Mazda Protege 1996 Workshop ManualWARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury and property damage increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Mazda- trained technicians in mind. This manual may be useful to non- Mazda trained technicians, but a technician with our service-re- lated training and experience will be at less risk when performing servicing operations. However, all users of this manual are ‘expected to know general safety procedures. This manual contains “Wamings” and “Cautions” applicable to risks not normally encountered in a general technician's experi- ‘ence. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the “Warnings” and “Cautions” are not exhaustive. Itis impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. ‘The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Nonre- commended procedures and tools should include consideration for safety of the technician and continued safe operation of the vehicle. Parts should be replaced with genuine Mazda replacement parts, not parts of lesser quality. Use of a nonrecommended replacement part should include consideration for safety of the technician and continued safe operation of the vehicle.1996 Mazda Protegé Workshop Manual FOREWORD A thorough familiarization with this, manual is important for proper repair and maintenance. It should always be kept in a handy place for quick and easy refer- ence. The contents of this manual, including drawings and specifications, are the latest available at the time of printing. As modifi- cations affecting repair or maintenance occur, relevant information supplementary to this volume will be made available at Mazda dealers. This manual should be kept up-to-date. Mazda Motor Corporation reserves the right to alter the specifications and con- tents of this manual without obligation or advance notice. All rights reserved. No part of this book may be reproduced or used in any form or by any means, electronic or mechani- cal—ineluding photocopying and record- ing, and the use of any kind of information storage and retrieval system—without per- mission in writing WARRANTY The manufacturer's warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by persons other than those at an Autho- rized Mazda Dealer. Mazda Motor Corporation HIROSHIMA, JAPAN APPLICATION: This manual ‘is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page. CONTENTS Section jeneral Information Engine brication System joling System Fuel and Emission Control Systems F25M-R Automatic Transaxle FASA-EL |Front and Rear Axles tering System [Braking System [Wheels and Tires| jody Body Electrics System [Heater and Air Conditioner Systems © 1995 Mazda Motor Corporation PRINTED IN U.S.A., JULY '95 Form No, 1495-10-95G Part No. 9999-95-017B-96VEHICLE IDENTIFICATION NUMBERS (VIN) JM1 BB141#TO 300001— JM1 BB142+TO 300001— JM1 BB143%TO 300001— JM1 BB144*TO 300001— RELATED MATERIALS. 1995 323/Protegé Service Highlights ........... 9999-95-064F-95 1996 Protegé, MX-3, MX-5, 626/MX-6, 929, MPV, Millenia Service Highlights ......- 9999-95-MODL-96 Engine Workshop Manual Z5-DOHC 9999-95-EWZ5-95 Engine Workshop Manual B6, BP-DOHC 9999-95-EWBP-95, Manual Transaxle Workshop Manual F25M- 9999-95-F25M-95 Automatic Transaxle Workshop Manual FA4A-E1 9999-95-FA4A-95 1996 Protegé Wiring Diagram .. 9999-95-019G-96GENERAL INFORMATION ‘SAFETY INFORMATION LUBRICANTS. JACKING POSITION AND POSITION: DYNAMOMETER .. . ‘COMPRESSED AIR PREPARATION OF TOOLS AND MEASURING EQUIPMENT Git )JUSTMENTS. ~GH13 [RUBBER PARTS AND TUBING... -..--2. G13) HOSE CLAMPS .. TEST LIGHT . JUMPER WIRE VOLTMETER, [OHMMETER ECTRICAL PARTS . (El N a WIRING HARNESS . FUSE... STALLATION OF RADIO SYSTEM . TOWING . Vi : ELIVERY INSPECTION TABLE. NANCE... SCHEDULED MAINTENANCE TABLE (EXCEPT CANADA) ... aoe SCHEDULED MAINTENANCE TABLE (CANADA) ....sesssceseenseeeee PRED . G20, . G23 Gl caGl SAFETY INFORMATION SAFETY INFORMATION LUBRICANTS ‘Avoid prolonged and repeated contact with petroleum-based oils. Used oil may irritate the skin, ard can ‘cause skin cancer and other skin disorders. Wash thoroughly after working with oil. We recommend water-soluble hand cleaners. Do not use kero- sene, gasoline, or any other solvent to remove oil from your skin. If repeated or prolonged contact with oil is necessary, wear protective clothing. Soiled clothing, particu- larly those soiled with used oils and greases containing lead, should be cleaned at regular intervals, JACKING POSITIONS Warning ‘+ Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle after it has been lifted. Front Rear At the front of the engine mount member At the center of the crossmember_ ‘SAFETY STAND POSITIONS Front Rear Both sides of the si Both sides of the side sill G2SAFETY INFORMATION Gl VEHICLE LIFT POSITIONS Front Rear Both sides of the side sill Both sides of the side DYNAMOMETER When test-running a vehicle on a dynamometer: ‘Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. Connect an exhaust gas ventilation unit. Cool the exhaust pipes with a fan. Keep the area around the vehicle unoluttered. Watch the water temperature gauge. COMPRESSED AIR When using compressed air to clean or remove parts: + Wear protective eye wear. ‘Hold a rag over the opening to prevent parts trom shooting out. ‘Take precautions so that people around you are not struck by flying debris. GI-3Gl HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL ADVISORY MESSAGES You'll ind several Warnings, Cautions, and Notes in this manual. Warning * A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution * A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note ‘+ ANote provides added information that will help you to complete a particular procedure. PREPARATION This points out the needed SSTs for the service operation. Itis best to gather all necessary SSTs before beginning work. Example: FRONT AXLE PREPARATION SST NUMBER USAGE Sst L I t Bore esoc For ; ee Fao of i od Pte, bat oe ’ ee T T SST NAME ‘SST ILLUSTRATION REPAIR PROCEDURE 1. Most repair operations begin with an overview illustration. It identifies the components, shows hew the parts fit together, and describes visual part inspection. If a damaged or wotn part is found, repair or replace it as necessary. 2. Expendable parts, tightening torques, and symbols for cil, grease, and sealant are shown in the over- view illustration 8. Pages related to service procedures are shown under the illustration. Refer to this information when servicing the related part. Gl-4Gl HOW TO USE THIS MANUAL. Example: sHows SPECIAL, SERVICE TOOL as z (SST) FOR SER- \ ‘ewscrnl a VICE OPERATION) \ x " a shows EXPENDABLE PARTS shows ‘APPLICATION POINT OF OIL, atesene Ere. eam avowe — wa RELATED mens a PAGE FOR pong = ‘SERVICE, ON. page M_2+ — ¥ vee oan pace ee ae Sete ae “1: The numbers (©, etc.) refer to part identification and servicing procedures. ‘SYMBOLS sHOWS TIGHTENING TORQUE SPECIFICATIONS. shows TIGHTENING ‘TORQUE UNITS, ‘SHOWS VISUAL Met INSPECTION INFORMATION There are seven symbols indicating oil, grease, and sealant. These symbols show the points of applying such materials during service. ‘Symbol Meaning Kind Wo wwe now eng oor ge spp Apply brake tid FMVSsi16: DOT-3 Apply groase Appropriate grease Apply seatant Appropriate sealant FB srtrautomaticransante tui Mull oF Dexron®It causes leaks. > 2, Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the pre- scribed locations (such as oil seals) before reassembly. GH12FUNDAMENTAL PROCEDURES GI ADJUSTMENTS Use suitable gauges and testers when meking adjust- ments, RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rutber parts or tubing. HOSE CLAMPS ‘When reinstalling, position the hose clamp in the original Y location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit. TORQUE FORMULAS When using a torque wrench-SST combination, the writ- ten torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the * torque by using the following formulas. Choose the for- mula that applies to you. Torgue Unt Fomua Nm Wimx(V-Al a o—— igh gmx (UILAAIT igtem gem (LILA ‘tr feBPTUTAN) int im [LA] ne length of the SST past the torque wrench drive. he length of the torque wrench. VISE ‘When usinga vise, put protective plates in the jaws of the vise to prevent damage to parts. G-13Gl ELECTRICAL TROUBLESHOOTING TOOLS saWors4w GROUND POWER SOURCE LINE OnWMETER, G14 ELECTRICAL TROUBLESHOOTING TOOLS TEST LIGHT The test light, as shown in the figure, uses a 12 V bulb. The two lead wires should be connected to probes. The test light is used for simple voltage checks and for check- ing for short circuits. Caution + Using a bulb over 3.4 W when chec! trol unit may damage the control unit. g the con- JUMPER WIRE ‘A jumper wire is used to create a temporary circuit. Con- neet the jumper wire between the terminals of a circuit to bypass a switch. Caution ‘+ Do not connect a jumper wire from the power source line to a body ground. This may cause burning or other damage to wiring harnesses or electronic components. VOLTMETER The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by con- necting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative (—) probe (black lead wire) to a body ground, OHMMETER The ohmmeter is used to measure the resistance between two points in a circuit, and to check for continu- ity and short circuits. Caution * Do not connect the ohmmeter to any circuit to which voltage is applied. This will damage the ‘ohmmeter.ELECTRICAL PARTS Gl — ELECTRICAL PARTS BATTERY CABLE Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable. CONNECTORS Data Link Connector Insert the probe into the service hole when connecting ‘a jumper wire to the data link connector. Caution © Inserting a jumper wire probe into the data link connector terminal may damage the terminal. Disconnecting Connectors When disconnecting two connectors, grasp the connec tors, not the wires. Connectors can be disconnected by pressing or pulling the lock lever as shown, Locking Connector When locking connectors, listen for a click that will indi- ot cate they are securely locked. GI-5ELECTRICAL PARTS Inspection 1, When a tester is used to check for continuity or te mea- sure voltage, insert the tester probe from the wiring har- ness side. 2. Check the terminals of waterproof connectors frem the connector side, as they cannot be accessed from the wiring hamess side. Caution * To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal. ‘TERMINALS Inspection Pull lightly on individual wires to check that they are secured in the terminal. Replacement Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it Until it locks securely. Insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down, pull the terminal out from the conrector. ‘SENSORS, SWITCHES, AND RELAYS Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.ELECTRICAL PARTS, INSTALLATION OF RADIO SYSTEM Gl S| ame eae am un cies ea as Inealedby @ two-coler code sym- The first letter indicates the base color of the wire and the feo yewow second the color of the stripe. cope | _coLoR cone | coLoR 8 sack | | 0 Orange leas G Green R Red oy Gray v Violet iy Light Blue es Yellow ts | tight Green p= E ee FUSE Replacement ‘When replacing a fuse, be sure to replace it with one of the specified capacity. Ifa fuse again fails after it has been replaced, the circuit probably has a short and the wiring should be checked. 2. Be sure the negative battery terminal is disconnected before replacing a main fuse. 3. When replacing a pullout fuse, use the fuse puller sup- PULLER plied in the fuse box cover. t INSTALLATION OF RADIO SYSTEM If radio system is installed improperly or if a high-powered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions: 1. Install the antenna at the farthest point from control modules. 2. Install the antenna feeder as far as possible from the control module hamesses (at least 30 cm { 11.8 in », 3. Ensure that the antenna and feeder are properly adjusted. 4. Do not install a high-powered radio system. GI-17TOWING TOWING Precautions ‘+ Proper towing equipment is necessary to prevent dam- age to the vehicle. ‘+ Laws and regulations applicable to vehicles in tow must always be observed. + Asa general rule, towed vehicles should be pulled with the driving wheels off the ground. If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies, ‘+ Ifall four wheels are on the ground, the vehicle may be towed only forward. Remember that power assist for the brakes and steering are not available when the engine is not running. Procedure With either automatic or manual transaxle: 1. Set the ignition switch in the ACC position. 2. Place the selector lever or shift lever in N (Neutral). 3. Release the parking brake. Caution + Do not tow the vehicle backward with driving wheels on the ground. This may cause internal, damage to the transaxle. Caution + Don't use the tiedown hooks under the front and rear for towing. They are designed ONLY fortying down the vehicle when it’s being transported. Using them for towing will damage the bumper.PRE-DELIVERY INSPECTION GI PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION TABLE EXTERIOR INSPECT and ADJUST, if necessary, the following items to specification: Glass, exterior bright metal, and paint for damage Wheel lug nuts (Tire pressure D Allweathorstrips for damage or detachment Operation of hood release and lock [Operation of fuo! lid and trunk lid opener (f equipped) [DiBoor operation and alignment (D)Headight aiming INSTALL the following parts: CoWheet caps (it equipped) UNDER HOOD—ENGINE OFF INSPECT and ADJUST, if necessary, the following items to specification: 1 Fuel, coolant, and hydraulic lines, fitings, connections, and ‘components for leaks Engine cil level [Power steering ud level (if equipped) [DiBrake and clutch fluid level Windshield washer reservoir fluid level DiRadiator coolant level and specific gravity Tightness of water hose clamps [DiTightness of battery terminals, electrolyte level, and specific gravity [1Manual transaxle of level 5 Drive bet(s) tension (1Accelerator cable and linkage for tree movement TERIOR INSTALL the following pats: {1 Fuse for accessories CHECK the operation of he following tems: 11 Seat controls (Sing and rectnng) and headrest (Dir bag system using warring ight {2 Cruge set using indicator ight (f equipped) {anion switch and steering lock (Power window (if equipped) Power dor lack (i equipped) {2 Door locks including chil proot door lacks 1 Transaxle range switch (ATX only) Aight including waming and incicatorghts Ci lgnition key reminder buzzer (if equipped) DHom, wipes, and washers (ron and rer, equipped) Antenna Cigarette lighter and clock DiPower outside mirrors (f equipped) Heater, defogger, and air conditioner at various mode selec- tions (it equipped) Sliding suntoot (if equipped) CHECK the folowing items: [DiPresence of spare fuse [Upholstery and interior finish CHECK and ADJUST, if necessary, the following items: Operation and fit of windows, C)Pedal height and free play of brake and clutch pedal CiParking brake UNDER HOOD—ENGINE RUNNING AT OPERATING TEMPERATURE ‘CHECK the folowing items: 7 Operation of idle-up system or electrcalload, air conditioner ‘or power steering (if equipped) Automatic transaxle fluid level ignition timing Dildle speed ON HOIST CHECK the following tems: [CJ.Underside fuel, coolant and hydraulic ines, tings, connec- tions, and components (ur eaks. (Tires for cuts or bruises Steering linkage, suspension, exhaust system, and all ‘underside hardware for laoseness or damage ROAD TEST | ‘CHECK the following items: Brake operation BiCutch operation D Steering contro! Operation of meters and gauges Squeaks, ratios, or unusual noises. DiEngine general performance Emergency locking tractors AFTER ROAD TEST REMOVE the seat and floor mat protective cavers CHECK for the necessary owner information materials, tools, and spare tie in vehicle GH19Gl SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE SCHEDULED MAINTENANCE TABLE (EXCEPT CANADA) ‘Schedule 1 (Normal driving conditions) The vehicle is mainly operated where none of the “unique driving conditions” apply. ‘Schedule 2 (Unique driving conditions) Repeated short-distance driving, Driving in dusty conditions. Driving with extended use of brakes. Driving in areas where road salt or other corrosive materials are used. Driving on rough or muddy roads. Extended periods of idling or low-speed operation. Driving for long prolonged periods in cold temperatures or extremely humid climates. GI-20SCHEDULED MAINTENANCE GI ‘Schedule 1 (Normal driving conditions) Wiaintenance Interval “Number af month or miles ( ilometers), whichever comes first] Months 6 | 12 | | 2 | 90 | 3 | | Too | Kitmaters | 12_[24 | a6 | 48 | 6072 | @4 | 96 Maintenance tem ae Miles [75 | 16) 225 | 30] 375 | 45 | 525 | 60 Engine Engine valve Gearance (25 engine) 7 Engine oil aya [ALA|A|A,A[A Oil titer Apa ,A|A|A|A|A]A Tension of all dive bets _ 1 i “Engine timing bel (except Calforna) Replace every 60,000 miles (96,000 Km] inspect at 60,000 miles {$6,000 km ), and Engine timing bet (California) ‘gain at 90,000 mils {144,000 km’) place every 106,000 miles 168,000 kn} Flos and tube or emission [eee |e] Air cleaner [Rirsioaner element Lore tt] Ignition system [Spans a F Fuel system Tale speed FE Fuel iter a 7 a | Fuct ines and hoses —__ re Fust hose (Calfornia) inspect every 105,000 ries (168,000 Wi} Cooling system Gooting system 7 ae place at fst 45,000 mils (72,000 km or 36 months Engine coolant after that, every 30,000 miles ( 48,000 km | or 24 months Chassis and body Brake fines, hoses, and connections Dise brakes Drum brakes: Steering operation and linkages: Front suspension bal joints Drive shaft dust boots Bolts and nuts on chassis and body Exhaust system heat shield ‘Alllocks and hinges (ajaGeee Air conditioner system (if equipped) Fefigerant amount 7 7 T 7 Compressor operation es T i T 1 Chart symbols: 1: Inspect and repair, clean, or replace if necessary. R : Replace L: Lubricate Remarks: ‘Alter 48 months or 60,000 miles { 96,000 km }, continue to follow the described maintenance at the rec- ommended intervals. “This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles. *2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability. a I-21Gl SCHEDULED MAINTENANCE ‘Schedule 2 (Unique driving conditions) Maintenance interval ‘Number of months or miles { kilometers }, whichever comes first Months: 4 [8] 12] 16) 20 | 24 | 28 | s2[ 36 [| 40| 44 46 vao00 | Kilometers |e | 16 [24 [32 | 40 | 48 | 56 [64 | 72 | 00 | 08 96 Maintenance Item Miles [5 | 10. 18 | 20) 25 | 30] a5 | 40 | 45 | 50_| 5560 Engine Engine valve clearance (25 engine) Engine ol R[A[;ALA|A|A[A|A|A [Ala Engine oil (Puerto Rico) Replace every 3,000 miles {4,800 ke } (or S months) Oifiter A[A[R[A[A|A[R[A[A[A[R “Tension ofall dive bats i T Engine timing bet (except Calfornia) Feplace every 60,000 miles {96,000 km inspect at 60,000 miles {96,000 km J, and Engine timing bet (California) ‘again at 90,000 miles {144,000 km’) place every 105,000 mies {168,000 ki. Toss and ibe or emission [es ee Jee eee Air cleaner [Aircleener element [ee ee fee re [ee | oe] Ignition system [Spancpiuge [ee er ee eee] Cooling system Cooling system Ty tT 7 {'] { T 7 7 I aay Replace at rt 45,000 miles (72,000 kn) oF 36 montis ‘a ater that, every 30,000 miles (48,000 km oF 24 months Fuel system Fost iter wy Fuel tines and hoses: r rT Tale speed e re 7 Fuel hose (Galforia) Trspect every 105,000 miles (168,000 Chassis and body ‘Brake lines, hoses, and connections ‘Drum brakes Disc brakes ‘Steering operation and linkages Front suspension ball joints Drive shaft dust Bools Boils and nus on chassis and body. i Exhaust system heat shield ‘Allocks and hinges. Air conditioner system (if equipped) Refrigerant amount T T T ia T ‘Compressor operation t 1 7 el 1 Chart symbols: 1: Inspect and repair, clean, or replace if necessary. (Inspect, and if necessary replace element only) Air cleaner R : Replace L : Lubricate Remarks: + After 48 months or 60,000 miles { 96,000 km }, continue to follow the described maintenance at the rec- ‘ommended intervals. “1” This maintenance is required for all states except California. However, we recommend that it also be performed on California vehicles. *2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability. Gl-22SCHEDULED MAINTENANCE Gl ‘SCHEDULED MAINTENANCE TABLE (CANADA) ‘Maintenance Interval ‘Number of months or miles { ki whichever comes first ] Months 3 [10 | 1 | 20 | 25 | 30 | 38 | 40 | 45 | 50 | 55] 60 Trang | Kilometers | 8 [16 [24 | 32] a0 | 48 | 56 | 6 | 72 | 00.| 68 | 96 Maintenance item Miles [5 [10] 18/20 | 25 | 90 | a5 [a0 | 45 | 50 | 55 | 60 Engine Engine valve clearance (75 engine) 7 Engine of wlatata ATA yAlAlaAyAyAlA Oil filter = R/R/A[A/ARI/A|A[A/R[A[AL[R [Tension of ail drive bats CC Engine timing belt"? RB Air cleaner [Aireleaner element ere san] [needs Jee eee [ee] Ignition system [Seampios a a Ee dL Cooling system Engine cocant vel an avongth ete) te] aa) ate ete | ete [ata atie| a [Cooling system for leaks z 7 T 7 i ee place a ret 45,000 miles (73,000 km’ or 45 mons Sore after that, every 30,000 miles { 48,000 km } or 30 months Fuel system Tale speed Fuel lines and hoses Fuel fiter PCV valve Emission hoses and tubes Chassis and body Tatomatio waneane Hid Tevel | Transaxte oll (MTX and ATX) Drive shaft dust boots Brake lines and hoses Brake and clutch fuid level Brake fic Disc brakes (front and rear) Rear drum brakes Tire inflation pressure and tire wear Tires Power steering Td evel ‘Steering operation and linkages (includes four whee! alignment) ‘Suspension components (front and rear) Al chasse and body nuts and bols Exhaust system heat shields [Alllocks and hinges Washer fuid level Function of all ights Air conditioner system (if equipped) Refrigerant amount ‘Compressor operationGl SCHEDULED MAINTENANCE Chart symbols: 1: Inspect and repair, clean, or replace it necessary. (Inspect, and if necessary replace ... Air cleaner ele- ment only) R : Replace L : Lubricate Rt: Rotation (tires) Remarks: ‘After 60 months or 60,000 miles { 96,000 km }, continue to follow the described maintenance at the rec- ‘ommended intervals. “1” Replacement of the timing belt is required every 60,000 miles { 96,000 km }. Failure to replace this belt may result in damage to the engine. “2 This maintenance is recommended by Mazda. However, it is not necessary for emission warranty coverage or manufacturer recall liability *3 This maintenance operation is recommended by Mazda. Gl-24B1 Before beginning any service procedure, refer to section T1 of this manual for air bag system service warnings. ENGINE (25) ONT OIL SEAL PREPARATION fa PREPARATION REPLACEMENT ENGINE, PREPAI [DISASSEMBLY ASSEMBLY... -.2...2.... 81-28)B1 DRIVE BELT DRIVE BELT PREPARATION SST 49 9200 0208 For inspection of ‘Tension ‘rive belt tension gauge, belt GENERATOR WATER INSPECTION / ADJUSTMENT PUMP Inspection GeNeRaTor PULLEY PULLEY CRANK: SHAFT PULLEY CCAANKSHAFT PULLEY Bi-2 WHEN MEASURED —/ wren ser 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. ‘Apply moderate pressure 98 N { 10 kgf , 22 Ibf } midway between the specified pulleys. Deflection mom {in} Drive belt "New Used Limit ae 55-70 | 60-75 | 80 a {022-027} | (0.24029) | (031) PS, 80-90 | 90-100 | 15 PIS!AC (0.32-0.35} | (0.36—0:39) | (045) "A balt that has been on a running engine for less than five minutos, 2. Ifthe deflection is not within the specification, adjust it Drive belt tension check 1. Belt tension can be checked in place of belt deflection ‘Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two puleys. Tension N (kgf, tot) Drive " [ oe New Used Limit eee [sees oo r00 500700 340 | Senerator| (50-76 , 110160} | (50—72, 10—150} |{ 95.77) PAS, 500680 420490 250) PIS+ AIC |{ 50-60, 110-190) | (43-50, e5—110) | 25.55) *Abelt that has been on a running engine for less than five minutos, 2. If the tension is not within the specification, adjust it,DRIVE BELT B1 GENERATOR Adjustment _ Generator drive belt 1, Loosen bolts @ and ®), 2. Adjust the belt deflection by turning adjusting bolt ©) Deflection (At 98N { 10 kgf , 22 Ibf}) New: 5.5—7.0 mm { 0.22—0.27 in } GenehaTor Used: 6.0—7.5 mm { 0.24—0.29 in } PULLEY Hee SHAFT sieerad 3. Tighten bolts ® and®. Tightening torque 98-51 Nem { 3.85.3 kgf-m , 28-38 ft-bf } 19—25 Nem { 1.9—2.6 kgf-m , 14—18 ft-lbt } PIS, PIS + A/C drive belt 1. Loosen the bolts and nuts marked @, ® and ©. 2. Adjust the belt deflection by turning adjusting bolt ©). Deflection (At 98 N { 10 kaf , 22 Ibf }) ‘New: 8.0—9.0 mm { 0.32—0.35 in } Used: 9.0—10.0 mm { 0.36—0.39 in } IS OIL PUMP PULLEY 3. Tighten the bolts and nuts marked ®, ® and ©. ‘CRANKSHAFT PULLEY Tightening torque 44—60 Nem { 4.4—6.2 kgf-m , 32—44 ftbt } 38—51 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } 38—51 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } P+ AC PISO PUMP. PULLEY CRANKSHAFT PULLEY ‘NC COMPRESSOR PULLEY B1-3Bi VALVE CLEARANCE VALVE CLEARANCE PREPARATION ssT soTo12080 ror s9T012001 ror rSocorent of Tplocomontot ter apet Seamer sin | Body eset in ate Sate oy ssTo12002 ror oro12008 = ‘placoment ot rStaconentot Shan Meamonstin | Cine, shat EES Shamront stn Parte are St ono Shs ono re Foe TSlcementt ot Seon sn _ Oanot INSPECTION / ADJUSTMENT Inspection 4. Remove the cylinder head cover. B1-4 Standard (Engine cold) .25—0.31 mm { 0.010—0.012 in } EX: 0.25—0.31 mm { 0.010—0.012 in } 2. Verify that the engine is in cold condition. 3. Measure the valve clearance (1) Tum the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke. (2) Measure the valve clearance at @) in the figure. (8) Ifthe valve clearance exceeds the standard, replace the adjustment shim.[{Refer to page B1-5. ® ® ® © (4) Turn the crankshaft 360 ° clockwise so that the No.4 = = piston is at TDC of the compression stroke. (6) Measure the valve clearance at @ in the figure. wf ogo ogo ago of) ‘Standard (Engine cold) Not No2 No3 Nos 1.25—0.31 mm { 0.010—0.012 in } ex ei fl EX: 0.25—0.31 mm { 0.010—0.012 in } 7 (6) If the valve clearance exceeds the standard, replace x the adjustment shim [[Befer fo page BT-5.31 ® oo 4. Install the cylinder head cover.VALVE CLEARANCE B1 Adjustment Perform this same procedure for all camshafts requiting valve clearance adjustment. cy 1. Tum the crankshaft clockwise so that the cams on the camshaft requiring valve clearance adjustment are posi- tioned straight up. 2. Remove the camshaft cap bolts as necessary. @: For EX side No.1, 2, 3 cylinder adjustment shim removal. ®: For IN side No.1, 2, 3 cylinder adjustment shim removal. ©: For EX side No.2, 3, 4 cylinder adjustment shim removal. For IN side No.2, 3, 4 cylinder adjustment shim removal. Note * For EX side No.2, 3 cylinder adjustment shim removal, remove bolts either @ or ©. + For IN side No.2, 3 cylinder adjustment shim removal, remove bolts either ©) or ©). 3. Install the SSTs on the camshaft using the camshaft cap bolt holes. jhtening torque: 11.3—14.2 Nam {115—145 kgf-cm , 99.9128 inlbf } 4, Align the marks on the SSTs (shaft and shaft clamp). ®| _§. Tighten bolts @ to secure the SST (shaft). EE 6. Face the SST (body) toward the center of the cylinder head, and mount it on the SST (shaft) at the point of adjustment shim to be replaced. B1-5VALVE CLEARANCE 10. 12. 13, B1-6 14. 15, 16. 7. 7. 1. Face the notch of the tappet so that a fine screwdriver can be inserted, Set the SST on the tappet by its notch. . Tighten bolt ©) to secure the SST (body). Caution + Cylinder head can be damaged when the tappet is pressed down. Tighten bolt ©, and press down the tappet. Using a fine screwdriver, pry up the adjustment shim through the notch on the tappet. Remove the shim by using a magnet, Select proper adjustment shim. New adjustment st = Removed shim thickness + Measured valve clearance — Standard valve clearance (0.28 mm {0.011 in}) Push the selected shim into the tappet. Loosen bolt ©) to allow the tappet to move up. Loosen bolt ®) and remove the SST (body). Remove the SSTs and tighten the camshaft cap bolts, Tightening torque: 11.3—14.2 Nm {(115—145 kgf.cm , 99.9—125 in-Ibf} ‘Check the valve clearance.((Refer to page BI=4.)COMPRESSION B1 COMPRESSION INSPECTION Ga Verify that the battery is fully charged. Recharge it if necessary. [(Refer to section G.)] Warm up the engine to the normal operating temperature. ‘Stop the engine and allow it to cool for about 10 minutes. Remove the spark plugs. Disconnect the distributor connectors. Install a compression gauge into the No.1 spark plug hole. Measure compression in the following procedure. (1) Fully depress the accelerator pedal or fully open the throttle valve. (2) Crank the engine and note the maximum gauge reading. NeaseNs Compression ea (kgtlen® psi) rpm Standard 1344 (197, 105) -900 Minimum 1010 (10:8, 146) 200 ‘Maximum dference between oyinders ——~—~S~idCSCSCSCS*~«R KP ZO eM, ZORI) (3) Check each cylinder as above. (4) If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the cylinder and recheck the compression. @ Ifthe compression increases, the piston, piston rings, or cylinder wall may be wom, @® Ifthe compression stays low, a valve may be stuck or improperly seated. @& If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 8. Remove the compression gauge. 9. Connect the distributor connectors. 10. Install the spark plugs. Tightening torque: 15—22 N-m { 1.5—2.3 kgf-m , 11—16 ftlbf } B1-7B1 TIMING BELT TIMING BELT PREPARATION SST 490011 102 For 49 GO17 5A0 For Prevention of support of ongine Lock tool, ‘rankshat Support, crankshaft rotation ‘engine 49G017 501 For 49 G017 502 For support of engine ‘support of ongine Bar ‘Support (Pan of (Part of 49 GO17 5A0) 49 GO17 5A0) 49.G017 503 For ‘support of engine Hook 2 = (Part of 49 GO17 5A0) REMOVAL / INSTALLATION Caution ‘= The crankshaft position sensor rotor is on the rear of the crankshaft pulley, and can be dam- aged ea Remove the right front wheel. . Install the right front wheel. Nogsepe Start the engine and Disconnect the negative battery cable. Connect the negative battery cable. . Remove in the order shown in the figure, referring tfRemoval Note] Install in the reverse order of removal, referring tolInstallation Note. | (1) check the pulleys and the timing belt for runout and contact. (2) check the ignition timing. B1-8TIMING BELT B1 69-107m Tomassinibt) (ro-NoKgtem, Sieaeainiy (7e—107, ss-773) © {20110 kgtem, 70-98.4inibt 2 a (19-23, 14-16) (S0-Nokgtem ,70-95.4insbt) or Nm (gmt) 1. Splash shield (RH) 9. No.3 engine mount bracket 2. Drive belt (Renaal Not pa =a] [Adjustment page Bi= 3] Installation Note page B1=1: 3. Water pump pulley 10. Timing belt cover, middle 4. Crankshaft pulley 11. Timing belt cover, lower 5. High-tension lead 12. Pulley boss, timing belt 6. Cylinder head cover Removal Note page B1-10 installation Note page Bina E 7. Dipstick and pipe stay 13, Idler pulley 8. Timing belt cover, upper 14. Tensioner pulley, tensioner spring Installation Note page BI-t B1-9 ae GaBi CE ROTATION ARROW Lock BOLT B1-10 TIMING BELT Removal Note No.3 engine mount bracket 1. Support the engine by using the SST. 2. Remove the No.3 engine mount bracket. Pulley boss, timing belt Note * Mark the timing belt rotation on the belt for proper reinstallation. 1. By using the SST, remove the pulley lock bolt 2. Remove the pulley boss. Caution © The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, or allowing oil or grease on it. 3. Loosen the tensioner pulley lock bolt. 4. Pull the tensioner pulley in the direction of the arrow to reduce tension of the timing belt, and remove the belt.TIMING BELT B1 Installation Note Tensioner pulley, tensioner spring Pa 1. Measure the tensioner spring free length. Ifnot within the Sly) |) “enero Free length: 71.0 mm { 2.80 in} 2. Install the tensioner and the tensioner spring. 3. Temporarily secure the tensioner with the spring fully extended. Pulley boss, timing belt MARK 2) — ZTIMING MARKS. 1. Verify that all timing marks are correctly aligned. 2. Install the timing belt on the pulleys in the order shown, below. @ Timing bett pulley @ No.2 idler pulley @) No.1 idler pulley @ Camshaft pulley ® Tensioner pulley 3. Install the pulley boss and pulley lock bolt. Turn the crankshaft clockwise 1 and 5/6 times, and verify that the timing mark on the timing belt pulley is aligned with tim- ing mark @ (tensioner set mark). PULLEY BOSS: Bi-11B1 TIMING BELT Lock Bor 4, Loosen the tensioner lock bolt to apply tension to the tim ing belt. Do not apply tension other than that of the ten- sioner spring. 5. Tighten the tensioner pulley lock bolt. Tightening torque: 38—51 Nem { 3.85.3 kgf-m , 28—38 ft-lbf} 6. Tum the crankshaft and 1/6 times clockwise, and verity that all timing marks are correctly aligned. Note ‘* The pin on the pulley boss and the “Z” mark on the camshaft pulley must face upward. 7. Check the belt deflection at the point indicated by epply- ing moderate pressure 98 N {10 kgf , 22 Ibf }. Deflection: 7.0—9.0 mm { 0.28—0.35 in} 8, Ifthe timing belt deflection is not correct, remove the tim- ing belt and repeat from step 1 9, Mount the SST on the pulley boss to hold the crankshaft. Tighten the lock bolt Tightening torqui 157—166 Nm { 16.0—17.0 kgf-m , 116—122 ftlbf } 10. Remove the SST. No.3 engine mount bracket 1. Install the No.3 engine mount bracket Tightening torque: @ 19-22 Nem { 1.92.3 kgf-m , 14—16 ftbt } @ 67—93 N-m { 6.8—9.5 kgf-m , 50—68 ft-bt } @ 75—104 Nem { 7.6—10.7 kgf-m , 55—77.3 ft-lbf } 2. Remove the SST (Support, engine).TIMING BELT B1 Cylinder head cover 1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material. 2. install the new cylinder head cover gasket into the cylin- der head cover. Caution * Silicone sealant hardens and causes oil leakage when it is left for an extended period. Therefore, install parts before sealant hardens. 3. Apply silicone sealant to the shaded areas as shown. Thickness: @ 3—4 mm { 0.12—0.15 in } 4, Install the cylinder head cover and tighten the bolts in five or six steps in the order shown. Tightening torque: 6.9—10.7 N-m { 70—110 kaf-cm , 61—95.4 in-tbf } 5, Retighten the bolts in the order shown. Tightening torque: 6.9—10.7 Nm { 70—110 kgf-cm , 61—95.4 in-Ibf } B1-13B1 CYLINDER HEAD GASKET CYLINDER HEAD GASKET PREPARATION Sst 49.6017 SAO For 496017501 For support of engine Support of engine Support, Bar engine (Part 49 6017 5A0) 49.6017 502 For 49.6017 508 For {support of engine Support of engine Support Hook (anol (Part of 49 6017 5A0) 49.6017 5A0) REPLACEMENT Warning «Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. + Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” on! 1. Disconnect the negative battery cable 2. Drain the engine coolant.(Heler to secton ED] 3. Remove the timing belt. [Refer to page BT-8.)) 4, Remove the alr leaner and front 5. Remove the exhaust manifold.[(Refer to section F7.)] 6. Remove in the order shown in the figure, referring to[ Removal Note.) 7. Instal\in the reverse order of removal, referring tollnstallaion Note:] 8: Install the exhaust manifold 9. Install the front pipe and air cleaner.| pater secion FU 10. Install the timing belt. (Refer to page B1-8.) 11. Fill the radiator and radiator reservoir Fee oe a ‘specified amount and type of engine coolant. 12. Connect the negative battery cable. 13, Start the engine and (1) check the engine oil and engine coolant leakage. (2) check the ignition timing and idle speed. [Refer to section FT.)] 14, Check the compression. (Refer to page B1-7.)] Bi-14CYLINDER HEAD GASKET Bi na-M2Nm CHE Aas aghem 988125 not) ate? EN meen Ch eg eye AN % 13-42Nm Cis =tWs gem ,98.6—125n or) om (agen 81) 1. Accelerator cable 6. Camshaft [Agiusiment scion FT] [Removal Note = page BI=T6, 2. Throttle cable (ATX) lation Not age BI=17 Adjustment. ection K] 7. Cylinder head bolt 3. Distributor [Removal Note one page B16 4. Intake manifold stay 5. Camshaft pull 8. Cylinder head assembly [BamovalNote-—------.-DaGeBT=16] 9. Cylinder head gasket installation Note page B1=18, B1-15B1 CYLINDER HEAD GASKET q DISTRIBUTOR CAP. © cransnrt]@ D @ © PULLEY (OROMOMOMO} ‘SIDE B1-16 Removal Note Camshaft pulley 1. Temporarily install the No.3 engine mount bracket to support the engine. 2, Remove the SST (Support, engine), 3. Hold the camshaft by using a wrench on the cast hexa- gon as shown, and loosen the camshaft pulley lock bolt 4, Remove the camshaft pulley. Camshaft 1. Tum the camshaft clockwise so that cams do not press- ing on the tappets. 2. Loosen the front camshaft cap bolts in five or six steps in the order shown 3. Remove the front camshaft cap bolts and the front cam- shaft cap. 4. Loosen the camshatt cap bolts in five or six steps in the order shown. Remove the camshaft cap bolts and camshaft caps. Remove the camshaft Remove the camshaft oil seals Noo Cylinder head bolt 1. Loosen the cylinder head bolts in two or three steps in the order shown. 2. Remove the cylinder head bolts.CYLINDER HEAD GASKET B1 cranksHart| @) @ ® crasunrr] ® ® OD ® © cee ®D®OOOw CHAIN ADJUSTER 205 m{ 0.1 in) Installation Note Cylinder head bol Before installation, measure the length of each bolt. Replace any that exceed the maximum length. Length: 99.2—99.8 mm { 3.91—3.92 in} Maximum: 100.5 mm {3.957 in } 2. Tighten the cylinder head bolts in two or three steps in the order shown. Tightening torque: 17.2—22.0 N-m {1,752.25 kgf-m , 12.7—16.2 ft-lbf } 3. Puta paint mark on each bolt head. 4. Using the marks as a reference, tighten the bolts by tum- ing each 85°—95° in the sequence shown. 5, Further tighten each bolt by turning another 85°—95° in the sequence shown. Camshaft 1. Before installation, insert the chain adjuster betweon camshafts. 2, Install the camshafts onto the cylinder head, aligning marks on the camshaft gear and the timing chain. 3. Apply silicone sealant to the shaded areas shown, Thickness: $1 mm {0.04 in} 4, Install the camshaft caps to the positions from which they were removed. B1-17‘CYLINDER HEAD GASKET 5. Hand tighten the camshatt cap bolts marked ©), @, @, and ®. 6. Tighten the camshaft cap bolts in five or six steps in the order shown, Tightening torque: 11.3—14.2 Nem {115-145 kgf-cm , 99.9125 in-Ibf } 7. Apply clean engine oil to the lip of the new camshaft oil seal. Paneer 8. Push the oil seal slightly in by hand. 9. Tap the oil seal in evenly by using a pipe and a hammer. HAMMER, “a PPE ‘CYLINDER HEAD Note * Oil seal outer diameter : 48.0 mm { 1.89 in} * Oil seal inner diameter : 34.2 mm { 1.35 in } er IN: 0—0.7 mm { 0—0.02 in } 1—1.7 mm { 0.04—0.06 in } OW SEAL Camshaft pulley 1. Align the “2” mark with the camshaft knock pin and install the camshaft pulley. 2. Hold the camshaft by using a wrench on the cast hexa- gon, and tighten the lock bolt. Tightening torque: ‘50—60 Nem { 5.0—6.2 kgf.-m , 37—44 ft-lbf } B1-18 3. Support the engine by using the SST. 4, Remove the No.3 engine mount bracket.FRONT OIL SEAL B1 FRONT OIL SEAL PREPARATION ‘ssT _ oe s980t400t For fnatatono tate ol into sal ‘2 HAMMER, REPLACEMENT 1. Disconnect the negative battery cabl 2, Remove the timing belt 3. Remove the timing belt pulley. 4, Remove the key. 5. Cut the oil seal lip by using a razor knife. 6. Remove the oil seal by using a screwdriver protected with a rag. Apply clean engine oil to the new oil seal. Push the oil seal slightly in by hand. Tap the oil seal in evenly by using the SST and a ham- mer. O@N 10. Install the timing belt pulley, aligning the key groove. 11. Insert the key with the tapered side toward the oil pump body. 12. Install the timing belt [(Refer to page B1-8)] 13. Connect the negative battery cable. 14. Start the engine and check the ignition timing. B1-19B1 REAR OIL SEAL REAR OIL SEAL PREPARATION SST 49 oss 105 Installer, oll seal For installation of, installation of ‘ear il seal Installer, rear oil seal «il seal 49 G090 795 For 49 G030 797 Handle (Part of 49 GO30 795) For Installation of, rear ol soal Olt SEAL LIP RAG. B1-20 REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the transaxle assembly. 3. Rameve the duich gover and clutch disc (MTX) 4, Remove the Aye (MTX) or drive plate (ATX). [(Refer to section JIK)] 5. Cut the oil seal lip by using a razor knife. 6. Remove the oil seal by using a screwdriver protected with a rag. ‘Apply clean engine oil to the new oil seal. Push the oil seal slightly in by hand. Tap the cil seal in evenly by using the SST and a ham- mer. 10. Install the flywheel (MTX) or drive plate (ATX). [{Refer to section J]K)) 11. Install the clutch disc and clutch cover (MTX). (Refer to section HJ] 12, Install the transaxle assembly. 13, Connect the negative battery cable. oonENGINE Bi ENGINE PREPARATION Sst 49 G017 5A0 For 49 G017 501 For support engine | ‘suppor of engine Support, 7 engine ~ (Part of 49 GO17 5A0) 49 G017 502 For 49.6017 503 For support of engine ‘support of engine ‘Support Hook: (Part of (Part of 49 GO17 5A0) 49 O17 5A0) REMOVAL / INSTALLATION Procedure Warnin: 2 Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” ot + Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Caution © Cover the fuel hoses with a rag because fuel will spray out when disconnected. Note * Plug the disconnected fuel hoses to prevent fuel leakage. 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove the hood and front wheels. 4. Drain the transaxle oi {(Refer to section JK] 5, Remove the radiator. 6. Remove the three way catalytic converter and front pipe.((Refer to section FT.]] 7. Remove the exhaust manifold {(efer to section F')] 8, Remove in the order shown in the figure, referring tol Removal 9. Install in the reverse order of removal, referring tolinstallation Note.] 10. Install the exhaust manifold, 11. Install the front pipe and three way catalytic converter. {Haferto section FT] 12. install the radiator [(Refer to section E.)] 18. Fill the transaxle with the specified amount and type of transaxle oil (Refer to section JIK] 14. Install the hood and front wheels. 15. Fill the radiator and radiator reservoir with the specified amount and type of engine coolant. (Refer to section E)] 16. Connect the negative battery cable. 17. Start the engine and (1) check the engine oil, transaxle oil, and engine coolant leakage. {2) check the ignition timing and idle speed {(Fefer to section F1,) 18. Tum off the engine and check the drive belt deflection. [Refer fo p: 19. Perform a road test. 20. Recheck the engine oil, transaxle oil, and engine coolant levels. B1-21B1 ENGINE Step 1 75-107 Wm (ao—tiakgtem, jovasainty 20-S8Nm (Somsolgtem . saint) 79107 ¥m (soto kgrem, 6s-S20Nm (7o—100Kgrem, Simeeniniiy Nem (gn 01) 1. Air cleaner 9. Throttle cable (ATX) 2. Battery clamp A = 3. Battery 10. Splash shield 4. Battery carrier 11. Drive belt 5. Radiator reservoir Adjusiment a page BT 6. Battery duct, bracket 12. AC compressor (if equipped) 7. Resonance chamber No.2 8. Accelerator cable 13. P/S oil pump [Adjustment ~ section F1] [Removal Note... below] Removal Note AIC compressor (if equipped) 1. Remove the A/C compressor with the hoses still connected (Refer to section U, 2. Position the compressor away from the engine and affix it with wire. PIS oil pump 1. Remove the P/S oil pump with the hoses still connected. 2. Position the pump away from the ongine and affix it with wire B1-22ENGINE B1 Step 2 3851 (38-53,28-38) rema(1s23,2-16) 280%m 70100 kgf om, Saat) 19-25(19-26 14-18} se60(44-62, 52-48) sa 55(44-60,92-43) So Gs se(ess0,s1) Nov (agen 181) Control rod (MTX) Extension bar (MTX) Selector cable (ATX) Clutch release oylinder (MTX) pepe EF IZ 8. Drive shaft Lin Stabilizer control link 9Bi Step 3 ENGINE 75104 (74-107 65-773) (30-53, 20-98) 6700 (68-0.7,60-65) 351 (38-62, 28-20) 7 ATX ay (88-85, 50-60) Non (kgm ft) 4. No.4 engine mount bracket 1. No.1 engine mount bracket Removal Note _. page B1=25 Removal Note page Bi Installation Note. page B1-27 Installation Note ............ page Bt 5. No.3 engine mount bracket 2. Engine mount member Removal Note age BI=27 Removal Note installation Note Installation Note 3. No.2 engine mount bracket 6. Engine and transaxi Removal Note _. page B1-25 jemoval Note... mo page B1-26 Installation Note Installation Note B1-24ENGINE B1 wrx AIX Removal Note No.1 engine mount bracket 4. Support the engine by using the SST. 2. Remove the No.1 engine mount bracket. Engine mount member 1, Remove the No.2 engine mount nuts @). 2. Remove the engine mount member bolts and nuts. 3. Remove the engine mount member. No.2 engine mount bracket 1. Remove the No.2 engine mount bracket batts ®) 2. Remove the No.2 engine mount bracket. No.4 engine mount bracket 1. Remove the engine and transaxle assemoly from the SST (Support, engine) and securely support it with the chain block, 2. Remove the No.4 engine mount bracket bolts and nuts, marked ©. 3. Remove the No.4 engine mount bracket. No.3 engine mount bracket Remove the No.3 engine mount bracket nuts. B1-25B1 ENGINE En e and transaxle assembly Slowly lift up the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into ‘components in the engine compartment. Installation Note Engine and transaxle assembly Slowly lower the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into components in the engine compartment. No.3 engine mount bracket Hand tighten No.3 engine mount bracket nuts (1). No.4 engine mount bracket 1. Hand tighten No.4 engine mount bracket bolts and nuts @. @. 2. Hand tighten No.4 engine mount bracket nuts @). No.2 engine mount bracket MTX ATX Install No.2 engine mount bracket. 38—51 N-m {3.85.3 kgf-m , 28-38 ft.lbf } B1-26ENGINE B1 Engine mount member 1. Install the engine mount member. Tightening torque: 67—89 N.m { 6.8—9.1 kgf-m , 50—65 ft-Ibf } 2, Hand tighten No.2 engine mount nuts @). No.1 engine mount bracket 1. Tighten No.1 engine mount bracket bolts ©), ®. Tightening torque ©): 64—89 N-m { 6.5—9.1 kgf-m , 48—65 ftbf } ©: 67-93 Nm { 6.8—9.5 kgt-m , 50—68 ft-Ibf } 2. Remove the chain block. 3, Tighten the engine mount bolts and nuts as follows. (1) No.2 engine mount. Tightening torque @: 38—51 Nem (3.85.3 kgf-m , 28—38 ft-lbf } (2) No.3 engine mount bracket. Tightening torque (D: 75—104 Nem { 7.6—10.7 kgf-m , 55—77.3 ft-lbf } (3) No.4 engine mount bracket. Tightening torque @: 44—60 N-m { 4.46.2 kgf-m , 32—44 ftlbf } @: 67—93 N-m { 6.8—9.5 kgf-m , 50—68 ftlbf } B1-27B1 ENGINE DISASSEMBLY / ASSEMBLY . Disconnect the engine and transaxle. [(Refer to section JIK.)] . Remove the clutch cover and clutch disc (MTX).|(Refer to section H.)) . Remove the intake-air system and crankshaft position sensor. Disassemble in the order shown in the figure. ‘Assemble in the reverse order of disassembly. . Install the intake-air system and crankshaft position sensor. . Install the clutch disc and clutch cover (MT). [Refer to section H.)] }. Connect the engine and transaxle. (Refer to section JJK.)] PNOMaEDS aw (218,713) sone {85119 69-050) —— (32552, 20-30) 1925 (1826, 14¢18) Nm {kgm bt) 1. Water bypass pipe 2. Water inlet pipe 3. AIC compressor bracket (if equipped) 7. No.3 engine mount 4. Oil fitter 8. Distributor 5. Oil pressure switch B1-28B2 jing any service procedure, refer to section T1 of this manual for air bag system service warnings. ENGINE (BP)B2 DRIVE BELT inspection of ‘ive belt tension DRIVE BELT PREPARATION SST 49.9200 020A For Tension ‘gauge, belt GENERATOR WATER PUMP PULLEY GENERATOR PULLEY CRANK SHAFT 4 PULLEY (CRANKSHAFT PULLEY B2-2 INSPECTION / ADJUSTMENT Inspection 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. ‘Apply moderate pressure 98 N{ 10 kaf , 22 Ibf } midway between the specified pulleys. Deflection mm (in} Drive belt "New Used Limit fees 55-70 | 60-75 | 60 {0.22027} | (024-029) | (031) 60-90 | 90-100 | 115 oe {0.32035} | (0.36038) | (045) “Abelt that has been on a running engine for less than five minutes 2. If the deflection is not within the specification, adjust it. Refer to page B2-3. Drive belt tension check 1, Belt tension can be checked in place of belt deflection ‘Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two puleys. Tension N {kgf, bf} Drive oa "New Used Limit Gees |e 00700) ‘500700 340 {50-76 , 110—160} | (50-72, 110150} |{ 95,77), PS, 500—880 +420—400 250 prs+ ac |{50—60, 110—130} | (49-50, 95—110) | 125,55) “Abelt that has been on a running engine for less than five minutes. 2. Ifthe tension is not within the specification, adjust it. (Refer tGENERATOR PULLEY ure PULLEY 7”pI8 OL PUMP. PULLEY PISOIL PUMP. PULLEY ® AIC COMPRESSOR PULLEY DRIVE BELT B2 Adjustment Generator drive belt 1. Loosen bolts ® and ®). 2. Adjust the belt deflection by turning adjusting bolt ©) Pee | Deflection (At 98 N { 10 kgf , 22 Ibf }) New : 5.5—7.0 mm { 0.20.27 in} Used: 6.0—7.5 mm { 0.24—0.29 in } 3. Tighten bolts ® and ®. Tightening torque @: 3851 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } ©: 19-25 Nem { 1.92.6 kgf-m , 14—18 ft-ibf } PIS, PIS + AIC drive belt 1. Loosen the bolts and nuts marked ®, @ and ©) 2. Adjust the belt deflection by turning adjusting bolt ©) Deflection (At 98 N { 10 kof , 22 Ibf }) New: 8.0—9.0 mm { 0.32—0.35 in } Used: 9.0—10.0 mm { 0.36—0.39 in } 3, Tighten the bolts and nuts marked @), ® end ©. Tightening torque @): 44-60 Nem { 4.46.2 kgf-m , 32—44 ftlbf } ©: 38-51 Nem {3.8—5.3 kgf-m , 28—38 ft-lbf } ©: 38-51 Nem { 3.85.3 kgf-m , 28-38 ft-lbf } B2-3B2 COMPRESSION COMPRESSION INSPECTION Warm up the engine to the normal operating temperature. Stop the engine and allow ito cool for about 10 minutes. Remove the spark plugs. Disconnect the distributor connectors. Connect a compression gauge into the No.1 spark plug hole. Measure compression in the following procedure. Negsens Verify that the battery is fully charged. Recharge it if necessary. (1) Fully depress the accelerator pedal or fully open the throttle valve, (2) Crank the engine and note the maximum gauge reading. ‘Compression kPa { kgtlem?, psi }-rpm Standard 1275 (180, 185}-200 Minimum 961 (98, 180)-300 Maximum diference between cylinders 196 kPa (2.0 katlom?, 28 psi) (8) Check each cylinder as above. (4) If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the ‘oylinder and recheck the compression @ Ifthe compression increases, the piston, piston rings, or cylinder wall may be worn. @ If the compression stays low, a valve may be stuck or improperly seated, If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted. 8. Disconnect the compression gauge. 9. Connect the distributor connectors. 10. Install the spark plugs. Tightening torque: 15—22 N-m { 1.5—2.3 kgf-m , 11—16 ft-lbf } B24TIMING BELT B2 TIMING BELT PREPARATION — ca 49 0011 102 For 49.6017 5A0 For prevention of Supsot of engine Lock too, Grankshatt Support, crankshalt Ge ‘otation cngme 49.6017 501 For 49 G17 502 For Suppor of engine Support of engine bar Support (Part of @arot 0.6017 5A0) {9.6017 5a0) 49.6017 503 For Suppor of engine Hook . (Part ot 49 GO17 5A0) REMOVAL / INSTALLATION Caution + The crankshaft position sensor rotor is on the rear of the crankshaft pulley, and can be dam- aged easily. B25B2 TIMING BELT Disconnect the negative battery cable. Remove the right front wheel. Remove in the order shown in the figure, referring td Removal Note. Install in the reverse order of removal, referring tc Install the right front wheel. Connect the negative battery cable. Start the engine and (1) check the pulleys and the belt for runout and contact. (2) check the ignition timing. (Refer to section F2.) Novseps {020 Kgten, se 7ainibn) (soto agtem Soresainbt) 73-107 Nm {e010 kgtem, 719-107 D {0110 kgtem, 70-95.) 187166 160—17.0, 116122), 123-174 (1254175,905-126) Nem (gn 061) B2-6TIMING BELT B2 1. Splash shield (RH) 9. No.3 engine mount bracket 2. Drive belt Sorc): ee Unstallation Note _............page B2-10] 3. Water pump pulley 10. Timing belt cover, middle 4. Crankshaft pulley 11. Timing belt cover, lower Ell 5, High-tonsion lead 12, Pulley boss, timing belt 6. Cylinder head cover (Homoval Noie <= ESTO] tallation Note... ~page B2-10) age Bo 7. Dipstick and pipe stay 13. Idler pulley 8, Timing belt cover, upper 14 Tensioner pully, tensioner spring Removal Note No.3 engine mount bracket 1. Support the engine by using the SST. 2. Remove the No.3 engine mount bracket. Pulley boss, timing belt Note + Mark the timing belt rotation on the belt for proper reinstallation, 1. By using the SST, remove the pulley lock bolt. 2. Remove the pulley boss. Caution The following will damage the belt and shorten its life; Forcefully twisting it, turning it inside out, or allowing oil or grease on it. 25 mm (4.01) MIN B2-7B2 TIMING BELT LOCK BOLT 3. Loosen the tensioner pulley lock bolt. 4. Pull the tensioner pulley in the direction of the arrow to reduce tension of the timing belt, and remove the belt. Installation Note Tensioner pulley, tensioner spring 1. Measure the tensioner spring free length. It not within the specification, replace the tensioner spring. Free length: 59.2 mm { 2.33 in } 2, Install the tensioner and the tensioner spring 3. Temporarily secure the tensioner with the spring fully extended. Pulley boss, timing belt 1. Verify that all timing marks are correctly aligned, 2. Install the timing belt on the pulleys in the order shown below. @ Timing belt pulley @ Idler pulley @ Camshaft pulley (LH) @ Camshaft pulley (RH) © Tensioner pulleyTIMING BELT B2 3. Install the pulley boss and pulley lock bolt. Turn the crankshaft clockwise 1 and 5/6 times, and verify that the timing mark on the timing belt pulley is aligned with tim- ing mark ® (tensioner set mark) 4. Loosen the tensioner lock bolt to apply tension to the tim- ing belt. Do not apply tension other than that of the ten- sioner spring. 5. Tighten the tensioner pulley lock bolt. Tightening torque: ‘38—51 Nem { 3.8—5.3 kgf-m , 28—38 ft.ibf } 6. Tum the crankshaft 2 and 1/6 times clockwise, and verity that all timing marks are correctly aligned. Note * The pin on the pulley boss must face upward. 7. Check the belt deflection at the point indicated by apply- ing moderate pressure 98 N { 10 kgf, 22 Ibf }. Deflection: 9.0—11.5 mm { 0.36—0.45 in } 8, Ifthe timing belt deflection is not correct, remove the tim- ing belt and repeat from step 1 9. Mount the SST on the pulley boss to hold tre crankshaft. Tighten the lock bolt. Tightening torque: '157—166 Nem { 16.0—17.0 kgf-m , 116—122 ftibf } 10. Remove the SST. B2-9B2-10 TIMING BELT No.3 engine mount bracket 1. Install the No.3 engine mount bracket. Tightening torque D: 19-22 Nem { 1.92.3 kgf-m , 14—16 ftlbf } @: 67—93 N-m { 6.8—9.5 kgf-m , 50—68 ft-lbf } @: 75104 N-m { 7.6—10.7 kgf-m , 55—77.3 ftlbf } 2. Remove the SST (Support, engine). Cylinder head cover 1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material. 2. Install the new cylinder head cover gasket into the cylin- der head cover. Caution * Silicone sealant hardens and causes oil leakage when it is left for an extended period. Therefore, install parts before sealant hardens. 3. Apply silicone sealant to the shaded areas as shown. 4. Install the cylinder head cover and tighten the bolts in five or six steps in the order shown. Tightening torque: '5.0—8.8 N-m { 50—90 kgf-om , 44—78 in-Ibf }CYLINDER HEAD GASKET B2 CYLINDER HEAD GASKET PREPARATION ssT a eomms = ea = said 49 GO17 5A0) excl SS sh se SE am REPLACEMENT Warning ‘+ Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. ‘+ Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure onl B2-11B2 CYLINDER HEAD GASKET 41. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove the timing belt [(Refer to page B2—5.) 4, Remove the air cleaner and front pi 5. Remove the exhaust manifold. 6. Remove in the order shown inthe figure, refering tl 7. Install in the reverse order of removal, referri ‘dinstalaton Note] 8. Install the exhaust manifold. 9. Install the front pipe and air cleaner. 10. Install the timing belt, 11. Fill the radiator and radiator reservoir with the specified amount and type of engine coolant. [{Befer to section E.)] 12. Connect the negative battery cable 13. Start the engine and (1) check the engine oil and engine coolant leakage. (2) check the ignition timing and idle speed |(Fefar to section F2. 14, Check the compression {(Fefer fo page B24.) @ | Nan (kgm 8 1. Accelerator cable 4. Cylinder head bolt [Adjustment Eames eecion ED | [Removal Note_. page 62-13 2. Throttle cable (ATX) [Installation Note... page 62-13] ‘Adjustment ................... sectionK] §. Cylinder head assembly 3. Intake manifold stay 6. Cylinder head gasket B2-12CYLINDER HEAD GASKET B2 Removal Note Cylinder head bolt 1. Temporarily install the No.3 engine mount bracket to support the engine. 2, Remove the SST (Support, engine). 3. Loosen the cylinder head bolts in two or three steps in the order shown. 4, Remove the cylinder head bolts. crausiart]@ D @ © @ PULLEY @2@@OOaOD SIDE Installation Note Cylinder head bolt 1. Tighten the cylinder head bolts in two or three steps in the order shown. xsiart|] © @ © © © i gas] © OO ® @ Tightening torque: SIDE: 020008 76—81 Nem { 7.7—8.3 kgf-m , 56—60 fbf } 2. Support the engine by using the SST. 3, Remove the No.3 engine mount bracket. B2-13B2 HLA HLA PREPARATION SsT conn = aa = outcome | ee = i, : ~ ore mo . 49 GO17 SAQ) > care = cons = a ae — = ered i GAS oxy St exo REMOVAL / INSPECTION / INSTALLATION Caution + Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting |(Refer to page B2-17, Disconnect the negative battery cable. Remove the timing belt. Remove the distributor. (Refer io section G1] Remove in the order shown in the figure, referring tolRemoval Note, installin the reverse order of removal referring tqInstallation Nate?) Install the distributor. [(Refer to section G.)] Install the timing belt. Connect the negative battery cable. Start the engine and (1) check the engine oil leakag: (2) check the ignition timin, le speed, SeNonsens 50£0(50-62,37—48) 79-40-71 {B00 Kgrem, forssAimibt) Nem (kgm fb) B2-141. Camshaft pulley HLA B2 3. Camshaft DISTRIBUTOR CAP. Removal Note Camshaft pulley 1. Temporarily install the No.3 engine mount bracket to support the engine. 2, Remove the SST (Suppor, engine). 3. Hold the camshaft by using a wrench on the cast hexa- gon as shown, and loosen the camshatt pulley lock bolt. 4, Remove the camshaft pulley. Camshaft 1, Rotate the camshaft clockwise so that cams do not pressing on the HLAs. 2. Loosen the camshatt cap bolts in five or six steps in the order shown. 3. Remove the camshafts. 4, Remove the camshaft oil seals. B2-15HLA DISTRIBUTOR CAP HAMMER, THR PIPE a CYLINDER HEAD Installation Note Camshaft 1. Install the camshafts. 2. Apply silicone sealant to the shaded areas shown. 3. Install the camshaft caps. 4. Tighten the camshaft cap bolts in five or six steps in the order shown. Tightening torque: 11.3—14.2 N-m {115—145 kgfcm , 99.9—125 in-Ibf} 5. Apply clean engine oil to the lip of the new camshaft oil seal. 6. Push the oil seal slightly in by hand. 7. Tap the oil seal in evenly by using a pipe and a hammer. Note * Oil seal outer diameter: 48.0 mm { 1.89 in} * Oil seal inner diameter: 34.2 mm { 1.35 in } ‘Camshaft pulley 1. Face the pin on each camshaft straight up. 2. Install the camshaft pulleys so that “I” mark (intake side) and “E" mark (exhaust side) face straight up. 3. Hold the camshaft by using a wrench on the casthexa- ‘gon, and tighten the lock bolt. ightening torque: ‘50—60 N-m { 5.06.2 kgf-m , 37—44 ft-lbf }B2 HLA 4, Support the engine by using the SST. 5. Remove the No.3 engine mount. Troubleshooting Guide Problem Possible cause ‘Action 7. Noise when engine is started immediately after ois changed, cone day or more. 7%, Noise when engine is started aftr setting {Gil leakage in oll passage or in HLA . Noise when engine is started after new HLA is installed. iveakage nA Run engine at 2,000—3,000 rpm, Ifnoise stops within 20 minutes", HLA is nor- mal If not, replace HLA. * Time required for engine oil to circulate within HLA includes tolerance for engine oi! condition and ambiont temperature, 4, Nose during idle after warm up. Insufficient oll pressure ‘Check ol pressure. Iflower than specification, check for cause. (Reter to section D.) Faulty HLA (Refer to page 82-14) Press down HLA by hand. Ititmoves, replace HLA. IHit does not move, HLA normal. Measure valve clearance. If mote than 0.15 mm { 0.0059in }, replace HLA. 5, Noise during ldo after high speed running, incorrect off amount ‘Chock olllevel. Drain or add oll as necessary. Deteriorated oil Check ot quay Hf deteriorated, replace with spocitied type and amount of oil B2-17B2 FRONT OIL SEAL PREPARATION SST FRONT OIL SEAL — = aot. FRONT O1L SEAL — TIMING BELT PULLEY OL PUMP HAMMER er E os4.0mm (088) exten x OL SEAL f TAPER B2-18 4980140001 For installation of Installer, oi front ol seal seal REPLACEMENT Disconnect the negative battery cable. Remove the timing belt Remove the timing belt pulley. Remove the key. Sep 5. Cut the oil seal lip by using a razor knife. 6. Remove the oil seal by using a screwdriver protected with a rag. . Apply clean engine oil to the new oil seal. Push the oil seal slightly in by hand. . Tap the oil seal in evenly by using the SST and a ham- mer. een 10. Install the timing belt pulley, aligning the key groove. 11. Insert the key with the tapered side toward the oil pump body. 12. Install the timing belt (Refer to page B2-5. 13, Connect the negative battery cable. 14. Start the engine and check the ignition timing, [(Refer to section F2.)]REAR OIL SEAL B2 REAR OIL SEAL PREPARATION sst 49 W033 105 For 49.6030 795 For installation of instalation of tts, Trees’ | mame, | Ravens oi seal oil seal @O 49.6030 797 For installation of Handle reroll seal = _ (Part of 49.030 726) iE S REPLACEMENT . 4. Disconnect the negative battery cable. ra vs 2. Remove the transaxle assembly. f 3. Remove the clutch cover and clutch disc (MTX). ¥ (Refer to section H.)] 5 se 4, Remove the flywheel (MTX) or drive plate (ATX). FEAR OU SEAL [Refer to section JIK.)] a EN 5. Cut the oll seal lip by using a razor knife. 6. Remove the oil seal by using a screwdriver protected with a rag. 7. Apply clean engine oil to the new oil seal iat 8. Push the oil seal slightly in by hand. 8. Tap the oil seal in evenly by using the SST and a ham- mer. a 10. Install the flywheel (MTX) or drive plate (ATX) 0-05 mm cael 11. Install the clutch disc and clutch cover (MTX). (Refer to section H.)] 12, Install the transaxle assembly. ‘Wt SEAL = 13. Connect the negative battery cable. B2-19B2 ENGINE ENGINE PREPARATION SST 49.G017 5A0 For 49 G017 501 For ‘support of engine ‘support of engine ‘Support, Bar enor (Pan ot ~ 49 GO17 5A0) 49 G017 502 For 49 G017 508 For support of engine Se support of engine ‘Support Hook (Pan of (Pant of 49 GO17 50) 49 GO17 5A0) REMOVAL / INSTALLATION Procedure Warning + Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” on/ + Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Caution * Cover the fuel hoses with a rag because fuel will spray out when disconnected. Note * Plug the disconnected fuel hoses to prevent fuel leakage 1. Disconnect the negative battery cable. 2. Drain the engine coolant. 3. Remove the hood and front wheels. 4. Drain the transaxle oil [(Refer to section JJK.)] 5. Remove the radiator.[{Heter to section E] 6. Remove the transverse member. [[Refer to section R.)] 7. Remove the front pipe and three way catalytic converter, (HoTero secon FE] 8. Remove the exhaust manifold. 9. Remove in the order shown in the figure, referring tol Removal Note, 10. Install in the reverse order of removal, referring tol Installation Note. 11. Install the exhaust manifold.|(Refer to section F2. 12. Install the front pipe and three wey catalytic converter [{Refer to section F2.)) 13. Install the transverse member. 14, Install the radiator. ((Flefer to section E.)| 15. Fill the transaxle with the specified amount and type of transaxle oil [eter to section JIKII 16. Install the hood and front wheels. 17. Fill the radiator and radiator reservoir with the specified amount and type of engine coolant. 18. Connect the negative battery cable, 19. Start the engine and (1) check the engine oil, transaxle oil, and engine coolant leakage. (2) check the ignition timing and idle speed.|(Refer to section F2. 20. Tum off the engine and check the drive belt deflection. |(Refer to page B22) 21. Perform a road test. 22. Recheck the engine oil, transaxle oil, and engine coolant levels. B2-20ENGINE B2 step 1 79-107 m {8010 kgf om, 70-96.4 inf) ® (200 kgrem, eosin) 79-1074 {e0—NOkgrem, joan {70100 kgtem, siassint Ne txtm et) 1. Air cleaner 8. Throttle cable (ATX) 2. Battery clamp Adjustment... sectonK] 3. Battery 9. Splash shield 4. Battery carrier 10. Drive belt 5. Radiator reservoir ‘Adjustment 6. Battery duct, bracket 7. Accelerator cable [Adjustment . ~ Section F2] 12. P/S oil pump Removal Note Removal Note AIC compressor (if equipped) 1. Remove the AIC compressor with the hoses still connected (Refer to section U)] 2. Position the compressor away from the engine and affix it with wire. PIS oil pump. 1. Remove the P/S oil pump with the hoses still connected [(Refer to section N. 2. Position the pump away from the engine and affix it with wire. B2-21B2 ENGINE Step2 AK, Teagan 1. Control rod (MTX) 2. Extension bar (MTX) 3. Selector cable (ATX) 7. Lower arm’ 4. Clutch release cylinder (MTX) [Removal installation... section R [Removal /Installation . sectionH] 8. Drive shaft 5. Stabilizer control link Removal / installation... ‘section M B2-22ENGINE B2 Step 3 . = aK teracsnr sara} tions 50-0) 6790(62-01,50-85) 351(38-53, 28-38) Non (stn 0) | 4. No engine mount bracket 1. No.1 engine mount bracket Removal Note _. mount member 5. No.3 engine mount bracket 2 En (Removal Note page 52-24) [Removal Note page B2-24] Installation Nofe........... page B2-26) installation Not a1. page B2-25 3. No.2 engine mount bracket 6. Engine and transaxle assembly Removal Note... page B2-24) [Removal Note. pada BE installation Note ‘page B2-25 B2-23ENGINE MTX aK B2-24 Removal Note No.1 engine mount bracket 1. Support the engine by using the SST. 2. Remove the No.1 engine mount bracket. Engine mount member 1. Remove the No.2 engine mount nuts @). 2. Remove the engine mount member bolts and nuts. 3. Remove the engine mount member. No.2 engine mount bracket 1. Remove the No.2 engine mount bracket bolts ®). 2. Remove the No.2 engine mount bracket No.4 engine mount bracket 1. Remove the engine and transaxle assembly from the SST (Support, engine) and securely support it wit the chain block. 2. Remove the No.4 engine mount bracket bolts and nuts marked ©, 3. Remove the No.4 engine mount bracket. No.3 engine mount bracket Remove the No.3 engine mount bracket nuts.ENGINE B2 Engine and transaxle assembly Slowly lift up the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into components in the engine compartment. Installation Note Engine and transaxle assembly Slowly lower the engine and transaxle assembly as a unit. Keep the engine from swinging or bumping into ‘components in the engine compartment. No.3 engine mount bracket Hand tighten No.3 engine mount bracket nuts (1). No.4 engine mount bracket 1. Hand tighten No.4 engine mount bracket bolts and nuts 2. Hand tighten No.4 engine mount bracket nuts @). No.2 engine mount bracket wx an Install No.2 engine mount bracket. Tightening torque: > on '38—51 N-m { 3.85.3 kgf-m , 28—36 ftbf } » ~ | 9) B2-25B2 ENGINE ux atx Engine mount member 1. Install the engine mount member. Tightening torque: 67—89 N-m { 6.8—9.1 kgf , 50—65 ft-lbf } 2. Hand tighten No.2 engine mount nuts @. No.1 engine mount bracket 1. Tighten No.1 engine mount bracket bolts ®), ©. Tightening torque 64—89 N-m { 6.5—9.1 kgf-m , 4865 ftlbf} ©: 67—93 N-m { 6.88.5 kgf-m , 50—68 ft-lbf } 2. Remove the chain block. 3, Tighten the engine mount bolts and nuts as follows. (1) No.2 engine mount Tightening torque @: 3851 Nem { 3.85.3 kgf-m , 2838 ftlbf } (2) No.3 engine mount bracket Tightening torque D: 75—104 Nem {7.6—10.7 kgt-m , 55—77.3 ft-lbf } (3) No.4 engine mount bracket Tightening torque @: 44—60 Nem { 4.4—6.2 kgf-m , 32—44 ftlbf } @: 67-93 N-m { 6.8—9.5 kgf-m , 50—68 ft-lbf }ENGINE. B2 DISASSEMBLY J ASSEMBLY Disconnect the engine and transaxle. Remove the clutch cover and clutch disc (MTX)-l(Refer to section HJ] Remove the intake-air system and crankshatt position sensor_[(Fefer to section F2.)] Disassemble in the order shown in the figure. Assemble in the reverse order of disassembly. Install the intake-air system and crankshatt position sensor, Install the clutch disc and clutch cover (MT3 2 Connect the engine and transaxle. [(Heterfo section JK) (Refer to section F2) |eNoaaons sw75 (19-28, 14-48) 2417 12-18,87-19) amd © 67-95 (6.8-95, 50-88) o1116 (85-119, 68-880) Gt-09(65—a1 47-65) oO 19735 (19-26,14-18) re... 49-25(19-25, 14-18) Nem Chg, 0) 1. Water bypass pipe 6. Generator and drive belt 2. Water inlet pipe 3. AIC compressor bracket (if equipped) . No.3 engine mount 4. Oil filter 8. Distributor Removal Installation... Ta Section D 5. Oilpressure switch B2-27D Before beginning any service procedure, refer to section T1 of this manual for air bag system service warnings. LUBRICATION SYSTEMD OIL PRESSURE OIL PRESSURE Warning * Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. PREPARATION SST 49.0187 280 sat CG) inspection of oll ih 2. 3. 4. 5. 6. Af We 7. 15-25mm (0.06-0.091n) a 8 | fo INSPECTION Remove the oil pressure switch. . Screw the SST into the oil pressure switch installation hole. Warm up the engine to normal operating temperature. . Run the engine at the specified speed, and note the gauge readings. Note ‘+ The oil pressure can vary with oil viscosity and tem- perature. Oil pressure: 99—196 kPa { 1.02.0 kgf/cm? 15—28 psi } 1000 rpm 295—392 kPa { 3.0—4.0 kgf/cm? , 43—56 psi } =3000 rpm If the pressure is not as specified, check for the cause and repair or replace as necessary. . Apply silicone sealant to the oil pressure switch threads ‘as shown. Remove the SST and install the oil pressure switch. Tightening torque: 1217 Nem { 1. .—1.8 kgf-m , 8.7—13 ttlbt } Start the engine and check for oil leaks.ENGINE OIL D ENGINE OIL INSPECTION 4. Position the vehicle on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and check the oil level and condi- tion. 5, Add or replace oil if necessary. Note «The distance between the L and F marks on the dip- stick represents 0.8 L { 0.85 US qt , 0.70 Imp at} REPLACEMENT Warning + When the engine and the engine oil are hot, they Don't burn yourself with either. ifted but not securely supported on catty stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it isnot securely supported on safety stands. * Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water im- mediately after this work. . Remove the oll filler cap and the oil pan drain plug. Drain the oil into a container. Install the drain plug. eyes Tightening torque: ‘30—41 Nem { 3.0—4.2 kgf-m , 22—30 ft-lbf } 4. Refill the engine with the specified type and amount of engine oil 5. Refit the oil filer cap. 6. Run the engine and check for oil leaks. 7. Check the oil level and add oil if necessary. Note * The actual oil level may vary from the specified capacity in some cases. Oil capacity L(US at Imp at} = B BP 32 36 il replacement ea (38°32) (Oil and ol fiter replace 35 38 ment (97,31) (40,33) Total 36 40 (ary engine) (38,32) (42,35) p-3D OIL FILTER, OIL PAN OIL FILTER PREPARATION SST 49.6014 001 For ror, intaaton of fiter fiter 1 2. 3. 4. OIL PAN REMOVAL / INSTALLATION . Disconnect the negative battery cable. . Drain the engine oil Remove the splash shield (RH). REPLACEMENT Remove the oil fiter by using the SST. . Use a clean rag to wipe off the mounting surface on the cylinder block Apply clean engine oil to the O-ring of the new oil filter. . Install the oil filer and tighten it by hand until the O-ring contacts the cylinder block. Tighten the filter 1 and 1/6 turns by using the SST. Note Tightening torque: 14—17 Nem { 1.41.8 kgt-m , 1113 ftlbf } Start the engine and check for oil leaks. Check the oil level and add oil if necessary. (Refer to page D-3.) Remove in the order shown in the figure, referring td Removal Note.| . Install in the reverse order of removal, referring to[Installation Note. . Install the front pipe and three way catalytic converter.|(Refer to section FITF2.)] 1 2. 3, 4. Remove the transverse member. (BP)| ‘8. Remove the front pipe and three way catalytic converter.[(Hefer to section FT,IF2.)) 6, 7, 8, 9, Install the transverse member. (BP) [(Refer to section R.)] 10. Install the splash shield (RH). 11. Fill with the specified amount and type of engine oil.[(Rafer to page D-3.)] 12. Connect the negative battery cable. 13. Start the engine and check for oil leaks. 14, Turn off the engine and check the oil level.o 78-107 Nm (2o—Tokgtem, 70-95.4inat) ke Nem (80-110 kgm 70-95. int) 3051 (38-53, 2638) Nom (agen 480) 1. Oilpan 3. Stiffener (BP) Removal Note page D-6 7 installation Note page D=7| installation Note. 2. OilstrainerOIL PAN Removal Note Oil pan Caution + Pry tools can easily scratch the oil pan mounting surfaces. Prying off the oil pan can also easi bend the olf pan flange. Refer to the following instructions before removing the oil pan. (25) 1. Remove the oil pan mounting bolts. 2. Insert a screwdriver or a seal cutter between the VRAS and oil pan. 3. Remove the oil pan. (BP) 1. Remove the oil pan mounting bolts. 2, Insert a screwdriver only at the points shown in the fig- ure. 3. Remove the oil pan. Stitfener (BP) 1. Insert a screwdriver ora seal cutter between the stiffener and oylinder biock. 2, Remove the stiffener.OIL PAN D ‘RACKS od ‘SEALANT BP ROY A Installation Note Stiffener @) 1. Remove all foreign material from the contact surfaces of the cylinder block and stiffener. 2. Apply silicone sealant to the shaded areas of the cylinder block as shown. 3. Apply silicone sealant to the stiffener along the inside of the bolt holes. 4, Install the stiffener before sealant hardens. Thickness: $ 2.5—3.5 mm { 0.099—0.137 in } Oil pan Caution * If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause thread damage. 1. Apply silicone sealant to the contact surfaces of new oil pan gaskets as shown. (BP) 2. Install the new gaskets onto the oil pump body and the rear cover with the projections in the notches as shown. (BP) D7z5 D-8 OIL PAN 3. Apply silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends. 4, Install the oil pan before sealant hardens. Thickness: p 2.5—3.5 mm { 0.099—0.137 in } (BP) $ 2.0—3.0 mm { 0.079—0.118 in } (25) Tightening torque: 7.9—10.7 Nem { 80—110 kgf-cm , 70—95.4 in-Ibf }Before beginning any service procedure, refer to section 1 of this manual for air bag system service warnings. COOLING SYSTEME ENGINE COOLANT ENGINE COOLANT PREPARATION SST 499200 148 For 499200146, For Fpecton o Iepecton o Adaptor set, Coding system — | Adapter | nar ot oe Po a eae es0tn 145) 499000 147 rer s9,018 040 For inspection of =] | inspection of Adapter Ceaingoysom | Adapter set, =. ory i ‘guess LO ae feseo0 145) oer 490018 002 For 49.0016 008 For Iepecton of Inpoction o Adopter SSeingeysen | Adapter toaing sytem ad OND | Gro Cate aang ebots 040) {bots 040) INSPECTION Warning «Removing the radiator cap or the radiator drain plug while the engine is running, or when the cause serious injury. It may also damage the engine and cooling system. * Turn off the engine and wait until it is cool. Even then, be very careful when remo e and radiator are hot is dangerous. Scalding coolant and steam may shoot out and g the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. ‘* When you're sure all the pressure is gone, press down on the cap—still using a cloth—turn it, and remove it. Eos EE Coolant Level (Engine cold) Verify that the coolant level in the radiator reservoiris be- tween the FULL and LOW marks. Note 2, Add coolant if necessary. * The distance between the FULL and LOW marks on the radiator reservoir represents 0.45 L { 0.48 US qt, 0.40 Imp qt }. Coolant Leakage . Remove the radiator cap. Connect a radiator cap tester and the SST to the radiator filler neck. Apply 103 kPa { 1.05 kgf/cm? , 15 psi } pressure to the system. Caution E-2 + Applying more than 103 kPa { 1.05 kgf/cm? , 15, psi} can damage the hoses, fittings, and other components, and cause leaks. 4. Verify that the pressure is held. If not, check the system for coolant leakage.ENGINE COOLANT Coolant Protection ‘COOLANT PROTECTION speciric GRAVITY Caution +300 ] + The engine has aluminum parts that can be dam- — | aged by alcohol or methanol antifreeze. Do not | use alcohol or methanol in the cooling system. 10801 “Nig Use only ethylene-glycol-based coolant. a ‘+ Use only soft (demineralized) water in the coolant ee | mixture. Water that contains minerals will cut 1080S | down on the coolant’s effectiveness. co 1 1. Measure the coolant temperature and specific gravity 1910/— } with a thermometer and a hydrometer. 000 2. Determine the coolant protection by referring to the graph shown, 140 SS 3. Ifthe coolant protection is not proper, add water or cool ag | ant as necessary. 000) T Antifreeze solution mixture percentage Ce otominev arnt states Vowume percentage | Gravity at 20 8 ee Coolant protectin ee Saag COOLANT TEMPERATURE “C (“F} ‘Above -16°0 (3 °F) o 35 "1054 [Above -26°C (16°F) | 86 4 “1068 | Above -40°6 (40°F) [45 55 “1078 REPLACEMENT Draining Warning + Removing the radiator cap or the radiator drain plug while the engine is running, or when the en- gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause seri- ous cooling system. + Turn off the engine and wait u jury. It may also damage the engine and cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. + When you're sure all the pressure is gone, press down on the cap—still using a cloth—turn it, and remove it. 1. Remove the radiator cap and loosen the radiator drain plug Drain the coolant into a container. E-3ENGINE COOLANT E4 Flush the cooling system with water until all traces of col- or are gone. 4, Left the system drain completely. 5. Tighten the radiator drain plug. Tightening torque: 0.7—1.1 Nem { 7.0—12 kgf-cm , 6.1—10 in-tbt } Refilling Use the proper_a mixture of ethylene-clycol- based coolant (Refer fo Coolant Protection, page 1. Slowly pour the coolani tor up to the coolant filer port. geen Filling pace: 1.0L {1.1 US qt, 0.9 Imp qt min. max. Fill the radiator reservoir up to the FULL mark, Fully install the radiator cap. Start the engine and let it idle until it warms up. If the temperature increases beyond normal, there is excessive air in the system. Stop the engine and allow it to cool; then repeat steps 1—3. . Run the engine at 2,200—2,800 rpm for five minutes; re- peat several times. . Stop the engine and allow it to cool. Warning + Removing the radiator cap or the radiator drain plug while the engine is running, or when the en- gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause seri- ous injury. It may also damage the engine and cooling system. ‘+ Turn off the engine and wait until it is cool, Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. ‘+ When you're sure all the pressure is gone, press down on the cap—still using a cloth—turn it, and remove it. }. Check the coolant level. ifthe coolant level has dropped, repeat the procedure from step 1.RADIATOR CAP E RADIATOR CAP PREPARATION ssT ao = 920045 For 499200147 For Iepcton ot rpcten of dates redatorcp | Adapter indo cop taator cap | as (anor tester (ATX) 49 9200 145) 490015080 ror 490015000 For © | inspection ot inspection of airs, radaorcap) | Adapter re fede exp o) | save ater vane er CD | oes, {8 0015 040) ware Warning + Removing the rai cap or the radiator drain plug while the engine is running, or when the en- gine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause seri- ‘ous injury. It may also damage the engine and cooling system. + Tum off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. * When you're sure all the pressure is gone, press down on the cap—still using a cloth—turn it, and remove it. INSPECTION Radiator Cap Valve 4. Remove the radiator cap. 2. Attach the radiator cap to a radiator cap tester with the SST. Apply pressure gradually to 74—102 kPa {0.75—1.05 kgf/cm? , 11—14.9 3. Verify that the pressure is held for at least 10 seconds. E-5E RADIATOR RADIATOR REMOVAL / INSTALLATION 1, Disconnect the negative battery cable. 2, Drain the engine coolant 8, Remove the radiator grile[[Retorte section ST] 4. Remove in the order shown in the figure, refering 5. Install in the reverse order of removal, referring tolInstallation Note.] 6. Install the radiator gril, 7. Fill the radiator and radiator reservoir with the specified amount and type of engine coolant. 8. Check the ATF level and add ATF if necessary, 9. Check the ATF and coolant leaks, _ ti 7.910. Nm (80110 kgtem, 70-954 nib) 79-107 Nm 80—M10.gtem,70—854inibty 79-107 {eo=nokgrem, Toa6sinry By 73-107 Nim {sotiongtem, ro-ossinioty | O 1. Safety lever 5. Radiator bracket 2. Radiator hose 6. Radiator assembly 3. Oilhose Arn 7. Condenser fan assembly (if equipped) 4. Cooling fan assembh Removal Note Cooling fan assembly 1. Move the cooling fan assembly to the engine side for easy removal of the radiator. 2, Remove the radiator, and then remove the cooling fan assembly. E-6THERMOSTAT E THERMOSTAT REMOVAL / INSPECTION / INSTALLATION Disconnect the negative battery cable. Drain the engine cnet Garona Remove the air cleaner! | Remove in the order shown in the figure. Install in the reverse order of removal, referring installation Note] install the air cleaner (Bafar to section FLIF2)] the radiator and radiator reservoir with the specified amount and type of engine coolant. Bepe Nog 14) 8, Connect the negative battery cable. 9, Start the engine and check for coolant leaks. GEEZ Kas 1945(19-26, 14-10) Na (eg feb) 1. Thermostat cover E7E THERMOSTAT Inspection Thermostat 1. Visually check that the thermostat valve is airtight. 2. Place the thermostat and a thermometer in water. 3. Heat the water gradually and check the following. Initial-opening temperature: 83.5—89.5 °C { 188—193 °F} Full-open temperature: 100 °C { 212 °F } Full-open lift: 8.0 mm { 0.31 in} min. Installation Note Thermostat 1. Install the thermostat into the cylinder head with the jiggle pin at the top. 2. Install a new gasket with the seal print side facing the cyl- inder head. aa 7, PRINT E-8WATER PUMP E WATER PUMP REMOVAL / INSTALLATION Disconnect the negative battery cable. Drain the coolant (Refer to page E-3.) |. Remove the timing belt (Rafer to section BT] ._ Remove in the order shown in the figure, Install in the reverse order of removal. Install the timing belt. the radiator and radiator reservoir with the specified amount and type of engine coolant. Negsere Connect the negative battery cable. . Start the engine and check for coolant leaks. oe 851 (33-53, 28-38) 19-25(19-26, 14-18) Nev (kg tebe} 1. Water pump inlet and gasket 3. Water pump gasket 2. Water pump assembly If the water pump is damaged, replace it. Do not repair it E-9E COOLING FAN MOTOR COOLING FAN MOTOR ETA INSPECTION Diss | 1. Verify that the battery is fully charged. [(Refer to section G.) 2. Disconnect the cooling fan motor connector. = 3. Connect battery positive voltage and an ammeter to the 7 of cooling fan motor connector. ® 4. Verify that the cooling fan motor operates smoothly at the standard current draw. ae Current: 2.6—4.2 A (25, BP: MTX) 5.2—7.2 A (BP: ATX) 5. Ifnot as specified, replace the cooling fan motor. REPLACEMENT Disconnect the negative battery cable. Remove the radiator. Remove in the order shown in the figure. . Install in the teverse order of removal. Install the radiator.[(Refer fo page E-6.)] . Connect the negative battery cable. ‘Warm up the engine to normal operating temperature. Check the cooling fan motor for smooth operation. J eNogaens 1-21Nen (IBZ kgtem, 1618 tot) 43-81 (49-83 kgtom, $846 nit) 1. Cooling fan assembly 3. Cooling fan motor 2. Cooling fan blade E-10COOLING FAN RELAY E COOLING FAN RELAY INSPECTION ® 1. Remove the cooling fan relay. 2. Apply battery positive voltage and check continuity be- ‘tween terminals of the cooling fan relay by using ohmme- ter. 8) Specification 0: Continuity B+: Battery positive voltage Terminal = A B c e F 1 2 Br _| Ground 3. If not as specified, replace the cooling fan relay. E-11F1 Before beginning any service procedure, refer to section T1 of this manual for | air bag system service warnings. | FUEL AND EMISSION CONTROL SYSTEMS (25) IT PARTS =. Fi= 34) POWERTRAIN CONTROL MODULE, (PCM) s2: Fim 35 [MASS AIR FLOW SENSO} FI 43 [CAMSHAFT POSITION SENSOR . Fi= 44 ‘CRANKSHAFT POSITION [THROTTLE POSITION SENSOR. FI- 45 ENGINE COOLANT TEMPERATURE INTAKE AIR TEMPERATURE EGH BOOST SENSOR ENSOR F1- 51 : Fi- 52 MAIN RELAY .. Fi= [ON-BOARD DIAGNOSTIC SYSTEM Fi— 54) [CHECK VALVE sersescsccsceeeseF1=30| PREPARATION .s..csesssssse: Fim 54] TANK PRESSURE CONTROL VALVE DIAGNOSTIC TROUBLE CODE (TPCV) . F1-30| NUMBER. Fi- sal SOAL CANISTER ... CANISTER DRAIN CUT VALVE USING THIS SECTION FI 2 [DIAGNOSTIC INDEX .stusssss2- FI= 95] [QUICK DIAGNOSIS CHART... F1— 96] [SYMPTOM TROUBLESHOOTING F1— 98] |_ DIAGNOSTIC INSPECTION .. F1-117| i= USYSTEM INSPECTION .......... F1-119} [EGR VALVE ae EGR BOOST SENSOR SOLENOID LAVALVE ett P1292)Fi ENGINE TUNE-UP ENGINE TUNE-UP PREPARATION SST 49.60199A0, For 49 ToBe oA0 For Inspection of inspection of system ‘gnton timing | NOS set ignton tig Sector {nd le speed Snd ile speed 49°T088 0108 For 49 Tose 002 For inepection of inspection ot Program Card iantion ming | Vehicle interface ignition sig < andidiespesd | Module Sha de speod (rar t | 4e'T088 0a0) 49 T0B8 001 For 49 T088 004 For | inepection ot Inspection ot | Control Unit | igntiontiming | Nas oBou fgnton ring Cartot | andicespecd | Adaptor Sndidle speed | {9 7088 oA0) (Partot | | fe"T088 of0) | | - 49 7088 008 For 497088 008A For inapecton ot Inspection of Batery Hook ‘gntton timing | Instruction (pron ting fate ndidie spesd | Manual Shae spose Caner 49 T088 OAO) ADJUSTMENT — — Prepar 1. Warm up the engine to normal operating temperature. 2. Shift the transaxle into Neutral (MTX) or P position (am. Precrnorensoneee ny Se — «Headlight oe Blower motor ERO RES MESSE Rear window defroster * Power steering 4. Wait until the cooling fan stops. F1-2 5. Connect the SSTs (NGS) to the data link connector-2 (fGtor fo page FIST jad select the PID/DATA MON- ITOR AND RECORD function. 6. Select the “RPM” on the NGS display. Ignition Timing 4. Perform “Preparation” [(Refer to above.)] 2. Verify that the idle speed is within the specification. Specification: 650—750 (700 = 50) rpm [MTX] 700—800 (750 = 50) rpm [ATX] 3. toot suscied ad lust the idle speed.ENGINE TUNE-UP F1 Connect the SST (System Selector) data link connector. Set switch A to position 1. Set the test switch to SELF TEST. ‘Connect a timing light to the high-tension lead of the No.1 cylinder. Verify that the timing mark (yellow) is within he specifica- tion. aaa Noose 2 system SELECT ‘TEST SWITCH Specification: BTDC 9—11 ° (10 + 1°) 9. If not as specified, loosen the distributor lock bolts and Ga tum the distributor to make the adjustment. ———_— 40. Tighten the distributor lock bolts to the specified torque. Tightening torque: 19-25 Nem { 1.9—2.6 kgf-m , 14—18 fbf} 14. Disconnect the SST (System Selector). 12. Verity that the timing mark (yellow) is within the specifica- tion Specification: BTDC 6—18 ° Idle Speed 4. Perform “Preparation. 2. Connect the SST (System Selector) to the data link con- hector. 3. Set switch A to position 1 4. Sot the test switch to SELF TEST. Caution + The throttle adjusting screw is set at the factory and must not be adjusted. Any adjustment will negatively effect the engine performance. 5. Adjust the idle speed by turning the air adlusting screw. Specification: 650—750 (700 + 50) rpm [MTX] 700—800 (750 = 50) rpm [ATX] 6. Disconnect the SST (System Selector). Idle Up Speed 1. Perform “Preparation” [{Refer to page Fi-2, 2. Verity that the idle speed is within the specification. Specification: 650—750 (700 + 50) rpm [MTX] 700—800 (750 + 50) rpm [ATX] Fi-3FA ENGINE TUNE-UP Fi4 3. Ifnot as speci adjust the idle speed, 4. Check the idle speed with the following load conditons. Specification sain Tale speed (rpm) Load condit “_ aS Fan switch ON at and or higher Headlight switch ON 650~750 Fear window defroster switch ON 700—8c0 PS ON ‘AIG ON aoe Note + Excludes temporary idle speed drop just after the electrical loads are tumed on. 5. Ifnot as specified with all load condition, inspect the idle air control valve.[(Refer to page F1-8,)] If not as specified with some load condition, check re- lated input switches, harnesses and connectors, Idle Mixture 1. Perform “Preparation” 2. Verify that the idle speed and ignition timing are within the specification. 3. Insert an exhaust gas analyzer to the tailpipe. 4. Verify that the CO and HC concentrations are within the regulation. 5. If not, inspect the following. ‘+ On-board diagnostic system|[Refer to page Fi-54)] * Heated oxygen sensor|(Refer to page Fi-48.)] ‘+ System inspection Intake manifold vacuum|[Rator to page FT—119)] Fuel line pressure|(Refer to page F1-120, Ignition timing control[(Refer to page F1—126. 6. Ifthe systems are normal, replace the three way catalytic converter and/or the warm up three way catalytic con- verter.INTAKE-AIR SYSTEM F1 INTAKE-AIR SYSTEM COMPONENT PARTS Removal / Installation Warning «Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” onipage Fi-10,| 4. Disconnect the negative battery cable. 2. Drain the coolant from the radiator.[(Refer to section E.)] 3. Remove in the order shown in the figure, referring ti Removal note.) Sree the rovers onder of ramoval referring tdlnetallation noe! 5. Refill the radiator with the specified engine coolant. (Refer to section E.)] STEP 1 79-107 Nm BO—MOKghem, 70-95.Ainsot) 79-10: Wm {80—MDkgtem , 70-95. tnt) 79--10.7 am (80110 kgtem , 70-95: 19-10. im (80—H10Kgtm, 70-95.) | 1. Air cleaner 5. Splash shield 2. Mass air flow sensor 6. Fresh-air duct 3. Air intake hose 4. Resonance chamber F1-5F1 INTAKE-AIR SYSTEM Removal note Fresh-air duct Before removing the fresh-air duct, remove the LH front mud guard mounting bolts, nut, and fasteners shown. FI-6STEP 2 79-107 79-1070m (aor kgeem, foceeaintty 30-51(38-83,20-38) n Accelerator cable. pection Throttle body Resonance chamber Fuel distributor EGR pipe pase {80Hakatom, 7096.4 ingot) INTAKE-AIR SYSTEM F1 19-25(19-26, 14-18) (aoe grem. 225m} 79-107 Ne (sono Ngrem, Torosainiet) 247 (22-48,24-28) Nem (Agtm 101) 7. EGR solenoid valve stay 8. PRC solenoid valve stay 9. Intake manifold stay 10. Intake manifold 11. EGR valve 12. Air filter 13. BAC valve F1-7F1 INTAKE-AIR SYSTEM INTAKE MANIFOLD F we ¥ CYLINDER HEAD SIDE FD Hor water LEAR CONTROL VALVE Installation note Intake manifold Face the bead of the gasket toward the intake manifold as shown, and install the intake manifold, AIR VALVE Inspection 1. Remove the BAC valve. 2. Circulate water in the BAC valve coolant passage to coo! the air valve. 3. Circulate hot water in the BAC valve coolant passage and verity that the air valve operates. 4. Ifnot, replace the BAC valve. [(Refer to page F1-7, IDLE AIR CONTROL VALVE Inspection 1. Verify that the ignition switch is OFF. 2. Disconnect the idle air control valve connector. 3. Measure the resistance of the idle air control valve by using an ohmmeter. Specificati 3 7.79.3 Q [23 °C {73°F }] 4. Ifnot as specified, replace the BAC valve. (Refer to page F1=7.) F1-8INTAKE-AIR SYSTEM F1 ACCELERATOR PEDAL Removal / Installation 1, Remove in the order shown in the figure. 2. Install in the reverse order of removal. ® 40-78% {4020 kgtem, 25-69 init) 1. Accelerator cable 5. Snap ring (with cruise contro!) inspection Adjustment... 6. Bracket (with cruise control) 2. Actuator cable (with cruise control) 7. Snap ring 3. Retainer 8. Accelerator pedal 4, Retainer (with cruise control) 9. Return spring : ACCELERATOR CABLE Inspection / Adjustment 1. Verify that the throttle vaive is at the closed ihrottle posi- tion, 2, Measure the free play of the accelerator cable. Free play: 1—3 mm { 0.04—0.11 in} 3. If not as specified, adjust by turning locknut ®) F1-9F1 FUEL SYSTEM FUEL SYSTEM PREPARATION ssT 49 L018 901 For inspection of fuel Injector injector checker PRECAUTION Fuel Pressure Release and Servicing Fuel System Warning + Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel in the fue! system is under high pressure when the engine is not running. Warning * Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the follow- ing “Fuel Line Safety Procedures”. Fuel Line Safety Procedures A. Release the fuel pressure before disconnecting a fuel line. 1, Remove the rear seat cushion. 2. Disconnect the fuel pump connector. 3. Start the engine. 4. After the engine stalls, turn the ignition switch to OFF. 5. Connect the fuel pump connector and install the rear seat cushion. B. Avoid leakage 1. When disconnecting a fuel line hose, wrap a rag around it to protect against fuel leakage. 2. Plug the hose after removal C. Install hose clamps to secure the fuel pressure gauge. F1-10FUEL SYSTEM F1 COMPONENT PARTS Removal / Installation Fuel tank Warning «Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. + Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures” onl «Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before re- pairing it. egsepe . Disconnect the negative battery cable. .. Remove the drain plug and dra fuel tank, Remove the rear seat cushion. (Refer to section S) Remove in the order shown in the figure. Install in the reverse order of removal, referring tinstallation note) Aiter installation, verify that the fuel tank is securely fixed. STEP1 eo {25-98 hgtom 22-31 nb) 72-1.7Nm (Go“tzo gem, 70-108 in) 25-31 (26-92, 19-25) see0(4462,32—48) 44-60 (44-62, 32-48) Nom kg fb) 1. Fuel pump cover 5. Joint hose. 2. Fuel hoses Installation note 7 page FI=12] 6. Fuel tank straps 3. Evaporative hoses 7. Fuel tank 8. Protector 9. Dust cover 10. Fuel filer pipe Fi-11Fi JOINT HOSE ©. = staalaieone © see ® see ® F1-12 FUEL SYSTEM Installation note Fuel hoses, evaporative hoses, breather hose * Push the ends of the fuel hoses, evaporative hoses, and breather hose onto the respective fittings. Specification: 25—30 mm { 0.99—1.18 in} + Be sure the hoses are not bent or twisted. Joint hose ‘* Push the ends of the joint hose onto the fitting. Specification: 85—40 mm { 1.38—1.57 in } ‘+ Install the clamps on the joint hose as shown. * Position the tabs of each clamp within the allowable range. Allowance ©: 10° to both directions ©: 90° to right * Be sure the hose is not bent or twisted.FUEL SYSTEM F1 STEP2 146 17,9518) oO Aan 4796-14) SEFUEL PUMP ~ Inspection la ‘a Ge} Fuel pump continuity : Cae \ 1. Remove the rear seat cushion. - A & 7 [(Befer to section S.)] ) 2. Remove the fuel pump cover. & J ][| 3. Disconnect the fuel pump connector. cue | 4. Check or continuity between fuel pump connector termi- ‘CONNECTOR g nals) > en o— EN \| 5: tte 20 conti, replace th uel pump. | Fuel pump maximum pressure Warning «Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Bifety Procedures” on page F1-10. 1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge to the fuel pump and plug the outlet of the gauge as shown. 3. Connect the negative battery cable. 4. Connect data link connector terminals F/P and GND by : ; using ajumper wire. 5. Tum the ignition switch to ON. Measure the fuel pump TLL pressure. Pressure: '500—630 kPa { 5.0—6.5 kgf/cm? , 72—92 psi } 6. Tum off the ignition switch and disconnect the jumper wire. 7. notes spoctiog feplace the fuel pump Fuel pump fuel hold pressure Warning + Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” onipage F110, ________] 4, Disconnect the negative battery cable. 2. Connect fuel pressure gauge to the fuel pump and plug the outlet of the gauge as shown. 3. Connect the negative battery cable. F1-19F1 FUEL SYSTEM 4. Connect data link connector terminals F/P and GND by using a jumper wire. 5. Turn the ignition switch to ON for approx. 10 sec. to oper- c ate the fuel pump. 6. Tum of the ignition switch. Wait for 5 min., and observe AL the fuel pressure, Pressure: More than 150 kPa { 1.5 kgf/cm? , 21 psi } ono XD) ee S 7. Disconnect the jumper wire. LW 8. Ifnotas spect d, repbce the fuel pump. FUEL INJECTOR Inspection Resistance 4, Disconnect the fuel injector connectors. 2. Measure the resistance of the fuel injectors, Resistance: Approx. 13.8 © [20 °C { 68 °F }] | > ligt as spectied replace tho ful injector. Fuel leakage test 1. Remove the fuel injectors together with the fuel distribu- tor 2. Fasten the fuel injectors firmly to the fuel distributor with wire and connect the fuel hoses. 3. Tilt the fuel injectors approx. 60 degrees from uplight position as shown, 4, Connect data link connector terminals F/P and GND by using a jumper wire. 5. Turn the ignition switch to ON and check for fuel leaks from the fuel injectors. Fuel leakage: Less than 1 drop/2 minutes 6. Turn off the ignition switch and disconnect the jumper wire. 7. If not as specified, remove the leaking fuel injector and reinstall the fuel injector, referring to Installation note. 8. Recheck the fuel leakage. If not as specified, replace the fuel injector. ND FIPoto LY) Fe FUEL PRESSURE GAUGE FUEL SYSTEM F1 Volume test 1. Remove the fuel injectors together with the fuel distribu- tor (Refer to page F1=16.)] 2. Fasten the fuel injectors firmly to the fuel cistributor with wire and connect the fuel hoses. 3. Connect data link connector terminals F/P and GND by using a jumper wire. 4, Turn the ignition switch to ON. 5. Connect the SST as shown in the figure. 6. Measure the injection volume of each fuel injector by using a graduated container. Injection volume: 38-50 ml { 3950 cc , 1.4—1.6 fl oz 15 sec. 7. Turn off the ignition switch and disconnect the jumper wire. 8. Ifnot as speci feplace the fuel injector. PRESSURE REGULATOR Inspection Warning ‘Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures” on(page F1=10.] |. Disconnect the negative battery cable. Remove the air intake hose ((Refer te page FI=5.)] 3. Connect a fuel pressure gauge between the fuel filter (high pressure side) and the main fuel hose. Install the air intake hose. Connect the negative battery cable ‘Start the engine and let it idle. Carry out the intake manifold vacuum inspection. . Measure the fuel line pressure, eye @ Nome Pressure: 200—240 kPa { 2.0—2.4 kgf/cm? , 29-34 psi} 9. Ifnotas specified, carry out the fuel line pressure inspec- tion(Refer to [—120,JJand inspect the PRC sole- noid valve, 10. Disconnect the vacuum hose from the pressure regula- tor. 11, Measure the fuel line pressure. Pressure: 280—310 kPa { 2.83.2 kgf/cm? 40—45 psi } 12. Ifnot as specified, replace the pressure regulator. (Hetero page ETT) F1-21F1 FUEL SYSTEM PRC SOLENOID VALVE (Except California) ofA Inspection oa 4. Remove the PRC solenoid valve (Refer to page F1-18) F1-22 2. Check for air flow between ports of the solenoid velve. 0: Continuity O—=0 : Airflow Bt: Battery positive voltage Terminal a B a B 1 o == 2 B+ | Ground Step 3. Ifnot as specified, replace the PRC solenoid valve. FUEL PUMP RELAY Inspection 1. Remove the fuel pump relay. 2. Check for continuity between terminals of the relay by using an ohmmeter. 0: Conti Terminal — a B © E ity B+: Battery postive voltage 1 2 B | Ground | o 3. Ifnot as specified, replace the fuel pump relay.F1 EXHAUST SYSTEM EXHAUST SYSTEM PREPARATION 49 TO18 001 For x replacement of Wrench, Op heated oxygen sensor sensor COMPONENT PARTS Inspection 1. Start the engine and check for exhaust gas leakage from each exhaust system components. 2. Ifleakage is found, repair or replace as necessary. F1-23F1 EXHAUST SYSTEM Removal / Installation 1, Disconnect the negative battery cable. 2. Remove in the order shown in the figure, referri 3. Install in the reverse order of removal, referring tere(19-23, 18-16) eed, 19-22(18-23, 14-16) (fo aly Ke! 90-49(30- 50,2236} a A Bas3, 78107 Nm 2o166Nm (0110 Rgtem, 70-25 tbe) {0070 tem, srtarintty [ao—ttokgrem, a TN jonasiniot) (so_tongtem, 4 ross iniot) 90-51 (98-53, 20-28) em (agin, tot) | 1. Main silencer 7. Exhaust manifok 2. Presilencer Removal note _ = 3. Three way catalytic converter Installation note = 4. Front pipe 8. Warm up three way catalytic converter Installation note page F125] (installation note... page F1=24] 5. Heated oxygen sensor 9. Insulator 6. Exhaust manifold insulator Removal note page F1-25] F1-24EXHAUST SYSTEM F1 Removal note Exhaust manifold insulator Remove the A/C pipe stay and remove the exhaust man- ifold insulator from over the vehicle. Exhaust manifold 1. Remove the air cleaner and disconnect the air hose. 2, Remove the water bypass pipe stay bolt. Tightening torque: ‘64—89 Nem { 6.5—9.1 kgf-m , 48—€5 ft-bf } 3. Loosen the EGR pipe mounting nut. Installation note Front pipe 1. Hand tighten the bolts and nuts in the order shown. 2. Tighten nut @). Tightening torque: ‘38—51 N-m { 3.85.3 kgf-m , 2838 ft-lbf } 38. Check for correct alignment at @) (front pipe and brack- et). 4. Check for correct alignment at @ (hanger bracket and Ubolt), then tighten nut @. Tightening torque: 10—16 N-m { 100—170 kgf-cm , 87—147 bt} 5. Verify that @) (frange and bracket) contacts with (D (cyt inder block and bracket), then tighten nut @). Tightening torque: 19-25 Nem { 1.9—2.6 kgf-m , 14—18 fbf } TEE view rroman 6. Tighten bolt @. Tightening torque: 38—51 Nm { 3.85.3 kgf-m , 28—38 ft-lbf } F1-25F1 EXHAUST SYSTEM Exhaust manifold EXHAUST MANIFOLD SIDE Face the bead of the gasket toward the exhaust manifold 4 as shown, and install the exhaust manifold. BEAD == + CYLINDER HEAD SIDE Warm up three way catalytic converter Install the warm up three way catalytic converter with the shaded area facing toward the engine as shown. F1-26EMISSION SYSTEM F1 EMISSION SYSTEM ‘COMPONENT PARTS Removal / Installation Fuel tank side 1 Remove the fue! tank. (Rafario page E1=11.] 2. Remove in the order shown in the figure. 3, Install in the reverse order of removal, referring 14-46 (1147, 96-14) 79-113 (€0—120, 70-108) 19-417 (@0—120, 70-108) am(kgtem, inde) 1. Rollover valve 5. Charcoal canister installation note page F1=28) Installation note... =.=... page FI=28 2. Tank pressure control valve (TPCV) 6. Airfiter 7. Canister drain cut valve (CDCV) 3. Fuel tank pressure sensor 4 F1-27F1 EMISSION SYSTEM Installation note Rollover valve, check valve (two-way), tank pressure control valve, charcoal canister + Push the ends of the evaporative hoses onto respective fittings. ication: 15—20 mm { 0.60—0.78 in } (except charcoal canister) 2: 25—30 mm { 0.99—1.18 in } (charcoal canister) Check valve (two-way) ‘+ Push the ends of the evaporative hose onto the fitting, Specification: 15—20 mm { 0.60—0.78 in } ‘+ Install the check valve (two-way) in the correct direction as shown. F1-28EMISSION SYSTEM F1 Engine compartment side 1. Disconnect the negative battery cable. 2, Remove the components shown. 3, Install in the reverse order of removal 13-107 Nm 79-10. Nm {80—M10Kghem 7095.4 inthe) [ooctolgtom,70-95.4inibt) 125 (19-26, 14-18) Non (hat fF} 1. Catch tank 4. EGR valve 2. PCV valve 5. EGR solenoid valve 3. Purge solenoid valve 6. EGR boost sensor solenoid valve i ROLLOVER VALVE Inspection 1. Remove the fuel tank, 2. Remove the rollover val 3. Verify that air flows through the valve from port the valve is held as shown. F1-29F1 EMISSION SYSTEM ] 4. Verify that no air flows through the valve from port ® when the valve is held as shown. 5. If not as specified, replace the rollover valve. e CHECK VALVE Inspection | Two-way ©} 4. Remove the check valve (two-way). 2. Blow air into port ® and verify that air smoothly flows Talla from port ©. Ne 3. Blow air into port © and verify that air smoothly flows © from port. 4. If not as specified, replace the check valve (two-way). TANK PRESSURE CONTROL VALVE (TPCV) GND ow Inspection’ 1. Remove the TPCV. 4 2. Apply pressure or vacuum to port ®) of the valve by using 1® a vacuum pump, and check for the air flow. kPa (mmHg , inHg) Airflow 5 Below 1.96 (1.47 0.08) No aie ‘Above 9.81 (7.36, 0.29) Yes Vacuum Below 9.61 (7.96, 029) Yes 3. Apply battery positive voltage to the valve connector and apply pressure to port @), and verify that air flows smoothly. 4, If not as specified, replace the TPCV. 186 195 $81 kPa (rary (735) |e97 (736) me ‘VACUUM «-}» PRESSURE CHARCOAL CANISTER Inspection . Remove the charcoal canister [Refer to page F1-27) 2. Plug the charcoal canister vent side port and purge sole- noid valve side port. 3. Blow air into the charcoal canister and verify that no air leaks. 4, If air leaks, replace the charcoal canister. FUEL TANK SIDE PURGE SOLENOID VALVE SIDEEMISSION SYSTEM F1 PCV VALVE CANISTER DRAIN CUT VALVE (CDCV) Inspection 1. Remove the canister drain cut valve. 2. Check for air flow between ports of the solenoid valve. 00: Continuity OO : Airflow B+: Battery oosiive voltage Ground 3. Ifnot as specified, replace the canister drain cut valve. PCV VALVE Inspection’ 1. Start the engine and let it idle. 2. Disconnect the PCV valve from the cylinder head cover. 3. Block the valve opening by hand and verify that vacuum, is felt 4. If not, check the PCV hose for clogging ard damage. If the hose is OK, replace the PCV valve. PURGE SOLENOID VALVE Inspection 1. Remove the purge solenoid valve. 2. Check for air flow between ports of the solanoid valva. 20: Continuity O==9 : Airflow B+: Battery postive voltage Te Por a 1 2 Br Ground 3. If not as specified, replace the purge solenoid valve. EGR VALVE Inspection 1. Start the engine and letit idle. 2. Connect a vacuum pump as shown and apply vacuum. 3. Verify that the engine runs roughly or stalls at the speci- fied vacuum. ‘Specification: 8.7—10.6 kPa { 65—79 mmHg , 2.6—3.1 inHg } 4, Ifnot as specie replace the EGR valve. F1-31EMISSION SYSTEM ala eno 6) sla}) GND Be EGR SOLENOID VALVE Inspection EGR solenoid valve (vacuum) 1. Remove the EGR solenoid valve (vacuum). 2. Check for air flow between por of the solenoid valve. +0: Continuity O==0 : Airflow B+: Battery postive voltage Terminal Por a B a 8 o 2 = | Ground Step 3. Ifnot as specified, replace the EGR solenoid valve (vac- uum). EGR solenoid valve (vent) 1. Remove the EGR solenoid valve (vent). 2. Check for air flow between ports of the solenoid valve, OO: Continuity O—=0 : Airflow B+: Battery positive voltage Terminal Port step = a 8 a B c 7 oo = SS=5 2 B+ | Ground | O—-=0 3. If not as specified, replace the EGR solenoid valve (vent) EGR BOOST SENSOR SOLENOID VALVE Inspection 1. Remove the EGR boost sensor solenoid valve. 2. Check for air flow between ports of the solenoid valve. F1-32 Continuity O—=0 : Airflow B+: Battery positive voltage 4) = Terminal Port a_|8 A 8 ¢ 7 oo I 2 Be | Ground | O 3. Ifnot as specified, replace the EGR boost sensor sole- noid valve.CONTROL SYSTEM Fl CONTROL SYSTEM PREPARATION Sst 49.9000 1624 For 49 7018 902 . For inspection of inepecton of Engine Signal Pekttermnal | Hames PeMterminal ‘Monitor voltage adapter ~ voltage 49 Fo18 903, For 49 Do8e 008 For ingpection of inepection of sheet Pci teminal | Harness Pout torminal votage adaptor, Power votage 49 7088 0A0 For 49 7088 0108 For inspection of inspection of NGS set Pet and Program Card eM and inputvoutput < fo Inpavourput devices dovecs 49.7086 002 . For 49 7088 001 For 5 ‘napection of Inepocton of Vehicle intortace ‘ Poh and conto Unit POM and Moduio == inpuvouput | (Partot input a spe en spam 49 T088 AO) 49,7088 008 For 49 T088 006 For Ay, | inepection of Sh inepecton of Nes oBoIt Poh and Battery Hookup PCM and ‘Adapter = inpuvoutput Adapter ‘Sx, inpwoutput (Partot & =O | eevices (Part of devices 497088 0A0) $9708 0A0) 49.T08e 008A For Inepecton of Instruction PCM and = ~ Manual inpuveutput devices F1-33F1 CONTROL SYSTEM COMPONENT PARTS No (gn 08) 1. Powertrain control module (PCM) 9. Heated oxygen sensor (Rear) is In spection page FLA eT gS it sada 2. Mass air flow sensor nspaction page F149 [inspection page F1-43] 11. EGR boost sensor 3. Camshaft position sensor [Inspection page F1-50] 12. Clutch switch. 4, Crankshaft position sensor Inspection page EL pagaFi=45] 13. Neutral switch 5. Throttle position sensor inspection page FI-52 inspection page Fi-45] 14. Power steering pressure switch [Adjustment page F1-46] = 6. Gpgine coolant temperature sensor 15. Main rela 7. Intake air temperature sensor 16. Fuel tank pressure sensor Inspection page Fi-si 8. Heated oxygen sensor (Front F1-34CONTROL SYSTEM F1 POWERTRAIN CONTROL MODULE (PCM) Removal / Installation 1, Disconnect the negative battery cable. 2, Remove the rear console, front console and undercover. (Refer to section S.)] 3, Remove in the order shown in the figure. 4, Install in the reverse order of removal. 79-107 (80110, 7005.4) Nen(xgtem nat) } 1. PCM connectors 2. Powertrain control module (PCM) F1-35Fi CONTROL SYSTEM F1-36 ny TERMINAL A TERMINAL B Inspection Caution ‘+ The PCM terminal voltages vary with cange in measuring conditions and vehicle conditions. Al- ways carry outa total inspectioin of the input sys- tems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. Disconnect the negative battery cable. sole, front console and undercover. Disconnect the PCM connector. ‘Connect the SST (Harness adapter) to the PCM connec- tor. ‘Connect the SSTs (Engine Signal Monitor and Hamess adapter, power) to the SST (Harness adapter). Use con- nector A of the hamess adapter for PCM terminals 14 through 1V and 3A through 3P. Use connector B for PCM. terminals 2A through 2L and 4A through 42. Place the SST (Sheet) on the SST (Engine Signal Moni- tor). . Measure the voltage at each PCM terminal by switching the selector switch and the monitor switch. It any incorrect voltage is detected, check related sys- tems, wiring hamesses and connectors referring to the possible malfunction in the terminal voltage list. Caution + Disconnecting the connectors of the PCM and the SST (Harness adapter) while the battery is con- nected can damage the PCM and the SST (Engine Signal Monitor). Disconnect the negative battery cable and the SST (Harness adapter, power) be- fore disconnecting the connectors. ‘+ Applying voltage to terminals A and B of the SST (Engine Signal Monitor) can damage the SST (En- gine Signal Monitor). Note + The indicator lights of the SST (Engine Signal Moni- tor), provided for confirmation of the voltmeter range, is also used for detection of the pulse such as the fuel injector control signal, which is difficult to detect by us- ing the voltmeter. + Terminals A and B of the SST (Engine Signal Monitor) are for connection of an external instrument. By con- negting an external instrument such as a circuit tester or an oscilloscope, various inspections in addition to the measurement of the PCM terminal voltages are made possible.CONTROL SYSTEM Fi DATALINK Using SST (NGS) CONNECTOR-2 1. In the passenger compartment, connect the SST (NGS) to the data link connector-2 as shown in the figure. 2. Referring to the NGS operational manual, select the PID/DATA MONITOR AND RECORD funcion. 3. Referring to the 1996 Service Highlights, inspect each PCM inpuvoutput signal. Note + The PID DATA MONITOR AND RECORD function is to monitor the calculation value of input/output sig- the PCM. Deviation in the value does not al- ways indicate maifunction in the related input/output devices. ‘+ When normal output signal cannot be detected when all input signals are normal, replace the PCM. F1-37F1 CONTROL SYSTEM Terminal voltage (Reference) — Binaata fk comocer 2 TX only J-anxonnr+| eee ec ol fle i cll us poled ol uch hn zr rea ao cel ef ln ax lr ne fol al a Tone Possible emt | signat | Connected to Test conlton votage cn] genesis ConcaraarTah O66 + Condsran in? |Condenserfan | Condenserfan | je cing | Below 1.0 |" elayl(Ftefer tol y ‘Condenser fan stop_ B+ Coatng Tan operating] Coal Senate | (eter tosecton Cooling fan con- | Ignition switch | Terminal TEN | Below 1.0 ie {oe Coating tan relay. 9 dae fs | incre 1 = = = = = Tanya pen accortng to age On ard diagnos wot ree cave eaysiem wp |Sevat Data inkeomes- |Bragnocietuble code ouputisapat | _ Sommunicalon |locBtmina KIN | of eal communication Susgomontby ema votage snot posebl : aaa Walfuneon indica [Malfunction indicator lamp OFF Be] > POM emirar TE torlamp ‘Malfunction indicator lamp ON Below to) MIL F 7 = = = + aT aw OW. 3 1a |accontet — |W relay 55 We apes ——| Bao 10} | ce ‘AG slop fe Headight switch OFF Balow 1.0 |* Headlight switch 1H | Headlight Headlight switch ~ (Refer to section | | Headlight wich ON Te Ef 71 | Diagnose west | Data nk cones | lgnion ewan [Oponterninal "TEN | B+» POM termina 1 mode | tor (rerminal TEN) | ON Shonteminal "TEN | Below 70] “TEN hamess ~ Fear window delo3t-| posoy q.g |* Rear window ty | Rearwindow | Rearwindow de- |ignion wach |erawich OFF | detostr euch arose” |fcaterawtch [Bu Rear window does |p, | [reer secton er switch ON nel + AG ov cswich action | oy 42 |» Air ors presei gch « wcanpiter [ise . resus Tac owien OFF ar | [fstrt ston ~ T = MTX ‘+ Neutral switch _— eon postion anseltch gs peat leased oe. |e cliek wach [eterto page) owas AK oon ete LoaaNotoad |ewtes(MtPx) | lgitn switch "ance vango tw postion Gowncion” |Traseate range [ON [postion | | “switch (ATX) {MIX | | Neatat postion or Chic pedal do pressed Below 10 a | P of N position l F1-38CONTROL SYSTEM F1 +: Battery positive voltage “1 In data Ink connector “2 ATK onl Signal | Conectata Test conden vores] fase ‘onion switch ON Oora9_ |» venigspaed im |Vericie speed |Veticle speed | ersoritater i] sensor Driving Approx. 3.0) Ceacion TI Dayfime running ight ON Bob 0 |> DAL wa AN [DRL (CANADA) | DRL unt [Datyime running ight OFF Rbove vi.0| [section 0 7 = = = = i= Fan switch OFF or |p, |» Earl lower an ste Ignition switch |ONat ist ene ae le! ON Fan switch ON at 274] pojow 10 7 : orhigher Brake podal released Below 1.0 | Brake atch 10 | Brake Brake switch ressed | Below 10 |" afro section Brake pedal depressed Br | Ley 7A = 7 = = 1s = == = = = 1 = = = = = eee Ignlion Sach ON Be] > Fuel pump wk sy |Fuetpumecor- | cue pump relay [Cranking [eter to page trol Below 1.0 | [fte2n vale W = = = = = [During shin oe) Santana ton |sritsoenoitA en comnaiaa [Dunst (Fiero section con Others o | Ik - During shiting ~ Be |+,Shiitsolenoid 8 vg _|Saitsoered® |opnanenaan [DAPI ee Ho Others o | ln it solenoi ; During shitting Bi |e Shiftsolenoid C ang |shitsalenos© | sooo eee conta Others o | lw Torque convert ing shi + | ogee comerer vean [reguacenvet [rogue conener [Dube siting ox | athsoionaa nodeontl | Mehsolenoid [Oper 3 | [ieee seen eB - woe |B 7 Tnsrarient clster sagg_|01D OFFindica- | O10 OFF indicator |igrition switch [1 OFF mod Below 1.0 |" (01D OFF indica torlight contol | ight on {onlfeterto see ‘otners eo | as = vange Transaxle range Drange Beet ar | Drang switch (Orange) [2° Others 3 =a Transaxle range | ag Brange Be 2G | 2 range switch 2 range) _ |‘ Others @ von [tran Transaxiorango | jg Trango a | “22H | 1 range switoh (1 range) _|' _ [others 0 O10 OFF Switch | Bojoy 40 [> OD OFF swatch : Ignition switen [pressed [terto scion] 10 OFF ‘wich | 221 |OIDOFF ewiteh |OrD OFF swich |! — —— [i : released e Tnputturbine | ignition switch ON z 7 inpaiturine vag |puitutine int 20K speed sensor (ur [Approx 2.5| speed sensor FE] speed sensor | fee ie re forte section ) Inputtubine | Inputturbine + POM terminal” “ta. |speod sonsor | speed'sensor | Constant Below 25 | Setunuly harness sound (ground i F1-39F1 CONTROL SYSTEM +: Battery positive voltage “1: In data link connector 2 mK only Teme ; Possible smi | gignat | Connected to Test conlton vonage cn] Passio Fae ank pressure o 7 Fue anc pressure Fuettank | Fueltankpressure|gnton swten |Aa(Ommng:© laconx o5| sensor = pressure sensor ON inHg } (Barometric | APPTOX.2.5) - Pressure) [rms ar sow [saat an [on svich ON Below 18 z ea soni Sensor (awe) [Sor i ioe ignitor sch ON prox. 0 | > Foaod oxygen Engine cold 0-09 nsor (Front) ac. |Hestedongen |Heated oxygen | ile ngine cokd_ Saao [Peter to page Sensor (ren) | sonoor roe _ Hag « ® x y ‘Acceleration After warm up. 05—1.0 [ocotraton —| wos _| ignitor sah ON pox. 0 | Hosea oaygen Ege aad Below to] Sansa (Rear ap [Heated oxygen | Heated oxygen | idle : 10 _| [{feter'o pase] Sensor esr)” | sensor ea) Fe TRIES —| Aner wer vp o=10 Deceleration o—1.0 | ae ae Transaxle fluid tem- © Transaxle fluid peraure20°C | Approx.s |" temperature sen- vege |Tlansavlefuid | Trasaxe uid tom: | gnitton ewten | 68°F galigercss tonporatue | pret sonaor”” | ON [Transeo 1 perature 130°C |Approx. 1.5) : {Fase _ Trap pA Closed rote pos oa-o7 |” sa Ee eee omen eee aa eee) (Tvo) ‘sensor ON + PCM terminal 31 Wide openthronte | a4—se |* RaMte a aeoonee + Engine cosa aq |Framocoouns [EEE Jiontonawicn | SEERTERET EN? [Amor 50” err tonporane on z n per sor [After warm up Below 1.0 Ignition switch ON | + EGR boost sensor Baronet pre = |roprox. a5] [eterispeee an /Baromete Pres | Ear boost a Approx 45} [eter pag ~ [rae poaon T > PCM terminal Constant vot: | sensor vovaye at |Conatantvek: Jonson alain tn ON |avprox 50 fon sonsor = } 7 EGA ae laon switch ON ‘etion sensor EGR val post | EGR valve posi |poprox on! [teteronene a Hien {i eoneot repro 08) |FGa ae : Intake airtem- | intake artemprae | into switch | intake artompera- |asenoy a9} tomate sensor Gs perature ture sensor ON ture 20 °C { 68 °F} Approx. 2.2 (Refer to page| Fin 3 = = 7 = = = am |Heatoa nygon [Heated oxygen | anton wien | pow 10 | cae aen sonacrheter” | sneer ce a 7 7 = 7 = Araiogne se | Grou = Tow 10 | POM 30 terminal | oo sor ground oom Constant pom harness (Open) F1-40CONTROL SYSTEM Fi Be: Battery positive voltage “1: In data irk connector 2: ATX only 7 Fossible Ter] signa | _Connectesto Test condition forage], Fassile ignition switch ON oe P everseateg Powersteerng |Powersteoring |= on pressure svtch al eetoure pesueawin lige [PS rot operating Serer oon PIS operating Below 10 | Le=c2) > PH 4A names POM ground | Ground onstant aA 3 o Below 1.0 [* Cou “ror cunoy {Main relay FUEL [soraon uaan LOPE Beto |= eT | 48 [Powersupply | inJrelay) anion switch TON Be + PCW 46 terminal ae [Fomtnecor | ceuna a Beiow 1.0 |” conn amo ae (Open + PCW 40 terminal a0 [Ovpdevce | grunt Constant Bulow 1.0 |” conan hams rot ns Ignition switch ON ‘+ Crankshaft posi- ae [NEO Crankshatt post | Approx. 2.4| _ tion senso tion sensor ns Tamshalt postion | jon ewtch Tor_|» Camshaft pasion ae |saT sensor (In distribu. | ‘9° a —__|nopree 5.0)” sensoritertal tor) Idle (Approx. 2.0| Cpage F1-44)] Camshaft postion | jrison ws dor ws [S5S, Sopot tou | eh ON hoor 50 (California ony) | $55 ids rAperoe 35 } ~ | ignition switch ON "© Crankshaft posi- at NEw a ee, avr. 2 | fonsonndie Z "© PCM 4i terminal a) [Backup power | pattory Constant B+ — battery hemese supply and connector ~~ | Pressure regula: Eas ‘ow 19 |* PRC soleno ty [tereoatol | PRC-solenoia [Ist Hetconston) Below 1.0 | yalvolFeter ts] teen” |e faa aK _ — — = GR boost sor |g nas senor [nlon ach ON * EGR bsl sensor aL | sorswitching | EGR boost sen ~ Be Rtorto page contol ide F128) = Full fuel ‘Approx. 6 | ° Fuel gauge ‘am |Fuctever | Fuetsauce | Ignition swteh o Fuel ga09e | sender unit ON Low fuel ‘Approx. 0 | [to section T) gnition co Ignition switch ON Below 1.0 |* Ignition controf an jig module (in dtr module (Retort tor) ‘do [Approx 0.3] _secton G) Ignition switch ON + EGR solenoid EGReontro! | EGR solenoid 40 B+ | valve (vent) (Fefar crew eee > EGR solenod witch ON gp |EGReonto| | EGRsotencia —_|'snton swt oe | paevcium (Vacuum) | valve (Vacuum foro page » fiat fn Tao a connor (aifon wich ON [Approx 07 |» leo air conrad 40 |idle air control air control “Ailey warm up (No |" valve valve ide ed Approx. 10 a = = = = = cg = = = = * Engine Signal Monitor: Green and red lights flash F1-41Fi CONTROL SYSTEM Bs: Battery positive voltage “rin data link connector “2 ATK only to Signal Connected to Test condition Voltage (V) Foseibis’ nal a malfunction lonoid | !shition switch ON + Purge solenoid 4T | Purge contro! _ | Purge solencid Bs | valvel(Feter to] homie Idle I Fi-2ni} wy Fuel injector No.t_|Tgnton swich ON 35 | Fuetingscor AV | Fuclinjector | Fuelinjector No2 (Relerio page “awW_|contel Fuel injector No | ite Be x Fuslinjotor Not En = = = ame = +O lanion swith ON oe | SeeealagT az [O0CKTPCY | cooy, rpoy Lm Diagnosis executed Below 1.0 * Engine Signal Monitor. Green and red ights flash F1i-42CONTROL SYSTEM Fi EEO Pom rE MASS AIR FLOW SENSOR Inspection 1. Check the mass air flow sensor for damage and cracks. 2. Connect the SSTs (Engine signal Monitor) to the PCM. (Refer to page F1=36. 3. Measure the volta Refer to page F1—40. at POM terminal 3B, 4. Verify that the voltage is within the specification, Specification Measuring condition PCid terminal 38 voltage (V) Tanition switch ON Below 2 Tale 10-2 rae aE 5. If not as specified, inspect the harness and connector between the mass air flow sensor and the PCM terminal. 6. If there is correct terminal voltage and harness continu- iy. replace the mass airflow sensor Using the NGS 1. Check the mass airflow sensor for damage and cracks. 2. Connect the SSTs (NGS) to the data link connector-2. 3. Select the PID/DATA MONITOR AND RECORD fune- tion 4, Select MAF V" on the NGS display. The NGS measures and shows the voltage Specification Weasuring condition Mass air flow signal Voltage (V)_| Ignition switch ON Below 10) Tale 10-25 5. If not as specified, inspect the hamess and connector between the mass air flow sensor and the FCM terminal. 6. If there is correct terminal voltage and harness continu- ity, replace the mass air flow sensor. (Refer to page FI-5.) Note ‘+ The scan tool shows the mass air flow rate and load value. Specification Tatake mass airflow Engine load (os) calculaied value (%) mx [aK | MTX [ATK Tale" 14-20 | 17-24 [130-180 [140-210 Engine speed = esa 50-64 | 62~78 |120—180| 160-220 *:No load, neutral or P position F1-43F1 CONTROL SYSTEM CAMSHAFT POSITION SENSOR Inspection Remove the distributor. (Refer to section G.) 2 Disconnect te fel injector connector. 3. Connect the distributor connector. (6-pin connector for California) Warning + Turning the ignition switch on with the fuel injec- tor connector still connected will actuate the fuel injector. + Turning the ignition switch on with the high ten- sion lead still connected will generate sparks, which can cause electrical shock. Disconnect the connector and avoid it from grounding to the ve- hicle body. 4, Connect the SSTS (Engine Signal Monitor) to the PCM. 5. Tum the ignition switch to ON. 6. Measure the voltage at PCM terminals 4F and 4G. 7. Rotate the distributor drive by hand and check the output signal. Specification POM terminal Signal F ‘SGT [Approx SV (4 pulsesiev) 4GicaLiFonia) | _scc__| Approx. 5 V(t puserev)_| 8. If not as specified, inspect the wiring hamess and con- nector between the distributor and the PCM terminal. 9. If there is correct terminal voltage and harness continu- ity, replace the distributor. (Refer to section G.) CRANKSHAFT POSITION SENSOR SENSOR, Inspection Resistance 1, Disconnect the crankshaft position sensor connector. 2. Measure the resistance between terminals A and B by using an ohmmeter. ‘CRANKSHAFT POSITION Specification: 500—600 © [20 °C { 68 °F }] 3. It not as specified, replace the crankshatt position sen- sor [(Refer to page Ft Air gap 1. Measure the air gap between the crankshatt pulley and the crankshaft position sensor by using a feeler gauge. ati Spe 2. If not as specified, replace the crankshaft pulley or the crankshaft position sensor.|(Refer to page F1=4 |5—1.5 mm { 0.020—0.059 in } F1-44CONTROL SYSTEM Fi [CRANKSHAFT POSITION SENSOR, CONNECTOR Oe Replacement 4. Remove the undercover. 2. Remove the crankshaft position sensor. 3. Install in the reverse order of removal. Tightening torque: 7,910.7 N-m { 80—110 kgf-om , 70-95. it THROTTLE POSITION SENSOR Inspection Using ohmmeter 1. Disconnect the throttle position sensor connector. 2. Measure the resistance between throttle position sensor connector terminals A and C by using an ohmmeter. Specification: 4.0—6.0 k2 3. If not as specified, replace the throttle posttion sensor. 4. Connect the throttle position sensor connector. 5. Adjust the throttle position sensor after installation. Using the Engine Signal Monitor 1, Remove the PCM. 2. Connect the SSTS. Engine ‘Signal Monitor) to the PCM. 2. Verify that the throttle valve is at the closes throttle posi- tion, 4, Turn the ignition switch to ON. 5. Measure the voltage at the PCM terminal 3F. (Refer fo page FT—40,] Specification Weasuring condition Vartage W) Closed thre postion 03-07 Wide open throttle 3a53 ‘Closed throttie position—-Wide open throttle | Increases smoothly 6. If not as specified, adjust the throttle position sensor. Using the NGS 1. Connect the SSTs (NGS) to the data link connector-2. 3. Select the PID/DATA MONITOR AND RECORD func- tion. 4, Select “TP V" on the NGS display. The NGS measures and shows the voltage. Specification Measuring condition Vortage Wy Glosod throtle position 03-07 Wide open throttle 3453 ‘Glosed thratleposition--Wide open throtle | Tnereases smoothiy 5. If not as specified, adjust the throttle positon sensor. FI-45,CONTROL SYSTEM Adjustment 1. Verify that the throttle valve is at the closed throttle posi- tion, . Disconnect the throttle position sensor connector. . Turn the ignition switch to ON. . Measure and record the voltage at the harness side con- nector terminal C by using the voltmeter. Por Specification: 4.5—5.5 V . Connect the throttle position sensor connector. . Remove the PCM. ”, Connect the SSTs {Engine Signal Monitor) to the PCM. . Verify that the throttle valve is at the closed throttle posi- tion. .. Turn the ignition switch to ON. . Loosen the throttle position sensor screw. Adjust the throttle position sensor so that PCM terminal 3F. otage is within ibe specification. Specification (closed throttle position) B30 @ Now Connector side terminal PCM terminal SF Voltage (V) Voltage (V) naa) 04-05 4881 “O06 L 05-06 12. Tighten the throttle position sensor screw. Tightening torque: 1.6—2.3 Nm { 16—24 kgf-cm , 14—20 in-lbf} 13. Fully open the throttle valve and verify that the voltage at PCM terminal 3F is within the specification. Specification (wide open throttle) ‘Connector side terminal PCM terminal SF Voltage (V) Voltage (V) 45-47 3544 4748 36-45, 48-49 3746 49-50 3748 BOS 3849 5183 40-50 i baa at BESS - 4252 14. If not as specified, rey Refer te F134, 15. Adjust the throttle position sensor after installation. ice the throttle position sensor. Fi-46CONTROL SYSTEM F1 Using the NGS 1. Verify that the throttle valve is at the closed throttle posi- tion. Disconnect the throttle position sensor connector. ‘Tum the ignition switch to ON. Measure and record the voltage at the hamess side con- nector terminal C by using the voltmeter. ‘Specification: PON 55.5 V 5. Connect the throttle position sensor connector. 6. Connect the SSTs (NGS) to the data link connector-2. 7. Select the PID/DATA MONITOR AND RECORD func- tion. 8. Select the “TP V" and verify that the throttle valve is at the closed throttle position. [ ar 9. Loosen the throttle position sensor screw. ae 10. Adjust the throttle position sensor so that throttle posi- SacsoS Pe URE oO tion signal voltage is with in the specification, Specification (closed throttle position) Connector side terminal © ‘Throttle position signal Voltage (V) Voltage (V) 4549 04-05, 49-81 04-06 BI-85 05-06 11. Tighten the throttle position sensor screw. Tightening torque: 1.6—2.3 Nem { 16—24 kgf.cm , 14—20 in-Ibf } 12. Fully open the throttle valve and verity that the voltage is within the specification, Specification (wide open throttle) ‘Connector side terminal’ | Throltle position signal Voltage (V) Voltage(V) 45-47 3546 478 3645 48-49 ace 49-50 3748 B0=81 3649 5163 40-50 i 53-54 aist : 5455 42-52 13. If not as specified, r 14, Adjust the throttle position sensor after installation. ce the throttle position sensor. Fi-47F1 CONTROL SYSTEM ENGINE COOLANT TEMPERATURE SENSOR: Inspec Remove the engine coolant temperature sensor. 2. Place the sensor in water with a thermometer, and heat the water gradually. 3, Measure the resistance of the sensor by using an ohm- meter. Water temperature (CF) Resistance (ka) 20 (68) 22-27 0 ( 176) 0304 4. If not as specified, replace the engine coolant tempera- ture sensor. INTAKE AIR TEMPERATURE SENSOR Inspection 1. Remove the intake air temperature sensor. 2, Place the sensor in water with a thermometer, and heat the water gradually. 3. Measure the resistance of the sensor by using an ohm- meter. Spcification ‘Water temperature (6 CF) Resistance (Ka) 20(68} 2e-27 301 176), 0280.34 4, If not as specified, replace the intake air temperature sensor. HEATED OXYGEN SENSOR Inspection Sensor 4. Warm up the engine to normal operating temperature. 2. Connect the SSTs (Engine Signal Monitor) to the PCM. 3, Measure the PCM terminal 3C and 3D voltages. SERGE | Seieton ———_ ide | 0—1.0V. O-1.0V ee ‘Acceleration | 08—1.0V_| _o—1.0V = Fe HEATED oxvcen | SENSOR (REAR) 4, If not as specified, inspect the following. ‘+ Hamess and connector between heated oxygen sen- sor and PCM. * On-board diagnostic systeml(Refer to page F1=54,)] * System inspection Intake manifold vacuum Fuel line pressure| [(Refer to page Fi-120)] 5. If all the systems are OK, replace the heated oxygen sensor (Refer to page Fi-24)]CONTROL SYSTEM F1 Using the NGS 1. Connect the SSTs (NGS) to the data link connector-2. 2. Select the PID/DATA MONITOR AND RECORD func- ii a TEMAATON TEST 3. Select “FHO2S" “RHO2S” on the NGS display. The NGS measures and shows the voltage. Specification Engine condilion | FHOZS volage (V)_] AHO2S voltage (V) idle O10 O10 Decoration 0-05 O10 ‘eceleraion os=10 = 4, Ifnotas specified, inspect the following, * Hamess and connector between heated oxygen sen- sor and POM. ‘* On-board diagnostic system[(Refer to page F1-54.)) ‘+ System inspection Intake manifold vacuum Fuel line pressurel(R [(Refer to page F1-120.)] 5. If all the systems are OK, replace the heated oxygen sensor lfiiar in. paga F128] jer to page Fi-119 a Heater 1. Disconnect the heated oxygen sensor connector. 2. Measure the resistance between heated oxygen sensor terminals B and C (Front) or D and C (Rear) by using an ohmmeter, : Approx. 6 £2 [20°C { 68 °F }] EGR VALVE POSITION SENSOR Inspection 1. Disconnect the EGR valve position sensor connector. 2, Measure the resistance between terminas A and B by using an ohmmeter. Specification: 2.7 k2 3. Ifnot as specified, replace the EGR valve, [(Refer to page F1-25.)] 4. Connect the EGR valve position sensor connector. 5. Connect the SSTs (Engine Signal Monitoi) to the PCM. 6. Disconnect the vacuum hose from the vacuum tube and install a vacuum pump to the valve. 7. Turn the ignition switch to ON. 8. Measure the voltage at the PCM terminal 3J. Speification Vacuum PCM Terminal 35 voltage (V) OWPa{OmmAg, OinHaT ‘Approx. 08 ‘Approx_17 KPa (126 mmHg , 5.04 inHg} ‘Approx. 48 Fi-49CONTROL SYSTEM SS 9. If not as specified, inspect the harness and connector between the EGR valve position sensor and the PCM terminal. 10. Ifthese hamess and connector are OK, replace the EGR valve.|(Refer to page F1-25, Using the NGS 1. Disconnect the EGR valve position sensor connector. 2. Measure the resistance between terminals A and B of the connector by using an ohmmeter. Specification: 2.7 kQ 3. Ifnot as specified, replace the EGR valve. ‘Connect the EGR valve position sensor connector. Connect the air intake hose. Connect the SSTs (NGS) to the data link connector-2. Select the PID/DATA MONITOR AND RECORD fune- tion. 7. 8. Disconnect the vacuum hose from the vacuum tube and 9. oon install a vacuum pump to the vaive. ). Select the “EGAP V" on the NGS display. The NGS mea- sures and shows the voltage. coe EGR BOOST SENSOR F1-50 vacuum PUMP Speci a EGR vaive position a signal voltage (V) OKPa(Ommig, OinHGy Approx. 0.8 ‘Approx. 17 kPa {128 mmHg, 6.04 inHg) Approx. 4.9 10. If not as specified, inspect the harness and connector between the EGR valve position sensor and the PCM terminal. 11. Ifthese hamess and connector are OK, replace the EGR vaive| EGR BOOST SENSOR Inspection 1. Connect the §: ine Signal Monitor) to the PCM. 2. Apply vacuum to the EGR boost sensor by using a vacu- um pump. Measure the pressure at PCM terminal 3H. Specification Vacuum 86.3 kPa { 660 mmHg , 26.0 inHg } | [i.3kPa (460mmig. 18.1 inHg) Appron 16 634Pa( 475mm, L9G) Approx 44 3. Ifnot as specified, replace the EGR boost sensor. Refer to page FI:CONTROL SYSTEM F1 nesoepiaySOS*~*~s~S*~S~S*S SCC ing the NGS 1. Connect the STs (NGS) to the data link connector-2. 2. Select the PID/DATA MONITOR AND RECORD fune- Taare Toe tion. ——— 3. Apply vacuum to the EGR boost sensor by using a vacu- Sucre RUE COO LEARY um pump. Aa 4, Select “BARO V" on the NGS display. The NGS mea- sures and shows the voltage. . Specification Baromettie pressure — signal voltage (V) 863 KPa [660 mig, 260inNG) ‘ABpIOX. 0:5 67.3 kPa (460 mmHg. 18.1 ing} ‘Approx. 1.6 6.3 KPa (47.5 mmHg, 19 inHg) ‘Approx. 4.4 5, Ifnot as specified, replace the EGR boost sensor. Refer to page F1-34. FUEL TANK PRESSURE SENSOR Inspection 4. Connect the SSTs {Engine Signal Monitor) to the PCM. 2. Apply vacuum to the fuel tank pressure sensor by using a vacuum pump. Measure the pressure at PCM terminal 3A. Specification vue PEM terminal 3A votage (V) ‘OKPa(Omambg , OmHGT Approx. 2.5 (67 KPa [50 mmHg, 20inHg) Approx. 05 3. If not as specified, replace the fuel tank pressure sensor. (Refer to page F113] eee Using the NGS 1. Connect the SSTs (NGS) to the data link connector-2, Refer to page F1-37,)] 2. Select the PID/DATA MONITOR AND RECORD func- tion, 3. Apply vacuum to the fuel tank pressure sensor by using a vacuum pump. 4, Select “FTP V" on the NGS display. The NGS measures and shows the voltage. Specification = Fuel tank pressure a “signal voltage (V) ‘OkPa [OmmAg , OinHG) ‘Aprox. 25 6:7 kPa (50 mmHg. 2.0 nig) ‘Aparox. 0.5 5. Ifnotas specified, replace the fuel tank pressure sensor. fer to page 0 Fi-51CONTROL SYSTEM CLUTCH SWITCH Inspection 1. Disconnect the clutch switch connector. 2. Check for continuity between terminals of the clutch switch by using an ohmmeter. +0: Continuity ————_—Terminat a . Condition Clutch pedal not depressed “| Clutch pedal depressed SEs 3. Ifnot as specified, replace the clutch switch. Replacement Install the clutch switch as shown in the figure. NEUTRAL SWITCH Inspection 1. Discontiect the neutral switch connector. 2. Check for continuity between terminals of the neutral switch by using an ohmmeter. +0: Continuity Terminal Condition — ia 5 ‘Nouital position Oo ‘Others 3. Itnot as specified, replace the neutral switch. POWER STEERING PRESSURE SWITCH Inspection 1. Disconnect the power steering pressure switch connec- tor. 2. Start the engine. 3. Check for the continuity between power steering pres- sure switch terminal and a ground by using an ohmme- ter. +0: Continuity PIS PRESSURE SWITCH Terminal Condition ‘Steering whee! not tumed ‘Steering wheel being turned Ee 4, If not as specified, replace the power steering pressure cuitch (Hetero page Fi=34] A GroundCONTROL SYSTEM F1 MAIN RELAY Inspection 1. Remove the main relay_ 2. Check the continuity between the relay teminals by us- ing an ohmmeter. ©—O: Continuity B+: Battory postive votage Terminal | 5 a a Step 1 2 Ground |_Be 3. If not as specified, replace the main relay. F1-53Fi ON-BOARD DIAGNOSTIC SYSTEM ON-BOARD DIAGNOSTIC SYSTEM PREPARATION SST 49 T088 OAD For 497088 0108, For diagnosis of PCM diagnosis of PCM NGS set and inputvoutput | Program Card and inputoutput systems systoms 49 T088 002 For 49 T088 001 For Vehicle Interface diagnosis of PCM andinputioutput | Control Unit =} diagnosis of POM and inpuvoutput Module systems (Pat of systoms (Part of 49 T088 040) 49 7088 0A0) 49 T088 004 For 49 TO88 008A, For | agnosis of POM lagnosis of PCM Nas opo1r andinputfoutput | Instruction ‘and inpuvoutput ‘Adapter systems | Manual systoms (Part ot 49 T088 0A0) 49 T088 006 For | diagnosis of PCM Battery Hookup and inpuvioutput S _ Adapter systems (Panof 49 T088 040) eS RSS F1-54 DIAGNOSTIC TROUBLE CODE NUMBER Inspection Connect the SSTs (NGS) to the data link connector-2 2. Refer to the manufacturer provided instruction manual ‘or the NGS operation. 3. Select “DIAGNOSTIC TEST MODE” function and press trigger. 4, When "NO CODES RECEIVED/SYSTEM PASSED” is displayed, all systems monitord are judged OK. 5. When any of the diagnostic trouble codes is displayed, carry out troubleshooting according to the code. 6. IFLINK MONITOR ERROR is displayed, check connec- tion of the NGS. 7. Alter all problems have been repaired, carry out “After Repair Procedure. (erin below l After Repair Procedure After repairs, connect the NGS to the data link connec- t0F-2. 2. Select “CLEAR” function and erase diagnostic trouble codes from the PCM memory. 3. Perform diagnostic trouble code inspection again and verity that no diagnostic trouble codes are displayed,ON-BOARD DIAGNOSTIC SYSTEM Diagnostic Trouble Code Numbers pte Display on the NGS Condition P0100 | MAF/VAF—CIRCUIT MALFUNCTION | Mass air flow circuit malfunction pero lit cnc MAL Eun TION Intake alr temperature cheut matunc- Engine coolant temperature circuit P0115. | ECT—CIRCUIT MALFUNCTION en P0120. | TP—CIRCUIT MALFUNCTION Throttle position circuit matfunction potes [EXCESSIVE TIME TO ENTER Excessive time to enter closed loop CLOSED LOOP fuel control P0130 |O2S 11—CIRCUIT MALFUNCTION | 0» sensor circuit matfunction 02S 11—CIRCUIT NO ACTIVITY poss | Oe Teo ©» sensor circuit no activity detected BOIdS | Ont einonOWT ee ae Qz sensor heater circuit malfunction Por4o | O28 12 CIRCUIT NO ACTIVITY | 0, sensor circuit no activity detected | BANK 1—FUEL TRIM : P0170. | MALFUNCTION Fuel trim malfunction | P0300 | RANDOM MISFIRE DETECTED Random misfire detected P0301 |CYLINDER 1 MISFIRE DETECTED — | Cylinder 1 misfire detected P0302 |CYLINDER 2MISFIRE DETECTED —_| Cylinder 2 misfire detected P0303 [CYLINDER 3MISFIRE DETECTED | Cylinder 3 misfire detected P0304 |CYLINDER 4 MISFIRE DETECTED — | Cylinder 4 misfire detected pogas _|CRANKSHAFT POS SENSOR—CKT | Crankshatt position sensor circuit mal- | req—7 MALFUNCTION function poa4g |CAMSHAFT POS SENSOR—CKT —_| Camshaft position sensor circuit mal- MALFUNCTION function oie |ece ow eT iCTiON Exhaust gas recrutation fw ma junction Podg9 |BANK 1 CATEFFICIENCY BELOW | Catalyst system effciency below uit threshold Evaporative emission control system P0440 | EVAP SYSTEM—MALFUNCTION | F¥aporatve Fi FI-55F1 ON-BOARD DIAGNOSTIC SYSTEM pre Display on the NGS Condition Page poaag_|EVAP SYSTEM—PURGE CTRL Evaporative emission control system VALVE CKT MALF purge control vaive circuit malfunction poago |EVAP SYSTEM—PRESSURE SEN _ | Evaporative emission control system MALFUNCTION pressure sensor malfunction | VEHICLE SPEED SENSOR— P0500 | EEE STON Vehicle speed sensor malfunction (E77 IDLE CONTROL SYSTEM— : P0505 | MALFUNCTION Idle control system malfunction (E1=zal TORQUE CONV/BRAKE SW— P0703 | MALFUNCTION Brake switch input malfunction (Fi=79] MORE DRIVING NEEDED TO Check of all OBD-II system is not P1000 | COMPLETE TEST complete since last memory clear (ei—zal P1170 | HO2St1—INVERSION {ieareg oayaen sensor (Front) P1195 | EGRBS—OPEN OR SHORT EGR boost sensor open or short PRC—OPEN OR SHORT P1250 | Cont oaitony PRC solenoid valve open or short SGC SIGNAL—NO SGC SIGNAL | P1945 | Catitornia) No SGC signal (E33) P1402 | EGRS—OPEN OR SHORT EGR valve position sensor open or (Fi=84l P1449 | CDCV—OPEN OR SHORT Canister drain cut valve open or short | [E1=85] FUEL TANK LEVEL SENSOR— Fuel gauge sender unit circuit open or P1485 | OPEN OR SHORT short Cet=al P1485 | EGR (VACUUM)—OPEN OR SHORT | EGA solenoid valve (vacuum) open or | [e4—a7] P1486 EGR (VENT|—OPEN OR SHORT | EGR solenoid valve (vent) open or | (E=ag] a — P1487. | EGRCHK SOL.—OPEN OR SHORT boon ee (Fi=8] P1608 | PCME (CPU)—MALFUNCTION PCM (CPU) malfunction (E190) P1794 | BAT—BAT OR CIRCUIT FAIL Battery or circuit malfunction (E1=30] Pose worn Cacrorn Por N ranger nouravtuch even | Tea F1-56ON-BOARD DIAGNOSTIC SYSTEM FI Sanon Inpu vag rom ass ar ow sonsoris below 0.8 Vor above 49, when infonavichis | Sen oe ales Posslecaue |: Sfenarsan cron wis fom mala oi Ooan at tenor eal ‘Does mass air flow sensor connector or PCM con- ‘Yes _| Repair or replace connector cee heen Ys Fei —= Is POM terminal 3B voltage OK? ~ ‘Yes | Goto step 6 No | Goto next step ee agate celeron” [He | Geckeroen etch mnetionas a Tings Sin nen anes a | Tor [eo OS feel Steam Seal aA No _ | Repair or replace wiring harness: OS icy ce cor Sono aa (eT terminal B and PCM terminal 26, No | Repair or replace wiring hamess 6 Erase diagnostic trouble code from memory. ‘Yes [Replace PCM 7 €S page F1-35 Is same code No. present ater rechecking? ~ No _| Intermittent poor connection of hamess or connector (Repair connector and/or harness) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-57FA ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble code No. PO110 TAT—CIRCUIT MALFUNCTION Input from intake air temperature sensor is below 0.1 V or above 4.8 V when ignition ewitch is ‘Symptom ‘turned on ‘STEP INSPECTION ACTION, | Pel eaatreamss Ye [Reetoenet + sFaiamir ig O ao eas + [Dem nas agpaas coeroomain | We festa Ba Semaertemnaahs SYS |W Se erg hearts 7 Titec amin emen gn is oamwan [feo os @ | Erase agnosie rouble code rom momeny Yes [Replace POM T= pape Fics] | !s same code No. present after rechecking? ‘No _ | Intermittent poor connection of hamess of connector (Reon pons Sar aL: HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-58ON-BOARD DIAGNOSTIC SYSTEM F1 Diagnostic trouble code No. POTS ECT—CIRCUIT MALFUNCTION Possiblecause | a ‘witch is turned on nal 3G input voltage from engine coolant temperature sensor is below 0.2 V or above 4.9 V when ignition + Engine coolant temperature sensor malfunction * Open or shor circuit in wiring from engine coolant temperature sensor terminal A to PCM termi: + Open or short circu in wing from engine coolant temperature sensor terminal B to PCM term oes | Daeg aman aman aera PE [Nar [ areas Seeea aoe emers to | ror 1s PCM terminal 3G voltage OK? ‘Yes | Goto step 6 - (page F140] | yo [Go to next etep | 3 _ | Disconnect engine coolant temperature sensor con- | Yes | Go to next step arte enton when vate | “(hii SEs oon ei ey ooorenes acme [vo SOUT |” 5 _ | Is engine coolant temperature sen Yes | Go to next step ee =n 's same code No, present after rechecking? ‘No | Intermittent poor connection of harness or connector (Repair connector andior harness) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) Fi-59Fi ON-BOARD DIAGNOSTIC SYSTEM ‘TPCIRCUIT MALFUNCTION Diagnostic trouble code No. P0120, ‘Symptom cone Input vollage from throttle position sensor is below 0.1 V or above 4.7 V when ignition switch © Possible cause ‘= Throtie position sensor malfunction ‘+ Open or short circuit in wiring from throttle position sensor terminal A to PCM terminal 30, = Open or short cieuit in wiring from throttle position sensor terminal B to PCM terminal 3F ‘+ Open or short circuit in wiring from throtle position sensor terminal C to PCM terminal 31 = reo fl 1 ‘Does throttle position sensor connector or PCM con- | Yes _| Repair or replace connector | Sesion stoner ws rar | 2 iPr rina 5kags OF telecon Niel eoen al 3 rvags ross as Somdog orate vake | Te [eos ‘opening angle? ‘No _ | Replace throttle position sensor LE page F134 | oe a eC cy 5 hinmas aay amon tape cowed [a [eo ora Shes RTT te {evra 6 _ | Is there continuity between hamess side connector | Yes | Replace throttle position sensor L&® page F134 | aul Clend ou mnie aie No _ | Repair or replace wiring hamess Erase diagnostic trouble code from memory. ‘| Yes | Replace PCM [= page Fi-as! eee ee ee |” No [intermittent poor connection of hamess or conrector | ie ps eer an clea} HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-60ON-BOARD DIAGNOSTIC SYSTEM FA Diagnostic trouble ‘code No. P0125 EXCESSIVE TIME TO ENTER CLOSED LOOP ‘Symptom Engine coolant temperature sensor signal does not rise normally because of engine coolant sys- tem malfunction Engine coolant temperature sensor matfunction ‘Thermostat malfunction Engine cooling fan system malfunction ‘Water pump malfunction Engine coolant passage clogged or leaks Engine coolant, level and protection INSPECTION ‘ACTION Tf cooing fan conve ayter OR? Yes [Gow nonstop 5 aa FT=T30| jo — | Repair or replace cooing fan sys 2 [Te engine colt temperature sensor resistance | Yes [Goto nex step wl sage FI=4e] | No | Replace engine nolan temperature sensor | [ais cooing system OK? Yes | Gortenexttep [etsectionE] | "No |Repairorrepace 7 | Erase aagnostc wouble code rom memory Is some | Yes | Replace PCM pee SoselNe pheweat aller recone No _ | Temporary system matfunction * During normal driving Diagnostic trouble code No. P0130 (02S 11—CIRCUIT MALFUNCTION Teated onygen sensor (Front) deterioration oe * Leakage in exhaust system : ‘STEP INSPECTION ‘ACTION 1 [Iisheated oxygen sensor (Front) OK? Yes_| Goto next step FE No | Rapair or replace heated oxygen sensar (Front) 2 | Erase diagnostic trouble code from memory. ls same | Yes _| Replace POM ‘code No. present after *rechecking? No _ | Intermittent poor connection of hares or connector (Repair connector andor hamess) * During normal driving F1-61FA ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble 02S 11—CIRCUIT NO ACTIVITY DETECTED. ‘code No. P0134 When heated oxygen sensor (Fron) signal does pol exceed 0 V afer engine m aed or says symptom | below 08 V for wo minutes afer engine has reached normal operating temperature and runing at 1,500 rpm or over ~ Heated oxygen sensor (Front) malfunction Possible cause | + Open or shor circuit in wiring from heated oxygen sensor (Front) terminal A to PCM terminal 3 + Intake-air system, fuel system, ignition system matfunction ‘STEP INSPECTION I ‘ACTION al 1 | Does heated oxygen sensor (Front) connector or [Yes _| Repair or replace connector PCM connector have poor connection? No | Go tonext stop 2 _|18 POM terminal 31 votage OK? Yes [Goto step 5 (ee pao F180) yo Goto next atop 3 | Disconnect heated oxygan sensor (Front) connector. | Yes | Goto next step | Is there continuity between hamess side connector | | ———— | ferinal A and PCM terminal 367 [No | Repair or replace wiring hamess ‘Are following units OK? Yes | Replace heated oxygen sensor (Front) and go to. Fuel injector = page Fi=20 next step, [= page F134 | Pressure regulator ee page Fi=21 Mass air flow sensor 5 page F1=43 Engine coolant temperature sensor = No | Repair or replace ‘Spark plug ‘= section G Parrorep Air suction (AitFue! ratio rich or lean) | 5 | Erase diagnostic trouble code from memory. ls same | ‘code No. present after rechecking? i | Yes | Replace POM page Fi-35 'No _ | Intermittent poor connection of hamess or connector (Repair connector andior hamess) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-62ON-BOARD DIAGNOSTIC SYSTEM F1 Diagnostic trouble ] 028 11—HEATER CIRCUIT MALFUNCTION code No. PO135 Symptom ‘pen or sor ccs observed hated oxygen sensor hear Fron} aytem when inion 7 “= Heated oxygen sensor heater (Front) maifunction | Possible cause | « Open or shor circuit in wiring from heated oxygen sensor (Front terminal C to ignition switch ‘= Open or short circuit in wiring from heated oxygen sensor (Front) terminal B to PCM terminal 3M ‘STEP INSPECTION ACTION 1 ‘Does heated oxygen sensor (Front) connector or POM connector have poor connection? Yes | Repair or replace connector No_|Gotonext step ccode No. pressent after rechecking? 7 [le POW ominal 3M voiags OR? Yeo [Geto sieps (page Fi=40] No [Goto next step 3] Bacon heated oygen sooo: (ond comeior | Yeo [Goto nen aap ie volageatfamese soconnacorteminaic? | N° | Ghee open or had creutin wing hamess, terminal C) OO ———— Goto ne ep {Gmina and Fw tomato? ee ee os canana | |e there continuty betwoon hamess side connector Goto next step terminals B and C? Replace heated oxygen sensor (Front pasar 6 | Erase diagnostic trouble code from memory. Is same | Yes | Replace PCM [es page F1-35] No intermittent poor connection of han (Repair connector andor hares) mess or connector HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CON (ECTOR) F1-63F1 ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble code No. PO140 028 12—CIRCUIT NO ACTIVITY DETECTED | When heated oxygen sensor (Rear) signal does not exceed 0.5 V after engine is started, or stays _| Symptom | below 0.5 V for two minutes after engine has reached normal operating temperature and running at 1,800 rpm or over * Heated oxygen sensor (Rear) malfunction ‘= Open of short circuit in wiring from (Rear) heated oxygen sensor (Rea) terminal A to PCM termi- Possible cause ral 3D + Open circuit in wiring from heated oxygen sensor (Rear) terminal B to PCM terminal 30. + Intake-air system, fuel system or ignition system malfunction ‘step | INSPECTION ‘ACTION 1 | Does heated oxygen sensor (Rear) connector or | Yes _| Ropair or replace connector PCM connector have poor connection? Now| Ganesan 2 | IS POM terminal 3D voltage OK? Yes [Goto stop 6 No _|Gotonext step 3 | Disconnect heated oxygen sensor (Rear) connector. | Yos [Goto next stop 's there continuity between harness side connector terminal B and PCM terminal 30? No. | Repair or replace wiring harness “4 | Is there continuity between hamess side connector | Yes | Goto next step terminal A and PCM terminal 30? Fuel injector Spark plug ‘Air suction 5 [Are following units OK? Pressure regulator ‘Mass air flow sensor Engine coolant temperature sens (AirFue! rato rich) Repair or replace wiring harness Replace heated oxygen sensor wy ke tl Fide] [No ‘section G Repair or replace EE 6 | Erase diagnostic trouble code from memory. Is same | Yes _| Replace PCM [ee page Fi-35 ] code No. present after rechecking? No | Intermittent poor connection of hamess or connector (Repair connector andior hamess) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) Fi-64ON-BOARD DIAGNOSTIC SYSTEM Fi gnostic trouble | BANK 1—FUEL TRIM MALFUNCTION ‘Symptom * Pressure regulator malfunction ‘= Fuel injector malfunction Fuel pump malfunction Engine coolant temperature sensor malfunction Mass airflow sensor malfunction Heated oxygen sensor matfunction ‘Airfluel ratio stays rch or lean longer than specified period because of system malfunction Possible cause | Purge solenoid valve malfunction {Leakage in intake syetam 2 PCM mattuncton 1 Open or short teuitin wing between PCM terminals AU, 4V, AW, 4X oul injector 1 Inlake air temperature sensor malfunction 5 EGR boost sensor malfunction {PCV valve malfunction sep INSPECTION “ACTION 7 [sterearieiageiniate-sreygemcanpaana? | Yos_[ Raper orepecmiaieat sion = = No | Go to next step | “2 [le tue ine pressure OK? Yes | Goto steps cm = No | Go to next step 3 [fuel parip maximum pressure OK? Yes. [Gotonext step No _| Repair or replace fuel pump [4 _ [Is pressure regulator OK? Yes | Go tonext step 5 |Is fuel injector OK? ~~} Yes [Go to next step : pageEl-20' No | Replace fuel injector | ls engine coolant temperature sensor OK? Yes [Gotonext step [No | Replace engine coolant tomperature sensor | 7 [le mass air ow sensor OK? Yes | Gotonex stop (es page FI=E8] |" No [Replace mass airflow sonsor CE paga FI-E @ | lethrotlo postion sensor OK? Yes_[Gotonextatep Ce page FIA] io ‘Adjust throttle position sensor — LE" page F1-46] © [is intake ar temperatre sensor OK? Yes | Goto noxt stop GE RRGRET-EE] No pae ike ai onpeat ont 10 [Te EGR boost consor OK? Yes _[Gotonex step [= page F=50] (“No | Replace EGR boost sensor LP anga FI=aa 11 | Is purge solenoid valve OK? Yes _| Goto next step CEE page FI=27] io | Replace purge solenoid vaive | (= page Fi=25) 12 | Is PCV valve OK? ~ ‘Yes | Go to next step Cee page FI=27] No | Ropiace POV valve page 1-25 73 | Erase diagnostic trouble code from memory. Yes _| Replace POM ~~ [es page F1=a5] Istsame code No. present ater “rechecking? Ta aon an manaon : Dunn ing F1-65F1 ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble | RANDOM MISFIRE DETECTED code No. P0300 ‘Symptom | PCM input signal from crankshaft position sensor signal is regular |= lonition system malfunction * Low fuet + Lon baton postive votage Possible cause | Fuel ystommatncon + Iaiiont compression 5 Clankahat poston sereor ar gp inorect + Eihaust gs elculston yt naureon sre | INSPECTION : AeTION 1 [lenin Seer OK? Yee [Gow nat iop No _| Repair or eplace as necsiary © | leant poaion sonora gap ane? Yee [ Goto nentstep Thies ERE |X| pio epaco anak panto 3 fue ayton OFF Yer [overex sep [& page F1=10 | | Repair or replace as ne [5 pageFI=101 [No [Repair or replace asnecessary 7 [Is exhaust gas eruiaton con} Yes oto nex siop seem OK? | es Wo | Real opie as necessary 3 |e compression ata ofndors normal Yee | Goo nertstep [= section B1] [ee section 81] [Wo | Repair or replace as necessary 6 | Erase diagnostic rouble code from memory. Is same | Yes_| Replace PCM (= page Fi-as] ‘code No. prosent after “rechecking? No_| Temporary system malfunction * During normal driving F1-66ON-BOARD DIAGNOSTIC SYSTEM F1 Diagnostic trouble ‘code No. P0301 CYLINDER 1 MISFIRE DETECTED ‘Symptom PCM input signal from crankshaft position sensor signal for eyinder No.1 is regular Possible cause Low fue! Low battery positive voltage Fuel system malfunction Insufficient compression in eylinder No.1 Ignition system of cylinder No.1 malfunction Crankshaft position sensor air gap incorrect Exhaust gas recirculation system malfunction ‘STEP INSPECTION T "ACTION 1 |Signition system of eylinder No.1 OK? Yes _|Goto next step a No _| Repair or replace as necessary 2 | ls crankshaft postion sensor air gap OK? Yes_|[ Goto next step i) [ee page FIA] | Nio | Repair or replace crankshaft posi [3 __| Is fuel injector ateyindor No.t OK? Yes_| Goto next step = BOI YN | Reps or elec el necor at xiggar aE | Is fuel system OK? Yes_[ Goto nex step Ce 'page FI=10] [Wo | Repair or replace as necessary | 5 _||Is exhaust gas recirculation control system OK? Yes [Goto next stop - a I=128" No _| Repair or replace as necessary 6 [Is compression at cylinder No.1 normal? Yes [Go to next step | a 7] Erase diagnostic trouble code from memory. Is same | Yes _| Replace POM (a page FI=351 ee Ne eee teaeecneeena [Tie Temporary system malfunction * During normal driving F1-67Fi ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble code No, P0302 CYLINDER 2 MISFIRE DETECTED ‘Symptom PCM input signal from crankshaft postion sensor signal for eylinder No is Iwegular * Low fuel + Low battery positive voltage Possible cause | + Fuel system malfunction + Insufficient comprossion in cyinder No.2 * Crankshaft position sensor airgap incorrect + Exhaust gas recirculation system maifunction * Ignition system of cylinder No.2 matfunction sree INSPECTION ‘ACTION 1 ]ls ignition sytem of cylinder No 2 OK? Yes [Gotonotaep No | Repair or replace as necessary 2 |e erankahaf poston soreor at gap OK? Yes [Go to next step No _ | Repair or replace crankshaft position sensor. is fol injctor at finder No2 OK? Yes [Goto nentsien = No | ens or repos fe npior at ypderio? | 4 [Is fuel system OK? Yes | Go to next step e ‘No | Repair or replace as necessary 5 is exhaust gas ocicuation conafavston OK? | Yos [Goo nox sop TE aoe ETI | airs a TOOT © [Te compression at finder No noma Yes [Goto nex step No [Repair or replace as necossary 7 | Erase diagnostic trouble code from memory. Is same | Yes | Replace PCM ‘code No, present alr rechockng? a * During nonmal driving F1-68ON-BOARD DIAGNOSTIC SYSTEM F1 Diagrostcvoublo [CYLINDERS MISFRE DETECTED Seis . Posts Sympton | PEMingl snl om cava poston sven Salo cinder NO emer + litin sytem of cy No. atnctn reer 1 Lim baton poste vtago Posstiecause 7 Frater nlncton 1 autigetconoreson nce oa 1 Gansta pean sero gap ineoet + Eshuuat ge octeuton sytem mation are INSPECTION eTION 7] ios sor a ender Ho A? Yeo [Goioronien [#s" section G] To [Repair orelace a racesany 2 | |s crankshaft position sensor air gap OK? Yes | Go tonext step ~ Te poe FIA] To] Rapa or ela rantahah pospnaansar 3 [i tao at ondor No Or Yoo [Goto nontaep To Repair place on jada a dare fe aoe =I) @ | Isfuel system OK? ‘Yes | Go to next step ~ To Repel or place an nave as garesininon comm | Yes_| Got wasp eo Fi=123 | No Repair or replace as necessary &[isconprosonal oink No noma? Yes" [6010 noxtsop To | Repairs evap 7] ras Sapreats ois cdo rom manors lesane [Yeo | place Po ‘Sie soso afer ochckng? vee Ponce * During normal driving F1-69F1 ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble | CYLINDER 4 MISFIRE DETECTED code No. PO304 ‘Symptom PCM input signal from crankshaft position sensor signal for cylinder No.4 is irregular q| * Ignition system of eylinder No.4 maifunction + Low fuel + Low battery positive voltage Possible cause | + Fuel system malfunction + Insuficient compression in cylinder No.4 ‘= Crankshaft position sensor air gap incorrect + Exhaust gas recirculation system maltunction INSPECTION ‘ACTION Is ignition system of eylinder No.4 OK? Yes [Goto noxt step I fis section] ‘No _| Repair or replace as necessary 2 | Is crankshaft position sensor air gap OK? Yes [Goto next step te peas Fas] Repair or replace crankshaft position sensor 3 _[lefuelinjecor a cyinder Nod OR? Yes [Goto next step mas 20 No er i “4 [Is fuel system OK? Yes | Go to next step [= page E1=10] No | Repair orrolace as necessary © | exhaust gas recreation cont 2 |"Yee | Goto nent step No _| Repair or replace as necessary @ [Is compression at cylinder No.4 normal? Yes | Go to next step [eS section B1] | Wo [Repair or replace as necessary 7 | Erase diagnostic trouble code from memory. is same | Yes _| Replace PCM ‘code No. present after “rechecking? hia aap eyeen amore * During normal driving F1-70ON-BOARD DIAGNOSTIC SYSTEM F1 Diagnostic trouble | CRANKSHAFT POS SENSOR—CKT MALFUNCTION ‘code No. P0335, ‘Symptom 'No NE signal input from crankshaft position sensor for 1.5 seconds while engine running * Crankshaft position sensor malfunction Possible cause | + Open or short circuit in wiring from PCM terminal 4€ to crankshatt position sensor terminal B + Open or short circuit in wiring from PCM terminal 4H to crankshaft position sensor terminal A ‘STEP INSPECTION ‘ACTION 7 | Does crankshaft position sensor connector or PCM | Yes _| Repair or replace connector ‘connector have poor connection? Tos | Goomaiap 2 _ | Disconnect crankshaft position sensor connector. | Yes | Go to next stop Ie there continuity between hamess side connector terminal B and PCM terminal 47 Is there continuity between harness side connector | No | Repair or replace wiring hamess terminal A and PCM terminal 4H? 3 ||s crankshaft position sonsor air gap OK? Yes [Goto next step "Cr page FIA een No | Replace crankshaft position sensor or crankshaft pulley page F145 Fa section BT | Ie erankshaft position sensor OK? Yes _|Gotonextstep (= page Fi-aa) No _ | Replace crankshaft position sensor Erase diagnostic trouble code from memory Yos | Replace PCM [et page Fi=35) le corneas Na: Drogas ate rece nee 'No _ Intermittent poor connection of hamess or connector (Repair connector andior hamess) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-71Fi ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble ‘code No. PO340 ‘CAMSHAFT POS SENSOR—CKT MALFUNCTION ‘Symptom [No SGT signal input from camshaft position sensor for 42 seconds while engine running '* Camshaft position sensor malfunction ae Possible cause | * Open or shor circuit in wiring from PCM terminal 4 to istbutr terminal © + Open or short cut in wing from PCM terminal 4A to dstrbutr terminal A STP INSPECTION ‘ACTION 1 | Does dstibutor connector or POM conneciorhave | Ves _| Ropar or replace connector poor connection? no] Geena ap 2 | Disconnect ditibutor connector Yes |Gotonext stop Is there contnuty between hamess side connector terminal C and PCM terminal 4? Is there continuity batwoen hamess side connector | NO | Repair oreplace wiring hamess terminal A snd PCM terminal 4X? ‘3 | Is camshaft position sensor OK? Yes_[Gotonext siop [= page Fi-44] (x page FI=I8] [No [Replace aistibutor section | Erase dagnostio rouble code from memory. Yee _|ieplace POM (pase F135] eee No | Intermittent poor connection of hamess or connector (Repair connector andior harness) CALIFORNIA EXCEPT CALIFORNIA HARNESS SIDE CONNECTOR (VIEW PROM REvRN OF CONNEETOR) F1-72ON-BOARD DIAGNOSTIC SYSTEM Fi Diagnostic trouble | EGR—FLOW MALFUNCTION ‘code No. P0400 Sana Esaus gas reieuaion system dos ot uncon nomaly because of lec ormecharicl [~ “> EGR valve maifunction ~ ‘+ EGR boost sensor malfunction + EGR boost sensor solenoid valve matfunction ‘+ EGR valve position sensor malfunction Possible cause | EGR solencd valve (vacuum, vont maltunction Clogs of leakage in piping connecting following units EGR boost sensor, EGR boost sensor solenoid valve and intake manifold Air cleaner housing, EGR solenoid valve (vent) and EGR valve Intake manifold, EGR solenoid valve (vaccum) and EGR valve |Warm up three way catalytic converter sTeP INSPECTION r “AGTION 7] agnostic Wouble oe for EGA solenoid valve | Ves | Gary oul ingpedtion as required according to dlag- (vaccum, vn), EGR boost sensor solenoid valve or hoste trouble code EGR boost aoneor depayed? Nop omnea sep 2 [Ie EGR valve postion sensor OKT Yes _|Gotornext step No _|Repairor replace EGR vane (iE pagaFicoe] 3” | Check each hose for damage, Aro they OK? Yes [Go tonext step ‘intake mantld-EGR solenoid valve (vent) EGR colenod valve vent) EGR solenoid valve | ey Wo | Ropar or replace as neceseary + EGF solenoid valve (vaccum)-EGR valve [EGR boost sonsor OK? Yes | Goto next step [page F150] : [= page FI-50] |i | Ropiace EGR boost sensor [& magn FI-Sa] Check each hose for damage. Are they OR? Yes |Go tonext etep "gh passage--COM poest sence solonotd vaNve {EGR boost Sencor EGR boost sensor solonad” yo] Repair orrepace as necessary vane 6 | Erase diagnostic trouble code from memory Is same | Yes _| Replace POM code No. present after ‘rechecking? Se * During driving when coolant temperature is over 85° G ( 131° F} and engine speed is over 1,000 rpm (10 kmh (6.2 mph }) Diagnostic rouble | BANK 1 CAT EFFICIENCY BELOW LIMIT ‘code No. P0420 ~ Warm up three way catalytic converter deterioration Symptom ‘+ Leakage in exhaust system | STEP INSPECTION ‘ACTION 1 [Is heated oxygen sensor (Rear) OK? ‘Yes | Replace warm up three way catalyic converter = page FIaS | Wo] opin Teted oxygen seo" eal Fi-73F1 ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble | EVAP SYSTEM—MALFUNCTION code No. POdao Symptom | Evapoave esi cant syste dss rl Rnclon somal Bocazo oT rechancal alo + Purge solenoid valve * Charcoal canister malfunction ** Check valve maifunetion ‘+ Fuel vapor valve malfunction ‘+ Clogs oF leakage in piping connecting following units Intake manifold and purge solenoid valve urge solenoid valve and charcoal canister Charcoal canister, check valve, and fuel vapor valve Possible cause ‘STEP ___ INSPECTION. ‘ACTION 1 [15 POM terminal 4T voltage OK? Yes [Goto next step (page Faz) No | Inapect purge solenoid valve 2 | Are evaporative emission contol systemrelaied | Yes _|Go to noxt step hose free of clogs and leakage? No _ | Repair or replace as necessary 3 |e charcoal canister OR? Yes Goto next tep No _| Repair or replace as necessary 4 | Is check valve OK? Yes _| Go to next step_ a No | Repair or replace as necessary 3 [is rotovervave OR? Yes [Go tonoxt stop No _ | Repair or replace as necessary © | Erase diagnostic wauble code fem memory Yes [Replace POM (page Fas | Is same code No. prosent after “rechecking? Nou] Tonponny aca nenraie ~ During diving alter engine warm up F1-74ON-BOARD DIAGNOSTIC SYSTEM Fi EVAP SYSTEM—PURGE CTRL VALVE CKT—MALF See ee sree eum Soe — [Sa SST a SE a TT ~ Purge solenoid valve malfunction ee | STEP INSPECTION ‘ACTION a i ‘Does purge solenoid valve connector or PCM con- ‘Yes _| Repair or replace connector corneaneae foal eesteoe 1s POM terminal 4T voltage OK? Yes | Goto step 6 . Disconnect purge solenoid valve connector. Yes _|Gotonext step ‘Slgratoree dis comaderemnaia | le eer page carina ome cH fs sy ion rae ceo {terminal B and PCM terminal 47? No | Repair or replace wiring hamess. eee a 6 | Erase diagnostic trouble code from memory. Is same | Yes | Replace PCM [Le page F1-35 | code No. present after rechecking? No _| Intermittent poor connection of hamess or connector (Repair connector andior hamess) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-75Fi ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble code No. P0450 EVAP SYSTEM—PRESSURE SEN MALFUNCTION Input voltage from fuel tank pressure sensor is below 0.1 V or above 4.8 V when ignition swith is oe tumed on ‘+ Fuel tank pressure sensor mattunction — . possible cause | OPen or shor crcutin wing from PCM termina Ito fuel tank pressure sensor erinal C 1 Open o short ciealtin wring fom PEM terminal 3 fo ual tank pressure senso terminal 8 £ Open ecu in wing from PM ternal 80 to fuel tank pressure senaor terminal A STEP INSPECTION "ACTION 1 _ [Does fel ank pressure sensor connector or POM | Yee | Repair or replace connector ‘connecter have poor connection? ete | 2 [le POM terminal GA vokage OR? Yes [Gow steps 7 4 F140] |" No | Go to next stop 3 [Are fel tank pressure sensor and connecting hose | Yes [Repair or replace free of reezing, breaking, and clogs? he | Disconnect fuel tank pressure sensor comesior [Yes [Go to next step Tum igen switch 19 ON. iether 5V atRamess| Ke — [check for open a how Sean wing hares {Gea tral 3h Fuel tan pressure sensortemi tale) & |e oe tank pressure sensor OK? Yes | Replace uo ak pressure sensor No [Repair or replace wiring harness © | Erase agnostic vouble code rom memory. Iesame | Yes | Replace PCM = page FE ‘code present after rechecking? No _ | Intermittent poor connector of hamess or connector (Repair connector andior hares) HARNESS SIDE CONNECTOR (VIEW FROM BEHINO OF CONNECTOR) F1-76ON-BOARD DIAGNOSTIC SYSTEM. F1 Diagnostic trouble ‘eode No. P0500 VEHICLE SPEED SENSOR—MALFUNCTION ‘Symptom Towle pad sonsr slang ram vail apood sont while ang Possible cause * Speedometer sensor malfunction * Open or shor circuit in wiring from ignition switch to speedometer sensor * Open or shor circuit in wiring from speedometer sensor to GND + Open or shor circuit in wiring from spoodometer sensor to vehicle speed sensor + Open oF short circuit in wiring fram vehicle speed sensor to PCM torminal 1M INSPECTION Does vehicle speed sensor connector or PCM con- ‘ACTION 1 Yes _| Repair or replace connector, rector have poor connection? nea lceieiaa 7 2 | IG PCM terminal 1M voltage OK? Yes_| Goto step 5 No [Goto next step = 3 | Is there continuity between vehicle speed sensor | Yes | Gotonextstep 7 terminal and PCM terminal 1M? ee 4 | Is there continuity between vehicle speed sensor | Yes | Gotonextstep ‘and speedometer sensor terminals ont] | No | Repair or replace speedometer sensor and wiing hamess | Erase diagnostic rouble code trom memory. Yes _| Replace PCM 5 page Fi-35 Salata oN tale 'No _ | Intermittent poor connection of harness or connector (Repair connector and/or hamess) F1-77FA ON-BOARD DIAGNOSTIC SYSTEM Do ae coves orere aunnrce mei ea cympton [= Nostale aise a coil oon * Open or short circuit is observed in idle air control system when ignition switch is turned on '¢ Idle air control valve malfunction gags Poastioace |: LOD RAEI a contol toi At iy rl i Soars ed ules teat cnet car 1 Does idle air control valve connector or PCM con- Yes | Repair or replace connector | cae aaron Ysa a 2 |Is PCM terminal 40 voltage OK? Yes | Goto step 6 | “No _|Go to next step al pets omer ema | ferences nal A) 7 [imeem mee nesta awa [eon oa aamseaaraaa ee Y= _|eerenste ~~5 | Is there continuity between idle air control valve con- | Yes [Goto next step ~ neotor terminals A and B? No | Replace BAC valve ‘= page Fi-7_ 6 _ | Erase diagnostic trouble code from memory. Yes_| Replace POM [page F1-351 ie ee Ne ree ores eee 'No | Intermittent poor connection of hamess or conrector | Resa aa Ti HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-78ON-BOARD DIAGNOSTIC SYSTEM F1 Diagnostic trouble ‘code No. P0703, ‘TORQUE CONVIBRAKE SW—MALFUNCTION ‘symptom ‘No signal input from brake ewitch to PM when brake pedal is Kept depressed for mare than 33 ‘seconds, or signal input when brake pedal is not depressed Possible cause * Brake switch maifunction + Open of short circuit in wiring from PCM terminal 1 to brake switch terminal + Open of short circuit in wiring from brake Switch terminal to battery terminal | STEP INSPECTION ‘ACTION 7 _ | Does brake switch connector or PCM connector Yes _| Repair or replace have poor connection? non Geman 2 [Is POM terminal 10 voltage OK? Yes _|Gotostep4 No _| Go to next step Is same code No. present after rechecking? 3 [ls there continuity between brake switch terminal | Yes | Check for open or short circuit in wiring harness. and PCM terminal 1@? Cary — Brake ewich Check akg {es section] No _ | Repair or replace wiring hamess, 4 | Erase diagnostic trouble code from memory Yes_| Replace POM (pace Fi-35] 'No | Intermittent poor connestion of hamess or connector (Repair connector and/or hares) Diagnostic trouble ‘code No. P1000 ‘MORE DRIVING NEEDED TO COMPLETE TEST Possible cause Following diagnostic trouble code detection conditions not satisfied Diagnosed circuit — Code No. = Excessive time to onter closed loop fuel control POIs (Oz sensor circuit malfunction O10 (2 sensor heater circuit malfunction POTSS Fuel rim matfunction POt70 Random misfire detected Gylinder 1 misfire detected P0300, P0301 Cylinder 2 misfire detected Po3o2, P0303 Gylinder 3 misfire detected Po304 Cylinder 4 misfire detected Exhaust gas recirculation flow malfunction PO400 Catalyst system efficiency below threshold P0420 Evaporative emission control system malfunction POs0 Note + DTC No.P 1000 wil be deleted while the MILis illuminated. Fi-79FA ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble | HO2S 11—INVERSION ‘code No. P1170 Heated oxygen sensor (Front) signal remains unchanged for more than 20 seconds aller engine is = In feedback zone . ‘= Heated oxygen sensor (Front) malfunction Possible cause —_|+ Open or short circuit in wiring from heated oxygen sensor (Front) terminal A to PCM terminal 30. + Intake-air system, fuel system, ignition system maltunction STEP INSPECTION ACTION 1 [Does heated oxygen sensor (Front) connector or | Yes _| Repair or replace connector PCM connector have poor connection? No |Gotonex stop 2 [Is PCM terminal 3G voltage OK? Yes_|Goto steps No [Goto next step 3 | Disconnect heated oxygen sensor (Front) connector, | Yes |Go to next step Is there continuity between hamess side connector _— terminal A and PCM terminal 30? No _| Repair or replace wing hamess 4 _ [Are folowing units OK? Yes. | Replace neated oxygen sensor Front Fuel injector = = a Pressure regulator = = Mass airflow sensor ca Engine coolant temperature sensor [eS page Fi=38] | No | Repair or replace ‘Spark plug [er section. Air suction (Air Fuel ratio rich or lean) ‘5 | Erase diagnostic trouble code from memory. Is same | Yes _| Replace POM [= page Fi-3s code No. present after rechecking? No _| intermittent poor connection of harness of connector (Repair connector andior harness) HARNESS SIDE CONNECTOR, (VIEW FROM BEHIND OF CONNECTOR) F1-80ON-BOARD DIAGNOSTIC SYSTEM F1 Diagnostic rouble J EGRBSOPEN OR SHORT code No Priae (eons Input vag rom EGR boost sensors below 02 Vor above 48 V when ignition sich tuned = '* EGR boost sensor malfunction possibie cause |= Open Orshocroutin wing om POM trina Ho EGR boost sensor terminal 8 + Spun orshot retin ng om PCM minal ito EO booet senor omar £ Ghen saat n wring lam PEM tominal 30 to EGR boost sensor torminal A ser INSPECTION ‘ACTION 7 | Bows EGR boost sao connector or POM cannes: [Yes | Ropalroreplace conocer ferhave por conecton? ee 3 |e Pow erminal volage OR? Yes [Govosteps : [=e page F1=40] [No | Goto noxt stop 3 | Bicones EGR bast sear comes Yee | Goro noxtaep Isto SV atnamese side conectorterminai cr | NO | Gheck or open or shor crc wing hamass. 7 |e coninaybawoon connecior imal And |_Yos | Rolaco EGR boos senor Pom tame ‘No | Repair or replace wiring hamess. 3 — | Base diagnostic wou cod om mony Yer Replace PCM [pase Fae] Lederer ratchet te ‘No | Intermittent poor connection of hamess or connector (Repair connector andior harness.) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-81F1 ON-BOARD DIAGNOSTIC SYSTEM Diagnostic trouble | PRC—OPEN OR SHORT ‘Open or short circuit is observed in PRC solenoid valve system when ignition switch is tumed on * PR solenoid valve malfunction Possible cause | + Open or short circuit in wiring from PRC solenoid valve terminal A to main relay terminal D * Open or shor circuit in wiring from PRC solenoid valve terminal B to PCM terminal 4J ‘STEP 2 INSPECTION ‘ACTION : 1 [Does PRC solenoid valve connecior or POM con- | Yes _| Repair or replace connector nector have poor connection? ofa Golenameisn 2 [Is POM terminal 4J voltage OK? Yes [Gotostepé (Se page FI=41] [No [Gotonextstep ‘3 | Disconnect PRC solenoid valve connector. 1, Le _[Sotonent step fora ctmat oa | nal A) ee i= [Scere SC eeiarto No [Replace PRG solenoid valve Ll page Fi-18] ‘code No. present after rechecking? No _| intermittent poor connection of hamess or connector (Repair connector andior hamess) 3. al HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-82ON-BOARD DIAGNOSTIC SYSTEM F1 Diagnostic trouble ‘code No. P1345, ‘SGC SIGNAL—NO SGC SIGNAL, ‘Symptom No SGC signal input from camhalt position sensor while engine rotates five cycles Possible cause > Camshaft postion sensor malfunction + Open or shor circuit in wiring from PCM terminal 4A to distributor terminal A + Open oF shot ctcut in wiring from PCM terminal 4G to distributor terminal D STEP. INSPECTION ‘ACTON | Baws cael poston conearcomodar or POM — | Ves _| Repro replace connor Conecir haven! somacion? Se = Disconnect distributor connector. Yes _| Go to next step Volagea fame ee conetertemina'se | N©_ | Chiko oponor shor etn wig Famess Ther contrulybenvon arose side comecar | Veo _|Go omen top ‘end Gand PEM tra 0? rs ee es 7s PEM torminal 46 vokage OR? Yee [Gow steps No | Gotonext step 3 [is camshal potion snsor ORF Yeo” | Goto next sep CE pe FT=HE [No Ropiaco dtibar T= aeaion a] 6 | Erase dagneteWoubo cada om manny camo | Yoo | Relace POM TE paseras] ‘code No. present after rechecking, ‘No | Intermittent poor connection of hamess or connector : (Ropar sonfecor anor hae) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-83F1 ON-BOARD DIAGNOSTIC SYSTEM Diagnostic rouble | EGRS—OPEN OR SHORT ‘code No. P1402, ee Trp yohnge em EGR valve postin snooris below 0.2 Vor above 48 V when ignition swith ie . ‘+ EGR valve position sensor matfunction ‘+ Open or short circuit in wiring from EGR valve position sensor terminal B to PCM terminal 31 ‘+ Open or short circuit in wiring rom EGR valve position sensor terminal C to PCM terminal 3) ‘+ Open or short circuit in wiring trom EGR valve position sensor terminal A to PCM terminal 30 ‘STEP INSPECTION ACTION =] 1 [Does EGR valve poston sensor connector or PCM | Yes | Repair or replace connector connector have poor connection? melee 4 2 ]is POM terminal 31 votago OK? Yes | Goto step7 Tea loa = No [Goto next step Yes | Goto next step Possible cause 3 _ | Disconnect EGR valve position sensor connect ‘Turn ignition switch ON Is there 6 V at hamess side connector orn No | Gheck for open or shot clrcultin wring hamess ee (PCM terminal 31 — EGR valve position sensor ‘er- minal 8) 4 | Is there continuity between hamess side connector | Yes | Goto next step terminal C and PCM terminal 37 nie | Beier eats ne ane 5 | Is there continuity between hamess side connector | Yes _|Go to next step terminal A and PCM terminal 30? No | Repair or replace wiring herness 6 | Is resistance of EGR valve position sensor OK? Yes [Goto next step No [Replace EGR valve 7 _ | Erase diagnostic vouble code from memory. Is same | Yes _| Replace POM ‘code No. present after rechecking? 'No _ [Intermittent poor connection of harass or connector (Repair connector andior harness) HARNESS SIDE CONNECTOR (VIEW FROM BEHIND OF CONNECTOR) F1-84