends, twists. Check all clamps for tightness. Check that the lines are clear of sharp edges. moving parts and the exhaust system.

.. 10-17

MAINTENANCE SERVICE FRONT DISC BRAKE PADS

Yl0EZOA

Check for fluid contamination and wear. Replace complete set of pads if defective. NOTE: If a squealing or scraping noise occurs from the brake during driving. check the pad wear indicator contacting the disc. the brake pad should be replaced. CAUTION The pads for the right and left wheels should be replaced at the same time. Never "split" or intermix brake pad sets. All pads must be replaced as a complete set. Thickness of pad lining "A" [Limit]

2.0 mm (0.079 in.)

REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS Yl0FAOA

1.

2.

Remove the brake drum and check the thickness of brake shoe lining for wear. Check the automatic brake adjusting system by hand to see if it operates smoothly. Also see if the gears are in proper mesh with each other. To assure smooth functioning, apply a very thin coat of grease to the friction surface of adjuster and link shaft. Inspect the wheel cylinder boots for evidence of a brake fluid leak. Visually check the boots for cuts, tears or heat cracks. (A slight amount of fluid on the boot may not be a leak, but may be preservative fluid used at assembly.) 1)

Checking the brake shoes for wear.

Thickness of lining "B" [Limit]

0.8 mm (0.031 in.)

CHECKING THE BRAKE FLUID LEVEL 1.

Yl0FBOA

Visually check the level of the brake fluid in the reserve tank of the master cylinder. 2. The level should be between the "MAX" and "MIN" marks. 3. If the level is lower than the "MIN" marks, add fresh brake fluid up to the "MAX" mark.

10-18

MAINTENANCE SERVICE

CHANGING OF THE BRAKE FLUID 1. 2.

lOfCOA

Refer to page 58-5 for air-bleeding procedures. Connect a vinyl tube to the bleeder screw of each wheel cylinder. Put the other end of the vinyl tube in a vessel for receiving the brake fluid.

3.

Depress the brake pedal a few times. Then loosen the bleeder (with the brake pedal still depressed), and tighten it after the brake fluid stops flowing. 4. Repeat the above operation until to air bubbles are in the brake fluid. 5. Repeat these steps for the other cylinders. 6. Add fresh brake fluid up to the "MAX" level in the reserve tank. Brake fluid

DOT 3 or equivalent

CHECKING OF THE TIRE INFLATION PRESSUE

Yl0FDOA

Check the Tire inflation Pressures as Follows.

TIRE INFLATION PRESSURE (Check with Tires Cool) Tire size

Front

Rear

P185170 R 14 P195170 R 14 (AI wheel)

207 kPa (30 psi)

207 kPa (30 psi)

T125170 0 15 (Temporary)

414 kPa (60 psi)

414 kPa (60 psi)

ROAD TEST

Yl0FEOA

Drive the vehicle and check for abnormal conditions. 1. 2. 3. 4. 5. 6. 7. 8.

Check Check Check Check Check Check

for oil, fluid, fuel, water and exhaust gas leaks. free play of clutch pedal and brake pedal. operation of brake booster. operation of service brake and parking brake systems. stroke of parking brake lever. driveability of engine. Che~k condition of instruments, gauges, indicators, exterior lamps, heater and ventilators. Check abnormal noise of each part.

10-19

ENGINE GENERAL

2

ENGINE MOUNTING

20

ENGINE AND TRANSAXLE ASSEMBLY

23

TIMING BELT

26

ROCKER ARMS AND ROCKER ARM SHAFTS

33

CAMSHAFT

38

CYLINDER HEAD

39

VALVES AND VALVE SPRINGS

42

JET VALVE ASSEMBLy

47

FRONT CASE. OIL PUMP AND COUNTER BALANCE SHAFT

50

PISTON AND CONNECTING ROD

56

CRANKSHAFT

61

CYLINDER BLOCK

66

OIL PRESSURE SWITCH AND SENDER ASSY

69

GENERAL

GENERAL

Y20CAOB

SPECIFICATIONS Description

Specification

General Type Number of cylinders

4

In-line OHV, OHC

Bore

86.49-86.53 mm (3.405-3.4067 in.)

Stroke Total displacement Compression ratio

100 mm (3.937 in.) 2.351 cc (143.4 cu. in.)

Firing order Idle R.P.M Ignition timing at curb idle Valve timing

Limit

8.5 1-3-4-2 750 ± 100 BTDC 5° ± 2°

Intake valve Opens (BTDC) Closes (ABDC) Exhaust valve Opens (BBDC) Closes (ATDC) Jet valve Opens (BTDC) Closes (ABDC)

20° 64°

Valve overlap Intake valve duration

40° 264°

Exhaust valve duration Jet valve duration Engine oil pressure

264°

At engine idle speed Compression pressure Between cylinder

20-2

264° 78 KPa (0.8 kg/cm 2 , 11 psi) or more [Engine oil temperature 75-90 0 C (167-190 0 F)] Min. 10.5 kg/cm 2 (1050 KPa, 150 psi)/250-400 rpm Max. 1.0 kg/cm 2 (100 KPa, 14 psi)

GENERAL

Description Rocket arm Material 1.0. Oil clearance Camshaft Drive mechanism Material Cam height Journal diameter Bearing oil clearance End play Cylinder head Material Flatness of gasket surface Flatness of manifold mounting surface Valve guide hole diameter 0.05 (0.002) 0.5 0.25 (0.010) 0.5 0.50 (0.020) 0.5 Intake valve seat ring hole diameter 0.3 (0.012) 0.5 0.6 (0.024) 0.5 Exhaust valve seat ring hole diameter 0.3 (0.012) 0.5 0.6 (0.024) 0.5 Valve Overall length Intake Exhaust Stem diameter Face angle Margin Intake Exhaust Clearance (stem-to-guide) Intake Exhaust Valve spring Free height Load Out of squareness

Specification

Limit

Aluminum die casting 18.910-18.928 mm (0.744-0.745 in.) 0.01-0.04 mm (0.0004-0.0016 in.)

0.1 mm (0.004 in.)

Cogged type belt Cast iron, Cam surface chilled 44.525 mm (1.753 in.) 33.935-33.950 mm (1.336-1.337 in.) 0.05-0.09 mm (0.0020-0.0035 in.) 0.1-0.2 mm (0.004-0.008 in.) Aluminum alloy Max. 0.05 mm (0.002 in.) Max. 0.15 mm (0.006 in.)

44.025 mm (1.733 in.)

0.2 mm (0.008 in.) 0.3 mm (0.012 in.)

13.050-13.068 mm (0.5138-0.5145 in.) 13.250-13.268 mm (0.5217-0.5224 in.) 13.500-13.518 mm (0.5315-0.5322 in.)

44.300-44.325 mm (1.7441-1.7451 in.) 44.600-44.625 mm (1.7559-1.7569 in.)

38.300-38.325 mm (1.5079-1.5089 in.) 38.600-38.625 mm (1.5197-1.5207 in.)

106.6 mm (4.197 in.) 105.2 mm (4.142 in.) 8.0 mm (0.315 in.) 45° 1.7 mm (0.067 in.) 2.5 mm (0.098 in.) 0.03-0.06 mm (0.0012-0.0024 in.) 0.05-0.09 mm (0.0020-0.0035 in.)

0.10 mm (0.0039 in.) 0.15 mm (0.0059 in.)

49.8 mm (1.961 in.) 32.9 kg/40A mm (72.5 Ib/1.591 in.)

48.8 mm (1.921 in.) 32.9 kg/41A mm (72.5 Ib/1.630 in.) Max 4°

20-3

GENERAL

Description Jet valve Length Stem 0.0. Seat angle Valve clearance Hot engine Cold engine Jet valve spring Free length Load Out of sQuareness Right counter balance 'shaft Drive mechanism Material Front journal diameter Rear journal diameter Oil clearance Front Rear Left counter balance shaft Drive mechanism Material Front journal diameter Rear journal diameter Oil clearance Front Rear Piston Material Type Diameter (Standard) Clearance (Piston-to-cylinder) Ring groove width NO.1 No.2 Oil Piston for service

Piston ring Number of rings per piston Compression ring Oil ring Compression ring type No.1 No.2 Oil ring type

20-4

Specification

97.53 mm (3.840 in.) 4.3 mm (0.169 in.) 45 0 0.25 mm (0.0098 in.) 0.17 mm (0.0067 in.) 29.60 mm (1.165 in.) 3.5 kg/21.5 mm (7.7 Ib/0.846 in.) 1.5 0 Cogged type belt Steel 41.959-41.975 mm (1.6519-1.6526 in.) 40.951-40.967 mm (1.6122-1.6129 in.) 0.020-0.061 mm (0.0008-0.0024 in.) 0.050-0.091 mm (0.0020-0.0035 in.) Cogged type belt Steel 18.467-18.480 mm (0.7270-0.7276 in.) 40.959-40.975 mm (1.6126-1.6132 in.) 0.020-0.054 mm (0.0008-0.0021 in.) 0.042-0.083 mm (0.0017-0.0033 in.) Aluminum alloy Autothermic (Steel strut incorporated) 86.47-86.50 mm (3.4043-3.4055 in.) 0.01-0.03 mm (0.0004-0.0012 in.) 1.52-1.54 mm (0.0598-0.0606 in.) 1.51-1.53 mm (0.0594-0.0602 in.) 4.015-4.045 mm (0.1581-0.1593 in.) 0.25 mm (0.010 in.), 0.50 mm (0.020 in.) 0.75 mm (0.030 in.), 1.00 mm (0.040 in.) Oversize

3 2 1 Barrel type, special cast iron Taper type, special cast iron 3-piece type

Limit

GENERAL

Description Ring end gap NO.1 No.2 Oil ring side rail Ring side clearance No.1 No.2 Rings for service

Specification

Limit

0.25-0.40 mm (0.0098-0.0157 in.) 0.20-0.35 mm (0.0079-0.0138 in.) 0.20-0.70 mm (0.0079-0.0276 in.)

0.8 mm (0.031 in.) 0.8 mm (0.031 in.) 1.0 mm (0.039 in.)

0.1 mm (0.004 in.) 0.03-0.07 mm (0.0012-0.0028 in.) 0.1 mm (0.004 in.) 0.02-0.06 mm (0.0008-0.0024 in.) 0.25 mm (0.010 in.), 0.50 mm (0.020 in.) 0.75 mm (0.030 in.), 1.00 mm (0.040 in.), over size

Connecting rod 20.974-20.985 mm (0.8257-0.8262 in.) Piston pin bore diameter 7,355-17,162 N (750-1,750 kg, 1,653-3,858 Ib) Piston pin press-in load 0.10-0.25 mm (0.0039-0.0098 in.) 0.4 mm (0.004 in.) Thrust clearance (Big end) Crankshaft Steel Material Hardening and tempering Treatment 56.980-56.995 mm (2.2433-2.2439 in.) Journal O.D. 44.980-44.995 mm (1.7709-1.7715 in.) Pin O.D. Out-of-roundness of journal and pin Max 0.015 mm (0.0006 in.) Max 0.005 mm (0.0002 in.) Taper of journal and pin Oil clearance 0.02-0.05 mm (0.0008-0.0020 in.) Main bearing journal 0.02-0.05 mm (0.0008-0.0020 in.) Connecting rod journal NO.3 main bearing Thrust taken by 0.05-0.18 mm (0.0020-0.0071 in.) End play 0.25 mm (0.010 in.), 0.50 mm (0.20 in.) Bearings for service 0.75 mm (0.030 in.) undersize (Connecting rod, crankshaft) Cylinder block Material Water jacket Cylinder bore Overall height Flatness of gasket surface Out-of-roundness and taper Oil pump Type Drive mechanism Tip clearance Drive gear Driven gear Side clearance Drive gear Driven gear Oil filter Type Engine oil Capacity including oil filter

Cast iron Siamese type 86.49-86.53 mm (3.4051-3.4067 in.) 290 mm (11.4 in.) Max. 0.05 mm (0.0020 in.) Max. 0.01 mm (0.0004 in.)

-0.2 mm(-0.0079 in.)

Gear Cogged type belt 0.16-0.21 mm (0.0063-0.0083 in.) 0.13-0.18 mm (0.0051-0.0071 in.)

0.25 mm (0.0098 in.) 0.25 mm (0.0098 in.)

0.08-0.14 mm (0.0031-0.0055 in.) 0.06-0.12 mm (0.0024-0.0047 in.)

0.25 mm (0.0098 in.) 0.25 mm (0.0098 in.)

Cartridge, full flow 3.90 lit (4.12 U.S.qts., 3.43 Imp.qts.)

Recommended oil (API classification) SF, SF/CC OR SG

20-5

GENERAL

TIGHTENING TORQUE Cylinder head bolts Cold engine Hot Engine Front case bolts Camshaft sprocket bolts Rocker cover bolts Rocker arm shaft bearing cap bolts (large) Rocker arm shaft bearing cap bolts (small) Intake and exhaust manifold nuts or bolts Main bearing cap bolts Connecting rod cap nuts Crankshaft pulley bolts Crankshaft sprocket bolts Water pump pulley bolt Water outlet fitting bolt Oil screen bolt Oil pump sprocket nut Flywheel bolts Drive plate bolts Oil pump cover bolts Oil filter Oil filter bracket bolt Oil pressure switch or gauge unit Oil pan bolt Oil pan drain plug Oil filter bracket bolt Oil relief valve plug Right counter balance shaft bolt Center member mounting bolt Engine mount insulator nut (large) Engine mount insulator nut (small) Engine mount bracket nut and bolt Front roll stopper insulator nut Front roll stopper bracket to center member Rear roll stopper insulator nut Rear roll stopper bracket to crossmember Transaxle mount insulator nut Transaxle mount bracket to body Timing belt tensioner bolt Timing belt tensioner "8" bolt Jet valve assembly Jet valve adjusting screw

20-6

Nm

kg.cm

Ib.ft

88-98 98-108 20-26 78-98 4.9-6.9 19-21 20-26 15-20 49-54 49-51 20-29 108-127 7.8-9.8 17-20 15-22 49-59 127-137 127-137 15-18 11-13 15-22 7.8-12 5.9-7.8 34-44 15-22 39-49 34-39 78-98 59-78 29-39 49-64 49-64 39-49 29-39 39-49 59-78 39-49 42-54 15-20 18-22 7.8-9.8

900-1,000 1,000-1,100 200-270 800-1,000 50-70 190-210 200-270 150-200 500-550 500-520 200-300 1,100-1,300 80-100 170-200 150-220 500-600 1,300-1 ,400 1,300-1,400 150-180 110-130 150-220 80-120 60-80 350-450 150-220 400-500 350-400 800-1.000 600-800

65-72 72-80 14-20 58-72 3.6-5.1 14-15 14-20 11-14 36-40 36--38 14-22 80-94 5.8-7.2 12-14 11-16 36-43 94-101 94-101 11-13 8.0-9.4 11-16 5.8-8.7 4.3-5.8 25-33 11-16 29-36 25-29 58-72 43-58 22-29 36-47 36-47 29-36 22-29 29-36 43-58 29-36 31-40 11-14 13-16 5.8-7.2

300~400

500-650 500-650 400-500 300-400 400-500 600-800 400-500 430-550 150-200 180-220 80-100

Y20CBOA

GENERAL

SPECIAL TOOLS Tool (Number and name)

09212-32000 Counter balance shaft

Y20CCOA

Illustration

Use Removal of front bearing of counter balance shaft

bearing puller

09212-32100 Counter balance shaft

Removal of rear bearing of counter balance shaft (use with 09212-32300)

bearing puller

09212-32200

Installation of counter balance shaft bear-

Counter balance shaft

ing front and rear (use with 09212-

bearing installer

32300)

09212-32300

Removal and installation of counter bal-

Guide plate

ance

shaft

rear

bearing

(use

with

09212-32100,09212-32200)

09214-32000

Installation of the crankshaft front oil seal

Crankshaft front oil seal installer

09214-32100

Installation of the crankshaft front oil seal

Crankshaft front oil seal guide

09221-32001 Cylinder head bolt wrench

09221-21000 Camshaft oil seal installer

Removal and tightening of the cylinder head bolt

Installation of the camshaft oil seal (use with 09221-21100)

20-7

GENERAL

Tool .

illustration

(Number and name)

Use

09221-21100 Camshaft oil seal guide

Use as a guide when pressing in the camshaft oil seal (use with 0922121000)

09222-21001 Valve spring compressor

1. Removal and installation of the intake or exhaust valve 2. Compression of spring when kickdown servo piston is removed or installed (use with 09456-21100)

09222-21300 Jet valve socket wrench

Removal and installation of jet valve

09222-21400 Jet valve spring plier

For assembling and reassembling jet valve

09222-21500 Jet valve stem 'seal installer

Installation of the jet valve stem oil seal

09222-32100 Valve stem oil seal installer

Installation of the valve stem oil seal

Removal and installation of the valve

09222-32200 Valve guide installer

09231-32000 Crankshaft rear installer

20-8

guide

Installation of the crankshaft rear oil seal oil

seal

GENERAL

Tool (Number and name) 09234-33001 Piston pin remove installer

Illustration

Use Removal and installation of the piston pin

and

09246-32000 Auto lach adjuster holder

Retaining of auto lash adjuster

09246-32100 Auto lash adjuster retainer

Air bleeding of auto lash adjuster (use with 09246-32200)

09246-32200 Air bleed wire

Air bleeding of auto lash adjuster (use with 09246-32100)

09246-32300 Leak down tester

Test for leak down of auto lash adjuster

09260-32000 Oil pressure switch wrench

Removal and installation pressure switch

of

the

oil

20-9

GENERAL

TROUBLESHOOTING

Y2OCDOA

Probable cause

Remedy

Worn main bearing Seized bearing Bent crankshaft Excessive crankshaft end play

Replace Replace Replace Replace thrust bearing

Worn bearing Seized bearing Worn piston pin Worn piston in cylinder Broken piston ring Improper connecting rod alignment

Replace Replace Replace piston and pin or connecting rod Recondition cylinder Repair or replace Re-align

Camshaft knocking

Worn bearing Excessive end gear Broken cam gear

Replace Replace Replace

Timing belt noise

Improper belt tension Worn and/or damaged belt Worn sprocket Worn and/or broken tension adjusting mechanism Worn and/or damaged tensioner

Adjust Replace Replace Replace Replace

Camshaft and valve mechanism knocking

Improper valve clearance Worn adjusting screw Worn rocker face Worn valve guide Weakened valve spring Seized valve

Adjust Replace Replace Replace guide Replace Repair or replace

Compression too low

Cylinder head gasket blown Piston ring worn or damaged Piston or cylinder worn

Replace gasket Replace rings Repair or replace piston and/or cylinder block Repair or replace valve and/or seat ring

Symptom Knocking of and bearing

crankshaft

Piston and connecting rod knocking

Valve seat worn or damaged

Oil pressure drop

Engine oil level too low Oil pressure switch faulty Oil filter clogged Oil pump gears or cover worn Thin or diluted engine oil Oil relief valve stuck (opened) Excessive bearing clearance

Check engine oil level Replace Replace Replace Change Repair Replace

Oil pressure too high

Oil relief valve stuck (closed)

Repair

20-10

GENERAL

Symptom

Probable cause

Remedy

Noisy valves

Incorrect auto-lash adjuster

Replace

Thin or diluted engine oil (low oil pressure) Valve stem or valve guide worn or damage

Change Replace

Shortage of engine oil

Add or replace

Dirty engine oil Poor oil quality

Check oil level on daily basis Replace Use proper oil

Overheating Wrong assembly of piston with connecting rod

Repair or replace Repair or replace

Improper piston ring clearance Dirty air cleaner

Replace Clean air cleaner replace filter

Excessively

worn

cylinder

and piston

and

Insufficient oil supply

Check engine oil level

bearing noise

Thin or diluted engine oil Excessive bearing clearance

Change Replace

Damaged crankshaft bearing

Shortage of engine oil

Add or replace Check oil level on daily basis

Low oil pressure Poor quality engine oil Worn or out-of round crankshaft journal Clogged oil passage in crankshaft Bearing worn

Adjust or repair Use proper engine oil Repair or replace

Bearing improperly assembled Non-concentric crankshaft or bearing

Repair or replace Replace

Excessive engine rolling and

Loose engine mounting bracket

vibration

Broken engine mounting

Re-tighten Replace

Connecting

rod

and/main

insula~or

Loose transaxle mounting bracket Broken transaxle mounting insulator Loose front roll stopper Broken front roll stopper insulator

Clean Replace bearing and check engine oil lubrication system

Re-tighten

Loose rear roll stopper

Replace Re-tighten Replace Re-tighten

Broken rear roll stopper insulator

Replace

20-11

GENERAL

ENGINE TUNE-UP

1.

Checking Engine Oil Refer to Page

2.

Checking Air Filter Refer to Page

3.

20~ 13.

28~4.

Checking Drive Belt Refer to Page 25-7.

4.

Checking Battery Refer to Page 27-17.

5.

Checking Spark Plugs Refer to page 27-35.

6.

Checking High-Tension Cables Refer to page 27-34.

20-12

GENERAL

VALVE CLEARANCE ADJUSTMENT

Y20CEOA

As the intake and exhaust valves are equipped with auto-lash adjustment mechanisms, there is no need for valve clearance adjustment. The proper functioning of the auto-lash mechanism may be determined by checking for valve noise. When there is valve noise or any unusual noise, check the auto-lash by removing it.

TIGHTENING CYLINDER HEAD BOLTS 1.

"-

Y20CFOA

09221-32001

Using special tool (09221-32001), first loosen slightly and then tighten to specified torque. Tightening torque Cylinder head bolts Cold [At engine temperature is approximately 20°C (68°F)] . 88-98 Nm (900-1,000 kg.cm, 65-72 Ib.ft) Hot [At engine temperature is approximately 80°C (176°F)] . 98-108 Nm (1,000-1,100 kg.cm, 72-80 Ib.ft)

2.

Be sure to follow the specific torquing sequence as shown in illusration.

NOTE Run the engine until normal operating temperature is reached, allow it to cool down, and then retorque bolts to specification for best results.

¢

Front of engine

0

0

0

8

6

1

~

4

0

0 3

2

5

0

0

~

jj 20YOO2

CHECKING ENGINE OIL 1. 2.

Y20CGOA

Position vehicle on a flat level. Warm up the engine and stop the engine.

NOTE In the case of a vehicle that has been out of service for a prolonged period, run the engine for serveral minutes and stop for some time before attempting to check oil level.

MAX MIN 20Y003

20-13

GENERAL 3.

Check to ensure that the engine oil level is within the level range indicated on the oil dipstick. If oil level is found to have fallen to the lower limit by the MIN mark, replenish the engine oil. CAUTION For replenishment, use the same type of engine oil as one currently used.

4.

Check to be sure that the oil is not noticeably dirty or mixed with coolant or gasoline, and that it has the proper viscosity.

SELECTION OF ENGINE OIL

Y20CHOA

Recommended API classification: SF, SF/CC OR SG Recommended SAE viscosity grades:

Temperature range anticipated before next oil change

Recommended SAE viscosity number

20W

16

o

60

32

-50

10W

-40

-50

5W

-20

-40

-40

-20

-30 -20:~

-23

*1. *2.

-10

Restricted by driving and climate condition. Not recommended for sustained high speed vehicle operation.

For best performance and for maximum protection of all engines for all types of operation, select only those lubricants which: 1. Conform to the requirements of API classification. 2. Have proper SAE grade number for expected ambient temperature range. Lubricants which do not have both a SAE grade number and an API service classification on the container should not be used.

20-14

GENERAL

CHANGING ENGINE OIL

Y2OCIOA

1. 2. 3.

Warm up the engine. Stop the engine. Remove the oil filler cap (on rocker cover) and the drain plug (on oil pan) and drain the old engine oil. 4. Tighten the drain plug to specified torque. Tightening torque Drain plug .... 34-44 Nm (350-450 kg.cm, 25-33 Ib.ft)

5. Fill the crankcase with fresh engine oil through the loil filler port. Dry fill 3.90 lit (4.12 U.S.qts 3.43 Imp.qts.) Drain and Refill Without oil filter; 2.9 lit (3.06 U.S.qts., 2.55 Imp.qts.) With oil filter; 3.3 lit (3.49 U.S.qts., 2.90 Imp.qts.)

CAUTION Do not overfill crankcase. This will cause oil aeration and loss of oil pressure.

6. 7. 8.

Install the filler cap. Start and run the engine. Stop the engine and then check the oil level. Add oil if necessary. Part number

REPLACING OIL FILTER

Y20CJOA

Filter Selection All Hyundai Motor Company engines are equipped with high quality, throw- away oil filter. This filter is recommended as a replacement filter on all vehicles. The quality of replacement filters varies considerably. Only high quality filters should be used to assure the most efficient service. Make sure that the rubber gasket from the old oil filter is completely removed from the engine block, before installing new

in, III

! :

U

I

i 20YOO5

filter.

Replacing Oil Filter 1. 2. 3. 4. 5.

Use a filter wrench to remove the oil filter. Before installing this oil filter on the engine, apply new engine oil to surface of the rubber gasket. Install and tighten the filter hand tight. Start and run the engine and check for engine oil leaks. After stopping the engine, check the oil level and add oil as r'''lcessary.

.

~

Apply engine oil

20Y006

20-15

GENERAL

JET VALVE INSPECTION AND ADJUSTMENT

~/=

Y20CKOA

1. 2.

Start the engine and allow it to warm up until the temperature of the coolant reaches BOoC to 95°C (176°F to 203°F). Check the ignition timing and idling speed, and adjust if necessary.

3. 4.

Disconnect the air intake hose and air intake pipe. Remove rocker cover.

5.

Remove timing belt front upper cover.

6.

Timing mark (on cylinder head)

Timing mark (on camshaft sprocket) ~ .'

Turn crankshaft clockwise and align the camshaft sprocket 20Y007

timing mark.

7.

Check that the jet valve clearance indicated in the diagram Intake valve side

is within specifications. Jet valve Clearance (at hot engine)

0.25 mm (0.010 in.)

NO.4 No 3

NO.2

NO.1

Exhaust valve side

8.

9.

20YOO8

If jet valve clearance is not within specifications, loosen rocker arm adjusting screw locking nut. Use feeler gauge and adjust jet valve clearance by turning adjusting screw. Secure rocker arm adjusting screw with screw driver so that it will not rotate and tighten locking nut.

10. Rotate the crankshaft clockwise one complete revolution (360 degrees). 11. Check that jet valve clearance indicated in the diagram is

Intake valve side

within specifications. 12. Repeat steps 8 and 9 to adjust the clearance of remaining valves.

NO.4 NO.3 NO.2 No. Exha ust va Ive side 20Y010

20-16

GENERAL

TIMING BELT TENSION ADJUSTMENT PROCE-

DURE

1. 2.

Y20CLOA

Remove the timing belt front upper cover. Turn the crankshaft clockwise and check to ensure that there is nothing abnormal about its operation.

20YOi 1

3.

Turn the crankshaft clockwise until the piston in No.1 cylinder is at top dead center.

CAUTION When aligning the timing mark, be sure not to turn the crankshaft in the counterclockwise direction as this can cause improper belt tension.

Timing mark

C,m,h," sprocket

4.

5.

Remove the two access covers. These are easily removed by inserting a screwdriver into the slots from the direction of the embossed arrow and pry. Loosen the timing belt tensioner tightening bolt and nut by inserting a 14 mm (0.55 in.) socket wrench.

Ir~/ Timing mark

~~ \~ I ,

'.

~

20Y012

Access cover

CAUTION loosen bolt and nut 1/2 to 3/4 of a turn. If they are loosened more than necessary, they might fall into inside the cover.

6.

Turn the crankshaft and the camshaft sprocket clockwise two teeth.

CAUTION Be sure not to turn the crankshaft counterclockwise. This causes stress on the tensioner and can throw belt tension out of adjustment.

Two teeth

Timing mark

20-17

GENERAL 7.

Insert a plain screwdriver from the top of the timing belt cover. Slightly push the tensioner bracket in the tensioning direction, and then release. Now belt tension will be automatically adjusted. CAUTION The purpose of pushing the tensioner with a screwdriver is to loosen tensioner which might have stuck due to many hours of operation in a preset position.

Insert the screwdriver here 20Y015

~~-,-.1~~-'l"-

Timing belt tensioner

~ 8.

III

20Y016

First tighten the timing belt tensioner mounting bolt (lower side), and then tighten the mounting nut (upper side). CAUTION Be sure to tighten the bolt (lower side) first. If the nut is tightened first, the tensioner will rotate with it and belt tension may become loose.

9.

Install the access cover. The access cover can be easily installed by sliding in such a way that the hook will pass between the guides. 10. Install the timing belt front upper cover.

Hook

Access cover

«=~:=-

Guides

20Y01S

20-18

GENERAL

TIMING BELT "B" TENSION ADJUSTMENT 1.

Y20CM3A

Temporarily fix the timing belt B tensioner such that the center of the tensioner pulley is to the left and above the center of the installation bolt, and temporarily attach the tensioner pulley so that the flange is toward the front of the engine.

2.

Holding the timing belt B tensioner up with your finger in the direction of the arrow, place pressure on the timing belt so that the tension side of the belt is strerhed tight. Now tighten the bolt to secure the tensioner.

CAUTION When tightening the bolt. ensure that the tensioner pulley shaft does not rotate with the bolt. Allowing it to rotate with the bolt can cause excessive tension on the belt.

3.

Push on the center of timing belt B with your index finger to check to see if tension is within the standard value. Timing belt "B" tension Standard value

5-7 mm (0.200-0.276 in.)

20-19

ENGINE MOUNTING

ENGINE MOUNTING COMPONENTS

39-49 (400-500, 29-36)

Engine mounting bracket

Transaxle mounting bracket

49-64 (500-650, 36-47)

29-39 (300-400, 22-29) 29-39 (300-400, 22-29)

59-78 (600-800, 43-58)

39-49 (400-500, 29-36) Rear roll stopper

Front roll stopper Crossmember Center member

49-64 (500-650, 36-47)

TORQUE: Nm (kg.em, Ib.ft)

20-20

20Y022

ENGINE MOUNTING

REMOVAL

Y20DAOA

Attach a cable or chain to the engine hooks, and then lift enough so that there is no pressure on the insulators.

Engine Mounting 1. 2.

Remove the engine mount insulator bolts. Remove the engine mount bracket from the engine.

Transaxle Mounting 1.

Remove the transaxle mount bolt.

2.

Remove the plugs from the inside of the right fender shield and remove the remaining transaxle mounting bolts. Remove the transaxle mounting bracket.

3.

Front Roll Stopper 1. 2.

Remove the front roll stopper upper and lower bolts. Remove the front roll stopper assembly.

20-21

ENGINE

Rear Roll Stopper

MOUNTING-====~==-

~\~

roll stopper.

1

the rearf ro m the cross member. . Remove the bolt from II stopper 2.. Remove t h e rear ro

INSPECTION ITEMS

Transax Ie mount

F ont roll stopper assembly r £IT

Eng.One mount

Rear roll stopper . assembly

~

20Y028

20-22

ENGINE AND TRANSAXLE ASSEMBLY

ENGINE AND TRANSAXLE ASSEMBLY

Y20EAOA

REMOVAL 1. Remove the battery. 2. Detach the air cleaner. 3. Disconnect the connectors for the backup lamp and engine harness.

4. Disconnect the connectors for the alternator harness, and the oil pressure switch and oil pressure sender assy wiring. 5. Drain the engine coolant. 6. For vehicles with an automatic transaxle, disconnect the transaxle oil cooler hoses.

NOTE When disconnecting the hoses, make identification marks to avoid making any mistakes in reconnecting them. CAUTION Be careful not to spill any of the oil or fluid out of the hoses, plug the opening to prevent the entrance of foreign material. 7. Disconnect the radiator upper and lower hoses on the engine side, and then remove the radiator assembly. 8. Disconnect the high tension cable and all wires to the distributor from the ignition coil section. 9. Disconnect the engine ground. 10. Disconnect the brake booster vacuum hose. 11. Remove the fuel main, return and vapour hoses from the engine side.

12. Disconnect the heater hoses (inlet and outlet) on the engine side. 13. Disconnect the accelerator cable at the engine side. 14. For vehicles with a manual transaxle. separate the clutch hose from the clutch tube. 15. For vehicles with an automatic transaxle, remove the control cable from the transaxle.

20-23

ENGINE AND TRANSAXLE ASSEMBLY 16. Disconnect the speedometer cable from the transaxle. 17. Detach the air conditioner compressor from the mounting bracket. 18. Remove the exhaust manifold cover. 19. Remove the power steering oil pump from the manifold bracket.

20Y033

20. 21. 22. 23.

Raise the vehicle. Remove the oil pan shield. Drain the transaxle oil (or fluid). Disconnect the front exhaust pipe from the manifold.

NOTE: Use wire to suspend the exhaust pipe from the bottom of the vehicle. 24. Remove the lower arm ball joint bolts and the stabilizer bar at the point where it is mounted to the lower arm. 25. Remove the drive shafts from the transaxle housing.

CAUTION 1 . Plug up the holes of the transax.le case to prevent entry of foreign material. 2. The circlips on the drive shafts should be replaced at each removal. 26. Hang the lower arm and drive shaft from the body with a string. 27. Attach a cable to the engine, and use a chain block to lift the engine only enough to pull the cable tight.

28. Remove the front roll stopper. 29. Remove the rear roll stopper.

20Y036

20-24

ENGINE AND TRANSAXLE ASSEMBLY 30. Remove the engine mount bolts. 31. Remove the engine mounting bracket from the engine.

32. Slowly raise the chain block (to the extent that the engine and transaxle weight is not applied to the mounting portions) and temporarily hold it in the raised condition.

CAUTION Confirm that all of the cables, hoses, harnesses, connectors etc., are disconnected from the engine. 33. Remove the blind plugs from the inside of the right fender shield and remove the transaxle mount bracket bolts. 34. Remove the left mount insulator bolt. While directing the transaxle side downward, lift the engine and transaxle assembly up and out of the vehicle.

20-25

TIMING BELT

TIMING BELT COMPONENTS

Right counter balance shaft sprocket 34-39 (350-400. 25-29) Spacer

Power steering pump pulley

42-54 (430-550.31-401 Tensioner spacer Tensioner "8" Timing belt front upper cover Tensioner spring ! 78-98 (800-1.000. 58-72) 'I:

Key

Camshaft sprocket Timing belt \

Tensioner

Spacer

Gasket

(,)

/

\\

~J

I

'~I

1

Flange

Timing belt under cover Crankshaft sprocket "8" Timing belt "8" Damper pulley

Gasket

15-20 (150-200,11-14) Access cover

49-59 (500-600, 36-43)

Oil pump sprocket Timing belt front lower cover 20-29 (200-300, 14-22) 49-59 (500-600, 36-43) 108-127 (1,100-1,300,36-43)1 Crankshaft sprocket

TORQUE

20-26

Nm (kg.em, Ib.ft)

20Y039

TIMING BELT

REMOVAL 1. 2.

3. 4. 5.

Y20FAOA

Place piston in No.1 cylinder at top dead center on compression stroke. Remove the water pump drive belt and pulley. Remove the crankshaft pulley and the upper and lower timing belt covers. Move the tensioner fully toward the water pump and temporarily secure tensioner. If timing belt is to be reused, make an arrow mark to indicate turning direction to ensure that belt is reinstalled in the same direction as before. Remove the timing belt from the sprockets.

Water pump

Nut

Spring end F

r=.'L--- Bolt

Tensioner

20Y040

6. 7. When the oil pump sprocket nut is removed, fjrst remove the plug at left side of the cylinder block and insert a screwdriver to keep the left counter balance shaft in position. Screwdriver used for this purpose should have a shaft 8 mm (0.3 in.) in diameter which can be inserted more than 60 mm (2.36 in.) 8. Remove the oil pump sprocket retaining nut and remove the oil pump sprocket.

"Front Plug

~

Screwdriver (8 mm (0.3 in.) shaft)

-~

--~.

~-ff

Counter balance

-shaft

-.:J1;C Ylinder block

20Y041

9.

Loosen the right counter balance shaft sprocket mounting bolt until it can be loosened by hand. 10. Next, remove tensioner "B" and remove timing belt "B".

CAUTION After timing belt "B" has been removed, do not attempt loosening bolt, while holding sprocket with pliers, etc. 11. Remove the crankshaft sprocket "B" from crankshaft.

INSPECTION 1.

Y20FBOA

Closely inspect the belt. If following flaws are evident, replace the belt with a new one. 1)

Hardened back surface rubber Back surface glossy. Non-elastic and so hard that even if a finger nail is forced into it, no mark is produced.

20Y043

20-27

TIMING BELT 2) 3) 4) 5)

Cracked back surface rubber Cracked or peeled canvas Cracked tooth bottom Side of belt cracked

~

~Crack

~ S'P'''~ 20Y044

/

6)

Side of belt badly worn

NOTE A normal belt should have clear-cut sides as if cut with a sharp knife.

~

Separation

Rounded belt side

/;;;;

Abnormal wear (Fluffy canvas fiber) 20Y045

7)

Badly worn teeth Initial state: Canvas on load side tooth flank worn (fluffy canvas fibers, rubber gone and colour changed to white, and unclear canvas texture) Last stage: Canvas on load side tooth flank worn down and rubber exposed (tooth width reduced)

8) Missing tooth

INSTALLATION

I t

~

20Y046

Y20FCOA

Install crankshaft sprocket "B" into crankshaft. CAUTION Pay special attention to the direction of the flange. If it is installed in the wrong direction, a broken belt could result.

Crankshaft sprocket "8"

.. Crankshaft sprocket

20-28

eXpOSed}".

Tooth missing end canvas fiber exposed

Sprocket and Tensioner 1.

Rubber

Flange Crankshaft 20Y047

TIMING BELT 2. Lightly apply engine oil to the outer surface of spacer, and then install spacer to the right counter balance shaft. Be sure to install in the direction as shown in illustration. 3. Install counter balance shaft sprocket onto right counter balance shaft, and then tighten flange bolt finger tight. 4. Install timing belt "B" and adjust the belt tension. 5. Tighten the right counter balance shaft sprocket bolt.

Right si lent shaft

Apply thin coat of oil

Oil sea!

Spacer

Tightening torque Right counter balance shaft sprocket bolt . 34-39 Nm (350-400 kg.cm, 25-29 Ib.ft)

Chamfer 20Y048

6. Install flange and crankshaft sprocket onto crankshaft. Be sure to install in the direction as shown in illustration. Crankshaft sprocket "B"

CAUTION Pay attention to direction of flange. If it is installed in wrong direction, a broken belt could result.

/

..

7. Install special washer and sprocket bolt to crankshaft, and then tighten the sprocket bolt. Tightening torque Crankshaft sprocket bolt . 108-127 Nm (1,100-1,300 kg.cm, 80-94 Ib.ft)

Crankshaft sprocket

Flange Crankshaft 20Y049

8. Install the camshaft sprocket to the camshaft and tighten bolt. Tightening torque Camshaft sprocket bolt . 78-98 Nm (800-1,000 kg.cm, 58-72 Ib.ft)

9. Install spacer, tensioner and tensioner spring.

10. Install end A of spring to predetermined position of tensioner bracket.

11. Install end B of spring to predetermined position of water pump.

12. Install the timing belt and adjust the belt tension. 13. Install the timing belt covers. 14. Install the crankshaft pulley and cranking adapter, and then

Tensioner spring

tighten bolts. Tightening torque Crankshaft pulley bolts

.

20-29 Nm (200-300 kg.cm, 14-22 Ib.ft)

Water pump

20-29

TIMING BELT Timing Belt Installation Procedure 1.

Timing mark (on sprocket)

Align timing mark on each sprocket with corresponding timing mark on the front case.

Timi~dO

(slot in front case)

2. 3.

4.

When timing belt "B" is installed, make certain that tension side has no slack. Install tensioner "B" with center of pulley located on the left side of mounting bolt and with pulley flange directed toward front of engine. Align timing mark on the right counter balance shaft sprocket with the timing mark on the front case.

5.

Lift tensioner "B" to tighten timing belt "B" so that its tension side will be pulled tight. In this condition, tighten bolt to secure ,tensioner "B". When bolt is tightened, use care to prevent shaft from turning together. If shaft is turned together, belt will be overtightened.

6.

Check to ensure that timing marks are in alignment.

7.

Check to ensure that when center of span on the tension side is depressed with index finger in direction of arrow, deflection of belt is within specification. Belt deflection

20-30

5-7 mm (0.2-0.3 in.)

Timing mark (on front case)

TIMING BELT 8.

Move tensioner fully toward water pump and temporarily secure tensioner.

Water pump Nut

Bolt

Tensioner

9. Align timing mark on camshaft sprocket with tJ1e timing mark on the cylinder head. 10. Align timing mark on crankshaft sprocket with the timing mark on front case. 11. Align timing mark on oil pump sprocket with the timing mark

20Y055

Timing mark (punch on sprocket) Timing mark (on cylinder head)

on front case.

Timing mark (notch in sprocket) 20Y056

12. When timing mark on oil pump pulley is aligned with the timing mark on front case, be sure to remove plug on left side of cylinder block and insert a screwdriver having a shaft 8 mm (0.3 in.) in diameter. If it can be inserted 60 mm (2.36 in.) or more, alignment is correct. If it can be inserted only 25 mm (1 in.), turn oil pump sprocket one revolution and realign timing marks. Check to ensure that screwdriver can be inserted more than 60 mm (2.36 in.). Keep screwdriver inserted until installation of timing belt is finished.

20-31

TIMING BELT 13. Install timing belt. While making sure that tension side of belt is not slackened, install timing belt onto crankshaft sprocket, oil pump sprocket and camshah sprocket in that order. 14. Loosen tensioner mounting bolt and nut. And tensioner will be moved by spring and will apply tension to belt. 15. Check that portion of belt which is indicated by arrow A to make sure that it is not floating up. 16. Tighten tensioner mounting nut and bolt. Tighten slot side bolt before tightening fulcrum side nut. If fulcrum side nut is tightened earlier, tension bracket will be turned together and belt will be overtensioned. 17. Check to ensure that timing marks on all sprockets are in alignment with respective timing marks. 18. Turn the crankshaft clockwise.

Tension side

CAUTION Do not turn crankshaft in reverse direction. Crankshaft should be turned clockwise only. 19. Loosen tensioner mounting nut and bolt. 20. Tighten tensioner mounting nut and bolt. Be sure to tighten fulcrum side nut and bolt in step 16.

Tension side

20Y059

f

! 1. Check to ensure that when center of belt span on tension side and seal line of under cover are held between thumb and forefinger, as illustrated, clearance "C" between belt and seal line is as follows: Clearance "C"

Approx. 14 mm (0.55 in.)

20Y060

20-32

ROCKER ARMS AND ROCKER ARM SHAFTS

ROCKER ARMS,AND ROCKER ARM SHAFTS COMPONENTS i--4.9-6.9 (50-70. 3.6-5.1)

® ®

Right rocker arm shaft

Rocker arm "D"

~"_

19-21 1190-210, 14-1511 20-26 (200-270. 14-20)

if

!

'

~ -.

·1

'i

Fmnt bea,;n. cap

. ~.

~

v

0.~

Rocker arm "D" / /

o

,

/- 7. 8-9.8 180-100, 5.8-7.2}

~ ~7'l

"

0,-,--~

:;;-~/

>
--:

(California only)

--~ )1 -----

29YOO5

E.

29Y(K)6

F 2-way valve

Thermo valve

2-waV valve 29YOO8

29YOO7

G.

H.

Catalytic converter

Canister

Catalytic converter 29V(X)9

29-5

GENERAL

VACUUM HOSE LAYOUT

[For Federal and Canada] Thermo valve

FRONT Fuel pressure regulator

U -ThfOttle body

Purge control

solenoid valve

rl----(Bi',--...

Canister

[For California] FRONT

Fuel pressure regulator

U

EGR valve

EGR control solenoid valve

"'-+---f-~y)--.J

Throttle body G : Y : L : R B :

29-6

Green Yellow Light blue Red Black

Purge control solenoid valve

R rt--~IB;--_

Canister

GENERAL SCHEMATIC DRAWING (FOR FEDERAL AND CANADA)

.,. *2. *3. *4. *5. *6.

Oxygen sensor Air-flow sensor Intake air temperature sensor Coolant temperature sensor Throttle position sensor Idle switch

*7. No.1 cylinder TOC sensor *8. Cronk angle sensor

* 1. Injector * 2. ISC servo * 3. Purge control solenoid valve

INPUT

Fuel pump control (control relay) . Air conditioner power relay

•

*9. MOlor position sensor

.'0. Atmospheric pressure sensor

Ignition timing control

Ignition switch·ST Power supply . Vehicle-speed sensor Air conditioner switch Inhibitor swilCh(AIT only)

ToC

Top Dead Center

All : Vehicles witch automatic Iransaxle

MRomE

.,

AIR FLOW SENSOR (AFS)

AIR CLEANER

OIS~TRIBUTOR

POSITION

CRA"K

"SANGlE

SENSOR (TPSI

"0 ATMOSPHERIC

(FOR

AIR·CONI

~,"~T"==~lV'PRESSURESENSOR

SENSOR *711'1 CYl TOC

AIRINLET¢

'3

AIR TEMP SENSOR

*'

ISC MOTOR

l'i~~?IiIi~THERMO VALVE

TWC

PCV : Positive Crankcase Ventilation TWC : Three-way Catalytic Converter 31Y032

29-7

GENERAL SCHEMATIC DRAWING (FOR CALIFORNIA)

.1. *2. *3. *4.

Ol(ygeo sensor Air-flow sensor Intake air temperature sensor Coolanl temperature sensor

* 1. Injector

*5. Throttle pashian sensor *6. Idle switch

*2. ISC servo *3. Purge control solenoid valve *4. EGA solenoid valve

*7. NO.1 cylinder TOC sensor

*8. Crank angle sensor *9. Motor position sensor .10. Atmospheric pressure sensor IgnitIon switch-S1

Fuel pump control (control relay) Air conditioner power relay Ignition liming COnlrol

Power supply . Vehicle-speed sensor . Air conditioner switch Inhibitor sw;tch(A/T only) *11. EGR temperature sensor

TOC Top Dead Center AIT : Vehicles witch automatic Iransaxle

.,

DI(YdSTRIBUTOR

THROTIlE

'2 AlA

POSITION SENSOR (TPS)

FLOW

SENSOR IAF71 AIR CCEANER-_

AIR INLET

~.

:i~OSPHERIC

IDLE POSITION SW

~ "'PRESSU:E~S~EN~'~O~R~_~,BAfb~~E~~~/,g==='1 ~ ~\..n.~

\·1

l'

j'

j

tFOR

::

AIR-CON) I

CRANK *8ANGlE SENSOR -*7/1'1 CVL

TOC SENSOR

~lr------~V==~(~Pi;;~ *2

ISC MOTOR

'3 AIR TEMP

:1~HoRI

SENSOR

POSITION

='-ilc~~~~~~i1~S;E;N;S;;O;R~~=ll=r:~~~~~~l=lI=r=='

~

~:~elPUMP

EGR

PURGE CONTROL

SO ENOIO

VALVE

..

,

COOLANT TEMP SENSOR

."

EGR TEMP SENSOR

C

PCV : Positive Crankcase Ventilation TWC : Three-way Catalytic Converter 31Y033

29-8

CRANKCASE EMISSION CONTROL SYSTEM

CRANKCASE EMISSION CONTROL SYSTEM COM PO N ENTS

Air Filter

Throttle Body

Air Intake Hose

Surge Tank

\

~------\-,-----~

--

pev Valve Ventilation Hose

---

_........ Injector

From Rocker Cover~

---

Blow-by Gas -----.. Fresh Air

INSPECTION 1.

2.

"

"

~~~

l=:::iln~take Manifold

~

To Intake Manifold

Plunger Spring

29Y017

Y29DAOA

Disconnect the ventilation hose from the positive crankcase ventilation (PCV) valve. Remove the PCV valve from the rocker cover and reconnect it to the ventilation hose. Run the engine at idle and put a finger on the open end of the PCV valve and make sure that intake manifold vacuum is felt.

NOTE The plunger inside the PCV valve will move back and forth. 3.

If vacuum is not felt, clean the PCV valve and ventilation hose in cleaning solvent or replace if necessary.

29-9

CRANKCASE EMISSION CONTROL SYSTEM

PCV Valve Operating ,.-,

•

Intake manifold side (No vacuum)

~ n

Intake manifold side (High vacuum)

~

t

I lr

\ Ir '--

f------'

Rocker cover side

Rocker cover side

29Y019

29Y020

Engine condition

Not running

Engine condition

Idling or decelerating

PCV valve

Not operating

PCV valve

Fully operating

Vacuum passage

Clogged

Vacuum

Small

rtf

pass~ge

mr

Intake manifold side (Moderate vacuuml

~

\ ffIf

Intake manifold side (Low vacuum)

In

~

\ Ir

Rocker cover side

Rocker cover side 29Y022

29V021

Engine condition

Normal operation

Engine condition

Accelerating and high load

PCV valve

Properly operating

PCV valve

Slightly operating

Vacuum passage

Large

Vacuum passage

Much larger

29-10

EVAPORATIVE EMISSION CONTROL SYSTEM

EVAPORATIVE EMISSION CONTROL SYSTEM COMPONENTS

Air filter

Overfill limiter

\

(2-way valve) Fuel filler cap (Vacuum relief)

Fuel injector

Overfill limiter

(Leveling pipe)

Purge-control

solenoid

I

valve

: Thermal expansion volume

l

t

Fuel gauge unit

Engine Canister Charcoal-H~h

, , - ,, ,

,

-

Fuel pump Filter

--CANISTER

Purge air Fuel vapour 29Y023

Y29EAOA

When the engine is not running, fuel vapours generated inside the fuel tank are absorbed and stored in canister. When the engine is running, the fuel vapours contained in canister are drawn into the surge tank through the pu'ge control solenoid valve.

Vapour from fuel tank To purge control valve

wf(t;~~~~ ~

Charcoal ~

29Y024

29-11

EVAPORATIVE EMISSION CONTROL SYSTEM

Inspection 1. 2. 3.

Look for loose connections, sharp bends or damage in the fuel vapour lines. Look for deformation, cracks or fuel leakage. After removing the charcoal canister, inspect for cracks or damage.

29Y025

PURGE CONTROL SOLENOID VALVE

Y29EBOA

The purge control solenoid valve is controlled by the ECU; when the engine coolant temperature is low, and also during idling, the valve closes so that evaporated fuel is not drawn into the surge tank. After engine warm-up, during ordinary driving, it opens to let stored vapors into the surge tank. To canister

.-€;:::::~~][r/

To throttle body

"-€;:::::~~l.V 29Y026

Inspection NOTE When disconnecting the vacuum hose. make an identification mark on it so that it can be reconnected to its original position.

1. 2.

Disconnect the vacuum hose (black with red stripe) from the solenoid valve. Detach the harness connector.

3.

Connect a manual vacuum pump to the nipple to which the red-striped vacuum hose was connected.

4.

Apply vacuum and check when voltage is applied to the purge-control solenoid valve and when the voltage is discontinued. Battery voltage

Normal condition

When applied

Vacuum is released.

When discontinued

Vacuum is maintained.

29Y028

29-12

EVAPORATIVE EMISSION CONTROL SYSTEM 5.

Measure the resistance between the terminals of the solenoid valve.

Purge control solenoid valve Coil resistance

36-44!1 [at 20°C (68°F)]

29Y029

OVERFILL LIMITER (TWO-WAY VALVE)

Y29ECOA

The overfill limiter consists of a pressure valve and a vacuum valve. The pressure valve is designed to open when the fuel tank internal pressure has increased over the normal pressure and the vacuum valve opens when a vacuum has been produced in the tank.

Pressure valve To fuel

check valve

29YOJO

FUEL CHECK VALVE

Y29EDQA

To overfill limiter

The fuel check valve is used to prevent fuel leaks when the car suddenly rolls over. This valve is connected in the fuel vapour line (between canister and overfill limiter) and is installed on the fuel tank. The fuel check valve contains two balls as shown in the illustration. Under normal conditions, the gasoline vapour passage in the valve is opened, but if roll-over occurs, one of the balls closes the fuel passage, thus preventing fuel leaks.

"

From fuel tank 29YQJl

29-13

EVAPORATIVE EMISSION CONTROL SYSTEM

FUEl FILLER CAP The fuel filler cap is equipped with a vacuum relief valve to prevent the escape of fuel vapour into the atmosphere.

Atmospheric pressure

Fuel vapour pressure Fuel tank vacuum

When pressure is in fuel

When vacuum is in fuel tank

tank

29Y032

CHECKING PURGE CONTROL SYSTEM

:t-

Thronle body,..

'"

Surge tank

Control relay

Purge control solenoid valve

Air-flow sensor

1

Coolant temperature sensor

=

Intake air temperature sensor

ECU Air conditioner switch

I 29Y033

29-14

EVAPORATIVE EMISSION CONTROL SYSTEM

Checking 1.

Y29EEOA

Disconnect the vacuum hose (red stripe) from the throttle body, and connect a manual vacuum pump to the vacuum hose.

I r- ---~--J::::\J o

r

2.

'

F·Y-C1\\\

29Y098

Check the following points when the engine is cold [coolant temperature 60 0 e (140°F) or below] and when it is warm [coolant temperature 70 0 (158°F) or higher].

e

When engine is cold Engine operating condition

Applying vacuum

Result

Idling 3,000 rpm

When engine is warm Engine operating

Apply vacuum

Result

Idling

50 kPa (7.3 psi)

Vacuum is maintained

Within 3 minutes

Try applying vacuum

Vacuum is released

50 kPa (7.3 psi)

Vacuum will be main-

condition

after engine start 3,000 rpm After 3 minutes have passed after engine start 3,000 rpm

tained momentarily, a!ter which, it will be released.

29-15

EXHAUST EMISSION CONTROL SYSTEM

EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM

Y29FAOA

Exhaust emissions (CO, HC, NOx) are controlled by a combination of engine modifications and the addition of special control components. Modifications to the combustion chamber, intake manifold, camshaft and ignition system form the basic control system. Additional control devices include a jet air system, an exhaust gas recirculation (EGR) system and catalytic converters. These systems have been integrated into a highly effective system which controls exhaust emissions while maintaining good driveability and fuel economy.

JET AIR SYSTEM

Y29FBOA

In addition to the intake valve and exhaust valve, a jet valve has been provided for drawing jet air into the combustion chamber. A jet air passage is provided in the throttle body, intake manifold and cylinder head. Air flows through the two intake openings provided near the throttle valve of the throttle body, goes through the passage in the intake manifold and cylinder head, and flows through the jet valve and the jet opening into the combustion chamber. The jet valve is actuated by the same cam as the intake valve and by a common rocker arm so that the jet valve and intake valve open and close simultaneously. The jet air flowing out of he jet valve scavenges the residual gases around the spark plug and creates an ideal ignition condition. It also produces a strong swirl in the combustionchamber which continues through out the compression stroke and improves flame propagation after ignition, assuring high combustion efficiency.

AIR/FUEL MIXTURE RATIO CONTROL SYSTEM [Multi Point Injection (MPI) System] V29FCOA The MPI system is a system which employs the signals from the oxygen sensor to activate and control the injector installed in the manifold for each cylinder, thus precisely regulating the air/fuel mixture ratio and reducing emissions. This in turn allows the engine to produce exhaust gases of the proper composition to permit the use of a three-way catalyst. The three-way catalyst is designed to convert the three pollutants (1) hydrocarbons (He), (2) carbon monoxide (CO), and (3) oxides of nitrogen (NOx) into harmless substances. There are two operating modes in the MPI system. 1. 2.

Open Loop-air fuel ratio is controlled by information programmed into the ECU at manufacture. Closed Loop-air fuel ratio is varied by the ECU based on information supplied by the oxygen sensor.

29-16

, Intake valve

29Y035

EXHAUST EMISSION CONTROL SYSTEM

CATALYTIC CONVERTER

Y29FDOA

Supporter

Exhaust air . .

Cover

Stainless steel

29YOJ6

The three-way catalytic converter which is a monolithic type with catalytic compositions applied to the integrally constructed honey-comb carrier surface installed in the center of the exhaust pipe. The converter working in combination with the air-fuel ratio feed-back control oxidizes CO and HC and reduces NOx.

Function The three-way catalytic converter removes CO, HC and NOx most effectively in the vicinity of the theore!ical air-fuel ratio. The air-fuel mixture to the theoretical air-fuel ratio and the catalytic converter promotes both oxidation and reduction of resultant exhaust gas to make it clean before it is released to atmosphere.

_..

1()()

HC

Vicinity (%) 50 . /

/

.1

/j

CO ...

0

_."~

.'

I

\

Theoretical air-fuel ratio

29Y037

CAUTION The catalytic converters require the use of unleaded gasoline only. Leaded gasoline will destroy the effectiveness of the catalysts as an emission control device. Under normal operating conditions, the catalytic converters will not require maintenance. However, it is important to keep the engine properly tuned. Engine misfiring may cause overheating of the catalysts. This may cause heat damage to the converters or vehicle components. This situation can also occur during diagnostic testing if any spark plug cables are removed and the engine is allowed to idle for a prolonged period of time.

29-17

EXHAUST EMISSION CONTROL SYSTEM

EXHAUST GAS RECIRCURATION SYSTEM

Y2"'08

Inspection (For Federal. Canada) 1.

Disconnect the vacuum hose (green stripe) from the throttle body, and connect a vacuum pump to the vacuum hose.

2.

Check the following points when the engine is cold [coolant temperature 50°C (122°F) or below] and when it is hot [Coolant temperature BQ-95°C (176-205°F) or higher].

\ Engine coolant temperature Cold

Hot

Vacuum

Engine condition

Normal condition

Apply

Idling

Vacuum is released

6 kPa (1.7 in.Hg)

Idling

Vacuum is held

26 kPa (7.5 in.Hg)

Idle is unstable

Vacuum is held

Inspection (For California) 1.

Disconnect the vacuum hose (green stripe) from the EGR valve, and connect a vacuum pump via the three way terminal.

2.

Check the following points when the engine is cold [Coolant temperature 20°C (6BOF) or below] and when it is hot [Coolant temperature 70°C (15BOF) or higher].

When the engine is cold Engine condition

Normal condition

Press the accelerator pedal suddely and race the engine.

Vacuum: no change (atmospheric pressure)

When the engine is warm

3.

4.

Engine condition

Normal condition

Press the accelerator pedal suddenly and race the engine.

Vacuum rises temporarily to 14 kPa (3.9 in.Hg).

Disconnect the three-way terminal and connect the hand vacuum pump directly to the exhaust gas recirculation (EGR) valve. Check whether the engine stalls or the idling is unstable when a vacuum of 20 kPa (5.9 in.Hg) or higher is applied during idling.

29-18

29Y099

EXHAUST EMISSION CONTROL SYSTEM EGR Valve 1.

Removethe EGR valve and check it for sticking. carbon depos-

2.

If such conditions exist, clean with solvent to ensure tight valve seat contact. Connect a vacuum pump to the EGR valve.

its, etc.

3. 4.

Apply a vacuum of 67 kPa (19.6 in.Hg) and check that vacuum is held. Blow in air from one passage of the EGR and check as 29Y()41

follows. Vacuum

Normal condition

6 kPa (1.7 in.Hg) or less

Air does not blow through

26 kPa (7.5 in.Hg) or more

Air blows through

NOTE When installing the EGR valve. use a new gasket and tighten to the specified torque. Tightening torque EGR~I~

. 19-27 Nm (190-280 kg.cm. 14-20 Ib.lt)

EGR Temperature Sensor (California Vehicles Only) 1.

Place the EGR temperature sensor in water. and then measure the resistance value between terminals 1 and 2 while increasing the water temperature. If out of specification, replace the EGR temperature sensor. Temperature °C (OF)

Resistance (Kn)

50 (122) 100 (212)

60-83 11-14

....... 2 if

50n5\1_ ____'Y____ - . - -- - - - -

CJ

(§) ~

, 29Y089

Tightening torque EGR temperature sensor ............... 10-12 Nm (100-120 kg.cm, 7.3-8.6Ibft)

29-19

EXHAUST EMISSION CONTROL SYSTEM Thermo Valve (Federal. Canada Vehicles Only)

NOTE 1} Do not use a wrench on the plastic section when removing or installing the thermo valve. 2) When installing. apply a coating of sealant to the thraads. and tighten to the spacified torque. Tightening torque Thermo valve . 20-39 Nm (200-400 kg.cm. 14-29 Ib.lt) 3) When disconnecting the vacuum hose. make an identification mark on it so it can be reconnected to the original position. 1.

2.

Disconnect the vacuum hoses (yellow stripe and green stripe) from the thermo valve. and connect a vacuum pump to the thermo valve. Apply vacuum and check the air passage through the thermo valve. Engine coolant temperature

Normal condition

50°C (122°F) or less

Vacuum is released

80°C (176°F) or more

Vacuum is held

EGR Control Solenoid Valve (California) NOTE When disconnecting the vacuum hose. make an identification mark on it so that it can be reconnected to the original position. 1. 2. 3. 4.

Disconnect the vacuum hoses (green stripe) from the solenoid valve. Disconnect the harness connector. Connect a vacuum pump to the nipple to which the green-striped vacuum hose was connected. Apply a vacuum and check for air-tightness when voltage applied directly to the EGR control solenoid valve when the voltage is discontinued. Battery voltage

Result

When applied

Vacuum is held.

When discontinued

Vacuum is released.

= ar;:: -=:, ,..I,

r

5.

Measure the resistance between the terminals of the

:!U..I

e

EEl 12V

solenoid valve. Standard value: 36-44!1 [at 20 0 e (68°F)]

29-20

29Y091

FUEL SYSTEM GENERAL

2

MPI SySTEM

15

INJECTOR AND THROTILE BODy

64

THROTILE BODy

67

FUEL TANK

6911

FUEL PUMP

74

FUEL LINE AND VAPOUR LINE

76

ENGINE CONTROL

78

GENERAL

GENERAL SPECIFICATIONS Fuel tank Capacity Fuel filter Type Fuel pump Type Driven by Throttle body Throttle position sensor (TPS)

Y31CAOA.

60 lit. (15.9 U.S. gal., 13.2 Imp.gal.) High pressure type Electrical, in-tank type Electric motor

Type Resistance Output voltage at curb idle Idle speed control (ISC) servo motor

Variable resistor type 3.5-6.5 Kfl 0.48-0.52 V

Type Resistance Idle position switch Type Motor position sensor (MPS) Type Resistance

Electric motor 5-35 fl at 20°C (68°F)

Input sensor Air flow sensor (AFS) Type Output voltage Atmospheric pressure sensor Type Output voltage Intake air temperature sensor Type Resistance Coolant temperature sensor Type Resistance Oxygen sensor Type Output voltage Vehicle speed sensor Type

31-2

Contact type within ISC servo Variable resistor type Approx. 4-6 Kfl

Karman vortex type 2.7-3.2V Semiconductor diffusion type 4V at 101 kPa (1.0 kg/em', 14.6 psi) 3.5V at 88 kPa (0.9 kg/em', 12.8 psi) Thermistor type 2.7 kfl at 20°C (68°F) Thermistor type 2.5 kfl at 20°C (68°F) 0.3 kfl at 80°C (176°F) Zirconia sensor

Approx. IV Reed switch type

GENERAL

No.1 cylinder TDC sensor Type Output voltage Crank angle sensor Type Output voltage Output actuator Injector Type Number Coil resistance Purge control solenoid valve Type Resistance EGR control solenoid valve [Only California] Type Fuel pressure regulator Regulated pressure

Photo diode sensor 0.2-1.2V Photo diode sensor 1.8-2.5V

Electromagnetic type

4 13-16

n

at 20 D C (68 D F)

ON/OFF type 36-44 n at 20 D C (68 D F) Duty cycle type solenoid valve 330 KPa (3.35 kg/em', 48 psi)

SEALANT Water temperature sensor

Y31CBOA

LOCTITE 962T or equivalent

31-3

GENERAL SERVICE STANDARD Basic ignition timing Curb idle speed Throllle-position sensor (TPS) adjustment voltage

TIGHTENING TORQUE Delivery pipe installation bolts Coolant temperature sensor Accelerator arm bracket bolts Oxygen sensor Oxygen sensor connector bracket bolt Throllie position sensor (TPS) installation screw Fuel pressure regulator lock nut High pressure hose and fuel main pipe eye bolt High pressure hose and fuel filter Fuel pump assembly to fuel tank High pressure hose and fuel tank Throllle body to surge tank Fuel tank drain plug Fuel filter mounting bolt Air intake pipe to rocker cover

31-4

Y31CCOA

BTDC 5° ± 2° at curb idle 700 ± 100 rpm 0.48-0.52V at curb idle

Nm

Kg.cm

Ib.ft

9.8-13 20-29 7.B-12 39-49 7.8-12 1.5-2.5 25-34 25-34 29-39 2-3 29-39 9.8-13 15-25 8.8-14 2.5-3.9

100-130 200-300 Bo-120 400-500 80-120 15-25 250-350 250-350 300-400 20-30 300-400 100-130 150-250 90-140 25-40

7.2-9.4 14-22 5.8-7.2 29-36 5.8-B.7 1.1-1.8 18-25 18-25 22-29 1.4-2.2 22-29 7.2-9.4 11-18 6.5-10 1.8-2.9

Y31CDOA

GENERAL SPECIAL TOOLS Tool (Number and name)

Use

Illustration

09273-24000 Harness connector

En9ine r.p.m. check

09391-33200 1. Multi-use tester

Diagnostic tester for MPI, automatic transaxle and cruise control systems

09391-33300 2. Test harness

09391-33500 3. Battery harness

1

09391-33600 4. Instruction manual 5

09391-33401 5. R.O.M. Pack (HMC-2)

09391-33700 6. Connector RS 232C

'4

For connection to the external communication device such as personal computer etc. in using Multi-Use Tester

31-5

GENERAL

Tool (Number and name)

Illustration

09353-24000 Fuel pressure gauge connector

09353-24100 Fuel pressure gauge & hose

t

r

~~

\ 09353-24200 Fuel pressure gauge adapter

ll(pmn

31-6

1~

(t1

Use Connection of fuel pressure gauge to delivery pipe for measurement of fuel pressure.

GENERAL TROUBLESHOOTING

Y31CFQA

When checking and correcting engine troubles, it is important to start with an inspection of the basic systems. If one of the following conditions exists, (A) engine start failure, (B) unstable idling or (e) poor acceleration, begin by checking the followir." basic systems. 1.

Power supply 1) Battery 2) Fusible link 3) Fuse

2. 3.

Body ground Fuel supply 1) Fuel line 2) Fuel filter 3) Fuel pump 4. Ignition system 1) Spark plug 2) High-tension cable 3) Distributor 4) Ignition coil 5. Emission control system 1) PCV syste m '2) EGR system 3) Vacuum leak 6. Others 1) 2)

Ignition timing Idle speed

Troubles with the MPI system are often caused by poor contact of the harness connectors. It is important to check all harness connectors and verity that they are securely connected.

31-7

GENERAL MPI TROUBLESHOOTING PROCEDURES

Z31CGOC

PROBLEM Engine will not start

Check electrical supply _ _ _ _ _ _, - -

-- -- -- --3' IL - Wrong

.cJ.

OK

------3'

Check starting system

Wrong

o Battery 1. Connection 2. Specific gravity. charging system 3. Drive belt 4. Voltage o Fusible links

o o o o

Ignition switch Starter relay Starter Wiring

PROBLEM Hard to start (Cranks OK)

Check self-diagnosis [Refer to page 31-39]

I- - - - - - - 7 Malfunction codes

Normal codes

Trouble codes o Using voltmeter [Refer to page 31-41) o Using MUT [Refer to page 31-44]

\

-----70

Check for vacuum leaks

Wrong

OK

o o o o o

Oil filler cap Oil dipstic Vacuum hose connections PCV hose EGR system

\

Check for ignition spark o Unplug injector connectors 0 Check for a strong spark by holding spark plug wire 8-10 mm (0.030-0.039 in.) away from engine block during cranking engine.

OK To be continued

31-8

-

----~ o High tension cables Wrong

o Distributor o Ignition coil. power transistor o Spark plugs

GENERAL

Check ignition timing Basic : 5° ± 2°BTDC at curb idle Actual : 100 BTDC

-

----~

o Ignition timing-adjust [Refer to page 27-36)

----~ Wrong

o o o o o

Wrong

OK

Check fuel supply to injector o Fuel in tank o Fuel pressure [Refer to page 31-34)

f-

Fuel line (leakage, deformation) Fuse Fuel pump [Refer to page 31-33) Fuel filter Fuel pressure regulator

OK

Check spark plugs Standard : 1.0-1.1 mm (0.0390.043 in.) o Check compression and valve clearance if necessary o Compression Limit: 10.5 kg/cm 2 (1050 kPa, 150 psil/[25D-400 rpm) o Valve clearance [Refer to page 10-61)

OK

II Check MPI electronic circuit

----~ o Wiring connections Wrong

o Power to ECU 1. Fusible links 2. Fuses 3. MPI control relay o Engine coolant temperature sensor o Intake air temperature sensor o Injection signal circuit 1. Injector wiring 2. ECU o TPS oAFS

31-9

GENERAL PROBLEM Rough idle or engine stalls

Check self-diagnosis [Refer to page 31-39]

- - -----;, Malf unction cod es

Normal codes

Check for vacuum leaks

- -----;, Wrong

OK

Trouble codes o Using voltmeter [Refer to page 31-41] o Using MUT [Refer to page 31-44]

o o o o o

Oil filler cap Oil dipstic Vacuum hose connections PCV hose EGR system

o o o o

Fuel line (leakage, deformation) Fuses Fuel pump [Refer to page 31-33] Fuel filter

,II

Check fuel supply to injector o Fuel in take o Fuel pressure [Refer to page 31-34]

f----

-----;, Wrong

o Fuel pressure regulator OK Check air cleaner element

-

- - - -;.J' -Element-Clean or replace ---------------

Wrong JOK Check idle speed Standard : 750 ± 100 rpm

- - -----;, Wrong

Idle speed-Adjust [Refer to page 31-29]

JiOK Check ignition timing Basic : 5° ± 2°BTDC at curb idle Actual : 100 BTDC

- - -----;,

\1 OK Check spark plugs Standard : 1.0-1.1 mm (0.039-0.043 in.) o Check compression and valve clearance if necessary o Compression Limit: 10.5 kg/cm' (1050 Kpa, 150 psi) [250-400 rpm]

,II

OK

To be continued

31-10

Wrong

Ignition timing-Adjust [Refer to page 27-361

GENERAL

Check fuel pressure [Refer to page 31-34)

~------3> Wrong

o Fuel pump [Refer to page 31-33) o Fuel filter o Fuel pressure regulator

OK

1/ Check injectors

Check MPI electronic circuit

----4 Wrong

------3> Wrong

Injection condition

'--'--------------~

o Wiring connections o Power to ECU 1. Fusible links 2. Fuses 3. MPI control relay o Engine coolant temperature sensor o Intake air temperature sensor o Injection signal circuit 1. Injector wiring 2. ECU

31-11

GENERAL PROBLEM Engine hesitates or accelerates poorly

----,

Check clutch or brakes

Wrong

OK

o Clutch-slip o Brake-drag L -_ _

-----.:=----

_

\11

Check vacuum leaks in intake air line

-

------7

o o o o o

- Wrong - - - 1L J

Element-Clean or replace

Wrong

OK

Check air cleaner element

Oil filler cap Oil dipstic Hose connections PCV hose EGR system

~ OK

Check self-diagnosis [Refer to page 31-39]

I- - - - - - - 7 Malfunction codes

Normal codes

Trouble codes o Using voltmeter [Refer to page 31-41] o Using MUT [Refer to page 31-44]

I

Check for ignition spark o Unplug injector connectors o Check for a strong spark by holding spark plug wire B-10 mm (0.31-0.39 in.) away from engine block during cranking engine

------7 Wrong

o High tension cables o Distributor o Ignition coil, power transister

II/OK Check ignition timing Basic: 5° ± 2°BTDC at curb idle Actual : 100 BTDC

1

-

------7 Wrong

Ignition timing-Adjust [Refer to page 27-36]

0K

Check fuel pressure [Refer to page 31-34]

~OK To be continued

31-12

-

------7 Wrong

o Fuel pump [Refer to page 31-33] o Fuel filter o Fuel pressure regulator

_

GENERAL

-----l1L----,r- - - - - -1

I

Check injectors

Wrong

Injector condition ---------------

Check spark plugs Standard : 1.0-1.1 mm (0.0390.043 in.) o Check compression and valve clearance if necessary o Compression Limit: 10.5 kg/cm 2 (1050 KPa. 150 psil/[25D-400 rpm]

JOK Check MPI electronic circuit

------;, Wrong

o Wiring connections o Power to ECU 1. Fusible links 2. Fuses 3. MPI control relay o Engine coolant temperature sensor o Intake air temperature sensor o Injection signal circuit 1. Injector wiring 2. ECU

31-13

GENERAL Fuel Tank And Fuel Line

Y31CHQA

Symptom

Probable cause

Remedy

Engine malfunctions due to insufficient fuel

Bent or kinked fuel pipe or hose Restricted fuel pipe or hose Restricted fuel filter or in-tank fuel filter Water in fuel filter

Repair or replace Clean or replace

supply

Evaporative emission control system malfunctions (when tank cap is removed, pressure releasing noise is heard)

31-14

Replace Replace the fuel filter or clean the fuel tank and fuel lines

Dirty or rusted fuel tank interior Malfunctioning fuel pump (Restricted filter in the pump)

Clean or replace Replace

Incorrect routing of a vapour line

Correct Correct Replace

Disconnected vapour line Folded, bent, cracked or clogged vapour line Faulty fuel tank cap Malfunctioning overfill limiter (Two-way valve)

Replace

MPI SYSTEM

MPI SYSTEM GENERAL INFORMATION

Y310AOA

The airIfuel ratio is controlled by varying the driving time of each injector. After passing through the in-tank filter, fuel is force-fed by the in-tank fuel pump delivery pipe through the fuel filter, and is distributed to each injector by the delivery pipe. The fuel pressur" applied to the injector is maintained at a fixed level by the fuel pressure regulator so that it may be higher that the internal pressure of the intake manifold where fuel injection takes place. After pressure regulation, excess fuel is returned to the fuel tank through the return hose. When the injector is energized, the valve inside the injector opens fully to inject the fuel. The injectors inspect fuel to each manifold port, in the sequential firing order of each cylinder, according to ECU signals.

Air flow sensor (AFSI Atmospheric pressure sensor Intake air temperature sensor Coolant temperature sensor

Throttle position sensor (TPS)

ECU

Idle switch

.l-''---''"'-l.Fuel pressure regulator

Crank angle sensor:

No.1 cylinder TDC sensor

-

To fuel tank

~====-

Ignition switch-5T terminal ~~--Fuel injector

Motor position sensor (MPS) Oxygen sensor

31YQOl

Delivery pipe

Fuel tank

-:r-"'-='-'i

31YOO2

31-15

MPI SYSTEM Electronic Control Unit (ECU)

V310BOA

Based on the information from various sensors, the ECU determines (computes) an optimum control for varying operating conditions and accordingly drives the output actuators. The ECU consists of an 8-bit microprocessor, random access memory (RAM), read only memory (ROM) and input/output (I/O) interface.

ECU r-

-

"

5

2"

""'

."g

"'c:

:;

0.

E

'--

Iprocessor Micro I

Jl

:;;

:; 0.

c:

~

::;; :

0: L.....-

HMC Part No. Abbr. Type Name Lot No.

r--

~

::;;

a0:

'--

5

.""

10 :> 13

1i'"

E

o'~~

:;'"

:; 0. :;

,

0.

:;

a

a

'--31YOO3

nr Q

C02-3

If III

5 4 3 2 1 098 7

C02-2

9 8 7 6 5 4

U3 2 1

L

C02-1

J

~~

J

0

31YOO4

U

~

12 11 10 9 8 7 6 5 4 3 2 1

6 18 716 15 14 13 12 11 10 24 23 22 21 20 19 817 16 514 13

II

II

II 31YOOS

C02-3 1. N.A (NOT AVAILABLE) 2. N. SW. 3. BAn (BACK-UP SOURCE) 4. BAn 5. GND 6. NA 7. FUEL PUMP RELAY SG B. ST SG. 9. BAn 10. GND

CAL: California * Mark is gold plating terminal

31-16

C02-2 1. ISC MOTOR (EXT) 2. ISC MOTOR (RET) 3. N.A. 4. FUEL PUMP RELAY 5. N.A. 6. IG. COIL (POWER TR) 7. EGR SOLENOID (CAL. only) 8 INJ. #2 CYL. 9. INJ #1 CYL. 10 NA 11. N.A. 12. N.A. 13. A/C RELAY (POWER) 14. EMISSION INDICATOR LAMP (U.SA only) 15. N.A. 16. PURGE SOLENOID 17. INJ. #4 CYL. 18. INJ. #3 CYL.

C02-1 1. SPARK TIMING ADJUST (+) 2. NA 3 AIR FLOW SENSOR 4. NA 5. A.T.S. 6. A/C SIG. 7.I.D.SW. B. PIS SW. 9. 0, SG. 10. NA 11. DIAGNOSIS CONTROL SG. 12. DIAGNOSIS 13. SENSOR GND 14. SENSOR SOURCE (5V) 15. CYL. DETECT SG. 16 CRANK ANGLE 17. W.T.S. 18. T.P.S 19. VEHICLE SPEED (0 Km/h) 20. ISC MOTOR POSITION SENSOR 21. B.P.S. 22. EGR TEMp. SENSOR (CAL. only) 23. SENSOR GND 24. SENSOR SOURCE (+)

MPI SYSTEM Fuel Injection Control

Y31DCOA

The fuel injection amount is basically determined by the number of injector activations, which corresponds to the engine rpm, and by the injector activation time, which corresponds to the amount of intake air during each cycle. Injector activation occurs for each cylinder, and is one time for each two engine rpm.

Injector Drive (Fuel Injection) Timing 1.

Y31DDQA

Simultaneous injection (Non-synchronous injection) During engine starting (cranking), there are two fuel injections (for each engine rpm) for each of the four cylinders. In addition, on acceleration, fuel in an amount proportionate to the magnitude of the acceleration during a fixed time (10 milliseconds) is injected to certain cylinders (2 cylinders) during the intake and exhaust strokes.

No1 cyl.

n '---

l

TOe signal L________

Crank angle signal Cylinder

No.1 _-L-L-L_LJL--LL-L-L-l.. No.2 --'---'--'_-'--'---'--'-_1.-1.--l.. NO.3 _-'---'--'_-'--'--'--'-_1-1---'No.4 _-L-L-L_LJ_LL-L...L-.L During engine starting

Cylinder

L....O.J

No.1 _ _--J

_

NO.2-----lLllJ

_

No.3 NO.4 _-l..LJL-

--.JLJ1-'__ .....L--.J-l..._ When acceleration

31YQ06

31-17

MPI SYSTEM 2.

Sequential injection (Synchronous injection) After the engine is started, the injectors are activated at the exhaust stroke of each cylinder, one cylinder after another. Injection is, therefore, synchronized to the signals of the crankshaft angle sensor. The No.1 cylinder signal is the standard reference signal for sequential injection; thus, using this signal as the standard reference, the cylinder for fuel injection is determined, and the fuel injection occurs in synchronization with the crankshaft angle sensor signals. For each cylinder, there is one injection for each two rotations of the crankshaft, in the firing order 1-3-4-2.

n

No.1 cyL --, TOC signal 1,-

----,

'-

_

Crank angle signal

Cylinder No.1

Combustion

E'J1 haus!

No.3

Com-

Com-

No.4

Intake

pressIOn

No.2

Inlake

".,,~ pression bustian haust ComCom-

E'hawsl .,J(.I

Intake

Com-

Com-

preSSion buslian

Intake

Compression

E'."l(.j

Intake bustian hausl ComCompression bustian hausl

E,-,,\:!

Llnjection

31YQ07

Injector Driving Time

Y310EOA

Injector activation occurs one time per cycle for each cylinder, and the injector activation time (amount of fuel injection), which is the theoretical air/fuel mixture ratio relative to the amount of intake air, is called the basic activation time. The ECU functions to, first of all, calculate this basic activation time according to air-flow sensor (AFS) signals and crankshaft angle sensor signals. When starting (cranking) the engine, the map value* determined by the engine coolant temperature sensor signal is used as the basic driving time. During the deceleration, the basic driving time is set at zero. The injector driving time is obtained by making the following corrections on the above-mentioned basic driving time. *Map value: The map value is a value set in advance and stored in the ROM inside the ECU. o

Oxygen sensor feedback correction (Closed loop control correction) In normal operation (including idling) after engine warm up, the air/fuel ratio is corrected to an ideal air/fuel ratio by using oxygen sensor signals. The three-way catalytic converter gives the best degree of purification at the ideal air/fuel ratio.

31-18

MPI SYSTEM o

o

o

o

o

Air-fuel ratio map correction (Open loop control correction) Correction to the optimum air/fuel ratio is made by the map values set by engine speed and amount of intake air. Engine coolant temperature correction To maintain driveability of a cold engine, correction is made to increase the amount of intake air relative to the temperature of the coolant. Intake air temperature correction Change in air/fuel ratio due to difference in intake air density caused by intake air temperature is corrected. Atmospheric pressure correction Change in air/fuel ratio due to difference in intake air density caused by change in atmospheric pressure is corrected. Acceleration/deceleration correction In accordance with the change in the amount of intake air, fuel amount is corrected, improving driveability on acceleration and deceleration.

o

Dead time correction The injectors opened by the driving signal from ECU have operational lag which changes according to difference due to battery voltage. This means that actual injector valve opening time becomes less than injector driving signal, failing to provide expected air/fuel ratio.

ON

Drive OFF signal

:::d

Dead I Valve open time time

I

I----L

Injector-----

I Valve open t;me 1

4

I "'1 31YOO8

Therefore, battery correction time corresponding to the battery voltage is added.

Time (ms)

L -_ _-,_-'-_-=_IV)

Battery 31YOO9

31-19

MPI SYSTEM Ignition Timing Control System

Y31DF3A

The ignition timing control system adjusts ignition timing by controlling the power transistor which supplies current to the ignition coil. Air flow sensor (AFSI Atmospheric pressure sensor Intake air temperature sensor

Power Coolant temperature sensor

transistor

Ignition coil

ECU Throttle position sensor (TPS) Idle switch

Crankshaft angle sensor

Vehicle speed sensor

~~~nition

Ignition switch-5T terminal

iWitCh Inhibitor switch (A/T only) Spark plug ~Battery

Terminal for ignition

timing adjustment

AIT : Vehicle with an automatic transaxle

(a) Control During Starting During engine starting, there is synchronization to the crankshaft angle sensor's signals, thus resulting in a fixed ignition timing (5° BTDC). (b) Control During Ordinary Driving For each engine revolution and intake of air, and with the preset map value as the reference ignition spark advance, the coolant temperature correction value or the atmospheric pressure correction value, whichever is greater relative to the reference ignition spark advance, is applied as the correction value, thus regulating to the optimum ignition spark advance. o

Coolant temperature correction In order to improve driveability when the engine is cold, the spark is advanced when the engine coolant temperature is low.

o

Atmospheric pressure correction In order to maintain good driveability at high altitude, the spark is advanced when the atmospheric pressure is low.

31-20

1 31'1'010

MPI SYSTEM Calculation Of Ignition Timing 1. The period (T) of the crankshaft angle sensor signal is measured, and from this the time (t) required for a rotation of 1° of the crankshaft is determined. t=T~180

2.

The ignition timing (T1) is caluculated, with 75° BTDC as the reference standard, and the ignition signals are sent to the power transistor. Example (at ignition at 20° BTDC): T1 = t x (75-20) sec

T (Crankshaft angle 180°)

BTD~BTDC 5°

75° I

Crank

:~~~:r~, Ignition pulse

b

_ _-I

'-----

Time count stan 31YQ11

(a) Control During Ignition Timing Adjustment When the ignition timing adjustment terminal is grounded, there is synchronization with the crankshaft angle sensor's signal, thus resulting in the fixed ignition timing (5° BTDC), and in this condition the reference ignition timing is adjusted. Note, however, that the spark advance becomes the same as control during ordinary driving if the engine rpm becomes the set rpm (1200 rpm) or higher. (b) Control During A Malfunction Of The Air-flow Sensor If a malfunction of the air-flow sensor occurs, there is control to the greatest load of the map value set to each engine revolution and intake air amount. This is equivalent to the centrifugal spark-advance characteristic of a conventional distributor.

31-21

MPI SYSTEM Idle Speed Control (lSC) System

Y31DG3A

The ISC system provides the following four modes of control.

ECU

.----

+--{) Motor drive signal .--------------j---oMotor drive signal

Retraction

side

Extension side

.------------,--I-<JSensor power supply .------------jf-----!---oSensor power supply .--------!---+--oMotor position sensor MPS .-----+--+--oldIe switch

Engine speed sensor Coolant temperature sensor Inhibitor switch (Vehicles with an automatic transaxle only) Air conditioner switch Vehicle-speed sensor

Ignition switch-5T terminal

L--------jf------j--I--oThrottle position sensor L

4

-j_o--, Sensor ground

31Y012

(a) Start Control The throttle valve opening is controlled to optimum position for start according to the engine coolant temperature and the altitude (atmospheric pressure). (bl Fast Idle Control When the idle switch is on, the engine speed is controlled to a target rpm according to the engine coolant temperature (rpm feedback control). When the idle switch is off, the ISC servo is actuated to move the throttle valve to a target opening position (throttle valve opening position) according to the engine coolant temperature (target opening control). (c) Idle Control When the air conditioner switch is turned on or when the transmission is shifted from N to D (vehicles with an automatic transmission), the system causes the idle speed to increase to the target rpm according to the load (rpm feedback control). When there is a load fluctuation (such as when the air conditioner is switched ON, etc.), there is control to the target position (throttle valve opening) before rpm feedback control, eliminating an rpm drop due to time lag. (target opening control) (d) Dash Pot Control The system provides dash pot control according to deceleration conditions to alleviate shock at deceleration.

31-22

MPI SYSTEM Air Conditioner Relay Control

Y310H3A

When the air conditioner switch is turned on while the engine is at idle, the ISC servo operates to increase the engine speed. However, there is some delay before the engine speed actually increases. To maintain the engine free from the air conditioner load during that delay period, the ECU keeps the power transistor off for a fixed time (about 0.5 seconds) to open the air conditioner power relay circuit. As a result, even if the air conditioner switch is on, the air compressor is not driven instantly, preventing engine speed drop due to compressor load. In addition, for automatic-transmission-equipped models, during acceleration when the throttle valve opening is great (approximately 65 0 or more), the air conditioner power relay circuit is cut off for a fixed time (about five seconds) for good acceleration performance.

Air conditioner switch

I ./": II I

Air conditioner switch

, ~

(

~

~

--'-

-=-Battery

ECU Inhibitor switch

01 ~~

~-~

•

IAIT only)

~'L

0';' Air conditioner compressor

Throttle position

sensor (A/T onl YI

0

(

Crank angle se nsor

Air conditioner relay

AIT : Vehicles with an automatic transaxle

31Y013

31-23

MPI SYSTEM Power Supply And Fuel Pump Control

Y31DI3A

To injector f_-~Purge control sol. valve

To fuel pumpl--~EGRsol. valve (only california) ECU Battery

til

Fusible link

7

S2

Power

-o-Lc:'3'--------;>-~)-+----...-~-+-L-f-T--\ supply

Ground

To AFS

31YQ14

o

While cranking (ignition switch at 5T), current flows through coil L, to close switch 5,. As a result, the fuel pump is driven. Current als,? flows through coil L3 to close switch 5,. As a result, power is supplied to the ECU, AF5, igniter

o o

and injectors. While the engine is running, the ECU turns on the power transistor to supply current to coil L, and to close switch 5,. As a result, the fuel pump is driven. In the event of engine stall or other abnormal conditions, the ECU turns off the power transistor and open the coil L, circuit. As a result. switch 5, opens to stop driving of the fuel pump, thus securing safety.

31-24

MPI SYSTEM

LOCATION OF COMPONENTS A

C

B

D

E

0

H

F

G

J

31YQ15

M

[][~ 0=3~===========~

"S

~. . r,;::m~======-~ ~~Dij

WL-°~L-]

[)

\! KN

L A. B. C. D. E. F. G. H.

Air conditioner relay Air flow sensor ISC servo (Motor position sensor) Throttle position sensor Coolant temperature sensor Power transistor Crank angle sensor Injector

31Y016

I. Oxygen sensor J. Inhibitor switch K. MPI control relay L Diagnosis terminal M. Vehicle speed sensor N. Electronic control unit O. EGR temperature sensor (Only California vehicles)

31-25

MPI SYSTEM B

31Y018

c

- ...LL... ~ \~ \r---Idle-speea ~~. control servo ..----:

1

~-J

If

~.~

~ t---.c ~. ~

~,;l;7...-------....:""""'" ~

\' Motor position

.

\/"

/ /

~

~:':'~

sensor (MPS) . .

", \

31Y260

~ ~

E

L{I _ Coolant \ temperature censor 'v-----. '--

...............

. ""-.

-./l W~ ---

Intake manifold

~~-

G

31-26

Crank

31Y021

MPI SYSTEM

In~ 31Y026

M Vehicle speed sensor

31YQ29

o

EGR temperature sensor

31-27

MPI SYSTEM

SERVICE ADJUSTMENT PROCEDURES

Y31DJOA

Idle Speed Check Procedure CAUTION The improper setting (throttle valve opening) will increase exhaust gas temperature at deceleration. reducing catalyst life greatly and deteriorating exhaust gas cleaning performance. It also has effect on fuel consumption and engine braking.

Checking conditions:

Z31DKOB

o o o o

Engine coolant temperature is 80 to 95°C (176 to 205°F). Lights, electric cooling fan and all accessories are off. Transaxle is in neutral ["P" or "N" range for AIT vehicles). Steering wheel is a straight ahead position (Vehicles with power steering).

1.

Install the tachometer and the timing light, or connect the multi-use tester to the diagnostic connector in the fuse box.

2. 3.

Run the engine at curb idle speed. Check the basic ignition timing and adjust if necessary. Refer to Group 27. Run the engine for more than 5 seconds at an engine speed of 2,000 to 3,000 rpm. Run the engine at idle for 2 minutes. Read the idling rpm. If the multi-use tester is used, press code No.22 and read the idling rpm. If it is not within the specified valve, check the idle speed control system.

4. 5. 6.

Curb idle rpm

750

± 100 rpm 09273-24000

31Z282

31-28

MPI SYSTEM

Idle Speed Control (lSC) And Throttle Position Sensor (TPS) Adjustment Z31DLDB Adjustment conditions: o Engine coolant temperature is 80 to 95°C (176 to 205°F) o Lights, electric cooling fan and all accessories are off. o Transaxle is in neutral ["P" or "N" range for AIT vehicles]. o Steering wheel is a straight ahead position (Vehicles with power steering).

1. Loosen the accelerator cable.

2. 3.

Connect the multi-use tester to the diagnostic connector in the fuse box. If the multi-use tester is not used, install a tachometer and a voltmeter.

092 3-24000

31-29

MPI SYSTEM 4.

Turn the ignition switch to ON (do not start the engine) and leave it in that position for 15 seconds or longer; then check to be sure that the idle speed control servo is fully retracted to the curb idle position. NOTE When the ignition switch is turned to ON, the ISC plunger extends to the fast idle position opening; then, after 15 seconds, it retracts to the fully close (curb idle) position. Motor position sensor : 0.9V

5. 6.

Turn the ignition switch OFF. Disconnect the ISC motor connector and secure the ISC motor at the fully retracted position.

7.

In order to prevent the throttle valve from sticking, open it two or three times; then release it to let it click shut. and sufficiently loosen the fixed SAS. Start the engine and let it run at idle speed. 9. Check that the engine rpms are within the standard value. If the multi-use tester is used, press code No. 22 and read engine rpms.

a.

Curb idle rpm

750

± 100 rpm

10. If the engine speed is not as specified, adjust the ISC adjusting screw to obtain the standard rpm. 11. Tighten the fixed SAS until the engine speed starts to increase. Then, loosen it until the engine speed ceases to drop (touch point) and then loosen a half turn from the touch point. 12. Stop the engine.

31-30

Fixed SAS

ISC adjusting~~~;":'; screw

31V266

MPI SYSTEM 13. Turn the ignition switch to ON (do not start engine) and check that the TPS output voltage is as specified. If the multi-use tester is used, press code No. 14 and read the voltage. Standard value ........•.•.................. 0.48-0.52V

14. Connect a digital-type voltmeter between terminal 24 and terminal 19 of the ECU, if the multi-use tester is not used. Standard value NOTE 1. Do not disconnect the ECU connector from the ECU. 2. Use an accurate digital voltmeter.

31Z280

15.

If it is out of specification, loosen TPS mounting screws and adjust by turning the TPS. NOTE Turning the TPS clockwise increases the output voltage. CAUTION Tighten the screws securely after adjustment.

16. Turn the Ignotlon switch to the OFF position. 17. Adjust the accelerator cable play. Standard value M/T

AlT

0-1 mm (0-0.04 in.) 2-3 mm (0.08-0.12 in.)

18. Connect the ISC motor connector. 19. Disconnect the voltmeter, and connect the TPS connector. 20. Start the engine and check to be sure that the idle speed is correct. 21. Turn the ignition switch to OFF and disconnect the battery terminal for 15 seconds and then re-connect. (This erases the data stored in memory during the ISC adjustment).

31-31

MPI SYSTEM Throttle Body (Throttle Valve Area) Cleaning

V31DMOA

NOTE Disconnect the air intake hose from the throttle body, and check the throttle valve surface for carbon deposits, rotating the valve. Apply the spray cleaning solvent on the valve to remove carbon deposits. 1. 2. 3. 4.

Warm up the engine, then stop it. Remove the air intake hose from the throttle body. Spray cleaning solvent into the lIalve through the throttle body intake port and leave it for about 5 minutes. Start the engine, race it several times and idle it for about 1 minute.

NOTE: If the idling speed becomes unstable (or if the engine stalls), slightly open the throttle valve to keep the engine running. 5. 6. 7.

Repeat steps 3 and 4. Attach the air intake hose. Adjust the idle speed control and throttle position sensor.

Fuel Filter Replacement 1.

V310NOA

Reduce the internal pressure of the fuel pipes and hoses making the following operations. o Disconnect the fuel pump harness connector at the fuel tank rear side. o Start the engine and after it stops by itself, turn the ignition switch to OFF. o Disconnect the battery negative (-) terminal. o Connect the fuel pump harness connector.

2.

Remove the eye bolts while holding the fuel filter nuts securely. 3. Remove the fuel filter mounting bolts, then remove the fuel filter from the fuel filter clamp.

31-32

MPI SYSTEM Overfill limiter (Two-way Valve) Replacement 1.

Y31DOQA

Disconnect the vapour hoses. and then remove the overfill limiter.

,~))

~j/ 31Y045

Fuel Gauge Unit Replacement

Y310POA

1.

Remove the fuel tank cap to lower the fuel tank's internal

2. 3.

pressure. Disconnect the harness connector from the fuel gauge unit. Remove the fuel gauge unit installation screws. then remove the fuel gauge unit from the fuel tank.

Fuel Pump Operation Check 1. 2.

Y31DQOA

Turn the ignition switch to OFF. Apply battery voltage to the fuel pump drive connector to check that the pump operates.

NOTE The fuel pump is in-tank type and its operating sound is hard to hear without removing the fuel tank cap.

3.

Pinch the fuel hose to check that fuel pressure is felt.

31-33

MPI SYSTEM Fuel Pressure Test

Y31DROA

1.

Reduce the internal pressure of the fuel pipes and hoses by the following procedures. o Disconnect the fuel pump harness connector at the fuel tank rear side. o Start the engine and after it stops by itself, turn the ignition switch to OFF. o Disconnect the battery negative (-) terminal. o Connect the fuel pump harness connector.

2.

Disconnect the high pressure fuel hose at the delivery side.

CAUTION Cover the hose connection with rags to prevent splashing of fuel that could be caused by residual pressure in the fuel pipe line.

"-. 31Y268

3.

Using the fuel pressure gauge adaptor, (09353-24000, 09353-24100, 09353-24200) install the fuel-pressure gauge to the delivery pipe. Tighten the bolt to the specified torque. Tightening torque Fuel pressure gauge to delivery pipe . 25-34 Nm (250-350 kg.cm, 18-25 Ib.lt)

4. 5.

Connect the battery's negative (-) terminal. Apply battery voltage to the terminal for the fuel pump drive and activate the fuel pump; then, with fuel pressure applied, check that there is no fuel leakage from the pressure gauge or connection part.

6.

Disconnect the vacuum hose from the pressure regulator, and plug the hose end. Measure the fuel pressure at idle.

Standard value

.

320-340 kPa (3.26-3.47 kg/em', 46-49 psi)

31-34

MPI SYSTEM 7.

Measure the fuel pressure when the vacuum hose is connected to the pressure regulator. Standard value

8.

. 270 kPa (2.75 kg/cm', 39 psi)

If the results of the measurements made in steps (6) and (7) are not within the standard value, use the table below to determine the probable cause, and then make the necessary repair.

Condition

Probable cause

Remedy

Fuel pressure too low

a. Restricted fuel filter. b. Fuel leakage to the return side, caused by poor seating of the valve within the fuel-pressure regulator c. Low discharge pressure of the fuel pump

a. Replace fuel filter b. Replace fuel pressure regulator.

c. Replace fuel pump

Fuel pressure too high

a. Replace fuel pressure regulator a. Sticking valve within the fuel-pressure regulator b. Restricted or bent fuel return hose or pipe. b. Repair or replace hose or pipe.

There is no difference in

a. Restricted, or damaged vacuum hose or fitting b. Sticking valve within the fuel-pressure regulator, or poor seating

fuel pressure between when the vacuum hose is connected and when it is not.

9.

a. Repair or replace the vacuum hose or fitting b. Replace fuel pressure regulator

Stop the engine and check for a change in the fuel pressure gauge reading, which should not drop. If the gauge indication drops, observe the rate of drop. Determine and remove the causes according to the following table.

Condition

Probable cause

Remedy

Fuel pressure drops slowly after engine is stopped

a. Injector leakage

a. Replace injector

Fuel pressure drops immediately after engine is stopped

a. The check valve within the fuel pump is not closed

a. Replace fuel pump

31-35

MPI SYSTEM 10. Reduce the fuel pressure in the fuel line. 11. Disconnect the high pressure hose and remove the fuel pressure gauge from the delivery pipe. CAUTION Cover the hose connection with a shop towel to prevent a splash of fuel that could be caused by residual pressure in the fuel line.

12. Install a new O-ring in the groove at the end of the high-pressure hose. 13. Connect the high pressure fuel hose to the delivery pipe, and tighten the screws to the specified torque. 14. Check for fuel leaks. o Apply battery voltage to the fuel pump drive terminal to operate the fuel pump. o With pressure, check the fuel line for leaks.

EGR Valve Control Vacuum Check

Y31DSOA

Checking Condition Engine coolant temperature: 80-95°C (176-203°F) 1. Disconnect the vacuum hose from the throttle body EGR vacuum fitting and connect a hand vacuum pump to the fitting. 2.

Start the engine and check to see that, after raising the engine speed by racing the engine, vacuum raises proportionately with the rise in engine speed. NOTE If there is a problem with the change in vacuum, it is possible that the throttle body port may be restricted and require cleaning.

E ~

.. ~

o

>

Engine speed (rpm) 31Y056

31-36

MPI SYSTEM Purge Port Vacuum Check

Y31DTOA

Checking Condition Engine coolant temperature: BO-95°C (176-203°F) 1. Disconnect the vacuum hose from the throttle body purge hose fitting and connect a hand vacuum pump.

2.

Start the engine and check to see that, after raising the engine speed by racing the engine, vacuum remains fairly constant.

NOTE If there is no vacuum created, it is possible that the throttle body port may be restricted and require cleaning.

Engine speed (rpm)

31Y058

31-37

MPI SYSTEM

MPI SYSTEM INSPECTION

Y31DUOA

If the MPI system components (sensors, ECU, injector, etc.) fail, interruption or failure to supply the proper amount of fuel for various engine operating conditions will result. The following situations can be encountered. 1. Engine is hard to start or does not start at all. 2. Unstable idle 3.

Poor driveability

If any of the above conditions is noted, first perform an inspection by self-diagnosis and subsequent basic engine checks (ignition system malfunction, incorrect engine adjustment, etc.), and then inspect the MPI system components with the multi-use tester (MUT). CAUTIONS 1) Before removing or installing any part, read the diagnosis code and then disconnect the battery negative (-) terminal. 2) Before disconnecting the cable from battery terminal. turn the ignition switch to OFF. Removal or connection of battery cable during engine operation or while the ignition switch is ON could cause inaccurate operation of the ECU or damage to semiconductors. 3) The control harnesses between the ECU and oxygen sensor are shielded wires with the shield grounded to the body in order to prevent the influence of ignition noises and radio interference. When the shielded wire is faulty the control harness must be replaced. Malfunction Indicator Light (Only U.S.A.) Among the self-diagnosis items, a malfunction indicator light comes on to notify the driver of the emission control items when an irregularity is detected. However, when an irregular signal returns to normal and the engine control unit judges that it has returned to normal, the malfunction indicator light goes out. Moreover, when the ignition switch is turned off, the light goes out. Even if the ignition switch is turned on again, the light does not come on until the irregularity is detected. Immediately after the ignition switch is turn on, the malfunction indicator light is lit for 5 seconds to indicate that the malfunction indicator light operates normally. Item Indicated By The MIL o Computer o Oxygen sensor o Air-flow sensor o o

Intake air temperature sensor Throttle position sensor

31-38

f

t---D .L.£, .'

I

'\

Malfunction indicator light 31Y059

MPI SYSTEM o Motor position sensor o Engine coolant temperature sensor o Crank angle sensor o No.1 cylinder top dead center sensor o Injector o Fuel pump o EGR temperature sensor (Only California Vehicles)

SELF-DIAGNOSIS

Y310VOA

The engine control unit monitors the input/output signals (some signals at all times and the others under specified conditions) of the engine control unit. When it is noticed that an irregularity has continued for a specified time or longer from when the irregular signal is initially monitored,passing a certain number, the engine control unit judges that an irregularity has occurred, memorizes the trouble code, and outputs the signal to the self-diagnosis output terminal. There are 14 diagnosis items, including the normal state, and the diagnosis results can be read out with a voltmeter or multi-use tester. Moreover, since memorization of the trouble codes is backed up directly by the battery, the diagnosis results are memorized even if the ignition key is turned off. The trouble codes will, however, be erased when the battery terminal or the engine control unit connector is disconnected. CAUTION If the sensor connector is disconnected with the ignition switch turned on, the diagnosis code is memorized, In this case, disconnect the battery negative terminal (-) for 15 seconds or more, and the diagnosis memory will be erased. The 13 diagnosis items are provided as follows, and if plural items are activated, they are all indicated sequentially from the smallest code number.

Trouble code

Diagnosis item

Trouble code

Diagnosis item

11

Oxygen sensor

23

No.1 cylinder top dead center sensor

12

Air-flow sensor

24

Vehicle-speed reed switch

13

Air temperature sensor

25

Atmospheric pressure sensor

14

Throttle position sensor

41

Injector

15

Motor position sensor

42

Fuel pump

21

Engine coolant temperature sensor

43

22

Crank angle sensor

EGR temperature sensor (For California Vehicles)

31-39

MPI

SYSTEM

CHECKING PROCEDURE (SELF-DIAGNOSIS) Y310WOA

CAUTION 1) When battery voltage is low, trouble codes can not be read. Be sure to check the battery for voltage and other conditions before starting the test. 2) Diagnosis memory is erased if the battery or the ECU connector is disconnected. Do not disconnect the battery before the trouble codes are completely read. 3) After checks and repairs are completed, disconnect the ground cable for 1 5 seconds or more from the negative terminal of the battery to erase any trouble codes.

Inspection Procedure (Using Multi-Use Tester) 1. 2. 3. 4. 5. 6.

7.

Y31DXOA

Turn OFF the ignition switch. Connect the the multi-use tester to the diagnosis connector in the fuse box. Connect the power-source terminal of the multi-use tester to the cigarette lighter socket. Turn ON the ignition switch. Use the multi-use tester to check the self-diagnosis codes. After completion of the repair or correction of the problem, turn OFF the ignition switch; then disconnect the battery terminals for 15 seconds or longer and then, after reconnecting them, check that no trouble codes are displayed by the multi-use tester. Disconnect the multi-use tester.

31-40

MPI SYSTEM Inspection Procedure (Using Voltmeter)

Y31DYOA

1.

Connect the voltmeter to the self diagnosis connector.

2.

Turn the ignition switch, and the engine control unit memory contents will immediately start. After recording the abnormal item, check and repair each part according to the check items in "Diagnosis Chart". When the defective parts have been repaired, disconnect the negative terminal of the battery cable for 15 seconds or more and connect it again to make sure that the trouble code has been erased.

3.

I I I

I

MPI diagnosis

I

I

LGround 31Y061

Diagnosis Chart Output preference order

1

Diagnosis item

Y310Z0A

Trouble code Check item (Remedy) No.

Output signal pattern

-

Engine control unit

Memory -

(Replace engine control unit)

:~ J1Y062

2

11

Oxygen sensor

Retained

Fuel pressure Injectors (Replace if defective.) o Intake air leaks o Oxygen sensor 0

:JLL

0

31Y063

3

Air flow sensor

o Harness and connector

12

:JLJUL

Retained

o Harness and connector (If harness and connector are normal, replace air flow sensor assembly.)

J1Y064

31-41

MPI SYSTEM Output preference order 4

Diagnosis item Air temperature sensor

Malfunction code Check item (Remedy) Output signal pattern

No.

Memory

13

Retained

o Harness and connector o Air temperature sensor

14

Retained

o Harness and connector

:~ 31Y065

5

Throttle position sensor

o Throttle position sensor o Idle position switch

:~ 31Y066

6

Motor position sensor

15

Retained

o Harness and connector 0

Motor position sensor

:~ 31Y067

7

Engine coolant temperature sensor

21

Retained

o Harness and connector

o Engine coolant temperature sensor

:~ 31Y068

8

Crank angle sensor

22

Retained

o Harness and connector (If harness and connector are normal, replace distributor assembly.)

23

Retained

o Harness and connector

:~ 31Y069

9

No.1 cylinder top dead center sensor

(If harness and connector are normal, replace distributor assembly.)

:~ 31Y070

10

24

Vehiclespeed sensor (reed switch)

:~ 31Y071

31-42

Retained

o Harness and connector o Vehicle-speed sensor (reed switch)

NOTE 1. Replace the engine control unit if a trouble code is read although the inspection reveals that there are no problems with the diagnosis item. 2. The diagnosis item marked' is applicable to California vehicles only.

31-43

MPI SYSTEM

CHECKING (USING THE MULTI-USE TESTER) 1. 2. 3. 4. 5.

Y31EAOA

Turn OFF the ignition switch. Connect the multi-use tester to the diagnosis connector in the fuse box. Connect the power-source terminal of the multi-use tester to the cigarette lighter socket. Turn ON the ignition switch. Use the multi-use tester to make the various checks, and repair if a problem is found.

NOTE If the malfunction indicator light(engine-check light) illuminates while the checks are being made, check the self-diagnosis output. 6. 7. 8. 9. 10.

After repair, check once again to be sure the problem has been corrected. Turn OFF the ignition switch. Disconnect the multi-use tester. Disconnect the battery terminals for 15 seconds or longer. This erases the self-diagnosis code. Restart the engine. Check (by a driving test and other means) to be sure that the problem has been corrected.

Cranking Check Check points Battery voltage o Service data o Item NO.16

31-44

Item No.: Multi-use tester code number Check conditions o Ignition switch: ON

Test specification

Probable cause of malfunction (or action)

11-13 V

o Low battery voltage o Power not supplied to the engine control unit 1) Check the power-supply circuit. 2) Check the ignition switch. 31 Check the control relay. o Malfunction of the engine control unit ground circuit

MPI SYSTEM

Check points Malfunction code read out o Self diagnosis

Check conditions o After holding for 15 seconds or longer with the ignition switch at "ON", move the ignition switch to "LOCK" and disconnect the ISC

Test specification Normal

o Crank for four seconds or longer. o Ignition switch: "ON" (Check for damage or disconnection of the injector, crank angle sensor circuit and other circuits.) Try under both conditions:

o Engine cranking o Fuel pump forced activation

Crank angle sensor o Service data o Item No.22

o Engine cranking o Tachometer connected (check, by using the tachometer for interruptions of the ignition coil primary current)

o Check in accordance with the diagnosis code. (Note that the diagnosis code will be erased if there is disconnection or damage of the engine control unit back-up power-supply circuit) o If various diagnosis codes are output, the most frequent cause is damage or disconnection of the power-supply or ground circuit

servo connector.

Fuel pump o Actuator test o Item NO.7

Probable causes of malfunction (or action)

Pinch closed the return hose.

The pulsations o Voltage is not supplied to the fuel of the fuel flow pump. can be fell. 1) Check the ignition switch (IG and ST) Listen close to The pump 2) Check the control relay. the fuel tank. drive sound 3) Check the related circuits. can be heard. o Malfunction of the fuel pump Cranking speed (rpm)

Engine speed (rpm)

Approx. 200

Approx. 200

o If the tachometer reading is 0, there is no interruption of the ignition coil primary current 1) Check the power transistor and the control circuit 2) Check the ignition coil. and the coil power supply circu it o If the multi-use tester's indicated rpm is abnormal 1) Malfunction of the crank angle sensor circuit

2) Malfunction of the crank angle sensor 3) Malfunction of the timing belt

31-45

MPI SYSTEM

Check points Injectors o Service data o Item No.41

Check conditions o Engine cranking

Test specification

Probable causes of malfunction (or action)

Listen for operation sounds.

Operation sounds of the injectors can be heard.

o Injector malfunction. o Improper contact of the connector and control relay contacts.

Engine coolant temperature [OC (OF)]

Injector activation time *2 (msec.)

o Malfunction of the engine coolant temperature sensor o Malfunction of the ignition switch-ST.

0(32)*'

Approx. 21

20 (68)

Approx. 43

80 (176)

Approx. 10

.

NOTE *': When the engine coolant temperature is (j°C (32°F). injectors inject simultaneously at 4 cylinders. *2: Injector activation times are indicated at a battery voltage of 11 V and a cranking speed of 250 rpm or lower.

31-46

MPI SYSTEM

Sensor Check Check points

Check conditions

Self-diagnosis output

o Engine: idling (2 minutes or'more after engine start)

Oxygen sensor o Service data o Item No.ll

o Engine warm-up (Make the mixture lean by engine speed reduction, and rich by racing.)

Engine: warm up (using the oxygen sensor signal, check the air/ fuel mixture ratio, and also check the condition of control by the engine control unit) Air-flow sensor o Service data o Item No.12

o Engine warm-up

Test specification Normal

Engine condition

Voltage (mV)

When sudden deceleration from 4,000 rpm

250 or lower

When engine is suddenly raced

600-1,000

750 rpm (Idling)

Probable cause of malfunction (or action) o Check in accordance with the diagnosis code. (Note that the diagnosis code will be erased if there is disconnection or damage of the engine control unit back-up power-supply circuit.) o If various diagnosis codes are output, the most frequent cause is damage or disconnection of the power-supply or earth circuit. o If the oxygen sensor output voltage is high during sudden deceleration 1) Check for injector leakage. 2) Check the oxygen sensor signal circuit.

o If the oxygen sensor output voltage is low during engine racing 1) Check the oxygen sensor and signal circuit.

400 mV or lower (changes)

2,000 rpm 600-1,000 mV Engine condition

Frequency (Hz)

750 rpm (Idling)

25-50

2,000 rpm

70-130

Racing

Increase caused by racing

o If the air-flow sensor output frequency suddenly changes greatly, improper contact of the air-flow sensor or connector is probable. o If the output frequency of the air-flow sensor is unusually high or low, check the air cleaner element. o If the output frequency of the air-flow sensor is high, an increase of engine resistance or leakage of compression pressure is probable.

31-47

MPI SYSTEM

Check points Air temperature sensor o Service data o Item No.13

Throttle-position sensor o Service data o Item No.14

Motor position sensor o Service data o Item No.15

o Ignition switch: ON, or engine running

Probable cause of malfunction (or action)

Air temperature °C (OF)

Temperature °C (OF)

o Malfunction of air temperature or related circuitry

-20 (-4)

-20 (-4)

o (32)

0(32)

20 (68)

20 (68)

40 (104)

40 (104)

80 (176)

80 (176)

o Ignition switch: ON

Warm by using hair dryer or other method.

Increases

o Hold for 15 sec-

Throttle valve

Voltage (mV)

Idling position

450-550

Opens slowly.

Becomes

onds or longer with the ignition switch at "ON".

o Engine: idling after warm-up (The idle position switch must be ON.)

31-48

Test specification

Check conditions

o Throttle-position sensor maladjustment o Throttle-position sensor or related circuitry malfunction

higher in proportion to valve opening Fully open

4,500-5,500

Engine condition

Voltage (mV)

Idle (750 rpm)

500-1,300

o If the voltage is low, check whether or not there is air intake. o If the voltage is high, the probable cause is: 1) Deposits adhered to the throttle valve 2) Increased engine resistance o If the voltage or idling speed is abnormal even though each part of the engine is normal, the probable cause is: 1) Improper adjustment of the idle speed control andlor the throttle position sensor 2) Malfunction of the motor position sensor or the related circuit

MPI SYSTEM

Check points

Check conditions

Motor position sensor o Service data o Item No.15

(The compressor Air conditioner clutch must be switch ON when (900 rpm) activated the air conditioner switch is switched ON.)

Air conditioner

Test specification 800-1,800

Probable cause of malfunction (or action) o If the engine speed does not increase when the air conditioner switch is switched from OFF to ON, check the DC motor drive circuit o Check the air conditioner system

900-1,900

switch: ON Shift lever: "D"

o Check the inhibitor switch and the signal circuit

range (700 rpm) Crank signal o Service data o Item No.18

o Ignition switch: Engine stopping OFF ON Engine cranking ON

Engine coolant tem- o Ignition switch: Engine coolant ON, or engine temperature perature sensor running °C (OF) o Service data o Item No.21

o Ignition switch-ST signal circuit check o Ignition switch check

Temperature 0C (OF)

-20 (-4)

-20 (-4)

o (32)

0(32)

20 (68)

20 (68)

40 (104)

40 (104)

80 (176)

80 (176)

Engine coolant Crank angle sensor o Engine: idling (Check with the temperature o Service data ignition switch 0C (OF) o Item No.22 ON.) -20 (-4)

Idling rpm

1,500-1,700

0(32)

1,350-1,550

20 (68)

1,200-1 ,400

40 (104)

900-1,100

80 (176)

650-850

o Engine coolant temperature sensor or related circuitry malfunction

o If the idling speed suddenly becomes greater, a malfunction of the crank angle sensor or improper contact of the connector is probable

31-49

MPI SYSTEM Check points Barometric

pres-

sure sensor

Test

Check conditions

specification o Ignition switch: ON

Altitude m (ft.)

o Service data o Item No.25

o Engine: racing at 2,000 rpm

Pressure mm Hg

0(0)

760

600 (1,968)

710

1,200 (3,937)

660

1,800 (5,905)

610

Gradually close the air-intake

Probable cause of malfunction (or action) o Barometric pressure sensor or related circuitry malfunction. (If the barometric pressure sensor pressure is low at high speed, restriction of the air cleaner element is probable.)

Decreases.

duct by using a hand. Idle switch o Service data o Item No.26

Power-steering

o Ignition switch: ON (Checking by using the accelerator pedal several times)

o Engine: idling

switch o Service data

Throttle valve

ON

idling position Open the throttle valve

OFF

slightly.

o Improper adjustment of the accelerator cable or cruise control cable. o Malfunction of the setting of the fixed SAS.

Steering wheel neutral

OFF

position (wheels straight-ahead direction)

o Item No.27

o Idle position switch or related circuitry malfunction

Steering wheel half

o Power-steering oil-pressure switch or signal circuit malfunction

ON

turn Air-conditioner

switch o Service data o Item NO.28

Inhibitor switch o Service data o Item No.29

31-50

o Engine: idling (The air conditioner com pressor could be activated when the air-conditioner switch is ON.)

o Ignition switch: ON (A/T models only)

Air-conditioner switch "OFF"

OFF

Air-conditioner switch "ON"

ON

o Check the air conditioner system.

Shift lever: "p" or "N"

"P", "N"

o Malfunction of the inhbititor

Shift lever: "0", "2", ilL" or "R"

"0", "2", "L",

switch or the signal circuit. o Improper adjustment of the control cable between the shift lever and the inhibitor switch.

"R"

MPI SYSTEM Test specification

Check conditions

Check points

EGR temperature o Engine: warmed up (Engine is sensor (California) maintained in a o Service data constant state o Item No.43 for 2 minutes or more)

Engine condition

Temperature °C (OF)

750 rpm

100 (212) or less

(idling)

o 3,500 rpm 150 (302) o Disconnect or more the vacuum hose (yel-

Probable cause of malfunction (or action) o Check the EGR temperatLire senSOT.

o Check the EGR control system. o Check the EGR valve. o ChElck the EGR control solenoid valve. o Check the EGR control vacuum.

low stripe) from the A port nipple of the throttle body, and pinch the hose end with fingers. Injectors o Actuator test o Item No. 1-4

o Engine: idling after warm-up (Cut off the injectors in sequence during idling after engine war-

Injector No. 1 2 3 4

m-up; check the idling condition.) Injector o Service data o Item No.41

Ignition advance (power transistor) o Service data o Item NO.44

0

Engine: warmed up

o Engine: warmed up o Timing light: set (The timing light is set so as to check the actual ignition timing.)

Engine condition

Engine Idling condition changes more. (Becomes more unstable, or

Activation time (msec.) 2.5-4.0

2,000 rpm

2.5-4.0

Rapid racing

Increases.

750 (Idling) 2,000

2) Check the spark plug and high-tension cable. 3) Check the power transistor unit and control circuit.

engine stalls.)

750 rpm (Idling)

Engine speed (rpm)

o If the idling condition doesn't change, check the cylinder. 1) Check the injector operation sound.

Ignition advance (OBTDe) 5-15 30-40

If the injector activation time is unusually long or short, there is a malfunction of the air-flow sensor, engine coolant temperature sensor, intake-air temperature sensor, or barometric pressure sensor. o If the injector activation time is long, increased engine resistance or leakage of compression pressure is probable. 0

o If the ignition advance and actual ignition timing are different, adjust the ignition timing. [The ignition timing may fluctuate !luring idling, but this is not a problem. The advance is greater (approx. 5°) at high altitude.]

31-51

MPI SYSTEM

Check points Air conditioner relay o Service data o Item NO.49

Check conditions o Engine: idling after warm-up

Purge control solenoid valve o Actuator test o Item No.8

o Ignition switch: ON

EGR control solenoid valve (California) o Actuator test

o Ignition switch: ON

o Item No.10

31-52

(Engine stop)

(Engine stop)

Test specifications

Probable cause of malfunction (or action)

Air conditioner switch

Air conditioner relay

OFF

OFF (compressor clutch nonactivation)

ON

ON (compressor clutch activa' tion)

Actuator forced actuation

Operation sound is audible

o Check the purge control solenoid valve.

Actuator forced actuation

Operation sound is audible

o Check the EGR control solenoid valve. o Check the EGR control solenoid valve drive circuit.

o If the air conditioner relay output is abnormal, check the air conditioner signal input circuit and the air conditioner system. o If the activation of the air conditioner compressor clutch is not normal, check the compressor clutch and the relay circuit.

o Check the purge control solenoid valve drive circuit.

MPI SYSTEM MPI SYSTEM COMPONENTS INSPECTION

Y31EBOA

Air Flow Sensor (AFS) The AFS measures the intake air volume. It makes use of a Karman vortex to detect the air flow rate and sends it to the ECU as the intake air volume signal. The ECU uses this intake air volume signal to decide the basic fuel injection duration.

31Y078

1.

Connect a voltmeter between 6 and 3 of AFS connector. Terminal 6 : Sensor ground Terminal 3 : AFS output

2. 3.

Warm the engine and bring it to a normal idle. Measure the voltage of terminals. Engine speed (rpm)

Output voltage (V)

Idling

2.7-3.2

3,000

NOTE If the air flow sensor fails, the intake air volume cannot be measured and as a result, normal fuel injection control is no longer available. The vehicle can be run, however, by a preset map value.

Air flow sensor assembly Airflow sensor output

fJl

SG

'-"-"

E

'6'

temperature B

'2' '4'

~

Intake air

-J-

Power (12V)

~

sensor

Sensor ground

Output

~

cD 's'

Atmospheric pressure sensor

Output

~ c..!..J

Sensor power (5V)

affi] 6

5

4

Air flow sensor (AFS) connector (sensor front view)

31Y080

31-53

MPI SYSTEM Atmospheric Pressure Sensor [For Australia]

Y31ECOA

The atmospheric pressure sensor installed on the AFS senses the atmospheric pressure and converts it into a voltage which is sent to the ECU. The ECU uses this signal to compute the altitude at which the vehicle is running and corrects accordingly the air-fuel ratio to the optimum and also corrects the ignition timing, thus improving driveability at high altitude.

Atmospheric pressure sensor

31Y081

1.

Connect a voltmeter between terminals 5 and 6 of the atmospheric pressure sensor connector. Terminal 5 : Atmospheric sensor connector. Terminal 6 : Sensor ground

2. 3.

Warm the engine and bring it to a normal idle. Slowly cover about half of the air cleaner air intake, checking the change in voltage. Pressure

Voltage

Fall

Drop

Reference Pressure mmHg (kPa, psi) Central voltage (V) 4.

150 (20, 2.9)

350 (49, 6.9)

760 (103, 15)

0.79

1.84

4.00

Replace the air flow sensor if necessary.

Intake Air Temperature Sensor

Y31EDOA

The intake air temperature sensor, located at the illustrated position on AFS, is a resistor-based sensor for detecting the intake air temperature. According to the intake air temperature information from the sensor, the ECU provides necessary fuel injection amount control.

31Y083

31-54

MPI SYSTEM 1. 2.

Disconnect the air flow sensor connectors. Measure the resistance between the terminals 4 and 6.

AFS side connector

..

Terminal 4 : Intake air temperature output Terminal 6 : Sensor ground

3.

4.

2

1

6"" 5

4

3

Temperature °C (OF)

Resistance (kfl)

o (32)

5.4-6.6

20 (68)

2.33-2.97

80 (176)

0.31-0.43

K~

l~

If

I

I

\

9

I J1Y084

Measure the resistance while heating the sensor using a hair drier. Temperature °C (OF)

Resistance (kfl)

Higher

Smaller

If the value deviates from the standard value or the resistance remains unchanged, replace the air flow sensor assembly.

~\

~ (;0 ~ ~

I

-;..~

I.

.

~../,

~

,...

Engine Coolant Temperature Sensor

Intake aIr

----J----tl ISC Motor

Idle switch output

2

L==H1

Reverse (-) Forward (+)

MPS connector (sensor side front view)

MPS connector (Front view at sensor side)

31Y275

31-58

MPI SYSTEM 4.

Connect a 6V battery between terminals 2 and 1 of the ISC motor connector and check to see that resistance changes smoothly when the ISC motor is activated. Approx 0.5 -

Standard value

ISC motor connector (front view at motor side)

(4--6) kO

1 2' 'f '1l

5.

I [ ! A 1 If

If the standard value is not achieved, or if the change is not smooth, replace the ISC servo assembly.

I

~ I" Ij-----J

31Y276

No.1 Cylinder TOC Sensor And Crankshaft Angle Sensor 1.

Z31EIOA

Connect a voltmeter between terminals 1 and 2, and 1 and

3. Terminal 1 Terminal 2 Terminal 3

2.

Sensor ground Crank angle signal No.1 TDC signal

Measure the output voltage of the terminals while cranking the engine. Crank angle signal (output)

Sensor

Terminal

Voltage

No.1 cylinder TDC sensor

Ground

0.2-1.2V (The needle fluctuates)

Crankshaft angle sensor

Ground

Ground

2

4 3 NO.1 TOC

Sensor power

1.8-2.5V

1

signal (output)

3. When the voltage is abnormal, check the sensor power and

Crank angle sensor connector (sensor front view)

ground circuit, and if nothing unusual is found, disassemble the distributor and check it. Oxygen Sensor

Z31EJOA

NOTE 1) Before checking, warm up the engine until engine coolant temperature reaches 80 to 95°C (176 to 203°F) 2) Use an accurate digital voltmeter. 1.

Disconnect the oxygen sensor connector and connect a voltmeter to the oxygen sensor connector. 2. While increasing engine RPM, measure the oxygen sensor output voltage.

(For Canada)

31Yl07

31-59

MPI SYSTEM

Engine

Oxygen sensor output voltage

Remarks

Increase RPM

Min.O.6V

Richens air/fuel mixture

Tightening torque Oxygen sensor . 39-49 Nm (400-500 kg.cm. 29-36 Ib.lt) (fo' U.S.A.)

Vehicle Speed Sensor

Y31EKOA

The vehicle speed sensor uses a reed type switch. The speed sensor built in the speedometer converts the speedometer gear revolution (vehicle speed) into pulse signals. which are sent to

~

-==-

the ECU. Inhibitor Switch (For A/T)

31Y109

Z31ELOA

Refer to Group 45.

I

::> u

~t·

I

w