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GENERALINFORMATION2-2
DIAGNOSISANDTESTING 2-2
SECONDARYSPARKTEST2-2
CYLINDERDROPTEST 2-2
ADJUSTMENTS 2-3
IGNITIONCOIL 2-3
TESTING 2-3
REMOVAL&INSTALLATION 2-3
POWERTRANSISTOR
(Ignition Module) 2-4
REMOVAL&INSTALLATION 2-4
DISTRIBUTOR 2-4
REMOVAL&INSTALLATION 2-4
INSTALLATION 2-4
CRANKSHAFTANDCAMSHAFTPOSITION
SENSORS 2-5
DISTRIBUTORLESS IGNITION
SYSTEM 2-5
GENERALINFORMATION2-5
DIAGNOSISANDTESTING 2-5
ADJUSTMENTS 2-5
IGNITIONCOIL(s) 2-5
TESTING 2-5
REMOVAL&INSTALLATION 2-6
POWERTRANSISTOR
(IGNITIONMODULE) 2-7
REMOVAL&INSTALLATION 2-7
CRANKSHAFTANDCAMSHAFTPOSITION
SENSORS 2-7
FIRING ORDERS 2-7
CHARGING SYSTEM 2-8
GENERALINFORMATION2-8
ALTERNATORPRECAUTIONS2-8
ALTERNATOR
TESTING 2-8 2-8 I
REMOVAL&INSTALLATION 2-9
REGULATOR 2-10
REMOVAL&INSTALLATION 2-10
STARTING SYSTEM 2-10
GENERALINFORMATION2-10
STARTER 2-10
TESTING 2-10
REMOVAL&INSTALLATION 2-11
SENDING UNITS 2-11
ENGINECOOLANTTEMPERATURE
SENDINGUNIT 2-11
TESTING 2-11
REMOVAL&INSTALLATION 2-11
OIL PRESSURESENDINGUNIT 2-12
TESTING2-12
REMOVAL&INSTALLATION 2-12
.~ P.X I_ - “, .- I .-., IS ” .~.I .r
2-2 ENGINE
ELECTRICAL
nn
Theignitionsystemonthe1.5L,1993-961.8L,
2.OLSOHC,1994-982.4LSOHC,3.OLSOHC,and
3.5Lenginesusesa pointless typedistributor,whose
advance mechanism is controlledbytheEngineCon-
trolUnit(ECU).Onthe1.5L,1.8L,2.4Land3.5Len-
gines,thedistributorhousesa builtin ignitioncoil
andignitionpowertransistor. The2.8LSOHCand
3.OLSOHCenginesutilizea separate coilandtran- 9105zp11
sisterassemblv. Fig. 1 This spark tester looks iust like a Fiu. 2 This spark tester has an adjustable
WhentheignitionswitchisturnedON,battery spark plug, attach the clip to ground and air-gap for measuring spark strength and
voltageisappliedtotheignitioncoilprimarywinding. crank the engine to checkfor spark testing different voltage ignition systems
Astheshaftof thedistributorrotates,signalsare
transmittedfromtheoowertrain controlmoduletothe .
ignitionpowertrarrsistor.Thesesignalsactivate
the
powertransistorto causeignitioncoilprimarywind-
ingcurrentflowfromtheignitioncoilnegative termi-
nalthroughthepowertransistor to groundrepeatedly.
Thisinterruptioninduces highvoltageintheignition
coilsecondarv windinas, whichis divertedthrouah
thedistributor,
sparkplugcableandsparkplug6
ground,thuscausingignitionin eachcylinder.
I l;h.4-
SECONDARYSPARKTEST !'$,L".~
>,%
Fig. 4 This spark tester is the easiest to use
If See Figures 1 thru 6 91rJszp12 iust alace it on a plug wire and the spark
Thebestwayto performthisprocedure isto usea Fig. 3 Attach the clip to ground and crank voltage is detectedand the bulb on the tof
sparktester(available
-. atmostautomotive partsstores). the engine to checkfor spark I I will flash with each pulse
I nreetypesotsparktestersarecommonly available.
TheNeonBulbtypeisconnected tothesparkplug
wireandflasheswitheachignitionpulse.TheAirGap
typemustbeadjusted totheindividualsparkpluggap
specified fortheengine. Thelasttypeofsparkplug
testerlookslikea sparkplugwitha grounding clipon
theside,butthereis nosideelectrode forthesparkto
jumpto.Thelasttwotypesof testersallowstheuserto
notonlydetectthepresence ofspark,butalsothein-
tensity(orange/yellow isweak,blueisstrong).
1. Disconnect a sparkplugwireatthesparkplug
end.
2. Connect theplugwireto thesparktesterand
groundthetesterto anappropriate locationonthe
engine.
3. Cranktheengineandcheckforsparkatthe
tester.
4. If sparkexistsatthetester,theignitionsystem
is functioning properly.
5. If sparkdoesnotexistatthesparkplugwire,
performdiagnosis of theignitionsystemusingindi-
vidualcomponent diagnosis procedures, 1. Placethetransaxlein P,engage theemer- and althoughit cannotkill you, it will shock
gencybrake,andstarttheengineandletit idle. you and it doeshurt.
CYLINDERDROPTEST 2. Usinga sparkplugwireremoving tool,prefer-
ablythepliertype,carefullyremovethebootfrom 3. Theenginewill sputter,runworse,andpossi-
p See Figures 7, 8, and 9 oneof thecylinders. blynearlystall.If thishappensreinstalltheplugwire
Thecylinderdroptestis performed whenanen- i ’ andmoveto thenextcylinder.If theenginerunsno
ginemisfireis evident.Thistesthelpsdetermine differently,
orthedifference is minimal,
shuttheen-
whichcylinderis notcontributingtheproperpower. gineoffandinspectthesparkplugwire,sparkplug,
Makesure your body is free from touching andif necessary, performcomponent diagnosticsas
Theeasiestwayto performthistestisto removethe any part of the car which is metal. Thesec-
plugwiresoneata timefromthecylinderswiththe coveredinthissection.Perform thetestonall cylin-
ondaryvoltage in the ignition systemis high dersto verifythewhichcylindersaresuspect.
enginerunning.
ENGINEELECTRICAL
2-3
91c6zp16
lion-2.4L SOHCengtne
L tflgn
tension
terminal
,3=%@ @
Fig. 11 Distributor connectorpins and loca- Fig. 12 Dlstrfbufor connectorplus and loca-
tio&.5L engine
2-4 ENGINEELECTRICAL
2. Installthedistributorin theenginesotherotor
is alignedwiththematchmark onthehousingandthe
housingis alignedwiththematchmark ontheengine.
4. Attachthedistributorharness connectors.
Beforeremoving thedistributor,positionNo.1 5. Installthedistributorcap.
‘cylinderatTopDeadCenter(TDC)onthecompres- 6. Connect thenegativebatterycable.
sionstrokeandalignthetimingmarks. 7. Adjusttheignitiontimingandtightenthehold-
1. Disconnectthenegative batterycable. downnutto 6 ft. Ibs.(11Nm).
2. Remove theignitionwirecover,if equipped.
3. Detachthedistributorharness connector. Timing Dlsturbed
4. Remove thedistributor
capwithall ignitionwires
stillconnected.
Remove thecoilwire,if necessary. 1. Installa newdistributorhousingO-ringand
5. Matchmark therotorto thedistributorhousing lubricate
withcleanoil.
andthedistributor housingtotheengine. 2. PositiontheenginesotheNo.1 pistonis at
6. Remove thehold-down nut. TopDeadCenter(TDC)of itscompression stroke
4.‘ Remove theretainingscrewsandcoilfromen- 7. Carefullyremove thedistributorfromtheengine. andthemarkonthevibrationdamperis alignedwith
gine. 0 onthetimingindicator.
5. Installation
is thereverseof theremovalproce- INSTALLATION 3. Alignthedistributorhousingandgearmating
dure. marks.Installthedistributorintheenginesotheslot
6 See Figures19 and 2g or grooveof thedistributor’s
installation
flangealigns
withthedistributorinstallation
studintheengine
Timing Not Disturbed block.Besurethedistributorisfullyseated.Inspect
alignmentof thedistributorrotormakingsurethero-
1, Installa newdistributorhousingO-ringand tnr ic dinnnd with thn qn,c$nn of the Nn innitinn
REMOVALS&
INSTALLATION lubricate
withcleanoil.
Remove
theretainingscrewsandpowertran-
n0
ECU/PCM,which calculatesthe sequenceof fuel in-
jection and enginerpm.
Whenthe ignition switch is turned ON, battery
voltage is appliedto the ignition coil primarywind-
ing. As the crankanglesensorshaft rotates,ignition
signals are transmittedfrom the multi port injection
control unit to the powertransistor.Thesesignals
activatethe powertransistorto cause ignition coil
primarywinding currentto flow from the ignition
coil negativeterminalthroughthe powertransistor 93152go9
to ground or be interrupted,repeatedly.This action
induceshigh voltagein the secondarywinding of
Fig. 21 Measuring ignition coil primary re-
the ignition coil. Fromthe ignitroncoil, the sec- sistance-1.6L and 1990 2.OL DDHCen-
ondarywinding current producedflows throughthe gines
spark plug to ground,thus causingignition in each
cylinder. . Fig. 23 Measuringthe primary ignition coil
For No 1 and No. 4
resistance-1991-93 2.OLDOHCenoines
I I
Referto DiagnosisandTestingunderDistributor FOR NO 1 AND NO. 4 CYLINDERS
Ignition in this section, Id
89572914
Fig. 26 Measuring ignition coil secondary 89572g13
resistance-1997-00 1.8L and 1994-00 Fig. 28 Measurethe primary coil resistance Fig. 27 Measure the secondary resistance
2.4L SOHCengines between the connector terminals-2.4L betweenthe towers of the coil-2.4L DOHC
DOHCenaine engine
1. Disconnect thenegative batterycableandigni-
tioncoil harness connector.
2. Measure theprimarycoil resistance asfollows: . 3. To.checkthesecondary coil resistance,
per- d. If themeasured valueis withinstandard al-
a. Measure theresistance between terminals termthetollowmg: lowance, thereareno brokenwiresor shortcir-
3 and2 (coilsat theNo.1 andNo.4 cylinder a. Taganddisconnect thesparkplugwires cuits.
sides)of theignitioncoil,andbetween terminals fromtheignitioncoil. 2. Measure theresistance of thesecondary igni-
3 and1 (coilsat theNo.2 andNo.3 cylinder b. Measure thesecondary resistance of the tioncoilasfollows:
sides). coil between thetowersof eachindividualcoil. 3. Insert
the leadof theohmmeter between coil
b. Compare readingto thedesiredprimary c. If theresistance
is notbetween 20.1-27.3 packcylinderterminals:
coil resistanceof 0.70-0.86ohms. kilo-ohms,replacetheignitioncoil. l Between coil terminalsl-4 for Co11A
3. Measure thecoilsecondary resistance asfol- l Between coil terminals2-5 for CoilB
3.OLDOHCEngine l Between coil terminals3-6 for CoilC
lows:
c. Detachtheconnector fromtheignitioncoil. 6 See Figures28 and 29 e. Measure theresistance andcompare to the
d. Measure theresistance between thehigh- desiredspecifications of 11.3-l5.3kilo-ohms.
voltageterminals for theNo.1 andNo.4 cylin- 1. Measure theresistanceof theprimaryignition f. If themeasured valueis withinstandard al-
ders,andbetween thehigh-voltage terminals for coilasfollows: lowance, therearenobrokenwiresor shortcir-
theNo.2 andNo.3 cylinders. a. Unplugtheelectricalconnector atthecoil cuits.
e. Thedesiredsecondary coil resistance is pack.Usinganohmmeter, measure theresis- g. If theactualreadingdiffersfromthede-
11.3-15.3kilo-ohms. tancebetween theterminalsof thecoil pack, siredspecification, replacetheignitioncoil pack.
4. Ifthereadings arenotwithinthespecified NOTTHEWIREHARNESS. Measure there-
value,replacetheignitioncoil. sistancebetween terminals: REMOVAL&INSTALLATION
l 2-3 for CoilA
1997-00 1.8L and 1999-00 2.4L SOHC l l-3 for Coil B 1.6L, 2.OLDOHC,and 2.4L DOHCEngines
Engines l 4-3 for CoilC
b. Measure theresistance andcompare to the # See Figure 30
+ See Figure 25 desiredspecifications of 0.67-0.81ohms.
c. If theactualreadingdiffersfromthede- 1. Disconnect thenegativebatterycable.
1. Measure theresistance
of thesecondarv
, iani-
- siredspecification, replacetheignitioncoil. 2. Tagandremove thesparkplugwiresfromthe
tioncoilasfollows: ignitioncoil bygrippingthebootandnotthecable.
a. Insertoneof thetestleadsintothesec-
ondaryignitioncoil terminalof thecoil.
b. Touchthesecondtestleadto terminal1 or
terminal2 of thecoil connector.
c. Measuretheresistance andcompareto
thedesiredspecifications of 9.4-12.8kilo-
ohms.
d. If themeasured valueis withinstandard al-
lowance, thereareno brokenwiresor shortcir-
cuits.
e. If theactualreadingdiffersfromthede- Fig. 28 Measuring ignition coil primary re-
siredspecification,replacetheignitioncoil. sistance-3.01 DOHCengine
2.4L DDHCEngines
# See Figures26 and 27
1. Disconnect thenegativebatterycable.
2. Tochecktheprimarycoil resistance, perform
thefollowing: I
a. Detachtheelectricalconnector fromthe ~::::L “1
coil pack. I
2
cemer Cwer
Scabpiwcabk
b. Usinganohmmeter, measure theresis- 3
I
5
SPaark piug
lgnlllancoll
Powertran3lrtor
tancebetween thetwoterminalsof thecoil,NOT 6
I
ThrotflsDcnv*w
Crankanglelmsm
THEWIREHARNESS. 93152g11
c. If theresistance
is notbetween 0.74-0.90 Fig. 29 Measuring ignition coil secondary Fig. 30 Ignition system component loca-
ohms,replacetheignitioncoil. resistance-3.01 DOHCenaine lions-l .6L and 2.OLDOHCengines
ENGINEELECTRICAL
2-7
3. Detachthe electricalconnectorsfor the COIL
4. Removethe retainingscrewsand coil from en-
gine.
5. Installationis the reverseof the removalproce-
dure.
wires beforedisconnectingany of them.Also, before (4693) engines :ig. 34 2.OL (4663) SOHC engine
removal,comparethe currentwiring with the accom- Firing order: l-3-4-2 ‘iring order: l-3-4-2
panyingillustrations.If the currentwiring doesnot Distributor rotation: Counterclockwise Distributor rotation: Clockwise
match,makenotesin your bookto reflecthow your
engineis wired.
.
2-8 ENGINEELECTRICAL
Front Front
of the of the
Vehicle Vehicle
792!33g26
Fig. 36 2.4L (4664) DDHCengine with dis- Fig. 39 3.OL(6672) SDHCand 3.5L (6674)
lributorless ignition engines :ig. 40 3.OL(6672) DDHCengine
Firing order: l-3-4-2 Firing order: l-2-3-65-6 Yring order: l-2-3-4-5-6
gistributorless ignition system Distributor rotation: Counterclockwise Iistributorless ignition system
To install:
10. Installthealternator
to thevehicleandcon-
nectthewiringharness. :z RtEWtiW~-~
3EGE$llaf
11 Install
.._. -.. the
.._ -alternatnr wnnnrt hrxket tn _.P
.._..._._. --rT-.. -.--..-. .- thp
I.._
vehicleandtightenthebracketmounting
boltsto
specifications.
ENGINE
ELECTRICAL
2-11
l.unVeMlil(GSflWtWJ
2.Gwwator harness con- connectk,,,
3. Engme OS, level d,pst,&
4 Generator
9315zp19
93152PM
Starter motor rotates engrne slowly * Battery charge low or battery . Charge or replace battery Noisy alternator * Loose mounbngs . Ttghten mountrng bolts
defecttve . Loose drive pulley . Tighten pulley
- Defective crrcurt between battery + Clean and ttghten, or replace . Worn beanngs * Replace alternator
and starter motor cables * Brush notse . Replace alternator
* Low load current * Bench-test starter motor Inspect * Internal circuits shorted (Hugh . Replace alternator
for wom brushes and weak pitched whrne)
brush springs.
Squeal when starting engtne or . Glazed or loose belt * Replace or adfust belt
* Hugh load current . Bench-test starter motor Check
engtne for fncbon, drag or coolant acceleratmg
rn cylinders. Check nng gear-to- Indicator light rematns on or . Broken belt . Install heft
prnton gear clearance. ammeter rndrcates drscharge . Broken or dksconnected wares - Repatr or connect Waring
(ejrgrne runmng) * Internal aitemator problems * Replace alternator
Starter motor wrll not rotate engrne * Battery charge low or battery * Charge or replaoe battery
. Defectrve voltage regulator . Replace vottage regulator/alternator
defecttve
* Faulty solenord . Check solenoid ground Reparr or Car Irght bulbs contmually bum out- * Alternator/regulator overchargtng . Replace voltage
replace as necessary. batter-v needs water conbnually regulatoriatternator
* Damaged drive pnron gear or * Replace damaged gear(s)
ring gear Car kghts flare on acceleratton . Battery low * Charge or replace battery
* Starter motor engagement weak . Bench-test starter motor . Internal alternator/regulator . Replace alternator/regulator
. Starter motor rotates slowly wtth . Inspect dnve yoke pull-down and problems
high load current pornt gap, check for worn end
Low voltage output (alternator lght * Loose or worn belt . Replace or adjust beit
bushtngs. check m-g gear clear-
fltckers conbnually or ammeter * Dkly or corroded connecttons . Clean or replace connecttons
ance * Replace alternator/regulator
needle wanders) * Internal alternator/regulator
. Engine setzed * Repatr engk7e
oroblems
Starter motor dnve wrll not engage . Defecbve contact pant assembly * Reparr or replace contact pornt
(solenotd known to be good) assembly
. Inadequate contact pornt assembly + Repatr connectron at ground screw
ground
- Defeckve hold-In co11 * Replace field w~ndrng assembly
Starter motor dnve wtli not - Starter motor loose on flywheel . Ttghten mounttng bolts
dtsengage houstng
. Worn drive end bustng . Replace bushtrg
* Damaged nng gear teeth . Replace ring gear or dnveplate
* Drive yoke return spnng broken or . Replace spnng
mtsstng
Starter motor dnve d&engages * Weak drive assembly thrust spnng * Replace dnve mechamsm
prematurely * Hold-tn co11defeckve . Replace field wtndtng assembly *
Low load current - Worn brushes . Replace brushes
* Weak brush springs * Replace spnngs