Hyundai Sonata 1991 Shop Manual

HYUnCRI 1991 Shop Manual son HYUnDRI SOndTd Shop Manual FOREWORD This shop manual is intended for use by service t...

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HYUnCRI

1991 Shop Manual

son

HYUnDRI

SOndTd Shop Manual FOREWORD

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

APR. 1990. Printed in Korea

CONTENTS TITLE

SECTION

General Information

00

Lubrication and Maintenance

10

Engine

20

Cooling System

25

Engine Electrical System

27

Intake & Exhaust System

28

Emission Control System

29

Fuel System

31

Clutch

41

Manual Transaxle

43

Automatic Transaxle

45

Drive Shaft and Front Axle

49

Front Suspension

54

Rear Suspension

55

Steering System

56

·Brake System

58

Body (Interior and Exterior)

60

Body Electrical System

90

Air Conditioning SyStem

97

Appendix (Electrical wiring system)

-

HVUnOr:l1 MOTOR COMPr:lnV

• •• •• •• •• •• •• •• •• ••

HVunDR MOTOR COMPRnY

Printing: APR. 28. 1990

Seoul Korea

Publication No.: YS-900406 Printed in Korea

GENERAL INFORMATION-

GENERAL INFORMATION GENERAL INFORMATION HOW TO USE THIS MANUAL

YOOCAOA

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

section

includes

the

essential

removal,

installation,

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

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

DEFINITION OF TERMS Standard Value (Service standard)

YOOCBOA

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

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

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

NOTE, WARNING AND CAUTION

YOOCCOA

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

00-2

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

VEHICLE IDENTIFICATION NUMBER

YOOCEOA

Vehicle identification number consists of 17 digit.

®~®®®G)@®®©@ @@@@@(D

~TTTTTTTT 1)

2)

3)

4)

5)

6)

7)

8)

I

10)

9)

1)

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

2)

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

3)

Body type F : 4 Door sedan

4)

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

5)

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

o:

6)

Engine type o : 1795 cc F : 1997 cc

7)

Check digit

8)

Product year L-1990 M-1991

9)

10)

3

Supper deluxe (GLS)

Passive system

S : 2351 cc T : 2972 cc V6

N-1992 P-1993

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

GENERAL INFORMATION ENGINE IDENTIFICATION NUMBER LOCATION VOOCfOA

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

ENGINE IDENTIFICATION NUMBER Engine identification number consists of 10 digits.

@®®®®

@@@@@G)

TTTTT 1)

1)

2)

3)

4)

I 6)

5)

Engine fuel G : Gasoline

2)

Engine range

4 : In line 4 cycle 4 cylinder 3)

Engine development order

A-Z: 4)

Engine capacity

M 1795 cc P : 1997 cc

S : 2351 cc T : 2972 cc V6

5)

Product year

6)

Engine production sequence number 0‫סס‬oo1-999999

00-4

YOOCGOA

GENERAL INFORMA, ;O~~ PROTECTION OF THE VEHICLE

YOOCHOA

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

A WORD ABOUT SAFETY

YOOCJOA

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

Block wheels. Use only specified jacking positions.

3.

Support vehicle with safety stands (rigid jacks)

4.

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

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

SPECIAL TOOLS

YOOCLOA

Use special tools when they are required.

00-5

GENERAL INFORMATION

REMOVAL OF PARTS

YOOCMOA

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

DISASSEMBLY

YOOCNOA

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

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

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

I J

~,

-U

00-6

GENERAL INFORMATION

PARTS

YOOCPOA

HYUnCRI

When replacing parts, use HYUNDAI genuine parts.

Genuine Parts

Made

REASSEMBLY

In

YOOCOOA

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

Oil seals

2.

Gaskets

3.

a-rings

4. 5.

Lock washers Coller pins (split pins)

6.

Plastic nuts

Q

o

Depending on where they are; 1.

Sealant should be applied to gaskets.

2. 3.

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

ADJUSTMENTS

VOOCROA

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

00-7

GENERAL INFORMATION

ELECTRICAL SYSTEM 1.

YOOCSOA

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

2. 3.

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

4.

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

RUBBER PARTS AND TUBING

YOOCTOA

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

PRECAUTIONS FOR A CATALYTIC CONVERTER YOQCUOA

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

1.

Use only unleaded gasoline.

2.

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

3.

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

4.

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

5.

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

6.

Avoid coasting with

7.

braking. Do not

dispose

of

ignition turned off and prolonged used

catalyst

contaminated with gasoline or oil.

00-8

along

with

parts

GENERAL INFORMATION VEHICLE LIFT AND SUPPORT LOCATiONS

YOOCVOA

.. . -.

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

The jack provided with the vehicle (for reference)

Rigid rack (Safety stand)

Garage jack (floor jack)

Single-post lift

Double-post lift

Free wheel type auto lift

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

00-9

LUBRICATION AND II MAINTENANCE SCHEDULED MAINTENANCE TABLE

2

RECOMMENDED LUBRICANTS AND CAPACiTIES

6

MAINTENANCE SERViCE

7

SCHEDULED MAINTENANCE TABLE

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

NO

DESCRIPTION

MILES X 1000

7.5

15

22.5

30

37.5

45

52.5

60

KILOMETER X 1000

12

24

36

48

60

72

84

96

MONTHS

5

10

20

30

40

50

60

70

R

R

R

R

R

R

R

R

EMISSION CONTROL ITEMS

1

ENGINE OIL AND FILTER

2

VALVE CLEARANCE (JET VALVE ONLY)

3

FUEL FILTER

R

4

FUEL LINES AND CONNECTIONS

I

5

VACUUM, CRANKCASE VENTILATION HOSES

I

6

FUEL HOSE, VAPOR HOSE & FUEL FILLER CAP

I

7

AIR CLEANER FILTER

R

R

8

SPARK PLUGS

R

R

I

I

I

I

GENERAL ITEMS 1

DRIVE BELT (WATER PUMP AND ALTERNATOR)

I

I

2

ENGINE COOLANT

R

R

3

TIMING BELT

4

MANUAL TRANSAXLE OIL

5

AUTO TRANSAXLE OIL

6

BRAKE FLUID

7

BRAKE HOSES, LINES

8

REAR BRAKE DRUMS/LININGS/PARKING BRAKE

9

BRAKE PADS, CALIPERS, ROTORS

R I I

R

I I

R I

I

R I

I

I

I

I I

I

R

I I

10

EXHAUST PIPE CONNECTIONS, MUFFLER & SUSPENSION BOLTS

I

11

STEERING GEAR RACK, LINKAGE & BOOTS

I

I

12

WHEEL BEARING GREASE

I

I

13

DRIVESHAFTS & BOOTS

10-2

I

I

I

I

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

MAINTENANCE ITEM

MAINTENANCE OPERATION

MAINTENANCE INTERVALS Every 3.000 miles (4,800 km)

DRIVING CONDITION A. B. C. F. H

ENGINE OIL AND FILTER

R

AIR CLEANER FILTER

R

SPARK PLUGS

R

BRAKE PADS. CALIPERS. ROTORS

I

More frequently

C. D. G. H

REAR BRAKE DRUMS/LININGS

I

More frequently

C. D. G. H

STEERING GEAR RACK LINKAGE & BOOTS

I

DRIVESHAFT & BOOTS

I

or 3 months

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

Every 7.500 miles (12.000 kml or 6 months

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

C. E B. H

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

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

10-3

SCHEDULED MAINTENANCE TABLE

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

DESCRIPTION

NO

I KILOMETER

I MILES

X 1DOD

X 1DOD

I

12

I

I

75

15

R

R

24

I I

36 22.5

I I

72

84

96

30

I 60 I I 37.5 I

45

52.5

60

R

R

R

R

R

48

EMISSION CONTROL ITEMS (or every 6 months)

1

ENGINE OIL AND FILTER

2

JET VALVE CLEARANCE

3

FUEL FILTER

4

FUEL LINES AND CONNECTIONS

I

5

VACUUM, CRANKCASE VENTILATION HOSES

R

6

FUEL HOSE, VAPOR HOSE & FUEL FILLER CAP

R

7

AIR CLEANER FILTER

R

R

8

SPARK PLUGS

R

R

I

I

I

R

I

I

I R

GENERAL ITEMS

1

DRIVE BELT (FOR WATER PUMP, ALTERNATOR AND PIS)

2

ENGINE COOLANT

3

TIMING BELT

(or every 2 years)

R

R R I

4

MANUAL TRANSAXLE OIL

5

AUTO TRANSAXLE FLUID

I

R

I I

6

BRAKE HOSES, LINES

I

I

I

7

BRAKE FLUID

8

REAR BRAKE DRUMS/LININGS/PARKING BRAKE

9

BRAKE PADS, CALIPERS, ROTORS

(or every 2 years)

R I

I R

I I

R

I I

I

10

EXHAUST PIPE CONNECTIONS, MUFFLER & SUSPENSION BOLTS

I

I

11

STEERING GEAR RACK, LINKAGE & BOOTS

I

I

12

WHEEL BEARING GREASE

I

13

DRIVESHAFTS & BOOTS

10-4

I

I

J I

J

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

MAINTENANCE ITEM

MAINTENANCE OPERATION

MAINTENANCE INTERVALS Every 3.000 miles (4.800 km)

DRIVING CONDITION

ENGINE OIL & FILTER

R

CLEANER FILTER

R

More frequently

C. E

SPARK PLUGS

R

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

B. H

BRAKE PADS. CALIPERS. ROTORS

I

More frequently

C. D. G. H

REAR BRAKE DRUMS/LININGS

I

More frequently

C. D. G. H

STEERING GEAR RACK LINKAGE & BOOTS

I

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

C. D. E. F

DRIVESHAFT & BOOTS

I

or 3 months

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

A, B. C. F. H

C. E. F

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

10-5

RECOMMENDED LUBRICANTS AND CAPACITIES

RECOMMENDED LUBRICANTS AND CAPACITIES RECOMMENDED LUBRICANTS Parts

Specifications

Remarks

Engine oil

API classification SF, SF/CC or SG

For further details, refer to SAE viscosity number

Manual transaxle

Hypoid gear oil, SAE 75W-85W

Automatic transaxle

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

Brake

Brake fluid DOT 3 or equivalent

Power steering

ATF DEXRON@II

Wheel bearing

SAE J310a Multipurpose grease NLGI grade #2 or equivalent

Coolant

Ethylene glycol base for AI radiator

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

SAE J310a Multipurpose grease NLGI grade #2 or equivalent

Door hinges

Engine oil

Pedal bearing, strut insulator bearing

SAE J310a Chassis grease NLGI grade #0 or equivalent

MOPAR ATF PLUS TYPE 7176 is recommended lubricant

LUBRICANTS CAPACITIES Description

Capacities

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

3.5 0.4 3.9 7.0 2.5 5.8 0.9

10-6

lit lit lit lit lit lit lit

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

Remarks

MAINTENANCE SERVICE

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

Y10EAOA

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

4.

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

5. 6. 7.

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

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

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

Y10E8OA

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

10-7

MAINTENANCE SERVICE 4.

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

VALVE CLEARANCE (Check and adjust as required)

Y10ECOA

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

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

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

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

3. 4. 5. 6.

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

10-8

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

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

MAINTENANCE SERVICE 7.

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

Exhaust

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

No.1

No.2 No.3

No.4

Intake

8.

9.

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

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

.Exhaust

• No. 1

No.2

No.3

No.4

Intake

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

Apply a coating of specified sealant

Cylinder head

10-9

MAINTENANCE SERVICE

CHECKING TENSION

AND

ADJUSTMENT

OF

V-BELT Vl0EDOA

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

REPLACEMENT OF THE AIR FILTER

Y10EEOA

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

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

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

COOLING SYSTEM

Y10EFOA

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

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

10-10

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

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

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

REPLACEMENT OF IGNITION CABLES

Y10EHOA

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

Correct

Incorrect

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

10-11

MAINTENANCE SERVICE

REPLACEMENT OXYGEN SENSOR

Yl0EJOA

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

Hexagon nut

Housing

'-~'~

.

""'

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

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

FUEL SYSTEM Tank, Lines And Connections 1.

Check for damage or leakage in the fuel

Y10EKOA

lines and

connections.

2.

3.

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

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

10-12

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

Air cleaner

Air intake hose

Throttle body

Surge tank

Ventilation hose PCVvalve

-

_..

~

Injector

4 - - Intake manifold

Blow-by gas _ Fresh air

--~

1.

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

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

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

10-13

MAINTENANCE SERVICE EVAPORATIVE EMISSION CONTROL SYSTEM Y10EMQA.

1.

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

Air filter

\

Fuel check valve

Filter Fuel pump Fuel filler cap (Vacuum relief)

Fuel injector

Overfill limiter (Leveling pipe)

Purge-control solenoid valve :

I Thermal expansion volume

t

--

Engine Canister Charcoal-i+--l_

...Jr~-- Fuel

._. . . ,

-

Fuel pump

Filter ... - -

CANISTER (Replace)

Yl0ENQA

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

10-14

Purge air

__

Fuel vapo(

MAINTENANCE SERVICE

MANUAL TRANSMISSION (Inspect oil level)

Y10€POA

mm (in.)

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

TRANSAXLE OIL (Replace) 1. 2. 3.

Y10EQOA

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

AUTOMATIC TRANSAXLE (Change fluid)

Y1QEROA

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

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

10-15

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

INSPECT STEERING LINKAGE 1.

Y10£SOA

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

2.

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

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

Yl0ETOA

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

POWER STEERING FLUID LEVEL (Inspect fluid level)

Y10EUOA

1.

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

10-16

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

Yl0EVQA

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

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

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

I J

REAR WHEEL BEARINGS (Inspect for grease leaks)

YlOEXOA

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

INSPECT BRAKE LINE 1. 2. 3.

Y10EVOA

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

.. 10-17

MAINTENANCE SERVICE FRONT DISC BRAKE PADS

Yl0EZOA

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

2.0 mm (0.079 in.)

REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS Yl0FAOA

1.

2.

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

Checking the brake shoes for wear.

Thickness of lining "B" [Limit]

0.8 mm (0.031 in.)

CHECKING THE BRAKE FLUID LEVEL 1.

Yl0FBOA

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

10-18

MAINTENANCE SERVICE

CHANGING OF THE BRAKE FLUID 1. 2.

lOfCOA

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

3.

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

DOT 3 or equivalent

CHECKING OF THE TIRE INFLATION PRESSUE

Yl0FDOA

Check the Tire inflation Pressures as Follows.

TIRE INFLATION PRESSURE (Check with Tires Cool) Tire size

Front

Rear

P185170 R 14 P195170 R 14 (AI wheel)

207 kPa (30 psi)

207 kPa (30 psi)

T125170 0 15 (Temporary)

414 kPa (60 psi)

414 kPa (60 psi)

ROAD TEST

Yl0FEOA

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

Check Check Check Check Check Check

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

10-19

ENGINE GENERAL

2

ENGINE MOUNTING

20

ENGINE AND TRANSAXLE ASSEMBLY

23

TIMING BELT

26

ROCKER ARMS AND ROCKER ARM SHAFTS

33

CAMSHAFT

38

CYLINDER HEAD

39

VALVES AND VALVE SPRINGS

42

JET VALVE ASSEMBLy

47

FRONT CASE. OIL PUMP AND COUNTER BALANCE SHAFT

50

PISTON AND CONNECTING ROD

56

CRANKSHAFT

61

CYLINDER BLOCK

66

OIL PRESSURE SWITCH AND SENDER ASSY

69

GENERAL

GENERAL

Y20CAOB

SPECIFICATIONS Description

Specification

General Type Number of cylinders

4

In-line OHV, OHC

Bore

86.49-86.53 mm (3.405-3.4067 in.)

Stroke Total displacement Compression ratio

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

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

Limit

8.5 1-3-4-2 750 ± 100 BTDC 5° ± 2°

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

20° 64°

Valve overlap Intake valve duration

40° 264°

Exhaust valve duration Jet valve duration Engine oil pressure

264°

At engine idle speed Compression pressure Between cylinder

20-2

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

GENERAL

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

Specification

Limit

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

0.1 mm (0.004 in.)

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

44.025 mm (1.733 in.)

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

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

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

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

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

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

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

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

20-3

GENERAL

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

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

20-4

Specification

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

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

Limit

GENERAL

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

Specification

Limit

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

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

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

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

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

-0.2 mm(-0.0079 in.)

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

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

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

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

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

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

20-5

GENERAL

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

20-6

Nm

kg.cm

Ib.ft

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

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

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

300~400

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

Y20CBOA

GENERAL

SPECIAL TOOLS Tool (Number and name)

09212-32000 Counter balance shaft

Y20CCOA

Illustration

Use Removal of front bearing of counter balance shaft

bearing puller

09212-32100 Counter balance shaft

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

bearing puller

09212-32200

Installation of counter balance shaft bear-

Counter balance shaft

ing front and rear (use with 09212-

bearing installer

32300)

09212-32300

Removal and installation of counter bal-

Guide plate

ance

shaft

rear

bearing

(use

with

09212-32100,09212-32200)

09214-32000

Installation of the crankshaft front oil seal

Crankshaft front oil seal installer

09214-32100

Installation of the crankshaft front oil seal

Crankshaft front oil seal guide

09221-32001 Cylinder head bolt wrench

09221-21000 Camshaft oil seal installer

Removal and tightening of the cylinder head bolt

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

20-7

GENERAL

Tool .

illustration

(Number and name)

Use

09221-21100 Camshaft oil seal guide

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

09222-21001 Valve spring compressor

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

09222-21300 Jet valve socket wrench

Removal and installation of jet valve

09222-21400 Jet valve spring plier

For assembling and reassembling jet valve

09222-21500 Jet valve stem 'seal installer

Installation of the jet valve stem oil seal

09222-32100 Valve stem oil seal installer

Installation of the valve stem oil seal

Removal and installation of the valve

09222-32200 Valve guide installer

09231-32000 Crankshaft rear installer

20-8

guide

Installation of the crankshaft rear oil seal oil

seal

GENERAL

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

Illustration

Use Removal and installation of the piston pin

and

09246-32000 Auto lach adjuster holder

Retaining of auto lash adjuster

09246-32100 Auto lash adjuster retainer

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

09246-32200 Air bleed wire

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

09246-32300 Leak down tester

Test for leak down of auto lash adjuster

09260-32000 Oil pressure switch wrench

Removal and installation pressure switch

of

the

oil

20-9

GENERAL

TROUBLESHOOTING

Y2OCDOA

Probable cause

Remedy

Worn main bearing Seized bearing Bent crankshaft Excessive crankshaft end play

Replace Replace Replace Replace thrust bearing

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

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

Camshaft knocking

Worn bearing Excessive end gear Broken cam gear

Replace Replace Replace

Timing belt noise

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

Adjust Replace Replace Replace Replace

Camshaft and valve mechanism knocking

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

Adjust Replace Replace Replace guide Replace Repair or replace

Compression too low

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

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

Symptom Knocking of and bearing

crankshaft

Piston and connecting rod knocking

Valve seat worn or damaged

Oil pressure drop

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

Check engine oil level Replace Replace Replace Change Repair Replace

Oil pressure too high

Oil relief valve stuck (closed)

Repair

20-10

GENERAL

Symptom

Probable cause

Remedy

Noisy valves

Incorrect auto-lash adjuster

Replace

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

Change Replace

Shortage of engine oil

Add or replace

Dirty engine oil Poor oil quality

Check oil level on daily basis Replace Use proper oil

Overheating Wrong assembly of piston with connecting rod

Repair or replace Repair or replace

Improper piston ring clearance Dirty air cleaner

Replace Clean air cleaner replace filter

Excessively

worn

cylinder

and piston

and

Insufficient oil supply

Check engine oil level

bearing noise

Thin or diluted engine oil Excessive bearing clearance

Change Replace

Damaged crankshaft bearing

Shortage of engine oil

Add or replace Check oil level on daily basis

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

Adjust or repair Use proper engine oil Repair or replace

Bearing improperly assembled Non-concentric crankshaft or bearing

Repair or replace Replace

Excessive engine rolling and

Loose engine mounting bracket

vibration

Broken engine mounting

Re-tighten Replace

Connecting

rod

and/main

insula~or

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

Clean Replace bearing and check engine oil lubrication system

Re-tighten

Loose rear roll stopper

Replace Re-tighten Replace Re-tighten

Broken rear roll stopper insulator

Replace

20-11

GENERAL

ENGINE TUNE-UP

1.

Checking Engine Oil Refer to Page

2.

Checking Air Filter Refer to Page

3.

20~ 13.

28~4.

Checking Drive Belt Refer to Page 25-7.

4.

Checking Battery Refer to Page 27-17.

5.

Checking Spark Plugs Refer to page 27-35.

6.

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

20-12

GENERAL

VALVE CLEARANCE ADJUSTMENT

Y20CEOA

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

TIGHTENING CYLINDER HEAD BOLTS 1.

"-

Y20CFOA

09221-32001

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

2.

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

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

¢

Front of engine

0

0

0

8

6

1

~

4

0

0 3

2

5

0

0

~

jj 20YOO2

CHECKING ENGINE OIL 1. 2.

Y20CGOA

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

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

MAX MIN 20Y003

20-13

GENERAL 3.

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

4.

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

SELECTION OF ENGINE OIL

Y20CHOA

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

Temperature range anticipated before next oil change

Recommended SAE viscosity number

20W

16

o

60

32

-50

10W

-40

-50

5W

-20

-40

-40

-20

-30 -20:~

-23

*1. *2.

-10

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

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

20-14

GENERAL

CHANGING ENGINE OIL

Y2OCIOA

1. 2. 3.

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

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

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

6. 7. 8.

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

REPLACING OIL FILTER

Y20CJOA

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

in, III

! :

U

I

i 20YOO5

filter.

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

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

.

~

Apply engine oil

20Y006

20-15

GENERAL

JET VALVE INSPECTION AND ADJUSTMENT

~/=

Y20CKOA

1. 2.

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

3. 4.

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

5.

Remove timing belt front upper cover.

6.

Timing mark (on cylinder head)

Timing mark (on camshaft sprocket) ~ .'

Turn crankshaft clockwise and align the camshaft sprocket 20Y007

timing mark.

7.

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

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

0.25 mm (0.010 in.)

NO.4 No 3

NO.2

NO.1

Exhaust valve side

8.

9.

20YOO8

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

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

Intake valve side

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

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

20-16

GENERAL

TIMING BELT TENSION ADJUSTMENT PROCE-

DURE

1. 2.

Y20CLOA

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

20YOi 1

3.

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

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

Timing mark

C,m,h," sprocket

4.

5.

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

Ir~/ Timing mark

~~ \~ I ,

'.

~

20Y012

Access cover

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

6.

Turn the crankshaft and the camshaft sprocket clockwise two teeth.

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

Two teeth

Timing mark

20-17

GENERAL 7.

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

Insert the screwdriver here 20Y015

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

Timing belt tensioner

~ 8.

III

20Y016

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

9.

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

Hook

Access cover

«=~:=-

Guides

20Y01S

20-18

GENERAL

TIMING BELT "B" TENSION ADJUSTMENT 1.

Y20CM3A

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

2.

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

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

3.

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

5-7 mm (0.200-0.276 in.)

20-19

ENGINE MOUNTING

ENGINE MOUNTING COMPONENTS

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

Engine mounting bracket

Transaxle mounting bracket

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

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

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

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

Front roll stopper Crossmember Center member

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

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

20-20

20Y022

ENGINE MOUNTING

REMOVAL

Y20DAOA

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

Engine Mounting 1. 2.

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

Transaxle Mounting 1.

Remove the transaxle mount bolt.

2.

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

3.

Front Roll Stopper 1. 2.

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

20-21

ENGINE

Rear Roll Stopper

MOUNTING-====~==-

~\~

roll stopper.

1

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

INSPECTION ITEMS

Transax Ie mount

F ont roll stopper assembly r £IT

Eng.One mount

Rear roll stopper . assembly

~

20Y028

20-22

ENGINE AND TRANSAXLE ASSEMBLY

ENGINE AND TRANSAXLE ASSEMBLY

Y20EAOA

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

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

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

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

20-23

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

20Y033

20. 21. 22. 23.

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

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

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

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

20Y036

20-24

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

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

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

20-25

TIMING BELT

TIMING BELT COMPONENTS

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

Power steering pump pulley

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

Key

Camshaft sprocket Timing belt \

Tensioner

Spacer

Gasket

(,)

/

\\

~J

I

'~I

1

Flange

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

Gasket

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

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

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

TORQUE

20-26

Nm (kg.em, Ib.ft)

20Y039

TIMING BELT

REMOVAL 1. 2.

3. 4. 5.

Y20FAOA

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

Water pump

Nut

Spring end F

r=.'L--- Bolt

Tensioner

20Y040

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

"Front Plug

~

Screwdriver (8 mm (0.3 in.) shaft)

-~

--~.

~-ff

Counter balance

-shaft

-.:J1;C Ylinder block

20Y041

9.

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

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

INSPECTION 1.

Y20FBOA

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

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

20Y043

20-27

TIMING BELT 2) 3) 4) 5)

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

~

~Crack

~ S'P'''~ 20Y044

/

6)

Side of belt badly worn

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

~

Separation

Rounded belt side

/;;;;

Abnormal wear (Fluffy canvas fiber) 20Y045

7)

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

8) Missing tooth

INSTALLATION

I t

~

20Y046

Y20FCOA

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

Crankshaft sprocket "8"

.. Crankshaft sprocket

20-28

eXpOSed}".

Tooth missing end canvas fiber exposed

Sprocket and Tensioner 1.

Rubber

Flange Crankshaft 20Y047

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

Right si lent shaft

Apply thin coat of oil

Oil sea!

Spacer

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

Chamfer 20Y048

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

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

/

..

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

Crankshaft sprocket

Flange Crankshaft 20Y049

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

9. Install spacer, tensioner and tensioner spring.

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

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

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

Tensioner spring

tighten bolts. Tightening torque Crankshaft pulley bolts

.

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

Water pump

20-29

TIMING BELT Timing Belt Installation Procedure 1.

Timing mark (on sprocket)

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

Timi~dO

(slot in front case)

2. 3.

4.

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

5.

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

6.

Check to ensure that timing marks are in alignment.

7.

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

20-30

5-7 mm (0.2-0.3 in.)

Timing mark (on front case)

TIMING BELT 8.

Move tensioner fully toward water pump and temporarily secure tensioner.

Water pump Nut

Bolt

Tensioner

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

20Y055

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

on front case.

Timing mark (notch in sprocket) 20Y056

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

20-31

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

Tension side

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

Tension side

20Y059

f

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

Approx. 14 mm (0.55 in.)

20Y060

20-32

ROCKER ARMS AND ROCKER ARM SHAFTS

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

® ®

Right rocker arm shaft

Rocker arm "D"

~"_

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

if

!

'

~ -.

·1

'i

Fmnt bea,;n. cap

. ~.

~

v

0.~

Rocker arm "D" / /

o

,

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

~ ~7'l

"

0,-,--~

:;;-~/

><

~Adjusting screw

'

~2J--RearbearingCap

l~l--.--'

.,~~::-ROCke,

~~ ~

a,m "8"

Bearing cap No, 4

~~ ~ Rocke' a'm "C" ~:~ ~j:J' ' Bearing cap NO~;cker arm "A" ,

'. - ~~»>" '1&1'

' ) / : ''''. 0

I ~ry", ()(i v ~~

~ ~

Rocker arm "B" Bearing cap No, 2

Rocker arm "e" Rocker arm "A"

TORQUE

Nm (kg.em, Ib.ft)

20Y061

20-33

ROCKER ARMS AND ROCKER ARM SHAFTS

SERVICE ADJUSTMENT PROCEDURE

Y2OGAOA

Bleeding Auto Lash Adjuster CAUTION Since the auto-lash adjuster is a precision part, use care to prevent entry of foreign substances such as dirt. Do not attempt disassembly of the auto-lash adjuster. Use clean Diesel .fuel for cleaning the auto-lash adjuster. 1.

Individual unit 1) Combine the auto-lash adjuster and the special tool (09246-32100), as shown in illustration, and immerse in Diesel fuel. 2) Using a special tool (09246-32200), lightly hold down the steel ball and move the plunger up and down 4 or 5 times. 3) Remove the air bleed wire and push the plunger strongly by finger. If it moves even slightly, repeat steps 1) and 2). If the plunger moves even after the steps have been repeated several times, replace the auto-lash adjuster.

09246-32200

CAUTION The fully bleed auto-lash adjuster should be held in an up-right position to make sure that the Diesel fuel in the adjuster is not spilled. Use care to make sure that dust and other foreign substances do not contaminate the adjuster. 2.

Engine assembly. After installing in the engine, if there is air in the auto-lash adjuster, abnormal noises may occur. If this happens, the air can be bleed and the noise eliminated by slowly racing the engine from idling speed to 3,000 rpm (for about 1 minute).

20Y062

3,000 rpm

Idling speed

Idling speed

----

1--

I·

About 1 minute 20Y063

Auto Lash Adjuster Leak-Down Test 09246-32300

Set a bleed auto-lash, adjuster in a special tool (09246-32300). After the plunger has'fallen slightly [0.2-0.5 mm (0.008-0.020 in.)], measure the subsequent fall-down rate. Standard leak-down rate: 3 to 20 seconds/mm [Gas oil, oil temperature 15-25°C (59-77°F)].

Auto-lash adjuster

20Y064

20-34

ROCKER ARMS AND ROCKER ARM SHAFTS NOTE If a leak-down tester is not available, check the auto-lash adjuster as follows. 1 . Check whether or not there is any abnormal noise with the engine idling (at normal operating temperature). 2. If there is abnormal noise, there may be a malfunction of the auto-lash adjuster's air bleeding. Bleed the air from the auto-lash adjuster, and then again check for abnormal noise while the engine is idling. 3. If there is still abnormal noise, replace the auto-lash adjuster.

20-35

ROCKER ARMS AND ROCKER ARM SHAFTS

REMOVAL

Y20GBOA

09246-32000

1.

Before removing the rocker arms and shafts assembly, use the special tool (09246-32000) to ensure that the auto-lash adjuster doesn't fall out. CAUTION

..

Put the rocker arms and auto-lash adjusters in order in cylinder No. separated places with clear distinction between the intake and exhaust ones to prevent confusion. 20Y065

INSPECTION

Y20GCOA

Rocker Arms 1. 2.

Check rocker arms for wear or damage. Replace if necessary. Check to ensure that oil holes are clear.

Oil hole

20Y066

Rocker Arm Shafts 1. 2.

Check rocker arm mounting portions of rocker arm shaft for wear or damage. Replace as necessary. Check to ensure that oil holes are clear.

Oil holes

~_601

[0 I

Rocker arm mounting portions

20Y067

INSTALLATION

Y20GDOA

Auto Lash Adjuster Insert the auto lash adjuster from below as illustrated, being careful not to spill the diesel fuel inside it. Then use the special tool (09246-32000) to prevent adjuster from falling while installing it.

20-36

ROCKER ARMS AND ROCKER ARM SHAFTS

Rocker Arms

Cap number (No front and rear)

Confirm identification mark and assemble correctly. Assembled cylinders

Intake

Exhaust

1 and 3

A

C

2 and 4

B

D

•

Timing belt side

Rocker arm shaft (right)

VVave • A • washer Front mark Rocker arm shaft Identification mark (left)

~

Rocker Arms Shaft

20Y069

Notch

Insert the rocker arm shaft into the front bearing cap so that the notch on the shaft faces up, and insert the installation bolt without tightening it.

Bearing Cap Caps 2,3 and 4 are of similar shape and require attention to the cap number (stamped on) during assembly.

Front bearing cap 20Y070

Rocker Cover Sealant to be applied

When rocker cover is installed, apply sealant to semi-circular packing and cylinder head top surfaces. Sealant Rocker cover

10 mm

Three-bond No.10 or equivalent

CAUTION Make sure that rocker cover bolts are tightened to specified torque. If they., are overtorqued. a deformed rocker cover or oil leakage could result. Tightening torque Rocker cover bolts

10 mm

(0.,3937 in.,~)~~;;;;;;;;6;t~~ (0.,3937 in.)

20Y071

. 4.9-6.9 Nm (50-70 kg.cm, 3.6-5.1 Ib.ft)

20-37

CAMSHAFT

CAMSHAFT COMPONENTS

Dowel pin Camshaft oil seal \

~

~

Cylinder head

0

20Y072

INSPECTION 1.

2. 3.

Y20HAOA

If following areas of camshaft are badly worn or damaged, replace. 1) Journals 2) Cam lobes 3) Fuel pump drive dam 4) Distributor drive gear teeth 5) Oil seal contacting surface If camshaft bearings are badly worn, replace cylinder head. If oil seal lip is worn, replace.

20-38

20Y073

CYLINDER HEAD

CYLINDER HEAD COMPONENTS 12-15 (120-150. 8.7-11) Exhaust manifold cover 15-20 (150-200, 11-14)

Exhaust manifold Exhaust manifold gasket Cylinder head bolt Cold engine: 88-98 (900-1000, 65-72) Hot engine: 98-108 (1000-1,100,72-82)

Intake manifold gasket

Cylinder head

Cylinder head gasket Intake manifold 15-20 (150-100. 11-14) Intake manifold stay 18-25 (180-250. 13-18)

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

20Y074

20-39

CYLINDER HEAD

REMOVAL

Y20lAOA

1.

Remove the intake manifold mounting bolts and nuts, and remove the intake manifold and gasket. 2. Remove the exhaust manifold mounting nuts and washers, and remove the exhaust manifold and gasket. 3. Remove cylinder head bolts in sequence as shown in illustration by using special tool (09221-32001). 4. Remove cylinder head and gasket from cylinder block.

¢

Front of engine

o 3

1

o

0 5 7

0

o

o

o

10

8

9

2

4

6

o

o

o

20Y075

INSPECTION 1.

2. 3.

:t2<:[

Y20lBOA

Remove scale, sealing compound and carbon deposits completely. After cleaning oil passages, apply compressed air to make certain that the passages are not clogged. Visually check the cylinder head for cracks, damage or water leakage. Check the cylinder head gasket surface for flatness with a straight edge and feeler as shown in illustration. Cylinder head flatness: Standard dimension Service limit

c

0

20Y076

Less than 0.05 mm (0.002 in.) 0.2 mm (0.008 in.)

Intake and Exhaust Manifolds 1. 2.

Visually check the manifold for cracks or damage. Check the EGR gas passage and water passage of intake manifold for clogging and clean if necessary.

INSTALLATION 1. 2. 3.

Y20lCOA

Clean both gasket surfaces of cylinder head and cylinder block. Confirm identification mark on cylinder head gasket. Direct gasket surface having identification mark toward cylinder head. CAUTION Apply sealant around the four oil drain holes of the cylinder head gasket as shown in illustration to improve the sealing effectiveness.

20-40

E

/Sealant

.~

SECTIONA-A

CYLINDER HEAD

-----------------------------------------_.............4. 5.

Install cylinder head bolts. Starting at top center, tighten all cylinder head bolts to V2 of specified torque in sequence as shown in illustration, using special tool (09221-32001).

¢

Front of engine

~"---I

o

o 6

0 1

0 3

0 I 9,

10

4

2

5

7

8

o

I

o

0

0

0

,I

i

/

'--

6.

20;07[,

Torque all cylinder head bolts to specification in same sequence. Tightening torque Cylinder head bolts Cold [At engine coolant temperature is approximately 20°C (68°F)] . 88-98 Nm (900-1,000 kg.cm, 65-72 Ib.ft) Hot [At engine coolant temperature is approximately 80°C (176°F)] . 98-108 Nm (1,000-1,100 kg.cm, 72-80 Ib.ft)

7. 8. 9.

Clean gasket surface on intake and exhaust manifold and cylinder head. Install the new intake and exhaust manifold gaskets. Install the intake and exhaust manifold and tighten nuts and bolts to specified torque. Tightening torque Intake manifold and exhaust manifold bolts and nuts ............. 15-20 Nm (150-200 kg.cm. 11-14 Ib.ft)

20-41

I

VALVES AND VALVE SPRINGS

VALVES AND VALVE SPRINGS COMPONENTS

Retainer

lock~

Retainer

~

~

•

seal--~~

@

e

sp"ng---l

Spring

~

seat--~e>

Intake valve guide

~'-Jet

Exhau", valve g U ; d e - - \ j

valve assembly 18-22 (180-220, 13-16)

.~/

.~

..""- ·v· ~--Cylinder

Intake valve

seat~

Intakeval~

TORQUE

20-42

Nm (kg.em, Ib.ft)

head

~Exhaust valve seat

\----Exhaust valve

20YOBO

VALVES AND VALVE SPRINGS

REMOVAL

Y20JAOA

1. Using special tool (09222-21001), remove retainer lock. Then remove spring retainer, valve spring, spring seat and valve. NOTE Keep these removed parts in order so that they can be reinstalled in their original position.

20Y081

2.

Remove valve stem seals with pliers and discard. CAUTION Do not reuse valve stem seals.

20Y082

INSPECTION

Y2OJBOA

Valve Guides

• A

Check the valve stem-to-guide clearance. If the clearance exceeds the service limit, replace the valve guide with newoversize part. Valve stem-to-guide clearance Standard valve 0.03-0.05· mm (0.0012-0.0020 Intake 0.05-0.09 mm (0.0020-0.0035 Exhaust Service limit Intake 0.10 mm (0.0039 Exhaust 0.15 mm (0.0059

in.) in.)

20Y083

in.) in.)

Valve Guide Oversizes Size mm (in.)

0.05 (0.002) 0.5. 0.25 (0.010) 0.5. 0.50 (0.020) 0.5.

Size mark Cylinder head hole size mm (in.) 5

25 50

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

Stem diameter Guide inside diameter

20-43

VALVES AND VALVE SPRINGS Valve Springs Offset

1. 2.

Check free height of each valve spring and replace if necessary. Using a square, test squareness of each valve spring. If spring is excessively out of square, replace it. Standard value Free length 49.8 mm (1.961 in.) Load 32.9 kg/40.4 mm (72.5 Ib/1.591 in.) Out of squareness Max 2° Service limit Free length .48.8 mm (1.921 in.) Load 32.9 kg/41.4 mm (72.5 Ib/1.630 in.) Out of squareness Max 4°

1.5°

\-- : : : -----.-1 IFree height

\~_J 20Y085

Valve Seat Reconditioning 1. 2. 3.

When correcting, check valve guide for wear. Replace worn guide, and then correct seat ring. To correct valve seat, use Valve Seat Cutter and Pilot. After correction, valve and valve seat should be lapped lightly with a lapping compound.

Valve Seat Rings 1.

2.

Check valve seat for evidence of overheating and improper contact with valve face. Correct or replace seat ring if necessary. Valve seat contact width should be of specified value. Valve seat contact width Intake Exhaust

0.9-1.3 mm (0.035-0.051 in.) 1.2-1.6 mm (0.047-0.063 in.) 20Y087

20-44

VALVES AND VALVE SPRINGS

INSTALLATION 1.

2.

Y20JCOA

Install spring seats. Using special tool (09222-32100), lightly tap seal into place. Seal is installed in specified position, using special tool.

Valve stem seal

CAUTION Do not reuse old valve stem seals. NOTE Incorrect installation of seal will adversely affect lip and eccentricity, resulting in oil leakage down valve guides.

3.

4.

Apply engine oil to each valve. Insert valves into guides. Avoid insertion valve into seal with excessive force. After insertion, check to see if valve moves smoothly. Valve springs should be installed with the enamel coated side toward the valve spring retainer.

20Y088

~~~f=TI~~- Spring

retainer

Enamel~

coated side Spri ng_-C"I;=F=f'j~~....J ~~-

Stem seal

Spring seat 20Y089

5.

Using special tool (09222-21001), or suitable tool, compress spring and install retainer lock. After installation of valves, make certain that retainer locks are positively installed. CAUTION When spring is compressed with Valve Spring Compressor or suitable tool, check to see that valve stem seal is not pressed against the bottom of retainer. 20Y090

6.

To install the jet valve assembly, apply engine oil to the O-ring, jet body threads and seat surface. CAUTION Be sure to use a new o-ring. Apply engine oil

20Y091

VALVES AND VALVE SPRINGS 7.

Screw the jet valve assembly into cylinder head by hand. Tighten the jet valve to the specified torque with special tool (09222-21300) and a torque wrench while holding the spe- . cial tool in line with the the centerline of jet valve. Tightening torque Jet valve assembly

. 18-22 Nm (180-220 kg.cm, 13-16 Ib.ft)

20-46

JET VALVE ASSEMBLY

JET VALVE ASSEMBLY COMPONENTS Retainer I O C k - - . Valve spring retainer ~

Valve S p r i n g - - l Stemseal~

JetbOdY~ Ij1

18-22(180-220.13-161

JetV'lve--j O-ring

TORQUE

~

Nm (kg.em, Ib.ft)

REMOVAL

20Y093

Y20KAOA

1.

Remove the valve spring retainer lock using the special tool (09222-21400). 2. Remove the valve spring retainer and valve spring. CAUTION Do not mix up the combination of the jet valve body after the disassembly of the jet valve assembly, otherwise gas leakage and mulfunctioning may result. 20Y094

3.

Pull off valve stem seals with pliers and discard.

20-47

JET VALVE ASSEMBLY

INSPECTION 1.

Y20KBOA

Make sure that the jet valve slides smoothly in the jet body and has no play. CAUTION Combination of the jet valve and jet body should not be distrubed and the jet valve and jet body should be replaced as an assembly.

2. 3.

,

Gl';\0---\--~J

t

Check the valve head and valve seat for damage or seizure. Check the spring for sag, cracks or breakage.

20Y095

Standard value Jet valve Length Stem 0.0 Jet valve spring Free length Load

97.53 mm (3.840 in.) 4.3 mm (0.169 in.)

Offset 1.5 0

29.60 mm (1.17 in.) 3.5 kg/21.5 mm (7.7 Ib/0.846 in.) Free length

20Y096

INSTALLATION

Y20KCOA

09222-21400

1. 2.

Using special tool (09222-21500), install the stem seal. Apply engine, oil to the jet valve stem when installing it to the jet body. Take care not to damage the valve stem seal lip. Make sure that the jet valve stem slides smoothly in the body.

20Y097

3. 4.

Mount the valve spring and valve spring retainer on jet body. Compress the valve spring with special tool (09222-21400), using care not to damage the valve stem by the bottom of valve spring retainer. 5. While the spring is compressed, install the retainer lock.

20Y098

20-48

JET VALVE ASSEMBLY

JET VALVE CLEARANCE ADJUSTMENT

Y20KDOA

CAUTIONS 1. The cylinder head bolts should be retightened before attempting this adjustment. 2. If the jet valve clearance is not good, this will affect not only the exhaust gas level, but also be the cause of engine trouble. It is, therefore, important that the correct adjustment procedures be followed, as described here. 1. 2. 3. 4. 5. 6. 7.

Start the engine and allow it to warm up until the temperature of the coolant reaches 80 to 95°C (176 to 203°F). Check the ignition timing and idling speed, and adjust if necessary. Disconnect the air intake hose and air intake pipe. Remove the rocker cover. Remove timing belt front upper cover. Turn crankshaft clockwise and align with camshaft sprocket timing mark. Check that valve clearance indicated in the diagram is at the standard value. Jet valve clearance Hot engine Cold engine

8.

9.

Exhaust

No. 1

0.25 mm (0.0098 in.) 0.17 mm (0.0067 in.)

No.2

No.3

No.4

Intake 20Yl00

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

20Yl01

10. Rotate the crankshaft clockwise one complete revolution

Exhaust

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

+ No. 1

No.2

No.3

Intake

No.4

20Yl02

20-49

FRONT CASE, OIL PUMP AND COUNTER BALANCE SHAFT

FRONT CASE, OIL PUMP AND COUNTER BALANCE SHAFT COMPONENTS

Right counter balance shaft

11-13/110-130.8.0-9.4) Oil filter

Left counter balance shaft

Front case gasket Oil pump driven gear Oil pump drive gear

Oil filter bracket

Front case Gasket

Oil plug cap

15-22 (150-220.11-16)

Relief plug 39-49 (400-500. 29-36)

o

Gasket Relief spring Relief plunger

Counter balance shaft sprocket Oil pan Oil drain plug 34-44 (350-450. 25-33)

TORQUE

20-50

Nm (kg.em, Ib.ft)

5.9-7.8 (60-80, 4.3-5.8)

20Yl03

FRONT CASE, Oil PUMP AND COUNTER BALANCE SHAFT

REMOVAL

Y20LAOA

1. 2.

Remove the oil filter. Remove the oil pan. 3. Remove the oil screen and gasket. 4. Remove the relief plunger and gasket, and then take off the relief spring and relief valve from the oil filter bracket. 5. Remove the four bracket securing bolts and remove the oil filter bracket and gasket.

6.

Remove the oil plug cap from the oil pump portion of front case.

7.

Remove the left side cylinder block plug and insert a screwdriver with an 8 mm (0.32 in.) diameter shaft into plug hole. Screwdriver shaft must be inserted more than 60 mm (2.4 in.)

8.

Remove the oil pump driven gear and left counter balance shaft retaining bolt.

20-51

FRONT CASE. OIL PUMP AND COUNTER BALANCE SHAFT 9. Remove the front case mounting bolts and remove front case assembly. and gasket. 10. Remove the two counter balance shafts fr0!TI the cylinder block.

11. Remove the oil pump cov'er from the front case. 12. Remove the oil pump gears from front case.

INSPECTION

Y20LBOA

Oil Pump 1.

2.

Visually check gear contact surfaces of front case and oil pump cover for step wear. If front case or pump cover has excessive step wear, replace front case assembly. Check the oil 'passage of front case and oil pump cover for clogging and clean if necessary.

Counter Balance Shaft Check journals for wear or seizure. If excessive wear or seizure is evident, check bearing as well. If necessary, replace counter balance shaft, bearing or both.

Oil Seals Check front case oil seals for damaged or worn lips. Replace defective seals.

Relief Plunger and Spring 1. 2.

Insert the relief plunger into the oil filter bracket and check for smooth operation. Clean or repair if necessary. Check free length of spring, replace springs which are excessively collapsed. Relief spring free length

20-52

46.6 mm (1.835 in.)

20Y111

FRONT CASE, OIL PUMP AND COUNTER BALANCE SHAFT

COUNTER BALANCE SHAFT BEARING REPLACEMENT Y20LCOA 1. Using special tool (09212-32000), remove right counter balance shaft front bearing from cylinder block.

20Y112

2.

Using special tool (09212-32100), remove left counter balance shaft rear bearing from cylinder block. At this time, install special tool (09212-32300) on front surface of cylinder block to hold bearing puller.

3. Using special tool (09212-32200), install left counter balance shaft rear bearing attaching special tool (0921232300) as at the time of removal. CAUTION Before bearing is installed, apply engine oil to inner surface of bearing.

4.

Using special tool (09212-32200), install right counter balance shaft front bearing.

20-53

FRONT CASE, OIL PUMP AND COUNTER BALANCE SHAFT

INSTALLATION 1. 2.

Y20LDOA

Timing mark is found on reverse side of each gear. Install oil pump cover and tighten five bolts. Tightening torque Oil pump cover bolt . 15-18 Nm (150-180 kg.cm, 11-13 Ib.ft)

20Yl16

3.

Insert left counter balance shaft in oil pump driven gear and temporarily tighten bolt. 4. Install special tool (09214-32100) on crankshaft front end and apply engine oil around. Oil seal guide has a conical periphery. Install guide so that its smaller diameter end will face front of engine.

09214-32100

Right counter balance shaft

NOTE If crankshaft front oil seal is already mounted to front case, use this special tool (09214-32100) for protection of oil seal. 5.

Install right counter balance shaft into cylinder block.

6. 7.

Install new front case gasket. While inserting left counter balance shaft into cylinder block, install front case.

20Y117

Left counter balance

8.

II!P-:

Sh~~""')l -..~

;;~u .',~, ~ ",(U .

-<

1

I

I::;

).

,~

20Y118

Insert screwdriver through plug hole in left side of cylinder block to keep shaft in position, and then tighten.

Screwdriver .;:.... J/

,

20-54

f.

..,.

; . ., J .. "

20Yl19

FRONT CASE, OIL PUMP AND COUNTER BALANCE SHAFT 9.

Install oil filter bracket and gasket and tighten front case mounting bolts. Tightening torque Front case bolts . 20-26 Nm (200~270 kg.cm, 14-20 Ib.ft) Oil filter bracket bolt . 15-22 Nm (150-220 kg.cm, 11-16 Ib.ft)

L

= 20

(0.79)

L = 20 (0.79)

L=40 4,=~~~' (1.57) Oil filter bracket

10. Install plug cap.

Also tighten tensioner L=length of bolt mm (in.)

20Yl20

11. Install the relief plug and gasket, and tighten plug. 12. Install the oil screen and gasket.

13. Clean gasket surfaces of cylinder block and oil pan. 14. Apply sealant into groove of oil pan flange. CAUTION Make the first cut from the end of the nozzle furnished with sealant to apply sealant approx. 4 mm in thickness. After application of sealant, do not exceed 15 minutes before installing the oil pan.

Both hole portion 20Yl22

15. Install the oil pan and tighten the bolts to the specified torque.

20Y123

20-55

PISTON AND CONNECTING ROD

PISTON AND CONNECTING ROD COMPONENTS No.1 piston r i n g - - Q No.2 piston r i n g - Q Oil ring

(.:::::,)

l

Piston---~'-''"".:'-:::4

Piston p i n - #

Connecting rod-----jllil

Piston and connecting rod

assembl\~-~~-~"'''''I

~'----Bearing

~----Bearing

~---connecting rod cap

i

49-51 (500-520.36-38)

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

20-56

20Y124

PISTON AND CONNECTING ROD

REMOVAL

Y20MAOA

Connecting Rod Cap 1.

Keep bearings in order for corresponding connecting rods (according to cylinder numbers) for proper reassembly. 2. Remove the connecting rod cap holding nuts and then remove caps and big end lower bearing. 3. Push each piston-connecting rod assembly toward top of cylinder. 20Y125

Piston Pin Removal and Installation Procedures

Universal fork

1. Using the special tools (09234-33001), to disassemble and 2.

re-assemble the piston and connecting rod. Place the proper insert in the fork of the tool. Position the insert between the connecting rod and the piston.

20Y242

3.

Insert the proper removal tool through the hole in the arch of the tool. Remover

CAUTION Center the piston, rod and pin assembly with the removal arbor. 4.

Press the piston pin out of the connecting rod.

Support fixture Support fork_

20Y281

5.

Install proper pin guide (refer to application chart) through piston and into connecting rod. Hand tap pin guide into piston for proper retention. Drop piston pin into the other side of the piston.

Pin guide

CAUTION The pin guide centers the connecting rod in the piston. When the piston, connecting rod, piston pin and pin guide assembly are positioned on the fork of the tool, the pin guide will also center this assembly in the tool. If a pin guide that is too small is used, the piston assembly will not be located centrally in the tool, and damage may occur to the fork and/or the insert of the tool.

20-57

PISTON AND CONNECTING ROD 6.

7.

8.

Install piston assembly onto fork assembly of tool. Tool will support connecting rod at the piston pin. Be sure piston assembly is slid onto the fork until the pin guide contacts the fork ~nsert. Adjust the installing arbor to the proper length by turning the numbered sleeve on the lettered shaft until the specified alphanumeric setting from the application chart is obtained. Turn knurled nut to lock numbered sleeve on shaft. Insert the installing arbor through the hole in the arch of the tool. Press piston pin into the connecting rod until the sleeve on the installing arbor contacts the top of the tool arch. The pin guide will fall out of the connecting rod as the piston pin is pressed in.

Press ram - - - - - - 1 -

Installer

Support fixture Adapter Piston pin ~iston_ Connecting rod

CAUTION Do not exceed 5000 pounds of force when stopping the installing arbor sleeve against the arch.

~

Pin gUide/

20Y2B4

INSTALLATION 1.

Y20MBOA

Install spacer.

20Y131

2.

Install upper side rail. To install side rail, first put one end of side rail between piston ring groove and spacer, hole it down firmly, and then press down the portion which is to be inserted into groove with a finger as illustrated.

Side rail gap

CAUTION Do not use piston ring expander when installing side rail. 3.

Install lower side rail by same procedure as Step 2. 20Y132

20-58

PISTON AND CONNECTING ROD 4. 5. 6.

Using piston ring expander, install No.2 piston ring. Install No.1 piston ring. I Apply engine oil around piston and piston rings.

~~~~l

No.1

)1 ~

~B""'_ ~.

Tapered

~type

20Y133

7.

Position each piston ring end gap as for apart from neighboring gaps as possible. Make sure that gaps are not positioned in thrust and pin directions. 8. Hold piston rings firmly in a piston ring compressor as they are inserted into cylinder.

Gap of lower ~ side rail

V

Engine front

~

~

!l

+

~

NO.2 ring gap and spacer expander gap

NO.1 ring gap

~ ~

IJ

.h Gap or upper

~

side rail 20Y134

9. Make sure that front mark of piston and front mark (identification mark) of connecting rod are directed toward front of engine. 10. When connecting rod cap is installed, make sure that cylinder numbers put on rod and cap at disassembly match. 11. When new connecting rod is installed, make sure that notches for holding bearing in place are on same side. 12. Tighten the connecting rod cap nuts. Tightening torque Connecting rod cap nuts , . 49-51 Nm (500-520 kg.cm, 36-38 Ib.ft)

20Y135

13. Check bearing clearance as follows: 1) Remove oil and dirt from bearings and journals. 2) Cut plastigauge to same length as width of bearing and place it in parallel with journal, off oil holes. 3) Install bearing and cap and tighten them to specified torque. During this operation, do NOT turn cranksha.ft. 4) Remove caps, measure width of plastigauge at the widest part by using a scale printed on plastigauge bag.

20-59

PISTON AND CONNECTING ROD Connecting rod cap Bearing clearance

. 0.02-0.05 mm (0.0008-0.0020 in.)

14. Check connecting rod side clearance. Side clearance

20-60

0.10-0.25 mm (0.004-0.010 in.)

CRANKSHAFT

CRANKSHAFT COMPONENTS Flywheel

Ring gear I

Rear plate

127-137 (1.300-1,400. 94-101)

10-12 (100-120. 7.2-8.7) Oil seal case Gasket 0;1 seal \ Oil separator \ •

•

~

h \-:f

•

[For MIT]

~Bell

housing cover

•

_Crankshaft

-~~~--

Crankshaft bushing

Adapter plate

Adapter plate ~Lowerbearing

~

~~

Drive plate

~

~

'It\~~ 11----

_Bearing cap

[For A/T]

49-54 (500-550. 36-401

~~

TORQUE

Nm (kg.em. Ib.ft)

20Y138

20-61

CRANKSHAFT

DISASSEMBLY 1.

2. 3.

Y20NAOA

Remove the timing belt train, front case, flywheel cylinder head assembly and oil pan. For details, refer to respective chapters. Remove the rear plate and the rear oil seal. Remove the connecting rod caps. NOTE Mark the main bearing caps to permit reassembly in the original position and direction.

4.

Remove the main bearing caps and remove the crankshaft. Keep the bearings in order by cap number.

INSPECTION

Y20NBOA

Crankshaft 1.

2.

Check the crankshaft journals and pins for damage, uneven wear and cracks. Also check oil holes for clogging. Correct or replace any defective part. Inspect out-of-roundness and taper of crankshaft journal and pin. Standard value Crankshaft journal 0.0

20Y139

.

56.980-56.995 mm (2.2433-2.2439 in.) : . 44.980-44.995 mm (1.7709-1.7715 in.)

Crankshaft pin 0.0

Main Bearings and Connecting Rod Bearings Visually inspect each bearing for peeling, melt, seizure and improper contact. Replace the defective bearings.

Oil Clearance Measurement To check the oil clearance, measure the outside diameter of the crankshaft journal and the crank pin and the inside diameter of the bearing. The clearance can be obtained by calculating the difference between the measured outside and inside diameters. Standard value Oil clearance Crankshaft main bearing

@[]

.

0.02-0.05 mm (0.0008-0.0020 in.) Connecting rod bearing

.

0.02-0.05 mm (0.0008-0.0020 in.)

20-62

• 20Y140

CRANKSHAFT Plastigauge Method Plastigauge may be used to measure the clearance. 1. Remove oil and grease and any other dirt from bearings and journals. 2. Cut plastigauge to the same length as the width of the bearing and place it in parallel with the journal, off oil holes. 3. Install the crankshaft, bearings and caps and tighten them to the specified torques. During this operation, do not turn the crankshaft. Remove the caps. Measure the width of the plastigauge at the widest part by using a scale printed on the gauge package.

20Y141

If the clearance exceeds the repair limit, the bearing should be replaced or an undersize bearing should be used. When installing anew crankshaft, be sure to use standard size bearings. Should the standard clearance not be obtained even after bearing replacement, the journal and pin should be ground to undersize and a bearing of the same size should be installed.

Oil Seal Check front and rear oil seals for damage or worn lips. Replace any seat that is defective.

Drive Plate Replace deformed, damaged, or cracked drive plates.

INSTALLATION

Y20NCOA

Main Bearing 1. 2. 3.

Install grooved main bearing (upper bearing) on cylinder block side. Install grooveless main bearing (lower bearing) on main bearing cap side. Both upper and lower bearings for center are grooveless.

({;"" Lower bearing (for No.1 ,2,4,5)

~

Upper bearing (for No. 1,2,4,5,)

Upper and lower bearings (for center) 20Y142

4. 5.

Install crankshaft. Apply engine oil to journal and pin. Caps should be installed with arrow mark directed toward front of engine. Cap number must be correct. 6. Tighten cap bolts to specified torque in sequence of center No.2, No.4, front and rear caps. Tightening torque Main bearing cap bolts . 49-54 Nm (500-550 kg.cm, 36-40 Ib.ft)

20-63

CRANKSHAFT 7.

8.

9.

Cap bolts should be tightened evenly in 4 to 5 stages before they are tightened to specified torque. Make certain that crankshaft turns freely and has proper end play.

Using special tool (09231-32000), install oil seal in oil seal case.

-+--09231-32000

20Y144

10. With 4 mm (0.16 in.) diameter oil hole. in the lower position (oil pan mounting surface side), push oil separator into case.

Oil seal case

C:=.::::":::~~:::=:====~~~::::J~~4mm Oil pan mounting surface

(0.16 in.) dia. oil hole 20Y145

11. Install the new oil seal case gasket and oil seal case assembly. 12. Install the rear plate to the cylinder block.

20-64

CRANKSHAFT 13. Install flywheel and tighten bolts to specified torque. Check clutch mounting surface for runout. Runout

MIT

0.1 mm (0.004 in.) max. Ring gear - - - - + 0

Tightening torque Flywheel bolts . 127-137 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)

- - ! - - - Flywheel

Identifiaction . mark

rr.. . . . .nr1~+--Flywheel

bolt

'L..-lUt--+--Pilot bearing

20Y146

14. With an Automatic Transaxle, install adapter and drive plate and tighten bolts to specified torque.

AIT

Tightening torque Drive plate bolts . 127-137 Nm (1,300-1,400 kg.cm, 94-101 Ib.ft)

Ring gear

~--Drive

"L"\

plate

Adapter plates

Drive plate bolt

Crankshaft bushing

Adapter

20Y147

20-65

CYLINDER BLOCK

CYLINDER BLOCK COMPONENTS

7.S-12 (S0-120, 5.S-S.7) Oil pressure switch

Cylinder block

30-41 (300-420, 22-30)

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

REMOVAL

20Y148

Y200AOA

Remove the cylinder head, timing belt train, front case, flywheel, piston and crankshaft. For further details, refer to the respective chapters.

INSPECTION

Y200BOA

Cylinder Block 1.

Visually check the cylinder block for scores, rust and corrosion. Also check for cracks or any other defects. Correct or replace the block if defective. 2. Measure cylinder bore with a cylinder gauge at three levels in directions of A and B. Level 1 : No.1 piston ring position with piston at TOC Level 2 : Center of cylinder Level 3 : Bottom of cylinder

20-66

m B

CYLINDER BLOCK 3.

If cylinder bores show more than specified out-of-round or taper, or if cylinder walls are badly scuffed or scored, cylinder block should be rebored and honed, and new oversize piston and rings are fitted. Standard value Cylinder bore

. 86.49-86.53 mm (3.4051-3.4067 in.) Out-of-roundness and taper of cylinder bore . Max. 0.01 mm (0.0004 in.)

4.

If cylinder top ridge is worn in stages, cut away with ridge reamer.

5.

Oversize pistons are available in four sizes. Piston service size and mark mm (in.) 0.25 (0.010) O.S 0.50 (0.020) O.S 0.75 (0.030) O.S 1.00 (0.039) O.S

0.25 0.50 0.75 1.00

6. To rebore the cylinder to oversize, keep the specified clearance between the oversize piston and the bore, and make sure that all pistons used are of the same oversize. The standard measurement of the piston outside diameter is taken at a level 2 mm (0.08 in.) above the bottom of the piston skirt and across the thrust faces. Piston-to-cylinder wall clearance

. 0.01-0.03 mm (0.0004-0.0012 in.)

7.

Check for damage and cracks.

8.

Check top surface for flatness. If excessive flatness is evident, grind to minimum limit or replace Standard value Flatness of gasket surtace Overall height. Service limit Flatness of gasket surface Overall height

. Max. 0.05 mm (0.0020 in.) 290 mm (11.4 in.)

0.1 mm (0.0039 in.) -0.2 mm (-0.0079 in.)

CAUTION The cylinder block gasket surface should be ground to within -0.2 mm (-0.0079 in.) even with the grind of cyl· inder head gasket surface.

20-67

CYLINDER BLOCK Boring Cylinder 1.

Oversize pistons to be used should be determined on the basic of the largest bore cylinder. Size

0.25 0.50 0.75 1.00

mm mm mm mm

(0.010 (0.020 (0.030 (0.039

Identification mark in.) in.) in.) in.)

O.S O.S O.S O.S

0.25 0.50 0.75 1.00

~_-::::::::P::is::;;to::;;n::;;O::.D::·::::::::-_--JThrust

direction

NOTE Size mark is stamped on top of piston. 2. 3.

Measure outside diameter of spring to be used. Based on measured piston 0.0.• calculate boring finish dimension. Boring finish dimension = Piston 0.0 +0.01-0.03 mm (0.0004-0.0012 in.) (clearance between 0.0. and cylinder) - 0.02 mm (0.008 in.) (honing margin.)

4.

Hone each of the cylinders to the calculated size.

CAUTION To prevent distortion that may result from temperature rise during honing, bore cylinders, working from No.2 to . No.4 to No.1 to No.3. 5.

Hone the cylinders. finishing them to the proper dimension (piston outside diameter + gap with cylinder). 6. Check clearance between piston and cylinder.

NOTE When boring cylinders,finish all of four cylinders to same oversize. Do not bore only one cylinder to an oversize.

REASSEMBLY 1.

Y200COA

Install the following parts by referring to the respective paragraphs. 1) Crankshaft 2) Flywheel 3) Piston 4) Cylinder head 5) Timing belt train 6) Front case

20-68

OIL PRESSURE SWITCH AND SENDER ASSY

OIL PRESSURE SWITCH AND SENDER ASSY

Y20PAOA

INSPECTION Oil Pressure Switch 1.

2.

If "OIL PRESSURE" indicating lamp lights when ignition switch is set to "ON" and goes out when engine is started and runs at idle, then everything is in order. If "OIL PRESSURE" lamp does not light when ignition switch is set to "ON", check switch, lamp and wiring. If there is current flow when ignition switch is set to "ON" and if there is no current flow when engine is running at idle, switch is good. It switch is good, check lamp and wiring.

20Y152

Oil pressure switch operation pressure . 2 20-39 kPa (0.2-0.4 kg/cm , 2.9-5.7 psi)

Oil Pressure Sender Assy 1.

Since bimetal type has constructional characteristics which vary its resistance as it repeats ON-OFF states, it cannot be changes in current. 2. It can be checked by use of an AC type ammeter measuring changes in current. Refer to page 90-19.

20Y153

INSTALLATION 1.

2.

Y20PBOB

Apply sealant to threaded portion. Using special tool (09260-32000), tighten switch to specified torque. Tightening torque Oil pressure switch

.

7.8-12 Nm (80-120 kg.cm, 5.8-8.7 Ib.ft) Oil pressure sender

.

14.7-21.6 Nm (150-220 kg.cm, 10.8-15.9 Ib.tt)

20-69

COOLING SYSTEM GENERAL

2

COOLING SySTEM

8

RADIATOR

10

RADIATOR FAN MOTOR ASSY

12

WATER PUMP

14

THERMOSTAT

16

WATER HOSE AND PiPE

17

WATER TEMPERATURE GAUGE UNIT AND SENSOR

18

•

GENERAL

GENERAL

Y25CAOA

SPECIFICATIONS Cooling method Cooling system Quantity Thermostat Type Normal opening temperature Opening temperature range Wide open temperature Radiator cap Main valve opening pressure Vacuum valve opening pressure

Water cooling, forced circulation with electric fan 7.0 lit (7.4 U.S.qts., 6.2 Imp.qts.) Wax pellet type with jiggle valve 88°C (190°F) 86.5-89.5°C (187.7-193.1°F) 100°C (212°F) 74-103 kPa (0.75-1.05 kg/cm 2 , 10.7-14.9 psi) -4.9 kPa (-0.05 kg/cm 2 • -0.71 psi)

Water temperature gauge unit Type Resistance

Thermistor type 88.5-119.50 at 70°C (158°F) 21.3-26.30 at 115°C (239°F)

Water temperature sensor Type Resistance

Thermistor type 2.21-2.69 KO at 20°C (68°F) 264-328 0 at 80°C (176°F)

Thermo sensor (On radiator) Type Operating temperature OFF --+ ON ON --+ OFF Coolant concentration

25-2

Wax pellet type 87-93°C (189-199°F) 83°C or more (181°F or more) 50%

GENERAL

LUBRICANT Engine coolant

Y25CBOA

Ethylene glycol base for aluminum

SEALANT Water temperature gauge unit Water temperature sensor

TIGHTENING TORQUE Alternator support bolt Alternator brace bolt Water pump to cylinder block bolt Head mark "4" bolt Head mark "7" bolt Water pump pulley bolt Water temperature gauge unit Water temperature sensor Thermo sensor (On radiator) Water outlet fitting attaching bolt

Y25CCOA

LOCTITE 962T or equivalent LOCTITE 962T or equivalent

Nm

Kg.cm

Ib.ft

20-25 12-15

200-250 120-150

14-18 8.7-11

12-15 20-26 7.8-9.8 9.8-12 20-39 20-25 17-20

120-150 200-270 80-100 100-120 200-400 200-250 170-200

8.7-11 14-20 5.8-7.2 7.2-8.7 14-29 14-18 12-14

Y25CDOA

25-3

GENERAL TROUBLESHOOTING

Y25CFOA

Symptom

Probable cause

Low coolant level

Leakage of coolant Damaged radiator core joint Corroded or cracked hoses (Radiator hose, heater hose, etc) Faulty radiator cap valve or setting of spring Faulty thermostat Faulty water pump

Remedy

Replace Replace Replace Replace Replace

Clogged radiator

Foreign material in coolant

Replace

Abnormally high coolant temperature

Faulty thermostat Faulty radiator cap Restriction of flow in cooling system Loose or missing drive belt Faulty water pump Faulty temperature gauge or wiring Fault)' electric fan Faulty thermo-sensor on radiator Insufficient coolant

Replace Replace Replace Adjust or replace Replace Repair or replace Repair or replace Replace Refill coolant

Abnormally low coolant temperature

Faulty thermostat Faulty temperature gauge or wiring

Replace Repair or replace

Leakage from oil cooling system

Loose hose and pipe connection Cracked or collapsed hose and pipe

Retighten Replace

Inoperative electrical cooling fan

Damaged

Replace or repair

25-4

GENERAL COOLANT LEAK CHECK

Y25CGOA

1. Loosen the radiator cap. 2. Confirm that the coolant level is up to the filler neck. 3. Install a radiator cap tester to the radiator filler neck and apply 150 kPa (21 psi, 1.53 kg/cm 2) pressure. Hold for two minutes in that condition, while checking for leakage from the radiator, hose or connections.

Radiator cap tester

CAUTIONS 1) Radiator coolant may be extremely hot. Do not open the system while hot, or scalding water could spray out causing personal injury. Allow vehicle to cool before servicing this system. 2) Be sure to completely clean away any moisture from the places checked. 3) When the tester is removed, be careful not to spill any coolant from it. 4) Be careful, when installing and removing the tester and when testing, not to deform the filler neck of the radiator. 4.

If there is leakage, repair or replace the appropriate part.

RADIATOR CAP PRESSURE TEST 1. 2.

25YOOl

Y25CHOA

Use an adapter to attach the cap to the tester. Increase the pressure until the indicator of the gauge stops moving. Main valve opening pressure . 74-103 KPa (0.75-1.05 kg/cm 2 , 10.7-14.9 psi) Limit 65 KPa (0.66 kg/cm 2 , 9.2 psi)

3.

Check that the pressure level is maintained at or above the limit. 4. Replace the radiator cap if the reading does not remain at or above the limit.

25YOO2

NOTE Be sure that the cap is clean before testing, since rust or other foreign material on the cap seal will cause an improper indication

SPECIFIC GRAVITY TEST

Y25CIOA

Hydrometer - - - I

1.

Measure the specific gravity of the coolant with a hydrometer. 2. Measure the coolant temperature, and calculate the concentration from the relation between the specific gravity and temperature, using the following table for reference.

25-5

GENERAL RELATION BETWEEN COOLANT CONCENTRATION AND SPECIFIC GRAVITY Coolant temperature °C (OF) and specific gravity 50 (122)

Freezing temperature °C (OF)

Y25CJOA

Safe operating temperature °C (OF)

Coolant concentration (Specific volume)

10 (50)

20 (68)

30 (86)

40 (104)

1.054

1.050

1.046

1.042

1.036

-16 (3.2)

-11 (12.2)

30%

1.063

1.058

1.054

1.049

1.044

-20 (-4)

-15 (5)

35%

1.071

1.067

1.062

1.057

1.052

-25 (-13)

-20 (-4)

40%

1.079

1.074

1.069

1.064

1.058

-30 (-22)

-25 (-13)

45%

·1.087

1.082

1.076

1.070

1.064

-36 (-32.8)

-31 (-23.8)

50%

1.095

1.090

1.084

1.077

1.070

-42 (-44)

-37 (-35)

55%

1.103

1.098

1.092

1.084

1.076

-50 (-58)

-45 (-49)

60%

Example The safe operating temperature is -15°C (5°F) when the measured specific gravity is 1.058 at coolant temperature of 20°C (68°F). CAUTION If the concentration of the coolant is below 30%, the anti-corrosion property will be adversely affected. In addition, if the concentration is above 60%, both the anti-freeze and engine cooling properties will decrease, affecting the engine adversely. For these reasons, be sure to maintain the concentration level within the specified range. Do not use togtlther with another brand.

RECOMMENDED COOLANT Antifreeze ETHYLENE GLYCOL BASE FOR ALUMINUM

25-6

Y25CKOA

Mixture ratio of anti-freeze in coolant 50%

GENERAL DRIVE BELT TENSION ADJUSTMENT Y25CLOA

The belt m!rlst be adjusted to the following specifications. 1. 2.

Center A

When 100 N (22 Ib) (tension or compression) is given perpendicularly to belt at center "A", sag is to be "L" mm. Or, tension gauge must read 'T' at center "A". New belt installed 7.5 -

Sag (L)

(0.30 Tension (T)

50 (110 -

Used belt installed

9.0 mm

10.0 mm

0.35 in.)

(0.39 in.)

70 kg 154 Ib)

40 kg (88Ib)

USAGE OF TENSION GAUGE

B

i Crankshaft pulley

Alternator pulley

25YOO4

Y25CMOA

Indication value

Using Tension Gauge

/

BORROUGHS 'BT-33-73F Type NIPPONDENSO BTG-2 Type -.n-..~ _

Measuring Method 1. 2.

Press down on the tension gauge handle and insert the belt between the spindle and hook of the gauge. Release the handle and read the measurement on the gauge.

Spindle

Hook V-ribbed belt Hook BORROUGHS

Reset point

Reset button

\ t:::~c..ml'--_Spindle f \ ~u--- Hook X\)''-----

V-ribbed belt

NIPPONDENSO 25YOO5

NOTE 1. Belt which has been in operation for 5 minutes or more, must be adjusted to the used belt specifications. 2. Ensure that the belt is installed correctly, as shown in the

illustration. 3. A loose belt will produce a high-pitched squealing noise. 4. A belt that is too tight will damage the alternator and water pump bearing. Incorrect

Correct

Incorrect

25Y006

COOLING SYSTEM

COOLING SYSTEM COMPONENTS Cold Engine

Thermostat (closed)

~++--Water

pump

Radiator

Hot Engine

Thermostat (opened)

~++--Water

pump

Radiator

25YOO7

25-8

COOLING SYSTEM t

DRIVE BELT AND PULLEY

Y25DAOA

Removal 1.

2.

3.

Loosen the alternator support bolt "A", nut and alternator brace bolt "B". Push the side of the alternator to relieve belt tension, a'nd remove the belt. Remove the water pump pulley bolts and remove the water pump pulley.

Inspection Check following items and replace if defective. 1. Check the surface for damage, peeling or cracks. 2. Check the belt surface for oil or grease. 3. Check the rubber for worn or hardened areas.

4.

Check the surface of the pulley for cracks or damage.

25YOO9

Installation 1.

Install the water pump pulley to the water pump pulley bracket and tighten the bolts firmly. Tightening torque Water pump pulley bolts . 7.8-9.8 Nm (80-100 kg.cm, 5.8-7.2 Ib.ft) CAUTION An overtensioned belt could cause not only premature wear of the belt but will also damage the water pump and alternator bearings.

2.

After installing the belt, adjust the belt tension.

25-9

RADIATOR

RADIATOR COMPONENTS 8.8-14 (90-140. 6.5-10)

Upper insulator Radiator cap Radiator upper hose

Thermo sensor B

20-25 (200-250. 14-18) (U.S.A. only) Thermo sensor A

20-25 (200-250. 14-18)

Drain plug Lower insulator

ri I

Reserve tank

--1--------

~__---fr:..' --

e

1J;

-=-_

Radiator fan motor connector ~

,

.~

Radiator lower hose

@.

Oil cooler hoses (A/T)

TORQUE

25-10

Nm (kg.em. Ib.ft)

25Y010

RADIATOR REMOVAL

Y25EAOA

1. 2.

Disconnect the fan motor plug. Set the warm water flow control lever of the heater control to the hot position. 3. Loosen the radiator drain plug to drain the coolant. 4. Disconnect the upper and lower hoses and overflow tube after making marks on the radiator hose and the hose clamp. 5. For vehicles with an automatic transaxle, disconnect the oil cooler hoses from the automatic transaxle. 25Y011

CAUTION Cover or plug the hose and nipple part of the radiator so that dust, foreign materials, etc. do not enter after the hose has been disconnected from the radiator.

6. 7. 8.

Remove the radiator mounting bolt. Remove the radiator together with the fan motor. Remove the fan motor from the radiator.

INSPECTION 1. 2. 3. 4. 5. 6.

Y25EBOA

Check for foreign material between radiator fins. Check the radiator fins for damage and straighten if necessary. Check the radiator for corrosion, damage, rust or scale. Check the radiator hoses for cracks, damage or deterioration. Check the reserve tank for damage. Check the automatic transaxle oil cooler hoses for cracking, damage or deterioration.

INSTALLATION

Y25ECOA

1.

Fill the radiator and reserve tank with clean coolant mixture.

2.

Run the engine until the coolant has warmed up enough so that the thermostat valve opens, and then stop the engine. Remove the radiator cap and pour in the coolant until it is up to the filler neck of the radiator. Fill the reserve tank to the upper level.

3.

4.

Check to be sure that there is no leakage from the radiator, hoses or connections.

25-11

RADIATOR FAN MOTOR ASSY

RADIATOR FAN MOTOR ASSY COMPONENTS

Radiator-----I

Fan mounting c l i p - - - Fan'----JIII

~.

Shroud----lI1

I ~~

Radiator fan motor 25Y016

REMOVAL

Y25GAOA

1. 2.

Disconnect the ground cable from the battery terminal. Disconnect the connectors from the fan motor and remove the harness from shroud. 3. Remove the two bolts and nut holding the shroud to the radiator and detach the shroud. 4. Remove the fan motor mounting bolts and detach the fan 5.

motor from the shroud. Detach the cooling fan from the fan motor by removing the 25Y047

clip.

INSPECTION

Y25GBOA

Radiator Fan Motor 1.

2.

Check to be sure that the radiator fan rotates when battery voltage is applied between the terminals (as shown in the figure). Check to see that abnormal noises are not produced while the motor is turning. 25Y041

25-12

RADIATOR FAN MOTOR ASSY Thermo Sensor A Check for continuity with the thermo sensor in hot water.

NOTE: Immerse the thermo sensor in hot water up to the mounting threads to check for continuity.

25Y019

Operating temperature OFF - ON 87-93°C (189-199°F) ON - OFF: 83°C or more (181°F or more)

ON OFF ~----r----r" ON L..-._-,4.---L.,

OFF

83°C

Water

..1..-

90±3°C

temperature

25Y020

Thermo Sensor B OFF

Operating temperature OFF - ON 108°C or more (226°F or more) ON - OFF: 112-118°C (234-244°F)

ON OFF

1

-----/: 7

ON

I

I

108°C

115±3°C

Water temperature

25Y043

INSTALLATION 1.

Y25GCOA

Installation is in the reverse order of removal procedures.

J;f--

.-/ O

CAUTION: 1) Make sure the cooling fan does not come into contact with the &hroud when installed. 2) After installation, make sure there is no unusual noise or vibration when the fan is rotated.

25Y021

25-13

WATER PUMP

WATER PUMP COMPONENTS Timing belt

7.8-9.8 (80-100, 5.8-7.2) Drive belt (Power steering)

Water pump pulley

Timing belt B

Water pump pulley (Power steering) Drive belt

')

Water pump gasket

TORQUE

Nm (kg.em, Ib.ft) 25Y022

25-14

WATER PUMP REMOVAL

Y25HAOA

1.

Drain the coolant and disconnect the radiator outlet hose and

2.

water by-pass hose from the water pump. Remove the drive belt and water pump pulley. Remove the timing belt covers and the timing belt tensioner.

3. 4.

Remove the water pump mounting bolts and then remove the alternator brace. 5. Remove the water pump assembly from the cylinder block.

INSPECTION

Y25HBOA

1.

Check the water pump for cracks, damage or wear, and replace the water pump assembly if necessary.

2.

Check the bearing for damage, abnormal noise and sluggish rotation, and replace the water pump assembly if. necessary. Check the seal unit for leaks, and replace the water pump assembly if necessary. Check for water leakage. If water leaks from hole "A", seal unit is defective. Replace water pump assembly.

3. 4.

25Y023

INSTALLATION

Y25HCOA

1.

Clean the gasket surfaces of the water pump body and the cylinder block. 2. Install the new O-ring onto the groove on the front end of the water pipe, then wet the O-ring with water. Do not apply oil or grease. 3. Install a new water pump gasket and water pump assembly. Tighten the bolts to the sp3cified torque. Tightening torque Water pump to cylinder block Head mark "4" bolt

O-ring

/

25Y024

.

12-15 Nm (120-150 kg.cm, 7.7-11 Ib.ft) Head mark "7" bolt

.

20-26 Nm (200-270 kg.cm, 14-20 Ib.ft) 4.

Install the timing belt tensioner and timing belt. Adjust the timing belt tension, and then install the timing belt covers. 5. Install the water pump pulley and drive belt, and then adjust the belt tension. 6. Refill the coolant.

7.

L = 20 (0.79)

L = 30 (1.18)

Run the engine and check for leaks. L

= Length

of bolt mm (in.)

25Y025

25-15

THERMOSTAT

THERMOSTAT COMPONENTS

17-20 (170-200, 12-14) ../"'J

Connection for radiator upper hose-----0 Radiator hose

(

c1amp~ ?~water U .

outlet fitting

I

Q--Gasket

~ Thermostat

-d

~-

TORQUE

Nm (kg.em, Ib.ft)

25Y026

REMOVAL AND INSPECTION 1. 2. 3. 4. 5. 6.

Y251AOA

Drain the coolant down to thermostat level or below. Remove the water outlet fitting and gasket. Remove the thermostat. Heat the thermostat as shown in the illustration. Check to see if the valve operates properly. Check to determine the temperature at which the valve begins to open.

Thermometer

eeoc

Valve opening temperature ............••... (190°F) Full opening temperature 100°C (212°F) Min. 6.6 mm (0.26 in.) Valve lift (at full open)

Water

25Y027

INSTALLATION 1.

2.

Y251BOA

Check to ensure that the flange of the thermostat is correctly seated in the socket of the thermostat housing. If the thermostat is installed in the wrong direction, the bottom of the thermostat will touch the rib inside the intake manifold, making it impossible to seat the flange in position. Install a new gasket and water outlet fitting. Tightening torque Water outlet fitting bolt . 17-20 Nm (170-200 kg.cm, 12-14 Ib.ft)

3.

Refill the coolant.

25-16

WATER HOSE AND PIPE

WATER HOSE AND PIPE COMPON~NTS

Connection for heater hose

O-ring Water inlet pipe

12-15 (120-150, 8.7-11)

Connection for radiator lower hose

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

INSPECTION

25Y028

Y25JAOA

Check the water pipe and hose for cracks, damage and restrictions. Replace if necessary.

25-17

WATER TEMPERATURE GAUGE UNIT AND SENSOR

WATER TEMPERATURE GAUGE UNIT AND SENSOR COMPONENTS Water temperature gauge unit

9.8-12 (100-120, 7.2-8.7)

Water temperature sensor

20-39 (200-400, 14-29)

TORQUE

Nm (Kg.em, Ib.ft)

REMOVAL

25Y039

YB25KBOA

1.

Drain the coolant down to the gauge unit level or below.

2. 3.

Disconnect the battery ground cable. Remove the coolant temperature gauge unit, sensor.

INSPECTION

Y25KBOB

Water Temperature Gauge Unit 1. 2.

Heat the coolant temperature gauge by submerging it in hot water. Check that the resistance is within the specified range. Resistance

90.5-117.50 at 70°C (158°F) 21.3-26.30 at 115°C (239°F) 25Y031

25-18

WATER TEMPERATURE GAUGE UNIT AND SENSOR Water Temperature Sensor 1. 2.

Heat the sensor by submerging It In hot water. Check that the resistance is within the specified range. Resistance

2.21-2.69 kO at 20°C (68°F) 264-328 0 at 80°C (176°F)

25Y032

INSTALLATION 1.

Y25KCOB

Apply sealant to the threaded portion and tighten to the specified torque.

Li",ant

Water temperature gauge unit

. LOCTITE 962T or equivalent Water temperature sensor ....•........................... LOCTITE 962T or equivalent

Tightening torque Water temperature gauge unit . 9.8-12 Nm (100-120 kg.cm, 7.2-8.7 Ib.ft)

.

25Y034

Water temperature sensor . 20-39 Nm (200-400 kg.cm, 14-29 Ib.ft) 2. 3. 4.

Connect the harness to the water temperature gauge unit, sensor. Connect the battery ground cable. Refill with coolant.

25-19

ENGINE ELECTRICAL SYSTEM I GENERAL

2

CHARGING SySTEM

4

STARTING SySTEM

22

IGNITION SySTEM

32

AUTOMATIC SPEED CONTROL (CRUISE) SySTEM

42

GENERAL GENERAL

Y27AAOA

SPECIFICATIONS Distributor Type Ignition interval

Contact pointless type No.1 No.2 No.3 No.4

Ignition order Advance mechanism Identification No.

cylinder cylinder cylinder cylinder

00 90 0 ± 0.5 0 1800 ± 0.5 0 270 0 ± 0.5 0 1-3-4-2 Controlled by electronic control unit 1EDOO31A (MAN DO) TO01542170 (MELCO)

Ignition Coil Type Primary coil resistance Secondary coil resistance

Mold coil 0.8 ± 0.08 fl 12.1 ± 1.21 Kfl

Spark Plug Type NGK

Champion Plug gap

8PR6EA-l1 RN9YC4 1.0-1.1 mm (0.039-0.043 in.)

Starter Motor Type Voltage Output Free running characteristics Terminal voltage Current Speed Number of pinion teeth Pinion gap

27-2

Reduction drive (with planetary gear) 12 V 1.2 KW 11 V Max. 90 A Min. 3000 rpm

8 0.5-2.0 mm (0.0197-0.079 in.)

GENERAL Alternator Type Rated output Rotor speed Voltage regulator setting Temperature compensated Voltage regulator type

Battery voltage sensing 12 V / 75 A 1,000 - 18,000 rpm 14.4 ± 0.3 V -10 ± 3 mV/OC Electronic built-in type

Battery

Type Cold cranking [at -17.8°C (OOF)] Reserve capacity Specific gravity [at 25°C (77°F)] Ampere hours (5HR) (20HR)

USA

CANADA

MF60B 420 A 92 min. 1.270 ± 0.01 48 AH 60 AH

MF68-AH 540 A 122 min. 1270 ± 0.01 55 AH 68 AH

NOTE 1. COLD CRANK AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 or greater at a specified temperature. 2. RESERVE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimum terminal voltage of 10.5 at 26.7°C (80°F).

TIGHTENING TORQUE Items Alternator terminal (B+) Starter motor terminal (B+) Battery terminal Spark plug

Y27ABOA

Nm

kg.cm

Ib.ft

4-6 10-16 4-6 20-30

40-60 100-160 40-60 204-306

2.9-4.3 7.3-11.8 2.9-4.3 15-21

27--3

CHARGING SYSTEM

CHARGING SYSTEM

Y278AOA

GENERAL INFORMATION The charging system includes a battery, an alternator with a built-in regulator, and the charging indicator light and wires. The alternator has six built-in diodes (three positive and three negative), each rectifying AC current to DC current. Therefore, DC current appears at alternator "B" terminal. In addition, the charging voltage of this alternator is regulated by the battery voltage detection system. The main components of the alternator are the rotor, stator, rectifier, capacitor, brushes, bearings and V-ribbed belt pulley. The brush holder contains a

Electronic voltage regulator·bu iIt into //("-F=J.."",.\'~~ brush holder U

V-ribbed belt

\.fJ(;;3!-I~~ f"-4

BrUSh~~~~.f'~~:"'i:j~bj Rectifier heat-sink

_-J1Il~ifurt-~~-t'\ttl.::....

pulley

Rotor

assembly

Stator

27Y015

built-in electronic voltage regulator.

TROUBLESHOOTING

Y27BBOA

Symptom

Probable cause

Remedy

Charging warning indicator does not light with ignition switch "ON" and engine off.

Fuse blown.

Check fuses.

Lamp burned out.

Replace lamp.

Wiring connection loose.

Tighten loose connections.

Electronic voltage regulator faulty.

Replace voltage regulator.

Drive belt loose or worn.

Adjust tension or replace drive belt.

Battery cables loose, corroded or worn.

Repair or replace cables.

Fuse blown.

Check fuses.

Fusible link blown.

Replace fusible link.

Electronic voltage regulator or alternator faulty.

Test alternator.

Wiring faulty.

Repair wiring

Drive belt loose or worn.

Adjust tension or replace drive belt.

Wiring connection loose or open circuit.

Tighten loose connection or repair

Charging warning indicator does not go out with engine running. (Battery requires frequent recharging).

Discharge battery.

wiring.

Overcharge

27-4

Fusible link blown.

Replace fusible link.

Poor grounding.

Repair.

Electronic voltage regulator or alternator faulty.

Test alternator.

Battery life.

Replace battery.

Electronic voltage regulator faulty.

Replace voltage regulator.

Voltage sensing wire faulty.

Repair wire

CHARGING SYSTEM SERVICE ADJUSTMENT PROCEDURES

Y27BCOA

VOLTAGE DROP TEST OF ALTERNATOR OUTPUT WIRE This test determines whether or not the wIring between the alternator B terminal and the battery (+) terminal' (including fusible link) is within specifications. Preparation

1. 2. 3. 4.

Turn the ignition switch to "OFF". Disconnect the battery GND cable. Disconnect the alternator output lead from the alternator "B" terminal. Connect a DC ammeter (0 to 1OOA) in series to the "B" terminal and the disconnected output lead. Connect the (+) lead of the ammeter to the "B" terminal and the (-) lead to the disconnected output wire. NOTE: Use of an inductive type ammeter that measures current without disconnecting the harness is preferred. The reason is that, while checking a vehicle that has low output current due to a poor connection of the alternator "B" terminal, when the terminal is loosened and a test ammeter is connected, the poor connection will be corrected. As a result, the cause may not be determined.

5.

6.

It r

~ VOLT meier

I

r,;®~-~

Ammeter

Battery

29YQ16

Connect a voltmeter between the alternator "B" terminal and battery (+) terminal. Connect the (+) lead wire of the voltmeter to the "B" terminal and the (+) lead wire to the battery (-) terminal. Connect the battery ground cable.

Test

1. Start the engine. 2.

Turn the headlamps ON and OFF. Adjust the engine speed so that the ammeter reads 20A and note the reading of the voltmeter.

Result 1.

The reading should be less than the standard value. Standard value : 0.2V max.

2.

If the voltmeter indicates a value larger than the standard value, poor wiring can be suspected. The wiring from the alternator "B" terminal to the fusible link and battery (+) terminal. Check for corroded or loose

connections.

27-5

CHARGING SYSTEM 3.

Upon completion of the tes!, let the engine idle. Turn off the

4. 5.

lights and ignition switch. Disconnect the battery ground cable. Disconnect the ammeter and voltmeter that were connected

6.

for test purposes. Connect the alternator output wire to the alternator "B"

7.

terminal. Connect the battery ground cable.

OUTPUT CURRENT TEST

Y278DOA

The test determines if the alternator output is within normal specifications. Preparation 1.

,...--<,......0------........ Load

Prior to the test, check the following items and correct as necessary.

1)

Check the battery installed in the vehicle to ensure that it is in good condition. The test method is described in

the "BATIERY" section. 2) Check the tension of the alternator drive belt. 2. 3. 4. 5.

Turn off the ignition switch. Disconnect the battery ground cable. Disconnect the alternator output wire from the alternator "B" terminal. Connect a DC ammeter (0 to 1OOA) in series between the "B" terminal and the disconnected output wire. Connect the (+) lead wire of the ammeter to the alternator

Battery

Ignition switch

Charge warning light

Relay with diode

D Voltmeter

D Ammeter

"B" terminal and the (-) lead wire to the disconnected output wire.

NOTE: Tighten each connection securely current flow. Do not rely on clips. 6.

27YOO2

because of heavy

7.

Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire of the voltmeter to the alternator "B" terminal and (-) lead wire to ground. Connect a tachometer and re-connect the battery ground

8.

cable. Leave the engine hood open.

27-6

CHARGING SYSTEM

Test 1.

Check to see that the voltmeter reads the same value as the battery voltage. If the voltmeter reads QV, an open circuit in the wire be1ween the alternator "S" terminal and battery (+) terminal, a blown fusible link or poor grounding is suspected. 2. Turn on the headlight switch and start the engine. 3. Set the headlight at high beam and the heater blower switch at HIGH, quickly increase the engine speed to 2,500 rpm and read the maximum output current value indicated by the ammeter.

NOTE: After the engine start up, the charging currant quickly drops. Therefore, above operation must be done quickly to read maximum current value correctly.

Result 1.

The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is normal, remove the alternator from the vehicle and check it. Limit value: 53A min

75A alternator

NOTE: ')

The nominal output current value is shown on the nameplate affixed to the alternator body. 2) The output current value changes with the electrical load and the temperature of the alternator itself. Therefore, the nominal output current may not be obtained if the vehicle electrical load at the time of test is small. In such a case, keep the headlights on to cause discharge of the battery or use lights of another vehicle as a load to increase the electrical load. The nominal output current may not be obtained if the temperature of the alternator itself or ambient temperature is too high. In such a case, reduce the temperature before testing again. 2.

Upon completion of the output current test, lower the engine speed to the idle speed and turn off the ignition switch. 3. Disconnect the battery ground cable. 4. Remove the test ammeter, voltmeter and the engine tachometer. 5. Connect the alternator output wire to the alternator "S" terminal.

6.

Connect the battery ground cable. 27-7

CHARGING SYSTEM REGULATED VOLTAGE TEST

Y27BEOA

The purpose of this test is to check that the electronic voltage regulator controls the voltage correctly.

Preparation 1.

necessary. 1) Check the battery installed on the vehicle to see that is is fully charged. For battery checking method, see the "BATIERY" section. 2. 3. 4.

Load

Prior to the test, check the following items and correct if

Fuse

IGN sw "

I

2) Check the alternator drive belt tension. Turn the ignition switch to "OFF". Disconnect the battery ground cable. Connect a digital voltmeter between the "S" terminal of the

Charging INO lamp I

....J

alternator and ground. Connect the (+) lead of the voltmeter to the "S" terminal of the alternator, inserting from the wire side of the 2-way connector and connect the (-) lead to 5. 6.

7.

ground or the battery (-) terminal. Disconnect the alternator output wire from the alternator "B" terminal. Connect a DC ammeter (0 to 1ooA) in series between the "B" terminal and the disconnected output wire. Connect the (+) lead wire of the ammeter to the alternator "B" terminal and the (-) lead wire to the disconnected output wire. Connect an engine tachometer and reconnect the battery ground cable.

=o Voltmeter

Ammeter

Test 1.

2. 3.

Turn on the ignition switch and check that the voltmeter indicates battery voltage. If it reads OV, there is an open circuit in the wire between the alternator "S" terminal and the battery (+), or the fusible link is blown. Start the engine. Keep all lamps and accessories off. Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator output current drops to 10A or less

Result 1.

If the voltmeter reading agrees with the value listed in the following table, the voltage regulator is functioning correctly. If the reading is other than the standard value, the voltage regulator or the alternator is faulty.

27-8

27YOOl

CHARGING SYSTEM Regulator Voltage Table Voltage regulator ambient temperature °C (OF) -20 (-4) 20 (68) 60 (140) 80 (176)

2. 3. 4. 5. 6.

Regulated voltage [Standard value) 14.2 13.9 13.4 13.1

-

15.4 14.9 14.6 14.5

After the test, lower the engine speed to idle speed and turn the ignition switch to "OFF". Disconnect the battery ground cable. Remove the test voltmeter, ammeter and engine tachometer. Connect the alternator output lead to alternator "B" terminal. Connect the battery ground cable.

27-9

CHARGING SYSTEM ALTERNATOR REMOVAL AND INSTALLATION

Adjusting bolt

/fJ@QJ'~""">Alternator 23 (234. 16)

\'

~ TORQUE: Nm (kg.cm, Ib.ft)

SERVICE POINTS OF REMOVAL REMOVAL OF ALTERNATOR 1.

Y27BFOA

Remove the installation bolt of the power steering oil pump. and hold the oil pump above the engine mount bracket. Use rags. etc. to prevent scarring or scratching of the rocker cover.

NOTE Do not disconnect the oil pump hose.

2.

With the alternator facing as shown in the figure. remove upward.

27-10

l!I,~Support bolt

CHARGING SYSTEM

COMPONENTS

Front bearing Bearing retainer Seal Rotor assembly

Pulley

Voltage regulator and brush holder

Slinger

\.

Brush spring

Rectifier

Rear bracket

Terminal

Plate Stator

27-11

CHARGING SYSTEM DISASSEMBLY 1. 2.

Y27BGOA

Remove the three through bolts. Insert a flat tip screwdriver between the front bracket and stator core and pry downward.

CAUTION 1) Do not insert the screwdriver too deep, as this may cause damage to the stator coil. 21Y023

2)

The rear cover may be hard to remove because a ring is used to lock the outer race of the rear bearing. To facilitate removal of the rear cover, heat the bearing section with a 200-watt soldering iron. Do not use a heat gun, as it may damage the diode assembly. Bearing box

27Y024

3.

Secure the rotor in a vise with the pulley side up.

CAUTION Be careful that the vise jaws do not damage the rotor.

, .

27Y025

4. 5. 6. 7. 8. 9.

Remove the pulley nut. spring washer and the pulley. Remove the front bracket and the two seals. Remove the rotor from the vise. Remove the brush holder screws, the rectifier screws, and the nut from the B terminal. Remove the stator assembly from the rear bracket. Detach the slinger from the brush holder.

27-12

CHARGING SYSTEM 10. When the stator is to be removed, unsolder the three stator leads to the main diodes on rectifier.

CAUTION 1) When soldering or unsoldering. make sure the heat of the soldering iron is not transmitted to the diode for a long period. 2) Use care that undue force is not exerted on the diode leads.

f J:;~-!",+-- Plate Plate

"B"

"L"

11. When seperating the rectifier from the brush holder, unsolder the two plates soldered to the rectifier.

INSPECTION ROTOR 1.

Check the rotor coil for continuity. Check to ensure that there is continuity between the slip rings. If resistance is extremely low. it means there is a short. If there is no continuity or is a short circuit, replace the rotor assembly. Resistance value

2.

Y278HOA

3.0

n

Check the rotor coil for ground. Check that there is no continuity between the slip ring and core. If there is continuity, replace the rotor assembly.

27-13

CHARGING SYSTEM STATOR

Y27BJOA

1.

Make a continuity check on the stator coil. Check to ensure that there is continuity between coil leads. If there is no continuity, replace stator assembly.

2.

Check coil for grounding. Check to ensure that there is no continuity between coil and core. If there is continuity, replace stator assembly.

RECTIFIERS

Y27BKOA

Positive rectifier test Check for continuity between the positive rectifier and stator coil lead connection terminal with a ohmmeter. The ohmmeter should rear continuity in only one direction. If there is continuity in both directions, diode is shorted. Replace rectifier assembly.

Negative rectifier test Check for continuity between negative rectifier and stator coil lead connection terminal. The ohmmeter should rear continuity in only one direction. If there is continuity in both directions, a diode is shorted, and rectifier assembly must be replaced.

27-14

CHARGING SYSTEM DIODE TRIO TEST

Y27BLOA

Check the three diodes for continuity by connecting a ohmmeter to both ends of each diode. The diode in the trio should have continuity in only one direction. Continuity in both directions, a diode is defective and heatsink assembly must be replaced.

BRUSH REPLACEMENT ,.

Y278MOA

Replace the brush by the following procedures if it has been worn to limit line. (( 0

2.

l W~imitline

Unsolder pigtail and remove old brush and spring.

Solder ~T,,"+,......o:~

3. 4.

Install brush spring and new brush in brush holder. Push brush into the brush holder end frame a distance of 0.079 to 0,118 in. (2 to 3 mm) or until a pin can be installed to retain the brush in there retracted position.

/

2-3 mm I '(0.079--0.118 in.)

p

27-15

CHARGING SYSTEM ASSEMBLY

Y27BNOA

Perform assembly in reverse procedure of disassembly, pay attention to the followings: Before rotor is attached to rear bracket. insert wire through small hole made in rear bracket to lock the brushs. After the rotor has been installed, the wire can be removed.

27-16

Rear bracket

Wire

CHARGING SYSTEM BATTERY BATTERY-MAINTENANCE FREE TYPE General Information

Y27BPOA

1.

The maintenance-free battery is. as the name implies. totally maintenance free. 2. Water never needs to be added to the maintenance-free battery. 3. The battery is completely sealed. except for small vent holes in the cover. 4. The battery contains a visual test indicator.

~[

6.

TROUBLESHOOTING Battery Visual Inspection (1)

Y278QOA

Check for obvious damage such as cracked or broken case or cover that could permit loss of electrolyte. Determine cause of damage and correct as needed. Clean corrosion with a soultion of baking soda and water. Not O.K.

I

O.K.

Replace battery

Check battery condition indicator and electrolyte level.

I

I

I

Green

White

Red

@

~ I

I

Specific gravity is 1.220 or greater and cell variation is less than 50 points. O.K. Reuse battery

I

I

I I

@

Acid level is above top of specific plates and gravity variation is more than 50 points.

Battery undercharged. Further testing needed

I Fluid level low. Adjust with distilled water then test

Not O.K. Replace battery

27-17

CHARGING SYSTEM

Check specific gravity. Refer to "Specific gravity check chart" for electrolyte temperature compensation, and then select proper reading below.

I 1.100 -

Below 1.100

1.220

Above 1.220

I Slow charge

Recharge

Slow charge battery at 6A for no more than 14 hrs., and then

Refer to charging guide and safety

Perform load test

precautions

perform load test.

I Load test battery Apply 200A load for 15 sec., then check battery voltage and compare below

I Above 9.6 volts

I Battery O.K. reuse

27-18

I

9.6 -

6.5 volts

I Fast charge battery and then perform load test again. NOTE: If battery is still less then 9.8 volts after second fast charge and load test, then it should be replaced

I I

Below 6.5 volts

I Battery no good. Replace

I

CHARGING SYSTEM SPECIFIC GRAVITY CHECK CHART

Y278ROA

The specific gravity of battery electrolyte changes with temperature. Heat thins the solution and lowers the specific gravity. Cold thicknens the solution and raises the specific gravity. A fully charged battery should have a specific gravity between 1.260 and 1.280. with the electrolyte temperature at 80°F. If the electrolyte temperature is above or below 80°F. the specific gravity reading must be corrected by adding 4 points (.004) for each 10° above 80°F or subtracting 4 points for every 10° below 80°F. Example: The hydrometer reading is 1.280. and the electrolyte temperature reading is 10°F. By using the chart. the specific gravity must be lowered by .02B points. The true corrected reading is 1.252. 1.280-.028 = 1.252

ELECTROLYTE TEMPERATURE

SPECIFIC GRAVITY CORRECTION

IF) 1200

-+.016

1100

- +.012

100°

-+.008

90°

-+.004

80°

-0

70° 60°

--.004

50°

--.012

40°

--.016

--.008

30°

--.020

20°

--.024

10°

--.028

0° _laO

--.032 --.036

_20 0

--.040

You should never take a hydrometer reading immediately after water has been added. The water and electrolyte must be mixed by either charging for a few minutes at a low rate or allowing the battery to sit for an hour. 27Y038

CAUTION A difference of 50 points (0.050) or more between one or more cells indicates a defective battery. It should be replaced.

27-19

CHARGING SYSTEM BATTERY CHARGE RATE Charge method Battery type Current Specific gravity

Slow charge

Fast charge MF60B

MF68AH

MF60B

MF68AH

20A

25A

5A

6A

Below 1.100

4 hours

4 hours

14 hours

14 hours

1.100-1.130

3 hours

3 hours

12 hours

12 hours

1.130-1.160

2.5 hours

2.5 hours

10 hours

10 hours

1.160-1.190

2.0 hours

2.0 hours

8 hours

8 hours

1.190 -

1.5 hours

1.5 hours

6 hours

6 hours

1 hours

1 hours

4 hours

4 hours

1.220

Above 1.220 *MF68AH (CANADA ONLY)

Battery Visual Inspection (2) 1.

Make sure ignition switch is in Off position and all battery feed

2.

accessories are Off. Disconnect battery cables at battery (negative first)

3.

Remove battery from vehicle.

CAUTION Care should be taken in the event the battery case is cracked or leaking to protect your hands from the electrolye. A suitable pair of rubber gloves (not household type) should be worn-when this removing the battery by hand.

4.

5. 6. 7.

27YOO6

Inspect the battery carrier for damage caused by the loss of acid from the battery. If acid damage is present. it will be necessary to clean the area with a solution of clean warm water and baking soda. Scrub the area with a stiff bristle brush and wipe oil with a cloth moistened with ammonia or baking soda and water. Clean the top of the battery with the same solutions as described in Step (4). Inspect the battery case and cover for cracks. If cracks are present. the battery must be replaced. Clean the inside surface olthe terminal clamps with a suitable battery terminal cleaning tool. Replace damaged or frayed cables and broken terminal clamps.

27-20

I I

I 27YOO7

CHARGING SYSTEM 8. Install the battery in vehicle. 9. Connect the cable clamps to the battery post. making sure the top of the clamp is flush with top of post. 10. Tighten the clamp nut securely. 11. Coat all connections with light mineral grease after tightening.

CAUTION When batteries are being charged. an explosive gas forms beneath the cover of each cell. Do not smoke near batteries on charge or which have recently been charged. Do not disconnect live circuits atthe terminals of the batteries on charge. A spark will occur where live circuit is broken. Keep all open flames away from the battery.

27-21

STARTING SYSTEM STARTING SYSTEM

Y27CAOA

"$" terminal

\

GENERAL INFORMATION "8" terminal_

The starting system includes the battery, starter motor, solenoid switch, ignition switch, inhibitor switch, connection wire and

Solenoid coil

IT~~~~\t- Shift lever IJ

L

@;'L'J~=J'l'''ijT+tl~

Overrunning

clutch

battery cables. When the ignition key is turned to the start position, current flows and energizes the coil of the starter motor's solenoid. When this happens, the solenoid plunger and clutch shift lever are activated, and the clutch pinion engages the ring gear. The

Pinion gear 27Y039

contacts close and the starter motor cranks. In order to prevent damage caused by excessive rotation of the starter armature when the engine is started an overrunning clutch is used on the pinion gear.

TROUBLESHOOTING

Y27CBOA

Symptom

Probable cause

Remedy

Engine will not crank.

Battery charge low

Charge or replace battery.

Battery cables loose, corroded or worn

Repair or replace cables.

Inhibitor switch faulty

Adjust or replace switch.

Fusible link blown

Replace fusible link.

Starter motor faulty

Repair starter motor.

Ignition switch faulty

Replace ignition switch.

Battery charge low

Charge or replace battery.

Battery cables loose, corroded or worn

Repair or replace cables.

Starter motor fa ulty

Repair starter motor.

Starter motor faulty

Repair starter motor.

Ignition switch faulty

Replace ignition switch.

Short in wiring

Repair wiring.

Pinion gear teeth broken or starter motor faulty

Repair starter motor.

Ring gear teeth broken

Replace flywheel ring gear or torque converter.

Engine cranks slowly.

Starter keeps running.

Starter spins but engine will not crank.

27-22

STARTING SYSTEM SERVICE ADJUSTMENT PROCEDURES

Y27CCOA

PINION GAP ADJUSTMENT 1.

Disconnect the field coil wire from the M-terminal of the

2.

solenoid. Connect a 12V battery between the S-terminal and the

3.

M-terminal. The pinion will move out.

12V

Field coil wire

CAUTION This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 4.

27Y04O

Check the pinion to stopper clearance (pinion gap) with a feeler gauge. Pinion gap : 0.5-2.0 mm (0.02-0.079 in.)

Stopper

Pinion

5.

27Y041

If the pinion gap is out of specification, adjust by adding or removing gaskets between the solenoid and the front bracket.

27Y042

MAGNETIC SWITCH PULL-IN TEST 1. 2.

Y27CDOA

Disconnect the field coil wire from the M-terminal of the magnetic switch. Connect a 12V battery between the S-terminal and the M-terminal.

CAUTION This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 3.

If the pinion moves out, then the pull-in coil is good. If it doesn't, replace the magnetic switch.

12V

'Field coil wire

27Y043

27-23

STARTING SYSTEM MAGNETIC SWITCH HOLD-IN TEST

Y27CFOA.

1.

Disconnect the field coil wire from the M-terminal of the

2.

magnetic switch. Connect a 12V battery between the S-terminal and the body.

s

e

@ 12V

CAUTION This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. 3.

Field coil wire

If the pinion remains out. everything is in order. If the pinion moves, the hold-in circuit is open. Replace the magnetic

'7YO«

switch.

FREE RUNNING TEST 1.

Y27CGOA

2.

as follows. Connect a test ammeter (1 DO-ampere scale) and carbon pile

3.

rheostat as shown in the figure. Connect a voltmeter (15-volt scale) across the starter motor.

4. 5.

Rotate the carbon pile to the off position. Connect a battery cable from the battery negative post to the

6.

starter motor body. Adjust the rheostat until the battery voltage shown on the

7.

Carbon-pile rheostat

Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to the starter motor

.. Banery V

Voltmeter

~ 12V

27Y045

voltmeter reads 11 volts. Confirm that the maximum amperage is within the specifications and that the starter motor turns smoothly and freely. Current: Max. 90 Amps (reduction drive type) Speed: Min. 3,000 rpm

MAGNETIC SWITCH RETURN TEST

Y27CHOA

1.

Disconnect the field coil wire from the M-terminal of the

2.

magnetic switch. Connect a 12V battery between the M-terminal and the body.

G

@ 12V

CAUTION This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning. Field coil wire

3.

Pull the pinion out and release. If the pinion returns quickly to its original position, everything is in order. If it doesn't, replace the magnetic switch.

27-24

27Y045

STARTER MOTOR

STARTING SYSTEM

REMOVAL AND INSTALLATION

Starter motor

. .3-11.7) 9.8-16(100-1607

TORQUE'N . m (kg.em. Ib.ft)

27-25

STARTING SYSTEM COMPONENTS (REDUCTION DRIVE TYPE)

Magnetic switch

Ball Packing A

Packing B Plate Lever

Screw

Internal gear Overrunning clutch.

Planetary gear Planetary gear holder

Stop ring

Screw

~

Snap ring Front bracket

Rear bracket Brush holder Brush Rear bearing Armature

Yoke assembly

27Y048

27-26

STARTING SYSTEM DISASSEMBLY

Y27CM2A

__ Socket

REMOVAL OF THE SNAP RING AND STOP RING 1.

Press against the stop ring, using an appropriate socket

Stop ring ...... Pinion gear

wrench, on the snap ring side. Armature

-

Overrunning clutch

27Y049

2. After removing the snap ring (using snap-ring pliers), remove the stop ring and the overrunning clutch. Snap ring--.....~~~

Snap ring pliers

Pinion gear-..f'b.-.&'l Overrunning__.~Q;.I".-1 clutch

I\

n" nnnn!1rt1

_Armature 27Y050

CLEANING STARTER MOTOR PARTS 1. Do not immerse the parts in cleaning solvent. Immersing the

2.

yoke and field coil assembly and/or armature will damage the insulation. Wipe these parts with a cloth only. Do not immerse the drive unit in cleaning solvent. The Overrunning clutch is pre-lubricated at the factory and

3.

solvent will remove lubrication from the clutch. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

INSPECTION

Y27CN2A

CHECKING THE COMMUTATOR 1. Place the armature on a pair of V-blocks, and check the runout using a dial indicator. Standard value: 0.05 mm (0.002 in.) Limit: 0.1 mm (0.0039 in.)

27Y051

27-27

STARTING SYSTEM 2.

Check the outer diameter of the commutator. Standard value: 29.4 mm (1.157 in.) Limit: 28.4 mm (1.118 in.)

27Y052

3.

Check the depth of the undercut between the commutator segments. Standard value: 0.5 mm (0.020 in.) Limit: 0.2 mm (0.0079 in.)

Undercut Segment

27Y053

BRUSH HOLDER Check for continuity between the brush holder plate and the brush holder. The normal condition is no continuity.

27Y054

OVERRUNNING CLUTCH 1.

2.

While holding the clutch housing, rotate the pinion. The drive pinion should rotate smoothly in one direction, but should not rotate in the opposite direction. If the clutch does not function properly, replace the overrunning clutch assembly. Inspect the pinion for wear or burrs. If the pinion is worn or damaged, replace the overrunning clutch assembly. If the pinion is damaged, inspect the ring gear for wear or burrs.

27-28

STARTING SYSTEM FRONT AND REAR BRACKET BUSHING Inspect the bushing for wear or burrs. If the bushing is worn or damaged, replace the front or rear bracket assembly.

REPLACEMENT OF BRUSHES AND SPRINGS 1. 2.

Brushes that are worn beyond the wear limit line, or oil-soaked, should be replaced. When replacing the field coil brushes, remove the pigtail by crushing the worn brush with pliers, taking care not to damage the pigtail.

o

TUmit line

L..-_ _..J

27Y056

3.

Sand the pigtail end with sandpaper to ensure a good solder

4.

joint. Insert the pigtail into the hole provided in the new brush and solder it. Make sure that pigtail and excess solder are not

5.

on the brush surface. When replacing the ground brush, slide the brush from the brush holder by prying the retaining spring back.

New brush Soldered

(Make sure that there is no excess solder on brush surface)

27Y0'57

TESTING THE ARMATURE TESTING THE ARMATURE FOR SHORT-CIRCUITS 1. 2.

Place the armature in an armature tester. Hold a thin steel blade parallel and just above the armature while rotating it slowly in growler. A shorted armature will cause the blade to vibrate and be attracted to the core. Replace a shorted armature. 27Y058

27-29

STARTING SYSTEM TESTING THE ARMATURE FOR GROUNDS Check the insulation between the armature coil cores and the commutator segments. They are normal if there is no continuity.

27Y059

CHECKING FOR ARMATURE COIL WIRING DAMAGE/DISCONNECTION Check for continuity between the segments. They are normal if there is continuity.

SERVICE POINTS OF ASSEMBLY

Y27CP2A

INSTALLATION OF THE STOP RING AND SNAP RING Using a suitable pulling tool, pull the overrunning clutch stop ring over the snap ring. Stop ring

Stop

overrun~ing r~tc: Snap ring

I 27Y061

27-30

STARTING SYSTEM INSPECTION OF CLUTCH START SYSTEM (IGNITION LOCK SYSTEM) Check clutch pedal Check that pedal height, pedal freeplay and clutch pedal clevis pin play are correct. (Refer to clutch group)

Check starter relay Remove the starter relay and check continuity between the terminals. If the continuity is not as specified, replace the relay. Terminal Condition

'"

5,

(3,

52

I

L"

B

141

When de-energized When energized

1

STARTER RELAY

Check ignition lock switch 1. 2.

Check for continuity between terminals when the switch is ON (pushed). Check for no continuity between terminals when the switch is OFF (free).

12±O.2 mrn

L-.J-~J''l(JizHlt o 0 210.2 mm

27-31

IGNITION SYSTEM IGNITION SYSTEM GENERAL INFORMATION

Y27DAOA

Cap

.", Ritor

Ignition timing is controlled by the electric control ignition timing system. The standard reference ignition timing data for the engine operating conditions are programmed in the memory of the electronic control unit (ECU). The engine conditions (rpm, load, warm-up condition, etc.) are detected by the various sensors. Based upon these sensor signals and the ignition timing data, signals to interrupt the primary current are sent to the power transistor. The ignition coil

I

\'0-

Disc

.I(n

'""" LU (r,

Gl +

II

+

• n

=

Unit

is activated, and timing is controlled this way.

TROUBLESHOOTING

Y27DBOA

Symptom

Probable cause

Remedy

Engine will not start or

Incorrect ignition timing

Adjust ignition timing

Ignition coil faulty

Inspect ignition coil

Power transistor faulty

Inspect power transistor

Distributor faulty

Inspect distributor

High tension cord faulty

Inspect high tension cord

Spark plugs faulty

Replace plugs

Ignition wiring disconnected or broken

Inspect wiring

Spark plugs faulty

Replace plugs

Ignition wiring faulty

Inspect wiring

Incorrect ignition timing

Adjust ignition timing

Ignition coil faulty

Inspect ignition coil

Power transistor faulty

Inspect power transistor

High tension cord faulty

Inspect high tension cord

Spark plugs faulty

Replace plugs

Ignition wiring faulty

Inspect wiring

Incorrect ignition timing

Adjust timing

Spark plugs faulty

Replace plugs

Incorrect ignition timing

Adjust ignition timing

Incorrect ignition timing

Adjust ignition timing

hard to start. (Cranks

OK)

Rough idle or stalls

Engine hesitates/poor acceleration

Poor gasoline mileage

Engine overheats

27-32

IGNITION SYSTEM

SERVICE ADJUSTMENT PROCEDURES SPARK TEST SPARK TEST (when engine can be cranked)

Disconnect the high tension cable from the center of the distributor cap. Hold the cable about 6-8 mm (0.24-0.31 in.) away from an engine ground and crank the engine.

I I

No spark produced

I

I

I

I

Spark produced

-I Check voltage at the negative side of the coil while cranking the engine

I I

Voltage does not fl uctuate

I

1

Check the coil, wiring, power transistor, ECU and the photo sensor assembly

I

I Voltage fluctuates

I

I Check the coil wire and connections

27-33

IGNITION SYSTEM

SPARK PLUG TEST (WHEN ENGINE CAN BE CRANKED)

Y27000A

Connect a spark plug to the high tension cable, ground the outer electrode (main body), and crank the engine. If the spark plug is good, however, sparks will be produced in the gap. In a defective spark plug, no sparks will occur.

Ignition coil

Spark plug

Distributor

~

,8.../

IGN SW

£,1 7 BAn

Defective insulation

Defection insulation

~---HJl:~1='1 Defective insulation Good

27Y063

CHECKING SPARK PLUG CABLES 1. 2.

Y270EOA

Check the cap and outer shell for cracks. Measure the resistance. Unit: kfl Spark plug cable

High tension cable

Approx. 2.7

27-34

No.1

No.2

No.3

No.4

10.6

13.1

16.7

22.1

27Y064

IGNITION SYSTEM

CHECKING SPARK PLUGS

Y27DFOA

INSPECTION AND CLEANING OF SPARK PLUGS 1.

Disconnect the spark plug cable from the spark plug. NOTE When the spark plug cable is pulled off, be sure to remove by pulling on the spark plug boot. If the spark plug cable is removed by pulling on the cable, it may be damaged.

2.

Using a plug wrench, remove all the spark plugs from the

27Y065

cylinder head. CAUTION Use care not to allow foreign matter to enter through the spark plug holes. 3.

Check the spark plugs for the following: 1) Broken insulator 2) Worn electrode 3) Carbon deposits 4) Damaged or broken gasket. 5)

IIIII111

Burnt condition of the porcelain insulator at the spark gap.

Condition

27Y066

Dark deposite

Description o Too rich a fuel mixture o Low air intake

4.

White deposite o Too lean a fuel mixture o Advanced ignition timing o Insufficient plug tightening

Check the spark plug gap using a wire gap gauge and adjust if necessary. Standard value: 1.0-1.1 mm (0.039-0.043 in.)

GAP 27Y067

27-35

IGNITION SYSTEM 5.

Tighten spark plug to specified torque. If it is overtorque, damage to threaded portion of cylinder head might result. Spark plug: 20-30 Nm (204-306 kg.cm. 15-21 Ib.ft)

IGNITION TIMING IGNITION TIMING ADJUSTMENT Adjustment conditions: Coolant temperature: 80-95°C (176-205°F) All accessories: Off Transaxle: N (Neutral) Parking Brake ON

1. 2.

Connect timing light. Start engine and run at curb idle speed. Curb idle speed: 750

± 100 rpm

3.

With the engine stopped, connect a lead wire with alligater clips to the terminal for ignition-timing adjustment (located in the engine compartment), and ground it.

4. 5.

Start and run the engine at curb idle speed. Check basic ignition timing and adjust if necessary. Basic ignition timing: 5°

27-36

± 2° BTDC

IGNITION SYSTEM 6.

If there is a deviation from the standard value, loosen the distributor's holding nut, and then turn the distributor itself and make the necessary adjustment. NOTE The ignition timing will be advanced if the distributor is turned to the left and retarded if it is turned to the right.

7.

Alter adjustment. securely tighten mounting nut. CAUTION Be careful, when tightening the nut, that the distributor does not move.

8. 9. 10. 11.

Stop the engine. Disconnect the lead wire connected at step 3. Start and run the engine at curb idle speed. Check to be sure that the idling ignition timing is the correct timing. Basic ignition timing: 10 0 BTDC

CHECKING IGNITION COILS 1.

Y27DHQA

Measurement of the primary coil resistance. Measure the resistance of the positive (+) terminal and negative (-) terminal of the ignition coil. Highvoltage ~terminal

Standard value: 0.8 ± 0.080 2.

Measurement of the secondary coil resistance. Measure the resistance between the ignition coil's positive (+) terminal and the high-voltage terminal. Standard value: 12.1

±

1.21 kO

POWER TRANSISTOR 1.

Connect the negative (-) terminal of the 3V power supply to terminal 2 of the power transistor; then check whether there is continuity between terminal 3 and terminal 2 when terminal 1 and the positive (+) terminal are connected and disconnected. Terminal 1 and (+) terminal

2.

Y270JOA

Terminal 3 and terminal 2

Connected

Continuity

Unconnected

No continuity

~ -/7)0 ='0 o 0

®

e

Replace the power transistor if there is a malfunction.

27-37

IGNITION SYSTEM

REMOVAL AND INSTALLATION

Spark plug

~ ,o-~'~-~~. ,'-'" Power transistor

Spark plug cable

High tension cable

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

INSTALLATION OF DISTRIBUTOR 1. 2.

Y27DKOA

Turn the crankshaft so that the No.1 cylinder is at top dead center. Align the distributor housing and gear mating marks.

~ _ Gear's mating

=".'a:k 'l~

Housing's

_mating mark

3.

Install the distributor to engine while aligning the fine cut (groove or protection) of the distributor's installation flange with the center of the distributor installation stud.

~

s~

~Housing's

;2:::-.___ mating mark

-

27-38

.~

IGNITION SYSTEM DISTRIBUTOR COMPONENTS

Unit

Plate

Cover

Packing

Distributor shaft

Bearing

lstributor ho uSIng .

0"

Lead wire

27-39

IGNITION SYSTEM

REMOVAL

Y27DlDA

1. 2.

Disconnect the battery ground cable. Remove the two distributor cap retaining clips and move cap to one side.

3. 4.

Disconnect the lead wire connector. Remove the distributor mounting nut and remove the distributor assembly.

DISASSEMBLY

Y270MOA

1.

Lightly clamp the distributor in a vise equipped with soft jaws.

2. 3. 4. 5.

Pull off the rotor from the rotor shaft. Remove the packing rubber. Lift off the cover. Remove the rotor shaft by using a driver.

7. 8. 9.

Remove the disc and spacer. Disconnect the lead wire connector. Lift off the plate and unit by removing the three mounting screws.

10. Remove the shaft bearing tightening screws. 11. Make a position identification mark (for the drive gear) on

..L--Punch

the distributor shaft. 12. Place the drive gear on a soft base (wooden block) so that the over will not be damaged. 13. Drive out the roll pin by using a pin punch.

27-40

Drive gear

'

Housing

IGNITION SYSTEM REASSEMBLY

Y27DNOA

DISTRIBUTOR SHAFT After coating the shaft with a small amount of engine oil, insert it into the housing.

CAUTION Do not use solvent or similar products.

DRIVE GEAR 1.

Align the drive gear with the mark made at the time of disassembly, and install the gear to the distributor shaft.

2.

When aligning the drive gear's mating mark ad the housing's mating mark, sure that notch "A" at the shaft end is at the position shown in the figure, and then align the roll pin hole and drive in a new roll pin.

CAUTION Drive in the roll pin so that the slits are at a right angle relative to the shaft.

DISC Insert the disc into the sensor part of the pick up unit assembly and install the alignment with the spacer.

CAUTION The disc's slits must not be clogged.

COVER Install the cover so that the cover's indentation "A" is aligned with the housing's notch "B".

27-41

AUTOMATIC SPEED CONTROL (CRUISE) AUTOMATIC SPEED CONTROL (CRUISE)

Y27EAOA

SPECIFICATIONS Items

Specifications

Speed control unit Operating voltage range Operating temperature range Voltage drop between unit and actuator Operating speed range

DC 11 - 16 V -30 - +80 o C (-22 - +176°F) 0.4 V Low speed limit: 40 ± 5 km/h (25 ± 3 mph) High speed limit: 137 ± 7 km/h (85 ± 4 mph)

Actuator Operating vqltage range Operating temperature range Maximum operating current Cruise main switch Rated voltage Operating force Voltage drop Stop lamp switch Rated voltage Rated load Stop lamp Cruise control Insulating resistance Clutch switch

DC 11 - 16 V -30 - +90 o C (-22 - +194°F) 1.7 A DC 12 V 0.3 - 1.0 kg 0.1 5 V or less DC 12 V 27 x 5 W (lamp load) 0.1 - 0.5 A (relay load) Min 3 Mil (by 500 V megger)

DC 12 V 1 A

Rated voltage Rated current

SPECIAL SERVICE TOOL Tool (Number and name)

09391-33000 Multi-use tester

27-42

Y27EBOA

Use

Illustration

<:?~~"~O', ~ ""M/-

Reading diagnosis code

AUTOMATIC SPEED CONTROL (CRUISE) Interior

Engine compartment

E

G

C

H

A

D

F

B

Name

Name

Symbol

Accelerator switch (vehicles with automatic transaxle)

A

Reed switch (Vehicle speed sensor)

E

Actuator

B

Speed-control switch

F

C

Speed-control unit (cruise control unit)

G

D

Stop lamp switch

H

Clutch switch (Vehicles with manual transaxle) Cruise main switch

Symbol

A Accelerator·

switch

27-43

AUTOMATIC SPEED CONTROL (CRUISE)

C

E

F

(Located into the cluster)

G

27-44

AUTOMATIC SPEED CONTROL (CRUISE) System Block Diagram Cruise Accelerator

~~

~dal

(~~

Thr ottle valve

CONTROL SWITCHES

Resume/Accel Set/Coast

Diagnosis connector

Pulley assembly

Electronic control

I Actuator : ~

ELC 4-speed Automatic transaxle control unit (if applicable)

f-------

unit

Cancel switches

Vehiclespeed sensor

Component parts and function outline COMPONENT PART

Y27ECOA

FUNCTION

Vehicle-speed sensor

Converts vehicle speed to pulse.

Electronic control unit (ECU)

Recieves signals from sensor and control switches; ECU controls all automatic speed control functions.

Actuator

Control switch

Regulates the throttle valve to the set opening by signals from the ECU. CRUISE main switch

Switch for automatic speed control power supply.

SET switch

Controls automatic speed control functions by SET (COAST) and RESUME (ACCEL).

RESUME switch CRUISE main switch indicator

Pieza alarm

Illuminates when CRUISE main switch is ON (Built into CRUISE switch). When the SET or RESUME switch is switched ON, the alarm sounds to notify the driver that the control unit has recieved the ON signal.

27-45

AUTOMATIC SPEED CONTROL (CRUISE) FUNCTION

COMPONENT PART Cancel switch

Stop lamp switch/ Brake switch Clutch switch (Vehicles with a manual (transmission)

Outputs the automatic speed control cancel signals.

Inhibitor switch (Vehicles with an automatic transmission) ELC 4-speed automatic transmission control unit (Vehicles with automatic transmission)

Controls the ON and OFF of the overdrive, based on overdrive ON and OFF signals from the ECU for the ASC.

Diagnosis connector

CONSTRUCTION AND OPERATION

By connecting the voltmeter or multi-use tester, control unit diagnosis codes can be read out.

Y27EOOA

Intermediate pulley A

ACTUATOR The actuator is motorized and controls the throttle valve through a series of intermediate pulleys. These pulleys are mounted as an assembly to the firewall on the right side of the engine compartment. The actuator located on the passenger side shock

Intermediate pulley B

tower VIEW A

27-46

AUTOMATIC SPEED CONTROL (CRUISE) Operation of the intermediate pulley

Accelerator cable B

(Throttle valve side) Accelerator cable A

(Accelerator side) Intermediate pulley B

(Throttle valve side) Intermediate pulley A,

(Accelerator side)

_____.,.~,~~~,+..t;;6:;2::::::-

VIEW A

i!ll-+-+-- VIEW

Actuator cable C

B

Intermediate pulley C (Actuator sideI PUlley assembly

Actuator Intermediate pulley B

Intermediate pulley C

VIEW B

1.

2.

DURING NORMAL DRIVING When the accelerator pedal is operated, the rotation of intermediate pulley A. which is connected to accelerator cable A (accelerator pedal side), causes intermediate pulley B to turn. Then accelerator cable B, which is connected to intermediate pulley B, opens and closes the throttle valve. DURING AUTOMATIC SPEED CONTROL DRIVING The retraction of the actuator causes intermediate pulley B to turn by operating intermediate pulley C. This action opens and closes the throttle valve. However, intermediate pulley A is not operated and accelerator cable A does not move, so the accelerator pedal remains stationary in its original position.

27-47

AUTOMATIC SPEED CONTROL (CRUISE)

CONSTRUCTION OF ACTUATOR INTERNAL CONSTRUCTION

Variable voltage position sensor

D.C. motor

Rack gear Electromagnetic

clutch· Reduction gearing

CIRCUIT DIAGRAM

Cruise MAIN switch Power

supply

(Df-----
j--B-rake---Ir=--i

1 __

~,-h' _ _---+~

I

:

,

I, I

.v--J

NC

t--_._--+---~

control

unit (ECU)

L

Pull

+

Electronic

I,,

Actuator"

Clutch coil

_

•

D.C. motor

Release

Variable voltage position sensor

The actuator unit consists of an electric motor with reduction gearing, electromagnetic clutch, actuating rack, and a variable voltage position sensor.

27-48

AUTOMATIC SPEED CONTROL (CRUISE)

OPERATION OF THE ACUTATOR

Y27EEOA

Pinion gear

Variable vollage position sensor

D.C. motor

Rack gear

Final drive gear

Clutch plate Electromagnetic clutch coil gear

Speed reduction gears

Clutch electrical contacts

1.

2. 3. 4. 5. 6.

When the vehicle reaches the specified speed, with the CRUISE switch at the ON position and the SET/COAST, switch is momentarily set to the ON position, the control unit causes current to flow to the actuator's electromagnetic clutch coil. The clutch plate is then attached, and at the same time, the path from the ECU to the· D.C. motor becomes conductive and the D.C. motor begins to rotate at high speed. As shown in the figure above, the rotation of the D.C. motor is transmitted to the speed reduction gears electromagnetic clutch coil gear - final drive gear - pinion gear - rack gear. The selection of the direction (PULL or RELEASE) of the rack gear is performed by the reversal of the direction of conductivity to the motor and this is automatically controlled by the ECU. When the driver switches OFF the CRUISE switch, or switches ON the cancel switch, thus canceling the ASC system, conductivity to the electromagnetic clutch is interrupted. As a result of the interruption of the conductivity to the electromagnetic clutch, the clutch plate is returned from the electromagnetic clutch side to its normal position. When the clutch plate is free from the electromagnetic clutch coil gear, the rack gear is free to return to its normal extended position.

27-49

AUTOMATIC SPEED CONTROL (CRUISE) NOTE The ECU has a built-in current detection circuit to prevent the actuator motor from becoming overloaded when the throttle valve is fully opened. The figure at the left shows control signals applied to the actuator motor under operation. The extension or retraction of the actuator rack gear is dependent of the direction of current flow to the actuator motor windings.

ACTUATOR MOTOR

Throttle (close direction) Throttle (open direction)

5

~

5

!

6

ELECTRONIC CONTROL UNIT (ECU) The ECU incorporates circuity which provides the set, coast, resume, acceleration, cancel, low-speed limitation, overdrive OFF control and automatic cancellation functions. The ECU inputs signals from the vehicle-speed sensor and the switches, and outputs control signals to the actuator's D.C. motor, the electromagnetic clutch, the automatic transaxle (ELC 4 AfT) control unit, and the alarm.

27-50

•

I

I

r 6

t

AUTOMATIC SPEED CONTROL (CRUISE)

CONTROL LOGIC BLOCK DIAGRAM

Ignition switch

-

~ I

,

Speed sensor

Input

I~ETI I COAST

Input

Motor

circuit

drive

switch

switch

Brake switch

(normal close)

,

I

Input circuit

Alarm

,

,

,

Alarm

switch (N.C.)

-

'2

00 OFF indicator lamp

o--®--t

--

'2

output

T ELC

:O~~I

.

Unit

I

I

00 switch

circuit Diagnostic input circuits

I

Accelerator

switch output circuit

00 control

I

,

drive circuit

ELC 4 AIT accelerator

,

rh

~~

Clutch drive circuit

,

I I

Actuator I

, Cruise control I.C.

1'1

II Inhibitor 1*2

switch

circuit

Cancel switch

Clutch

main

,

,

I I

Cruise

,

,

IACCEL RESUMEI I

Stop lamp switch

I

IPower supplyl I circuit I

circuit

Control switch

II II

ECU

, Diagnosis

I.C.

Diagnosis output circuit

Diagnosis connecto

I

I

-

I I

I I

I

I I I I I I

(Use voltmeter or multi·

use tester)

*, :

Vehicles with a manual transaxle *2 : Vehicles with an automatic transaxle

27-51

AUTOMATIC SPEED CONTROL (CRUISE)

CONTROL UNIT FUNCTIONS 1.

Y27EGOA

SET (Fixed-speed control) When, with the CRUISE switch set to ON, the SET switch is switched from ON to OFF while the vehicle is being driven within the speed range in which speed settings are possible (approximately 40-137 km/h (25-85 mph)), the vehicle speed at. the moment the SET switch was switched from ON to OFF is memorized as the "set vehicle speed", and thereafter the actuator is controlled so that f.ixed-speed driving at that speed is possible. The figure below shows the timing charts.

CRUISE switch SET switch

ON OFF NO OFF

- J

Acceleration (forward rotation )

Actuator (motor) Stop Deceleration (reverse rotation)

Electromagnetic clutch

..

[Initial pulse

I

~ Control pulses

III

1\ (TRIM

PULSE)

\

I I

I

ON OFF

Manual driving

Fixed-speed driving

Manua I driving

1)

INITIAL PULSE The initial pulse opens the throttle valve to a degree of opening which approximately corresponds to the vehicle .speed. This pulse is output when the ASC system is set. 2) TRIM PULSE The trim pulse is a control pulse for correcting the vehicle speed which is output is response to detected speed errors. The output pulse width is determined based upon the amount of deviation between the current vehicle speed and the set vehicle speed, and upon throttle position. 2.

Y27EHOA COAST During fixed-speed driving, while the SET switch is ON, the acuator's D.C. motor is caused to rotate to the REL (release) side. The vehicle speed when the switch is switched OFF as deceleration continues is entered in the memory, and is thereafter controlled as the fixed speed.

3.

RESUME SPEED Y27E.lOA When (after the ASC system is canceled by the cancel conditions described in item 5 during fixed-speed driving) the RESUME switch is switched from OFF to ON, while driving at a vehicle speed which is the low-speed limit (approximately 40 km/h (25 mph) or higher, the vehicle speed memorized before cancelation of the ASC system will be controlled as the fixed speed.

4.

ACCELERATION mEKOA During fixed-speed driving or above the low-speed limit, while the RESUME switch is ON, the actuator's D.C motor is caused to rotate to the PULL side. The vehicle speed when the switch is switched OFF as acceleration continues is entered in the memory, and is thereafter controlled as the fixed speed.

27-52

AUTOMATIC SPEED CONTROL (CRUISE) 5.

Y27ELOA CANCELLATION When the signals below are input (during fixed-speed driving), conductivity to the electromagnetic clutch is interupted, thus canceling the ASC system. 1) Stop lamp switch ON (brake pedal depressed) 2) Clutch switch ON (clutch pedal depressed) 3) Inhibitor switch ON (selector lever at "P" or "N" position)

NOTE When the brake pedal is depressed and the stop lamp switch is switched ON, the ASC system will be canceled even if there is wiring damage or disconnection at the fuse for the stop lamp.

CANCEL SWITCH CIRCUIT DIAGRAM

Fuse Ignition

,----

-...,r

switch

ST

Cruise MAIN I

LLo~\~

+~y Inhibitor switch

(ON at "P" or "N"

r~-l . , .

Fuse

Clutch switch

r /o-J__

To starter motor

~::::::l....o-----l I· I

I

'C

(Vehicles with a manual transaxle)

+B (12V)

. '?

Consta [voltage c jc----l

l

BV

r;:-:::l

~. L __

~

Actuator

I

clutch coil

....-r------+-----1~.5

I

' ~ --

I'U

I

' '-'

l~ 8 I~

Cruise

control I.C.

I

~

""t 0 .:t

Stop ;r lamp"

-- ---

-~

I

I

position) (Vehicles with an automatic transaXle}r"F~~r=;-.J r -, Starter relay -

I

!::J! ~-w.

ACC

...J...

1

switch

ECU

---=-~-

.£ .-

g

~

'"

u

:'0';..' -Hr--j- ~l----+--1--'---+----1"H_ I ' I I

_

f-----J

I

u-

:~~rc~a(~~) ~:~~h

NO: Normal open

(NC)

Clutch drive

L

?'

tra~tor

.+1 2V

_

NC: Normal close

6.

LOW-SPEED LIMIT Y27EMO' There is automatic cancelation at or below the low-speed limit vehicle speed (approximately 40 km/h (25 mph)).

27-53

AUTOMATIC SPEED CONTROL (CRUISE) 7. HIGH-SPEED LIMIT The vehicle cannot be driven at a fixed speed which is at or higher than the high-speed limit (approximately 137 km/h (85 mph)). Note that the vehicle speed memorized when the SET switch is pressed while the vehicle is traveling at the high-speed limit or higher will be the high-speed limit speed.

8. AUTOMATIC CANCELLATION When, during fixed-speed driving, the signals described below are input, conductivity to the electromagnetic clutch is interrupted, thus canceling the ASC system. 1) If the vehicle speed decreases to a speed which is approximately 18 km/h (11 mph) or more below the 2) 3) 4)

memorized vehicle speed. If there is no input of the vehicle speed signal for a time (greater than 0.5 second). If there is damaged or disconnected wiring of the input line (stop lamp switch load side) of the stop lamp switch. If the cancel switches (stop lamp switch, clutch switch or inhibitor switch) and command switches SETswitch or RESUME switch) are switched on at the same time. NOTE If the SET and RESUME switches are ON at the same time the cruise control will operate in the COAST mode and the speed will decrease.

9.

PIEZO ALARM When, while the CRUISE switch is ON, SET switch or RESUME switch ON signals are recieved, the alarm is activated for approximately 0.2 second. NOTE 1) Power is supplied from the fuse No.8 (10AI to the alarm. 2) This alarm is also used as the alarm for warning of operation of passive seat belt system.

ECU PIEZO ALARM B+

E1

E2

TO PASSIVE SEAT BELT CONTROL UNIT 27Yl00

10. ACCELERATOR SWITCH (Vehicles with an automatic transaxle) The accelerator switch is a switch that functions to detect the condition of the accelerator pedal, and is one of the ELC 4 AIT sensor. Because the accelerator pedal is not used during fixed-speed driving, the ground circuit (transistor Tn) of the accelerator switch is switched OFF during this time only, so as not to adversely affect the function of the ELC 4 AlT.

27-54

AUTOMATIC SPEED CONTROL (CRUISE)

ASC system ECU (for ASC)

I,

In operation

Tr' OFF

Not in

ON

operation

~

ASC OFF

---

4T

I

---------,

ASC ON

f, .Battery

I I I I I I I I I I

,

I

~ Trl

I

-I

OFF)

J

I

______ -l

------

IGN SW

SW.

I

,(Depressed:

~

6 1tBrake

Accelerator switch

--1,

----,

,

J

L

ELC 4 AIT control unit

11. OVERDRIVE-CANCEL FUNCTION (Vehicles with an automatic transaxle) vmSOA When, during fixed-speed driving, the actual vehicle speed decreases to (or below) a speed which is a certain fixed value below the memorized vehicle speed, and the actual vehicle speed continues at that reduced speed, or during the resume operation described in item 3 or the acceleration operation described in item 4, etc., it becomes necessary to return to the vehicle speed for a short time and to accelerate, the overdrive function of ELC 4 A/T-equipped models is canceled for a certain time.

Overdrive signal ON OFF

ECU (for ASC) - - - - - _. - - Microcomputer

--------, I I I

I

00 ON

~ -----.r00 OFF

-

- --

I I

r

Tr2 ON OFF

ON

1 ..,

--I

.:.. Battery

T

-<::r 0 Ignition switch IG2

I

overdriVe()

-.;

switch

I

Trt"'~TTr2

, -

I

~

-t

I

I

---'

-

Trl OFF

Cluster

I~I

~'§~ (Rheostat)

~ - -

I

L

- ---; ELC 4 AIT r . ____ -.-J control unil

27-55

AUTOMATIC SPEED CONTROL (CRUISE) Y27ETOA 12. SELF-DIAGNOSIS FUNCTION When there is a cancellation of the ASC system operation not intentionally made by the driver, it is possible to determine which circuit or what operation caused the cancellation of the ASC system by (without stopping the engine) stopping the vehicle (with the MAIN switch still ON) and then connecting a voltmeter and multi-use tester to the diagnosis harness connector.

NOTE The display of the malfunction data starts if the vehicle speed decreases to less than approximately 20 km/h (12 mph) after the cancelation of the ASC system function, and stops if the vehicle speed increases to approximately 20 km/h (12 mph) or higher.

Self-diagnosis Descriptions and Displays CODE NO.

-

DIAGNOSIS ITEM

-

SELF-DIAGNOSIS DESCRIPTION

DISPLAY PATIERNS

ON 0.5 °.5 (12V) Continuous (0.5° OFF ~ ......... signal sec. ON ,.5 (OV) sec. OFF)

11I

11

Actuator clutch coil drive circuit

(Example) Code No. 13

12

Vehicle-speed signal circuit malfunction

ON (12V)

13

Low-speed limitter circuit

14

Redundant brake

3

OFF (OV)

CD

(3)

1.5

05hf·5 2

ITTj~.~ cb @@

4:>

15

ing has been set. Open brake switch, or open ECU output transistor.

3

I

cb

Pause time,3 seconds OFF "Tens" rank signal: 1.5 seconds ON

(called "1O") Control switch malfunction

Display pattern (when ECU normal) when vehicle speed is approximately 20 km/h (12 mph) or higher, and before fixed-speed driv-

@

Rank division: 2 seconds OFF

0

"Units" rank signal: 0.5 seconds ON 0.5 seconds OFF

Vehicle speed signal is not input for 0.5 second or longer. When the vehicle speed decreases to 40 km/h (25 mph) or lower. When vehicle speed actual decreases to approximately 18 km/h (11 mph) or more below the memorized vehicle speed. When the SET switch and the RESUME switch are switched ON at the same time.

signal. (The number

of ON periods is the number of

16

27-56

When cancel signal is input

"unit" ranks.)

When the stop lamp switch, clutch switch or inhibitor switch is switched ON, or there is damaged or disconnected wiring between the stop lamp switch and the ECU.

AUTOMATIC SPEED CONTROL (CRUISE) TROUBLESHOOTING

Y27EUOA

BEFORE TROUBLESHOOTING The ASC (Automatic speed-control) system performs control functions for the setting or cancellation of the fixed-speed driving speed based upon the data provided by input signals. As a result. when the ASC system is canceled, the cause of the cancellation is memorized in a separate circuit by the ECU, regardless of whether or not the ASC system condition is normal or abnormal, thus providing the ECU with the self-diagnosis function by certain fixed patterns, as well as the function of being able to check whether or not the ECU's input switches or sensor are normal. Thus, by effectively using these function, the time required checking and repair can be shortened.

NOTE When the computer (ECU) power supply (ignition switch and main switch) is switched OFF, the memorized diagnosis codes are erased, and so for this reason the power supply must be left ON until the checking is completed.

SELF-DIAGNOSIS CHECKING

Y27EVOA

Self-diagnosis checking is performed when there has been an automatic cancellation, without cancel switch operation. 1. The following two methods can be used for checking the diagnosis. Note that the diagnosis check connector is located in the fuse box. 1)

If a multi-use tester is used Connect the multi-use tester's socket and connector to the cigarette lighter socket and the self-diagnosis check connector, and set the tester. Use the tester according to its operation instructions; display the diagnosis code number and then check.

27-57

AUTOMATIC SPEED CONTROL (CRUISE) 2)

2.

If a voltmeter is used Connect a voltmeter between the ground terminal and the terminal for ASC of the diagnosis check connector. It is possible to discover which circuit is the cause of the cancellation by verifying the indication shown by the voltmeter with the display patterns shown on the next page. When diagnosis code No. 11, 12, 15 or 16 is displayed, check by referring to the troubleshooting symptom applicable to that number. NOTE There are six diagnosis items, including the one for the normal condition. As examples of the normal condition, code No. 16 is entered in the memory as cancel switch ON signal input if the system is canceled by depressing the brake pedal. and code No.13 or No.14 is entered when there is an automatic cancellation because the vehicle speed drops when the vehicle is driven up a steep slope with the preset speed setting left set, etc .. when however, there is a cancellation not intentionally made by the driver, the cause might be damaged or disconnected stop lamp switch input wiring, a malfunction of the stop lamp switch ON, etc., even though the same code No.16 is displayed.

DIAGNOSIS CONNECTOR (IN THE FUSE BOX)

DISPLAY SIGNAL PATTERN (FOR EXAMPLE CODE 23) 0.5

0.5

3

OFF '-

v

0.5

t ""If" "'" frt2

I

/'-

~ v

I

3

Ie

rmn

/'----y--/~'

v

I

~I

/

I

Pause time

Unit digit Pause time (Digit) 10 digit Pause time Dimension: Second

27-58

AUTOMATIC SPEED CONTROL (CRUISE) Diagnosis Display Patterns and Codes Code No. 11

Display patterns (output codes) (Use with voltmeter)

12V~

Probable cause Abnormal condition of actuator drive system

OV

12

12V~

Abnormal condition of vehicle-speed signal system

OV

13'

12V~

Low-speed limiter activation (The system is normal if it can be reset.)

OV

14'

12V

15'

12V

1

OV~ t

OV

16'

4

12V OV

,

Automatic cancellation activated by vehicle speed reducion. (The system is normal if it can be reset)

~~h~

Control switch malfunction (when SET and RESUME switches switched ON simultaneously)

m~1 6m~

Cancel switch ON signal input (including stop lamp switch input wiring damage or disconnection)

,~

NOTE 1. Codes indicated by the' symbol are displayed, if the conditions are satisfied, even if the system is normal. In either case, the system is normal if it can be reset. If there is an automatic cancellation not intentionally made by the driver, however, excluding cancellations explicitly made by the cancel procedure, there may be a temporary malfunction such as poor contact of a harness connector even though the system can be reset, and for that reason it is necessary to check according to each individual check chart that is applicable. 2. Diagnosis codes are displayed when, after cancellation of the ASC system, the vehicle speed decreases to less than approximately 20 km/h (12 mph), and are erased by switching OFF the ignition switch or the MAl N switch. After the diagnosis codes in the memory are erased, if (when the power supply of the electronic control unit is switched ON once again) the power supply of the electronic control unit is normal, the Display when vehicle speed is approximately 20 km/h (12 mph) or higher, diagnosis output code display will be as below, regardless or before the ASC system is set of whether the system condition is normal or not. 1)

If a multi-use tester is used: "NORMAL!!" will be displayed. 2) If a voltmeter is used: Continuous ON/OFF signals will be displayed at 0.5-second intervals. (Refer to the figure at the right.)

0.5

se~.5

ON 112VI

III

sec

~ ~ ~ E:'il ~ ~

f:I

~

OFF~

_

IOV)

27-59

AUTOMATIC SPEED CONTROL (CRUISE) TROUBLESHOOTING PROCEDURES

Y27EWOA

First, select the applicable malfunction symptom from the Trouble Symptom Charts. Conduct self-diagnosis check following the directions provided by the charts. Determine condition of all function circuits. CAUTION Because the computer (self-diagnosis) memory data will be erased. when the system is unintentionally canceled during fixed-speed driving the ignition switch and/or the cruise main switch of the ASC system should not be switched OFF. and the battery should not be disconnected. 1.

Make following preliminary inspections. 1) Check to be sure that the installation of the actuator, accelerator cables are correct, and that the cables and links are securely connected. 2)

Check to be sure that the accelerator pedal move smoothly. 3) Adjust the cables so that there is not excessive tension or excessive play to the accelerator cable. 4) Check to be sure that the ECU, actuator, cruise main and control switch and the connector of each cancel switch are connected securely.

2. 3.

Check in the sequence indicated in the Trouble Symptom Chart. If these checks indicate nothing abnormal, replace the ECU. ASC : Automatic speed control ECU : Electronic control unit

27-60

AUTOMATIC SPEED CONTROL (CRUISE) TROUBLE SYMPTOM CHARTS

Y27EXOA

Trouble Symptom 1

ASC symptom is canceled when cancellation not wanted. Or, the ASC system cannot be set after an automatic cancellation.

After the OCCurrence of the problem, was the ignition switch and cruise main switch left ON?

No

I I

I

Can the ASC System be set now? Yes

No

Yes

Set the ASC system and conduct a road test.

Continue to Trouble Symptom 2 (next page)

Did the problem reoccur? Yes

With the cruise main switch ON and the engine running, check the diagnosis code.

No (now normal)

Check whether or not. then, the vehicle was driven on a steep slope, or the SET and RESUME control switches were operated simultaneously. (The cause is not clear under the present circumstances.)

27-61

AUTOMATIC SPEED CONTROL (CRUISE) Trouble Symptom

2

NOTE If. after the occurrence of the problem, the ignition switch and the cruise main switch have not been switched OFF, it is possible to determine (by checking the diagnosis output code) which circuit canceled the system's operation. This chart is to be used, then, for troubleshooting if it is not

ASC system cannot be set

possible to use the self-diagnosis for checking.

Check the ECU power supply circuit and SET or RESUME switch. Is there

o Damaged or disconnected wiring of the ECU powersupply circuit o Damaged or disconnected wiring of the SET or RESUME switch

No

normal? Yes

Check the input check items

Input check items Probable ca use

Remedy

SET switch ON malfunction

Replace the control switch

SET switch input line short-circuit

Repair the harness

RESUME switch ON malfunction

Replace the control switch

RESUME switch input line short-circuit

Repair the harness

Malfunction of the CANCEL circuit (ON malfunction)

Check or repair each CANCEL circuit

Malfunction of the vehicle-speed sensor circuit (damaged or disconnected wiring, or short-circuit)

Check or repair the vehicle speed sensor circuit

Normal

Check the actuator circuit

NOTE If the results of the check of the actuator circuit and of the actuator itself reveal no abnormal condition, replace the electronic control unit (ECU)

27-62

AUTOMATIC SPEED CONTROL (CRUISE) Trouble Symptom 3 Trouble symptom

Probable cause

Remedy

o The set vehicle speed varies greatly upward or downward o "Hunching" (repeated alternating acceleration and deceleration)

Malfunction of the vehicle

Repair the vehicle speed sensor system, or replace the part

occurs after setting is made

speed sensor circuit

Malfunction of the speedometer cable or speedometer drive gear Actuator circuit poor contact Malfunction of the actuator

Repair the actuator system, or replace the part

Malfunction of the ECU

Replace the ECU

Trouble symptom

Probable cause

Remedy

The ASC system is not canceled when the brake pedal is depressed

Damaged or disconnected wiring of the stop lamp switch

Repair the harness or replace the stop lamp switch

Actuator drive circuit short circuit

Repair the harness or replace the actuator

Malfunction of the ECU

Replace the ECU

Trouble symptom

Probable cause

Remedy

The ASC system is not canceled when the clutch pedal is depressed (Vehicles

Damaged or disconnected wir-

Repair the harness, or repair or

ing of clutch switch input circuit

replace the clutch switch

Trouble Symptom 4

Trouble Symptom 5

with a manual transaxle) (It is canceled, however, when the brake pedal is depressed)

Clutch switch installation malfunction (won't switch ON) Malfunction of the ECU

Replace the ECU

27-63

•

AUTOMATIC SPEED CONTROL (CRUISE) Trouble Symptom 6 Trouble symptom

Probable cause

Remedy

The ASC system is not canceled when

Repair the harness or repair or

the shift lever is moved to the "N" posi-

Damaged or disconnected wiring of inhibitor switch input cir-

tion

cuit

(Vehicles with an automatic transaxle) (It is canceled, however, when theen brake pedal is depressed)

replace the inhibitor switch

Improper adjustment of inhibitor switch Malfunction of the ECU

Replace the ECU

Trouble symptom

Probable cause

Remedy

Cannot decelerate (coast) by using the SET switch

Temporary damaged or disconnected wiring of SET switch input circuit

Repair the harness or replace the SET switch

Trouble Symptom 7

•

Actuator circuit poor contact Malfunction of the actuator

Repair the harness or replace the actuator

Malfunction of the ECU

Replace the ECU

Trouble symptom

Probable ca use

Remedy

Cannot accelerate or resume speed by using the RESUME switch

Damaged or disconnected wiring, or short circuit. or

Repair the harness or replace the RESUME switch

Trouble Symptom 8

RESUME switch input circuit Actuator circuit poor contact Malfunction of the actuator Malfunction of the ECU

27-64

Repair the harness or replace the actuator Replace the ECU

AUTOMATIC SPEED CONTROL (CRUISE) Trouble Symptom 9 Trouble symptom

Probable cause

Remedy

ASC system can be set while traveling at a vehicle speed of less than 40 km/h (25 mph), or there is no automatic cancellation at that speed

Malfunction of the vehiclespeed sensor circuit

Repair the vehicle speed sensor system, or replace the part

Malfunction of the speedometer cable or the speedometer drive gear Malfunction of the ECU

Replace the ECU.

Trouble symptom

Probable cause

Remedy

The cruise main switch indicator lamp does not illuminate (But ASC system is normaL)

Damaged or disconnected bulb of cruise main switch indicator lamp

Repair the harness or replace the part.

Trouble Symptom 10

Harness damaged or disconnected

Trouble Symptom 11 Trouble symptom

Probable cause

Remedy

No alarm sound when SET switch or RESUME switch is used. (But ASC system is normaL)

Malfunction of the alarm circuit

Repair the harness or replace the part

Malfunction of the ECU

Trouble Symptom 12 Trouble symptom

Probable cause

Remedy

Malfunction of control function by ON/OFF switching of ELC 4 A/T accelerator switch (Vehicles with an automatic transaxle)

Malfunction of circuit related to accelerator switch OFF func-

Repair the harness or replace the part

tion

Malfunction of the ECU

(Non-operation of damper clutch, No. 2nd gear hold, etc.)

27-65

AUTOMATIC SPEED CONTROL (CRUISE) Trouble Symptom 13 Probable cause

Remedy

Overdrive is not canceled during fixed

Malfunction of circuit related to

speed driving. (Vehicles with an automatic transmis-

overdrive cancelation, or malfunction of ECU

Repair the harness or replace the part

Trouble symptom

sion) No shift to overdrive during manual driving. (Vehicles with an automatic transmission)

27-66

AUTOMATIC SPEED CONTROL (CRUISE) SERVICE ADJUSTMENT PROCEDURES ASC CABLE INSTALLATION AND ADJUSTMENT

To accele70r pedal

Adjusting bolts Intermediate Pulley B (Throttle valve side)

Accelerator cable (Throttle valve side)

(Insert 1.5 mm shim between both stops on assembly)

Pulley

attached to

Intermediate pulley C (Actuator side)

~---

(I

Surge tank (Reverse view shown for clarity)

throttle valve

Throttle stop

Actuator (Shown without mounting bracket attached)

I

I

'[/

'-""=:=:;

Accelerator Cable (Accelerator pedal side) 1.

Y27EYOA

With lock nut A at end of cable, assemble the accelerator cable to the intermediate pulley A.

Typical cable to pulley attachment

27-67

AUTOMATIC SPEED CONTROL (CRUISE) 2.

Pull cable tight in bracket with pulley against stop. Tighten nut B against bracket. Back nut B off one turn. :3. Tighten nut A. 4. Cable should have approximately 1 mm of slack with pulley against stop.

Pulley housing stop

.~

[ ~b [

i"-Intermediate pulley A stop

I'-- Accelerator

cable

Cable adjustment stop location

Accelerator Cable (Throttle valve side) 1.

Y27EZOA

Assemble the accelerator cable to the intermediate pulley B.

Typical cable to pulley attachment

2.

The locking nuts should be adjusted and tightened securely at approximately the mid-point of the threaded area of the accelerator cable.

l

. Threaded_ portion o

i':I:!II!!

Pulley /

. hDusmg

i

~ locking

nuts

• ~~. ·1

\

Accelerator cabl~ (Throttle valve side)

Accelerator cable adjustment

Actuator Cable 1.

Y27E10A

With nut A at end of cable. assemble the actuator cable to the intermediate pulley C.

Typical cable to pulley attachment

27-68

AUTOMATIC SPEED CONTROL (CRUISE) 2.

3. 4.

r

Pull cable tight in bracket with pulley against stop. Tighten nut B against bracket. Back nut B off 1-1/2 turn

Pulley housing stop

P} J n..

Tighten nut A. Cable should have approximately 1.5 mm of slack with pulley

[

....L Intermediate pulley C stop

against stop. Actuator ~ cable

Cable adjustment stop location

Final Cable Adjustment

Y27E2OA

Assemble the accelerator cable to the throttle valve pulley (if not assembled.) Attach the cable casing to the surge tank using the appropriate supplied adjusting bolts. Do not tighten the bolts at this time. 2. Insert a shim or similar tool, 1.5 mm thick, between the two pulley stops (intermediate pulley B and C).

Intermediate pulley 8 stop

1.

1.5 mm

Actuator cable

Accelerator cable

Cable adjustment stop location

3.

4.

Adjust the cable casing at the rear side of the surge tank to allow ALL the slack to be removed from the inner cable. Make sure the throttle valve pulley remains in the "NORMAL" idle position. Tighten the adjustment bolts to the proper torque setting. Remove the shim from between the two intermediate pulleys Band C. CAUTION Prior to proceeding with the final cable adjustments, make sure that the pulley attached to the throttle valve is in the "NORMAL" idle position.

No SLACK in accelerator cablel

Accelerator cable adjustment

AUTOMATIC SPEED CONTROL SWITCH INSPECTION CHECKING AUTOMATIC SPEED CONTROL MAIN SWITCH Y27E30A 1. 2.

Turn the ignition switch to ON. When turning on the main switch, confirm that the indicator lamp on the switch comes on.

27-69

AUTOMATIC SPEED CONTROL (CRUISE) CHECKING AUTOMATIC SPEED CONTROL SETTING CHECKING AUTOMATIC SPEED CONTROL MAIN SWITCH Y27E40A 1.

Switch ON the MAIN switch.

2.

Drive at the desired speed within the range of approximately

40-137 km/h (25-85 mph). 3. 4.

Press the SET button (of the control switches). Check to be sure that the alarm sounds when the switch is pressed, and that when it is released the speed is the desired constant speed. NOTE If the vehicle speed decreases to approximately 20 km/h (12 mph) below the set speed. because of climbing a hill for example, the automatic speed control will be cancelled.

CHECKING SPEED INCREASE SETTING 1. 2. 3.

Y27E50A

Set to the desired speed. Press the RESUME button (of the control switches). Check to be sure that the alarm sounds when the switch is pressed, that acceleration continues while the switch is pressed. and that when it is released the constant speed at the time when it was released becomes the driving speed. NOTE Even if, during acceleration. the vehicle speed reaches or exceeds the high limit [approximately 137 km/h], acceleration will continue, and. when the button is released, the speed at that time ("memorized speed") will becomes the high limit of the vehicle speed.

27-70

_-'"... <0 ... -.' ,

-""' -"

-

AUTOMATIC SPEED CONTROL (CRUISE) CHECKING SPEED REDUCTION SETTING 1. 2.

3.

Y27E60A

Set to the desired speed. Press the COAST button (of the control switches). Check to be sure that the alarm sounds when the switch is pressed, that deceleration continues while the switch is pressed, and that when it is released the constant speed at the time when it was released becomes the driving speed. NOTE When the vehicle speed reaches the low limit [approximately 40 km/h (25 mph)) during deceleration, the automatic speed control will be cancelled.

CHECKING AUTOMATIC SPEED CONTROL CANCELATIO N Y27E70A 1. 2.

Set the automatic speed control. Check to be sure that there is a return to ordinary driving when either of the operations below is performed. 1) The brake pedal is depressed. 2) The clutch pedal is depressed. (Vehicles with a manual transmission) 3) 4)

The shift lever is moved to the "N" range. (Vehicles with an automatic transmission) The automatic speed control MAIN switch is switched OFF.

CHECKING RETURN TO THE SET SPEED BEFORE CANCELLATION Y27ESOA 1. 2.

3.

4.

Set the automatic speed control. Check to be sure that the automatic speed control is cancelled when either of the operations below is performed. 1) The brake pedal is depressed. 2) The clutch pedal is depressed. (Vehicles with a manual transmission). 3) The shift lever is moved to the "N" range. (Vehicles with an automatic transmission). Press the RESUME button (of the control switches) while driv-

.' -

ing at a vehicle speed of approximately 40 km/h (25 mph) or higher. The alarm will sound when the switch is pressed, there will be a return to the automatic speed control speed before the automatic speed control speed will be cancelled and the vehicle will travel at the constant speed.

INDIVIDUAL PARTS INSPECTION

Y27E90A

CHECKING AUTOMATIC SPEt:D CONTROL SWITCH Refer to Group 90 Multifunction switch.

27-71

AUTOMATIC SPEED CONTROL (CRUISE) STOP LAMP SWITCH

Pushing ~

INSPECTION After operating the stop lamp switch. check continuity between the terminals.

~I Position

a

b

c

d

n

~

I

L'l=

'-T

L1f-

OF I ON ""-'j+!-,"-' Cruise circuit ON

Pushing

~

[ I

I OFF

S

I

c

a

~

..

top amp CircuIt

Not pushing

b

d

..

CLUTCH SWITCH

Pushing

INSPECTION Check following item by using an ohmmeter. Pushing Not pushing

Continuity Not continuity

3(ON) Max. 1 (OFF)

CHECKING INHIBITOR SWITCH ("N" AND "P" POSITIONS) N

1.

Disconnect the connector.

2.

Check to be sure that there is continuity between connector (E12) terminals 3 and 5. 3 and 4 when the shift lever is moved to the "N" range and the "P" range.

2

.-

P

tG2

,l

1...... 1

II:".

']4:31':'

J(.12 11 10 918

ST~

JM

~Gl

7

BACK

(COMPONENT SIDE)

CHECKING ACTUATOR 1. 2.

Disconnect the connctor. Measure the resistance value of the clutch coil.

3

2

6

5

Resistance of clutch coil between connector terminals (1) - (2) Standard value : Approx. 550

27-72

4

0

INTAKE & EXHAUST SYSTEM GENERAL

2

AIR CLEANER

3

SURGE TANK AND INTAKE MANIFOLD

5

EXHAUST MANIFOLD

11

MUFFLERS

12

GENERAL

GENERAL

Y28CAQA

SPECIFICATIONS Air cleaner Type Element

Dry type Unwoven cloth type 5.4 m3 /min

Rated air flow Exhaust pipe Muffler Suspension system

Expansion resonance type Rubber hangers

TIGHTENING TORQUE

Nm

Air cleaner mounting bolts Air cleaner mounting bracket bolts Intake manifold to cylinder head Intake manifold stay to cylinder block Throttle body to surge tank Exhaust manifold to cylinder head Exhaust manifold cover to exhaust manifold Oxygen sensor to exhaust manifold Front exhaust pipe to exhaust manifold Front exhaust pipe bracket Front exhaust pipe to catalytic converter Catalytic converter to center muffler assy Center muffler assy to main muffler Main muffler hanger support bracket

7.8-9.8 15-22 15-20 18-25 9.8-13 15-20 12-15 39-49 29-39 20-29 39-59 29-39 29-39 9.8-20

kg.cm

lb.-It

80-100 150-220 150-200 180-250 100-130 150-200 120-150 400-500 300-400 200-300 400-600 300-400 300-400 100-200

5.8-7.2 11-16 11-14 13-18 7.2-9.4 11-14 8.7-11 29-36 22-29 14-22 29-43 22-29 22-29 7.2-14

TROUBLESHOOTING

Y28CCOA

Symptom

Probable cause

Remedy

Exhaust gas leakage

Loose connections Broken pipe or muffler

Re-tighten Repair or replace

Abnormal noise

Detached baffle plate in muffler Broken rubber hanger Pipe or muffler contacting vehicle body Broken pipe or muffler

Replace Replace Correct Repair or replace

28-2

Y28CBOA

AIR CLEANER

AIR CLEANER COMPONENTS Air cleaner Air duct

7.8-9.8 (80-tOO. 5.8-7.2)

~

Cover

GrommtJt II <

Air flow sensor Air cleanert element

~".

_@olD

Air flow sensor gasket ""

Air cleaner body

Air cleaner cover

TORQUE

Nm (kg.em. Ib.ft)

REMOVAL

28YOO1

Y28DAOA

,.

Remove the air intake hose and air duct connected to the

2.

air cleaner. Remove the three bolts attaching the air cleaner mounting brackets.

3.

Detach the air cleaner.

28-3

AIR CLEANER 4.

Remove the air flow sensor from the air cleaner case.

CAUTION Do not pull on the air flow sensor harness. because the grommet is attached to the air cleaner case.

28YOO3

INSPECTION 1.

Y28DBOA

Check the air cleaner body. cover or packing for deformation.

Cover

corrosion or damage. 2.

....J~;I)--Packing

Check the air duct for damage.

28YOO4

3.

Check the air cleaner element for restriction. contamination or damage. If element s,lightly restricted. remove dust and debris by blowing air from inside of the element.

4.

Check the air cleaner for restriction. contamination or damage.

28YOO5

INSTALLATION Install the air cleaner in the reverse order of removal.

28-4

Y280CQA

SURGE TANK AND INTAKE MANIFOLD

SURGE TANK AND INTAKE MANIFOLD COMPONENTS

9.8- 13 (100-130, 7.2-9.41

I

Throttle body

~ '\

9.8-13 (100-130, 7.2-9.4) Fuel regulator

i

~ Fuel injector

@~ @O

@~@@

\

\

Intake manifold gasket

\----Intake manifold

~y 15-20 (150-200, 11-141

., .

~

!/ -~~a-25 1180-250, 13-18)

!:-:~:.~c IllOlllfOlU SHtv----1 \

~

TORQUE: Nm (kg.em, Ib.ft) 28Y056

28-5

SURGE TANK AND INTAKE MANIFOLD

REMOVAL 1.

Y28EAOA

Remove the air intake hose connected to the throttle body.

2.

Remove the accelerator and cruise control cables.

3.

Remove the water hose and throttle body.

28Y058

4.

Remove the P.C.v. hose and brake booster vacuum hoses.

5.

Disconnect the vacuum hose connections.

28-6

SURGE TANK AND INTAKE MANIFOLD 6.

Disconnect the high pressure fuel hose connection after relieving pressure in the fuel pipe line to prevent fuel overflow. (Refer to "Fuel system").

7.

Remove the surge tank assembly and gasket.

28Y012

8.

Disconnect the fuel injector harness connector.

9.

Remove the delivery pipe with the fuel injectors and pressure regulator attached.

CAUTION Be careful not to drop the injectors when removing the delivery pipe.

28-7

SURGE TANK AND INTAKE MANIFOLD 10. Remove the insulator from intake manifold and disconnect the heater hose.

Insulator

28V015

11. Disconnect the wiring harness connector between the water temperature gauge unit. water temperature sensor.

12. Remove the water outlet fitting and gasket. 13. Remove the thermostat. 14. Remove the distributor and ignition coil.

15. Remove the intake manifold stay.

o 2aVQ18

28-8

SURGE TANK AND INTAKE MANIFOLD 16. Remove the intake manifold.

INSPECTION

Y28EBOA

Surge Tank 1. 2. 3.

Check the surge tank for defects or cracks. Replace if necessary. Check cooling water and jet air passages for restrictions. Check the deflection of the mounting surface with a straight edge and feeler gauge. Within 0.15 mm (0.006 in.) Standard value Service limit ......•....•............. 0.2 mm (0.008 in.)

28Y020

Intake Manifold 1. 2.

Check for damage or cracking of any part. Check the cooling water and jet air passages for restrictions.

3.

Clean if required. Check the deflection of the mounting surface with a straight edge and feeler gauge. Standard value Within 0.15 mm (0.006 in.) Service limit ......•....•............. 0.3 mm (0.012 in.) 2aV021

INSTALLATION 1.

Y28ECOA

For installation of the intake manifold stay, first temporarily tighten the bolts at both ends, and then, after confirming that there is close adherence at the installation surface tighten the bolts at the specified torque. Tightening torque . Intake manifold stay to cylinder block 18-25 Nm (180-250kg.cm, 13-18 Ib.ft)

28-9

SURGE TANK AND INTAKE MANIFOLD 2.

Insert the insulators (4) il)to the intake manifold.

lav023

3.

Ensure that the insulators are correctly inserted into the delivery pipe hole.

28-10

EXHAUST MANIFOLD

EXHAUST MANIFOLD COMPONENTS 12-15(120-150.

8.7-111~

"-

~~""",~~~1/---

Exhaust manifold cover

15-20 (150-200. 11-14) ~~rfI'.~--- Exhaust manifold

2eVQ2S

INSPECTION

Y28FAOA

1.

Check for damage or cracking.

2.

Using a straight edge and a feeler gauge. check for distortion on the cylinder head mating surface. Standard value 0.15 mm (0.006 in.) or less Service limit .........•....... 0.3 mm (0.012 in.) or less

28Y026

3.

Check for flaking or damage of the gasket.

28Y027

28-11

MUFFLERS

MUFFLERS COMPONENTS

20-2i /200-300. 14-22)

10-15 (100-150. 7.2-111Center muffler assy

Rubber hanger

!

Catalytic converter

Main muffler

Gasket

"-"';;;;";"""'-"'--Hanger bracket Cover

a-r 29-39 (300-400. 22 -29)

TORQUE: Nm (kg.cm. Ib.ft)

REMOVAL

28Y028

Y2BGAOA

Main Muffler Caution

Before removing or inspecting the exhaust system. ensure that the exhaust system is cool enough. 1. 2.

Disconnect the main muffler from the center exhaust pipe. Remove the rubber hangers and take out the main muffler.

Center Muffler Assy 1.

Disconnect the center muffler assy from the main muffler and the catalytic converler.

2.

Remove the rubber hangers and take out the center muffler assy.

28-12

MUFFLERS Catalytic Converter 1.

Disconnect the catalytic converter from the center exhaust pipe and the front exhaust pipe. 2. Remove the rubber hangers and take out the catalytic converter.

28Y031

Front Exhaust Pipe 1. 2.

Remove the front exhaust pipe-to-catalytic converter mounting bolts. Remove the front exhaust pipe clamp bolt and remove the exhaust manifold-to-front exhaust pipe mounting nuts.

28Y032

3.

Remove the front exhaust pipe from the rubber hanger.

INSPECTION 1. 2.

Y28GBOA

Check the mufflers and pipes for corrosion and damage. Check the rubber hanger and hangers for deterioration and cracks.

28-13

MUFFLERS INSTALLATION 1.

Y28GCOA

Temporarily install the front exhaust pipe, the catalytic converter assembly, the center exhaust pipe, and the main muffler, in that order.

2.

Install the rubber hangers so that they are identical (left and

3.

right) in length. Tighten the parts securely, and then confirm that there is no interference with any body components.

28-14

EMISSION CONTROL SYSTEM 2. GENERAL

CRANKCASE EMISSION CONTROL SySTEM.........

9

EVAPORATIVE EMISSION CONTROL SySTEM

11

EXHAUST EMISSION CONTROL SySTEM

16

GENERAL

GENERAL

Y29CAOA

SPECIFICATIONS Components

Function

Crankcase Emission Control System Positive crankcase ventilation (PCV) valve

HC reduction

Evaporative Emission Control System Canister Purge control solenoid valve

HC reduction

Exhaust Emission Control System Jet air system MPI system (air-fuel mixture control device) 3-way catalytic converter Exhaust gas recirculation system EGR valve Thermo valve

Remarks

Variable flow rate type

ON/OFF solenoid valve

CO reduction CO, HC, NOx reduction CO, HC, NOx reduction NOx reduction

Jet swirl type Oxygen sensor feedback type Monol ith type Single type Bimetal type

SERVICE STANDARD Purge control solenoid valve Coil resistance Thermo valve temperature Opening temperature Closing temperature

TIGHTENING TORQUE Positive crankcase ventilation valve EGR valve installation bolt Thermo valve

V29CBOA

MIN. 50°C (122°F) 61-69°C (142-156°F)

Nm

kg.cm

Ib.ft

7.8-12 19-27 20-39

80-120 190-280 200--400

5.8-8.7 14-20 14-29

Y29CDOA

SEALANT Thermo valve thread portion

29-2

Y29CCOA

Threebond 1104 or equivalent

GENERAL

TROUBLESHOOTING

Y29CEOA

Symptom

Probable cause

Remedy

Engine will not start or hard to start

Vacuum hose disconnected or damaged The EGR valve is not closed

Repair or replace Repair or replace

Malfunction of the purge control solenoid valve

Repair or replace

The EGR valve is not closed

Repair or replace Repair or replace Replace

Rough idle or engine stalls

Vacuum hose disconnected or damaged Malfunction of the PCV valve Malfunction of the purge control system

Check the system; if there is a problem, check its component parts Check the system; if there is a pro-

Engine hesitates or poor acceleration

Malfunction of the exhaust gas recirculation system

blem, check its component parts

Excessive oil consumption

Positive crankcase ventilation line

Check positive crankcase venti la-

clogged

tion system

Malfunction of the exhaust gas recircula-

Check the system; if there is a problem, check its component parts

Poor fuel mileage

tion system

29-3

GENERAL EMISSION CONTROLS LOCATION

29y001

F

29'(002

A. PCV valve B. Purge control solenoid valve C. EGR valve D. EGR temperature sensor (California only) E. Thermo valve F. 2·way valve

G.

Catalytic converter

H.

Canister

29-4

GENERAL

EMISSION CONTROL SYSTEMS A.

B.

PCV valve

Purge control solenoid valve Purge control solenoid valve

PCV valve \

29YOO4

C.

D.

EGR valve

EGR temperature sensor (California)

EGA

,

temperature

sensorr

>--:

(California only)

--~ )1 -----

29YOO5

E.

29Y(K)6

F 2-way valve

Thermo valve

2-waV valve 29YOO8

29YOO7

G.

H.

Catalytic converter

Canister

Catalytic converter 29V(X)9

29-5

GENERAL

VACUUM HOSE LAYOUT

[For Federal and Canada] Thermo valve

FRONT Fuel pressure regulator

U -ThfOttle body

Purge control

solenoid valve

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

Canister

[For California] FRONT

Fuel pressure regulator

U

EGR valve

EGR control solenoid valve

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

Throttle body G : Y : L : R B :

29-6

Green Yellow Light blue Red Black

Purge control solenoid valve

R rt--~IB;--_

Canister

GENERAL SCHEMATIC DRAWING (FOR FEDERAL AND CANADA)

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

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

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

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

INPUT

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

•

*9. MOlor position sensor

.'0. Atmospheric pressure sensor

Ignition timing control

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

ToC

Top Dead Center

All : Vehicles witch automatic Iransaxle

MRomE

.,

AIR FLOW SENSOR (AFS)

AIR CLEANER

OIS~TRIBUTOR

POSITION

CRA"K

"SANGlE

SENSOR (TPSI

"0 ATMOSPHERIC

(FOR

AIR·CONI

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

SENSOR *711'1 CYl TOC

AIRINLET¢

'3

AIR TEMP SENSOR

*'

ISC MOTOR

l'i~~?IiIi~THERMO VALVE

TWC

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

29-7

GENERAL SCHEMATIC DRAWING (FOR CALIFORNIA)

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

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

* 1. Injector

*5. Throttle pashian sensor *6. Idle switch

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

*7. NO.1 cylinder TOC sensor

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

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

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

TOC Top Dead Center AIT : Vehicles witch automatic Iransaxle

.,

DI(YdSTRIBUTOR

THROTIlE

'2 AlA

POSITION SENSOR (TPS)

FLOW

SENSOR IAF71 AIR CCEANER-_

AIR INLET

~.

:i~OSPHERIC

IDLE POSITION SW

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

\·1

l'

j'

j

tFOR

::

AIR-CON) I

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

TOC SENSOR

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

ISC MOTOR

'3 AIR TEMP

:1~HoRI

SENSOR

POSITION

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

~

~:~elPUMP

EGR

PURGE CONTROL

SO ENOIO

VALVE

..

,

COOLANT TEMP SENSOR

."

EGR TEMP SENSOR

C

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

29-8

CRANKCASE EMISSION CONTROL SYSTEM

CRANKCASE EMISSION CONTROL SYSTEM COM PO N ENTS

Air Filter

Throttle Body

Air Intake Hose

Surge Tank

\

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

--

pev Valve Ventilation Hose

---

_........ Injector

From Rocker Cover~

---

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

INSPECTION 1.

2.

"

"

~~~

l=:::iln~take Manifold

~

To Intake Manifold

Plunger Spring

29Y017

Y29DAOA

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

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

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

29-9

CRANKCASE EMISSION CONTROL SYSTEM

PCV Valve Operating ,.-,

•

Intake manifold side (No vacuum)

~ n

Intake manifold side (High vacuum)

~

t

I lr

\ Ir '--

f------'

Rocker cover side

Rocker cover side

29Y019

29Y020

Engine condition

Not running

Engine condition

Idling or decelerating

PCV valve

Not operating

PCV valve

Fully operating

Vacuum passage

Clogged

Vacuum

Small

rtf

pass~ge

mr

Intake manifold side (Moderate vacuuml

~

\ ffIf

Intake manifold side (Low vacuum)

In

~

\ Ir

Rocker cover side

Rocker cover side 29Y022

29V021

Engine condition

Normal operation

Engine condition

Accelerating and high load

PCV valve

Properly operating

PCV valve

Slightly operating

Vacuum passage

Large

Vacuum passage

Much larger

29-10

EVAPORATIVE EMISSION CONTROL SYSTEM

EVAPORATIVE EMISSION CONTROL SYSTEM COMPONENTS

Air filter

Overfill limiter

\

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

Fuel injector

Overfill limiter

(Leveling pipe)

Purge-control

solenoid

I

valve

: Thermal expansion volume

l

t

Fuel gauge unit

Engine Canister Charcoal-H~h

, , - ,, ,

,

-

Fuel pump Filter

--CANISTER

Purge air Fuel vapour 29Y023

Y29EAOA

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

Vapour from fuel tank To purge control valve

wf(t;~~~~ ~

Charcoal ~

29Y024

29-11

EVAPORATIVE EMISSION CONTROL SYSTEM

Inspection 1. 2. 3.

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

29Y025

PURGE CONTROL SOLENOID VALVE

Y29EBOA

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

.-€;:::::~~][r/

To throttle body

"-€;:::::~~l.V 29Y026

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

1. 2.

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

3.

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

4.

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

Normal condition

When applied

Vacuum is released.

When discontinued

Vacuum is maintained.

29Y028

29-12

EVAPORATIVE EMISSION CONTROL SYSTEM 5.

Measure the resistance between the terminals of the solenoid valve.

Purge control solenoid valve Coil resistance

36-44!1 [at 20°C (68°F)]

29Y029

OVERFILL LIMITER (TWO-WAY VALVE)

Y29ECOA

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

Pressure valve To fuel

check valve

29YOJO

FUEL CHECK VALVE

Y29EDQA

To overfill limiter

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

"

From fuel tank 29YQJl

29-13

EVAPORATIVE EMISSION CONTROL SYSTEM

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

Atmospheric pressure

Fuel vapour pressure Fuel tank vacuum

When pressure is in fuel

When vacuum is in fuel tank

tank

29Y032

CHECKING PURGE CONTROL SYSTEM

:t-

Thronle body,..

'"

Surge tank

Control relay

Purge control solenoid valve

Air-flow sensor

1

Coolant temperature sensor

=

Intake air temperature sensor

ECU Air conditioner switch

I 29Y033

29-14

EVAPORATIVE EMISSION CONTROL SYSTEM

Checking 1.

Y29EEOA

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

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

r

2.

'

F·Y-C1\\\

29Y098

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

e

When engine is cold Engine operating condition

Applying vacuum

Result

Idling 3,000 rpm

When engine is warm Engine operating

Apply vacuum

Result

Idling

50 kPa (7.3 psi)

Vacuum is maintained

Within 3 minutes

Try applying vacuum

Vacuum is released

50 kPa (7.3 psi)

Vacuum will be main-

condition

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

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

29-15

EXHAUST EMISSION CONTROL SYSTEM

EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM

Y29FAOA

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

JET AIR SYSTEM

Y29FBOA

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

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

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

29-16

, Intake valve

29Y035

EXHAUST EMISSION CONTROL SYSTEM

CATALYTIC CONVERTER

Y29FDOA

Supporter

Exhaust air . .

Cover

Stainless steel

29YOJ6

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

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

_..

1()()

HC

Vicinity (%) 50 . /

/

.1

/j

CO ...

0

_."~

.'

I

\

Theoretical air-fuel ratio

29Y037

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

29-17

EXHAUST EMISSION CONTROL SYSTEM

EXHAUST GAS RECIRCURATION SYSTEM

Y2"'08

Inspection (For Federal. Canada) 1.

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

2.

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

\ Engine coolant temperature Cold

Hot

Vacuum

Engine condition

Normal condition

Apply

Idling

Vacuum is released

6 kPa (1.7 in.Hg)

Idling

Vacuum is held

26 kPa (7.5 in.Hg)

Idle is unstable

Vacuum is held

Inspection (For California) 1.

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

2.

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

When the engine is cold Engine condition

Normal condition

Press the accelerator pedal suddely and race the engine.

Vacuum: no change (atmospheric pressure)

When the engine is warm

3.

4.

Engine condition

Normal condition

Press the accelerator pedal suddenly and race the engine.

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

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

29-18

29Y099

EXHAUST EMISSION CONTROL SYSTEM EGR Valve 1.

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

2.

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

its, etc.

3. 4.

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

follows. Vacuum

Normal condition

6 kPa (1.7 in.Hg) or less

Air does not blow through

26 kPa (7.5 in.Hg) or more

Air blows through

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

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

EGR Temperature Sensor (California Vehicles Only) 1.

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

Resistance (Kn)

50 (122) 100 (212)

60-83 11-14

....... 2 if

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

CJ

(§) ~

, 29Y089

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

29-19

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

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

2.

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

Normal condition

50°C (122°F) or less

Vacuum is released

80°C (176°F) or more

Vacuum is held

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

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

Result

When applied

Vacuum is held.

When discontinued

Vacuum is released.

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

r

5.

Measure the resistance between the terminals of the

:!U..I

e

EEl 12V

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

29-20

29Y091

FUEL SYSTEM GENERAL

2

MPI SySTEM

15

INJECTOR AND THROTILE BODy

64

THROTILE BODy

67

FUEL TANK

6911

FUEL PUMP

74

FUEL LINE AND VAPOUR LINE

76

ENGINE CONTROL

78

GENERAL

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

Y31CAOA.

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

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

Variable resistor type 3.5-6.5 Kfl 0.48-0.52 V

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

Electric motor 5-35 fl at 20°C (68°F)

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

31-2

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

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

Approx. IV Reed switch type

GENERAL

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

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

Electromagnetic type

4 13-16

n

at 20 D C (68 D F)

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

SEALANT Water temperature sensor

Y31CBOA

LOCTITE 962T or equivalent

31-3

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

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

31-4

Y31CCOA

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

Nm

Kg.cm

Ib.ft

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

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

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

Y31CDOA

GENERAL SPECIAL TOOLS Tool (Number and name)

Use

Illustration

09273-24000 Harness connector

En9ine r.p.m. check

09391-33200 1. Multi-use tester

Diagnostic tester for MPI, automatic transaxle and cruise control systems

09391-33300 2. Test harness

09391-33500 3. Battery harness

1

09391-33600 4. Instruction manual 5

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

09391-33700 6. Connector RS 232C

'4

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

31-5

GENERAL

Tool (Number and name)

Illustration

09353-24000 Fuel pressure gauge connector

09353-24100 Fuel pressure gauge & hose

t

r

~~

\ 09353-24200 Fuel pressure gauge adapter

ll(pmn

31-6

1~

(t1

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

GENERAL TROUBLESHOOTING

Y31CFQA

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

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

2. 3.

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

Ignition timing Idle speed

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

31-7

GENERAL MPI TROUBLESHOOTING PROCEDURES

Z31CGOC

PROBLEM Engine will not start

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

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

.cJ.

OK

------3'

Check starting system

Wrong

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

o o o o

Ignition switch Starter relay Starter Wiring

PROBLEM Hard to start (Cranks OK)

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

I- - - - - - - 7 Malfunction codes

Normal codes

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

\

-----70

Check for vacuum leaks

Wrong

OK

o o o o o

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

\

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

OK To be continued

31-8

-

----~ o High tension cables Wrong

o Distributor o Ignition coil. power transistor o Spark plugs

GENERAL

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

-

----~

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

----~ Wrong

o o o o o

Wrong

OK

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

f-

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

OK

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

OK

II Check MPI electronic circuit

----~ o Wiring connections Wrong

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

31-9

GENERAL PROBLEM Rough idle or engine stalls

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

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

Normal codes

Check for vacuum leaks

- -----;, Wrong

OK

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

o o o o o

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

o o o o

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

,II

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

f----

-----;, Wrong

o Fuel pressure regulator OK Check air cleaner element

-

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

Wrong JOK Check idle speed Standard : 750 ± 100 rpm

- - -----;, Wrong

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

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

- - -----;,

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

,II

OK

To be continued

31-10

Wrong

Ignition timing-Adjust [Refer to page 27-361

GENERAL

Check fuel pressure [Refer to page 31-34)

~------3> Wrong

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

OK

1/ Check injectors

Check MPI electronic circuit

----4 Wrong

------3> Wrong

Injection condition

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

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

31-11

GENERAL PROBLEM Engine hesitates or accelerates poorly

----,

Check clutch or brakes

Wrong

OK

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

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

_

\11

Check vacuum leaks in intake air line

-

------7

o o o o o

- Wrong - - - 1L J

Element-Clean or replace

Wrong

OK

Check air cleaner element

Oil filler cap Oil dipstic Hose connections PCV hose EGR system

~ OK

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

I- - - - - - - 7 Malfunction codes

Normal codes

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

I

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

------7 Wrong

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

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

1

-

------7 Wrong

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

0K

Check fuel pressure [Refer to page 31-34]

~OK To be continued

31-12

-

------7 Wrong

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

_

GENERAL

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

I

Check injectors

Wrong

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

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

JOK Check MPI electronic circuit

------;, Wrong

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

31-13

GENERAL Fuel Tank And Fuel Line

Y31CHQA

Symptom

Probable cause

Remedy

Engine malfunctions due to insufficient fuel

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

Repair or replace Clean or replace

supply

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

31-14

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

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

Clean or replace Replace

Incorrect routing of a vapour line

Correct Correct Replace

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

Replace

MPI SYSTEM

MPI SYSTEM GENERAL INFORMATION

Y310AOA

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

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

Throttle position sensor (TPS)

ECU

Idle switch

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

Crank angle sensor:

No.1 cylinder TDC sensor

-

To fuel tank

~====-

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

Motor position sensor (MPS) Oxygen sensor

31YQOl

Delivery pipe

Fuel tank

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

31YOO2

31-15

MPI SYSTEM Electronic Control Unit (ECU)

V310BOA

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

ECU r-

-

"

5

2"

""'

."g

"'c:

:;

0.

E

'--

Iprocessor Micro I

Jl

:;;

:; 0.

c:

~

::;; <>:

0: L.....-

HMC Part No. Abbr. Type Name Lot No.

r--

~

::;;

a0:

'--

5

.""

10 :> 13

1i'"

E

o'~~

:;'"

:; 0. :;

,

0.

:;

a

a

'--31YOO3

nr Q

C02-3

If III

5 4 3 2 1 098 7

C02-2

9 8 7 6 5 4

U3 2 1

L

C02-1

J

~~

J

0

31YOO4

U

~

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

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

II

II

II 31YOOS

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

CAL: California * Mark is gold plating terminal

31-16

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

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

MPI SYSTEM Fuel Injection Control

Y31DCOA

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

Injector Drive (Fuel Injection) Timing 1.

Y31DDQA

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

No1 cyl.

n '---

l

TOe signal L________

Crank angle signal Cylinder

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

Cylinder

L....O.J

No.1 _ _--J

_

NO.2-----lLllJ

_

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

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

31YQ06

31-17

MPI SYSTEM 2.

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

n

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

----,

'-

_

Crank angle signal

Cylinder No.1

Combustion

E'J1 haus!

No.3

Com-

Com-

No.4

Intake

pressIOn

No.2

Inlake

".,,~ pression bustian haust ComCom-

E'hawsl .,J(.I

Intake

Com-

Com-

preSSion buslian

Intake

Compression

E'."l(.j

Intake bustian hausl ComCompression bustian hausl

E,-,,\:!

Llnjection

31YQ07

Injector Driving Time

Y310EOA

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

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

31-18

MPI SYSTEM o

o

o

o

o

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

o

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

ON

Drive OFF signal

:::d

Dead I Valve open time time

I

I----L

Injector-----

I Valve open t;me 1

4

I "'1 31YOO8

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

Time (ms)

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

Battery 31YOO9

31-19

MPI SYSTEM Ignition Timing Control System

Y31DF3A

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

Power Coolant temperature sensor

transistor

Ignition coil

ECU Throttle position sensor (TPS) Idle switch

Crankshaft angle sensor

Vehicle speed sensor

~~~nition

Ignition switch-5T terminal

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

Terminal for ignition

timing adjustment

AIT : Vehicle with an automatic transaxle

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

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

o

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

31-20

1 31'1'010

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

2.

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

T (Crankshaft angle 180°)

BTD~BTDC 5°

75° I

Crank

:~~~:r~, Ignition pulse

b

_ _-I

'-----

Time count stan 31YQ11

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

31-21

MPI SYSTEM Idle Speed Control (lSC) System

Y31DG3A

The ISC system provides the following four modes of control.

ECU

.----

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

Retraction

side

Extension side

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

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

Ignition switch-5T terminal

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

4

-j_o--, Sensor ground

31Y012

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

31-22

MPI SYSTEM Air Conditioner Relay Control

Y310H3A

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

Air conditioner switch

I ./": II I

Air conditioner switch

, ~

(

~

~

--'-

-=-Battery

ECU Inhibitor switch

01 ~~

~-~

•

IAIT only)

~'L

0';' Air conditioner compressor

Throttle position

sensor (A/T onl YI

0

(

Crank angle se nsor

Air conditioner relay

AIT : Vehicles with an automatic transaxle

31Y013

31-23

MPI SYSTEM Power Supply And Fuel Pump Control

Y31DI3A

To injector f_-~Purge control sol. valve

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

til

Fusible link

7

S2

Power

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

Ground

To AFS

31YQ14

o

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

o o

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

31-24

MPI SYSTEM

LOCATION OF COMPONENTS A

C

B

D

E

0

H

F

G

J

31YQ15

M

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

"S

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

WL-°~L-]

[)

\! KN

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

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

31Y016

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

31-25

MPI SYSTEM B

31Y018

c

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

1

~-J

If

~.~

~ t---.c ~. ~

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

\' Motor position

.

\/"

/ /

~

~:':'~

sensor (MPS) . .

", \

31Y260

~ ~

E

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

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

. ""-.

-./l W~ ---

Intake manifold

~~-

G

31-26

Crank

31Y021

MPI SYSTEM

In~ 31Y026

M Vehicle speed sensor

31YQ29

o

EGR temperature sensor

31-27

MPI SYSTEM

SERVICE ADJUSTMENT PROCEDURES

Y31DJOA

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

Checking conditions:

Z31DKOB

o o o o

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

1.

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

2. 3.

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

4. 5. 6.

Curb idle rpm

750

± 100 rpm 09273-24000

31Z282

31-28

MPI SYSTEM

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

1. Loosen the accelerator cable.

2. 3.

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

092 3-24000

31-29

MPI SYSTEM 4.

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

5. 6.

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

7.

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

a.

Curb idle rpm

750

± 100 rpm

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

31-30

Fixed SAS

ISC adjusting~~~;":'; screw

31V266

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

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

31Z280

15.

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

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

AlT

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

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

31-31

MPI SYSTEM Throttle Body (Throttle Valve Area) Cleaning

V31DMOA

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

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

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

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

Fuel Filter Replacement 1.

V310NOA

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

2.

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

31-32

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

Y31DOQA

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

,~))

~j/ 31Y045

Fuel Gauge Unit Replacement

Y310POA

1.

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

2. 3.

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

Fuel Pump Operation Check 1. 2.

Y31DQOA

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

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

3.

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

31-33

MPI SYSTEM Fuel Pressure Test

Y31DROA

1.

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

2.

Disconnect the high pressure fuel hose at the delivery side.

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

"-. 31Y268

3.

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

4. 5.

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

6.

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

Standard value

.

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

31-34

MPI SYSTEM 7.

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

8.

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

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

Condition

Probable cause

Remedy

Fuel pressure too low

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

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

c. Replace fuel pump

Fuel pressure too high

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

There is no difference in

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

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

9.

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

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

Condition

Probable cause

Remedy

Fuel pressure drops slowly after engine is stopped

a. Injector leakage

a. Replace injector

Fuel pressure drops immediately after engine is stopped

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

a. Replace fuel pump

31-35

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

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

EGR Valve Control Vacuum Check

Y31DSOA

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

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

E ~

.. ~

o

>

Engine speed (rpm) 31Y056

31-36

MPI SYSTEM Purge Port Vacuum Check

Y31DTOA

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

2.

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

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

Engine speed (rpm)

31Y058

31-37

MPI SYSTEM

MPI SYSTEM INSPECTION

Y31DUOA

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

Poor driveability

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

Intake air temperature sensor Throttle position sensor

31-38

f

t---D .L.£, .'

I

'\

Malfunction indicator light 31Y059

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

SELF-DIAGNOSIS

Y310VOA

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

Trouble code

Diagnosis item

Trouble code

Diagnosis item

11

Oxygen sensor

23

No.1 cylinder top dead center sensor

12

Air-flow sensor

24

Vehicle-speed reed switch

13

Air temperature sensor

25

Atmospheric pressure sensor

14

Throttle position sensor

41

Injector

15

Motor position sensor

42

Fuel pump

21

Engine coolant temperature sensor

43

22

Crank angle sensor

EGR temperature sensor (For California Vehicles)

31-39

MPI

SYSTEM

CHECKING PROCEDURE (SELF-DIAGNOSIS) Y310WOA

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

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

7.

Y31DXOA

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

31-40

MPI SYSTEM Inspection Procedure (Using Voltmeter)

Y31DYOA

1.

Connect the voltmeter to the self diagnosis connector.

2.

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

3.

I I I

I

MPI diagnosis

I

I

LGround 31Y061

Diagnosis Chart Output preference order

1

Diagnosis item

Y310Z0A

Trouble code Check item (Remedy) No.

Output signal pattern

-

Engine control unit

Memory -

(Replace engine control unit)

:~ J1Y062

2

11

Oxygen sensor

Retained

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

:JLL

0

31Y063

3

Air flow sensor

o Harness and connector

12

:JLJUL

Retained

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

J1Y064

31-41

MPI SYSTEM Output preference order 4

Diagnosis item Air temperature sensor

Malfunction code Check item (Remedy) Output signal pattern

No.

Memory

13

Retained

o Harness and connector o Air temperature sensor

14

Retained

o Harness and connector

:~ 31Y065

5

Throttle position sensor

o Throttle position sensor o Idle position switch

:~ 31Y066

6

Motor position sensor

15

Retained

o Harness and connector 0

Motor position sensor

:~ 31Y067

7

Engine coolant temperature sensor

21

Retained

o Harness and connector

o Engine coolant temperature sensor

:~ 31Y068

8

Crank angle sensor

22

Retained

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

23

Retained

o Harness and connector

:~ 31Y069

9

No.1 cylinder top dead center sensor

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

:~ 31Y070

10

24

Vehiclespeed sensor (reed switch)

:~ 31Y071

31-42

Retained

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

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

31-43

MPI SYSTEM

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

Y31EAOA

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

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

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

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

31-44

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

Test specification

Probable cause of malfunction (or action)

11-13 V

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

MPI SYSTEM

Check points Malfunction code read out o Self diagnosis

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

Test specification Normal

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

o Engine cranking o Fuel pump forced activation

Crank angle sensor o Service data o Item No.22

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

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

servo connector.

Fuel pump o Actuator test o Item NO.7

Probable causes of malfunction (or action)

Pinch closed the return hose.

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

Engine speed (rpm)

Approx. 200

Approx. 200

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

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

31-45

MPI SYSTEM

Check points Injectors o Service data o Item No.41

Check conditions o Engine cranking

Test specification

Probable causes of malfunction (or action)

Listen for operation sounds.

Operation sounds of the injectors can be heard.

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

Engine coolant temperature [OC (OF)]

Injector activation time *2 (msec.)

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

0(32)*'

Approx. 21

20 (68)

Approx. 43

80 (176)

Approx. 10

.

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

31-46

MPI SYSTEM

Sensor Check Check points

Check conditions

Self-diagnosis output

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

Oxygen sensor o Service data o Item No.ll

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

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

o Engine warm-up

Test specification Normal

Engine condition

Voltage (mV)

When sudden deceleration from 4,000 rpm

250 or lower

When engine is suddenly raced

600-1,000

750 rpm (Idling)

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

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

400 mV or lower (changes)

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

Frequency (Hz)

750 rpm (Idling)

25-50

2,000 rpm

70-130

Racing

Increase caused by racing

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

31-47

MPI SYSTEM

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

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

Motor position sensor o Service data o Item No.15

o Ignition switch: ON, or engine running

Probable cause of malfunction (or action)

Air temperature °C (OF)

Temperature °C (OF)

o Malfunction of air temperature or related circuitry

-20 (-4)

-20 (-4)

o (32)

0(32)

20 (68)

20 (68)

40 (104)

40 (104)

80 (176)

80 (176)

o Ignition switch: ON

Warm by using hair dryer or other method.

Increases

o Hold for 15 sec-

Throttle valve

Voltage (mV)

Idling position

450-550

Opens slowly.

Becomes

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

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

31-48

Test specification

Check conditions

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

higher in proportion to valve opening Fully open

4,500-5,500

Engine condition

Voltage (mV)

Idle (750 rpm)

500-1,300

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

MPI SYSTEM

Check points

Check conditions

Motor position sensor o Service data o Item No.15

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

Air conditioner

Test specification 800-1,800

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

900-1,900

switch: ON Shift lever: "D"

o Check the inhibitor switch and the signal circuit

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

o Ignition switch: Engine stopping OFF ON Engine cranking ON

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

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

Temperature 0C (OF)

-20 (-4)

-20 (-4)

o (32)

0(32)

20 (68)

20 (68)

40 (104)

40 (104)

80 (176)

80 (176)

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

Idling rpm

1,500-1,700

0(32)

1,350-1,550

20 (68)

1,200-1 ,400

40 (104)

900-1,100

80 (176)

650-850

o Engine coolant temperature sensor or related circuitry malfunction

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

31-49

MPI SYSTEM Check points Barometric

pres-

sure sensor

Test

Check conditions

specification o Ignition switch: ON

Altitude m (ft.)

o Service data o Item No.25

o Engine: racing at 2,000 rpm

Pressure mm Hg

0(0)

760

600 (1,968)

710

1,200 (3,937)

660

1,800 (5,905)

610

Gradually close the air-intake

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

Decreases.

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

Power-steering

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

o Engine: idling

switch o Service data

Throttle valve

ON

idling position Open the throttle valve

OFF

slightly.

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

Steering wheel neutral

OFF

position (wheels straight-ahead direction)

o Item No.27

o Idle position switch or related circuitry malfunction

Steering wheel half

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

ON

turn Air-conditioner

switch o Service data o Item NO.28

Inhibitor switch o Service data o Item No.29

31-50

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

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

Air-conditioner switch "OFF"

OFF

Air-conditioner switch "ON"

ON

o Check the air conditioner system.

Shift lever: "p" or "N"

"P", "N"

o Malfunction of the inhbititor

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

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

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

"R"

MPI SYSTEM Test specification

Check conditions

Check points

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

Engine condition

Temperature °C (OF)

750 rpm

100 (212) or less

(idling)

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

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

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

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

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

Injector No. 1 2 3 4

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

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

0

Engine: warmed up

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

Engine condition

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

Activation time (msec.) 2.5-4.0

2,000 rpm

2.5-4.0

Rapid racing

Increases.

750 (Idling) 2,000

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

engine stalls.)

750 rpm (Idling)

Engine speed (rpm)

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

Ignition advance (OBTDe) 5-15 30-40

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

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

31-51

MPI SYSTEM

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

Check conditions o Engine: idling after warm-up

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

o Ignition switch: ON

EGR control solenoid valve (California) o Actuator test

o Ignition switch: ON

o Item No.10

31-52

(Engine stop)

(Engine stop)

Test specifications

Probable cause of malfunction (or action)

Air conditioner switch

Air conditioner relay

OFF

OFF (compressor clutch nonactivation)

ON

ON (compressor clutch activa' tion)

Actuator forced actuation

Operation sound is audible

o Check the purge control solenoid valve.

Actuator forced actuation

Operation sound is audible

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

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

o Check the purge control solenoid valve drive circuit.

MPI SYSTEM MPI SYSTEM COMPONENTS INSPECTION

Y31EBOA

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

31Y078

1.

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

2. 3.

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

Output voltage (V)

Idling

2.7-3.2

3,000

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

Air flow sensor assembly Airflow sensor output

fJl

SG

'-"-"

E

'6'

temperature B

'2' '4'

~

Intake air

-J-

Power (12V)

~

sensor

Sensor ground

Output

~

cD 's'

Atmospheric pressure sensor

Output

~ c..!..J

Sensor power (5V)

affi] 6

5

4

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

31Y080

31-53

MPI SYSTEM Atmospheric Pressure Sensor [For Australia]

Y31ECOA

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

Atmospheric pressure sensor

31Y081

1.

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

2. 3.

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

Voltage

Fall

Drop

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

150 (20, 2.9)

350 (49, 6.9)

760 (103, 15)

0.79

1.84

4.00

Replace the air flow sensor if necessary.

Intake Air Temperature Sensor

Y31EDOA

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

31Y083

31-54

MPI SYSTEM 1. 2.

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

AFS side connector

..

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

3.

4.

2

1

6"" 5

4

3

Temperature °C (OF)

Resistance (kfl)

o (32)

5.4-6.6

20 (68)

2.33-2.97

80 (176)

0.31-0.43

K~

l~

If

I

I

\

9

I J1Y084

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

Resistance (kfl)

Higher

Smaller

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

~\

~ (;0 ~ ~

I

-;..~

I.

.

~../,

~

,...

Engine Coolant Temperature Sensor

Intake aIr

-<..Ztemperature

~1=::""-

sensor

31YOBS

Y31EEOA

The engine coolant temperature sensor installed in the engine coolant passage of the intake manifold is a resistor-based sensor. The ECU judges engine warm-up state by the sensor output voltage and provides optimum fuel enrichment when the engine is cold.

Terminal 1

Terminal 2 3lY086

1.

Remove the engine coolant temperature sensor from the intake manifold.

2.

With the sensing portion of the engine coolant temperature sensor immersed in hot water, check resistance. The sensor should be held with its housing 3 mm (0.12 in.) away from the surface of the hot water.

31Y087

31-55

MPI SYSTEM Temperature °C (OF)

Resistance (KO)

o (32)

5.9

20 (68)

2.5

40 (104)

1.1

80 (176)

0.3

Coolant temperature sensor

3.

If the resistance deviates from the standard value greatly, replace the sensor.

I

I

Coolant temperature sensor connector

(sensor side front view) 31Z040

Throttle Position Sensor (TPS) 1. 2.

Z31EFOB

Disconnect the throttle position sensor connector. Measure the resistance between terminals 1 and 4 of the throttle position sensor connector. Terminal 1 Sensor ground Terminal 4 Sensor power Standard value ...................•.•....... 3.5-6.5 KO

TPS connector (Sensor side front view) 31Z270

31-56

•

MPI SYSTEM 3.

Connect an analog type ohmmeter between terminals 1 and

3.

4.

Terminal 1 : Sensor ground Terminal 3 : Sensor output Slowly open the throttle valve from the idle position to the fully open position and check that the resistance values change smoothly with the opening of the throttle valve. Standard value

Approx 0.5 -

(3.5-6.5) kO 312262

5.

If the resistance is out of specification, or if the change is not smooth, replace the throttle position sensor. Tightening torque Throttle position sensor . 1.5-2.5 Nm (15-25 kg.cm, 1.1-1.8 Ib.ft)

jGround

Output I Sensor

power

312263

Idle Switch 1. 2.

Z3lEGOB

Disconnect the ISC motor connector. Check for continuity between the terminal 3 and the body ground. Terminal 3 : Idle Switch Accelerator pedal

Continuity

Depressed

Non-conductive (000)

Released

Conductive (00)

(Motor side front view)

II 312268

31-57

MPI SYSTEM Motor Position Sensor IMPS)

Z31EHOA

1.

Connect an ohmmeter between terminals 4 and 1 of the motor position sensor connector. Terminal 1 ; Sensor power Terminal 4 ; Sensor ground 2. Measure the resistance of the terminals. Standard value

3.

4-6 kO

Attach an ohmmeter between terminals 2 and 4 of the motor position sensor connector.

Terminal 2 MPS output Terminal 4 ; Sensor ground

ISC servo assembly

Sensor power

Supply (5VI

~~--+-+I

MPS output

::.

Sensor ground

r>---J----tl ISC Motor

Idle switch output

2

L==H1

Reverse (-) Forward (+)

MPS connector (sensor side front view)

MPS connector (Front view at sensor side)

31Y275

31-58

MPI SYSTEM 4.

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

Standard value

ISC motor connector (front view at motor side)

(4--6) kO

1 2' 'f '1l

5.

I [ ! A 1 If

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

I

~ I" Ij-----J

31Y276

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

Z31EIOA

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

3. Terminal 1 Terminal 2 Terminal 3

2.

Sensor ground Crank angle signal No.1 TDC signal

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

Sensor

Terminal

Voltage

No.1 cylinder TDC sensor

Ground

0.2-1.2V (The needle fluctuates)

Crankshaft angle sensor

Ground

Ground

2

4 3 NO.1 TOC

Sensor power

1.8-2.5V

1

signal (output)

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

Crank angle sensor connector (sensor front view)

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

Z31EJOA

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

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

(For Canada)

31Yl07

31-59

MPI SYSTEM

Engine

Oxygen sensor output voltage

Remarks

Increase RPM

Min.O.6V

Richens air/fuel mixture

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

Vehicle Speed Sensor

Y31EKOA

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

~

-==-

the ECU. Inhibitor Switch (For A/T)

31Y109

Z31ELOA

Refer to Group 45.

I

::> u

~t·

I

w

<-

Rotor

ffi

~

~

31Z044

Injectors

Z31EMOA

Operation Check Using a multi-use tester. check as described below. o Cut off the fuel injection of the injectors in sequence. o Check the operation time of the injectors.

Operation Sound Check using a stethoscope. check the operation sound (tick. tick) during idle or cranking. Check that the sound is produced at shorter intervals as the engine speed increases. NOTE 1) Other injectors may produce sound as they operate even if the injector being checked does not operate. 2) Ensure that the sound from an adjacent injector is not being transmitted along the delivery pipe to an inoperative injector.

31-60

MPI SYSTEM Resistance Measurement Between Terminals 1. Disconnect the connector for the injector. 2. Measure the resistance between the terminals. Standard value 3.

13-16 !1 [at 20°C (68°F)]

Connect the connector for the injector.

o

o

31Y113

Idle Speed control (ISC) Servo 1.

Z31ENOB

Measure resistance between terminal 1 and 2 using an

Reverse {-I

Forward (+)

ohmmeter. Standard value

5-35!1 [at 20°C (68°F)] 2 ISC motor connector side (Front view) 31Z271

2.

Connect 6V DC to terminals 1 and 2 and check that the idle speed control servo extends and retracts by itself. Idle speed control servo motion When terminal 2 is +

Retracts

When terminal 1 is +

Extends

If the idle speed control servo does not move, replace the idle speed control servo assembly.

ISC motor connector side Forward

Reverse

1,1,

'1'1

(Front view) 31Z272

CAUTION Apply only a 6V DC or lower voltage. Application of higher voltage could cause locking of the servo gears. 4.

If the servo does not operate, replace it as an assembly.

31-61

MPI SYSTEM Control Relay

Y31EOOA

CAUTION When applying battery voltage directly, make sure that it is applied to the correct terminal. Otherwise, the relay could be damaged. 2

NOTE Failure of the control relay interrupts power supply to the fuel pump, injectors and ECU, resulting in start failure. 1.

3 4

Check continuity between the terminals when the relay coil is energized and when it is not. NOTE In the following tables. the arrows indicate the direction of the current flow. Confirm circuit tester polarity before checking continuity.

Ignition switch "IG"

Injector

Battery

ECU ECU

Coils L, and L,

o

Ground

Ignition

Condition

Measuring terminals

1-4 Not energized

Energized

Continuity <--.

Non-conductive (000)

3-8

31Y118

Conductive (approx. 950)

6-7

Conductive (approx. 350)

1-4

Conductive (00)

7.

Not energized

Energized

Lr~

=

f-o~.

fr~~
'--

I

Coil L3 Condition

.-----i

2-8

NOTE: "Energized" means voltage applied across terminals 6 and

o

switch "ST"

1

~

Measuring terminals

Ie

Continuity

12V

(1)1 31Y119

1-3

Non-conductive (000)

7..,.5

Non-conductive (000)

7_5

Conductive (00)

1-3

Conductive (00)

r-

~

NOTE: "Energized" means voltage applied across terminals 5 and

Ir:i

L-f-o ~

~ ~II

'--

7. ~

2.

If the result is not satisfactory, replace the control relay.

IeI

12V

1 III I 31Y120

31-62

MPI SYSTEM Power Transistor

Y31EPOA

The power transistor is installed on the intake manifold; it functions to control the ignition timing by controlling the ignition coil primary current by the signals from the ECU.

2 (Ground)

~

3 (ECU)

1 (Coil 0)

C?

" f- I

31'1'121

31'1'122

1. 2.

Disconnect the power transistor connector. Connect a power supply of 1.5V (one dry cell) between the power transistor and then check for continuity between terminals 1 and 2 under power-ON and power-OFF conditions:

NOTE 1) When checking for continuity, connect the ohmmeter to terminal 2 on the positive side and terminal 1 on the negative side. 2) Check with an analog-type circuit tester.

2-3 Terminal

1-2 Terminal

Power ON

Continuity

Power OFF

Non-continuity

31'1'123

31-63

INJECTOR AND THROTTLE BODY

INJECTOR AND THROTTLE BODY COMPONENTS

9.8-13 (100-130.7.2-9.4)

25-34 (250-350. 18-25)

(

Fuel pressure regUlator,

!

y

0-rin 9

.'

";'..,,"'\\

I

.All. @W@o

.@6®@

;,/l

tl\----Dellvery pipe

~

Injector

~~~ ~

71nsulator

~I I

"~

~

/~,~

-j "

~vacuum hose

~7water hose

Grommet

O-ring

Throttle body assembly Gasket

TORQUE

REMOVAL 1.

Nm (kg.cm. Ib.ft)

31Y124

Y31FAOA

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

2.

Remove the delivery pipe with the fuel injector and pressure regulator.

31-64

-----..

INJECTOR AND THROTTLE BODY INSPECTION 1.

Measure the resistance of the injectors between the terminals using an ohmmeter. Resistance

2.

Y31EBOA

13-16!l. [at 20°C (68°F))

rn

-0 .

If the resistance is not within specifications. replace the injector.

31Y126

INSTALLATION 1.

Y31FCOA

Insulator

Install a new insulator to the intake manifold.

31Y127

2. 3.

Install a new grommet and O-ring to the injector. Apply a coating of solvent, spindle oil or gasoline to the O-ring of the injector.

O-ring

/ 1

Grommet 31'1'128

4. 5.

While turning the injector to the left and right. install it on to the delivery pipe. Be sure the injector turns smoothly.

NOTE If it does not turn smoothly, the O-ring may be jammed; remove the injector and re-insert it into the delivery pipe and re-check. Delivery pipe

31Y129

31-65

INJECTOR AND THROTILE BODY 6.

When installing the delivery pipe. check to be sure that the insulator is correctly inserted into the delivery pipe's installation hole.

7.

When installing the fuel pressure regulator, apply a coating of spindle oil or gasoline to the O-ring.

8.

Install the pressure regulator onto the delivery pipe.

Lock nut _ _L

31Y131

9.

Position the pressure regulator as shown in the figure. and tighten the nut to the specified torque.

Fuel pressure regulator

3tY132

31-66

THROTTLE BODY

THROTTLE BODY COMPONENTS

Throttle position sensor

I"~

Throttle valve set screw

...

.

~

Idle control servo assembly

Throttle body

TORQUE: Nm (kg.em. Ib.ft) 31Z275

REMOVAL

Y31GAOA

CAUTION The throttle valve must not be removed.

31-67

THROTTLE BODY 1.

Remove the throttle position sensor by unscrewing the phillips-head screws. NOTE Except when necessary for replacement. the throttle position sensor must not be removed.

2.

Remove the ISC servo assembly. NOTE 1) Except when necessary for replacement. the ISC servo assembly should not be removed. 2) The ISC servo assembly should not be disassembled.

3.

Use an open-end wrench or box wrench to remove the adjustment screw.

INSPECTION

Y31GBOA

Cleaning Throttle Body Components 1.

2.

Clean all components. The following components must not be cleaned by immersion in cleaning solvents. o Throttle position sensor o ISC servo assembly The insulation of these components will be damaged if they are immersed in a cleaning solvent. They should be cleaned by using only a piece of cloth. Check for restriction of the vacuum port or passage. Clean the vacuum passage by using compressed air.

31-68

FUEL TANK

FUEL TANK COMPONENTS

2.0-2.9 (20-30. 1.4-2.2) 20-2.9 (20-30. High pressure hose

,~ O - - - F u e l ~

Fuel gauge unit

Elect"cal fuel pump

tank cap

)-----Fuel filler neck Fuel tank

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

Vapour hose Filler hose Return hose

Leveling hose Fuel check valve

Two-way valve

Self locking nut

15-25 (150-250. 11-18)

TORQUE

REMOVAL 1.

Nm (kg.cm, Ib.ft)

Tank band

31Y137

Y31HAOA

To reduce the internal pressure of the fuel main pipes and hose. first start the engine and then disconnect the electrical fuel pump connector. NOTE Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose otherwise fuel will spill out.

2.

Disconnect the battery cable from the negative terminal of the battery.

31Y139

31-69

FUEL TANK 3. 4.

Remove the fuel tank cap. Remove the drain plug and drain the fuel.

5.

Disconnect the return hose and vapour hose.

----------------

_____.-

6.

Disconnect the fuel gauge unit connector.

7.

Disconnect the high pressure hose from the fuel tank.

31-70

31Y141

FUEl TANK 8.

Detach the fuel filler hose and leveling hose.

\

\

31Y144

9.

Loosen the two self-locking nuts, that hold tank in the position and remove the two tank bands. 10. Remove the fuel vapour hose and remove the fuel tank.

INSPECTION

Y31HBOA

1. 2. 3.

Check the hoses and the pipes for cracks or damage. Check the fuel tank cap for proper operation. Check the fuel tank for deformation, corrosion or cracking.

4. 5.

Check the inside fuel tank for dirt or foreign material. Check the in-tank fuel filter for damage or restriction.

6. 7.

Test two-way check valve for proper operation. To check the two-way valve, lightly breathe into the inlet and outlet. If the air passes through after slight resistance, then the valve is good. Check side

Caniste r side

nl

+0-

III

31Y146

31-71

FUEL TANK INSTALLATION

Y31HCOA

1.

Confirm that the pad is fully bonded to the fuel tank, and install the fuel tank by tightening the self-locking nuts to the tank bands until the rear end of the tank band contacts the body.

2.

Connect the leveling hose to the tank and approximately 40 mm (1.6 in.) to the filler neck. When connecting the filler hose, the end with the shorter straight pipe should be connected to the tank side.

3.

filler hose

Tank side F"--

cP' ·'·,-{b

leVeling hose

t

40 mm (1.6 in.)

~

A <.8

Filler hose side

4.

31V148

Connect the vapour hose and return ·hose. When attaching the fuel hose to the pipe, be sure that the hose is attached as shown in the illustration.

25-30 mm (1.0-1.2 in.) 31Y149

5.

To connect the high pressure hose to the fuel pump, temporarily tighten the flare nut by hand, and then tighten it to the specified torque. Be careful that the fuel hose does not twist.

Flare nut

Tightening torque . High pressure hose flare nut 29-39 Nm (300--400 kg.cm, 22-29 Ib.lt)

CAUTION When tightening the flare nut. be careful not to bend or twist the line to prevent damage to the fuel pump connection.

Secure side 31Yl50

31-72

FUEL TANK 6.

Connect the electrical fuel pump and fuel gauge unit connector.

7.

Tighten the drain plug to the specified torque. Tightening torque Drain plug . 15-25 Nm (150-250 kg.cm, 11-18 Ib.lt)

31-73

FUEL PUMP

FUEL PUMP Fuel (to main pipe)

COMPONENTS Discharge port

t

Check valve-------11E21 Relief valve

DC motor

O-ring

Amature assy nner rotor

t21t----Outer rotor O-ring

Intake port

GENERAL INFORMATION

t

Fuel (from fuel tankl 31Y153

Y31lAOA

Fuel within the fuel tank is pumped tothe injectors under pressure. This fuel pump, is installed within the fuel tank, and is submerged in the fuel. It features excellent performance while having low operating noise. This pump is also called a "wet type" of pump because the inside is also filled with fuel. It consists of a ferritetype DC motor unified with a Ge-rotor type pump. The pump itself is composed of a motor-driven gear, casing and cover. A relief valve and check valve are also used.

31-74

FUEL PUMP Relief Valve If, for some reason, fuel is not expelled at the discharge port, the pressure within the fuel pump would increase. In such a case, the relief valve opens in order to relieve the pressure, preventing fuel pressure in the fuel line from rising above the specified pressure. Check Valve When the pump stops, the check valve is closed by spring force, thus assuring that residual pressure will remain in the fuel line. By maintaining fuel pressure in this way, restarting of the engine becomes easier. In addition vapour locks at high temperature are prevented.

REPLACEMENT 1.

2. 3. 4.

Y311BOA

Disconnect the fuel pump connector. Remove the fuel tank cap. Drain the fuel. Disconnect the fuel high pressure hose. CAUTION Cover the hose connection with rags to prevent splashing of fuel that could be caused by residual pressure in the fuel pipe line.

5.

Remove the fuel pump installation screws and the bolt for holding the fuel pump (at the lower side of the fuel tank), and then remove it from the fuel tank.

6.

Align the three POSitioning projections of the packing with the holes in the fuel pump.

Positioning projection 31Y155

31-75

FUEL LINE AND VAPOUR LINE

FUEL LINE AND VAPOUR LINE Aust. : Australia M/East : Middle East

COMPONENTS 25-34 (250-350, 18-25) 8.8-14 (90-140, 6.5-10)

High pressure fuel

Fuel vapour pipe

Fuel filter

Fuel ma,n

\

e>

((-

~

0;;;:

I' ~

T

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

:om

n

~~e

~

~~~::~~p Wr~

~::~~~:::~~;;

Fuel vapour pipe

REMOVAL 1.

"""'=

Nm (kg.cm, Ib.ft)

Fuel return pipe

main hose

L",

[For Aust., Holland) [For Aust., Holland) ";"0RQUE

_

Ir

-=

Aust~aH~~I:~d]l· Fuel vapour hose

(P

.~

~el

return hose

e

h~ose _ ~,J\ om

~rj~

[For

"'I ~Fuel

~

[For Aust., Holland)

Fuel vapour hose [For Aust., Holland]

X;:::::::->...

Clip

Wlo

~~

~

Q,,-i

31Y156

Y31JAOA

Remove the upper eye bolt while holding the fuel filter nut securely and remove the high pressure fuel hose. CAUTION 1) Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose, otherwise fuel will spill out. 2) Cover the hose connection with rags to prevent splashing of fuel that could caused by residual pressure in the fuel line.

2. 3. 4. 5.

31Y157

Remove the lower eye bolt while holding the fuel filter nut assembly. Remove the fuel filter mounting bolts, and then remove the fuel filter from the bracket. Remove the fuel return hose and pipe. Remove the fuel vapour hose and pipe.

31Y158

31-76

FUEL LINE AND VAPOUR LINE

INSPECTION 1. 2. 3.

Check the hoses and pipes for cracking bending, deformation or restrictions. Check the canister for restrictions. Check the fuel filter for restrictions and damage.

INSTALLATION 1.

Y31JBOA

Y31JCOA

Install the fuel vapour hose and return hoses. o If the fuel pipe has a stepped, connect the fuel hose to the pipe securely, as shown in the illustration. o If the fuel pipe does not have a stepped section, connect the fuel hose to the pipe securely.

'i

:' / I / I :; /I

":t:J

/I

31Y159

2. 3.

Install the fuel filter, and tighten the fuel filter bracket. Insert the main pipe on the filter and tighten the eye bolts while holding the fuel filter nuts.

High-pressure hose

9

Eye bolt

~>GaSket Fuel main hose

~

~ Gl

r!t 31Y160

4. 5.

Install the clips and make sure that they do not interfere with other components. When installing the check valve, install it so that the valve is facing in the direction as shown in the illustration.

\ \

31Y161

31-77

ENGINE CONTROL

ENGINE CONTROL COMPONENTS ~""">---*--Throtllebody

Adjusting

side inner cable

bOlt--~===~==~:; Accelerator arm bracket

Bushing--------'~

~ Accelerator side inner cable

LAccelerator switch (AfT)

~~_.-.

~

It),.,..

.

----\-\,..---'-1'1.. ·0.1_ r.-'.~~.,J Return spring " "V:J '" ~

Accelerator switch

connector (AfT)

~SPlitPin Accelerator arm----j

•

""'78-12 (80-120.5.8-87)

~~Acceleratorpedal TORQUE

Nm (kg.em, Ib.ft) 31Y162

REMOVAL 1.

Y31KAOA

Remove the bushing and inner table of the accelerator arm side.

2.

Pull the left side of the accelerator pedal toward you, and then remove the accelerator pedal from the accelerator arm.

31Y163

3.

After disconnecting the accelerator switch connector, loosen the bolts of the accelerator arm bracket and remove.

/ /'

31Yl64

31-78

ENGINE CONTROL

INSPECTION the the the the the

Y3'KBOA

1. 2. 3. 4. 5.

Check Check Check Check Check

inner and outer cable for damage. cable for smooth movement. accelerator arm for deformation. return spring for deterioration. connection of the bushing to end metal fitting.

6.

Check the accelerator switch proper operation.

INSTALLATION 1.

Y3,KCO'

When installing the return spring and accelerator arm, apply multi-purpose grease around each moving point of the accelerator arm.

31Y165

2.

Apply sealant to the bolt mounting hole, and tighten the accelerator arm bracket. Tightening torque Accelerator arm bracket bolts

/ Apply sealant

.

/'

7.8-12 Nm (80-120 kg.cm, 5.8-7.2 Ib.ft)

31Y167

3.

Securely install the resin bushing of the accelerator cable on the end of the accelerator arm.

4.

Apply multipurpose grease around the cable end.

Accelerator cable

Accelerator arm

31Y168

31-79

CLUTCH GENERAL ..........•................................... 2 CLUTCH PEDAL

10

CLUTCH MASTER CYLINDER AND TUBE

12

CLUTCH MASTER CyLINDER

15

CLUTCH RELEASE CyLINDER

18

CLUTCH COVER AND DiSC ................•......... 21

II

GENERAL

GENERAL

Y41CAQA

SPECIFICATIONS Clutch operating method Clutch disc Type Facing diameter (Outside x Inside) mm (in.) Clutch cover assembly Type Setting load N (Ib) Clutch release cylinder

1.0.

mm (in.) Piston 0.0. mm (in.) Clutch master cylinder 1.0. mm (in)

CAUTION When servicing the clutch assembly or components. Do NOT create dust by sanding. cleaning clutch parts with a dry brush or with compressed air. (A water dampened cloth should be used). The clutch disc contains "Asbestos Fibers" which can become airborne during service operations. Breathing dust containing "Asbestos Fibers" may cause serious bodily harm.

41-2

Hydraulic type Single dry with diaphragm.

225 x 150 (8.9 x 5.9)

Diaphragm spring strap

4230-4970 (951-1117) 19.05 (0.75) 19.05 (0.75) 15.87 (0.62)

)

GENERAL

SERVICE STANDARD Clutch disc thickness (when free) Clutch pedal height Clutch pedal free play (includes both pedal and clevis pin play) Clutch pedal to floorboard clearance (when the cl utch is disengaged)

Y41CBOA

8.5-9.1 mm (0.335-0.358 in.) 177-182 mm (6.97-7.17 in.) 6-13 mm (0.24-0.51 in.) 55 mm (2.2 in.)

Limit Clutch disc Rivet sink Diaphragm spring End height difference Clutch release cylinder Clearance to piston Master cylinder Clearance to piston

Y41CCOA

0.3 mm (0.012 in.) 0.5 mm (0.02 in.) 0.15 mm (0.006 in.) 0.15 mm (0.006 in.)

TIGHTENING TORQUE Clutch tube Clutch cover bolt Eye bolt to clutch release cylinder Clutch tube flare nut Clutch master cylinder to pedal support member Clutch pedal pivot bolt and nut

Y41CDOA

13-17 15-22 25 Nm 13-17 10-15 25-35

Nm (130-170 Nm (150-220 (250 kg.cm. 18 Nm (130-170 Nm (100-150 Nm (250-350

kg.cm. kg.cm. lb. It) kg.cm. kg.cm. kg.cm.

9-12 Ib.ft) 11-16 Ib.lt) 9-12 Ib.lt) 7-10 Ib.lt) 18-25 Ib.ft)

41-3

GENERAL LUBRICANTS

Y41CEOA

Items

Specified lubricants

Quantity

Contact surface of release bearing and fulcrum of clutch release fork

MOLYWHITE TA NO.2

As required

Inner surface of clutch release bearing

MOLYWHITE TA NO.2

As required

Inner surface of clutch release cylinder and outer circumference of piston and cup

Brake fluid DOn

As required

Inner surface of clutch disc spline

MOLYWHITE TA No.2

As required

Inner surface of clutch master cylinder and outer circumference of piston assembly

Brake fluid DOn

As required

Clutch master cylinder push rod, clevis pin and

Wheel bearing grease SAE J310, NLGI No.2

As required

washer

Clutch pedal shaft and bushings

Chassis grease SAE J310, NLGI NO.1

As required

Contact portion of release fork to release cylinder push rod

MOLYWHITE TA NO.2

As required

1_I_n_p_u_t_s_h_a_ft_s_p_l_in_e

41-4

L-_M_O_LYW __H_I_T_E_T_A_N_O_.2

-"--_A_s_r_eq_u_i_re_d----'

GENERAL SPECIAL TOOLS Tool (Number and name)

09411-11000

Y41CFOA

Illustration

Use Centering flywheel and clutch disc

Clutch disc guide

41-5

GENERAL TROUBLESHOOTING

Y41CGOA

Symptom

Probable cause

Remedy

Clutch slipping o Car will not respond to engine speed during acceleration.

Insufficient pedal free play

Adjust

Clogged hydraulic system

Correct or replace parts

Excessive wear of clutch disc facing

Replace

Hardened clutch disc facing, or oil on surface

Replace

Damaged pressure plate or flywheel

Replace

VVeak or broken pressure spring

Replace

Excessive pedal free play

Adjust

Hydraulic system fluid leaks, air trapping or clogging

Repair or replace parts

Unusual wear or corrosion of clutch disc

Replace

0 0

Insufficient car speed Lack of power during uphill driving

Difficult gear shifting (gear noise during shifting)

spline

Clutch noisy

Excessive vibration (distortion) of clutch disc

Replace

VVhen clutch is not used

Insufficient play of clutch pedal

Adjust

Excessive wear of clutch disc facing

Replace

A noise is heard after clutch is

Unusual wear and/or damage of release bearing

Replace

Insufficient grease on the sliding surface of bearing sleeve

Repair

Improperly installed clutch assembly or bearing

Repair

Damaged pilot bushing

Replace

Insufficient lubrication of clutch pedal

Repair

Insufficient lubrication of spline part of clutch disc

Repair

Insufficient lubrication of clutch release lever shaft

Repair

Insufficient lubrication of front bearing retainer

Repair

disengaged A noise is heard when clutch is disengaged

A noise is heard when car is suddenly rolled of with cl utch partially engaged Hard pedal effort

41-6

GENERAL

Symptom

Probable cause

Remedy

Hard to shift or will not shift

Clutch pedal free play excessive

Adjust pedal free play

Clutch release cylinder faulty

Repair release cylinder

Clutch disc out of true, runout is exces-

Inspect· clutch disc

sive or lining broken

Clutch slips

Clutch grabs/chatters

Clutch noisy

Spline on input shaft or clutch disc dirty or burred

Repair as necessary

Clutch pressure plate faulty

Replace clutch cover

Clutch pedal free play insufficient

Adjust pedal free play

Clogged hydraulic system

Repair or replace parts

Clutch disc lining oily or worn out

Inspect clutch disc

Pressure plate faulty

Replace clutch cover

Release fork binding

Inspect release fork

Clutch disc lining oily or worn out

Inspect clutch disc

Pressure plate faulty

Replace clutch cover

Clutch diaphragm spring bent

Replace clutch cover

Worn or broken torsion spring

Replace clutch disc

Engine mounts loose

Repair as necessary

Damaged clutch pedal bushing

Replace clutch pedal bushing

Loose part inside housing

Repair as necessary

Release bearing worn or dirty

Replace release bearing

Release fork or linkage sticks

Repair as necessary

41-7

GENERAL

SERVICE ADJUSTMENT PROCEDURE

Y41CHOA

Clutch pedal height

CLUTCH PEDAL INSPECTION AND ADJUSTMENT 1.

Clutch pedal cleVIS

pin play

,

Measure the clutch pedal height (from the face of the pedal pad to the floorboard) and the clutch pedal clevis pin play (measured at the face of the pedal pad.)

B

Standard value: (A) 177-182 mm (6.8-7.0 in.) (B) 1-3 mm (0.04-0.12 in.) 2.

If either the clutch pedal height or the clutch pedal clevis pin play are not within the standard value range, adjust as follows: 1)

2)

Disconnect the clutch switch connector and turn the switch for standard clutch pedal height. Then lock with the lock nut.

Clutch SWitch

Turn the push rod .to adjust the clutch pedal clevis pin play to agree with the standard value and then secure the push rod with the lock nut. Caution When adjusting the clutch pedal clevis pin play, be careful not to push the push rod toward the master cylinder.

3.

After completing the adjustments, confirm that the clutch pedal free play (measured at the face of the pedal pad) and the distance between the clutch pedal (the face of the pedal pad) and the firewall when the clutch is disengaged are within the standard value ranges. Standard value: IC) 6-13 mm (0.2-0.5 in.) (D) 55 mm (2.2 in.) or more

4.

If the clutch pedal free play and the distance between the clutch pedal and the firewall when the clutch is disengaged do not agree with the standard values, after adjusting it is probably the result of either air in the hydraulic system or a faulty master cylinder or clutch. Bleed the air, or disassemble and inspect the master cylinder or clutch.

41-8

Lock nut Auto cruise only

Clutch pedal free play

Distance between the

clutch pedal and the firewall when the clutch is disengaged

.. ..",, . .. -.

,, ,

','

",

'~'\ ','

GENERAL BLEEDING

Y41CJOA

Whenever the clutch tube, the clutch hose, and/or the clutch master cylinder have been removed, or if the clutch pedal is spongy, bleed the system. Caution Use the specified brake fluid. Specified brake fluid : DOT3

41-9

CLUTCH PEDAL

CLUTCH PEDAL COMPONENTS

18-251

Clutch pedal mounting bolt

I

Ignition lock sWitch

58~ ~J

8-10 (80-100,

L:J

I , .

L-W

J)

0. G

~8UShing

I ~ c,,~

~~.J

· SpIIt pin

\

Washer

TORQUE

Nm (kg.cm. Ib.ft)

Removal 1.

Remove the return spring.

2.

Remove the split pin, washer, clevis pin.

3.

Remove the clutch pedal mounting bolt.

41-10

Clutch pedal

Y410AOA

~

I

Return spring

CLUTCH PEDAL INSPECTION

Y410BOA

1.

Check the pedal shaft and bushing for wear.

2. 3. 4.

Check the clutch pedal for bend or torsion. Check the return spring for damage or deterioration. Check the pedal pad for damage or wear.

IGNITION LOCK SWITCH INSPECTION 1. 2.

Ohmmeter

,-,

Disconnect the connector. Check to be sure that there is continuity between connector 1

terminals.

EJ ,

2

D

J

INSTALLATION 1.

Y41DCOA

Apply the specified grease to the clutch pedal and bushings. Specified grease: Chassis grease SAE J310. NLGI No.O

2. 3.

Install the clutch pedal mounting bolt. Apply the specified grease to the clevis pin and washer.

o

Specified grease : Wheel bearing grease SAE J310. NLGI No.2 4. 5. 6.

Install the push rod to the clutch pedal. Adjust the clutch pedal height. Adjust the clutch pedal clevis pin play

41-11

CLUTCH MASTER CYLINDER AND TUBE

CLUTCH MASTER CYLINDER AND TUBE COMPONENTS Clutch tube 13-17 (130-170, 9-12)

Clutch hose _ - - , f/

I'--

r~ei~)in- ~asher

"

r

13-17 (130-170, 9-12)

Hose c1ip~

Clutch tube

.~~ 'S'~

~~11~ 0;

Clutch master cylinder

..;f\-

TORQUE

Nm (kg.em, Ib.ft)

REMOVAL

Y41EAOA

1. 2. 3. 4.

Drain the clutch fluid through bleeding plug. Remove clevis pin, split pin, washer. Disconnect the clutch tube (master cylinder side). Remove the master cylinder mounting bolt.

5. 6.

Remove the clutch tube clips. Secure the nut on the clutch hose and loosen the flare nut on the clutch tube.

41-12

I

""-

,91 ~ Sealer

~~~~

=--' L-....J

• '"", '"

Spirt pin

CLUTCH MASTER CYLINDER AND TUBE 7.

Remove the clip from the clutch hose to remove clutch hose from bracket. 8. Remove the clutch tube.

rCIUICh

tube

.,...f'\.,

,JJ~

Hose clip

Clutch hose

9.

Disconnect the clutch tube (release cylinder side).

INSPECTION 1.

Check the clutch hose or tube for cracks or clogging.

INSTALLATION 1.

Y41EBOA

Y41ECOA

Connect the clutch tube (release cylinder side).

41-13

CLUTCH MASTER CYLINDER AND TUBE 2.

Temporarily tighten the flare nut by hand, and then tighten it to the specified torque, being careful that the clutch hose does not become twisted.

Secure side

3.

Install the clutch tube and clips.

4.

Install the master cylinder.

5.

Apply the specified grease to the clevis pin and washer. Specified grease: Wheel bearing grease SAE J310, NLGI No.2

6. 7. 8.

Install the push rod to the clutch pedal. Supply the clutch fluid. Bleed the Clutch tube (Refer to 41-9)

41-14

CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER COMPONENTS

~f--------Reservoir

cap

~==,?--------Reservoir tank bracket

r~~~I------Reservoir

Clip ..---

~

I--

Nipple

------e=r

tank

Hos e

Damper and push rod

Boot Piston stop ring Piston assembly

Reservoir band

Master cylinder body

DISASSEMBLY 1. 2. 3.

Y41FAOA

Remove the piston stop ring. Pull out the push rod and piston assembly. Remove the reservoir cup band, reservoir hose clip, reservoir tank bracket. CAUTION 1) Do not damage the master cylinder body and piston assembly. 2) Do not disassemble the piston assembly.

I 41-15

CLUTCH MASTER CYLINDER

INSPECTION 1. 2.

3. 4.

Y41FBQA

Check the inside of cylinder body for rust or scars. Check the piston cup for wear or deformation. Check the piston for rust or scars. Measure the master cylinder inside diameter and the piston outside diameter with a cylinder gauge and a micrometer. Limit : 0.15 mm (0.006 in.)

NOTE Measure the inside diameter of the master cylinder at three places (bottom. middle, and top), each in two perpendicular directions.

5.

If the master cylinder-to-piston clearance exceeds the limit, replace the master cylinder and/or piston assembly.

REASSEMBLY

Y41FCOA

1.

Apply the specified fluid to the inner surface of the master cylinder body and to the entire periphery of the piston assembly.

2.

Install the piston assembly. Specified fluid : DOT 3

3.

Install the push rod.

NOTE: ADJUSTMENT OF THE PUSH ROD 1) Adjust the pedal height to the standard value by turning the lock nut of the push rod. 2) Adjust free play to the standard value on condition that push rod is pulled to" .. direction and then lock the push rod.

41-16

~ush rod

CLUTCH MASTER CYLINDER 4.

Install the reservoir cap, reservoir hose, reservoir tank, reservoir tank bracket.

.

41-17

CLUTCH RElEASE CYlIhiDER

CLUTCH RELEASE CYLINDER COMPONENTS Bleeder plug

15-21 (150-210. 11-25)

Conical spring

Piston and Cap

Boot

13-17 (130-170. 10-120)

Push rod 25 (250. lB)

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

REMOVAL 1.

Remove the clutch tube. union.

2.

Remove the release cylinder mounting bolt.

Y41GAOA

I 41-18

:I

'III,

CLUTCH RELEASE CYLINDER

INSPECTION 1. 2.

Check the clutch release cylinder for fluid leakage. Check the clutch release cylinder boots for damage.

DISASSEMBLY 1. 2.

Y41GBOA

Y41GCOA

Remove the valve plate, spring, push rod, boots. Remove the piston from the release cylinder using compressed air. CAUTION 1) Cover with rags to prevent the piston from popping out. 2) Apply compressed air slowly to prevent brake fluid from splashing.

INSPECTION 1. 2.

Y41GDOA

Check the release cylinder bore for rust and damage. Measure the release cylinder bore at three locations (bottom, middle and top) with a cylinder gauge and replace the release cylinder assembly if the clearance to the piston outside exceeds the limit. Cylinder gage

Limit: 0.15 mm (0.006 in.)

REASSEMBLY 1.

Y41GEOA

Apply specified brake fluid to the release cylinder body inside and outer surface of the piston and piston cup and push the piston cup assembly in the cylinder. Specified brake fluid: DOT 3

2.

Install the valve plate, spring, union.

41-19

CLUTCH RELEASE CYLINDER

INSTALLATION

Y41GFOA

Release fork 1.

Apply a coating of the specified grease to the contact parts of the release fork and release cylinder push rod.

Specified grease: MOLVWHITE TA NO.2

2.

Install the clutch release cylinder, clutch tube.

41-20

CLUTCH COVER AND DISC

CLUTCH COVER AND DISC COMPONENTS

Fulcrum

Release fork boot

Release fork Transaxle assembly

\

Clutch release bearing

15-22 (150-220. 11-16)

Clutch cover assembly

Clutch disc

TORQUE

Removal 1. 2. 3.

Nm (kg.cm. Ib.ft)

¥41HAOA

Remove the transmission. Insert the special tool at the center spline (in order to prevent the clutch disc from falling). Diagonally loosen bolts which attach clutch cover to flywheel. Back off bolts in succession. one or two turns at a time. to avoid bending cover flange. Caution DO NOT clean clutch disc or release bearing with cleaning solvent.

41-21

CLUTCH COVER AND DISC

INSPECTION CLUTCH COVER ASSEMBLY 1. 2.

Y41HBOA

Check the diaphragm spring end for wear and uneven height. Replace if wear is evident or height difference exceeds the limit. Limit: 0.5 mm (0.02 in.)

3. 4.

Check the pressure plate surface for wear, cracks and color change. Check the strap plate rivets for looseness and replace the clutch cover assembly if loose.

CLUTCH DISC 1.

2.

Rivet sink Y41HCOA

Check the facing for loose rivets, uneven· contact. deterioration due to seizure, adhesion of oil or grease and replace the clutch disc if defective. Measure the rivet sink and replace the clutch disc if it is out of specification. Limit: 0.3 mm (0.012 in.)'

3. 4.

Check for torsion spring play and damage and if defective, replace the clutch disc. Combine the clutch disc with the inpu! shaft and check sliding condition and check for play in the rotating direction. If it does not slide smoothly, check after cleaning and reassembling. If the play is excessive, replace the clutch disc and/or the input shaft.

CLUTCH RELEASE BEARING 1. 2.

3.

The release bearing is packed with grease, so don't use cleaning oil, etc. to clean it. Check for bearing heat damage, other damage, abnormal noise and/or improper rotation. Also check whether or not there is wear at the point of contact with the diaphragm spring. If there is abnormal wear at the point of contact with the release fork, replace the bearing.

RELEASE FORK 1.

Y41HOOA

Y41HEOA

If there is abnormal wear at the point of contact with the bearing, replace the release fork.

41-22

CLUTCH COVER AND DISC INSTALLATION 1.

Y41HFOA

Apply a coating of the specified grease ot the point of contact with the fulcrum and the point of contact with the release bearing. Specified grease

MOLYWHITE TA NO.2

Caution When installing the clutch, apply grease to each part, but be careful not to apply excessive grease; excessive grease will cause clutch slippage and shudder. 2.

Apply a coating of the specified grease to the end of the release cylinder's push rod and to the push rod hole in the release fork. Specified grease

3.

MOLYWHITE TA NO.2

Pack the inner surface of the clutch release bearing and the groove with the specified grease. Specified grease: MOLYWHITE TA NO.2 Apply grease

41-23

CLUTCH COVER AND DISC 4.

Apply a coating of the specified grease to the clutch disc spline, and then use a brush to rub it in. Specified grease: MOLYWHITE TA NO.2

5. 6.

7.

Using the special tool (clutch disc guide), position the clutch disc to the flywheel. Install the clutch cover assembly. Tighten the bolts a little at a time, working in a diagonal sequence, finally tightening them to the specified torque. Before installing the transmission assembly, apply a coating of the specified grease to the input shaft spline, and then rub in by using a brush.

Flywheel

Nl±:::~'H--Clutch

disc

Specified grease: MOLYWHITE TA NO.2 Clutch cover assembly

41-24

MANUAL TRANSAXLE GENERAL ............................•........•....•... 2 MANUAL TRANSAXlE CONTROL

12

SHIFT lEVER ASSEMBly

14

MANUAL TRANSAXlE

16

MANUAL TRANSAXlE ASSEMBLY

19

5TH SPEED SYNCHRONIZER ASSEMBly

27

INPUT SHAFT

29

INTERMEDIATE SHAFT

37

OUTPUT SHAFT

43

SHIFT FORK

44

DIFFERENTIAL .................................•...... 45 CLUTCH HOUSiNG SPEEDOMETER DRIVEN GEAR ASSEMBly MANUAL TRANSAXlE ASSEMBly

49

I

53 54

III

GENERAL

GENERAL SPECIFICATIONS

Y43CA2A

Manual Transaxle Type Gear ratio

5-speed floor-shift 3.166 1.833 1.240 0.896 0.666 3.166 4.067 29/36

1st 2nd 3rd 4th 5th Reverse

Final gear ratio speedometer gear ratio (driven/drive)

SERVICE STANDARD

Y43CB2A

Standard value Input shaft bearing end play Intermediate shaft bearing end play Intermediate shaft end play Output shaft end play Differential case end play Differential side gear and pinion backlash Limit Synchronizer ring and clutch gear clearance

0.01 0.01 0.05 0.05 0.05 0.025 -

0.12 mm (0.0004 0.11 mm (0.0004 0.10 mm (0.002 0.10 mm (0.002 0.10 mm (0.002 0.150 mm (0.001

0.0047 in.) 0.0044 in.) 0.004 in.) 0.004 in.) 0.004 in.) - 0.006 in.)

0.5 (0.02)

LUBRICANTS

Transaxle oil lit (U.S. qts., Imp.qts.) Return spring and bracket sliding part Drive shaft oil seal lip Shift lever bushing

Y43CClA

Recommended lubricant

Quantity

Hypoid gear oil, SAE 75W-85W Multipurpose grease SAE J310, NLGI NO.2 Hypoid gear oil, SAE 75W-85W Multipurpose grease SAE J310, NLGI NO.2

2.5 As As As

(2.6, 2.1) required required required

SEALANTS AND ADHESIVES

Y43CD2A

Recommended sealants and adhesives

Quantity

Transaxle case and clutch housing alignment surface Transaxle case and rear cover

THREE BOND 1216

As required

THREE BOND 1216

As required

alignment surface Differential drive gear bolt 8earing retainer bolt (flush bolt only)

THREE BOND1303 or LOCTITE 648 THREE 80ND 1303 or LOCTIT E 648

As required As required

43-2

GENERAL SNAP RING FOR ADJUSTMENT AND SPACER Part name Snap ring (for adjustment of input shaft front bearing end play)

Snap ring (for adjustment of intermediate shaft front bearing end play)

Spacer (for adjustment of intermediate shaft end play)

Y43CEOA

Thickness mm (in.)

Identification mark

2.24 (0.0882)

None

2.31 (0.0909)

Blue

2.38 (0.0937)

Brown

1.40 (0.0551)

Red

1.50 (0.0590)

Blue

1.60 (0.0630)

Yellow

1.70 (0.0669)

Green

0.80 (0.0315)

80

0.83 (0.0327)

83

0.86 (0.0338)

86

0.89 (0.0350)

89

0.92 (0.0362)

92

0.95 (0.0374)

95

0.98 (0.0386)

98

1.01 (0.0398)

01

1.04 (0.0409)

04

1.07 (0.0421)

07

1.10 (0.0433)

10

1.13 (0.0445)

13

1.16 (00457)

16

1.19 (0.0468)

19

122 (0.0480)

22

1.25 (0.0492)

25

1.28 (0.0504)

28

1.31 (0.0516)

31

1.34 (0.0527)

34

1.37 (0.0539)

37

43-3

GENERAL

Part name

Thickness mm (in.)

Identification mark

0.83 (0.0327)

83

0.86 (0.0338)

86

0.89 (0.0350)

89

0.92 (0.0362)

92

0.95 (0.0374)

95

0.98 (0.0386)

98

1.01 (0.0398)

01

1.04 (0.0409)

04

1.07 (0.0421)

07

1.1 0 (0.0433)

J

1.13 (0.0445)

D

1.16 (0.0457)

K

1.19 (0.0468)

L

1.22 (0.0480)

G

1.25 (0.0492)

M

1.28 (0.0504)

N

1.31 (0.0516)

E

1.34 (0.0527)

0

Spacer

1.43 (0.0563)

Q

(for adjustment of differential case end play)

1.46 (00575)

R

1.49 (0.0587)

C

1.52 (0.0598)

S

1.55 (0.0610)

T

1.58 (0.0622)

8

1.61 (0.0634)

U

1.64 (0.0646)

V

1.67 (0.0657)

A

1.70 (0.0669)

W

1.73 (0.0681)

X

1.76 (0.0692)

F

1.79 (0.0705)

y

1.82 (0.0716)

Z

1.85 (0.0728)

H

1.88 (0.0740)

AA

Spacer (for adjustment of output shaft end play)

43-4

GENERAL TIGHTENING TORQUE

Shift lever to lever (A) Lever (A) to bracket assembly Air filter installation bolts Clutch tube flare nut Tie rod end to knuckle Lower arm ball joint to knuckle Transmission mount bracket to transmission Bell housing cover to transmission Bell housing cover bolt Starter motor to transmission Filler plug Drain plug Transmission mounting bolt [10 mm (0.39 in.) diameter bolt] Transmission mounting bolt [B mm (0.31 in.) diameter bolt] Rear cover bolt Backup lamp switch Poppet plug Speedometer sleeve bolt Input shaft lock nut Intermediate shaft lock nut Reverse idler gear shaft bolt Transmission case tightening bolt Stopper bracket bolt Restriction ball assembly Reverse shift lever assembly installation bolt Bearing retainer bolt Differential drive gear bolt Interlock plate bolt

Y43CFOA

Nm

Kg.cm

Ib-ft

19-28 19-28 8-10 13-17 24-34 60-72 40-50 15-22 10-12 22-32 30-35 30-35 43-55 30-35 15-22 30-35 30-42 3.0-5.0 140-160 140-160 43-55 35-42 15-22 30-35 15-22 15-22 130-140 20-27

190-285 190-285 80-100 130-170 245-345 610-730 405-510 150-220 100-120 220-325 305-355 305-355 435-560 305-355 150-220 305-355 305-425 30-50 1425-1630 1425-1630 435-560 355-425 150-220 305-355 150-220 150-220 1325-1425 200-275

14-20 14-20 6-7 9-12 17-25 43-52 29-36 11-16 7-9 16-23 22-25 22-25 32-39 22-25 11-15 22-25 22-30 2.5-3.5 102-115 102-115 32-38 26-30 11-15 22-25 11-15 11-15 94-101 15-19

43-5

GENERAL

SPECIAL TOOLS Tool (Number and Name)

09214-21000 Cranksahft front oil seal installer

09414-11000 Lock pin extractor

09414-11100

Y43CG2A

Illustration

Use Installation of the differential tapered roller bearing

1) Driving out the spring pin of the clutch shaft 2) Driving out the spring pin of the shift fork

Driving in the spring pin of the shift fork

Lock pin installer

09431-21000

Installation of the input shaft front oil seal

Front oil seal installer

09431-21200

Installation of differential oil seal

Oil seal installer

09432-21101 Input shaft holder

Holding the input shaft when loosening input shaft nut

09432-21201

Removal of input shaft snap ring

Snap ring remover

09432-21300 Removing plate

43-6

Removal of input shaft front and rear bearing

GENERAL

Tool (Number and Name) 09432-21500 Bearing installer

09432-33100 Removing plate

Illustration

Use 1) Installation of the input shaft front bearing 2) Installation of the output shaft synchronizer hub and gear sleeve

~

Removal of 1st gear and 2nd gear

~

09432-33200

Removal of tapered roller bearing ,

Removing plate

, ::::1t

.'

-

09432-33300 Bearing installer

1) Installation of synchronizer assy 2) Installation of bearing sleeve and bearing

~ 09432-33600 Output shaft bearing outer race installer

09433-21000 Removing plate

09455-21000 Bearing and gear puller

09455-21100 Bearing installer

Installation of output shaft bearing outer race

@ ~ G£);;}

~~

1) Removal of differential ball bearing (use with 09532-11301) 2) Removal of differential bearing

Removal of ball bearing and gear

,ij,

Installation of differential bearing

~ 43-7

GENERAL

Tool (Number and Name) 09455-32200 Oil seal puller

Illustration

Use Removal of output shaft bearing outer race and intermediate shaft bearing outer race

09500-11000 Bar

Installation of differential bearing outer race and output shaft bearing outer race (use with 09500-11500)

09500-21000 Bar

Installation of output shaft bearing outer race (use with 09432-33400)

09532-11000 Tapered roller bearing puller

Removal of the differential case side

09532-11100 Side bearing remover adaptor

bearing (use with 09532-11100 and 09532-11301 )

Removal of the differential case side bearing (use with 09532-11000 and 09532-11301

09532-11301 Puller cup

Removal of the differential case side bearing (use with 09532-11000 and 09532-11100)

09532-11500 Pinion bearing outer race installer

Installation of differential bearing outer race and output shaft bearing outer race (use with 09500-11000)

43-8

GENERAL TROUBLESHOOTING

Y43CH2A

Symptom

Probable ca use

Remedy

Vibration, noise

Loose or damaged transaxle and engine mounts

Tighten or replace mounts

Inadequate shaft end play

Correct end play

Worn or damaged gears

Replace gears

Use of inadeq uate grade of oil

Replace with specified oil

Low oil level

Replenish

Inadequate engine idle speed

Adjust idle speed

Oil leakage

Broken or damaged, oil seal or a-ring

Replace oil seal or a-ring

Hard shift

Faulty control cable

Replace control cable

Poor contact or wear of synchronizer ring and gear cone

Correct or replace

Weakened synchronizer spring

Replace synchronizer spring

Use of inadequate grade of oil

Replace with specified oil

Worn gear shift fork or broken poppet spring

Replace shift fork or poppet spring

Synchronizer hub to sleeve spline clearance too large

Replace synchronizer hub and sleeve

Jumps out of gear

43-9

GENERAL SERVICE ADJUSTMENT PROCEDURES

Y43CJ2A

REPLACEMENT OF TRANSAXLE OIL 1.

With the vehicle on a flat and level surface, remove the drain plug and drain out the transaxle oil.

2.

Fill transaxle oil (through the filler plug part) until the oil level is the same level as the plug hole. Transaxle oil: Hypoid gear oil. SAE 75W-85W conforming to API GL-4 [2.5 LIT. (2.6 U.S.qts.• 2.2 Imp.qtsl

REPLACEMENT OF DRIVE SHAFT OIL SEALS Y43CK2A.

t~e

1.

Disconnect shaft).

drive shaft from the transaxle (Referto drive

2.

Using a flat-tip (-) screwdriver, remove the oil seal.

---.......r------:"~o~\\

-'.:11,--0_

\.!"LO

...-.e:\

Oil seal

L.H. side

Fro';;;-

/

43-10

e~aust /

pipe

GENERAL 3.

Using the special tool (09431-21200), tap the drive shaft oil seal into the transaxle.

4.

Apply a coating of the transaxle oil to the lip of the oil seal.

09431-21200

REPLACEMENT OF SPEEDOMETER CABLE v.,eLZA 1. 2.

Remove the old cable. When connecting the cable to the speedometer, insert the cable until its stopper properly fits to the meter side groove.

3.

Install the grommet so that. as shown in the illustration, the cable attachment part and the projecting part are horizontal.

..

Caution The cable arrangement should be made so that the radius of cable bends is 150 mm (5.9 in.) or more.

4.

At the transaxle end of the speedometer cable, the key joint should be inserted into the transaxle, and the nut should then be securely tightened. Caution If the cable is not correctly and securely connected, it may cause incorrect indication by the speedometer or abnormal noise.

43-11

MANUAL TRANSAXLE CONTROL

MANUAL TRANSAXLE CONTROL COMPONENTS

Clip (Transmission side)

Shift cable Select cable

Retainer

Clip (Shift lever side)

Cotter pin

Shift lever assembly

REMOVAL 1. 2. 3.

Remove the console box (Refer to console box). Remove the cotter pins and clips (shift lever side). Remove the shift lever assembly.

Y43DA2A

/~ g

a

Shift cable

flange s,de

~I C'

_ ---:l

cable

Resin bushing

c=O 43-12

---I

Shift lever

-,-,'11',' """....,.."

MANUAL TRANSAXLE CONTROL 4. 5. 6. 7.

Remove Remove Remove Remove

the the the the

retainer and bolts. air cleaner. colter pins and clips (Transaxle side). shift cable and select cable.

INSPECTION 1. 2.

Check the select cable for function and for damage. Check the shift cable for function and for damage.

INSTALLATION 1. 2.

Y43DB2A

Y43DC2A

Install the shift lever assy. Install the colter pins and clips (shift lever side and transaxle side) with select cable and shift cable.

NOTE: 1)

The flange side of the resin bushing at the shift cable end should be at the split pin side. 2) The flange side of the resin bushing at the selector cable end should be at the lever B end surface.

3. 4.

Install the retainer and bolts. Install the air cleaner.

43-13

SHIFT LEVER ASSEMBLY

SHIFT LEVER ASSEMBLY COMPONENTS

Shift lever Bushing

19-28 (190-285. 14-20)

Lever (Al

llll®

Bracket assembly

14-20)

TORQUE

Nm (kg.em. Ib.ft)

INSPECTION 1.. Cheek the bushing for wear or damage. 2.

Check the return spring for damage or deterioration.

43-14

Y43EA2A

SHIFT LEVER ASSEMBLY ASSEMBLY 1.

Y43EB2A

Apply specified grease to points shown in illustration. Specified grease: Multipurpose grease SAE J310 NLGI No.2 Section A-A

,

,-1

FORWARD ••- -

II

hnn.

~

"r

'--lI

Section

'AI

B-B

C

~J W Section C-C

Section D-D

D

2. 3.

Install so that the return spring is in secure contact with the bracket end surface. Apply a coating of the specified grease to the return spring and bracket sliding part.

Lever A

Return spring

Specified grease: Multipurpose grease SAE J310. NLGI No.2

43-15

MANUAL TRANSAXlE

MANUAL TRANSAXlE COMPONENTS Select cable

Shift cable

Transaxle mount bracket

/

r

./

~'

Drain plug

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

43-16

30-35 (300-350, 22-25)

MANUAL TRANSAXLE REMOVAL

Y4JFA2A

1. 2. 3. 4.

Remove the clutch release cylinder (Refer to clutch part). Remove the drain plug and drain out the transmission oil. Remove the air cleaner assembly. Remove the select cable and shift cable (Refer to MANUAL TRANSAXLE PART).

5. 6.

Remove the backup lamp switch connector. Remove the speedometer cable

7.

Remove the starter motor.

Remove the stabilizer bar, tie rod end, lower arm ball joint, drive shaft side cover, under cover (Refer to drive shaft and front axle). 9. Remove the bell housing cover.

fJJII--l~

8.

~..--J

~..--J

l-ji/

I I ~bI • " '<:f UO£.~';

~

f

~ ~

'=

0

= -------=

I

II " / II

Ir

-==::,~ ~

o

I,

::--s:

fO

~

/

...,..,

43-17

MANUAL TRANSAXLE 10. Remove the cap and transaxle mounting bracket.

11. Remove the transaxle assy.

43-18

MANUAL TRANSAXlE ASSEMBLY MANUAL TRANSAXlE ASSEMBLY COMPONENTS

30-35 (300-350, 22-35)

15-22 (150-220,

Restriction ball assembly

Poppet ball Poppet spring I

Poppet plug Spring pin

Shift rail assembly

I

R ar Cover

i

i

~o o

Transmission Oil guide

TOROUE

case~~~~~

Nm (kg.em. Ib.ft)

43-1~

MANUAL TRANSAXlE ASSEMBLY DISASSEMBLY

Y43GA2A

1.

Remove the rear cover bolt and rear cover.

2.

Remove the backup light switch, gasket and mounting bracket.

3.

Remove the poppet plugs, poppet springs and poppet balls.

4.

Remove the speedometer driver gear assembly.

43-20

MANUAL TRANSAXLE ASSEMBLY 5.

Remove the spring pin using the special tool (0941411000). 09414- 11000

6.

Removal of the lock nuts 1) Unstake lock nuts of the input shaft and intermediate shaft.

2)

Shift the shift lever in reverse using the control lever and select lever. SeleCI lever --~

Control lever ~:;o-,-~/:-~\'.'

3)

Install the special tool (09432-21101) onto the input shaft. 4) Screw a bolt 10 mm (0.39 in.) into the hole on the periphery of clutch housing and attach a spinner handle to the special tool. 5) Remove the lock nut, while using the bolt as a spinner handle stopper.

Spinner handle

43-21

MANUAL TRANSAXll; ASSEMBLY 7. Remove the 5th speed synchronizer sleeve and 5th speed shift fork. S. Remove the 5th speed synchronizer hub, synchronizer ring, 5th speed gear and needle bearing.

9. Remove the intermediate gear (09455-21000).

using the

09455-21000

special tool

09455-21000

10. Remove the reverse idler gear shaft bolt and restriction ball assembly.

11. Remove thetransaxle cover bolts (13 EA) and transaxle cover.

43-22

MANUAL TRANSAXLE ASSEMBLY 12. Remove the differential oil seal and oil guide.

13. Remove the output shaft bearing outer· race and spacer using the special tool (09455-32200). 14. Remove the intermediate shaft bearing outer race and spacer. 15. Remove the differential bearing outer race and spacer.

09455-32200

16. Remove the reverse shift lever and the reverse shift shoe.

17. Remove the reverse gear shaft and reverse gear.

43-23

MANUAL TRANSAXlE ASSEMBLY 18. Remove the spring pins using the special tool (0941411000).

19. Disassembly of shift rail assembly. 1) Shift the 1st-2nd speed shift fork to the 2nd speed. 2) Shift the 3rd-4th speed shift fork to the 4th speed.

3rd-4th ""-"-'\.-f shi ft

fork

3)

Remove the shift rail assembly.

20. Remove the bearing retainer.

43-24

MANUAL TRANSAXlE ASSEMBLY 21. Lift up the input shaft assembly and remove the intermediate shaft assembly.

22. Remove the output shaft assembly and differential gear assembly.

23. Remove the intermediate shaft bearing outer race and spacer and oil guide using the special tool (09455-32200).

24. Remove the output shaft bearing outer race and spacer using the special tool (09455-32200).

9455-32200

9455-32200

43-25

MANUAL TRANSAXLE ASSI:MBLY 25. Remove the differential bearing oil seal and the differential bearing outer race.

26. Remove the input shaft oil seal.

43-26

5TH SPEED SYNCHRONIZER ASSEMBLY

5TH SPEED SYNCHRONIZER ASSEMBLY COMPONENTS

Synchronizer key Synchronizer sleeve

Synchronizer hub

Synchronizer spring

Stop plate

Synchronizer spring

I

INSPECTION

Y43HAlA

SYNCHRONIZER SLEEVE AND HUB 1. 2. 3.

Combine the synchronizer sleeve and hub and check that they slide smoothly. Check that the sleeve is free from damage at its inside front and rear ends. Check for wear of the hub front end (surface in contact with the 5th speed gear). Caution Replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING 1. 2.

Y43HBlA

Check for wear of the synchronizer key center protrusion. Check the spring for weakness, deformation and breakage.

43-27

5TH SPEED SYNCHRONIZER ASSEMBLY ASSEMBLY

Y43HC2A

Oil channel

1.

Assemble the synchronizer hub, sleeve and key noting their direction.

.~ Clutch housing

2.

key

The synchronizer sleeve has teeth missing at six portions. Assemble the hub to the sleeve in such a way that the center tooth "T" between two missing teeth wi:' touch the synchronizer key.

<:=J

T

One-loath-skipped pans

/-z:~==::

"~"'"~

3.

Install the synchronizer spring in such a way that its stepped portions will rest on the synchronizer keys. Caution When installing the synchronizer springs. make sure that the front and rear ones are not faced in same direction.

Slepped

Spflng part

43-28

INPUT SHAFT

INPUT SHAFT COMPONENTS

Needle bearing

~

Input shaft

Ball bearing Bearing sleeve

~)~~

Ball bearing

Needle bearing

Snap ring

Corn spring Sub gear gear

Needle bearing

I

.

Synchronizer ring

r spring Synchronize . hub 3rd-4th speed sy nchromzer

43-29

INPUT SHAFT

DISASSEMBLY 1.

Y4JJA2A

Remove the snap ring using the special tool (0943221201 ).

09432-21201

2.

Remove the front bearing using the special tool (0943221300).

3.

Remove the bearing sleeve using the special tool (0945521000). Remove the snap ring.

4.

9455-21 ()()()

5.

Remove the rear bearing using the special tool (0943221300).

43-30

09432-21300

+

INPUT SHAFT 6. 7.

+

Remove the 4th speed gear and needle roller bearing, synchronizer ring, 3rd-4th speed synchronizer sleeve. Remove the needle roller bearing sleeve, 3rd-4th synchronizer hub, synchronizer ring, 3rd speed gear, needle roller bearing using the special tool (09432-21300).

INSPECTION INPUT SHAFT 1. 2.

(Ill

Y43JB2A

Check the outer surface of the input shaft where the needle bearing is mounted for damage or abnormal wear [portion (A)]. Check the splines for damage or wear.

.

L

-~

NEEDLE BEARING 1.

2.

--.. . . . -r~ Spline

Y43JC2A

Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play. Check the needle bearing cage for deformation.

SYNCHRONIZER RING 1. 2.

~....----

Y43JD1A

Damage and wear

Check the clutch gear teeth for damage and breakage. Check the internal surface for damage, wear and broken threads.

Damage and breakage

43-31

INPUT SHAFT 3.

Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.

_~A

Limit: 0.5 mm (0.02 in.)

Synchronizer nng

SYNCHRONIZER SLEEVE AND HUB 1. 2. 3.

Y43JE2A

Combine the synchronizer sleeve and hub and check that they slide smoothly. Check that the sleeve is free from damage at its inside front and rear ends. Check for wear of the hub.end surfaces (in contact with each speed gear). Caution Replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING 1. 2.

1.

Y43JF2A

Check for wear of the synchronizer key center protrusion. Check the spring for weakness, deformation and breakage.

SPEED GEARS

Y43JG2A

Check the bevel gear and clutch gear teeth for damage and wear.

2.

Check the synchronizer cone for rough surface, damage and wear.

3.

Check the gear bore and front and rear ends for damage and wear.

43-32

Ge;u

/ J

INPUT SHAFT ASSEMBLY 1.

Y43JH2A

Install the synchronizer hub and sleeve so that they are positioned as shown in the figure.

Clutch housing side

..

30o~lL

Identificatron mark

2.

The synchronizer sleeve has teeth missing at six portions. Assemble the hub to the sleeve in such a way that the center tooth "T" between two missing teeth will touch the synchronizer key.

Synchronizer key

3.

Install the synchronizer spring in such a way that its stepped portions will rest on the synchronizer keys. Caution When installing the synchronizer springs. make sure that the front and rear ones are not faced in same direction.

Key

~

Spring stepped part

43-33

INPUT SHAFT 4. 5.

Install the needle roller bearing and 3rd speed gear to the input shaft. Install the 3rd-4th speed synchronizer assembly over the input shaft using the special tool (09432-21500).

09432-21500

Caution 1. . When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in respective grooves of the -synchronizer ring. 2. After installing of the synchronizer assembly, check that the 3rd speed gear rotates smoothly.

I

6. 7.

Install the needle roller bearing sleeve .using the special tool (09432-21500). Install the synchronizer ring, needle roller bearing. 4th gear and spacer.

09432-21500

43-34

INPUT SHAFT 8. 9.

Install the rear bearing using the special tool (0943221500). Install the snap ring.

+ 09432-21500

10. Install the rear bearing sleeve using the special tool (09432-21500).

09432-2' 500

43-35

INPUT SHAFT 11. Install the front bearing using the special tool (0943233300). 12. Install the snap ring.

09432-33300

43-36

INTERMEDIATE SHAFT

INTERMEDIATE SHAFT COMPONENTS

Needle bearing 2nd speed gear Synchronizer spring Synchronizer ring Synchronizer spring

J ~

Synchronizer key

1sl-2nd speed synchronizer sleeve Synchronizer spnng Synchronizer ring

:..--::::

, st speed gear

43-37

INTERMEDIATE SHAFT DISASSEMBLY 1.

Y43KA2A

Remove the snap ring using the special tool (0943221201 ).

09432-21201

2.

Remove the taper roller bearing, 1st speed gear and bearing sleeve and needle roller bearing using the special tool (09432-33100).

CAUTION 1 . Do not reuse the bearing removed from the shaft. 2. Replace the inner and outer races of the tapered roller bearing as a set.

3.

Remove the 1st-2nd speed synchronize'r assembly and 2nd speed gear, needle roller bearing together using the special tool (09432-33100).

09432-33100

4.

Remove the taper roller bearing using the special tool (09432-33200).

CAUTION 1 . Do not reuse the bearing removed from the shaft. 2. Replace the inner and outer races of the tapered roller bearing as a set.

43-38

09432-33200

INTERMEDIATE SHAFT

INSPECTION INTERMEDIATE SHAFT 1.

2.

Y43KB2A

Check the outer surface of the intermediate shaft where the needle bearing is mounted for damage or abnormal wear [portion (All. Check the splines for damage and wear.

NEEDLE BEARING

Y43KC2A

1. Combine the needle bearing with the shaft or bearing sleeve

2.

and gear and check that it rotates smoothly without abnormal noise or play. Check the needle bearing cage for deformation.

SYNCHRONIZER RING

Y43KOZA

Oamage and wear

1. Check the clutch gear teeth for damage and breakage. 2.

Check the internal surface for damage, wear and broken threads.

Damage and breakage

3.

Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.

---..I A

Limit: 0.5 mm (0.02 in.)

Synchronizer ring

Ge;tf

43-39

INTERMEDIATE SHAFT

SYNCHRONIZER SLEEVE AND HUB 1. 2. 3.

Y43KE2A

Combine the synchronizer sleeve and hub and check that they slide smoothly. Check that the sleeve is free from damage at its inside front and rear ends. Check for wear of the hub end surfaces (in contact with each speed gear). Caution Replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING 1. 2.

Check for wear of the synchronizer key center protrusion. Check the spring for weakness, deformation or breakage.

SPEED GEARS 1.

Y43KF2A

Y43KG2A

Check the bevel gear and clutch gear teeth for damage and wear.

2.

Check the synchronizer cone for a rough surface, damage or wear.

3.

Check the gear bore and front and rear ends for damage or wear.

43-40

INTERMEDIATE SHAFT

ASSEMBLY ,.

..

Y43KHQA

Install the tapered roller bearing over the intermediate shaft using the special tool (09432-21500). CAUTION When installing the bearing, push on the inner race only.

2.

Install the 1st synchronizer ring noting its identification mark.

3.

Combine the 1st-2nd speed synchronizer hub and sleeve.

09432-21500

Clutch housing side

Identification

4.

5.

The synchronizer sleeve has teeth missing at six portions. Assemble the hub to the sleeve in such a way that the center tooth "r between two missing teeth will touch the synchronizer key.

T

One-loath-skipped parts

Install the synchronizer spring in such a way that its stepped portions will rest on the synchronizer keys.

Key

Caution When installing the synchronizer springs, make sure that the front and rear ones are not facing in the same direction. Spflng stepped part

43-41

INTERMEDIATE SHAFT 6.

Install the needle roller bearing, 2nd gear, 1st-2nd speed synchronizer assembly over the intermediate shaft using the special tool (09432-21500). Caution 1. When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in respective grooves of the synchronizer ring. 2, After installation of the synchronizer assembly, check that the 3rd speed gear rotates smoothly.

7.

8.

Install the needle roller bearing, 1st 'speed gear, bearing sleeve together using the special tool (09432-21500) as illustrated.

09432-21500

Install the tapered roller bearing using the special tool (09432-215OO). Caution When installing the bearing, push on the inner race only,

9.

09432-21500

Install the snap ring.

43-42

09432-21500

OUTPUT SHAFT

OUTPUT SHAFT COMPONENTS

Tapered roller bearing

DISASSEMBLY 1.

Y43LA2A

Remove the tapered roller bearing using the special tools

0943221300

t

0943321000

t

(09432-21300, 09433-21000). CAUTION Do not reuse the bearing removed from the shaft.

ASSEMBLY 1.

Install the tapered roller bearing

Y43LB2A

using the special tool

(09432-21500).

..

09432-21500

CAUTION When installing the bearing, push on the inner race only.

43-43

SHIFT FORK

SHIFT FORK COMPONENTS 8---lnterlock plunger

3rd-4th shift fork 5-r shift rail

1sl-2nd shift fork

3rdAth shift rail

1sl-2nd shift rail

ASSEMBLY

Y43MA2A

Interlock plunger ,.

Reverse shift lug

Insert the interlock plunger as illustrated on the 3rd-4th speed shift rail.

\

o

\

3rd-4th shift rail

43-44

DIFFERENTIAL

DIFFERENTIAL COMPONENTS

~ Side gear ~

Pinion

Washer

Differential case

TORQUE

Nm (kg.em. Ib.ft)

'----------------------------------------,--~

DISASSEMBLY 1. 2.

J

Y43NA2A

Clamp the differential case in a vise. Remove the differential drive gear retaining bolts and remove the differential drive gear from differential case.

43-45

DIFFERENTIAL 3.

Remove the tapered roller bearings using the special tool

(09532-11000, 09532-11100, 09532-11301).

09532-11000

09532-11301 ~~~~

"U9532-11100

9532-11000

~R=:=::::-09532-11301

~~~F=f-----O'9532-11100

4. 5. 6.

Drive out the lock pin from the hole·A using a punch. Drive out the pinion shaft. Remove the pinion gears, washers, side gears and spacers.

Lock pin

Pinion shaft-

/

\ ~

Differential case

ASSEMBLY 1.

Y43NB2A

Install the spacer on the back of the side gear and then install the gear in the differential case. CAUTION 1. When installing a new side gear, use a spacer of medium thickness [0.93-1.00 mm (0.036-0.04 in.)] 2. Do not reuse the lock pin. 3. The lock pin head must be sunk below the flange surface of the differential case.

43-46

DIFFERENTIAL 2.

3.

Set the washer on the back of each pinion and insert the two pinions to specified position while engaging them with the side gears by turning them. Insert the pinion shaft.

Pinion shaft

Pinion u,,_~gear

, Lock pin hole

4.

Side gear

Mesure the backlash between the side gears and pinions. Standard value : 0.025-0.150 mm (0.001-0.006 in.)

5.

If the backlash is out of specification, disassemble and use the correct spacer, reassemble and remeasure. Caution Adjust the backlash of both side gears to the same specification.

6.

Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pin. Caution 1. Do not reuse the lock pin. 2. The lock pin head must be below the flange surface of the differential case.

7.

Install the tapered roller bearings on both sides of the differential case using the special tool (09214-21000).

Pinion shaft LocI< pin Lock pin (large beveled

areClI/

I

Dtfferentarl case

I '~\\ " \\

I~ "'~,

Press-In dlrectlon

+:

Press

Caution When press-fitting the bearings, push the inner race only.

09214-21000

43-47

DIFFERENTIAL 8.

Apply specified sealant to the entire threads of the bolts and tighten in the order shown in figure to specified torque with the differential case clamped in a vise. Specified sealant: 3M Stud Locking No. 4170 Caution If a bolt is reused. remove the old sealant from the threads. The numerals CD to ® indicate the tightening sequence.

43-48

CLUT CH HOUSING

CLU TC H HOUSING COMPONENTS

Selee.! lever a ssembly Control shaft

Coo,m' ''"" "••

,~

Select leve

" .." ..,,,"" --0 Oil seal----t:'

b/'

:r

:::~:;".~;%;"=",,~S10ppe~\~~

I, /r$.~~/

r shoe

~

flnge~r~ t'\S\tRo:ptp~nernrp~ :~ng \

cont,rOI

~SP"ng pin

'

. Interlock Plate Spring pin

~

Neutral return spring

Neel bearing

Clutch housing

TORQUE

Nm (k g. em . Ib.ft·,I ~

_

43-49

CLUTCH HOUSING

DISASSEMBLY

Y43PA2A

1. 2.

Remove the select lever assembly and the select lever shoe. Remove 'the interlock plate bolt and gasket.

3.

Drive out the spring pin from the control finger using the special tool (09414-11000).

4,

Drive out the spring pin from the stopper body using the special tool (09414-11000). Pull out the control shaft and remove the control shaft boots and oil seal.

5.

6. 7.

Remove the neutral return spring assembly, control finger, interlock plate, stopper body, neutral return spring. Remove the control shaft oil seal the needle bearings.

43-50

CLUTCH HOUSING ASSEMBLY

Y43PB2A

A 1.

Install the needle bearing flush with the surface A of the clutch housing.

Needle beanng

2.

Install the control shaft oil seal using a socket wrench.

Socket wrench

Oil seal

3.

Install the neutral return spring assembly, control finger, interlock plate, stopper body, neutral return spring with the control shaft.

4.

Install new spring pins using the special tool (0941411100). Caution 1. Do not reuse the spring pins. 2. Install the spring pins with their slit at right angle to the control shaft center.

43-51

CLUTCH HOUSING

Slit

5. 6.

Install the interlock plate bolt and gasket. Install the select lever assembly and select shoe.

43-52

SPEEDOMETER DRIVEN GEAR ASSEMBLY

SPEEDOMETER DRIVEN GEAR ASSEMBLY COMPONENTS

Oil seal

".. . ' ' I'" ,-, "

Speedometer driven gear

o ASSEMBLY

Y430A2A

1.

Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.

2.

Install the spring pin in such a way that it slit does not face the gear shaft.

Silt

43-53

MANUAL TRANSAXLE ASSEMBLY

INSTALLATION

Y43RA2A

1.

Install the drive shaft oil seal using the special tool (09431-21200).

2.

Install the input shaft front oil seal using the special tool (09431-21000).

09431-21000

3.

Install the differential gear bearing outer race and spacer using the special tool (09532-11500, 09500-11000).

4.

Install the output shaft bearing outer race and spacer using the special tool (09432-33600, 09500-11000).

43-54

MANUAL TRANSAXLE ASSEMBLY 5.

Install the oil guide and intermediate shaft bearing outer race and spacer using the special tools (09500-21000, 09532-11500).

6.

Install the differential gear assembly and output shaft assembly. While lifting up the input shaft assembly, install it simultaneously with the intermediate shaft assembly.

7.

8.

Install the retainer.

9.

Reassembly of shift rail assembly. 1) Set the 1st-2nd speed shift sleeve at 2nd speed. 2) Set the 3rd-4th speed shift sleeve at 4th speed.

43-55

MANUAL TRANSAXLE ASSEMBLY 4)

Install the 3rd-4th/5th-reverse shift rail and fork assembly together with the select lever fully pushed to 1st-2nd rail side. 5) Install the 3rd-4th/reverse shift rail and fork assembly each other with the select lever fully pushed to 1st-2nd rail side. 6) Turn the shift rail to engine shift lug.

10. Reassembly of spring pin. 1) Install the spring pins using the special tool (09414111 ()()). 2) When installing, make sure that the slit of the spring pin is aligned with the shift rail center line. Caution Do not reuse the spring pins.

5111-+----;

Spring pm

Shift rail

11. Install the reverse gear lever assembly. 12. Install the reverse gear shaft and reverse gear in the direction illustrated.

43-56

MANUAL TRANSAXLE ASSEMBLY 13. Install the reverse shift lever and shoe.

14. Install the intermediate shaft bearing outer. race and spacer to the transmission case using the special tools (0950021000, 09532-32000).

15. Install the output shaft bearing outer race and spacer to the transmission case using the special tools (09500-11000, 09532-11500).

09500- 11 000

09532~11500

16. Install the differential bearing outer race and spacer to the transmission case using the special tools (09500-11000, 09532-11500).

43-57

MANUAL TRANSAXLE ASSEMBLY 17. Insall the drive shaft oil seal to the transaxle case using. the special tool (09431-21200).

18. Reassembly of spacers (adjustment of end play). 1) Place two pieces of solder measuring about 10 mm (0.4 in.) in length and 3 mm (0.12 in.) in diameter on the bear-

Transaxle case

ing outer race as shown in illustration, and install the outer race. 2) Install the transmission case and tighten the bolts to specified torque. 3) Remove the transmission case. 4) Remove the outer races and remove the solder. o

5)

Measure the thickness of the crushed solder with a micrometer and select and install a spacer of thickness that gives standard end play. Standard value: Intermediate shaft end play: 0.05-0.10 mm (0.002-0.004 in.) Output shaft end play: 0.05-0.10 mm (0.002-0.004 in.) Differential case end play: 0.05-0.10 mm (0.002-0.004 in.)

19. Install the oil guide to the transaxle case.

43-58

00

MANUAL TRANSAXLE ASSEMBLY 20. Apply specified sealant to the clutch housing side of the transmission case. Specified sealant : TH REE 121 6

1-2 mm .~

104-08_;1

~Amountof ,

~~=:.go~~

sealant

/~

21. Install the transaxle case to the clutch housing assembly and tighten the bolt (13 EA).

22. Install the restriction ball and gasket. 23. Center the shaft with a phillips screwdriver. 24. Tighten the reverse idler gear shaft bolt to the specified torque.

25. Install the poppet balls, poppet springs and poppet plugs. 26. Install the backup lamp assembly.

43-59

MANUAL TRANSAXLE ASSEMBLY 27. Install the intermediate gear using the special tool (09432-21500). 28. Install the 5th speed gear and needle roller bearing synchronizer ring, synchronizer hub. 29. Install the 5th speed shift fork and the 5th speed synchronizer sleeve at the same time.

09432-21500

30. Install the spring pin using the special tool (09414-11100). 09414-11100

31. When installing, make sure that the slit of the spring pin is aligned with the shift rail center line.

Slit-+----:

Spring pin

Caution Do not reuse the spring pin.

Shift rail

32. Reassembly of lock nuts. 1) Install the special tool (09432-21101) onto the input shaft. 2)

Screw a bolt [10 mm (0.39 in.)] into the hole on the surface of clutch housing and attach a spinner handle to the special tool (09432-21101).

43-60

MANUAL TRANSAXLE ASSEMBLY 3)

Shift the transaxle in reverse using _control lever and select lever. 4) Tighten the lock nut to specified torque. 5)

Select lever ---€ff

Stake the lock nut. Control lever -'?-c~~~~~,((

33. Apply specified sealant to the rear cover and install the rear cover.

Specified sealant

THREE BOND 1216

Amount of sealant

34. Install the mounting bracket.

35. Install the speedometer driven gear assembly.

43-61

AUTOMATIC TRANSAXLE GENERAL

2

TRANSAXLE CONTROL

47

SHIFT LEVER ASSEMBLy

53

AUTOMATIC TRANSAXLE

55

AUTOMATIC TRANSAXLE OIL COOLER ASSEMBLY

59

AUTOMATIC TRANSAXLE ASSEMBLy

60

OIL PUMP ASSEMBLy

96

FRONT CLUTCH ASSEMBLy

100

REAR CLUTCH ASSEMBLy

103 •

END CLUTCH ASSEMBLy

106

PLANETARY GEAR SET

108

INTERNAL GEAR AND TRANSFER DRIVE GEARSET

112

DIFFERENTIAL

114

VALVE BODy

117

KICKDOWN SERVO

135

SPEEDOMETER SLEEVE

136

TRANSAXLE CASE

;

AUTOMATIC TRANSAXLE HYDRAULIC CiRCUiT

137 138

GENERAL

GENERAL SPECIFICATIONS Type Torque converter Type Engine stall speed Stall torque ratio Transmission Type Gear ratio First Second Third Fourth Reverse Final gear ratio Speedometer gear ratio

45-2

Y45CAOA

Automatic four speed with torque converter and integral differential-KM175 With damper clutch 2,200 ± 200 rpm 2.17 Electronically controlled 4-speed full-automatic

2.551 (2.4R), 2.846 (1.8R, 2.OR) 1.488 (2.4R), 1.581 (1.8R, 2.OR) 1.000 0.685 2.176 4.007 Drive 36/Driven 29

GENERAL

TIGHTENING TORQUE Air filter mounting bolt Tie rod end to knuckle Lower arm ball joint to knuckle Transaxle mounting bracket to transaxle Transaxle mounting bracket to body Selector knob set screw Selector lever mounting nut Indicator panel mounting screw Starter motor mounting bolt Bell housing cover to transaxle Bell housing cover bolt Engine to transaxle Torque converter to drive plate Drive plate-to-converter tightening bolt Transaxle mounting bolt [10 mm (0.39 in.) diameter bolt] Transaxle mounting bolt [8 mm (0.31 in.) diameter bolt] Drain plug Pressure check plug Pulse generator mounting bolt Bearing retainer screw Lock plate bolt Oil cooler connector Converter housing bolt Oil pan bolt Kickdown servo piston plate screw One-way clutch outer race bolt Differential drive gear bolt Manual control lever nut Manual control shaft set screw Inhibitor switch Sprag rod support bolt Pump housing-to-reaction shaft support bolt Oil pump assembly mounting bolt Valve body bolt Valve body assembly mounting bolt Oil filter bolt Speedometer sleeve locking plate bolt

Y45CC1B

Nm

kg.cm

8--10 80--100 24--34 250--340 60--72 600--720 60--80 600--800 40--50 400--500 2.0 20 14--20 140--200 1.5 15 22--32 220--320 15--22 150--220 10--12 100--120 Refer to page 45--55 130--140 1300--1400 46--53 460--530 43--55 430--550 30--35 300--350 30--35 300--350 8--10 80--1 00 10--12 100--120 17--22 170--220 20--27 200--270 15--22 150--220 19--23 190--230 10--1 2 100--1 20 6--8 60--80 8--10 80--100 130--140 1300--1400 17--21 170--210 8--10 80--100 10--1 2 100--1 20 20--27 200--270 10--1 2 100--1 20 15--22 150--220 4--6 40--60 10--1 2 100--1 20 5--7 50--70 3--5 30--50

Ib.ft 6--7 17--25 43--52 43--57 29--36 1.5 10--14 1.1 16--23 11--16 7--9 94--101 34--38 32--39 22--25 22--25 6--7 7.5--8.5 12--15 15--19 11--16 14--16 7.5--8.5 5--6 6--7 94--101 13--15 6--7 7.5--8.5 15--19 7.5--8.5 11--15 3--4 7.5--8.5 4--5 2.5--3.5

45--3

GENERAL

LUBRICANTS

Y45CDIA

Items

Specified lubricant

Quantity

Transaxle fluid lit. (U.S.qts., Imp.qts.)

GENUINE HYUNDAI ATF AUTOMATIC TRANSMISSION FLUID, *MOPAR ATF PLUS TYPE 7176, DIAMOND ATF SP, BP AUTRAN MM SP (For Australia)

5.8 (6.1, 5.1)

Drive shaft oil seal lip

Automatic transaxle fluid DEXRON II type

As required

Sliding part of bushing

Chassis grease SAE J310, NLGI No.O

As required

Selector lever sliding portion

Multipurpose grease SAE J310, NLGI No.2

As required

*MOPAR ATF PLUS TYPE 7176 is recommended lubricant.

45-4

GENERAL

SPECIAL TOOLS Tool (Number and name)

Y45CE1B

III ustration

Use

09222-21001 Valve spring compressor

Removal and installation of the kickdown servo

09391-33200 1. Multi-use tester

Diagnostic tester for MPI, automatic transaxle and cruise control systems

09391-33300 2. Test harness

2

09391-33500 3. Battery harness

6

09391-33600 4. Instruction manual 5

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

09391-33700 6. Connector RS 232C

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

09431-21200 Oil seal installer

Installation of differential oil seal

45-5

GENERAL

Tool (Number and name)

III ustration

Use

09432-21000 Bearing outer race remover

Removal of transfer shaft bearing outer race

09432-21601 Bearing installer

Installation of transfer shaft bearing

09432-21701 Bearing outer race installer

Installation of transfer shaft bearing outer race (use with 09500-21000)

09432-33500 bearing puller

Removal of transfer shaft bearing

09433-21000 Removing plate

Removal bearing

09452-21001 Oil pressure gauge adapter

Measurement of the oil pressure (use with 09452-21500 and 09452-21002)

09452-21002 Oil pressure gauge adapter

Measurement of the oil pressure (use with 09452-21500 and 09452-21001)

09452-21200 Oil pump oil seal installer

1) Installation of the oil pump seal 2) Installation of differential case taper roller bearing

~aper

45-6

of

differential

tapered

roller

GENERAL

Tool (Number and name)

Assembling the oil pump

09452-21301 Oil pump band

Use

IIIustration

o 1) Assembling the oil pump 2) Installation of the oil pump

09452-21401 Guide pin

09452-21500

Measurement of the oil pressure (use with

Oil pressure gauge

09452-21001 and 09452-21002)

09452-33100

Removal of the oil pump

Oil pump remover

09453-24000

09455-2100

Spring compressor

Spring compressor

09453-21100 Spring compressor

09453-21200 Spring compressor

09453-21400 Dial gauge support

Removal and installation of snap ring and return spring of front clutch (use with

09453-21000)

Removal and installation of the rear clutch (use with 09453-21000)

Removal and installation of snap ring of low-reverse brake (use with

09453-21000

1) Measurement of the input shaft end play (use with dial gauge) 2) Measurement of the transfer shaft end play (use with dial gauge)

45-7

GENERAL

Tool (Number and name)

Illustration

Use

09453-33000 Snap ring installer

Installation of end clutch snap ring

09453-33100 Dial gauge extension

Measurement of the low and reverse brake end play (use with a dial indicator and 09453-21400)

09453-21 31 0 Center support remover and installer

09454-21100 Wrench adapter

~ i ='

~-

- --=

~

Removal and installation of the center support

/,

~

Loosening and tightening of the transfer idler shaft

09454-33000 Kickdown servo wrench

Adjustment of kickdown (use with 09454-33100)

09454-33100 Socket wrench

Adjustment of kickdown (use with 09454-33000)

09455-21000 Bearing and gear puller

Removal of ball bearing

09455-21100 Bearing installer

Installation of ball bearing and transfer drive gear

45-8

GENERAL

Tool (Number and name)

III ustration

Use

Bearing installer

1) Installation of the transfer shaft rear side bearing 2) Installation of the transfer driven gear

09455-21301

Supporting the transfer shaft

09455-21100

Transfer shaft retainer

09456-21000

Assembly of the valve body and transfer plate

Guide pin

09456-21100

Removal and installation of kickdown servo (use with 09222-21001)

Adapter set

09458-33000

Preload measurement of transfer idler shaft

Wrench adapter

09500-11000

Installation of differential bearing outer race (use with 09532-11500)

Bar

09500-21000

Installation of transfer shaft bearing outer race (use with 09432-21701)

Bar

o

09532-11500 Pinion bearing installer

outer

race

Installation of differential bearing outer race (use with 09500-11000)

45-9

GENERAL

TROUBLESHOOTING

Y45CF1B

Malfunctions of the KM 175-4A/T can lead to other problems, such as those described below: 1. Improper maintenance and/or adjustments 2. Malfunctions of the electronic control functions 3. Malfunctions of mechanical functions 4. Malfunctions of hydraulic control functions 5. Malfunctions of engine performance etc. In order to properly Troubleshoot the source of these malfunctions, it is first essential to methodically question the owner concerning the problem, the situation at the time the problem occurred, and any other relevant information, all in as much detail as possible. The user should also be asked whether or not the problem has occurred more than once. Subsequently, certain tests should be conducted in a certain order, as described at the right.

Based upon use of the troubleshooting guide, the probable location of the problem should be estimated.

Checks should be made of fluid levels and the condition of the ATF, as well as the condition of the manual control cables; adjustments should then be made if found to be necessary.

If a presumption has been made that there is an abnormal condition somewhere in the electronic-control system, the diagnosis tester should be used to estimate the proba91e location by checking the malfunction-indication pattern. If the ignition key was already turned to OFF, however, check by making a road test.

When the abnormal system is discovered during the road test, check each element (sensors, etc.) one by one, and make repairs as necessary.

When the abnormal condition is presumed to be in the oil-pressure-control system, check by making an oil-pressure test.

When the result of the oil-pressure test does not satisfy the specified pressure, check each system at places related to the valve body, check the oil-pressure passages for leakage, etc.

If the problem is unusually dirty ATF, abnormal noises, oil leakage, or slippage of the clutch or brakes, or an abnormal condition of the transaxle itself. disassemble and repair the transaxle.

45-10

GENERAL

TROUBLESHOOTING GUIDE

J45CG4A

Driving impossible or abnormal (before start-off) .c

C>

al

Problem

c

E

t;

E

.2 C

~

-

'c 0

;:

Presumed cause

<5

15

c.c

al

c

C

al ,III

x 'Ill'-

al

1 2 3 4 5 6 7

~ ;: I- 0 ~

8 9 10 11 12 ~ c E al 13 E

al al >al

.,(/l

c

~.9

.,., .-t; :::l 'al'-

al

> 0

E

C>

o.c

o=='6:::l U

14 15 16 17 18 19

:§. 20 21 22 23 24 E 7ii al

.,

25 26

>

E E 0 <J

.~ c ~ t; al

W

27 28 29 30 31 32 33 34 35 36 37 38

.,0

'(;;

0.

.~

"EIII ;:

E al

III .oal

0

.>t: <J

E ~;e ,-., Qi Ill., t: ;:0 ,-0. III en U.°E._

W._

.,c

al

al

:0

E al

>

E "Q

~

:0

0

.c .2' .c

.,0

S

S

0

E

E

e-

E

I Z

iii

0.

E al

E

C al

.c

>

;:

E

!!!

"Q

al

0

~

;:

.>t: <J

U.

CD

III

Abnormal idling rpm Performance malfunction

~

1ii

1ii

X

Operation malfunction of oil pump

X X X

Malfunction of one-way clutch

X X X

<5 Q.

;: .2

1ii

.>t: <J

al

0

~

.c "Q ~o "0 ,-z .c

al

"S;

IllZ

0

iii

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7ii

.g.

.g.

iii

iii

E

7ii c

"Q

.c

.c

al

U

U

iii

,-C>_;:

c

:::l

:§ .c

al al C al

:;

~

e-

E

al

>

WOO

iii c '0. c

W

<J

X X X

en

al

0

al

C:

0 .;: a:

S

0

.,

.c

o '-

.,

X X

Improper adjustment of manual linkage Malfunction of torque converter (including damper clutch)

;:

E Z

III

~ a:

c al .c

0

e-

0

.,

III al >

0

<5

'(;;

~

0

a:

:E

c

al

C>

~

III

Q.

~~ N E

0

-

0 '- _ 0 c_ .0 ,-

pi:~ X

X X

X

X

X

X

X

X X X

X

X

Damaged or worn gear or other rotating part, or improper adjustment of the preload Malfunction of parking mechanism Cracked drive plate, or loose bolt

X

X

X

Worn inside diameter of front clutch retainer Low fluid level Line pressure too low (seal damaged, leakage, looseness, etc.)

X X X

Malfunction of valve body (sticking valve, working cavity, adjustment, etc.) Malfunction of front clutch or piston Malfunction of rear clutch or piston

X X X

X X X X

X

X X X

X X

X X X X

X

X

X

X

X X

X X

X

X

Malfunction of kickdown band or piston Improper adjustment of kickdown servo Malfunction of low-reverse brake or piston O-ring of low-reverse brake circuit between valve body and case not installed Malfunction of end clutch or piston (check ball hole, other) Malfunction of inhibitors switch, damaged or disconnected wiring, or improper adjustment

X

X X

X

X

Malfunction of TPS, or improper adjustment

X

X X

Pulse generator (A) damaged or disconnected wiring, or short-circuit Pulse generator (8) damaged or disconnected wiring, or short-circuit Malfunction of kickdown servo switch

.

X

SCSV-A or 8 damaged or disconnected wiring, or short-circuit or sticking (valve open) Malfunction of ignition signal system Incorrectly grounded ground strap PCSV damaged or disconnected wiring, or short-circuit PCSV damaged or disconnected wiring (valve open) DCCSV damaged or disconnected wiring (valve closed) DCCSV short-circuit or sticking (valve open)

X

X

X

X

X

X

Malfunction of 00 switch Malfunction of accelerator switch, or improper adjustment

X

Malfunction of oil-temperature sensor Malfunction of reed switch Poor contact of ignition switch Malfunction of transaxle control unit

X

NOTE: X indicates items of high priority during inspection. Abbreviations: TPS = Throttle position sensor SCSV = Shift control solenoid valve

45-11

~

en

I ... N

o"tl n(l) nn (1)< < II II

WW ww ww W W WN CO-..l Cl tTl

","w

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OlD CO-..l

NN CltTI

N

~

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N

WN

N

N

~o

~

~

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IDCO -..ICl tTl","

X

X

~

~

WN

~

~

~o

X

IDCO

-..I

Cl

tTl

"'"

W

N

~

X

Won't shift from 2nd to 3rd

"tl X

X

.

X

X

3 ~.. CD

~

X

o ; III Ul 'tJ

N

CD

xx

X

X

X

Won't shift to 4th

00 switch doesn't function

(')

(') C (')

.. .

0 :::J .. 0

XX

(')

Ul

X

:::J ..

o..

CD :::J 0_.

Ul

<

Doesn't shift according to shift pattern (shifting is possible)

X

X

X

-Q.

2. III CD :::J < o CD

c: <

Ql

)(

Improper start-off (starts off from 2nd, etc.)

X X X

X

X

X

i»

3

Ql

X

X

X

~ Excessive creeping or idling vibration :::l

... (")

X

X

><

X X

X

X

XX

X

X X

X

X

X

Excessive vibration-shock when shift '-2 or 3-4

X

X

Excessive vibration-shock when shift 2-3 or 4-3

X

Excessive vibration-shock during upshift

III

i"

Ql

:::l

l/l

:::r-

o 2.

:;t

X X

X

X X

X

XX X X

X

X

X

X

X

X

>

XX

>

xx

xx

X

X

X

X

X

X X

X

X

X

X

X

XX

X

X

X

X

X

X

X

XX

X X

Excessive vibration-shock during 0-2 downshift Sudden engine rpm increase during upshift

X

xx

Sudden engine rpm increase 3-2 shift, excessive vibration

X

X

Excessive vibration-shock (other than already described)

X X

X

Excessive vibration shock only when cold

XX

X

X

X

X X

X

X

l/l

";j

::f en ";j

0

....

(")

iil

;:t

~

~

Ql

::1

Damper clutch won't function

X

Abnormal vibration in high-load region in low gear (approx. , Hz) Abnormal noise from convertor housing together with engine rpm

X

X

So

6 ·3 during

X

X

o' :::l

Mechanical noise (clatter noise) from convertor housing

X

Abnormal noise inside transaxle case

X

» 0" :::l 0

3 Ql

:::l 0 (ii'

!P 0

XX X

X

X XX

XX

X

X

>

X

X X

XX>

XX >

X

X

Locked in 3rd gear

:T

~

C)

m m

Z

:::D

» ....

GENERAL

DIAGNOSIS AND TEST

Y45CH18

FLUID LEVEL AND CONDITION 1. 2. 3. 4. 5.

6.

Place vehicle on level floor. Before removing dipstick, wipe all dirt from area around dipstick. With selector lever in "P" Park and parking brakes applied, start engine. Engine should be running at idle speed. Fluid should be at normal operating temperature [70-80°C (16Q-1800F)]. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid, then place lever in "N" Neutral position. This operation is necessary to be sure that fluid level check is accurate. Check. to see if fluid level is in "HOT" range on dipstick. If fluid is low, add automatic transaxle fluid until level reaches "HOT" range. Low fluid level can cause a variety of conditions because it allows pump to take in air along with fluid. Air trapped in hydraulic circuit forms bubbles which make fluid spongy. Therefore, pressure will be erratic. Improper filling can also raise fluid level too high. When transaxle has too much fluid, gears churn up foam and cause same conditions which occur with low fluid level. resulting in accelerated deterioration of automatic transaxle fluid. In either case, air bubbles can cause overheating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch, and servo operation. Foaming can also result in fluid escaping from transaxle vent where it may be mistaken for a leak. Along with fluid level, it is important to check the condition of the fluid. When fluid smells burned, and is contaminated with metal bushing or friction material particles, a complete transaxle overhaul is needed. Be sure to examine fluid on dipstick closely. If there is any doubt about its conditions, drain out sample for double check. After fluid has been checked, seat dipstick fully to seal out water and dirt.

45-13

GENERAL

MANUAL CONTROL CABLE

Y45CJ1A

Whether manual linkage is properly adjusted can be confirmed by checking whether inhibitor switch is performing well. 1. Apply parking brakes and service brakes securely. 2. Place selector lever to "R" range. 3. Set ignition key to "ST" position. 4. Slowly move the selector lever upward until it clicks at it fits in notch of "P" range. If starter motor operates when lever makes a click, "P" position is correct. 5. Then slowly move selector lever to "N" range by the same procedure as in foregoing paragraph. If starter motor operates when selector lever fits in "N", "N" position is correct. 6. Also check to be sure the vehicle doesn't begin to move and the lever doesn't stop between P-R-N-D. 7. The manual-control cable is properly adjusted if, as described above, the starter motor starts at both the "P" range and the "N" range.

OBTAINING FAULT CODES 1. 2.

J45CKIB

Connect the voltmeter or multi-use tester to the connector for diagnosis.' Read the output fault codes. Then follow the remedy procedures according to the "FAULT CODE DESCRIPTION" on the following page.

NOTE o As many as ten fault codes, in the sequence of occurrence, can be stored in the Random Access Memory (RAM) incorporated within the control unit. o The same fault code can be stored as many as three times. o If the number of stored fault codes or fault patterns exceeds ten, already stored fault codes will be erased, in sequence beginning with the oldest. o Do not disconnect the battery until all fault codes or fault patterns have been read out, because all stored fault codes or fault patterns will be canceled when the battery is disconnected.

II

I Ground

45-14

T

I

ELC 4-speed automatic transaxle'

GENERAL 3.

If the fail-safe system is activated and the transaxle is locked in 3rd gear, the fault code in the Fail-Safe Code Description will be stored in the RAM. Three of these fault codes can be stored. 4. The cancelation will occur if, with the transaxle locked in 3rd gear, the ignition key is turned to the OFF position, but the fault code is stored in the RAM.

<Multi-use tester>

Cigarette lighter socket

Diagnosis connector

09391-33200

45-15

GENERAL

FAULT CODE DESCRIPTION Fault code

Fault code (for voltmeter)

21

J45CLlB

Cause

Remedy

Abnormal increase of TPS output

o Check the throttle position sensor connector. o Check the throttle position sensor itself. o Adjust the throttle position sensor. o Check the accelerator switch (No.28: output or not). o Check the throttle position sensor output circuit harness.

5V --------nn n OV --- - - --.J U UL..

22

Abnormal decrease of TPS output

23

Incorrect adjustment of the throttle-position sensor system

24

Damaged or disconnected wiring of the oil temperature sensor system

o Check the oil temperature sensor circuit harness. o Check the oil temperature sensor connector. o Check the oil temperature sensor itself.

25

Damaged or disconnected wiring of the kickdown servo switch system, or improper contact

26

Short circuit of the kickdown servo switch system

o Check the kickdown servo switch output circuit harness. o Check the kickdown servo switch connector. o Check the kickdown servo switch itself.

27

Damaged or disconnected wiring of the ignition pulse pick-up cable system

o Check the ignition pulse signal line.

28

Short circuit of the accelerator switch system or improper adjustment

o Check the accelerator switch output circuit harness. o Check the accelerator switch connector. o Check the accelerator switch itself. o Adjust the accelerator switch.

31

Malfunction of the microprocessor

0

45-16

Replace the control unit.

GENERAL

Fault code

Fault code (for voltmeter)

32

-llIlI1JIIL 33

Cause

Remedy

First gear command during highspeed driving

o Replace the control unit

Damaged or disconnected wiring of the pulse generator B system

o Check output o Check o Check switch

Damaged or disconnected wiring of the shift control solenoid valve A system

o Check the solenoid valve connector. o Check shift control solenoid valve A itself. o Check the shift control solenoid valve A drive circuit harness

JIIlfU1lIL 41

J1JlflfUL 42

JITlflJUL 43

~ 44

J1fTIUlJ1L 45

J1JlffiJlJlJlJL 46

~ 47

J1f1JlfUl1I1IUl 48

JlflJlfUI11lPJ1JlJlL

Short circuit of the shift-control solenoid valve A system

Damaged or disconnected wiring of the shift control solenoid valve B system Short circuit of the shift control solenoid valve B system

Damaged or disconnected wiring of the pressure control solenoid valve system Short circuit of the pressure control solenoid valve system

Damaged or disconnected wiring of the damper clutch control solenoid valve system Short circuit of the damper clutch control solenoid valve system

the pulse generator B circuit harness. pulse generator B itself. the vehicle speed reed (for chattering).

o Check the solenoid valve connector. o Check shift control solenoid valve B itself. o Check the shift control solenoid valve B drive circuit harness.

o Check the solenoid valve connector. o Check the pressure control solenoid valve itself. o Check the pressure control solenoid valve drive circuit harness. o Check the solenoid valve connector. o Check the damper clutch control solenoid valve itself. o Check the damper clutch control solenoid valve drive circuit harness.

45-17

GENERAL

Fault code

Cause

Remedy

Malfunction of the damper clutch system

o Check the damper clutch control solenoid valve drive circuit harness. o Check the damper clutch hydraulic pressure system. o Check the damper clutch control solenoid valve itself. o Replace the control unit.

51

First gear non-synchronous

o Check the pulse generator output circuit harness. o Check the pulse generator connector. o Check pulse generator A and pulse generator B themselves. o Kickdown brake slippage.

52

Second gear non-synchronous

o Check the pulse generator A output circuit harness. o Check the pulse generator A connector. o Check pulse generator A itself. o Kickdown brake slippage.

53

Third gear non-synchronous

o Check the pulse generator A output circuit harness. o Check the pulse generator connector. o Check pulse generator A and pulse generator B themselves. o Front clutch slippage. o Rear clutch slippage.

54

Fo,urth gear non-synchronous

o Check the pulse generator A output circuit harness. o Check the pulse generator A connector. o Check pulse generator A itself. o Kickdown brake slippage.

Fault code (for voltmeter)

49

---.nnnJlJlIUll1JlJlJUlIL

45--18

GENERAL

FAIL-SAFE ITEM Output code

Note (relation to fault code)

Description

Fail-safe

Malfunction of the microprocessor

Locked in 3rd gear

When code No. 31 is generated 4th time.

12

First gear command during high speed driving

Locked in 3rd (D) or 2nd (2, L) gear

When code No. 32 is generated 4th time.

13

Damaged or disconnected wiring of the pulse generator B system

Locked in 3rd (D) or 2nd (2, L) gear

When code No. 33 is generated 4th time.

14

Damaged or disconnected wiring, or short circuit, of shift control solenoid valve A

Locked in 3rd gear

When code No. 41 or 42 is generated 4th time.

15

Damaged or disconnected wiring, or short circuit, of shift control solenoid valve B

Locked in 3rd gear

When code No. 43 or 44 is generated 4th time.

16

Damaged or disconnected wiring, or short circuit, of the pressure control solenoid valve

Locked in 3rd (D) or 2nd (2, L) gear

When code No. 45 or 46 is generated 4th time.

17...

Shift steps nonsynchronous

Locked in 3rd (D) or 2nd (2, L) gear

When either code No. 51, 52 53 or 54 is generated 4th time.

I------.-----------------l

Code No.

Output pattern (for voltmeter)

11 5V OV

---------n n

------1 LJ L.-

45-19

GENERAL

CHECKING THE CONTROL SYSTEM (WHEN A MULTI-USE TESTER IS USED) No. 1

2

3

4

5

6

7

Standard value for judgement

Description and display data

Check conditions

Pulse generator A o Upper No.19 Kickdown drum rpm o Lower No.38 Shift step

D range (3rd) 50 km/h (31 mph) constant speed driving

Upper: 1,600 ± 200 rpm

D range (4th) 50 km/h (31 mph) constant speed driving

Upper: 0 rpm

D range (creep), stop idle

Upper: 0 rpm

Pulse generator B o Upper No.13 Transaxle output shaft rpm o Lower No.33 Vehicle speed reed switch Vehicle speed reed switch o Upper No.33 Vehicle speed reed switch o Lower, no designation

Lower: 3rd

Lower: 4th

Lower: 0 km/h (0 mph) D range (4th) 50 km/h (31 mph) constant speed driving

Upper: 1,800 ± 200 rpm

P range, idle

Upper: 0 km/h (0 mph)

Lower: 50 km/h (31 mph)

D range, speedometer reading 50 km/h (31 mph) driving

Upper: 50 km/h (31 mph)

-

Throttle position sensor o Upper No.21 TPS output o Lower No.28 Accelerator switch

Accelerator fully open (engine stopped, ignition switch : ON)

Upper: 4.5-5.0V

Accelerator fully closed (engine stopped, ignition switch : ON)

Upper: 0.5-0.6V

Kickdown servo switch o Upper No.25 Kickdown servo switch o Lower No.38 Shift step

L range, idle

Upper: ON

Oil temperature sensor o Upper No.24 Oil temperature sensor o Lower, no designation Accelerator switch o Upper No.28 Accelerator switch o Lower No.21 TPS output

45-20

Lower: OFF

Lower: ON

Lower: 1st D range, idle

Upper: OFF Lower: C (creep)

Start when transaxle cold, urban driving.

Upper: temperature rises

After driving, stop engine and leave as is.

Upper: temperature eventually decreases.

Depress accelerator pedal slowly.

Upper: change from ON to OFF at a throttle-position sensor output of about 0.5V.

Release accelerator pedal slowly.

Upper: change from OFF to ON at a throttle-position sensor output of about 0.5V.

GENERAL

No. 8

Description and display data

Check conditions

Standard value for judgement

Overdrive control switch o Upper No.35 Overdrive control switch o Lower, no designation

Overdrive control switch ON

Upper: OO-ON

Overdrive control switch OFF

Upper: OO-OFF

-

9

Ignition signal line o Upper No.27 Ignition pulse o Lower, no designation

o

range, idle

± 50 rpm

Upper: 700

-

o

range, tachometer reading 2,500 rpm

Upper: 2,500 rpm

10

Inhibitor switch o Upper No.34 Shift lever position o Lower, no designation

Move shift lever in P-R-N-O-2-L sequence.

Upper: changes in P-R-N-O2-L sequence in accordance with the lever position.

11

Power Economy select switch o Upper No.36 Power Economy select switch o Lower, no designation

Select power pattern.

Upper: ON

Air conditioner relay o Upper No.37 Air conditioner relay o Lower. no designation

Switch ON the air conditioner switch (while idling in 0 range).

12

13

14

Select economy pattern.

Upper: OFF -

Switch OFF the air conditioner switch (while idling in 0 range).

Upper: ON -

Upper: OFF

-

Amount of damper clutch slippage o Upper No.47 Amount of damper clutch slippage o Lower No.21 TPS output

o range tachometer reading 1,500 rpm TPS output approx. 1V

Upper: 250

o range tachometer reading 3,500 rpm TPS

Upper: 40

Transaxle gear position o Upper No.38 Shift step o Lower No.21 TPS output

o

output approx. 2.5V

range, idle

± 50 rpm

Lower: 1.0V

± 10 rpm

Lower: 2.5V

Upper: C (creep) Lower: 0.5-0.6V

Economy pattern 0 range (overdrive possible condition) Accelerate to 100 km/h (62 mph) with fixed throttle position sensor output of 2.5V

Upper: 1st-2nd-3rd-4th Lower: 2.5V

45-21

GENERAL

Standard value for judgement

No.

Description and display data

Check conditions

15

DCCSV control o Upper No.49 DCCSV control duty o Lower No.21 TPS output

D range tachometer reading 1,500 rpm Throttle-position sensor output approx. 1.OV

Upper: 0%

D range tachometer reading 3,500 rpm Throttle position sensor output approx. 2.5V

Upper: 0-60% change according to load

Lower: 1.0V

Lower: 2.5V

ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER Selector lever position

Overdrive control switch

Shifting gear

P

-

Neutral

R

-

Reverse

2.176

N

-

Neutral

-

D

D

2 L

45-22

Gear ratio

-

Engine start

Parking mechanism

Possible

0

Brake

Clutch C1

C2

C3

OWC

B1

0

B2

0

Possible -

1st

2.846

0

2nd

1.581

0

3rd

1.000

OD

0.685

1st

2.846

0

2nd

1.581

0

3rd

1.000

1st

2.846

0

2nd

1.581

0

1st

2.846

0

ON

OFF

0

0

0

0 0 0

0

0

0 0 0

0 0

-

-

0 0

GENERAL

SHIFT PATTERNS Two shift patterns are pre-stored in the control unit of this transaxle. One is the power pattern (for more powerful performance), and the other is the normal pattern (for improved fuel consumption and quieter operation). (Refer to the diagram below.) The driver can select and switch to the desired pattern by using the power/normal select switch on the center console: The solid lines shown in these shift patterns indicate up-shifts, and the broken lines indicate down-shifts. The reason why there is a difference between the shift points for up-shifts and for down-shifts is so that up-shifts and down-shifts will not occur frequently when driving at a speed in the vicinity of the shift point. When the vehicle is stopped, there is a shift to 2nd gear in order to obtain a suitable "creeping", but when the accelerator pedal is then depressed the vehicle starts off is 1st gear.

45-23

GENERAL POWER RANGE

5400

100

80

5400 Engine rpm

5400

f-------+---+----;:.~-__+---~--i+---:.;tL-----__+---~~-+_---I__-__l

60 f------7--+---+------l---~;L-f--~,L---if____~"'---'=-----__+--~~--+_-----__I ":!!. o OJ C

g 40 f--t--T"--=---;--+---+---:~~+-----------=:;;>"",!F------__+------__+_-------j 0o

§

20

L

f-

f--t---+-r---+-7'''------.J--__+-+---------1+----~-__+------__+_-----____I

2 (L)

Idle L-_.l-.L_--'-------'----'1000

o

10

20

30

3 (2,L) 2 ------'L-

-'---------<_--'----

---'-

2000 3000 Transfer shaft rpm speed

40

5000

4000

I

I

I

I

I

I

50

60

70

80

90

100

110

3-----' 4 6000 (D 3 )

......L..

120

130

150

140

160

170

Vehicle speed (km/h)

NORMAL RANGE

4600

100

4600

5400

Engine rpm

I

-~

80 4 60

":!!. 0 OJ

c c

0

40 I

~

I I

§ L

f-

20

I I

I

1~2 (L) Idle

0

2000

1000

10

20

30

2

40

50

60

3 (2,L)

3

3000 Transfer shaft rpm speed

70

80

90

100

Vehicle speed (km/h)

45-24

4 (D 3 )

4000

110

5000

120

130

140

6000

150

160

170

GENERAL

INSPECTION OF ELECTRONIC CONTROL SYSTEM COMPONENTS

1. Wiring

-

Based on the wiring diagram, check whether the continuity and grounding of each harness is OK.

--I

t

Improper connection of connector, damaged or disconNo continuity ~ nected harness, or incorrect wiring connection.

t

Continuity

Reconnect the connector; repair or replace the harness.

•

Normal

2. Oil-temperature sensor

-

Vary the thermo-sensitive part from low temperature to high temperature . and check the resistance between .. .. the positive (+) and negative (-) sides of the connector terminal.

. . . , No continUity Damaged or disconnected wlr(. ) I-, resistance: 00 ing L..-------r--------l

Replace sensor.

t Changes of the resistance con-I tinuous and smooth.

•

1: (+) side 2: (-) side

TPS terminal

I~I LJ

LJ

1: ground 3: output 4: power supply

Check the resistance between terminals 1 and 4 of the TPS. -

_____t

the

t

oil-temperature

I

Normal

3. Throttleposition sensor (TPS)

Y45CTlA

_

Resistance: Damaged or disconnected wirhigh or infinite '--L...ing ----, ---l

_____t

3.5-6.5 O/20 o C (68°F)

_

Replace the TPS.

T

Resistance: Check the resistance between more or less terminals 3 and 1 with the engine .than 0.4 idling after throttle-valve opening kilohm/20°C warm-up. (68°F)

~

•

I

I installation. I

Improper adjustment

T Readjust the TPS

Resistance (actual measurement) between terminals 1 and 3: approx. 0.4 kilohm/20°C (68°F)

j Check for changes of the resisI tance between terminals 1 and 3

Changes of the resistance are not continuous.

Poor contact Replace the TPS.

Changes of the resistance continuous and smooth.

t Normal

45-25

GENERAL 4. Pulse generator A or B

r-

Pulse generator terminals 1-2: pulse generator A

H

pulse generator B

jrITDl ~ 2 1

5. Pulse generator A or B (checking I - by an oscilloscope)

Ociloscope waveform Noise

~~i

Check the resistance between Resistance: Short-circuit. or damaged or disf-lvery low or connected wiring terminals 1 and 2 or 3 and 4. very high

• •

•

215-275 O/20 o C (68°F)

Replace the pulse generator.

Normal

Connect the pulse generator and body harness, and connect an oscilloscope. Check with the chassis on a dynamo or with the front wheels raised. With the selector lever at the "L" position and the engine running at 1,000 rpm, check the between waveform voltage terminals 1 and 2.

~

Incorrect installation of the pulse generator, or malfunction of the pulse generator.

Very low voltage

•

Correct the installation condition, or replace the pulse generator.

1,000 mVp-p or higher Noise in the waveform

..-

Improper grounding of the pulse generator circuit's shielded wiring.

,

Replace the pulse generator. Noise

io

l

~

With the selector lever at the "L" position and the engine running at 1,000 rpm, check the voltage waveform between terminals 3 and 4.

f-t~

Very low voltage

Incorrect installation of the pulse generator, or malfunction of the pulse generator.

•

•

Correct the installation condition, or replace the pulse generator.

500 mVp-p or higher

l.o

Noise in the Improper grounding of the pulse Iwaveform generator circuit's shielded wiring.

1 Replace the pulse generator.

Normal

45-26

I

GENERAL Pull the parking brake to set it securely.

6. Damper clutch system

1 Set the selector lever to "P" or "N", and start the engine.

~ With the engine idling, depress the foot brake firmly.

T Set the selector lever to the "R" or "0" range.

--

Stop the engine

---rl

Improper adjustmnt of idling

•

Readjust the idling.

•

Let the engine continue idling.

~

I

Normal

I

Poor closure (sticking) of the damper clutch control solenoid Ivalve.

1 Replace the damper control solenoid valve.

-

clutch

Sticking of the clutch control valve

~ Overhaul the valve body.

I.e

Sticking '(seizure) of the damper clutch.

T Replace the torque converter assembly.

45-27

GENERAL 7. Damper clutch control solenoid valve (DCCSV)

I-

Short-circuit, or damaged Resistance: Check the resistance between 1-1-- or disconnected wiring terminal 1 of the solenoid valve too low or too connector and the transaxle case. high

~ 2 1

DCCSV 2: PCSV 3: SCSV-B 4: SCSV-A

Replace the DCCSV.

3 O/20 0 C

Solenoid valve connector terminals

1iJ"

~

~

~ Foreign terminal caught Connect 12V between the tranNo operation between the valve and saxle case and terminal 1; switch noise. Check 1-1--guide ON and OFF and check for for sticking. * (Valve stroke: operation noise. 0.3 mm (0.012 in.) or less) Replace the DCCSV. Noise exists. *Sticking is usually at the release side. Normal

~

~

~

Resistance: 8. PressureCheck the resistance between control sole- I----l terminal 2 of the solenoid valve 1--- too low or too high noid valve connector and the transaxle case.

--

Short-circuit, or damaged or disconnected wiring

(PCSV) Solenoid valve connector terminals

ma ~ 2

1

2.9 ±

0.30/20o C

(68°F)

I

Replace the PCSV

1: DCCSV

2: PCSV

3: SCSV-B 4: SCSV-A

Connect 12V between the transaxle case and terminal 2; switch I _ ON and OFF and check for operation noise.

Foreign material caught No operation noise. (stroke: 1_ between the valve and guide 0.3 mm (0.012 in.) or less) Replace the PCSV.

Noise exists.

Normal

45-28

GENERAL Short-circuit, or damaged Check the resistance between Resistance: 9. Shift-control I-or disconnected wiring solenoid valve 1- terminal 3 or 4 of the solenoid f-- too low or too valve connector and transaxle high (SCSV) A or B case. Replace the SCSV. Solenoid valve

1

connector terminals

[i BiH 2 1

1: DCCSV

22.3 ± 1.5!V200C (68°F)

2: PCSV

3: SCSV-B 4: SCSV-A

Connect 12V betwe~n the tran- I-- No operation noise. (stroke: saxle case and term mal 3 or 4; 0.25 mm (O.010 switch ON and OFF and check for .in.) or less) operation noise of the solenoid valve, and check the valve stroke.

~

Residue accumulated valve and core.

in

Replace the SCSV.

Noise exists.

Normal

10. Accelerator switch

m': (-) ~

sid, 2: (+) side

With the accelerator pedal not depressed, check the resistance between terminals 1 and 2.

I

-

Check the installation of No continuity I-(resistance: 00) the accelerator switch; adjust if necessary.

-

~ Problem not solved.

Continuity exists (resistance: 0)

1 Replace switch. accelerator pedal Continuity With the depressed slightly (about 5%), I---- exists (resistance: 0) check the resistance between terminals 1 and 2.

the

accelerator

I-

No continuity (resistance: 00)

Normal

45-29

GENERAL In the "P" range, check for continuity between terminals 3 and 4, and terminals 10 and 11.

11. Inhibitor switch

3

2

1

~

12 11 10 9

8

7

Continuity exists

....

6

5

4

"

I--

~ In the "R" range, check for continuity between terminals 3 and 12, I-and terminals 8 and 9.

~ Continuity exists

~ In the "N" range, check for continuity between terminals 3 and 5, and terminals 10 and 11.

I--

~ Continuity exists

•

In the "D" range, check for continuity between terminals 1 and 3.

1

~ I--

~ Continuity exists

~ ~ Continuity exists

~ Normal

45-30

Poor contact, or damaged or disconnected wiring.

~ Replace switch

Continuity exists

In the "L" range, check for continuity between terminals 2 and 3

~

-

~ In the "2" range, check for continuity between terminals 3 and 6.

No continuity

I-

the

inhibitor

GENERAL 12. Kickdown (KID) servo switch

[tJ

Check for continuity between the kickdown servo switch terminal and the transaxle case.

H

No continuity

1-

Poor contact, or damaged or disconnected wiring

!

t

Replace switch

Continuity

KID

the

servo

•

Start the engine, set to the "L" range, and let the engine idle; Continuity check for continuity between the I-exists kickdown servo switch terminal and the transaxle case. NOTE: Be sure the brakes are applied during this check.

Poor contact (sticking)

1 Replace switch.

t

the

KID

servo

No continuity

~ Normal

13. Transaxle control unit (TCU)

The problem Disconnect the harness (both A f---- does not and B connectors) from the occur vehicles TCU. Then connect, via an intermediate harness for checking, a new TCU to this harness and make a road test.

----

Malfunction of the original TCU

! Install a new TCU.

t Consider the original TCU to be normal. and again check the sensors, wiring, etc.

•

Same problem (as before TCU exchange) occurs.

45-31

GENERAL

OIL PRESSURE TESTS

Y45CUIA

~~ 6 TOCq"e"ooverte~ ~

1. 2.

Completely warm up the transaxle. Raise the vehicle by using a jack so that the front wheels can be rotated. 3. Connect an engine tachometer and place it in a position where it's easy to see. 4. Attach the special oil-pressure gauge 30 kg/cm 2 (09452-21500) and the adaptor (09452-21001) to each oil-pressure outlet port. When the reverse pressure is to be tested, the 30 kg/cm 2 type of gauge should be used. 5.

pressure @ Front clutch' ------pressure \\
"

Measure the oil pressure under various conditions, and check to be sure that the me3sured results are within the standard value range shown in the "Standard oil pressure table" below. If the oil pressure is not within the specified range, check and repair as described in the section "Remedial steps if oil pressure is not normal" on the next page.

Standard Oil Pressure Table Standard oil pressure KPa (psi)

Conditions No.

(Reference) Selector lever ,vehicle speed position km/h (mph)

Engine speed rpm

Shift position

1 Reducing pressure

2 Kickdown brake pressure

Neutral

363-480 (52-69)

Idling

2nd gear

363-480 (52-69)

110 (68)

Approx, 2,500

4th gear

363-480 813-882 (52-69) (118-128)

75 (47)

Approx. 2,500

3rd gear

363-480 813-882 (52-69) (118-128)

1

N

o (0)

2

0

o (0)

3

0 (SW-ON)

4

0 (SW-OFF)

Idling

-

98-206 (14-30)

3 Front clutch pressure

4 End clutch pressure

5 Low-reverse brake pressure

-

-

-

-

-

-

813-882 (118-128)

-

392-588 (56-84)

813-882 (118-128)

-

392-588 (56-84) 392-588 (56-84)

2

50 (31)

Approx. 2,500

2nd gear

363-480 813-882 (52-69) (118-128)

-

-

-

6

L

o (0)

Approx. 1,000

1st gear

363-480 (52-69)

-

-

294-441 (43-63)

35 (22)

Approx. 2,500

0(0)

Approx. 1,000

7

R

Reverse

363-480 (52-69)

-

NOTE: - must be 9.8 kPa (1.4 psi) or less. SWoON : Switch ON the overdrive control switch. SW-OFF : Switch OFF the overdrive control switch. *: : Hydraulic pressure is generated, but not the standard value.

45-32

1,607-2,195 (233-318) 1,470 (213) or more

* *

813-882 (118-128)

5

-

6 Torqueconverter pressure

-

1,607-2,195 (233-318) 1,470 (213) or more

* 392-588 (56-84)

GENERAL

Remedial Steps If Oil Pressure Is Not Normal Trouble symptom

Probable cause

Remedy

1. *Line pressures are all low (or high). NOTE *"Line pressures" refers to oil pressures 2, 3, 4 and 5 in the "Standard oil pressure table" on the previous page.

a. Clogging of oil filter

a. Visually inspect the oil filter; replace the oil filter if it is clogged. b. Measure line pressure 2 (kickdown brake pressure); if the pressure is not the standard value, readjust the line pressure, or, if necessary, replace the valve body assembly. c. Check the operation of the regulator valve; repair if necessary, or replace the valve body assembly. d. Tighten the valve body tightening bolt and installation bolt. e. Check the side clearance of the oil pump gear; replace the oil pump assembly if necessary.

b. Improper adjustment of oil pressure (line pressure) of regulator valve

c. Sticking of regulator valve

d. Looseness of valve body tightening part e. Improper oil pump dischange pressure

2. Improper reducing pressure

a. Improper line pressure

b. Clogging of the filter (L-shaped type) of the reducing-pressure circuit c. Improper adjustment of the reducing pressure d. Sticking of the reducing valve

e. Looseness of valve body tightening part 3. Improper kick-down brake pressure

a. Malfunction of the O-ring or seal ring of the sleeve or kickdown servo piston.

b. Looseness of valve body tightening part c. Functional malfunction of the valve body assembly

a. Check the 2 kickdown brake pressure (line pressure); if the line pressure is not the standard value, check as described in item 1 above. b. Disassemble the valve body assembly and check the filter; replace the filter if it is clogged. c. Measure the 1 reducing pressure; if it is not the standard value, readjust, or replace the valve body assembly. d. Check the operation of the reducing valve; if necessary, repair it, or replace the valve body assembly. e. Tighten the valve body tightening bolt and installation bolt. a. Disassemble the kickdown servo and check whether the seal ring or O-ring is damaged. If it is cut or has scratches, replace the seal ring or O-ring. b. Tighten the valve body tightening bolt and installation bolt. c. Replace the valve body assembly.

45-33

GENERAL

Trouble symptom

Probable cause

Remedy

4. Improper front clutch pressure

a. Malfunction of the O-ring or seal ring of the sleeve or kickdown servo piston.

a. Disassemble the kickdown servo and check whether the seal ring or O-ring is damaged. If it is cut or has scratches, replace the seal ring or O-ring. b. Tighten the valve body tightening bolt and installation bolt. c. Replace the valve body assembly.

b. Looseness of valve body tightening part c. Functional malfunction of the valve body assembly d. Wear of the front clutch piston or retainer, or malfunction of the O-ring and seal ring. (Refer to the figure on the next page.)

d. Disassemble the transaxle itself and check whether or not there is wear of the front clutch piston and retainer inner circumference, or damage of the O-ring or seal ring. If there is any wear or damage, replace the piston, retainer, O-ring and/or seal ring.

5. Improper end clutch pressure

a. Malfunction of a seal rings, O-ring of the end clutch or O-ring 8 of the pipe (Refer to the following figure.)

b. Looseness of valve body tightening part c. Functional malfunction of the valve body assembly 6. Improper low-reverse brake pressure

c. Looseness of valve body tightening part d. Functional malfunction of the valve

a. Remove the valve body assembly and check to be sure that the O-ring at the upper surface of the upper valve body is not missing or damaged; install or replace the O-ring if necessary. b. After removing the valve body assembly, check the tightened condition of the bolt; re-tighten it if necessary. c. Tighten the valve body tightening bolt and installation bolt. d. Replace the valve body assembly.

/:lody assembly e. Malfunction of the O-ring 4 of the low-reverse brake piston or the O-ring 3 of the retainer (Refer to the figure on the next page)

e. Disassemble the transaxle itself and check the O-ring and O-ring for damage; replace if there are cuts, scars, scratches or damage.

a. O-ring between valve body and transaxle damaged or missing

b. Looseness or improper tightening or center support tightening bolt

45-34

a. Disassemble the end clutch and check the seal ring, O-ring of the piston, seal ring of the retainer, O-ring of the pipe, etc.; replace if there are cuts, scars, scratches or damage. b. Tighten the valve body tightening bolt and installation bolt. c. Replace the valve body assembly.

GENERAL

D-ring D-ring

Seal ring

D-rlng

""Seal ring

Seal ring ~

Trouble symptom

Probable cause

Remedy

7. Improper torque converter pressure

a. Sticking of the damper clutch control solenoid valve (DCCSV) or the damper clutch control valve. b. Clogging or leaking of the oil cooler and/or piping c. Damaged seal ring of the input shaft (Refer to the figure above.)

a. Check the operation of the damper clutch system and the DCCSV.

d. Malfunction of the torque converter

b. Repair or replace, as necessary, the cooler and/or piping. c. Disassemble the transaxle itself and check for damage of the seal ring; replace the seal ring if there is damage. d. Replace the torque converter.

45-35

GENERAL

CONVERTER STALL TEST

Y45CV1A

Stall test consists of determining maximum engine speed obtained at full throttle in "0" and "R" positions. This test checks torque converter stator overrunning clutch operation, and holding ability of the transaxle clutches and the low-reverse brake.

Warning: During this test, make sure that no one stands in front of or behind vehicle. 1.

Check transaxle fluid level. Fluid should be at normal operating temperature [70-80 0 C (160-180 0 F)]. Engine coolant should also be at normal operating temperature

[80-90 0 C (1 80-1 90° F)]. 2. 3. 4.

Apply chocks to both rear wheels. Attach engine tachometer. Apply parking and service brakes fully.

5. 6.

Start engine. With selector lever in "0" position, depress accelerator pedal fully to read engine maximum rpm. Do not hold throttle wide open any longer than is necessary to obtain maximum engine rpm reading, and never longer than 5 seconds at a time. If more than one stall test is required, operate engine at approximately 1,000 rpm in neutral for 2 minutes to cool transaxle fluid between test.

Stall speed: 2,200 ± 200 rpm 7.

Place selector lever to "R" position and perform stall test by the same procedure as in foregoing item.

Stall Speed Above Specification in "0" If stall speed is higher than specification, rear clutch or overrunning clutch of transaxle is slipping. Perform hydraulic test.

Stall Speed Above Specification in "R" If stall speed is higher than specification, front clutch of transaxle or the low-reverse brake is slipping. Perform .hydraulic test.

Stall Speed Below Specification in "0" and "R" If stall speed is lower than specification, insufficient engine output or a faulty torque converter is suspected. Check for engine misfiring, ignition timing, valve clearance etc. If these are good, torque converter is faulty.

45-36

GENERAL

FLUID LEAKAGE-TRANSAXLE CONVERTER HOUSING AREA 1.

Y45CWIA

Check for any source of leakage. Since fluid leakage at or around the converter area may originate from engine oil leak, area should be examined closely. Transaxle factory fill fluid is dyed red and,therefore, can be distinguished from engine

oil. 2. Prior to removing transaxle, perform following checks: When leakage is determined to originate from transaxle. check the fluid level prior to removal of transaxle and torque converter. High oil level can result in oil leakage out of vent located in top of oil pump. If fluid level is high, adjust to proper level and recheck for leakage. 3. After completing these steps, recheck once more for leakage.

45-37

GENERAL

E.L.C. 4-SPEED AUTOMATIC TRANSAXLE CONTROL COMPONENTS LAYOUT

Y45CX1A

LIST OF CONTROL COMPONENTS Name

Symbol

A

E.L.C. 4-speed automatic transaxle control unit

D

M.P.I. control unit

C

Pulse generator A

B

Pulse generator B

B

Self diagnosis check connector

G

Solenoid

A

Throttle position sensor

E

Oil temperature sensor

F

c

B

E

F

D

G

Pulse generator A

Cowl side trim (right side)

45-38

Manual control lever

GENERAL

):;

Self diagnoSIS check connector

45-39

GENERAL

SERVICE ADJUSTMENT PROCEDURES

Y45CYIA

INSPECTION OF TRANSAXLE FLUID QUANTITY 1. 2. 3. 4.

5.

6.

Place vehicle on level floor. Before removing dipstick, wipe all dirt from area around dipstick. With selector lever in "P" park and parking brakes applied, start engine. Engine should be running at idle speed. Transaxle should be sufficiently warmed up [fluid temperature 70-80°C (160-180 0 F)]. Move selector lever sequentially to every position to fill torque converter and hydraulic circuit with fluid, then place lever in "N" Neutral position. Check to see if fluid level is in "HOT" range on dipstick. If fluid level is low, add automatic transaxle fluid until level reaches "HOT" range. Transaxle fluid : GENUINE HYUNDAI ATF AUTOMATIC TRANSMISSION FLUID, MOPAR ATF PLUS TYPE 7176, DIAMOND ATF SP, BP AUTRAN MM SP (For Australia) Low fluid level can cause a variety of conditions because it allows pump to take in air along with fluid. Air trapped in hydraulic circuit forms bubbles which make fluid spongy. Therefore, pressures will be erratic, causing delayed shift, slippy clutch and brakes, etc. Improper filling can also raise fluid level too high. When transaxle has too much fluid, gears churn up foam and cause the same conditions which occur with low fluid level, resulting in accelerated deterioration of automatic transaxle fluid. In either case, air bubbles can cause overheating, fluid oxidation, and varnishing, which can interfere with normal valve, clutch, and servo operation. Foaming can also result in fluid escaping from transaxle vent where it may be mistaken for a leak. Along with fluid level. it is necessary to check conditions of fluid. When fluid smells burned, indicating contamination with metal bushing or friction material particles, a complete transaxle overhaul is needed. Be sure to examine fluid on dipstick closely. If there is any doubt about its condition, drain out sample for double check. After fluid has been checked, seat dipstick fully to seal out water and dirt.

REPLACEMENT OF TRANSAXLE FLUID Refer to LUBRICATION AND MAINTENANCE PART.

45-40

HOT

Fluid level must be within this range

GENERAL

INHIBITOR SWITCH AND CONTROL CABLE ADJUSTMENT

Y45CZ1A

1. 2.

Place selector lever in "N" (Neutral) position. Loosen control cable to manual control lever coupling adjusting nut to set cable and lever free. 3. Place manual control lever in "N" (Neutral) position.

4.

Turn inhibitor switch body until 12 mm (0.47 in.) wide end of manual control lever aligns with switch body flange [12 mm (0.47 in.) wide portion]. Or turn switch body until 5 mm (0.20 in.) hole in manual control lever aligns with 5 mm (0.20 in.) hole in switch body. 5. Tighten attaching bolts (2 pcs.) carefully so that switch body is not displaced. 12 mm(.47 in.) Section A-A

6. 7. 8.

Make sure that selector lever is in "N" (Neutral) position. Remove slackness of control cable by adjusting nut and then check that selector lever moves smoothly. Check that control cable has been adjusted correctly.

45-41

GENERAL

ADJUSTMENT OF KICKDOWN SERVO 1. 2. 3. 4.

Y45CllA

Completely remove all dirt and other materials adhered around the kickdown servo cover. Remove the kickdown servo switch. Remove the snap ring and cover. Loosen the lock nut.

5. While holding with special tool (09454-33000) so that the kickdown

6.

servo

piston won't turn, use special tool (09454-33100) to "tighten", at 9.8 Nm (100 kg.cm, 7.2 Ib.ft), and "return" the adjustment screw two times each, and then tighten at a torque of 4.9 Nm (50 kg.cm, 3.6 Ib.ft). Then return the adjustment screw 2 to 2-1/4 turns. While holding with special tool (09454-33000) so that the kickdown servo piston won't turn, tighten the lock nut to the specified torque.

Loek nut: 25-32 Nm (255-326 kg.em, 18-23 Ib.ft) 7.

8.

After fitting a new O-ring in the groove around the cover, install the cover to the case so that the O-ring won't be twisted, and then install the snap ring. Install the kickdown servo switch to the cover.

Kiekdown servo switeh screw: 1.0-1.4 Nm (10.2-14.3 kg.em, 0.7-1.0 Ib.ft)

ADJUSTMENT OF LINE PRESSURE 1. 2. 3. 4. 5.

Y45C21A

Drain out the ATF. Remove the oil pan. Remove the oil filter and oil temperature sensor. Remove the valve body assembly. The manual valve can come out, so be careful not to drop it. Turn the adjustment screw of the regulator valve and adjust so that the line pressure (kickdown brake pressure) becomes the standard value.

45-42

\

0945~-33100

O~454-33000~

GENERAL When the adjustment screw is turned to the right. the line pressure becomes lower; when it is turned to the left. it becomes higher. Standard value: 870-890 kPa (124-126 psi, 8.9-9.1 kg/cm 2 ) Oil pressure change for each turn of adjustment screw : 38 kPa (4.6 psi, 0.39 kg/cm 2 ) 6.

Check to be sure that the O-ring is installed on the upper surface of the valve body at the place shown in the figure.

7.

Replace the O-ring of the solenoid valve connector with a newone. 8. Install the valve body assembly to the case and then insert the solenoid valve connector into the case. Be sure. at this time. that the notched part of the connector faces as shown in the figure. Also be careful that the lead wiring isn't caught.

9.

Tighten valve body assembly mounting bolts (10 pieces) to

10-12 Nm (100-120 kg.cm. 7.5-8.5 Ib.ft). B

A bolt: 20 mm (0.787 in.) long B bolt : 28 mm (1.102 in.) long C bolt: 45 mm (1.772 in.) long

A

10. Install the oil filter. 11. Install a new oil pan gasket and oil pan. and tighten the 2 bolts.

12. Pour in the specified amount of ATF. 13. Make the oil pressure test. Readjust if necessary.

ADJUSTMENT OF REDUCING PRESSURE

Y45C31A

1. Remove parts up to the oil filter in the same way as for adjustment of the line pressure. The valve body need not be removed. 2. Turn the adjustment screw of the lower valve body and adjust so that the reducing pressure is the standard value. When the adjustment screw is turned to the right. the reducing pressure becomes lower; when it is turned to the left. it becomes higher.

45-43

GENERAL Standard value : 425 ± 10 kPa (60 ± 1 psi, 4.3 ± 1 kg/cm 2 ) Oil pressure change for each turn of adjustment screw : 30 kPa (4.3 psi, 0.3 kg/cm 2 ) 3. 4.

Install the oil filter and oil pan in the same way as for adjustment of the line pressure. Make the oil pressure test. Readjust if necessary.

ADJUSTMENT OF THROTTLE-POSITION SENSOR (TPS)

Y45C41A

Refer to FUEL SYSTEM-Service Adjustment Procedures.

REPLACEMENT OF DRIVESHAFT OIL SEALS

Y45C51A

R.H. side

1.

Disconnect the drive shaft from the transaxle. (Refer to FRONT SUSPENSION-Drive Shaft) 2. Using a flat-tip (-) screwdriver. remove the oil seal.

o

45-44

GENERAL 3. 4.

Using the special tool (09431-21200), tap the drive shaft oil seal into the transaxle. Apply a coating of the transaxle fluid to the lip of the oil seal. Transaxle fluid: GENUINE HYUNDAI ATF AUTOMATIC TRANSMISSION FLUID OR MOPAR ATF PLUS TYPE 7176, BP AUTRAN MM SP (For Australia), DIAMOND ATF SP 09431-21200

REPLACEMENT OF SPEEDOMETER CABLE

Y45C61A

1. 2.

Replace the cable assembly if there is a malfunction. When connecting the cable to the meter, insert the cable until its stopper properly fits to the meter side groove.

3.

Install the grommet so that, as shown in the illustration, the cable attachment part and the projecting part are horizontal. CAUTION The cable arrangement should be made so that the radius of cable bends is 150 mm (5.9 in.) or more.

4.

At the transaxle end of the speedometer cable, the key joint should be inserted into the transaxle, and the nut should be securely tightened. CAUTION If the cable is not correctly and securely connected, it may cause incorrect indication by the speedometer, or abnormal noise. Be sure the connect it correctly.

45-45

GENERAL

ACCELERATOR SWITCH CHECK AND ADJUSTMENT

Y45C41A

1. After warming up the engine, confirm that the accelerator switch is on with the accelerator pedal in the free state.

NOTE Check that the accelerator switch is on or off by checking the voltage between the G wire and the ground wire at the accelerator switch connector (2-pin). When the accelerator switch is ON : 0 V When the accelerator switch is OFF : 12 V 2.

Measure stroke B, shown in the illustration of the accelerator pedal. at the point when the accelerator switch goes from ON to OFF when the pedal is depressed.

Standard value : 4-8 mm (0.16-0.31 in.) 3.

If the figured stroke B deviates from the standard value, adjust it by the adjusting bolt.

Adjusting bolt

0--0: Continuity

~

O.5G (L)

O.5G(L)

O.5GR (E)

OFF (FREE)

O.5GR(E)

ON (PUSH)

Accelerator switch

OVER DRIVE SW.

r IGN

sw.

IND. LAMP

...L

l-

rJ-

IGN

CRUISE ONLY

sw.

L ELC-4 ATM CONTROL UNIT

E

ACCELERATOR

sw.

T

CRUISE EXCEPT 45-46

TRANSAXLE CONTROL

TRANSAXLE CONTROL COMPONENTS

Selector knob

Overdrive switch connector Cover

~

Parking position switch

f

Nut

/

~~_ ~

Clip

Cable band

~~J ~\~ I '

Position indicator light connector, I

Bush

Control cable Shift lever assembly Shift lock solenoid assembly

TORQUE

Nm (kg.em, Ib.ft)

45-47

TRANSAXLE CONTROL REMOVAL

Y45DAIB

1. 2. 3.

Remove the console box assembly. (Refer to Body Group). Remove the selector knob installation screws. Disconnect the overdrive switch connector and then remove the selector knob.

4. 5. 6.

Remove the indicator panel, slider. Disconnect the position indicator light connector. Remove the indicator panel lower.

7.

Remove the snap ring, cable end pin, nut. And remove, the parking position switch connector and the shift lock solenoid connector.

8.

Remove the cable mounting bolt.

45-48

TRANSAXLE CONTROL 9. Remove the air cleaner assembly. 10. Remove the clip, cotter pin, adjusting nut.

INSPECTION 1. 2. 3. 4.

Check Check Check Check

the the the the

Y46DB1A,

control cable for function and for damage. bushing for wear or damage.. spring for damage or deterioration. overdrive switch for continuity.

0-0 : Continuity

~ Switch position

1

2

3

(O.5-RW)* (O.5-LR)* (O.5-BrW)*

_.-1-11

ON ...

/

@

~

Overdrive activation

Overdrive non-activation

OFF.

~

~

NOTE *Color code

Color of wire

*Color code

Color of wire

R

Red

Br

Brown

W

White

L

Blue

45-49

TRANSAXLE CONTROL 5.

Check the PIN switch for continuity ILl(-)

0--0: Continuity

~

NORM

IG

PWR

ILL(+)

IG

ILL(-)

Position

o---®-O

Normal (Free)

0- --D

Power (Push)

o---@-o

ILl(+)

SWITCH ---,

FREE r-<:r--o---:I:::-G-----{).._fr--¢ NOR M IGNSW ILL(+)

PUSH

PWR

TAILSW

/

ILL(-)

I INSTALLATION 1.

Y45DC1A

Apply a coating of the specified grease to the interior of the bushing. Specified grease: Chassis grease SAE J310, NLGI No. 0

2.

Move the shift lever and the inhibitor switch to the "N" position, and install the control cable.

45-50

TCU( PWR)

TRANSAXLE CONTROL 3.

When connecting the control cable to the uansaxle mounting bracket, install the clip until it contacts the control cable, in position switch in the figure. 4. Install the cable mounting bolt. 5. Install the air cleaner assembly.

6.

Install the nut, cable end pin, snap ring.

7.

Connect the position indicator light connector, the overdrive switch connector, the parking position switch connector, and

8.

the shift lock solenoid connector. Install the indicator panel, slider, indicator panel lower.

9.

Apply the specified grease at the places shown in the figure. Specified grease: Multipurpose grease SAE J310 NLGI

No. 2

45-51

TRANSAXLE CONTROL 10. Place the shift lever in the "N" position, and then turn the sleeve so that the clearance between the sleeve and the lever assembly end in within the standard value. Sleeve

Standard value (A) : 15.2-15.9 mm (0.598-0.625 in.)

NOTE Be sure to face B of the adjusting cam to the push button (driver's side).

11. Install the selector knob. 12. Install the console box. (Refer to BODY GROUP).

ADJUSTMENT OF CONTROL CABLE 1. 2.

Y45DD1A

Eliminate slack from the control cable with the adjusting flange nut and check that the select lever operates smoothly. Driving the car, check that the transaxle is set in the proper range when the select lever is shifted to each position.

45-52

A

Lever assembly

SHIFT LEVER ASSEMBLY

SHIFT LEVER ASSEMBLY COMPONENTS lever assembly

(J-

Sleeve

Pin

SP,;ng-~ 0 L

Ball support Steel ball Spring

-7

I

Rod assembly

L-~'-------

Spring

Pin------.....,~ ~7

~BUShing iL..~::::::::;::>.-:-_[) 0),.-.... 14-20 (140-200, 10-14) 0J .I

~~--.:"

QJ

Bracket assembly

TORQUE

Nm (kg.cm, Ib.ft)

INSPECTION o o o o

Check Check Check Check

the the the the

detent place for wear. bushing for wear or damage. spring for damage or deterioration. pin at the end of rod assembly for wear.

ASSEMBLY 1.

Y45EA1A

Y45EBIA

Apply a coating of grease to the sliding part of the bushing.

I

Lever assembly

Specified grease: Chassis grease SAE J310, NLGI No. 0

45-53

SHIFT LEVER ASSEMBLY 2.

Apply the specified grease at the places shown in the figure.

Specified grease: Multipurpose grease SAE J310, NLGI No.2

45-54

AUTOMATIC TRANSAX,-E

AUTOMATIC TRANSAXLE COMPONENTS

A

E

o

B

Nm A B C

D E F G

43-55 43-55 22-32 30-35 10-12 15-22 35-42

Kg.cm 430-550 430-550 220-320 300-350 100-120 150-220 350-420

Ib.ft

31-40 31-40 16-23 22-25 7-9 11-16 25-30

O.D. x Length mm (in.) 7 7 7 10 7 7

10 10 10 10 8 8

x x x x x x

40 65 55 60 14 20

(1.6) (2.6) (2.2) (2.4) (0.6) (0.8)

Bolt identification

(J:J

AxB

~~A

45-55

AUTOMATIC TRANSAXLE REMOVAL

Y45FA1A

1. 2.

Remove the drain plug and drain out the transaxle oil. Remove the air cleaner assembly.

3. 4.

Remove the control cable. Remove the speedometer cable.

5.

Disconnect the pulse generator connector, inhibitor switch connector, kickdown servo switch connector, solenoid connector.

6. 7.

Remove the starter motor. Remove the stabilizer bar, tie rod end, lower arm ball joint, drive shaft under cover. (Refer to drive shaft and front axle).

45-56

AUTOMATIC TRANSAXLE 8.

Remove the bell housing.

-=o============o=====-

9.

2

Remove the special bolts. 1) Remove the three special bolts connecting the converter to th~ drive plate.

NOTE To remove the special bolts of torque converter, turn engine crankshaft with a box wrench to bring one of the bolts to the position appropriate for removal. After removing the bolt, turn the crankshaft in the same manner as above and remove all remaining bolts one after another. 2)

After removing the special bolts, push the torque converter toward the transaxle so that it does not remain on the engine side.

10. Disconnect the oil cooler hose.

11. Remove the caps and bolts.

45-57

AUTOMATIC TRANSAXLE 12. Remove the transaxle assembly.

45-58

=-------1

AUTOMATIC TRANSAXLE OIL COOLER ASSEMBLY

AUTOMATIC TRANSAXLE OIL COOLER ASSEMBLY

,-

COMPONENTS

, I

Oil cooler tube Iassembly

~~\ft

Return .hose

~~

Oil cooler assembly

Radiator assembly

REMOVAL AND INSTALLATION 1. 2. 3.

Y45GA1A

Remove the battery assembly and air cleaner assembly. Remove the front bumper assembly. Disconnect the automatic transaxle oil cooler hoses from the automatic transaxle.

CAUTION Plug the ends of the oil cooler hoses and the automatic transaxle port to prevent the transaxle fluid from spilling out and foreign material from getting in. Plug the nipple at the automatic transaxle in order to prevent entrance of foreign material into the automatic transaxle. NOTE When removing each part. avoid spilling the transaxle fluid. 3.

Installation is the reverse of removal.

45-59

AUTOMATIC, TRANSAXLE ASSEMBLY

DISASSEMBLY Caution Because the automatic transaxle is composed of component parts of an especially high degree of precision, these parts should be very carefully handled during disassembly and assembly so as not to scar or scratch them. A rubber mat should be placed on the workbench, and it should always be kept clean. During disassembly, cloth gloves or rags should not be used. If such items must be used, use articles made of nylon, or use paper towels. All disassembled parts must be thoroughly cleaned. Metal parts may be cleaned with ordinary detergents, bet must be thoroughly air dried. Clean the clutch disc, resin thrust plate and rubber parts by using ATF (automatic transmission fluid), being very careful that dust, dirt, etc. do not adhere. If the transaxle main unit is damaged, also disassemble and clean the cooler system. 1. Clean away any sand, mud, etc. adhered around the transaxle. 2. Place the transaxle assembly on the workbench with the oil pan down. 3. Remove the torque converter. 4. Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required (except when major parts are replaced). Thrust washers are located between reaction shaft support and rear clutch retainer, and between reaction shaft support and front clutch retainer. Mount a dial indicator to converter housing with the Dial Indicator Support Make sure that the indicator plunger is seated against end of input shaft. When checking end play, pull out or push in the input shaft with pliers. Be careful not to scratch the input shaft. Record indicator reading for reference when reassembling transaxle. 5.

Remove the pulse generator "A" and "B".

45-60

09453-21400

AUTOMATIC TRANSAXLE ASSEMBLY

.

6.

Remove manual control lever, then remove inhibitor switch.

7.

Remove snap ring then remove kickdown servo switch.

-,II\--=:::: s:s:::::c::::~........

,'JI

Kickdown servo switch

Snap ring

8.

Remove the oil pan and gasket.

9.

Remove the oil filter from the valve body.

45-61

AUTOMATIC TRANSAXLE ASSEMBLY 10. Remove the oil-temperature sensor installation bolt; then, after removal from the bracket, pull out from the connector side.

11. Press the tabs of the solenoid valve harness grommet, and then push into the case and remove the ELC connector.

12. Remove 10 bolts and remove valve body.

13. Remove the end clutch cover mounting bolt the cover holder, and the end clutch cover.

45-62

AUTOMATIC TRANSAXLE ASSEMBLY 14. Remove the end clutch assembly.

15. Remove the thrust plate.

16. Remove the end clutch hub and thrust bearing.

17. Pull out the end clutch shaft.

45-63

AUTOMATIC TRANSAXLE ASSEMBLY 18. Remove 14 bolts and remove converter housing.

19. Remove six oil pump mounting bolts. Screw special tool (09452-33100) into two oil pump removing holes in oil pump housing. Turn both removers simultaneously and uniformly to remove oil pump assembly. Oil pump may sometimes tilt to A side, because straight line connecting oil pump removing holes does not pass center of pump. If this is the case, tap oil pump lightly on B side or tilt removers to B side as pump is removed. 20. Remove the oil pump gasket and adapter.

21. Remove the spacer and the differential. assembly.

22. Remove the fiber thrust washer.

45-64

09452-33100

AUTOMATIC TRANSAXLE ASSEMBLY 23. Pull up the input shaft, and then remove the front clutch assembly and the rear clutch assembly together.

24. Remove the thrust bearing.

25. Remove the clutch hub.

26. Remove the thrust race and bearing.

45-65

AUTOMATIC TRANSAXLE ASSEMBLY 27. Remove the kickdown drum.

28. Remove the kickdown band.

29. Using special tools (09222-21001, 09456-21100), push in the kickdown servo and remove the snap ring.

30. Remove the kickdown servo piston and spring.

45-66

AUTOMATIC TRANSAXLE ASSEMBLY 31. Remove the anchor rod.

UU U

~II--

c

~ 32. Remove the snap ring.

33. Attach special tool (09453-21310) on center support. Holding handle of tool, pull center support straight upward.

34. Remove reverse sun gear and forward sun gear together.

45-67

AUTOMATIC TRANSAXLE ASSEMBLY 35. Remove planet carrier assembly and thrust bearing.

36. Remove the wave spring, return spring, reaction plate, brake disc, and brake plate.

37. Since screw lock paste is coated on the bolt threads, tap the bolt head for easier removal.

38. Using an impact driver, loosen the bolt.

45-68

AUTOMATIC TRANSAXlE ASSEMBLY If an impact driver is not available, use a punch or something similar.

39. Remove idler shaft lock plate.

40. Loosen transfer idler shaft with special tool.

09454-21100

41. Pull out transfer idler shaft. Remove transfer idle gear bearing inner races (2 pieces) from inside of case.

45-69

AUTOMATIC TRANSAXlE ASSEMBLY 42. Remove the spacer.

43. Remove snap ring from bearing.

44. Remove internal gear, output flange: transfer drive gear and bearing as assembly from case.

45. Remove the transfer shaft cover.

45-70

AUTOMATIC TRANSAXLE ASSEMBLY 46. Stand the transfer shaft lock nut rotation stopper up.

47. Fix the transfer shaft converter housing side.

48. Remove the locking nut.

NOTE The lock nut is left-hand threaded.

49. Knock off the transfer shaft to the converter housing side.

45-71

AUTOMATIC TRANSAXLE ASSEMBLY 50. Using a screwdriver, remove the outer race.

51. Remove two bolts and parking sprag rod.

52. Remove the set screw and the manual control shaft assembly. Remove the steel ball, the seat and the spring together at· this time.

8-10 Nm (80-100 kg.em. 6-7 Ib.ft)

\ Spring

45-72

AUTOMATIC TRANSAXLE ASSEMBLY

REASSEMBLY Caution Do not reuse gaskets, oil seals and rubber parts. Replace them with new ones at every reassembly. O-ring of oil level dipstick need not be replaced. Do not use grease other than petrolatum or industrial vaseline. Apply automatic transaxle fluid to friction element, rotating parts, and sliding parts before installation. Refer to page 45-4 concerning automatic transaxle fluid. New clutch disc should be immersed in automatic transaxle fluid for more than two hours before installation. Do not apply sealer or adhesive to gaskets. When bushing must be replaced, replace assembly which includes it. Do not use shop towels during disassembly and reassembly operation. The oil in the cooler should also be replace.

1.

Before assembly of the transaxle. measure the end play of the low-reverse brake, and select a pressure plate to the used so that the end play will be the standard value. 1) Install the brake reaction plate, brake plate and brake disc to the transaxle case. Caution If new brake discs are used, be sure to immerse them in ATF for two hours or longer. 2)

Install the appropriate pressure plate and then install the return spring. Caution Be sure that the return spring is installed so that it faces in correct direction.

Rear s i d e Brake plate

)

45-73

AUTOMATIC TRANSAXLE ASSEMBLY 3)

Apply a coating of petroleum jelly to the wave spring and attach it to the center support.

4)

Install the special tool (09453-21310) to the center support.

5)

Install the snap ring.

6)

Install the special tools (09453-21400, 09453-33100) and a dial gauge at the rear side of the transaxle case.

Caution Install the dial gauge so that it contacts the brake reaction plate at a right angle from the transfer idler shaft hole.

45-74

09453-21400

"

09453-33100

AUTOMATIC TRANSAXLE ASSEMBLY 7)

Using a manual pump, pump air in from the position shown in the illustration; then read the indication of the dial gauge, and select the pressure plate that will provide the standard value. Standard value: 0.975-1.287 mm.

2.

Using the special tools (09500-11000, 09532-11500), tap in the bearing outer race.

3.

Insert manual control shaft into transaxle case and push it fully toward manual control lever. At this time, do not install O-ring (larger one of two O-rings) on manual control shaft.

Set screw hole Manual control shaft

NOTE If installed before inserting shaft. the O-ring will interface with shaft set screw hole.

4.

After installing new O-ring on manual control shaft, draw shaft back into case, then install set screw and gasket. Also install detent steel ball, seat and spring at the same time.

8-9.5 Nm ~Rt:~(6_7 fUbs.) Manual control shaft

Spring

45-75

AUTOMATIC TRANSAXLE ASSEMBLY 5.

Install parking sprag rod to detent plate (manual control shaft). Install sprag rod support and tighten two bolts. Sprag rod support bolts: 20-27 Nm (200-270 kg.em, 15-19 Ib.ft)

6.

Press-fit the bearing inner race to the transfer driven gear, and press-fit the bearing outer race to the transaxle end

09432-21601

clutch side. Transfer driven gear

7.

Press-fit the bearing inner race to the transfer shaft, and press-fit the bearing outer race to the transaxle case converter housing side.

09432-21601 Transfer shaft

8.

Attach the transfer shaft to the transaxle case.

45-76

AUTOMATIC TRANSAXLE ASSEMBLY 9.

Install the special tool (09455-21301) to the transaxle case to support the transfer shaft.

10. Insert the thickest 1.80 mm (0.0709 in.) spacer.

11. Attach the transfer driven gear. 09455-21100/

12. After removing the special tool, affix the converter housing side of the transfer shaft.

45-77

AUTOMATIC TRANSAXLE ASSEMBLY 13. Tighten the lock nut to the specified torque.

Transfer lock nut: 200-230 Nm (2000-2300 kg.cm, 145-166 Ib.ft)

14. After installing the special tool, measure the end play of the transfer shaft; then select the spacer(s) needed to obtain the standard value, and refit.

Transfer shaft end play: 0-0.025 mm (0-0.0010 in.)

15. Using a punch, lock the lock nut to prevent rotation. 16. Attach the transfer cover.

17. Insert an assembly of the annular gear, output flange, transfer drive gear and bearing into the case.

45-78

AUTOMATIC TRANSAXLE ASSEMBLY 18. Install snap ring on output flange rear bearing.

19. Coat petroleum jelly on the spacer and attach it to the transaxle case.

20. Install two taper roller bearings and spacer to transfer idle gear.

~

Torque converter side

Inner race

4---'ld::::-~=--- Outer race

Transfer idle gear

21. Place the transfer idler gear (assembled in the preceding section) into the case, and then insert the idler shaft from the outer side of the case and screw it in.

45-79

AUTOMATIC TRANSAXLE ASSEMBLY 22. Tighten the idler shaft by using special tool (09454-21100).

23. Insert special tool (09458-33000) into output flange and measure preload using a low reading torque wrench. Adjust preload by tightening or loosening transfer idler shaft.

Preload: 1.5 Nm (15 kg.em. 1.0 Ib.ft)

24. After the preload adjustment is completed. eliminate the backlash between the idler shaft and the lock plate by moving the idler shaft in the loosening direction. Attach the lock plate and tighten the lock plate bolt.

Loek plate bolt: 38-60 Nm (480-600 kg.em. 35-43 Ib.ft)

25. Install bearing retainer and tighten screws to specified torque, apply a 5 mm (0.2 in.) width of sealant (3M Stud Locking No. 4176) the top. Sealant should not stick out of screw head.

Serew: 17-22 Nm (170-220 kg.em. 13-15 Ib.ft)

26. Using a punch. lock the flush head screw to prevent rotation.

45-80

AUTOMATIC TRANSAXLE ASSEMBLY

'/

~ ~ ~#4 #1 #2 (selection)

#3 (selection)

#6

1

~#8 ~#1~ ~#13 #7

#9

#11

#12

#5

Identification of thrust bearings. thrust races and thrust washers Outer diameter Inner diameter

Thickness

70 (2.756)

55.7 (2.193)

1.4 (0.055)

70 (2.756)

55.7 (2.193)

1.8 (0.071)

Code No. Outer diameter Inner diameter

Unit: mm (in.) Thickness· Code No.

48.1 (1.906)

34.4 (1.354)

-

#4

40 (1.575)

21 (0.827)

2.4 (0.094)

#5

#1

-

70 (2.756)

55.7 (2.193)

2.2 (0.087)

42.6 (1.677)

28 (1.102)

70 (2.756)

55.7 (2.193)

2.6 (0.102)

54 (2.126)

38.7 (1.524)

70 (2.756)

55.7 (2.193)

1.8 (0.071)

52 (2.047)

36.4 (1.433)

-

#8

48.9 (1.925)

37 (1.457)

1.0 (0.039)

41 (1.614)

28 (1.102)

-

#9

48.9 (1.925)

37 (1.457)

1.2 (0.047)

39 (1.535)

28 (1.102)

48.9 (1.925)

37 (1.457)

1.4 (0.055)

38 (1.496)

22.2 (0.874)

-

#11

48.9 (1.925)

37 (1.457)

1.6 (0.063)

52 (2.047)

36.4 (1.433)

-

#12

58 (2.283)

44 (1.732)

-

#13

#2

1.6 (0.063)

1.2 (0.047)

#6 #7

#10

#3 48.9 (1.925)

37 (1.457)

1.8 (0.071)

48.9 (1.925)

37 (1.457)

2.0 (0.079)

48.9 (1.925)

37 (1.457)

2.2 (0.087)

48.9 (1.925)

37 (1.457)

2.4 (0.094)

45-81

AUTOMATIC TRANSAXlE ASSEMBLY 27. Apply a coating of petrolatum to thrust bearing #12 and attach to the planetary carrier.

Thrust bearing #12

28. Install the planetary carrier to the case.

29. Assemble the reverse sun gear and the forward sun gear in the following order: 1) Attach th,e seal ring and the snap ring to the reverse sun gear. When attaching, squeeze the seal ring as shown in the figure. 2) Attach the thrust race #9 to the forward sun gear. 3) Attach the thrust race #10 to the forward sun gear.

4)

Assemble the reverse sun gear and the forward sun gear.

Forward sun gear Thrust bearing #9 Reverse sun gear

45-82

AUTOMATIC TRANSAXLE ASSEMBLY 30. Install both of the previously assembled sun gears inside the planetary carrier.

31. Install the brake disc and brake plate.

32. Install the selected brake pressure plate.

33. Install the return spring.

45-83

AUTOMATIC TRANSAXLE ASSEMBLY 34. Apply a coating of petrolatum to the wave spring and attach

Wave spring

it to the center support.

35. Install two new O-rings to the center support.

36. After applying a coating of ATF to the O-rings. install the special tool (09453-21310) to the center support. and install within the case. Caution Be sure that the wave spring is not out of position.

37. Install the snap ring. Caution The mating hole of the snap ring must be aligned with the installation hole of pulse generator A.

/) 45-84

AUTOMATIC TRANSAXLE ASSEMBLY 38. Install the anchor rod.

39. Assemble a new seal ring (large diameter) and O-ring (small diameter) to the kickdown servo piston, and install a new O-ring in the groove around the sleeve; then assemble the kickdown servo spring, piston and sleeve in the transaxle case.

40. Press the kickdown servo and sleeve in by using special tools (09222-21001, 09456-21100), and then install the snap ring.

41. Install kickdown band; attach the ends of band to the ends of anchor rod and servo piston rod.

45-85

AUTOMATIC TRANSAXLE ASSEMBLY 42. Install kickdown drum with its splines in mesh with sun gear. Place kickdown band on kickdown drum and tighten kickdown servo adjusting screw to keep band in position.

43. Apply a coating of petrolatum to thrust bearing #8, and then attach to the kickdown drum.

44. Apply a coating of petrolatum to thrust race #7, and then attach to the rear clutch hub.

45. Install clutch hub to sun gear splines.

45-86

AUTOMATIC TRANSAXLE ASSEMBLY 46. Attach thrust bearing #6 onto the hub with petrolatum.

47. Apply a coating of petrolatum to thrust washer #2 and thrust bearing #4, and then attach to the rear clutch assembly.

Thrust bearing #4

48. Combine the rear clutch assembly and the front clutch assembly.

Rear clutch Front clutch

49. Install the clutch assembly.

45-87

AUTOMATIC TRANSAXlE ASSEMBLY 50. Install the differential assembly.

51. If end play which was measured and recorded at disassembly is not standard value, 'adjust end play to specification by selecting thrust washer #1. Standard value: 0.3-1.0 mm (0.012-0.040 in.) When thrust race is replaced with that of different thickness, replace also thrust race #3 located between oil pump and front clutch with washer of proper thickness corresponding to thrust race. Find correct pair of thrust races (metal) and thrust washers (fiber) from following table. Thrust washer #1 (metal)

Thrust race #3 (fiber)

Thickness mm (in.)

Thickness mm (in.)

1.4 (0.055) 1.4 (0.055) 1.8 (0.071) 1.8,(0.071 ) 2.2 (0.087) 2.2 (0.087) 2.6 (0.102) 2.6 (0.102)

1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

(0.039) (0.047) (0.055) (0.063) (0.071) (0.079) (0.087) (0.095)

Example: When thick thrust race is selected. thrust washer is one to be paired with it.

52. Attach the reused thrust washer #1, or the one selected in step 51 to the front clutch by using petrolatum.

45-88

AUTOMATIC TRANSAXLE

AS_S:E:M:B:L=Y_----===~~~

53. Install special too 1(0945 2 - 21401) to the case.

h 51 to the

d thrust race #3 or the one selected in step

54. Attac the reuse . ump by USIn . g petrolatum. 011

p

55. Install neW oil pu mp gasket an d the oil pump assembly. ,

. g and apply housln in groove of oil PU~:e surface of O-ring. 56 Install new fluid lightly to outs, g six bolts evenly. . automatic transax . mbly by tightenln I be careful that ump asse 57. Install 01'1 P'n this oil pump assemb y, When install! g . drop. thrust wa sher will not

o-"n~e .

45·89

AUTOMATIC TRANSAXlE ASSEMBLY 58. Check input shaft end play. Readjust if necessary (see step 51 ). Standard value: 0.3-1.0 mm (0.012-0.040 in.)

59. Apply solder [length approx. 10 mm (0.40 in.) and diameter 3 mm (0.118 in.)] to the differential assembly at the locations shown in the illustration.

60. Install new case gasket to transaxle case. 61. Install converter housing and tightening 14 bolts to 19-23 Nm (49O-2~0 kg.cm. 14-16 Ib.ft).

62. Remove the converter housing and gasket. 63. Remove the crushed solder from outer race of differential bearing.

64. Measure the thickness of the crushed solder micrometer and select and install a spacer of thickness that gives standard preload.

Standard value : 0.080-0.130 mm (0.003-0.005 in.)

45-90

Solder

AUTOMATIC TRANSAXLE ASSEMBLY 65. Apply silicone grease to hatched area of transaxle case. 66. Install new case gasket on transaxle case.

67. Install converter housing and tighten 14 bolts to 19-23 Nm (190-230 kg.cm, 14-16 Ib.ft).

68. Install end clutch shaft. Be sure to install the longest spring toward the front as shown.

69. Fit the thrust washer to the return spring at the end clutch side.

45-91

AUTOMATIC TRANSAXLE ASSEMBLY 70. Install the end clutch hub to end clutch.

71. Attach, by petrolatum, thrust bearing #13 to the end clutch hub.

72. Install end clutch assembly.

73. Attach a new O-ring and O-ring to the end clutch cover. Caution 1. Install so that the O-ring is not twisted. 2. Apply a sufficient amount of automatic transmission fluid to the bearing.

45-92

AUTOMATIC TRANSAXLE ASSEMBLY 74. Attach the end cover and fasten it with four bolts. Caution When installing the end cov!tr, be sure the screw hole is correctly aligned. If the end cover is turned (after it is installed) in order to align with the screw hole, the O-ring and/or the O-ring may be twisted as a result.

75. Install O-ring at center of top ot-valve body assembly (brake oil pressure passage). 76. Install valve body assembly to case, fitting detent plate (manual control shaft) pin in slot of manual valve.

77. Replace the O-ring of the solenoid valve connector with a new one.

78. Insert the solenoid valve connector into the case. Be sure that the notched part of tt)e connector faces as shown in the figure.

79. Tighten valve body assembly mounting bolts (10 pieces) to 10-12 Nm (100-120 kg.cm, 7.5-8.5 Ib.ft) A : 18 mm (0.709 in.) long B : 25 mm (0.984 in.) long C : 40 mm (1.575 in.) long

45-93

AUTOMATIC TRANSAXLE ASSEMBLY 80. Install oil filter. Tighten four oil filter mounting bolts to 5-7 Nm (50-70 kg.em, 4-5 Ib.ft).

81. Install five magnets in the five depressions provided on the oil pan. I

.

82. Install new oil pan gasket and oil pan ~y tightening 12 bolts to 10-12 Nm (100-120 kg.em, 7.5-8.5 Ib.ft).

83. Install a new O-ring to the kiekdown servo switch; then press into the case and secure it by using a snap ring.

Snap ring

45-94

AUTOMATIC TRANSAXLE ASSEMBLY 84. Install inhibitor switch and manual lever. Adjust inhibitor switch.

85. Install the pulse generator A and B.

86. After applying automatic transaxle fluid to outside surface of oil pump-side cylindrical portion of torque converter, install torque converter carefully so as not to damage oil seal lip. Make certain that torque converter is in mesh with oil pump drive gear. Measure distance between ring gear end and converter housing end. Torque converter has been properly installed when measurement is about 12 mm (0.47 in.).

45-95

OIL PUMP ASSEMBLY

OIL PUMP ASSEMBLY COMPONENTS

Driven gear Drive gear Housing Seal ring

~

Steel ball

DISASSEMBLY 1. 2. 3. 4. 5.

6.

Remove O-ring from oil pump housing. Remove five· bolts and remove reaction shaft support from housing. Remove oil pump. drive and driven gears from pump housing. Make reassembly alignment marks on drive and driven gear. Remove steel ball from housing.

Remove the snap ring and the oil seal from the oil pump drive gear.

45-96

Oil PUMP ASSEMBLY 7.

Remove two seal rings from reaction shaft support. Seal rings

INSPECTION 1.

Measure the side clearance of the oil pump gear; if the clearance exceeds the standard value, or if an inspection of the surface (of the oil pump housing) that contacts the oil pump gear reveals indications of interference, replace the entire oil pump assembly.

Standard value: 0.03-0.05 mm (0.0012-0020 in.) 2.

Check the surface of the reaction shaft support that contacts the oil pump gear; if there are indications of interference, replace the entire oil pump assembly.

REASSEMBLY 1.

Install the oil seal to the oil pump drive gear.

(

2.

Install the snap ring.

. 45-97

OIL PUMP ASSEMBLY After immersing driv~ and driven gears in automatic transaxle fluid. install them to pump housing. When reusing' gears. install with mating marks properly aligned. 4. Fit a new O-ring into the groove at the inner circumference 'of the drive gear. 5. Install, steel ball in hole as shown in the illustration. 3.

6.

Install two seal rings coated with automatic transaxle fluid to reaction shaft support.

7. 8.

Make sure that oil pump gear turns freely. Install new O-ring in groove provided in circumference of pump housing and apply petrolatum or industrial vaseline to circumference of O-ring. 9. Loosely install reaction shaft support on pump housing. Tighten five bolts fingertight.

10. With reaction shaft support properly positioned on pump housing using special tools (09452-21301. 09452-21401) tighten five bolts to 10-12 Nm (100-120 kg.cm. 7.5-8.5 Ib.ft).

45-98

~~x~~~~ 09452-21301

OIL PUMP ASSEMBLY

OIL SEAL REPLACEMENT 1.

Pry off pump housing oil seal using a screwdriver.

2.

Using special tool (09452-21200) install oil seal to pump housing. Apply thin coat of automatic transaxle fluid to oil seal lip before installation. 09452-21200 Pump housing

45-99

FRONT CLUTCH ASSEMBLY

FRONT CLUTCH ASSEMBLY COMPONENTS

Clutch reaction plate (4)thickness 3.8 mm (.150 in.)

Snap ring-select

Clutch disc (3)

O-ring

45-100

WIRING HARNESS LAYOUT

ENGINE WIRING HARNESS E03-2 E03-3 E04 E05 E06 E07

Engine extension wiring harness (MIT) Engine extension harness (A/T) Headlamp relay (in the relay box) AlCON r81ay (in the relay box) Taillamp relay (in the relay box)

E08

Condenser fan motor relay HIGH (in the relay box) Blower relay Kick down switch (A/T) Inhibitor switch (A/T) Pulse generator (A/T) Radiator fan motor relay (LOW) (in the relay box) Condenser fan motor relav (LOW) Thermo sensor (For U.S.A.)

E09 Ell E12 E13 E14-l E14-2 E15 E16 E17 E19 E20 E22 E24-l E24-2 E24-3 E25

E27 E28 E29-l E29-2 E30 E31-1 E31-2 E34 E35 E36

E38 E40

E41 E42 E43 E44 E45

Sub fusible link \

Radiator fan motor relay HIGH (in the relay box)

Washer Low washer sensor (For CANADA) Front combination lamp (RH) Headlamp (RH)

E03-3

~"" E40

E41~

ti' .'

I!lE4~

E03-2~ fl1"'--·

,.

".

Dedicated fuse

•

,.,.,1

E4 l

lZ1

, E42

_-., ,E13

Horn (RH) Resistor Radiator fan motor

RELAY BOX

Thermo sensor Turn signal (RH) Condenser fan motor Horn (LH) Oil pressure sender Oil pressure switch Power steering switch Alternator (B+) Alternator (S or L) Turn signal (LH) Press switch 2 (AlCon) Headlamp (LH) Front combinatior. lamp (LH) AIT solenoid extension wire Starter motor Compressor Back-up lamp switch

Oil temperature sensor Day time running light (For CANADA)

E01-1 E01-2 EM01 EM02 EM03 EM04 EM05 EI01

EC01-1 EC01-2

Connection with CONTROL harness (MIT) Connection with CONTROL harness (A/T)

EC01-3

Connection with CONTROL harness (AlCON)

Electronic lock-up control unit Electronic lock-up control unit Connection with MAIN harness Connection with MAIN harness Connection with MAIN harness (A/T) Connection with MAIN harness Connection with MAIN harness (D.R.L.) Connection with INSTRUMENT harness