FOREWORD This repair manual has been prepared to provide information covering general service repairs for the 1FZ-F, 1FZ-FE engine equipped in the TOYOTA LAND CRUISER, Applicable modals: FZJ70, 73, 75, 80 series. Please note that the publications below have also been prepared as relevant service manuals for the components and system in this engine. Manual Name Pub. No. © 1FZ-F Engine Emission Control Repair ERMOB6E Manual © 1FZ-FE Engine Emission Control Repair ERMOS6E Manual All information in this manual is based on the latest product in- formation at the time of publication. However, specifications and procedures are subject ta change without notice. TOYOTA MOTOR CORPORATION Please Note! This is not an interactive manual.. Goto Pages need to be selected ©2004 TOYOTA MOTOR CORPORATION All rights reserved, This book may not be repra- duced oF copied, in whole or in part, without the written permission of Toyota Motor Corporation, First Printing: ‘Qet, 19, 1992 01-021019-00. Nineteenth Printing: Apr. 1, 2004 19-040d01-05-3IN-2 INTRODUCTION — HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX +H An INDEX is provided on the first page of each section to guide you to the item to be repaired. To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. GENERAL DESCRIPTION At the beginning of each section, a General Description (Precautions) is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnose the problem and find the cause. PREPARATION Preparation lists the SST (Special Service Tools). recommended tools, equipment, lubricant and ‘SSM (Special Service Materials) which should be prepared before beginning the operation and explains the purpose of each one. REPAIR PROCEDURES Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: No.1 Heat insulator Spring (zriate. 731] @——# Gasket S—— pug [49 (609. 357] Tear Kgirer, TbH) : Spectied torque ‘@ Non-reusable partINTRODUCTION — HOW TO USE THIS MANUAL, isd The procedures are presented in a step—by—step forma © The illustration shows what to do and Where to d © The task heading tells what to do. © The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example: Awl les the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed information. Important specifications and warnings always stand out in bold type. REFERENCES References have been kept to a minimum, However, when they are required you are given the page to refer to. SPECIFICATIONS Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found at the end of each section, for quick reference.at INTRODUCTION — IDENTIFICATION INFORMATION CAUTIONS, NOTICES, HINTS: © CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. © NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired. iv @ HINTS are separated from the text but do not appear in bold. They provide additional information to help you efficiently perform the repair. SI UNIT The UNIT given in this manual are primarily expressed with the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the yard/pound system. Example: Torque: 30 N-m (310 kaf-cm, 22 ftbt) IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block as shown.INTRODUCTION — GENERAL REPAIR INSTRUCTIONS Seal Lock Adhesive IN-5 GENERAL REPAIR INSTRUCTIONS 1. Use fender, seat and floor covers to keep the val clean and prevent damage. 2. During disassembly, keep parts in the appropriate order to facilitate reassembly. 3. Observe the following: (a) Before performing electrical work, disconnect the negative cable from the battery terminal. (0) If it is necessary to disconnect the battery for inspection or repair, always disconnect the cable from the negative (—-) terminal which is grounded to the vehicle body. (c) To prevent damage to the battery terminal post, loosen the terminal nut and raise the cable strai- ght up without twisting or prying it. (4) Clean the battery terminal posts and cable termi- nals with a clean shop rag. Do not scrape them with a file or other abrasive objects. (e) Install the cable terminal to the battery post with the nut loose, and tighten the nut after installa- tion. Do not use a hammer to tap the terminal onto the post. (f) Be sure the cover for the positive (+) terminal is properly in place. 4. Check hose and wiring connectors to make sure that they are secure and correct. 5. Non—reusable parts (2) Always replace cotter pins, gaskets, O—rings and oil seals etc, with new ones. (b) Non—reusable parts are indicated in the compo- nent illustrations by the “®" symbol. 6. Precoated parts Precoated parts are bolts and nuts, etc. that aro coated with a seal lock adhesive at the factory. (a) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive.IN-6 INTRODUCTION — GENERAL REPAIR INSTRUCTIONS Fuse Equal Amperage Rating + @ on a 10. i. 12. (b) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads (c) Precoated parts are indicated in the component illustratiions by the "%” symbol. When necessary. use a sealer on gaskets to prevent leaks. Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. Use of special service tools (SST) and special service materials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where specified and follow the proper work proce- dure, A list of SST and SSM can be found at the back of this manual. When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating. Care must be taken when jacking up and supporting ‘the vehicle. Be sure to lift and support the vehicle at the proper locations. (@) If the vehicle is to be jacked up only at the front ‘or rear end, be sure to block the wheels at the opposite end in order to ensure safety. After the vehicle is jacked up, be sure to support it on stands. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a small job that can be finished quickly. Observe the following precautions to avoid damage to the p arts: {a) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are tou- ched, the IC may be destroyed by static electric- ity.) (b) To disconnect vacuum hoses, pull on the end, not the middle of the hose. To pull apart electrical connectors, pull on the connector itself, not the wires. Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (b) (ec) ()INTRODUCTION — GENERAL REPAIR INSTRUCTIONS. a (2) When steam cleaning an engine, protect the dis- WRONG coRRECT tributor, air filter, and VCV from water. Z (f) Never use an impact wrench to remove or install temperature switches or temperature sensors. (@) When checking continuity at the wire connector, insert the tester probe carefully to prevent termi- t nals from bending. (h) When using a vacuum gauge, never force the snoxee hose onto a connector that is too large. Use a step—down adapter instead. Once the hose has been stretched, it may leak. Example] 13. Tag hoses before disconnecting them: (2) When disconnecting vacuum hoses, use tags to (een identify how they should be reconnected, (b) After completing a job, double check that the @ vacuum hoses are properly connected. A label under the hood shows the proper layout.INTRODUCTION — ABBREVIATIONS USED IN THIS MANUAL. ABBREVIATIONS USED IN THIS MANUAL AAP asv Ar Switching Valve AT ‘Automatic Transmission erbe Betore Top Dead Genter oe CHock Breaker DOHe Double Over Head Gam DP Dash Pot ECU Elactronie Control Unit ESA Electronic Spark Advance x ‘Exhaust (Manifold, Valve) Ee Except rica Fast Idle Cam Breaker FPG | Formed in Ploce Gasket 7 FL Fusible Link 1c 7 Integroated Circuit oe 6 Ignition Ww Intake (Manifold, Valve) 7) Junetion Block io} LeftHand Max. Maximum 7 Min ‘Minin NP Multipurpose. MT ‘Manual Transmission o/s Oversize ‘ovev ‘Outer Vent Control Valve Pov Positive Grankoase Ventilation RH Right Hand ‘ssM Special Service Materials SST Special Service Tools ‘sD Standard Tees Toyota Computer Gontrolied System i Top Dead Center TEMP. Temperatur 1% Throttle Positioner us Undersize vev Vacuum Control Valve vev Vacuum Switching Valve ws with 7 withoutINTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS STANDARD BOLT TORQUE SPECIFICATIONS HOW TO DETERMINE BOLT STRENGTH IN-9 vee el Lae sy tenine | Homa so-| set wna w/ washer bedi aT Grooved rwsnonto or head bolt Ss) Two ie flange bolt Two hexagon bolt anes ves head bott Three fe « wes head bolt aIN-10 INTRODUCTION — STANDARD BOLT TORQUE SPECIFICATIONS SPECIFIED TORQUE FOR STANDARD BOLTS Spas torque Case Pach Tiexagon oad bot Tixagon fongo bat Nem kgf-cm ft-lbf Nem kgf-cm ftlbt e [4 3 ss asinswt | co Bin e | 125 | is 10 8 “ws 10 «| % | 135 | 38 2018 202k 2 | 125 | a a0 as 535030 wu | 1s | 7% 7805s east we | ois |e 1a80 as e Ee 6 1 6588 Sener | 7878 Cine 8 ts | iss 1802 7888 wo | 125 | 32 330 828 7 12 1.25 59 600 43 65 670 48 | ts) oat 930 or 1001405078 te | 1s | ts 1400 401 Pee s | 4 e samme | 8 50 Bini s | 125 | 1 1 te nots wo | 125 | 39 40028 408 7 12 1.25 nM 730 53 80 810 59 ie | ts | 0 4100 a0 125 1,250 99 te) 18 | a0 1780129 = eee ef 4 0s 10S 28 8 | iz | 2 260 19 228021 a} 2 | tas | se 0 ae 58580 a8 2 | 128 | 9 97% 70 108 1.08078 a | 1s) | ta 1,800 108 tes 1.700123 ws | 15 | 230 2300 168 . eee 2 | 125 | 2 30 22 33g et} 1 | 128 | ot 0a e690 50 12 | 128 | 110 4.0080 120 1,280 99 o | 125 | os 2 378? a | 1 | tz | 7 70 81 7% 70 iz | 125 | 128 1308 1401480108 8 1.25 38 390 28 42 430, a wor} 10 | 125 | 7 © G00 58 se 800 12 | 128 | 140 180108 155 1,600,118 e | 1s | 2 0 7480 nt] i | 128 | a7 a0 we e780 2 | 128 | 186 160 116 175 1.800EG-2 ENGINE — ENGINE MECHANICAL ENGINE MECHANICAL DESCRIPTION The 1FZ—FE and 1FZ—F engine is an in—line, 6—cylinder, 4.5 liter DOHC 24 valve engine. 1FZ-FEENGINE — ENGINE MECHANICAL Eee The 1FZ—FE and 1FZ—F engines are an in—line, 6—cylinder engine with the cylinders numbered 1—2~3-4—5—6 from front. The crankshaft is supported by 7 bearings inside the crankcase. These bearings are made of aluminum alloy. The crankshaft is integrated with 12 weights for balance. Oil holes are provided in the crankshaft to supply oil to the connecting rods, bearing, pistons and other components. The firing order is 1—5—3—6—2—4. The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and pent—roof type combustion chambers. The spark plugs are located in the center of the combustion chambers. Exhaust and intake valves are equipped with irregular pitch springs made of special valve spring carbon steel which are capable of following for the full range of engine speeds. The intake camshaft is driven by a timing chain, and a gear on the intake camshaft engages with a gear on the exhaust camshaft to drive it. The cam journal is supported at 7 places between the valve lifters of each cylinder and on the front end of the cylinder head. Lubrication of the cam journals and gears is accomplished by oil being supplied through the oiler port in the center of the camshaft. Valve adjusting shims are located above the valve lifters. Pistons are made of high temperature—resistant aluminum alloy, and a depression is built into the piston head to prevent interference with the valves. Piston pins are the full—floating type, with the pins fastened to neither the piston boss nor the connecting rods. Instead, snap rings are fitted on both ends of the pins, preventing the pins from falling out. The No.1 compression ring is made of stianless steel and the No.2 compression ring is made of cast iron. The oil ring is made of a stainless steel. The outer diameter of each piston ring is slightly larger than the diameter of the piston and the flexibility of the rings allows them to hug the cylinder walls when they are mounted on the piston. No.1 and No.2 compression rings work to prevent gas leakage from the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combustion chambers. The cylinder block is made of cast iron. It has 6 cylinder which are approximately twice the length of the piston stroke. The top of each cylinder is closed off by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders No.1 and No.2 oil pans are bolted onto the bottom of the cylinder block. The No.1 oil pan is an oil reservoir made of combination of aluminum alloy. The No.2 oil pan is an oil reservoir made of combination of pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient oil in the bottom of the pan even when the vehicle is tilted. This dividing plate also prevents the oil from making waves when the vehicle is stopped suddenly and the oil shifts away from the oil pump suction pipe. Plastic region tightening bolts are used for the cylinder head, main bearing cap and connecting rod.e EG-4 ENGINE — ENGINE MECHANICAL PREPARATION SST (SPECIAL SERVICE TOOLS) 9032-00160 ) oH (09165-16100 Spark Plug Wrench (09201-18010 Valve Stem Guide Remover & Replacer (09202-70010 Valve Spring Comareseor ® 2s 08218-58012 2 ‘Grankshaft Pulley Hoolaing Too! on Too ae RT Gan Sa tea (08213-00020) Body With Bolt <— (08213-00030) Henaie (oeai9-ooobo) ai se a TERIOR “ing Goa ever S —_ OSTISTEOGO 01 Son & Bera Rtas Sanka aro al oo Gen38 MOTT OW Fier Wrench DO2R5=001OT Water Pri Oval Tar StENGINE ~ ENGINE MECHANICAL Ee (09236-15010) Beering Stay Valve stem cit seal (09243-00020 ale Adjusting Serew Wranch (08248-66011 (ovzay—o5310) (08248-06020) Valve Clearance Adjust Tool Sot Valve Lifter Prose Valve Litter Stopper (09316-60010 (09316-00010) (03316-00050) (09930-00021 ‘09608-30012 (os608-o4ez0) (useus—vaubo) Transmission & Transfer Bearing Replaces Replacer Pipe epiacer D* ‘Companion Flange Holding Toot Handle Front Hub Outer Bearing Cup Replacer Crankshaft front ot seal Crankehatttront ol seal Crankshaft pulley Crankshaft rear ci! cos! Spark plug tube aasket Spark plug tube gasket i (09631-20031 i Seal "B Remover Gonseting rod bushing ‘09636-20010 Upper Bal Joint Dust Gover Repacer CGrankshoft timing overEG-6 ENGINE — ENGINE MECHANICAL a) 18816-30010 Oil Prossure Switch Socket Knock sencor Eee, SB See SSS (08960-20017 Universal Puller RECOMMENDED TOOLS (08200-00010 Engine Adjust Kit (09258-00020 Hone Plug Sot Plug for the vasuum Aoee, fuel hase ete, EQUIPMENT Battery specific gravity gauge Caliper gauge ‘CO/HC meter Compression gauge Connecting red aligner Cylinder gauge Dial indicator Dye penetrant Engine tune—up tester Heater ‘Magnetic finger Micrometer Piston ring compressor Piston ring expander Plastigage Precision straight edgeENGINE — ENGINE MECHANICAL una Sofa Seslsar vara | Thermometer Valve seat cutter Vernior calipers SSM (SPECIAL SERVICE MATERIALS) Pet (08826-00080 Seal packing or equivalent. Over the space between the 7 finder block and timing ein Timing chain cover (06826-00080 Seal packing or eau ‘Semi—creular plus Oitpan Rear oil sear retainer (08833-00070 Adhesive 1324, Plug tube THREE BOND 1324 or equivalent (06833-00080 Achesive 1244, Bvsv THREE BOND 1344, LOGTITE 242 or equivEG-8 ENGINE — ENGINE MECHANICAL TROUBLESHOOTING You will find the troubles easier using the table well shown below. In this table, each number shows the priority of causes in troubles. Check each part in order. If necessary, replace these parts. Dod == fect ES} see pece ee \ Suspect ea \ Tgition Signs Crewe Temp. Sensor Circuit Throttle Position ‘Sensor Circuit STA Signal Cetwot SV ceut Air Flow Meter Circuit Knock Sensor ‘Oxygen Sensor Cine Coolant Temp. Sensor Circuit Circuit wo) NSW Signal ‘AIC Signal Creu Fuel Pump Cirouit Fuel Pressure |_| Regulator Fue! Lines: Fuel Presse é. Symptom Fa ES Intake Chews [Enaine does not crank B [Sterier suns — engine Goes] {nt erank | 2 5\ho nia combustion [21 3 e No complete combustion |_| 5 2 a | [a0 Engine cranks slowly 2 [Under normal conaition [13 14 z (Cota engine 1 Hot engine 1 Tncorrect fist idle 2 High engine iale speeo 2f4 3 7] se), 3 1 3 7 737 9 fro s + [Low engine idle speed Rough idling 76 Mistire 5 [Hesitation Poor acceleration 2 jBacktire 7 {Mutfer explosion after fro) 5S 7 10 a 14) 13] 18] 18. To} 9 [ii] 12 4" Poor drvability iKeocking n [Soon after starting a 8 4/3 /s {0 ‘after accelerator pedal doprossos /Aftor accelerator pedal released | During AJC operation [When N t0 O shift t Paar fuel econamy [fis } 74] 20 [76 | #5 vie 32) 73 Engine overheat | Engine oversoo! T Excessive oil consumption | Low oil pressure High off pressure ‘Starter keeps running [Battory often discharges L Engine stalt others HINT: When inspecting a wire harness or circuit, the electrical wiring diagrams at the end of repair manual should be roferred to and the ciccuits of related systems also should be checked,EG-9 ENGINE — ENGINE MECHANICAL yo BURL, 4 16 Bunul aaron, 10 12 is 7 a 20ueie9i9 anren 14 16 uojssordwo 9 10 a 7 warshs, wey Butjoo3 paseaiey vaya luons Beig soxeq SUPT Ped 201819)900y waists ¥O3 soangusig 16 8nig >Heds seueig 2609007 ‘oBexe97 uinee, ‘3609099 quejoog ‘2604907 ong ‘Anyeng yong 52 nga 13 8 a 1 18 i 19 1 10 v1 fwoishs ang jong coo Suywado no tinouig Abu Ure 13. =a = [= (e243) a fy Ey rea al kay [eic-54 NaH @neA 91 10kisah ENGINE — ENGINE MECHANICAL See page fa ze [eas cd G1 [cH-10] fec-352] o el Fea ec-138} Connecting Rod Bearing Suspect eree Symptom, Radiator and Radiator Cap Water Pump Vaive Stem Guide Bu: Oli Pump. Crankshaft Bearing Piston Ring Drive Plate Thermostat Drive Belt ECT Sender Fly Wheel Switch Alternator Cylinder Block Engine does not crank ‘Starter runs — engine does} 2 not crank Does not start No initial combustion No complete combustion 7 [Engine cranks slowly 3] 4 ‘Under normal condition W (Cold engine Difficult to start Hot engine Incorrect first idle High engine idle speed ‘Low engine idle speed Poor idling Rough idling 20 | 12 Misfire Hesitation | Poor acceleration Backfire Muffter explosion (after fire) Poor drivability ‘Surging Knocking 2 ole ‘Soon aiter starting ‘Alter accelerator pedal depressed ‘After accelerator pedal released Engine stall During AIC operation (When N to D shift Poor fual economy 10 JEngine overheat 6 10 Ti 3/4 3 Engine overcoo! 2 3 Excessive oll consumption 2 a[4 Others Low oil pressure 2/3 [4 High ofl pressure 1 2 Starter keeps running Battery often discharges 1ENGINE — ENGINE MECHANICAL isabel TUNE-—UP ENGINE COOLANT INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The coolant level should be between the “LOW” and "FULL" lines at low temperature. If low, check for leaks and add coolant up to the ame “FULL” line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not EK remove it while the engine and radiator are still hot, as fluid and steam can be blown out under pressure, a (b) There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the coolant should be free from oil If excessively dirty, replace the coolant. (c) Reinstall the radiator cap. ENGINE OIL INSPECTION Recommended Viscosity (SAE) | 1. CHECK OIL QUALITY i Check the oil for deterioration, entry of water, disco- | pes 1 loring or thinning. oI il If oil quality is poor, replace it. cr Oil grade: reer Manor ane ne net ox Sac Inersldaalsg ov teeter sco If it is impossible to got SG or better you may use SF grade Recommended viscosity: Refer to illustration i 2. CHECK ENGINE OIL LEVEL The oil level should be between the “L” and "F” marks on the dipstick. If low, check for leakage and add oil up to the *F” mark.EG-12 SS TY roan ENGINE — ENGINE MECHANICAL BATTERY INSPECTION 1. CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL (a) Check the electrolyte quantity of each cell If insufficient, refill with distilled (or purified) water. {b) Check the specific gravity of each cell Standard specitic gravity at 20°C (68°F): 1.27 — 1.28 105D31L 1.25 — 1.27 others If not within specifications, charge the battery. 2. CHECK BATTERY TERMINALS, FUSIBLE LINKS AND FUSES (a) Check that the battery terminals are not loose or corroded. (b) Check the fusible links and fuses for continuity. AIR FILTER INSPECTION AND CLEANING 1. REMOVE AIR FILTER Remove the air cleaner cap and air filter. 2. INSPECT AND CLEAN AIR FILTER ‘A. (Paper type) (a) Visually check that the air filter is not excessively damaged or oily. If necessary, replace the air filter. (o) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the air filter. B. (Fabric type) (a) Visually check that the element is not excessively dirty damaged or oily. (b) Blow dirt off in the element with compressed air from the inside.EG-13 ENGINE — ENGINE MECHANICAL (c) Submerge the element in the water and agitate it up and down ten or more times. (d) Repeat rinsing in clean water until rise water is clear. (e) Remove excess water by shaking the element or blo- wing with compressed air. NOTICE: Do not beat or drop filter element. (f) Wipe off dust on the air cleaner case interior. 3. REINSTALL AIR FILTER HIGH— TENSION CORDS INSPECTION (See IG section) Moximum resistance: 25 kQ per cord SPARK PLUGS INSPECTION (See IG section) Recommended spark plug: ND K16R—U NGK — BKR5EYA Correct electrode gap: 0.8 mm (0.031 in.)EG-14 ENGINE — ENGINE MECHANICAL | CORRECT WRONG ¥ io Clearance| rove. Water Purp Alternator Idler Pulley caithott 2 — e——~ SSTA A SSTA a mee Lock Bolt ALTERNATOR DRIVE BELT INSPECTION (See CH section) INSPECT DRIVE BELTS (a) Visually check the drive belt for cracks, ciliness or wear. Check that the belt does not touch the bottom of the pulley groove. If necessary, replace the drive belts as a set. Drive belt deflection (w/ 98N (10kaf, 22Ibf)) New belt 11-15 mm (0.43—0.59 in.) Used belt 15~20 mm (0.59-0.79 in.) (b) (Reference) Using SST, measure the belt tension. SST 95506-00020 Drive belt tension(w/ SST): New belt (33-57 kof Used belt 15—35 kgf If the belt tension is not as specified, adjust it. HINT: © "New belt” refers to a belt which has been used less than 6 minutes on a running engine. * "Used belt” refers to a belt which has been used on a running engine for 5 minutes or more. ‘© After installing @ new belt, run the engine for about 5 miutes and recheck the belt tension.ENGINE — ENGINE MECHANICAL Ee te VALVE CLEARANCE INSPECTION AND ~ ADJUSTMENT HINT: Inspect and adjust the valve clearance when the engine is cold. = 1. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. 2, DISCONNECT HIGH—TENSION CORDS FROM SPARK PLUGS {a) Remove the two mounting bolts of the No.1 and No.2 cord clamps. {b) Disconnect the high ~ tension cords at the rubber boot. Do Not pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 3. (1FZ—FE) REMOVE THROTTLE BODY {a) Disconnect the throttle position sensor connector. {b) Disconnect the ISC valve connector.(e) (a) (e) @ (9) (hy (a) ENGINE — ENGINE MECHANICAL Disconnect the three vacuum hoses. Disconnect the EVAP hose. Disconnect the water hose from the No.2 water by— pass pipe. Remove the four bolts, and disconnect the throttle body from the air intake chamber. Remove the throttle body gasket. Disconnect the No.1 water by—pass hose from the throttle body, and remove the throttle body. REMOVE CYLINDER HEAD COVER Remove the 13 bolts, cylinder head cover and gasket. SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley, and align its groove with the timing mark “0” of the timing chain cover.£G-17 ENGINE — ENGINE MECHANICAL (b) fa) (b) (c) Check that the timing marks (one and two dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°) and align the marks as above. le INSPECT VALVE CLEARANCE Check only the valves indicated. * Using a thickness gauge, measure the clearance between the valve lifter and camshaft. © Record the out — of — specification valve clear- ance measurements. They will be used later to determine the required replacement adjusting shim, Valve clearance (Cold): Intake 0.15 — 0.25 mm (0.006 — 0.010 in.) st 0.25 — 0.35 mm (0.010 ~ 0.014 in.) Exhi Turn the crankshaft pulley one revolution (360°) and align the its groove with timing mark “0” of the timing chain cover. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a))ENGINE — ENGINE MECHANICAL 7 A fa) (b) ADJUST VALVE CLEARANCE except for Rear valves of No.6 cylinder Remove the adjusting shim. * Turn the crankshaft to position the cam lobe of the camshaft on the the adjusting valve upward. * Position the notch of the valve lifter toward the spark plug side. * Using SST (A), press down the valve lifter and place SST (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-66011 (09248-05310, 09248-06020) HINT: © Apply SST (B) at slight angle on the side marked with "11", at the position shown in the illustra- tion * When SST (8) is inserted too deeply, it will get pinched by the shim. To prevent it from being stuck, insert it shallowly from the outside of the cylinder head, at a slight angle. © Remove the adjusting shim with a small screw- driver and magnetic finger. Determine the replacement adjusting shim size by following the Formula or Charts: * Using a micrometer, measure the thickness of the removed shim. Calculate the thickness of a new shim so that the valve cllearance comes within specified value. Thickness of removed shim Measured valve clearance Thickness of new shim . N=T + (A ~ 0.20 mm (0.008 in.)) Exhaust: N=T + (A = 0.30 mm (0.012 in.) *® = Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0,05 mm (0.0020 in), from 2,50 mm (0.0984 in.) to 3.30 mm (0.1299 in.)ENGINE — ENGINE MECHANICAL (c) (a) fa) (b) (ce) (d) (e) (f) (9) th) EG-19 Install a new adjusting shim. * Place a new adjusting shim on the valve lifter. * Using SST (A), press down the valve lifter and remove SST {B). SST 09248-66011 (09248-05310, 09248-06020) Recheck the valve clearance. Rear valves of No.6 cylinder Remove the distributor. (See IG section) Remove the camshafts. (See step 39 on|pages EG— 49] to[5 1} Remove the adjusting shim with a small screwdriver. Determine the replacement adjusting shim size by following the Formula or Charts: * Using a micrometer, measure the thickness of the removed shim. © Calculate the thickness of a new shim so that the valve cllearance comes within specified value, Thickness of removed shim Measured valve clearance Thickness of new shim N=T + (A — 0.20 mm (0.008 in.) Exhaust: N=T + (A — 0.30 mm (0.012 in.) * Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0,05 mm (0.0020 in.), from 2.50 mm (0.0984 in.) to 3.30 mm (0.1299 in.). Place a new adjusting shim on the valve lifters, Install the camshafts. (See step 7 on [pages EG—73]t. Recheck the valve clearance. Install the distributor, (See IG section)ENGINE — ENGINE MECHANICAL EG-20 200) a4p Uo poruudus s1o}ou TMs ZL "ON © MAHA UnYs UL pene same aT “WW uy ssauyoIy au anEy SUIS MON “LNIH ZOL LO) ww COS'e aM eseIdoy ("4 EZ LO‘O) WU [er] — ear = eva aro = enirorooez] rosa sore) deon aie oof eee Sere (ezro coe] 21 [(ezi Vo) OsBz |B {4} 0L0'0 — 900'0) wu gz"0 — S1°0 0 Woszrorosee| 91 [oro cose] (9109) eoweseaIo eniea ofe.U) esse = wo ee (oazi'o ooze] st [lesororosce] 9 Saw (owzto) ost’ | vl |(€901°0) COL] G ‘eeetoroove| et Teroror ease] + treet orosoe] 21 [ttororo0s'¢| {| error aoo't| ti |Wwooro) oss] _z ane oa {1g9tt-o) oge'z! OL | (~Réo°o) OOS'z/ OL ‘wero ~ gael oso = Teo swe |aas|_ Se See eon | (ara mec oe peecanean | SUES See RIF ARE ESE SABRE BSCE RERERE eee E EER EE TERER) aan lela BISWAS GIES EE SLs Blt lolol Alb eel Sele SilaleeiLleTEE REEL Sere on (ayequy) yt iP£G-21 ENGINE — ENGINE MECHANICAL Eee Bi “a0e} 04) uo paruudws si0r0us dda otclentecialataat cb nur uy SSOUNOUNR OUP OABY SURE MON “LNIM Or oh imu boare bin eneydols ul 6210 0) il T= aS Oe Orv’ s1 aoues29/9 paunseous aun pus “paljersul a eee 81 WHYS (UI ZOE LO) WHI OOB'Z SUL TEAS ae Tens ew O we (66210) OOE'E| ct | (zt 10) os8'e (M1 bLO'O — 010°0) uH gE"0 — Gz°0 Tego wore wo — Teor acto) 0gz°e| 91 [torr 0) Oz sipjog) eouese0p9 ean ssneuxa ooo were a (sero) oz | et | eaor or Osz Tezro) oove| et [levoro ose Wozro) osoe| zi [trzoro) 06s eed eee e z g (overo) OSbe| pi |eaoro core! v & z t (eto) 0008 | It | {oor Ol OSS z Seas ea (t9tto) os6z] OL [{PB60'O) 00S" ive = sieod oo — TO, ON a "ON sae SsouVML J iyg] SSPE | wus 7 asso HeRH LEO Tee (Cup uw Seay ou TS MON ieee = wba ea =e eatefetereefotatstapstetetsretepsts|epplyre Heat ene Sows ET iss 5/8) 8/8] |8)3)8|8 18) 3) 8|a|s|8|8|2 3)3|2 se EI 5/33 3] 3(8 |e Te IE EIS |e eee IEE eine pnt, elelelele|etele/ele|elelelelejelelealelelele le le Pe lelp le le eieie ele ele ejelee|ele (ele e(e[2|218|8] corm Bae els 5 als |e is[zlela 3 {eile [8 82/2 (88 iS ielz sis lela 2 [3 S15 (812) Ee SUE |e EB Uz/el| ee en (asneyxa| 1OnDe|9g WIYS BunsnipyEG.22 8 tb) (a) (b) (c f (9) {a) ) (d) () ENGINE — ENGINE MECHANICAL REINSTALL CYLINDER HEAD COVER Install the gasket to the cylinder head cover. Install the cylinder head cover with the 13 bolts. (1FZ—FE) INSTALL THROTTLE BODY Connect the No.1 water by—pass hose to the throttle body. Install a new gasket and throttle body with the four bolts. Torque: 21 N-m (210 kgf-cm, 15 ft-Jbt) Connect the water hose to the No.2 water by—pass pipe. Connect the EVAP hose. Connect the three vacuum hoses. Connect the ISC valve connector. Connect the throttle position sensor connector.ENGINE — ENGINE MECHANICAL Ge 10, RECONNECT HIGH—TENSION CORDS TO SPARK PLUGS (a) Connect the high—tension cords. (b) Install the No.1 and No.2 cord clamps with the two. bolts. “EG 11, REINSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the four bolts.Eo-24 ENGINE — ENGINE MECHANICAL IGNITION TIMING INSPECTION AND ADJUSTMENT 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER AND TIMING LIGHT OLC) A (1FZ—FE) ragionste Connect the test probe of a tachometer to terminal 1G @ of the check connector. Using SST,connect terminals TE1 and E11 of the check connector SST 09843-18020 B. (IFZ—F) Remove the cap and connect the test probe of a tester to the service connector from the igniter. NOTICE: * NEVER allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. * As some tachometer: are net campatibie with thie ignition system, we recommend that you contiem ‘the compatibility of your unit befare use. 3. INSPECT AND ADJUST IGNITION TIMING With the engine idling as specified, use a timing fight to check the timing. Ignition timing: 3° BTDC @idle (w/ Terminals TE1 and £1 connected for 1FZ—FE)EG-25 ENGINE — ENGINE MECHANICAL C RPM conse Tachometer as If necessary, loosen the distributor bolt and turn the distributor to align the marks. Recheck the timing alter tightening the distributor bolt. Torque: 21 N-m (210 kgf-cm, 15 ft-lbf) (1FZ—FE) IDLE SPEED INSPECTION HINT: Initial conditions (See step 1 on[page EG— 33) Idle speed: 650 + 50 rpm (1FZ—F) IDLE SPEED INSPECTION AND ADJUSTMENT 1. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 2. CONNECT TACHOMETER 3. INSPECT IDLE SPEED Idle speed: 600 + 50 rpm If not as specified, adjust according to the following procedure: CAUTION: . Always use @ CO meter when adjusting the idle mixture. It is not necessary to adjust with the idie mixture adjusting screw in most vehicles if they are in good condition. + 14.860 meter is not avaliable and it is absolutely necessary to adjust with the idle mixture adjusting Eyre mt stern mand Ge oe EE 2:Q ' Eze ENGINE — ENGINE MECHANICAL A. METHOD WITH CO METER 1. VISUALLY INSPECT CARBURETOR (a) Check for loose screws or a loose mounting to the manifold, (b) Check for wear in the linkage, missing snap rings or excessive looseness in the throttle shaft. Correct any problems found, 2. INITIAL CONDITIONS (a) Air cleaner installed (b) Normal operating coolant temperature (c) Choke fully open (d) All accessories switched off (e) All vacuum lines connected {f) Ignition timing set correctly (a) Transmission in the "N” range (h) Fuel level should be about even with the correct level in the sight glass (i) CO meter operates normally Fuel Level 3. ADJUST IDLE SPEED AND IDLE MIXTURE HINT: Use SST if necessary. SST 09243-00020 (a) Start the engine. aes ol {b) Using a CO meter to measure the CO concentration in the exhaust, turn the idle speed and idle mixture adjusting screws to obtain the specified concentra- tion value at idle speed. Idle speed: wae Soee 600 rom Adjusting ScrewENGINE — ENGINE MECHANICAL oe 2,500 rpm Ne RPM Tachometer scons eumnae 180 Seconds CO Meter Sr 4, (a) (b) (c) INSPECT CO CONCENTRATION Check that the CO meter is properly calibrated. Race the engine at 2,500 rpm for approx. 180 sec- onds before measuring concentration. Insert co Meter testing probe at least 40 cm (1.3 ft) into the tailpipe, during idling. Immediately check the co concentration at Idle. Idle CO concentration: 15 40.5% © If the CO concentration is within specification this adjustment is complete. © If the CO concentration is not within specifica- tion, turn the idle mixture adjusting screw to obtain the specified concentration value. © If the CO concentration cannot be corrected by adjusting the idle mixture, see table below for other possible causes.£G-28 ENGINE — ENGINE MECHANICAL TROUBLESHOOTING co HC Problems Causes Normal High Rough idle Faulty ignition: © Incorrect timing + Fouled, shorted or improperly gapped plugs ‘+ Open or crossed ignition wires * Cracked distributor cap Leaky exhaust valves Leaky cylinder High Rough idle (Fluctuating HC reading) Vacuum leak: * Vacuum hose: © Intake manifold © PCV line * Carburetor base High High Rough idle (Black smoke from exhaust! Restricted air filter . Plugged PCV valve Faulty carburetion: * Faulty choke action + Incorrect float setting + Leaking needle or seat * Leaking power valveEG-29 ENGINE — ENGINE MECHANICAL Idle Mixture Adjusting we Idle Spood Adjusting Screw B. ALTERNATIVE METHOD To be used only if CO moter is not available. 1. VISUALLY INSPECT CARBURETOR (2) Check for loose screws or loose a mounting to the manifold. (b) Check for wear in the linkage, missing snap rings or excessive looseness in the throttle shaft. Correct any problems found. 2. INITIAL CONDITIONS (2) Air cleaner installed (b) Normal operating coolant temperature () Choke fully open {d) All accessories switched off {e) All vacuum lines connected {f) Ignition timing set correctly (g) Transmission in the “N” range 3. ADJUST IDLE SPEED AND IDLE MIXTURE HINT: Use SST if necessary. SST 09243-00020 (2) Start the engine. {b) Set to the maximum speed by turning the idle mixture adjusting screw. (c) Set to the idle mixture speed by turning the idle speed adjusting screw. Idle mixture speed: 650 rpm (a) Before moving to the next step continue adjustments {b) and (¢) until the maximum speed will not rise any further no matter how much the idle mixture adjusting screw is adjusted, {e) Set to the idle speed by screwing in the idle mixture adjusting screw. Idle speed: 600 rpm This is Lean Drop Method for setting idle speed and mixture.EG-30 ENGINE — ENGINE MECHANICAL raise ee Adjusting Screw (1FZ—F) FAST IDLE SPEED INSPECTION AND ADJUSTMENT 1. WARM UP AND STOP ENGINE 2. CONNECT TACHOMETER TO ENGINE. 3. CUT OPERATION OF FAST IDLE CAM BREAKER (FICB) SYSTEM Disconnect the vacuum hoses from the FICB and CB. and plug the hose ends. This shuts off the FICB and CB systems. 4. SET FAST IDLE CAM Lightly race the engine and release the throttle, and check that the fast idle cam is set at the 4th step. 5. INSPECT AND ADJUST FAST IDLE SPEED (a) Check the fast idle speed. Fast idle speed: G.c.c. 800 — 1,000 rpm Others 1,100 — 1,300 rpm If the fast idle speed is not as specified, adjust the fast idle speed by turning the fast idle adjusting screw. Fast idle speed: Gl 900 rpm Others 1,200 rpm (b) Lightly race the engine and release the throttle, and repeat steps 4 and 5. 6. RECONNECT VACUUM HOSES TO FICB AND CBEG-31 ENGINE — ENGINE MECHANICAL j on DP Adjusting Screw (1FZ—F) DASH POT (DP) INSPECTION AND ADJUSTMENT 1. WARM UP AND STOP ENGINE 2. CONNECT TACHOMETER TO ENGINE 3. START ENGINE 4. INSPECT AND ADJUST DASH POT (DP) SETTING SPEED (a) Disconnect the vacuum hose from the DP and plug the hose end. (b) Race the engine to 2,500 rpm for a few seconds, release the throttle and check the DP setting speed Dash pot setting speed: 1,400 — 1,600 rpm If the DP setting speed is not as specified, adjust the setting speed by turning the DP adjusting screw. Dash pot setting speed: 1,500 rpm (c}_ Race the engine to 2,500 rpm for a few seconds, (d) release the throttle and recheck the DP setting speed. Reconnect the vacuum hose to the DP, xeEG-32 ENGINE — ENGINE MECHANICAL TP Adjusting Scrow aes (1FZ—F) THROTTLE POSTIONER (TP) SETTING SPEED INSPECTION AND ADJUSTMENT 1. WARM UP AND STOP ENGINE 2. CONNECT TACHOMETER TO ENGINE 3. START ENGINE 4. INSPECT AND ADJUST THROTTLE POSITIONER (TP) SETTING SPEED (@) Disconnect the vacuum hoses from the gas filter and VSV. (b) Connect the vacuum hose which you have discon- nected from the VSV onto the gas filter. () Check the TP setting speed, TP setting sp 1,150 — 1,250 rpm If the TP setting speed is not as specified, adjust the setting speed by turning the TP adjusting screw. TP setting spee 1.200 rpm (d) Lightly race the engine and release the throttle, and recheck the TP setting speed. (e) Reconnect the vacuum hoses to the proper locations.EG-33 ENGINE ~ ENGINE MECHANICAL 2,500 rpm RPM Tachometer coona7 ewoae 180 Seconds IDLE CO/HC CHECK (1FZ—FE) fa) (b) (e) (a) le) (f) (9) (h) @ HINT: This check is used only to determine whether or not the idle CO/HC complies with regulations. INITIAL CONDITIONS Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected All accessories switched OFF All vacuum lines properly connected HINT: All vacuum hoses for EGR systems, ete. should be properly connected. EFI system wiring connectors fully plugged Ignition timing set correctly Transmission in neutral position Tachometer and CO/HC meter calibrated by hand START ENGINE RACE ENGINE AT 2,500 RPM FOR APPROX. 180 SECONDS INSERT CO/HC METER TESTING PROBE INTO TAILPIPE AT LEAST 40 cm (1.3 ft) DURING IDLING IMMEDIATTELY CHECK GO/HC CONCENTRATION AT IDLE HINT: When performing the test, follow the meas- urement order prescribed by the applicable local reg- ulations. 7 as xLan ENGINE ~ ENGINE MECHANICAL Troubleshooting If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below. (a) Check oxygen sensor operation Bee page FG—290) (b) See the table below for possible causes, and then inspect and correct the applicable causes if neces- sary. He co Problome Causes High Normal | Rough idle 1. Faulty ignitions: © Incorrect timing ‘+ Fouled, shorted or improperly gapped plugs © Open or crossed high-tension cords = Cracked distributor cap 2. Incorrect valve clearance } 8. Leaky EGR valve | 4, Leaky intake and exhaust valves i 5._Lesky cylinder High Low Rough idle 1. Vacuum leaks: | (Fluctuating HE reading! PCV hose EGR valve Intake manifold ‘Air intake chamber Throttle body ISC valve Brake booster line 2. Lean mixture causing misfire High High Rough ide 1. Restiicted air fiter (Black smoke from exhaust) | 9 . Faulty EFI systems: ‘Faulty pressure regulator Clogged fue! return tine Defective water temp. sensor Faulty ECU Faulty injoctor Faulty throttle position sensor Faulty air flow metENGINE ~ ENGINE MECHANICAL Lica COMPRESSION CHECK HINT: — If there is lack of power, excessive oil co! sumption or poor fuel economy, measure the com- pression pressure. 1, WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature "EG 2. DISCONNECT DISTRIBUTOR CONNECTOR — 3. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. 4, DISCONNECT HIGH—TENSION CORDS FROM SPARK PLUGS {a} Remove the two mounting bolts of the No.1 and No.2 cord clamps. {b) Disconnect the high — tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. 5. REMOVE SPARK PLUGS Using SST, remove the spark plug. SST 09155-16100£G-36 ENGINE — ENGINE MECHANICAL <7 Compression Gauge 6. fa) (b) (ec) (d) (e) CHECK CYLINDER COMPRESSION PRESSURE Insert a compression gauge into the spark plug hole. Fully open the throttle, While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine speed of 250 rpm or more. Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short @ time as possible. Compression pressure: 1,176 kPa (12.0 kaf/em?, 171 psi) or more 1FZ—FE 900 kPa (9.2 kat/em?, 131 psi) or more 1FZ—F (Low octane) 1.030 kPa (10.5 kaf/em’, 149 psi) or more 1FZ—F (Others) Minimum pressure: 883 kPa (9.0 kgf/em*, 128 psi) 1FZ—FE 785 kPa (8.0 kgf/cm*, 114 psi) 1FZ—F Difference between each cylinder: 98 kPa (1.0 kgf/cm’, 14 psi) or less If the cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylin- der through the spark plug hole and repeat steps (a) through (c) for cylinders with low compression. © If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damage. © If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket, INSTALL SPARK PLUGS Using SST, install the spark plug. SST 09155-16100 Torque: 20 N-m (200 kaf-cm, 14 ftbf)ENGINE — ENGINE MECHANICAL Leeda 8. RECONNECT HIGH—TENSION CORDS TO SPARK PLUGS (a) Reconnect the high—tension cords to the spark plugs. (b) Install the No.1 and No.2 cord clamps with the two bolts. 9. INSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the four bolts. 10. CONNECT DISTRIBUTOR CONNECTORrere ENGINE — ENGINE MECHANICAL CYLINDER HEAD (1FZ—FE) i COMPONENTS Only for Europe Only for Europe EGR Pipe Z No.3 Cylinder Satara ao | Cover and Modulator ° 7 No.2 Cylinder a a Air Pipe He Cover . e _ eGasket a No.2 Heat Insulator Ta S| No.1 Heat ae bee” = AS Reed Valve Insulate 7206 se 21 210, 78) * EQS No.2 Exhayst Manifold : @. #Gasket SE, #Gasket No.1 Exhaust Manifold 1 Nearer Inter 8 s “ Trot Bony No.2 Engne Water By-Pass “2° Emission eo-Ring—2, Control Woter By-Pass-— Eon Valve Set Pipe a Engine Wire No.1 Water Assembly e0.Ring A, BvPareHowe § ‘Gasket U 21 (reel 18) Gasket nao Weler in Talento Hinge By-Pass Pipe ee Bracket Grom 7 ee Pi | so Fuel Return Pipe “@Gasket O-Ring t 1 water Outlet | istector \ 43 (440, a] Insulator |_Fuel Return Hose Drive Belk Generator . ew \ ar ° Oit Dipstick t oo Filter Se F came ya selene 04 Nem ikgf-om, (tibfi] : Specified torque Ring ee ‘@ Non-reusable part i Dipstick © end Guide Fuel inlet "——— HoseENGINE — ENGINE MECHANICAL bites PCV Valve Cylinder Head Cover 3 ——Gasket S—+ Spark Plug g— Adjusting Shim Tube Gasket @ Valve Lifter ‘Spark Plug 8-—Keeper Camshaft Spring Retainer Boaring Cap Valve Spring Oil Seal Spring Seat Valve Guide Bushing Valve ‘Camshaft Gear Spring ‘st 39 (400, 29) 2nd Turn 90°" 3rd Turn 90° Cylinder Head Water Temp. Sensor Water Temp. Cut Switch Water Temp. Sender Gauge Cylinder Head Gasket Tem (kgfem, (1BH} : Specified torque % Non-reusable part % Precoated part eeEG-40 ENGINE — ENGINE MECHANICAL CYLINDER HEAD REMOVAL (See Components for Removal and Installation) (a) (b) {ce} REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. REMOVE DISTRIBUTOR Remove the two mounting bolts of the No.1 and No.2 cord clamps. Disconnect the high — tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. Remove the hold—down bolt and distributor.ENGINE — ENGINE MECHANICAL 3. fa) (b) () (d) fe) co) (a) () (ec) EG-41 REMOVE ALTERNATOR Loosen the lock bolt, pivot bolt and adjusting bolt, and remove the drive belts. Disconnect the alternator connector. Remove the nut, and disconnect the alternator wire. Disconnect the wire harness from the clip. Remove the lock bolt, bolt, nut and drive belt adjus- ting bar. Remove the pivot bolt and alternator. REMOVE ALTERNATOR BRACKET Remove the two bolts and alternator bracket. REMOVE WATER OUTLET Disconnect the radiator inlet hose. Disconnect the No.3 water by—pass hose. Remove the two nuts, water outlet and gasket.EG-42 ENGINE — ENGINE MECHANICAL 6. (a) (b) (c) (d) (2) ) (9) (bh) fa) {b) (e) REMOVE THROTTLE BODY Disconnect the throttle position sensor connector. Disconnect the ISC valve connector. Disconnect the three vacuum hoses. Disconnect the EVAP hose. Disconnect the water hose from the No.2 water by— pass pipe, Remove the four bolts, and disconnect the throttle body from the air intake chamber. Remove the throttle body gasket. Disconnect the No.1 water by—pass hose from the throttle body, and remove the throttle body. REMOVE NO.2 WATER BY—PASS PIPE WITH HOSES Disconnect the two vacuum hoses from the PAIR reed valve and No.2 emission control valve set. Disconnect the water hose from the timing chain cover. Remove the three bolts and No.2 water by —pass pipe with hoses.EG-43 ENGINE — ENGINE MECHANICAL 8. fa) (b) (ec) (d) (a) (b) (c) 10. 1. DISCONNECT CONNECTOR FOR EMISSION CONTROL VALVE SET ASSEMBLY (Europe) REMOVE EGR VALVE AND VACUUM MODULATOR Disconnect three vacuum hoses from the EGR valve. Loosen the EGR pipe union nut. Remove the two nuts holding the EGR valve and air intake chamber. Using vise pliers, remove the two stud bolts, EGR valve and vacuum modulator assembly and gasket. REMOVE BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER REMOVE OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION Remove the two mounting bolts. Pull out the dipstick together with dipstick guide, Remove the Oring from the dipstick guide,ENGINE — ENGINE MECHANICAL 12, REMOVE AIR INTAKE CHAMBER (a) Disconnect the following hoses: (1) Two vacuum hoses from gas filter (2) Vacuum hose from fuel pressure regulator (3) Two vacuum hoses from BVSV (4) Brake booster hose from brake booster union (5) EVAP hose from 3—way {b) Remove the four bolts, six nuts, air intake chamber and two gaskets. (c) Disconnect the air hose. (d) Disconnect the vacuum hose (e) Remove the four bolts and emission control valve set assembly from the air intake chamber. 13, REMOVE FUEL RETURN PIPE {a) Disconnect the fuel hose from the fuel pressure reg- ulator. {b) Remove the two bolts and fuel return pipe. 14, REMOVE NO.1 WATER BY-PASS HOSE 15. REMOVE NO.1 FUEL PIPE Remove the two union bolts, bolt, four gaskets and No.1 fuel pipe. 16. DISCONNECT FUEL INLET HOSE Remove the union bolt and two gaskets and discon- nect the fuel inlet hose from the fuel filter.EG-45 ENGINE — ENGINE MECHANICAL (a) (b) (e) (d) (e) (a) (b) (c) (a) (e) 17, 18, 19. REMOVE DELIVERY PIPE AND INJECTORS Disconnect the six injector connectors. Remove the three bolts and delivery pipe together with the six injectors. NOTICE: Be careful not to drop the injectors when removing the delivery pipe. Remove the six insulators and three spacers from the intake manifold. Pull out the six injectors from the delivery pipe. Remove the O-ring and grommet from each injector. DISCONNECT ENGINE WIRE Disconnect the following connectors: (1) Water temp. sender gauge connector (2) Water temp. cut switch connector (3) Water temp. sensor connector (4) Two knock sensor connectors (8) Oxygen sensor connector (with clamps) {6) Four connectors from transmission (7) Starter connector {8) Oil level sensor connector Remove the bolt and disconnect the engine wire from the intake manifold. Remove the two bolts and disconnect the engine wire from the cylinder block. Disconnect the engine wire clamp. Remove the three bolts and disconnect the engine wire from the cylinder head and intake manifold. REMOVE HEATER PIPE Remove the two bolts, two nuts, heater pipe and gasket.ENGINE — ENGINE MECHANICAL 20. (Europe) REMOVE AIR PIPE Remove the two bolts, six nuts, air pipe and three gaskets. 21. (Europe) REMOVE AS REED VALVE Remove the two bolts and AS reed valve. 22. REMOVE NO.1 AND NO.2 EXHAUST MANIFOLDS (a) Remove the six bolts, No.1 heat insulator and No.2 heat insulator. {b) Remove the 13 nuts, No.1 exhaust manifold, No.2 exhaust manifold and two gaskets. 23, REMOVE NO.1 ENGINE HANGER Remove the two bolts and No.1 engine hanger. Te WweENGINE — ENGINE MECHANICAL (a) (b) fa) 24. 25. 26. 27. 28. £G-47 REMOVE NO.2 ENGINE HANGER Remove the two bolts and No.2 engine hanger. REMOVE WATER BY-PASS OUTLET AND PIPE Remove the two bolts and water by—pass outlet and pipe. Remove the three O-rings from the water by—pass outlet and pipe. REMOVE CYLINDER HEAD COVER Remove the 13 bolts, cylinder head cover and gasket. REMOVE SPARK PLUGS Using SST, remove the spark plug. SST 09155~ 16100 SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley and align its groove with the “0” mark on the timing chain cover.EG-48 ENGINE — ENGINE MECHANICAL AS ‘One Dot Mark \ {b) Check that the timing marks (one and two dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°) and align the marks as above. 29. REMOVE CHAIN TENSIONER Remove the two nuts, chain tensioner and gasket. 30. REMOVE CAMSHAFT TIMING GEAR (a) Remove the semi—circular plug. (b) Place the matchmarks on the camshaft timing gear and timing chain. {c) Hold the intake camshaft with a wrench, remove the bolt and distributor gear. (d) Remove the camshaft timing gear and chain from the intake camshaft and leave on the slipper and damper.EG-49 ENGINE — ENGINE MECHANICAL 31. Main Gear (e) (d) (e) REMOVE CAMSHAFTS. NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Remove exhaust camshaft Bring the service bolt hole of the driven sub—gear upward by turning the hexagon wrench head portion of the intake camshaft with a wrench. Secure the exhaust camshaft sub—gear to the driven gear with a service bolt. Recommended service bolt: Thread diameter 6 mm Thread pitch 1.0 mm Bolt length 16 — 20 mm (0.63 ~ 0.79 in.) HINT: When removing the camshaft, make sure that the torsional spring force of the sub—gear has been eliminated by the above operation Set the timing mark (two dot marks) of the camshaft driven gear at approx. 35° angle by turning the hex- agon wrench head portion of the intake camshaft with a wrench. Lightly push the camshaft towards the rear without applying excessive force. Loosen and remove the No.1 bearing cap bolts, al- ternately loosening the left and right bolts uniformly.EG-50 ENGINE — ENGINE MECHANICAL (f) (9) (h) 0) (a) Loosen and remove the No.2, No.3, No.5 and No.7 bearing cap bolts, alternately loosening the left and right bolts uniformly in several passes, in the se- quence shown. NOTICI Do not remove the No.4 and No.6 bearing cap bolts at this stage. Remove the four bearing caps. Alternately and uniformly loosen and remove the No.4 and No.6 bearing cap bolts. HINT: * As the four No.4 and No.6 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level, * Ifthe camshaft is not being lifted out straight and level. retighten the four No.4 and No.6 bearing cap bolts, Then reverse the order of above steps from (g) to (a) and repeat steps from (a) to (f) once :: Do not pry on or attempt to force the cam- shaft with a tool or other object. Remove the two bearing caps and exhaust camshaft. Remove intake camshaft Set the timing mark (two dot marks) of the camshaft drive gear at approx. 25° angle by turning the hexa- gon wrench head portion of the intake camshaft with a wrench. HINT: The above angle arrows the No.1 and No.4 cylinder cam lobes of the intake camshaft to push their valve lifters evenly. Lightly push the intake camshaft towards the front without applying excessive force. Loosen and remove the No.1 bearing cap bolts, al- ternately loosening the left and right bolts uniformly.ENGINE — ENGINE MECHANICAL EG-51 (d) Loosen and remove the No.3, No.4, No.6 and No.7 bearing cap bolts, alternately loosening the left and right bolts uniformly in several passes, in the se- quence shown, NOTICE: Do not remove the No.2 and No.5 bearing cap bolts at this stage. (e) Remove the four bearing caps. (f) Alternately and uniformly loosen and remove the No.2 and No.5 bearing cap bolts. HINT: © As the four No.2 and No.5 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level. © If the camshaft is not being lifted out straight and level, retighten the four No.2 and No.6 bearing cap bolts. Then reverse the order of above steps from (f) to (a) and repeat steps from (a) to (g) once again. NOTICE: Do not pry on or attempt to force the cam- shaft with a tool or other object. (g) Remove the two bearing caps and exhaust camshaft. 32. DISASSEMBLE EXHAUST CAMSHAFT (a) Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. {b) Insert a service bolt (A) into the service hole of the camshaft sub—gear. {c) Using a screwdriver, turn the sub~gear clockwise, and remove the service bolt (B). NOTICE: Be careful not to damage the camshaft.aie ENGINE — ENGINE MECHANICAL (¢)_ Using snap ring pliers, remove the snap ring. (e) Remove the following parts: (1) Wave washer (2) Camshaft sub—gear (3) Camshaft gear spring 33. REMOVE CYLINDER HEAD (a) Remove the two bolts in front of the head before the other head bolts are removed. (b) Using SST, uniformly loosen and remove the 14 cyl- inder head bolts in several passes, in the sequence shown. SST 09011-38121 NOTICE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. BES 2sENGINE — ENGINE MECHANICAL {co} 35. 36. 37. EG-53 Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block. leg. (Europe) REMOVE EGR PIPE Remove the two bolts, EGR pipe and gasket. REMOVE HEATER INLET PIPE AND HOSE Disconnect the heater hose, and remove the bolt and heater inlet pipe. REMOVE INTAKE MANIFOLD WITH FUEL FILTER Remove the six bolts, two nuts, intake manifold and gasket. REMOVE FUEL FILTER Remove the two bolts and fuel filter.Eee. ENGINE — ENGINE MECHANICAL CYLINDER HEAD DISASSEMBLY {See Components for Removal and Installation) 1, REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct order. \ gio : 2, REMOVE VALVES (a) Using SST, compress the valve spring and remove the two keepers. SST 09202-70010 {b) Remove the spring retainer, valve spring and valve. (c) Using needie—nose pliers, remove the oil seal. (4) Using compressed air and a magnetic finger, remove the spring seat by blowing air.EG-55 ENGINE — ENGINE MECHANICAL wd i AALS \ Ol oe S50 oat P8708 eee fa) (b) (c) (d) HINT: Arrange the valves, valve springs, spring seats and spring retainers in correct order. | REMOVE FOLLOWING PARTS: Water temperature sender gauge Water temperature cut switch Water temperature sensor BvsvEG-56 ENGINE — ENGINE MECHANICAL K = FF CYLINDER HEAD COMPONENTS INSPECTION, CLEANING AND REPAIR 1, CLEAN TOP SURFACES OF PISTONS AND CYLINDER BLOCK (a) Turn the crankshaft, and bring each piston to top dead center (TDC). Using a gasket scraper, remove all the carbon from the piston top surface. (b) Using a gasket scraper, remove all the gasket material from the cylinder block surface. {c) Using compressed air, blow carbon and oil from the bolt holes. CAUTION: Protect your eyes when using high—com- 2. GLEAN CYLINDER HEAD A. Remove gasket material Using a gasket scraper, remove all the gasket material from the cylinder block contact surface. NOTICE: Be careful not to scratch the cylinder block contact surface. B. Clean combustion chambers Using a wire brush, remove all the carbon from the combustion chambers. NOTICE: Be careful not to scratch the cylinder block contact surface. . Clean valve guide bushings Using 2 valve guide bushing brush and solvent, clean all the guide bushings.ENGINE — ENGINE MECHANICAL eer D. Clean cylinder head Using a soft brush and solvent, thoroughly clean the cylinder head. 3. INSPECT CYLINDER HEAD A. Inspect for flatness Using a precision straight edge and thickness gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage. Maximum warpage: Cylinder block side 0.15 mm (0.0059 in.) Manifold side 0.10 mm (0.0039 in.) If warpage is greater than maximum, replace the cyl- inder head. B. Inspect for cracks Using a dye penetrant, check the combustion cham- bers, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head. 4. CLEAN VALVES (a) Using a gasket scraper, chip off any carbon from the valve head. (b) Using a wire brush, thoroughly clean the valve.EG-58 ENGINE — ENGINE MECHANICAL 5. (a) eb (b) (c) (a) INSPECT VALVE STEMS AND GUIDE BUSHINGS Using a caliper gauge, measure the inside diameter of the guide bushing. Bushing inside diameter: 7.010 — 7.030 mm (0.2760 — 0.2768 in.) Using a micrometer, measure the diameter of the valve stem. Valve stem diameter: Intal 6.970 — 6.985 mm (0.2744 — 0.2750 in.) Exhaust 6.965 — 6.980 mm (0.2742 — 0.2748 in.] ‘Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement. Standard oil clearance: Intel 0.025 — 0.060 mm (0.0010 — 0.0024 in.) Exhaust 0.030 ~ 0.065 mm (0.0012 — 0.0026 in.) Maximum oil clearance: Intake 0.08 mm (0.0031 in.) Exhaust 0.10 mm (0.0039 in.) If the clearance is greater than maximum, replace the valve and guide bushing. IF NECESSARY, REPLACE VALVE GUIDE BUSHINGS Gradually heat the cylinder head to 80 — 100°C (176 — 212°F),ENGINE — ENGINE MECHANICAL hawea {b) Using SST and a hammer, tap out the guide bushing. SST 09201-15010 ot (ee (c) Using a caliper gauge, measure the bushing bore di- ameter of the cylinder head. (@) Select a new guide bushing (STD size or 0/S 0.08). Both intake If the bushing bore diameter of the cylinder head is Siig bodeaved ant | anaes a greater than 11.513 mm (0.4533 in, machine the i ~ ———. bushing bore to the following dimension: ioe one Use st0 11.542 — 11.563 mm (0.4544 — 0.4562 in.) — var -——- If the bushing bore diameter of the cylinder head is Meesaeil Use OFS 0.05 greater than 11.563 mm (0.4552 in.), replace the cylinder head. voor (e) Gradually heat the cylinder head to 80 — 100°C (176 — 212°F). (f) Using SST and a hammer, tap in a new guide bushing at | to where there 8.2 — 8.6 mm (0.323 — 0.339 in) T protruding from the cylinder head. SST 09201-15010eee ENGINE — ENGINE MECHANICAL (a) Using a sharp 7 mm reamer, ream the guide bushing | to obtain the standard specified clearance (See page vo EG—58) between the guide bushing and valve stem. 7. INSPECT AND GRIND VALVES (a) Grind the valve enough to remove pits and carbon. (b) Check that the valve is ground to the correct valve face angle. Valve face angle: 445 445" esozss Euoreo, oes A {c) Check the valve head margin thickness. Standard margin thickness: 1.2 mm (0.047 in.) Minimum margin thickness: 1.0 mm (0.039 in.) If the margin thickness is less than minimum, replace Margin Thickness the valve. T ewoigt (d) Check the valve overall length. Standard ovorall length: Intal a} 98.4 mm (3.874 in.) Overall Length Exhaust 97.9 mm (3.854 in.) Minimum overall length: Intal 97.9 mm (3.864 in.) Exhaust 97.4 mm (3.835 in.) If the overall length is less than minimum, replace the valve.£G-61 ENGINE — ENGINE MECHANICAL (e) (a) (b) (c) Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve. NOTICE: Do not grind off more than minimum. INSPECT AND CLEAN VALVE SEATS Using a 45° carbide cutter, resurface the valve seats. Remove only enough metal to clean the seats Check the valve seating position. Apply a light coat of prussian blue (or white lead) to the valve face. Lightly press the valve against the seat. Do not rotate valve. Check the valve face and seat for the followin: * If blue appears 360° around the face, the valve is concentric. If not, replace the valve. * If blue appears 360° around the valve seat, the guide and face are concentric. If not, resurface the seat. © Check that the seat contact is in the middle of the valve face with the following width: Intake 1.2 ~ 1.6 mm (0.047 — 0,063 in.) Exhaust 1.0 — 1.4 mm (0.039 — 0.085 in.) If not, correct the valve seats as follows: (1) (Intake) If the seating is too high on the valve face, use 30° and 45° cutters to correct the seat. (2) If the seating is too low on the valve face, use 78° and 45° cutters to correct the seat.EG-62 ENGINE — ENGINE MECHANICAL Deviation cot — \ t (d) (e) a) (b) (e) (b) Hand—lap the valve and valve seat with an abrasive compound. After hand—lapping, clean the valve and valve seat. INSPECT VALVE SPRINGS Using a steel square, measure the squareness of the valve spring. Maximum squareness: 2.0 mm (0.079 in) If the deviation is greater than maximum, replace the valve spring. Using a vernier caliper, measure the free length of the 43.94 ~ 45.06 mm (1.7299 — 1.7740 in.) If the free length is not as specified, replace the valve spring. Using a spring tester, measure the tension of the valve spring at the specified installed length. Installed tension: 214 — 238.N (21.8 — 24.2 kaf, 48.1 ~ 63.4 Ibf) at 36.5 mm (1.437 in.) If the installed tension is not as specified, replace the valve spring. INSPECT CAMSHAFTS AND BEARINGS Inspect camshaft for runout Place the camshaft on V—blocks. Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the camshaft.ENGINE — ENGINE MECHANICAL Free Distance nose EG-63 B. Inspect cam lobes Using a micrometer, measure the cam lobe height. Standard cam lobe height: 50.61 ~ 50.71 mm (1.9925 ~ 1.9966 in.) Minimum cam lobe height: 50.51 mm (1.9886 in.) If the cam lobe height is less than minimum, replace the camshaft. GC. inspect camshaft journals Using a micrometer, measure the journal diameter. Journal diameter: 26.959 — 26.975 mm(1.0614 — 1.0620 in.) If the journal diameter is not as specified, check the oil clearance. D. Inspect camshaft bearings Check that bearings for flaking and scoring, If the bearings are damaged, replace the bearing caps and cylinder head as a set. E. Inspect camshaft gear spring Using a vernier caliper, measure the free distance between the spring ends. Free distance 18.2 — 18.8 mm (0.717 — 0.740 in.) If the free distance is not as specified, replace the gear spring. F. Inspect camshaft journal oil clearance (a) Clean the bearing cops and camshaft journals, {b) Place the camshafts on the cylinder head. {c)_ Lay a strip of Plastigage across each of the camshaft journals.EG-64 ENGINE — ENGINE MECHANICAL (d) (e) f (9) (a) (b) Install the bearing caps. (See step 7 onfpages EG ~73]to| Torque: 16 N-m (160 kgf-em, 12 ftlbf) NOTICE: Do not turn the camshaft. Remove the bearing caps. Measure the Plastigage at its widest point. Standard oil clearance: 0.025 — 0.062 mm (0.0010 — 0.0024 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set Completely remove the Plastigage. Inspect camshaft thrust clearance Install the camshaft. (See step 7 on[pages EG—73}to| Using a dial indicator, measure the thrust clearance while moving the camshaft back and forth. Standard thrust cle: ee: 0.030 — 0.080 mm (0.0012 — 0.0031 in.) Maximum thrust clearance: 0.10 mm (0.0038 in.) If the thrust clearance is greater than maximum, re- place the camshaft. If necessary, replace the bearing caps and cylinder head as a set.EG-65 ENGINE — ENGINE MECHANICAL H. (a) (bo) "1 fa) (b) (o) Inspect camshaft gear backlash Install the camshafts without installing the exhaust cam sub—gear. (See step 7 orfpages EO 79]t Using a dial indicator, measure the backlash. Standard backlash: 0,020 — 0.200 mm (0.0008 — 0.0079 in.) Maximum backlash: 0.30 mm (0.0188 in.) If the backlash is greater than maximum, replace the camshafts. INSPECT VALVE LIFTERS AND LIFTER BORES Using a caliper gauge, measure the lifter bore diame- 34,000 — 34.021 mm (1.3386 — 1.3394 in.) Using @ micrometer, measure the lifter diameter. Lifter diamotor: 33.966 — 33.976 mm (1.3372 — 1.337 Subtract the lifter diameter measurement from the lifter bore diameter measurement. Standard oil clearance: 0.024 — 0.055 mm (0.0009 ~ 0.0022 in.) Maximum oil clearance: 0.07 mm (0.0028 in.) If the oil clearance is greater than maximum, replace the lifter. If necessary, replace the cylinder head.EG-66 ENGINE — ENGINE MECHANICAL oom 1FZ-FE Cylinder Head Side Ait Intake Chamber Side 12. INSPECT AIR INTAKE CHAMBER Using a precision straight edge and thickness gauge, measure the surface contacting the intake manifold for warpage. Maximum warpags 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the air intake chamber. 13, INSPECT INTAKE MANIFOLD Using a precision straight edge and thickness gauge, measure the surface contacting the cylinder head and air intake chamber for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the manifold. 14, INSPECT EXHAUST MANIFOLDS. Using a precision straight edge and thickness gauge, measure the surface contacting the cylinder head for warpage. Maximum warpage: 0.30 mm (0.0118 in.) If warpage is greater than maximum, replace the manifold.ENGINE — ENGINE MECHANICAL, eet 15, INSPECT CHAIN TENSIONER {a) Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. (b) Released the ratchet pawl and check that the plung- eris locked in place by the ratchet paw! and does not move when pushed with your finger. 16. IF NECESSARY, REPLACE SPARK PLUG TUBE GASKETS (a) Using a screwdriver, pry off the tube gasket. {b) Using SST and a hammer, tap in a new tube gasket as. shown in the illustration. SST 09608-60012 (09608-04020, 09608-04060) (c) Apply a light coat of MP grease to the gasket lip. 17, INSPECT CYLINDER HEAD BOLTS Using vernier calipers, measure the thread outside diameter of the boit. Standard outside diameter: 10.85 — 11.00 mm (0.4272 ~ 0.4331 in.) Minimum outside diameter: 10.6 mm (0.417 in.) If the diameter is less than minimum, replace the bolt. (0.98 — 1.18 indoe ENGINE — ENGINE MECHANICAL CYLINDER HEAD ASSEMBLY {See Components for Removal and Installation) HINT: © Thoroughly clean all parts to be assembled. ‘© Before installing the parts, apply new engine oil to all sliding and rotating surfaces. © Replace all gaskets and oil seals with new ones. Peed 1. INSTALL SPARK PLUG TUBES 45.5 mm_— HINT: When using a new cylinder head, spark plug tubes must be installed. (@) Mark the standard position away from the edge, onto \ the spark plug tube. Standard protrusioi 45,5 mm (1.791 in.) (b) Apply adhesive to the spark plug tube hole of the a cylinder head. Sealant: WS Part No. 08833 ~ 00070, Adhesive 1324, THREE x \ SS X BOND 1324 or equivalent SASHES (c) Using @ press, press in a new spark plug tube until there is 45.5 mm (1.791 in) protruding from the camshaft bearing cap installation surface of the cyl- inder head. NOTICE: Avoid pressing a new spark plug tube in too far by measuring the amount of protrusion while press- ing. 2. INSTALL FOLLOWING PARTS: HINT: Apply adhesive to two or three threads of the TW. Adhesive: Part No.08833—00080, THREE BOND 1344, LOCTITE 242 or equivalent ooENGINE — ENGINE MECHANICAL EG-69 oa y fa) Water temperature sender gauge SSOBROAIS (0) Water temperature cut switch DAT CS (6) Water temperature sensor (d) BYSV 3. INSTALL VALVES (a) Using SST, push in a new oil seal SST 09236-00101 (09236-15010) HINT: Different oil seals are used for the intake and exhaust. Intake Exhaust {b) Install the following parts: (1) Valve (2) Spring seat (3) Valve spring (4) Spring retainer (c]_ Using SST, compress the valve spring and place the two keepers around the valve stem. SST 09202~70010EG-70 ENGINE — ENGINE MECHANICAL (a) Using a plastic—faced hammer, lightly tap the valve stem tip to assure proper fit. 4. INSTALL VALVE LIFTERS AND SHIMS (a) Install the valve lifter and shim. {b) Check that the valve lifter rotates smoothly by hand CYLINDER HEAD INSTALLATION (See Components for Removal and Installation) 1, INSTALL FUEL FILTER TO INTAKE MANIFOLD Install the fuel filter with the two bolts. Torque: 21 Nem (210 kgf-om, 15 ftbf) INSTALL INTAKE MANIFOLD (a) Place a new gasket so that the rear mark is toward the rear side. {b) Install the intake manifold with the six bolts and two nuts. Torque: 21 N-m (210 kaf-cm, 15 ftbf)ENGINE — ENGINE MECHANICAL ii 3. INSTALL HEATER INLET PIPE AND HOSE Install the heater hose to the cylinder head, and con- nect the pipe to the intake manifold. Torque: 21 Nm (210 kgf-cm, 15 ft4bf) 4. (Europe) INSTALL EGR PIPE Install a new gasket and the EGR pipe with the two bolts. Torque: 21 N-m (210 kgf-em, 15 ftlbf) 5. INSTALL CYLINDER HEAD A. Place cylinder head on cylinder block (a) Apply seal packing to two locations as shown. Seal packing: Part No.08826—00080 or equivalent NOTICE: Do not apply too much seal packing (b) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be careful of the installation direction. (c) Place the cylinder head in position on the cylinder head gasket.rave ENGINE — ENGINE MECHANICAL B, Install cylinder head bolts HINT: * The cylinder head bolts are tightened in two progressive steps (steps (b) and (d)). © If any cylinder head bolt is broken or deformed. replace it. (2) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (b)_ Using SST, install and uniformly tighten the 14 cylin- der head bolts and plate washers in several passes, in the sequence shown. SST 09011-38121 Torque: 38 N.m (400 kgf-cm, 29 ft-lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. (c) Mark the front of the cylinder head bolt head with paint. (4) Retighten the cylinder head bolts 90° in the numerical order shown. {e) Retighten the cylinder head bolts by an additional 90°. {f) Check that the painted mark is now facing rearward. (g)_ Install and torque the two mounting bolts. Torque: 21N-m (210kgf-cm, 15ft bf)ENGINE — ENGINE MECHANICAL 6. (a) (b) (c) (a) (e) EG-73 ASSEMBLY EXHAUST CAMSHAFT Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. ES Install the following parts: (1) Camshaft gear spring (2) Camshaft sub—gear (3) Wave washer HINT: Align the pins on the gears with the spring ends. Using snap ring pliers, install the snap ring. Insert a service bolt (A) into the service hole of the camshaft sub—gear. Using a screwdriver, align the holes of the camshaft main gear and sub—gear by turning camshaft sub— gear clockwise, and install a service bolt (B). NOTICE: Be careful not to damage the camshaft. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is ‘small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.EG] ENGINE — ENGINE MECHANICAL A fa) (b) (ce) (d) (e) (f) (9) (hy) i) Install intake camshaft Apply engine oil to the thrust portion of the intake camshaft. Lightly place the intake camshaft on top of the cyl- inder head as shown in the illustration so that the No. 1 and No.4 cylinder cam lobes face downward. Lightly push the camshaft towards the front without applying excessive force. Place the No.2 and No.5 bearing caps in their proper location. Temporarily tighten these bearing cap bolts uniformly and alternately in several passes until the bearing caps are snug with the cylinder head. Place the No.3, No.4, No.6 and No.7 bearing caps in their proper location, Temporarily tighten these bearing cap bolts, aiter- nately tightening the left and right bolts uniformly. Place the No.1 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap. Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly. Uniformly tighten the fourteen bearing cap bolts in several passes Torque: 16 N-m (160 kef-om, 12 ft-lbf)EG-75 ENGINE — ENGINE MECHANICAL B. (a) (b) (c) (a) (e) (f) (g) (h) @ oO tk) Install exhaust camshaft Set the timing mark (two dot marks) of the camshaft drive gear at approx. 35° angle by turning the hexa- gon wrench head portion of the intake camshaft with a wrench, Apply engine oil to thrust portion of the exhaust camshaft. Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks (two dot marks) on each gear. Roll down the exhaust camshaft onto the bearing Journals while engaging gears with each other. Lightly push the intake camshaft towards the front without applying excessive force. Install the No.4 and No.6 bearing caps in their proper location. Temporarily tighten the bearing cap bolts uniformly and alternately in several passes until the bearing caps are snug with the cylinder head. Place the No.2, No.3, No.5 and No.7 bearing caps in their proper location. Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly. Place the No.1 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap. ‘Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly. kes,« EG-76 eo0es3 YAN sw CoN Dot Mark, ‘SS Straight Pin Matchmarks () (m) (n) {o) fa) (b) (a) ENGINE — ENGINE MECHANICAL Uniformly tighten the fourteen bearing cap bolts in several passes. Torque: 16 N-m (160 kaf-cm, 12 ft-lbf) Bring the service bolt installed in the driven sub—gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. Remove the service bolt. Check that the intake and exhaust camshafts turn smoothly. SET NO.1 CYLINDER TO TDG/COMPRESSION If necessaly turn the crankshaft pulley, and align its groove with the timing mark “0” of the timing chain cover. Turn the camshafts so that the timing marks with one and two dots will be in straight line on the cylinder head surface as shown in the illustration. INSTALL CAMSHAFT TIMING GEAR HINT: Check that the matchmarks on the camshaft timing gear and timing chain are aligned. Place the gear over the straight pin of the intake camshaft.EG-77 ENGINE — ENGINE MECHANICAL (b) (c) fa) (b) (ec) 10. n the straight pin of distributor gear with the straight pin groove of the intake camshaft gear as shown. Hold the intake camshaft with a wrench, install and torque the bolt. Torque: 74 N-m (750 kaf-cm. 54 ft-lbf) INSTALL CHAIN TENSIONER Place a new gasket so that the front mark is toward the front side. Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out. Turn the crankshaft pulley clockwise to provide some slack for the chain on the tensioner side. NOTICE: Do not turn the pulley counterclockwise.(d) (e) (a) u. 12. ENGINE — ENGINE MECHANICAL Push the tensioner by hand until it touches the head installation surface, then install the two nuts. Tighten the two nuts. Torque: 21 Nm (210 kgf-cm, 15 ft-lbf) Check that the hook of the tensioner is not released. NOTICE: If the plunger springs out during installation of the chain tensioner, repeat the operation in step (b) before installing the tensioner. ‘SET CHAIN TENSIONER Turn the crankshaft to the left so that the hook of the chain tensioner is released from the pin of the plunger, causing the plunger to spring out and the slipper to be pushed into the chain. HINT: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released and the plu- nger springs out. CHECK VALVE TIMING Turn the crankshaft pulley, and align its groove with the timimg mark "0" of the timing chain cover. NOTICE: Always turn the crankshaft clockwise.ENGINE — ENGINE MECHANICAL 83 (b) 13, 14, @) (b) (co) 15. 16, fa) (b) EG-79 Check that the timing marks (one and two dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°) and align the marks as above. CHECK AND ADJUST VALE CLEARAN (See steps 6 to 7 onfoages E@—17}eq sah Turn the camshaft and position the cam lobe upward and check and adjust the valve clearance. Valve clearance (Cold): Intake 0.15 — 0.25 mm (0.006 — 0.010 in.) Exhaust 0.25 — 0.35 mm (0.010 — 0.014 in.) INSTALL SEMI—CIRCULAR PLUG Remove any old packing (FIPG) material Apply seal packing to the cylinder head installation surface of the semi-circular plug. Seal packin, Part No. 08826~-00080 or equivalent Install the semi—circular plug to the cylinder head. INSTALL SPARK PLUGS Using SST, install the spark plug. SST 09155-16100 Torque: 20 N-m (200 kgf.cm, 14 ftlbf) INSTALL CYLINDER HEAD COVER Install the gasket to the cylinder head cover. Install the cylinder head cover with the 13 bolts.a EG-80 ENGINE — ENGINE MECHANICAL 17. {a) (b) (c) (d) (e) 18. 19. INSTALL WATER BY-PASS OUTLET AND PIPE Install a new O-ring to the water by—pass outlet Install two new O-rings to the water by—pass pipe. Apply soapy water to the O-rings. Assemble the water by—pass outlet and pipe. Install the water bypass outlet and pipe with the ‘two bolts. Torque: 21 N-m (210 kgf-cm. 15 ft-lbf) INSTALL NO.1 ENGINE HANGER Install the No.1 engine hanger with the two bolts. Torque: 41 N-m (420 kgf-cm, 30 ft-bf) INSTALL NO.2 ENGINE HANGER Install the No.2 engine hanger with the two bolts. Torque: 41 N-m (420 kgf-cm, 30 ftlbf)ENGINE — ENGINE MECHANICAL EG-81 20. INSTALL NO.1 AND NO.2 EXHAUST MANIFOLDS {a)_ Install two new gaskets, No.1 exhaust manifold and No.2 exhaust manifold with the 13 nuts. Torque: 39 N-m (400 kgf-cm, 29 ftbf) = {b) Install the No.1 heat insulator and No.2 heat insulator with the six bolts, Torque: 19 N-m (195 kgf-cm, 14 ft-bf) 21. (Europe) INSTALL AS REED VALVE Install the PAIR reed vaive with the two bolts. Torque: 20 N-m (200 kaf-cm, 14 ft bf) 22. (Europe) INSTALL AIR PIPE Install three new gaskets and air pipe with the two bots and six nuts Torque: 20 N.m (200 kgf-cm, 14 ft-lbf} for Bolt Torque: 21 N-m (210 kgf-om, 15 ftibf) for Nut 23. INSTALL HEATER PIPE Install a new gasket and heater pipe with the two bolts and two nuts. Torque: 20 N-m (200 kgf-cm, 14 fbf) for Bolt Torque: 21 N-m (210 kgf-cm, 15 ftbf) for NutENGINE — ENGINE MECHANICAL a 24, (a) (b) {c) (d) (e) 28. fa) (b) (c) (a) {e) CONNECT ENGINE WIRE Connect the engine wire to the cylinder head and intake mamifold with the three bolts. Connect the engine wire clamp. Connect the engine wire to the cylinder block with the two bolts. Connect the following connectors: (1) Water temp. sender gauge connector (2) Water temp. cut switch (2) Water temp. sensor connector (4) Two knock sensor connectors (5) Oxygen sensor connector (with clamps) (6) Four connectors to transmission (7) Starter connector (8) Oil level sensor connector Connect the engine wire to the intake manifold with the bolt. INSTALL INJECTORS AND DELIVERY PIPE Install a new grommet to the injector. Apply a light coat of gasoline to a new O-ring and install it to the injector. While turning the injector left and right, install it to the delivery pipe. Install the six injectors. Position the injector connector upward. Place six new insulators and the three spacers in position on the intake manifold.EG-83 ENGINE ~ ENGINE MECHANICAL. (i) (9) (h) (i) 0 28. 29. (a) (b) 26. 27. Place the six injectors together with the delivery pipe in position on the intake manifold, Temporarily install the three bolts holding the delivery pipe to the intake manifold. Check that the injectors rotate smoothly. HINT: If injectors do not rotate smoothly, the prob- able cause is incorrect installation of O-rings. Re- place the O-rings. Position the injector connector upward. Tighten the three bolts holding the delivery pipe to the intake manifold. Torque: 21 N-m (210 kgf-cm, 15 ftlbf) CONNECT FUEL INLET HOSE Connect the fuel inlet hose to the fuel filter with two new gaskets and union bolt. Torque: 29 N-m (300 kgf-cm, 22 ft-lbf) INSTALL NO.1 FUEL PIPE Install the No.1 fuel pipe with four new gaskets, the two union bolts and bolt. 9 N-m (300 kgf-em, 22 ft-Ibf) for Union bolt 20 N-m (200 kgf-cm, 14 ft-lbf) for Bolt INSTALL NO.1 WATER BY~PASS HOSE INSTALL FUEL RETURN PIPE Install the fuel return pipe with the two bolts. Torque: 20 N-m (200 kgf-cm, 14 ft-lbf) Connect the fuel hose to the fuel pressure regulator.EG-84 ENGINE — ENGINE MECHANICAL 30, (a) (b) (c) {e) 32. . INSTALL AIR INTAKE CHAMBER Install the emission control valve set assembly to the air intake chamber with the four bolts. Torque: 20 N-m (200 kaf.cm, 14 ft-lbf) Connect the air hose. Connect the vacuum hose. Install two new gaskets and the air intake chamber with the four bolts and six nuts. Torque: 21 N-m (210 kgf-cm, 15 ft-lbf) Connect the following hoses: (1) Two vacuum hoses to gas filter (2) Vacuum hose to fuel pressure regulator (3) Two vacuum hoses to BVSV (4) EVAP hose to 3—way (8) Brake booster hose to brake booster union . INSTALL OIL DIPSTICKS AND GUIDES FOR ENGINE AND TRANSMISSION Install a new O-ring to the dipstick guide. Apply light coat of engine oil on the O—ring. Push in the dipstick guide into the guide hole of the oil pan. Install the dipstick guide with the two bolts. Torque: 20 N-m (200 kgf-cm, 14 ftlbf) INSTALL BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER Torque: 20 N-m (200 kaf.cm, 14 ft-lbf)EG-85 ENGINE — ENGINE MECHANICAL stud Bolt, 33. fa) (e) (<) (d) fa) (b) (c) (a) 34. 35. 36. (Europe) INSTALL EGR VALVE AND VACUUM MODULATOR Using vise pliers, temporarily install a new gasket, and EGR vaive and vacumm modulator assembly with the two stud bolts Torque: 10 N-m (105 kgf-cm, 8 ftlbf) Install the two nuts holding the EGR valve and air intake chamber. Torque: 19 Nem (195 kgf-cm, 14 ftibf) Tighten the union nut of the EGR pipe. Torque: 64 N-m (650 kgf-cm, 47 ftibf) Connect the vacuum hose to the EGR valve. CONNECT CONNECTOR FOR EMISSION CONTROL VALVE SET ASSEMBLY INSTALL NO.2 WATER BY—PASS PIPE AND HOSES. Install the No.2 water by—pass pipe and hoses with the three bolts. Torque: 20 N-m (200 kgf-cm, 14 ftibf) Connect the water hose to the timing chain cover, Connect the two vacuum hose to the PAIR reed valve and No.2 emission control valve set. INSTALL THROTTLE BODY ‘Connect the No.1 water by—pass hose to the throttle body,ie ENGINE — ENGINE MECHANICAL (0) (o (d) (e) (f (9) (a) (b) {c) 37. 38. Install a new gasket and throttle body with the four bolts. Torque: 21 N-m (210 kgf-cm, 15 ftbf) Connect the water hose to the No.2 water by—pass pipe. Connect the EVAP hose. Connect the three vacuum hoses. Connect the ISC valve connector. Connect the throttle position sensor connector. INSTALL WATER OUTLET Install a new gasket and water outlet with the two nuts. Torque: 21 N-m (210 kgfcm, 15 ftlbf) Connect the No.3 water by—pass hose. Connect the radiator inlet hose. INSTALL ALTERNATOR BRACKET Install the generator bracket with the two bolts. Torque: 43 N-m (440 kgf-cm, 32 ftbf)EG-87 ENGINE — ENGINE MECHANICAL Align 39. 40. fa) (b) (c) @) {e) @ (9) INSTALL ALTERNATOR AND DRIVE BELTS (See CH section) INSTALL DISTRIBUTOR Install a new O—ring to the distributor. HINT: Always use a new O-ring when installing the distributor. Align the groove of the distributor housing with the protrusion on the driven gear. Apply a light coat of engine oil on the O-ring insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. Lightly tighten the hold —down boit. Connect the high—tension cords, Firing order: 1-5-3- 4 Install the No.1 and No.2 cord clamps with two mounting bolts. =EG-88 ENGINE — ENGINE MECHANICAL 41, INSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the four bolts. 42. INSTALL NO.1 AND NO.2 PCV HOSESENGINE — ENGINE MECHANICAL Feat CYLINDER HEAD (1FZ—-F) ea COMPONENTS No.3 Cylinder No.2 Cylinder Head Cover & 7 Head Cover ei Air Connector No.2 Exhaust »—— (210, 1] a eae] Distibutor TP) 0.2 engine =) Henger 4 Water By-Pass wren rt , Pipe Y 2, i" io Insulator ' ® # O-Ring —~re 2 Water By-Pass ' ‘ Fuel Pump | ipe with Hoses | K - | @ Gasket Intake Manifold ¢ " (with Carburetor) 7 ca 1 Engine Hanger 3B 7 (4120, 301], po Atromator Bracket OY p cE 13 ETT [a3iado. 32 © Gasket ee Ess Tie] © 2 ; : Y TIBI TH)] worer By-Pass Flange Dive Bek PaseaScaaT i Alternator Gil Dipstick “3 214210, 151 ead eee 201200, 14) Species torque (zoaoo-ray,__,|5aaee.t8 Nem ikohom, fib @ Non-reusable part Water OutletFe, ENGINE — ENGINE MECHANICAL }——— Gasket mA ——cyinder tess cover = za # Spark Plug oS Tube Gasket o— Adjusting Shim Spark Plug &— vaive Lifter &—Keeper Camshatt Camshaft Gear Spring Bearing Cap, Spring Retsiner Valve Spring Camshaft Sub-Gear Weve Washer gv t Snap Ring Chain Tensioner & Pe Lae @ TS (Rae @Gasket eoiseet Ce Sina at # Valve Guise f Basti few wee Se avy Water Tempersture Sensor Water Temperature Switch Semi-Circular Pug —— @ cylinder Head Gasket > i Tem (kgh-om, fieibil] : Specified torque @ Non-reusable part ok Precosted partEG-91 ENGINE — ENGINE MECHANICAL (a) (b) fa) (b) {c) CYLINDER HEAD REMOVAL, 1. REMOVE INTAKE AIR CONNECTOR Disconnect the PCV hose. Remove the two bolts, nut and air connector. ee REMOVE NO. 2 AND NO. 3 CYLINDER HEAD COVERS Remove the four bolts and head covers. REMOVE DISTRIBUTOR Remove the No.1 cord clamp mounting bolt. Disconnect the high — tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor inside. Remove the bolt and distributor.betta ENGINE — ENGINE MECHANICAL 4, REMOVE ALTERNATOR (a) Loosen the lock bolt, pivot bolt and adjusting bolt, and remove the drive belts. {b) Remove the pivot bolt, lock bolt and alternator. 5, REMOVE ALTERNATOR BRACKET Remove the two bolts and alternator bracket. . REMOVE WATER OUTLET {a) Disconnect the vacuum hoses. (b) Disconnect the No.1 water by—pass hose. (c) Remove the two nuts, water outlet and gasket.EG-93 ENGINE — ENGINE MECHANICAL es 7 fa) {b) (a) (b) (c) REMOVE FUEL PUMP Disconnect the fuel outlet hose. Remove the three bolts, fuel pump and gasket. DISCONNECT PCV HOSE REMOVE NO. 2 WATER BY — PASS PIPE WITH HOSES Disconnect the two water hoses. Disconnect the hose clamp. Remove the three bolts and No.2 water by—pass pipe with hoses. . DISCONNECT TWO VACUUM HOSES FROM BVSVENGINE ~ ENGINE MECHANICAL ce (a) (b) {ce} (a) 12, 13. (a) (b) {c) 14, 15. (a) DISCONNECT FOLLOWING CONNETORS: Spark control VSV (for G.C.C.) Water temperature switch Water temperature sensor (for G.C.C.) TP VSV REMOVE ACCELERATOR CABLE BRACKET Remove the two bolts and accelerator cable bracket. REMOVE OIL DIPSTICK AND GUIDE Remove the two mounting bolts and ground strap. Pull out the dipstick together with dipstick guide. Remove the O—ring from the dipstick guide, REMOVE INTAKE MANIFOLD WITH CARBURETOR Remove the six bolts, two nuts, intake manifold and gasket. IF NECESSARY, REMOVE WATER BY — PASS FLANGE Remove the six bolts and two nuts.EG-95 ENGINE — ENGINE MECHANICAL (b) fa) (b) (a) (b) 16. 17. 18. Insert the blade of SST between the intake manifold and water by—pass flange, and cut off applied sealer and remove the flange. SST 09302-00100 NOTICE: Be careful not to damage the intake manifold and flange. REMOVE NO.1 AND NO.2 EXHAUST MANIFOLDS. Remove the six bolts, No.1 heat insulator and No.2 heat insulator, Remove the 13 nuts, No.1 exhaust manifold, No.2 exhaust manifold and two gaskets. REMOVE NO.1 AND NO.2 ENGINE HANGERS REMOVE WATER BY-PASS OUTLET AND PIPE Remove the two bolts and water by—pass outlet and pipe. Remove the three O-rings from the water by—pass outlet and pipe.£G-96 ENGINE — ENGINE MECHANICAL 19. 20. 21. 22. fa) (b) DISCONNECT ENGINE WIRE Remove the bolt and disconnect the engine wire from the cylinder head. REMOVE SPARK PLUGS Using SST, remove the spark plug. SST 09155-16100 REMOVE CYLINDER HEAD COVER Remove the 13 bolts, cylinder head cover and gasket. SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley and align its groove with the “0” mark on the timing chain cover. Check that the timing marks (one and two dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°) and align the marks as above.ENGINE — ENGINE MECHANICAL lain 23, REMOVE CHAIN TENSIONER Remove the two nuts, chain tensioner and gasket. EG 24, REMOVE CAMSHAFT TIMING GEAR (a) Remove the harf—circular plug. (b) Place the matchmarks on the camshaft timing gear and timing chain. (c) Hold the intake camshaft with a wrench, remove the bolt and distributor gear. (d) Remove the camshaft timing gear and chain from the intake camshaft and leave on the slipper and damper. 25. REMOVE CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. if the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.EG-98 ENGINE — ENGINE MECHANICAL ‘A. Remove exhaust camshaft (a) Bring the service bolt hole of the driven sub—gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench. {b) Secure the exhaust camshaft sub—gear to the driven gear with a service bolt. Recommended service bolt: NX Service Bon SON” Thread diameter 6 mm Se NSN? PES oes Thread pitch 1.0 mm Bolt length 16 — 20 mm (0.63 ~ 0.79 in) HINT: When removing the camshaft, make sure that the torsional spring force of the sub—gear has been eliminated by the above operation. (c)_ Set the timing mark (two dot marks) of the camshaft driven gear at approx. 35° angle by turning the hex- agon wrench head portion of the intake camshaft with a wrench. (d)_ Lightly push the camshaft towards the rear without applying excessive force. {e) Loosen and remove the No.1 bearing cap boits, al- ternately loosening the left and right bolts uniformly. (f) Loosen and remove the No.2, No.3, No.5 and No.7 bearing cap bolts, alternately loosening the left and right bolts uniformly in several passes, in the se- quence shown, NOTICE: Do not remove the No.4 and No.6 bearing cap bolts at this stage. (g) Remove the four bearing caps.ENGINE — ENGINE MECHANICAL (h) wi @) (b) (c) (d) fe) EG-99 Alternately and uniformly loosen and remove the No.4 and No.6 bearing cap bolts. HINT: As the four No.4 and No.6 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level © If the camshaft is not being lifted out straight and level, retighten the four No.4 and No.6 bearing cap bolts. Then reverse the order of above steps from (g) to (a) and repeat steps from (a) to (f) once again. NOTICE: Do not pry on or attempt to force the cam- shaft with tool or other object. Remove the two bearing caps and exhaust camshaft Remove intake camshaft Set the timing mark (two dot marks} of the camshaft drive gear at approx. 25° angle by turning the hexa- gon wrench head portion of the intake camshaft with a wrench. HINT: The above angle arrows the No.1 and No.4 cylinder cam lobes of the intake camshaft to push their valve lifters evenly. Lightly push the intake camshaft towards the front without applying excessive force. Loosen and remove the No.1 bearing cap bolts, al- ternately loosening the left and right bolts uniformly. Loosen and remove the No.3, No.4, No.6 and No.7 bearing cap bolts, alternately loosening the left and right bolts uniformly in several passes, in the se- quence shown NOTICE: Do not remove the No.2 and No.5 bearing cap bolts at this stage. Remove the four bearing caps. eSEG-100 ENGINE — ENGINE MECHANICAL Service, Bole 8) fi) {g) (b) (Co) (a) Alternately and uniformly loosen and remove the No.2 and No.5 bearing cap bolts. HINT: * As the four No.2 and No.5 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level. © Ifthe camshaft is not being lifted out straight and level, retighten the four No.2 and No.5 bearing cap bolts, Then reverse the order of above steps from (f) to (a) and repeat steps from (@) to (g) once again. NOTICE: Do not pry on or attempt to force the cam- shaft with a tool or other object. Remove the two bearing caps and exhaust camshaft. DISASSEMBLE EXHAUST CAMSHAFT Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. Insert @ service bolt (Aj into the service hole of the camshaft sub—gear. Using a screwdriver, turn the sub~gear clockwise, and remove the service bolt (B). NOTICE: Be careful not to damage the camshaft. Using snap ring pliers, remove the snap ring.EG-101 ENGINE — ENGINE MECHANICAL n 2) brad a9 (e) 27. (a) (b) (e) Remove the following parts: (1) Wave washer (2) Camshaft sub—gear (3) Camshaft gear spring REMOVE CYLINDER HEAD Remove the two bolts in front of the head before the other head bolts are removed. Using SST, uniformly loosen and remove the 14 cyl- inder head bolts in several passes, in the sequence shown. SST 09011—38121 NOTICE: Cylinder head warpage or cracking could result from removing bolts in incorrect order. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench. HINT: If the cylinder head is difficult to lift off, pry be tween the cylinder head and cylinder block with a ‘screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.EG-102 ENGINE — ENGINE MECHANICAL CYLINDER HEAD DISASSEMBLY (Bee page EG—90] 1. REMOVE VALVE LIFTERS AND SHIMS HINT: Arrange the valve lifters and shims in correct, order. 2. REMOVE VALVES (2) Using SST, compress the valve spring and remove the two keepers, SST 09202~70010 (b) Remove the spring retainer, valve spring and valve. (c)_ Using needle—nose pliers, remove the oil seal. (d) Using compressed air and magnetic finger, remove the spring seat by blowing air.ENGINE — ENGINE MECHANICAL. EG-103 HINT: Arrange the valves, valve springs, spring Front * ab seats and spring retainers in correct order. eo n“ @ : ge ote 6 g ben. f x Je Ai a a aga By abe = 2 N gat EG) 3. REMOVE FOLLOWING PARTS: (a) Water temperature switch (b) Water temperature sensor (for G.C.C.) {c) BYSV CYLINDER HEAD COMPONENTS INSPECTION, CLEANING AND REPAIR [See page EG— 56} CYLINDER HEAD ASSEMBLY HINT: * Thoroughly clean all parts to be assembled. * Before installing the parts, apply new engine oil to all sliding and rotating surfaces. © Replace all gaskets and oil seals with new ones. 1. INSTALL SPARK PLUG TUBES Protrusion 45.5 mma HINT: When using a new cylinder head, spark plug \ tubes must be installed, (a) Mark the standard position away from the edge, onto the spark plug tube. ‘Standard protrusion: 45.5 mm (1.791 in.) MarkEG-104 ENGINE — ENGINE MECHANICAL OAR ‘Sealant a AW ISIS Oe NR \ (b) (c) (a) {b) {e) (a) Apply adhesive to the spark plug tube hole of the cylinder head. Sealant: Part No. 08833 — 00070, Adhesive 1324, THREE BOND 1324 or equivalent Using a press, press in a new spark plug tube until there is 45.5 mm (1.791 in) protruding from the camshaft bearing cap installation surface of the cyl- inder head. NOTICE: Avoid pressing a new spark plug tube in too far by measuring the amount of protrusion while press- ing. INSTALL FOLLOWING PARTS: Apply adhesive to two or three threads of the Part No.08833—00080, THREE BOND 1344, LOC- TITE 242 or equivalent Water temperature switch Water temperature sensor (for G.C.C.] BVSV INSTALL VALVES Using SST, push in a new oil seal. SST 09236—00101 (09236-15010)EG-105 ENGINE ~ ENGINE MECHANICAL (b) (c) @ @ (b) HINT: Different oil seals are used for the intake and exhaust. Install the following parts: (1), Valve (2) Spring seat (3) Valve spring (4) Spring retainer Using SST, compress the valve spring and place the two keepers around the valve stem. SST 0920270010 Using a plastic—faced hammer, lightly tap the valve stem tip to assure proper fit, INSTALL VALVE LIFTERS AND SHIMS Install the valve lifter and shim. Check that the valve lifter rotates smoothly by hand.EG-106 ENGINE — ENGINE MECHANICAL CYLINDER HEAD INSTALLATION 1, INSTALL CYLINDER HEAD A. Place cylinder head on cylinder block (a) Apply seal packing to two locations as shown. Seal packing: Part No.08826— 00080 or equivalent (b) Place a new cylinder head gasket in position on the cylinder block. NOTICE: Be careful of the installation direction. {c) Place the cylinder head in position on the cylinder head gasket. B. Install cylinder head bolts HINT: © The cylinder head bolts are tightened in two progressive steps (steps (b) and (d)). © If any cylinder head bolt is broken or deformed, replace it. (2) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts. (0) Using SST, install and uniformly tighten the 14 cylin- der head bolts and plate washers in several passes, in the sequence shown. SST 09011-38121 Torque: 39 N.m (400 kgf.cm, 29 ft-lbf) If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt. {c) Mark the front of the cylinder head bolt head with paint.EG-107 ENGINE ~ ENGINE MECHANICAL Painted Mark 90° 90° a ae (d) fe) (f) (9) fa) (b) (c) Retighten the cylinder head bolts 90° in the numerical order shown. Retighten the cylinder head bolts by an additional 90°. Check that the painted mark is now facing rearward, Install and torque the two mounting bolts. Torque: 21N-m (210kaf-cm, 15ft-lbf) ASSEMBLY EXHAUST CAMSHAFT Mount the hexagon wrench head portion of the camshaft in a vise. NOTICE: Be careful not to damage the camshaft. Install the following parts: (1) Camshaft gear spring (2) Camshaft sub—gear (3) Wave washer HINT: Align the pins on the gears with the spring ends. Using snap ring pliers, install the snap ring,23 EG-108 ENGINE — ENGINE MECHANICAL Service. (d) {e) (b) {o) Insert a service bolt (A) into the service hole of the camshaft sub~gear. Using a screwdriver, align the holes of the camshaft main gear and sub~gear by turning camshaft sub— gear clockwise, and install a service bolt (8). NOTICE: Be careful not to damage the camshaft. INSTALL CAMSHAFTS NOTICE: Since the thrust clearance of the camshaft is |, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out. Install intake camshaft Apply engine oil to the thrust portion of the inteke camshaft. Lightly place the intake camshaft on top of the cyl- inder head as shown in the illustration so that the No. 1 and No.4 cylinder cam lobes face downward. Lightly push the camshaft towards the front without applying excessive force, Place the No.2 and No.6 bearing caps in their proper location. Temporarily tighten these bearing cap bolts uniformly and alternately in several passes until the bearing caps are snug with the cylinder head. Place the No.3, No.4, No.6 and No.7 bearing caps in their proper location. Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly.ENGINE — ENGINE MECHANICAL EG-109 (h) Place the No.1 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap. () Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly. (i) Uniformly tighten the fourteen bearing cap bolts in several passes. Torque: 16 N-m (160 kafem, 12 ft-1bf) B, Install exhaust camshaft (a) Set the timing mark (two dot marks) of the camshaft drive gear at approx. 35° angle by turning the hexa- gon wrench head portion of the intake camshaft with a wrench. (b) Apply engine oil to thrust portion of the exhaust camshaft. {c) Engage the exhaust camshaft gear to the intake camshaft gear by matching the timing marks (two dot marks) on each gear. (4) Roll down the exhaust camshaft onto the bearing journals while engaging gears with each other. (e) Lightly push the intake camshaft towards the front without applying excessive force. (#) Install the No.4 and No.6 bearing caps in their proper location, (g) Temporarily tighten the bearing cap bolts uniformly and alternately in several passes until the bearing caps are snug with the cylinder head.EG-110 ENGINE ~ ENGINE MECHANICAL {h) Place the No.2, No.3, No.5 and No.7 bearing caps in their proper location. (i) Temporarily tighten these bearing cap bolts, alter- nately tightening the left and right bolts uniformly. (i) Place the No.1 bearing cap in its proper location. When doing this, check that there is no gap between the cylinder head and the contact surface of bearing cap. {k) Temporarily tighten the bearing cap bolts, alternately tightening the left and right bolts uniformly. © oon () Uniformly tighten the fourteen bearing cap bolts in several passes. Torque: 16 N-m (160 kaf-cm. 12 ft-lbf) (m) Bring the service boit installed in the driven sub—gear upward by turning the hexagon wrench head portion of the camshaft with a wrench. {n) Remove the service bolt. (co) Check that the intake and exhaust camshafts turn smoothly. 4, SET CAMSHAFTS TO FOLLOWING POSITION: ‘Turn the camshafts so that the timing marks with one and two dots will be in straight line on the cylinder head surface as shown in the illustration.ENGINE — ENGINE MECHANICAL Feu 5. INSTALL CAMSHAFT TIMING GEAR HINT: Check that the matchmarks on the camshaft timing gear and timing chain are aligned. (a) Place the gear over the straight pin of the intake camshaft. ‘Straight Pin| Matehmarks (b} Align the straight pin of distributor gear with the straight pin groove of the intake camshaft gear as shown, (c) Hold the intake camshaft with a wrench, install and torque the bolt. Torque: 74 N-m (750 kgf-cm, 54 ftbf) 6. INSTALL CHAIN TENSIONER (a) Place a new gasket so that the front mark is toward the front side, (b) Release the ratchet pawl, fully push in the plunger and apply the hook to the pin so that the plunger cannot spring out.ENGINE — ENGINE MECHANICAL (c) {e) {b) Install the chain tensioner with the two nuts, Torque: 21 N-m (210 kgf-cm, 15 ftlbf) NOTICE: If the plunger springs out during installation of the chain tensioner, repeat the operation in step (b) before installing the tensioner. SET CHAIN TENSIONER ‘Turn the crankshaft to the left so that the hook of the chain tensioner is released from the pin of the plunger, causing the plunger to spring out and the slipper to be pushed into the chain. HINT: If the plunger does not spring out, press the slipper into the chain tensioner with a screwdriver or your finger so that the hook is released and the plu- nger springs out. CHECK VALVE TIMING Turn the crankshaft pulley two revolutions from TOC to TDC. Notici Always turn the crankshaft clockwise. Check that the timing marks (one and two dots) of the ‘camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°) and align the marks as above.EG-113 ENGINE — ENGINE MECHANICAL 9. 10. fa) (b) (c) n, (a) (b) 12. 13, CHECK AND ADJUST VALE CLEARANCE Turn the camshaft and position the cam lobe upward and check and adjust the valve clearance. Valve clearance (Cold): Intake 0.15 — 0.25 mm (0.008 — 0.010 in.) Exhaust 0.25 — 0.35 mm (0.010 — 0.014 in.) INSTALL SEMI—CIRCULAR PLUG Remove any old packing (FIPG) material Apply seal packing to the cylinder head installation surface of the half—circular plug. ‘Seal packing: Part No.08826—00080 or equivalent Install the half—circular plug to the cylinder head. INSTALL CYLINDER HEAD COVER Install the gasket to the cylinder head cover. Install the cylinder head cover with the 13 bolts. INSTALL SPARK PLUGS Using SST, install the spark plug. SST 09155-16100 Torque: 20 N-m (200 kgf-cm, 14 ftbf) CONNECT ENGINE WIRE Connect the engine wire to the cylinder head with the bolt.EG-114 ENGINE — ENGINE MECHANICAL 14, INSTALL WATER BY-PASS OUTLET AND PIPE {e) Install a new O—ring to the water by—pass outlet. {b) Install two new O-rings to the water by—pass pipe. (©) Apply soapy water to the O-rings. {c} Assembie the water by~ pass outlet and pipe, fox {e) Install the water by—pass outlet and pipe with the two bolts, Torque: 21 Nm (210 kgf-om, 15 ftlbf) 15. INSTALL NO.1 AND NO.2 ENGINE HANGERS Torque: 41 Nom (420 kgf-cm, 30 fbf) 16, INSTALL NO.1 AND NO.2 EXHAUST MANIFOLDS (2) install two new gaskets, No.1 exhaust manifold and No.2 exhaust manifold with the 13 nuts. Torque: 39 N-m (400 kgf-cm, 29 ft bf]EG-115 ENGINE — ENGINE MECHANICAL Seal Packing {b) 17. {a) (b) (ce) Install the No.1 heat insulator and No.2 heat insulator with the six bolts, Torque: 19 Nm (195 kgf-cm, 14 ftbf) INSTALL WATER BY~PASS FLANGE Remove any old packing (FIPG) material and be car- eful not to drop any oil on the contact surfaces of the water by—pass and intake manifold. * Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. ¢ Thoroughly clean all components to remove all the loose material. Using a non—residue solvent, clean both sealing surfaces. Apply seal packing to the water by~pass flange as shown in the illustration. Seal packing: Part No.08826~00080 or equivalent * Install a nozzle that has been cut toa 3 — 4mm {0.12 — 0.16 in.) opening. HINT: Avoid applying an excessive amount to the surface. * Parts must be assembled within 5 minutes of application, Otherwise the material must be re- moved and reapplied. * Immediately remove nozzle from the tube and reinstall cap. Install the water by~pass flange with the six bolts and two nuts. Torque: 21 N-m (210 kgf.cm, 15 ft-lbf)nee EG-116 ENGINE — ENGINE MECHANICAL fa) (b) fa) (b) (c) (d) (a) (b) {e) (d) 18. 19. 20. 21. INSTALL INTAKE MANIFOLD WITH CARBURETOR Place a new gasket so that the rear mark is toward the rear side. Install the intake manifold and ground strap with the six bolts and two nuts. Torque: 21 N-m (210 kgf-om, 15 ft-Ibf) INSTALL OIL DIPSTICK AND GUIDE Install a new O-ring to the dipstick guide. Apply light coat of engine oil on the O-ring. Push in the dipstick guide into the guide hole of the No.1 oil pan. Install the ground strap and dipstick guide with the two bolts. Torque: 20 N-m (200 kaf-om, 14 ft-lbf) INSTALL ACCELERATOR CABLE BRACKET Install the accelerator cable bracket with the two bolts. Torque: 18 Nm (185 kgf.cm, 13 ftbf) CONNECT FOLLOWING CONNECTORS: Spark control VSV (for G.C.C,) Water temperature switch Water temperature sensor (for G.C.C.] TP VSVENGINE — ENGINE MECHANICAL eae 22. CONNECT TWO VACUUM HOSES TO BVSV 23. INSTALL NO.2 WATER BY—PASS PIPE AND HOSES Install the No.2 water by~pass pipe and hoses with the three bolts. Torque: 20 Nm (200 kgf-em, 14 ftlbf) Connect the hose to the hose clamp. a (b) (c) Connect the two water hoses. 24. CONNECT PCV HOSE 28. INSTALL FUEL PUMP (a) Install a new insulator and fuel pump with the three bolts, Torque: 21 N-m (210 kaf-cm, 18 ftlbf) {b) Connect the fuel outlet hose.ont 26. (a) (b) (c) 27. 28. 29. fa) ENGINE — ENGINE MECHANICAL INSTALL WATER OUTLET Install a new gasket and water outlet with the two nuts. Torque: 21 Nem (210 kgf-om, 15 ft-lbf) Connect No.1 water by—pass hose. Connect the vacuum hoses. INSTALL ALTERNATOR BRACKET Install the alternator bracket with the two bolts. Torque: 43 Nem (440 kgf-cm, 32 ftlbf) INSTALL ALTERNATOR AND DRIVE BELTS, (See CH section) INSTALL DISTRIBUTOR Install a new O-ring to the distributor. HINT: Always use a new O—ring when installing the distributor.ENGINE — ENGINE MECHANICAL ae {b) Align the groove of the distributor housing with the protrusion on the driven gear. {c) Apply a light coat of engine oil on the O-ring, (d)_ Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. {e) Lightly tighten the hold—down bolts. (f) Connect the high~tension cords. Firing order: 1-5-3~6-2-4 (g)_ Install the No.1 cord clamp mounting bolt. 30. INSTALL NO. 2 AND NO. 3 CYLINDER HEAD COVERS Install the head covers with the four bolts. 31. INSTALL INTAKE AIR CONNECTOR {a) Install the air connector with the two bolts and nut. Bolt Torque: 20 N-m (200 kgfom, 14 ftlbf) Nut Torque: 5.4 N.m (55 kaf-om, 48 ft.lbt) {b) Connect the PCV hose.EG-120 ENGINE ~ ENGINE MECHANICAL TIMING CHAIN COMPONENTS FOR REMOVAL AND INSTALLATION Chain Tensioner Slipper Cran Front Oil Seal Crankshat Pulley aaa 14.200, 304) Timing Chain Camshaft Timing Gear 20 1200, 14) j Jet ee. ee f eee No.1 Ol Pan 4)) Timing Pulley Pump Drive Shaft Gear il Pump Drive Shatt Gear Chain Vibration Damper Timing Chain Cover kshatt f ¢0-Ring O-Ring ‘ ip 5 ft (2rz10.757)} [ETRE eal e* Drive Belt ‘Adjusting Bar (8.8.00, 78 in.) Drive Belt Idler Pulley ag (480, 32) & T8160, 68 inhi] Specified torque Tiel 4 et No.2 Of Pan SEOENGINE — ENGINE MECHANICAL, £G-121 TIMING CHAIN REMOVAL 1. REMOVE WATER PUMP (a) Stretch the belts and loosen the fan pulley mounting nuts. (b) Loosen the pivot and adjusting bolts of the alternator, and remove the drive belts. {c) Remove the four nuts, fan with fluid coupling and water pump pulley. {d) Remove the four bolts, two nuts, water pump and gasket. 2. REMOVE CYLINDER HEAD 3. (Europe) REMOVE OIL LEVEL SENSOR {a) Remove the four bolts and level sensor. (b) Remove the gasket from the level sensor. 4, REMOVE NO.2 OIL PAN (a) Remove the 17 mounting bolts and two nuts. (bp) Insart the blade of SST batween the No.1 and No.2 oil pans, cut off applied sealer and remove the No.2 oil pan, SST 09032-00100 NOTICE: * Be careful not to damage the No.2 oil pan contact surface of the No.1 oil pan. * Be careful not to damage the oil pan flange.EG-122 ENGINE — ENGINE MECHANICAL. 5. (a) (b) (a) (b) REMOVE NO.1 OIL PAN Remove the 21 mounting bolts and two nuts. Remove the No.1 oil pan by prying the portions (A) between the cylinder block and No.1 oil pan with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and No.1 oil pan. REMOVE CRANKSHAFT PULLEY Using SST, remove the pulley bolt. SST 09213-58012, 09330—00021 Remove the crankshatt pulley. HINT: If necessary, remove the pulley with SST. SST 09213-60017 (09213-00020, 09213-00030, 09213-00060}, 09950-20017£G-123 ENGINE — ENGINE MECHANICAL ra (a) (b) (ce) (¢) CHECK THRUST CLEARANCE OF OIL PUMP DRIVE SHAFT GEAR Using a dial indicator with lever type attachment, measure the thrust clearance, Standard thrust clearance: 0.050 — 0.150 mm (0.0020 — 0.0059 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) If the thrust clearance is greater than maximum, re- place the oil pump drive shaft gear and/or timing chain cover, REMOVE DRIVE BELT IDLER PULLEY Remove the bolt and idler pulley. REMOVE TIMING CHAIN COVER Remove the nine mounting bolts, two mounting nuts and drive belt adjusting bar. Remove the timing chain cover by prying the portions between the cylinder block and timing chain cover with a screwdriver. NOTICE: Be careful not to damage the contact surfaces of the cylinder block and oil pump. Remove the O-rings from the timing chain cover. Remove the gasket fram the timing chain cover. EGLaila ENGINE — ENGINE MECHANICAL 10. REMOVE TIMING CHAIN AND CAMSHAFT TIMING GEAR 11, REMOVE CRANKSHAFT TIMING GEAR HINT: If necessary, remove the gear with SST. SST 09213-36020, 09950-20017 . - 12. REMOVE CHAIN TENSIONER SLIPPER AND Hexagon §\ 2 VIBRATION DAMPER ~ (2) Using a 10mm hexagon wrench, remove the bolt and slipper. {b) Remove the two bolts and damper. 13. REMOVE OIL JET Remove the bolt and oil jet.ENGINE ~ ENGINE MECHANICAL, Eee 14. REMOVE OIL PUMP DRIVE SHAFT GEAR 15. REMOVE PUMP DRIVE SHAFT GEAR If the pump drive shaft gear cannot be removed by hand, use two screwdrivers. NOTICE: Position shop rags as shown to prevent damage.(Ese EG-126 ENGINE — ENGINE MECHANICAL SS 16 Links: PS i a @ Air TIMING CHAIN COMPONENTS INSPECTION 1, INSPECT TIMING CHAIN AND TIMING GEARS (2) Measure the length of 16 links with the chain fully stretched. Maximum chain elongation: 146.6 mm (8.772 in.) If the elongation is greater than maximum. replace the chain, HINT: Make the same measurements pulling at three or more places selected at random. (b) Warp the chain around the timing gear. (c) Using vernier calipers, measure the timing gear di- ameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum gear diameter (w/chain): Crankshaft 126.0 mm (4.961 in.) Camshaft 65.4 mm (2.875 in.) If the diameter is less than minimum, replace the chain and gears. 2, INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPER Measure the chain tensioner slipper and vibration damper wears. Maximum w 1.0 mm (0.038 in.) If the wear is greater than maximum, replace the slipper and/or damper. 3. INSPECT OIL JET Check the oil jet for damage or clogging. If necessary, replace the oil jetENGINE — ENGINE MECHANICAL EG-127 CRANKSHAFT FRONT OIL SEAL REPLACEMENT HINT: There are two methods (A and B) to replace the oil seal which are as follows: REPLACE CRANKSHAFT FRONT OIL SEAL A. If timing chain cover is removed from cylinder block: (a) Using a screwdriver and a hammer, tap out the oil seal, (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09316~60010 (09316-00010, 08316~00050) (c) Apply MP grease to the oil seal lip. B. If timing chain cover is installed to the cylinder block: {a) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (b) Apply MP grease to a new oil seal lip. (c)_ Using SST and a hammer, tap in the oil sea! until its surface is flush with the timing chain cover edge. SST 09316-60010 (09316-00010, 09316-00050)EG-128 ENGINE — ENGINE MECHANICAL TIMING CHAIN INSTALLATION SET CRANKSHAFT Turn the crankshaft until the set key on crankshaft facing downward. 2. INSTALL PUMP DRIVE SHAFT GEAR . INSTALL OIL PUMP DRIVE SHAFT GEAR (2) Apply light coat of engine oil on the shaft portion of the gear. (b) Install the gear. 4. INSTALL OIL JET Install the oil jet with the bolt. Torque: 20 N-m (200 kgf-em, 14 ft-lbf) a 5. INSTALL CHAIN TENSIONER SLIPPER AND, i S VIBRATION DAMPER 37 (2) Install the damper with the two bolts. Torque: 20 N-m (200 kaf-em, 14 ft-lbf) (b) Using a 10 mm hexagon wrench, install the slipper with the bolt. S ‘Torque: 69 N-m (700 kgf-em, 51 ft-Ibf) 19 mm Hexagon' Wrench£G-129 ENGINE — ENGINE MECHANICAL rs {c) Check that the slipper moves smoothly. ca 6. INSTALL CRANKSHAFT TIMING GEAR HINT: if necessary, install the gear with SST. SST 09636—20010 7. INSTALL TIMING CHAIN AND CAMSHAFT TIMING GEAR (a) Install the timing chain on the camshaft timing gear with the bright link aligned with the timing mark on the camshaft timing gear. (b) Install the timing chain on the crankshaft timing gear with the other bright link aligned with the timing mark on the crankshaft timing gear.EG-130 roan () (a) {b) {c) ENGINE ~ ENGINE MECHANICAL Tie the timing chain with a cords as shown in the illustration and make sure it doesn’t come loose. INSTALL TIMING CHAIN COVER Remove any old packing (FIPG) material and be car- eful not to drop any oil on the contact surfaces of the timing chain cover and cylinder block. © Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. ‘© Thoroughly clean all components to remove all the loose material. Using a non—residue solvent, clean both sealing surfaces. Apply seal packing to the timing chain cover as shown in the illustration. ‘Seal packing: Part No.08826 —00080 or equivalent ‘* Install a nozzle that has been cut toa 2 — 3mm (0.08 — 0.12 in. opening. HINT: Avoid applying an excessive amount to the surface. * Parts must be assembled within 5 minutes of application, Otherwise the material must be re- moved and reapplied. @ Immediately remove nozzle from the tube and reinstall cap. Place two new O-ring in position on the timing chain cover.ENGINE — ENGINE MECHANICAL eee (4) Engage the gear of the oil pump drive rotor with the gear of the oil pump drive gear, and slide the oil pump. (e) Install the oil pump and drive belt adjusting bar with the nine boits and two nuts. Torque: 21 N-m (210 kgf-cm, 15 ftlbf) HINT: Each bolt length is indicated in the illustration. A 30 mm (1.18 in) B50 mm (1.97 in.) © 60 mm (2.38 in.) 9. INSTALL DRIVE BELT IDLER PULLEY Install the pulley with the bolt, Torque: 43 N-m (440 kgf-cm, 32 ftibf) 10. INSTALL CRANKSHAFT PULLEY (a) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install and torque the pulley bolt. SST 09213-68012, 09330-00021 Torque: 412 N-m (4,200 kgf.om, 304 ftlbf) 11. INSTALL NO.1 OIL PAN (2) Remove any old packing (FIPG) material and be car- eful not to drop any oil on the contact surfaces of the timing chain cover and cylinder block. ¢ Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. * Thoroughly clean all components to remove all the loose material.£G-132 ENGINE — ENGINE MECHANICAL A seatwian 3— 4mm 8 © Using a non—residue solvent, clean both sealing surfaces. {b) Apply seal packing to the No.1 oil pan as shown in the Part No.08826— 00080 or equivalent © Install @ nozzle that has been cut toa 3 — 4mm (0.12 — 0.16 in.) opening. HINT: Avoid applying an excessive amount to the surface. * Parts must be assembled within 5 minutes of application, Otherwise the material must be re- moved and reapplied. @ Immediately remove nozzle from the tube and reinstall cap. (c)_ Install a new gasket in position. (6) Pour in approximately 15 cm? (0.9 cu in.) of engine oil in position. (e) Install the No.1 oil pan with the 21 bolts and two nuts. 14mm he Torque: 43 Nem (440 kgf-em, 32 ft-ibf) 12mm he: Torque: 20 N-m (200 kgf-cm, 14 ftibf)EG-133 ENGINE — ENGINE MECHANICAL A Y seat width 3— 4mm 8 Seal Width 2—3mm 12, INSTALL NO.2 OIL PAN (a) Remove any old packing (FIPG) material and be car- eful not to drop any oil on the contact surface of the No.1 oil pan. * Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. © Thoroughly clean all components to remove all the loose material. * Using @ non—residue solvent, clean both sealing surfaces, (b) Apply seal packing to the No.2 oil panas shown in the illustration. NOTICE: Do not use @ solvent which will affect the painted surfaces. Seal packing: Part No.08826—00080 or equivalent ‘© Install a nozzle that has been cut to a 2 — 3mm (0.08 — 0.12 in.) opening or 3 — 4 mm (0.012 — 0.016 in.) opening, HINT: Avoid applying an excessive amount to the surface. * Parts must be assembled within 5 minutes of application. Otherwise the material must be re- moved and reapplied. © Immediately remove nozzle from the tube and reinstall cap. (c) Install the No.2 oil pan with the 17 bolts and two nuts. Bolt Torque: 7.8 N-m (80 kgf-cm, 68 in-Ibf) Nut Torque: 8.8 N-m (90 kgf-em, 78 in-lbf) 13, (Europe) INSTALL OIL LEVEL SENSOR (a) Install a new gasket to the level sensor.ENGINE — ENGINE MECHANICAL {b) Install the level sensor with the four bolts. ‘Straight Pin Blight Link 14, INSTALL CYLINDER HEAD [See page EG—70]or ORE be NOTICE: However, for the instllation of the camshaft timing gear and timing chain, follow the blow procedure. Align the blight link of the timing chain and camshaft ir mark, and install them to the camshaft. 15, INSTALL WATER PUMP Install a new gasket and water pump with the four bolts and two nuts. Torque: 21N-m (210 kgf-em, 14 ft bf) AI! na 16. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELTS (a) Install the water pump pulley and fan with fluid cou- pling with the four nuts. (b) Place the crive belts on to each pulley. () Stretch the belts tight and tighten the four nuts. (d)_ Adjust the drive belts.ENGINE — ENGINE MECHANICAL EG-135 CYLINDER BLOCK ; COMPONENTS FOR DISAEEMBLY AND” ASSEMBLY T— Piston Ring (Side Rail) Piston Ring (Expander) 4 Snap Ring < wir Mounting 2 "S o-Connecting Rod 2nd Tum 9 racket Bushing ith (Mpsttato) Connecting Rod (atzi0. Te}. Oil Cooter ES Connecting Rod Cover Go_] Bearing Flywhee! With (St oae) Qo—comeating os Cap O— [Seepage £6-760 ® Front Spacer @Reer Oil Seal Rear Oil Seal Retainer SCs Union 44 (450, 33) son -@ OCB Sizer" SS 7 Rear Spacer Drive Plate ‘Mounting Bracket ‘Crankshaft (Wi sor) Insulator, Crankshaft Thrust Washer Main Bearing BP oil Nozzle Check Valve 725 (250, 18) = cena See [Nem Kagem, fifi] : Specified torque ‘@ Non-reusable part eg feedENGINE — ENGINE MECHANICAL PREPARATION FOR DISASSEMBLY 1. REMOVE DRIVE PLATE Uniformly loosen and remove the drive plate bolts in several passes, in the sequence shown. EG 2. INSTALL ENGINE TO ENGINE STAND FOR DISASSEMBLY 3. REMOVE CYLINDER HEAD [see rave £628) 4, REMOVE TIMING CHAIN AND GEARS (See page EG— 120) 5. REMOVE OIL FILTER Using SST, remove the oil filter. SST 09228-44011 6, REMOVE OIL FILTER UNION 7. (1FZ-FE) REMOVE KNOCK SENSORS Using SST, remove the two knock sensors. ‘SST 09816-30010EG-137 ENGINE — ENGINE MECHANICAL esas 8. {a) (b) (a) (b) 10. (a) (b) 1. REMOVE PS PUMP Remove the two nuts and pump. Remove the O—ring from the pump. REMOVE RH ENGINE MOUNTING BRACKET Remove the nut and insulator. Remove the four bolts and bracket. REMOVE LH ENGINE MOUNTING BRACKET Remove the nut and insulator. Remove the four bolts and bracket. REMOVE OIL COOLER COVER AND OIL COOLER Remove the ten bolts, two nuts, oil cooler cover with the oil cooler and gasket.Feiss ENGINE — ENGINE MECHANICAL CYLINDER BLOCK DISASSEMBLY (See Components for Disassembly and Assembly) 1, REMOVE REAR OIL SEAL RETAINER Remove the four bolts and retainer. 2. CHECK CONNECTING ROD THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while moving the connecting rod back and forth. Standard thrust clearance: 0,160 — 0.262 mm (0.0063 ~ 0.0103 in.) Maximum thrust clearance: 0.362 mm (0.0143 in.) If the thrust clearance is greater than maximum, re- place the connecting rod assembly. If necessary, re- place the crankshaft. 3. REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE (a) Check the matchmarks on the connecting rod and cap to ensure correct reassembly. (b) Remove the connecting rod cap nuts. (c) Using a plastic—faced hammer, lightly tap the con- necting rod bolts and lift off the connecting rod cap. HINT: Keep the lower bearing inserted with the connecting rod cap.ENGINE — ENGINE MECHANICAL EG-139 (d) Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage. ed {e) Clean the crank pin and bearing. (Check the crank pin and bearing for pitting and ser- atches. If the crank pin or bearing is damaged. replace the bearings. If necessary, grind or replace the crankshaft. (9) Lay a strip of Plastigage across the crank pin. (bh) Install the connecting rod cap with the two nuts. Torque: 48 N-m (490 kgf-cm, 35 ft bf) 2nd Turn 90° NOTICE: Do not turn the crankshaft. (i) Remove the two nuts and connecting rod cap. (See procedure (b) and (c) above)EG-140 ‘i @ ENGINE — ENGINE MECHANICAL Measure the Plastigage at its widest point. Standard oil clearance: sTD 0.032 — 0.050 mm (0.0013 — 0.0020 in.) Us 0.26 0.033 — 0.073 mm (0.0013 — 0.0029 in.) Maximum oil clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crank- shaft. HINT: If using a standard bearing, replace with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the con- necting rod and crankshaft, then selecting the bearing with the same number as the total. There are five sizes of standard bearings, marked "2", "3", "4", "6" and “6” accordingly. ‘Number marked Connecting rod 1 2 2 Crankshaft t[2[s}i[2[ahi [2 Use bearing 2[s[a[sfa{s[a|s EXAMPLE: Connecting rod “'3"" + Crankshaft “"1"" = Total number 4 (Use bearing ‘4’ vase (Reference) Connecting rod big end inside diameter: Mark “1” 60.526 — 60.532 mm (2.3829 — 2.3831 in.) Mark “2° 60.532 — 60.538 mm (2.3831 — 2.3834 in.) Mark “3° 60.538 — 60.544 mm (2.3834 — 2.3836 in.)EG-141 ENGINE — ENGINE MECHANICAL (k), fa) (b) Crankshaft crank pin diamete Mark "1" 56.994 — 57.000 mm (2.2439 — 2.2441 in.) Mark "2" 56.988 — 56,994 mm (2.2436 — 2.2439 in.) Mark "3" 56.982 — 56.988 mm (2.2434 — 2.2436 ‘Standard sized bearing center wall thickness: Mark “2° 2.489 — 2.492 mm (0.0980 — 0.0981 in.) Mark “3° 2.492 — 2.495 mm (0.0981 — 0.0982 in.) Mark “4° 2.495 — 2.498 mm (0.0982 — 0.0983 in.) Mark “5° 2.498 — 2.501 mm (0.0983 — 0.0985 in.) Mark “6” 2.501 — 2.504 mm (0.0985 — 0.0986 in.) Completely remove the Plastigage. ) REMOVE PISTON AND CONNECTING ROD ASSEMBLIES Using a ridge reamer, remove the all carbon from the top of the cylinder. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block. HINT: * Keep the bearings, connecting rod and cap to- gether. © Arrange the piston and connecting rod assembl- ies in correct order. CHECK CRANKSHAFT THRUST CLEARANCE Using a dial indicator, measure the thrust clearance while prying the crankshaft back and forth with a screwdriver. Standard thrust clearanc 0.020 — 0.220 mm (0.0008 — 0.0087 in.) Maximum thrust clearance: 0.30 mm (0.0118 in.) EaEG-142 fa) (b) (c) (d) (e) ENGINE — ENGINE MECHANICAL if the thrust clearance is greater than maximum, re- place the thrust washers as a set. Thrust washer thickness: STD 2.440 — 2.490 mm (0.0961 — 0.0980 in.) O/S 0.125 2.503 — 2.553 mm (0.0985 — 0.1005 in.) O/s 0.250 2.565 — 2.615 mm (0.1010 — 0.1030 in.) REMOVE MAIN BEARING CAPS AND CHECK OIL CLEARANCE Uniformly loosen and remove the main bearing cap bolts in several passes, in the sequence shown, Using the removed main bearing cap bolts, pry the main bearing cap back and forth, and remove the main bearing caps, lower bearings and lower thrust was- hers (No.4 main bearing cap only). HINT: Keep the lower bearing and main bearing cap together. * Arrange the main bearing caps and lower thrust washers in correct order. Lift out the crankshaft. HINT: Keep the upper bearing and upper thrust washers together with the cylinder block. Clean each main journal and bearing. Check each main journal and bearing for pitting and scratches. If the journal or bearing is damaged, replace the bearings. If necessary, grind or replace the crankshaft.ENGINE — ENGINE MECHANICAL Plastigage C) (9) (h) fi) a) EG-143 Place the crankshaft on the cylinder block. Lay a strip of Plastigage across each journal. Install the main_beari (Gee step 6 onjoage EG— 10%] Ast Torque: 74 N-m (750 kgf-cm, 54 ft-ibf) 2nd Turn 90° NOTICE: Do not turn the crankshaft. Remove the main bearing caps. (See procedure (a) and (b) above) Measure the Plastigage at its widest point. Standard clearance: sTD 0.042 — 0.060 mm (0.0017 — 0.0024 in.) B/S 0.25 0.041 — 0.081 mm (0.0016 — 0.0032 in.) Maximum clearance: 0.10 mm (0.0039 in.) If the oil clearance is greater than maximum, replace the bearings. If necessary. grind or replace the cra- nkshaft.£G-144 ENGINE — ENGINE MECHANICAL No.3 | No.4 x2 No.3 4 Mark age te 20rd No.7 No.6 No.5 HINT: If using a standard bearing, replace with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylin- der block and crankshaft, then selecting the bearing with the same number as the total. There are five sizes, of standard bearings, marked "2", "3°, "4", "5" and “6” accordingly. So Noibor marked Gyinder block 7 | 2 3 Crankshatt *[2]2[*]213[*]2]8 Use beating 2lsfalslalslals|s EXAMPLE: Cylinder block "2" + Crankshaft “1” = Total number 3 (Use bearing 3") (Reference) Cylinder block mai Mark "1" 74.026 — 74,032 mm (2.9144 — 2.9146 in.) Mark “2° 74.032 — 74.038 mm (2.9146 — 2.9149 in.) Mark “3° 74.038 — 74.044 mm (2.9149 — 2.9151 in.) Crankshaft journal Mark “1 68.994 — 69.000 mm (2.7163 — 2.7165 in.) Mark *2" 68.988 — 68.994 mm (2.7161 — 2.7163 in.) Mark “3” 68.982 -- 68.988 mm (2.7158 — 2.7161 in.) ‘Standard sized bearing center wall thickness: Mark "2" 2.489 — 2.492 mm (0.0980 — 0.0981 in.) Mark "3 2.492 — 2.495 mm (0.0981 — 0.0982 in.) Mark "4" 2.495 — 2.498 mm (0.0982 — 0.0983 in.) Mark "5" 2.498 — 2.501 mm (0.0983 — 0.0985 in.) Mark "6" 2.501 — 2.504 mm (0.0985 — 0.0986 in.) journal bore diameter: jameter: (k) Completely remove the Plastigage.ENGINE — ENGINE MECHANICAL, EG-145 7. REMOVE CRANKSHAFT {a) Lift out the crankshaft. (b) Remove the upper main bearings and upper thrust washers from the cylinder block. HINT: Arrange the main bearings and thrust washers in correct order. 8. REMOVE CHECK VALVES AND OIL NOZZLES Remove the six check valves and oil nozzles. 9. REMOVE CYLINDER BLOCK ORIFICEEG-146 ENGINE — ENGINE MECHANICAL. CYLINDER BLOCK INSPECTION 4, CLEAN CYLINDER BLOCK A. Remove gasket material Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block. B. Clean cylinder block Using a soft brush and solvent, thoroughly clean the cylinder block. 2. INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and thickness gauge. measure the surfaces contacting the cylinder head gasket for warpage. Maximum warpage: 0.05 mm (0.0020 in.) If warpage is greater than maximum, replace the cyl- inder block. 3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the six cyl- inders. If necessary, replace the cylinder block. 4. INSPECT CYLINDER BORE DIAMETER HINT: There are three sizes of the standard cylinder bore diameter, marked “1°, "2" and “3” accordingly. The mark is stamped on the top of the cylinder block us Mark 1, 2 or 3ENGINE — ENGINE MECHANICAL eee Using a cylinder gauge, measure the cylinder bore @ Thrust diameter at positions A, B and C in the thrust and axial Front = (>) bata directions. @ Axi iameter: © Sian | Santer ane oo £10. mm Mark "1" AFF {0.39 in) 100.000 — 100.010 mm (3.9370 ~ 3.9374 in} }- Bt Middle Mark “2° _fe a aan , 100.010 — 100.020 mm (3.9374 — 3.9378 in.) Mark “3 100.020 — 100.030 mm (3.9378 — 3.9382 in.) Maximum diameter: sTD 100.23 mm (3.9461 in.) o/s 0.50 100.73 mm (3.9658 in.) 0/8 1.00 101.23 mm (3.9854 in.) If the diameter is greater than maximum, rebore all the six cylinders. If necessary, replace the cylinder block. 5. REMOVE CYLINDER RIDGE If the wear is less than 0.2 mm (0.008 in.), using a ridge reamer, grind the top of the cylinder. 6. INSPECT MAIN BEARING CAP BOLTS Measuring Using vernior calipers, measure the thread outside Point diameter of the bolt. ‘Standard outside diameter: 10.85 — 11.00 mm (0.4271 — 0.4331 in.) i inimum outside diameter: ei 10.8 mm (0.417 in.) 25 ~ 30mm If the diameter is less than minimum, replace the bolt. (0.98 = 1.18 in) 7. INSPECT CYLINDER BLOCK OLIFICE Check the olifice for clogging. If necessary, replace the olifice.fo ENGINE — ENGINE MECHANICAL 8, INSPECT BEARING OF OIL PUMP DRIVE SHAFT GEAR Check the bearing for pitting and scratches. If the bearing is damaged, replace the bearing. PISTON AND CONNECTING ROD ASSY “~~ DISASSEMBLY 1. CHECK FIT BETWEEN PISTON AND PISTON PIN Try to move the piston back and forth on the piston pin, If any movement is felt, replace the piston and pin as a set. 2. REMOVE PISTON RINGS (2) Using a piston ring expander, remove the two com- pression rings. (b) Remove the two side rails and oil ring by hand. HINT: Arrange the rings in correct order only. 3. DISCONNECT CONNECTING ROD FROM PISTON (a) Using a small screwdriver. pry out the two snap rings.ENGINE ~ ENGINE MECHANICAL renee (b) Gradually heat the piston to 80 — 90°C (176 — 194° F). (c) Using plastic—faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod, = = HINT: © The piston and pin are a matched set. * Arrange the pistons, pins, rings, connecting rods and bearings in correct order. PISTON AND CONNECTING ROD INSPECTION 1. CLEAN PISTON (a) Using a gasket scraper, remove the carbon from the piston top. (b) Using a groove cleaning tool or broken ring, clean the piston ring grooves.EG-150 ENGINE — ENGINE MECHANICAL =] (e) Using solvent and a brush, thoroughly clean the Lo piston. NOTICE: Do not use a wire brush. 2. INSPECT PISTON AND PISTON RING Mark A. Inspect piston oil clearance oe HINT: There are three sizes of the standard piston diameter, marked "1", "2" and “3” accordingly. The mark is stamped on the piston top. Front Mark (Cavity) {a) Using a micrometer, measure the piston diameter at ring angles to the piston pin center line, 42 mm (1.65 in.) from the piston head. Piston diameter: sto Mark "1" 99.950 — 99.960 mm (3.9350 — 3.9354 in.) Mark *2" 99,960 — 99.970 mm (3.9354 ~ 3.9358 in.) Mark “3" 99,970 — 99.980 mm (3.9358 — 3.9362 in.) 07s 0.50 100.450 — 100.480 mm (3.9547 — 3.9559 in.) 0/8 1.00 100.950 — 100.980 mm (3.9744 — 3.9756 in.) (b) Measure the cylinder bore diameter in the thrust di- rections. ; Front No.1No.2No.3 No.4 nese 6 (See step 4 on page EG— 146} (c) Subtract the piston diameter measurement from the Mark 1, 2 or 3 cylinder bore diameter measurement. ‘Standard oil clearance: Front Mark Mork 0.040 — 0.060 mm (0.0016 — 0.0024 in.) (Cavity) 1, 20r3 If the oil clearance is greater than maximum, replace all the six pistons and rebore all the six cylinders. If necessary, replace the cylinder block. HINT (Use new cylinder block): Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.EG-151 ENGINE — ENGINE MECHANICAL erase fa) (b) (c) Inspect piston ring groove clearance Using a thickness gauge, measure the clearance be- tween new piston ring and the wall of the piston ring groove. Ring groove clearance No.1 0.040 — 0.080 (0.0016 — 0.0031 in.) No.2 0.030 — 0.070 (0.0012 — 0.0028 in.) If the clearance is greater than maximum, replace the piston. Inspect piston ring end gap Insert the piston ring into the cylinder bore Using a piston, push the piston ring a little beyond the bottom of the ring travel, 125 mm (4.92 in.) from the top of the oylinder block. Using a thickness gauge, measure the end gap. Standard end gap: No.t 0.300 — 0.520 mm (0.0118 — 0.0208 in.) No.2 0.450 ~ 0.670 mm (0.0177 — 0.0264 in.) Oil (Side rail) 0.150 — 0,520 mm (0.0059 — 0.0205 in.) Maximum end gap: No.1 1.12 mm (0.0441 in.) No.2 1.17 mm (0.0461 in.) Oil (Side rai 1.42 mm (0.0441 in.) If the ond gap is greater than maximum, replace the piston ring. If the end gap is greater than maximum, ‘even with a new piston ring, rebore all the six cylin- ders or replace the cylinder block.EG-152 ENGINE — ENGINE MECHANICAL — D. (b) Inspect piston pin fit At 80 ~ 90°C (176 ~ 194°F), you should be able to push the piston pin into the piston pin hole with your thumb. INSPECT CONNECTING ROD Inspect connecting rod alignment Using a rod aligner and thickness gauge, check the connecting rod alignment. © Check for bend. Maximum bend: 0.05 mm (0.0020 in.) per 100 mm (3.94 in.) If bend is greater than maximum, replace the conne- cting rod assembly. © Check for twist Maximum twist: 0.15 mm (0.0059 in. ) per 100 mm (3.94 in.) If twist is greater than maximum, replace the conne- cting rod assembly. Inspect piston pin oll clearance Using a caliper gauge, measure the inside diameter of the connecting rod bushing. Bushing inside diameter: 26.008 ~ 26.020 mm (1.0239 ~ 1.0244 in.) Using a micrometer, measure the piston pin diameter. Piston pin diameter: 26.000 — 26.012 mm (1.0236 — 1.0241 in.)EG-153 ENGINE — ENGINE MECHANICAL (ec) fa) (b) {c) (d) Subtract the piston pin diameter measurement from the bushing inside diameter measurement. Standard oil clearance: 0.004 — 0.012 mm (0.0002 — 0.000! Maximum oil clearance 0.05 mm (0.0020 in.) If the oil clearance is greater than maximum, replace the bushing. If necessary, replace the piston and "Eq" piston pin as a set. = If necessary, replace connecting rod bus! Using SST and a press, press out the bushing SST 09608 — 30012, (09608-04020), 09631-20031 Align the oil holes of a new bushing and the conne- cting rod, Using SST and a press, press in the bushing. SST 09608 ~30012, (08608-04020), 09631-20031 Using a pin hole grinder, hone the bushing to obtain the standard specified clearance (see step B above) between the bushing and piston pin.EG-154 ENGINE ~ ENGINE MECHANICAL (e) Check the piston pin fit at normal room temperature. Coat the piston pin with engine oil, and push it into the connecting rod with your thumb. D. Inspect connecting rod bolts (a) Install the cap nut to the connecting rod bolt. Check that the cap nut can be turned easily by hand to the end of the thread. (b) If the cap nut cannot be turned easily. measure the outside diameter of the connecting rod bolt with vernier calipers. Standard outside diameter: 8.40 ~ 8.60 mm (0.3307 — 0.3386 in.) Minimum outside diameter: 8.00 mm (0.3150 in.) HINT: If the location of this area cannot be judged sox by visual inspection, measure the outer diameter at the location shown in the illustration. If the outside diameter is less than minimum, replace the connecting rod bolt and nut as a set.EG-155 ENGINE — ENGINE MECHANICAL CYLINDER BORING (b) HINT: © Bore all the six cylinders for the oversized piston outside diameter. © Replace ail the piston rings with ones to match the oversized pistons. a SELECT OVERSIZED PISTONS Oversized piston diamete 0/8 0.50 100.450 ~ 100.480 mm (3.9547 — 3.9559 in.) 0/8 1.00 100.950 ~ 100.980 mm (3.9744 — 3.9756 in.) CALCULATE AMOUNT TO BORE CYLINDERS Using a micrometer, measure the piston diameter at right angles to the piston pin center line, 42 mm (1.65 in.) from the piston head. Calculate the amount of each cylinder is to be rebored as follows: Size to be rebored = P + C — H P = Piston diameter © = Piston clearance 0.040 — 0.060 mm (0.0016 — 0.0024 in.) H = Allowance for honing 0.20 mm (0.0008 in.) or less BORE AND HONE CYLINDER TO CALCULATED DIMENSIONS Maximum honing: 0.02 mm (0.0008 in.) NOTICE: Excess honing will destroy the finished rou- ndnoss.EG-156 ENGINE — ENGINE MECHANICAL, CRANKSHAFT INSPECTION AND REPAIR 1. INSPECT CRANKSHAFT FOR RUNOUT (2) Place the crankshaft on V—blocks. (b) Using a dial indicator, measure the circle runout at the center journal. Maximum circle runout: 0.06 mm (0.0024 in.) If the circle runout is greater than maximum, replace the crankshaft. 2. INSPECT MAIN JOURNALS AND CRANK PINS (2) Using a micrometer, measure the diameter of each main journal and crank pin. Main journal diameter: STD size 68.982 — 69.000 mm (2.7158 — 2.7165 in.) U/S 0.25 68.745 — 68.755 mm (2.7065 — 2.7069 in.) Crank pin diameter: STD size 56.982 — 57.000 mm (2.2434 — 2.2441 in.) U/S 0.25 56.745 — 56.755 mm (2.2341 ~ 2.2344 in.) If the diameter is not_as specified, check the oil cle- arance Bee pages EG— 142] to |144). If necessary, grind or replace the crankshaft. (b) Check each main journal and crank pin for taper and out—of—round as shown. Maximum taper and out—of—round: 0.02 mm (0.0008 in.) If the taper and out—of—round is greater than maxi- mum, replace the crankshaft. 3. IF NECESSARY, GRIND AND HONE MAIN JOURNALS AND/OR CRANK PINS Grind and hone the main journals and/or crank pins to the finished undersized diameter (See procedure in step 2). Install new main journal and/or crankshaft pin un- dersized bearings.ENGINE — ENGINE MECHANICAL Ferre CRANKSHAFT OIL SEALS REPLACEMENT HINT: There are two methods (A and B) to replace the oil seal which are as follows: 1. REPLACE CRANKSHAFT FRONT OIL SEAL A. If timing chain cover is removed from cylinder block: (a) Using a screwdriver and a hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge. SST 09316~60010 (09316-00010, 09316~ 00050) (c]_ Apply MP grease to the oil seal B. If timinh chain cover is installed to the cylinder block: {a) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. (b) Apply MP grease to a new oil seal lip. (c)_ Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover edge. SST 09316-60010 (09316-00010, 09316-00050)EG-158 ENGINE — ENGINE MECHANICAL ros om ~ t ssT room a Cut Position oe 2. A. (a) (b) te) {a) (b) {ce} (d) REPLACE CRANKSHAFT REAR OIL SEAL If rear oil sal retainer is removed from cylinder block: Using a screwdriver and a hammer, tap out the oil seal. Using SST and a hammer, tap in a new oil seal until its surface is flush with the rear oil seal edge. SST 09223-15030, 09608-30012 (09608 — 04020) Apply MP grease to the oil seal lip. lf rear oil seal retainer is installed to cylinder black: Using a knife, cut off the oil seal lip. Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape the screwdriver tip. Apply MP grease to a new oil seal lip. Using SST and @ hammer, tap in the oil seal until its surface is flush with the rear oil seal retainer edge. SST 09223— 15030, 09608-30012 (09608 04020)EG-159 ENGINE ~ ENGINE MECHANICAL Front Wok eed (Cavity) Front Mark {Protrusion) i PISTON AND CONNECTING ROD ASSEMBLY 1. ASSEMBLE PISTON AND CONNECTING ROD {a) Install a new snap ring on one side of the piston pin hole. (b) Gradually heat the piston to 80—90°C (176—194°F). (c) Coat the piston pin with engine oi {d) Align the front marks of the piston and connecting rod, and push in the piston pin with your thumb. (0) Install a new snap ring on the other side of the piston pin hole, 2. INSTALL PISTON RINGS. {a) Install the oil ring expander and two side rails by hand.EG-160 ENGINE — ENGINE MECHANICAL. (b) Using a piston ring expander, install the two com- pression rings with the code mark facing upward. Code mark: No.1 1R = No.2 =P 2R Virol Si0b Ma (c) Position the piston rings so that the ring ends are as. Rall Compression shown. Ring NOTICE: Do not align the ring ends. Front Mark/ (7 (Cavity Xx | ) Lower Side Rail Expander - No.2 Compression Ring sur 3. INSTALL BEARINGS (a) Align the bearing claw with the groove of the con- necting rod or connecting cap. (b)_ Install the bearings in the connecting rod and conne- ting rod cap.EG-161 ENGINE — ENGINE MECHANICAL CYLINDER BLOCK ASSEMBLY (See Components for Disassembly and Assembly) (a) (b) (a) (b) oa HINT: * Thoroughly clean all parts to be assembled. ‘* Before installing the parts, apply new engine oil to all sliding and rotating surfaces. © Replace all gaskets, O-rings and oil seals with “6G! RES, new parts. INSTALL CYLINDER BLOCK ORIFICE INSTALL OIL NOZZLES AND CHECK VALVES Align the pin of the oil nozzle with the pin hole of the cylinder block. Install the oil nozzle with the check valve, install the six oil nozzles and check valves. Torque: 25 N-m (280 kgf-cm, 18 ftlbf) INSTALL MAIN BEARINGS Align the bearing claw with the claw groove of the cylinder block, and push in the seven upper bearings, Align the bearing claw with the claw groove of the main bearing cap, and push in the seven lower bear- ings. HINT: A number is marked on each main bearing cap to indicate the installation position.1353, 8,6, 0r7 on ENGINE — ENGINE MECHANICAL fa) (b) INSTALL UPPER THRUST WASHERS. Install the two thrust washers under the No.4 journal position of the cylinder block with the oil grooves facing outward. PLACE CRANKSHAFT ON CYLINDER BLOCK INSTALL MAIN BEARING CAPS AND LOWER ‘THRUST WASHERS Place main bearing cap and lower thrust washers on cylinder block Install the two thrust washers on the No.4 bearing cap with the grooves facing outward. Install the seven main bearing caps in their proper locations. HINT: Each bearing cap has a number and front mark.ENGINE — ENGINE MECHANICAL Front Painted Mark a) (b) {c) (d) (e) (f) (9) (a) EG-163 Install main bearing cap bolts HINT: The main bearing cap bolts are tightened in two progressive steps (steps (b) and (d)) ‘@ If any one of the main bearing cap bolts is broken or deformed, replace it. Apply a light coat of engine oil on the threads and under the heads of the main bearing cap bolts. Install and uniformly tighten the 14 bolts of the main bearing caps in several passes. in the sequence shown. Torque: 74 Nem (750 kaf-om, 54 ftlbf) {If any one of the main bearing cap bolts does not meet the torque specification, replace the main bearing cap bolt, Mark the front of the main bearing cap bolt with paint. Retighten the main bearing cap bolts 90° in the nu- merical order shown above. Check that the painted mark is now at a 90° angle to the front. Check that the crankshaft turns smoothly. Check the crankshaft thrust clearance. (See stop 6 0 INSTALL PISTON AND CONNECTING ROD ASSEMBLIES: Cover the connecting rod bolts with a short piece of hose to protect the crankshaft from damage.EG-164 ENGINE — ENGINE MECHANICAL Front Merk SS (Cavity aa’ Front Front Mark (Provrusion) rs Front (b) (b) (a) (b) (co) Using a piston ring compressor, push the correctly numbered piston and connecting rod assemblies into each cylinder with the front mark of the piston facing forward. INSTALL CONNECTING ROD CAPS Place connecting rod cap on connecting rod Match the numbered connecting rod cap with the connecting rod. Install the connecting rod cap with the front mark facing forward. Install connecting rod cap nuts HINT: ‘* The connecting rod cap nuts are tightened in two progressive steps (steps (b) and (d)). If any connecting rod bolt is broken or deformed, replace it. Apply a light of engine oil on the threads and under the nuts of the connecting rod cap. Install and alternately tighten the nuts of the conne- ting rod cap in several passes. Torque: 48 N-m (490 kgf-cm, 35 ft-lbf) If any one of the connecting rod cap nuts does not meet the torque specification, replace the connecting rod bolt and cap nut as a set. Mark the front of the connecting rod cap nut and bolt with paint.EG-165 ENGINE — ENGINE MECHANICAL (a) Painted Mark (e) a) > { (a) (a) Fi 0) Seal Packing ot {e) Retighton the connecting rod cap nuts 90° as shown. Check that the painted mark on the nut is at 90° angle in relation to the mark on the bolt. Check that the crankshaft turns smoothiy. Check the conne: rod thrust clearance. (See step 2 on|page EG ~ 13: INSTALL REAR OIL SEAL RETAINER Remove any old packing (FIPG) material and be car- eful not to drop any oil on the contact surfaces of the retainer and cylinder block. © Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing groove. © Thoroughly clean all components to remove all the loose material © Using a non—residue solvent, clean both sealing surfaces. Apply seal packing to the retainer as shown in the illustration. ‘Seal packing: Part No. 08826-00080 or equivalent ‘© Install a nozzle that has been cut toa 2 — 3 mm (0.08 — 0.12 in.) opening. HINT: Avoid applying an excessive amount to the surface, © Parts must be assembled within 5 minutes of application. Otherwise the material must be re- moved and reapplied. * Immediately remove nozzle from the tube and reinstall cap. Install the retainer with the four bolts, Torque: 20 N-m (200 kgf-cm, 14 ftlbf)EG-166 ENGINE — ENGINE MECHANICAL. oss POST ASSEMBLY 1, INSTALL OIL COOLER COVER AND OIL COOLER Install a new gasket, oil cooler cover and oil cooler with the ten bolts and two nuts. Torque: 21 N.m (210 kaf-cm, 15 ftbf) 2. INSTALL LH ENGINE MOUNTING BRACKET (a) Install the bracket with the four bolts. Torque: 69 N.m (700 kaf-om, 51 ft-bf) (b) Install the insulator with the nut. Torque: 72 N-m (730 kgf-cm, 43 Ftlbf) 3. INSTALL RH ENGINE MOUNTING BRACKET {a) Install the bracket with the four bolts. Torque: 69 N-m (700 kaf-em, 51 ftlbf) {b) Install the insulator with the nut, Torque: 72 N-m (730 kgf-em, 43 ftbf)ENGINE ~ ENGINE MECHANICAL Laced 4. INSTALL PS PUMP (a) Place a new O-ring to the pump. (b) Install the pump with the two nuts. Torque: 36 N-m (370 kgf-cm, 27 ftlbf) 5. INSTALL KNOCK SENSORS Uing SST, install the two knock sensors. SST 09816-30010 Torque: 37 N-m (380 kgf-cm, 27 ftibf) 6. INSTALL OIL FILTER UNION Torque: 44 N-m (450 kgf-cm, 33 ft-lbf) 7. INSTALL OIL FILTER (2) Lubricate the filter rubber gasket with engine oil. (b) Tighten filter until the gasket contacts seat of the filtar mounting. Then using SST, give it an additional 3/4 turn to seat the filter. SST 09228-44011 8. INSTALL TIMING CHAIN INSTALL CYLINDER HEAD [Ses pose ES—71 or [106 10. REMOVE ENGINE STANDENGINE — ENGINE MECHANICAL Painted Mark Ww (a) (b) fa) (b) (e) {d) (e) INSTALL DRIVE PLATE (A/T) Install the front spacer, drive plate and rear plate on the crankshaft. Install and uniformly tighten the ten drive plate bolts in several passes, in the sequence shown. Torque: 100 N-m (1,000 kgf-om, 74 ftbt) . INSTALL FLYWHEEL (M/T) Inspect flywheel bolts Using vernier calipers, measure the outside diameter of the flywheel bolt. Stondard outside diameter: 10.3— 10.5 mm (0.406—0.413 in.) Minimum outside diameter: 9.5 mm (0.374 in.) If the diameter is less than minimum, replace the bolt. Install flywheel bolts HINT: © The flywheel bolts are tightened in two progres- sive steps (steps (b) and (¢)). © If any flywheel bolt is broken of deformed, re- place it Apply a light of engine oil on the threads and under the heads of the flywheel bolts. Install and uniformly tighten the ten flywheel bolts in several passes, in the sequence shown. Torque: 20 N-m (200 kaf-cm, 14 ftlbf) If any one of the flywheel bolts does not meet the torque specification, replace the flywheel bolt. Mark the flywheel bolt with paint. Retighten the flywheel bolts 90° in the numerical order shown above. Check that the painted mark is now at a 90° angle to (o).EG-169 ENGINE — ENGINE MECHANICAL SERVICE SPECIFICATIONS SERVICE DATA Tuneup Engine oll API grade ‘SG or better Battery epecitic gravity 1.25 - 127 (whon fully charged at 20°C (68°F) High—tonsion cord resistance Limit | 25 ko por cord Spark plug (Recammanded spark plva) no | kier—u | NGK | BKRSEYA Spark plug (Correct electrode gap) 0.8 mm (0.081 in) Alternator érive belt tension, New bott 11 = 15 mm (0.43 ~ 0.69 in.) Used belt 15 ~ 20 mm (0.89 ~ 0.79 in.) Aternator étive belt tension with SST Now bett 38 ~ 87 kof Used bolt 18 ~ 35 kof Valve clearance (Cold) Intake | mm (0.008 ~ 0.010 in) Exraust | 0.25 ~ 0.35 mm (0.010 ~ 0.014 in} Ienition timing 3° BTDC @ idle Ile speed 850 + 80 rpm | lle C0 concentration (General) 15 05% | Fast ite speed (6.0.6) 1900 «om Fast Idle speed (Others) 1,200 rpm P sotting speed 1,500 rpm TP setting speed 1,200 rpm Compression | at 250 pm — STD ~TFR=FE | 1,176 KPa (12.0 kgl/em®, 171 psi) or more presauro 1F2—F (Low octane model) | 900 kPa (9.2 kat/em’, 131 psi) or more (Others) | 1,080 kPa (10.5 kgt/om’, 149 psi) or more {8 260 rpm — Limit TF2-FE | 862 KP (8.0 kot/om’, 128 psi 1r2—-F | 785 kPe (8.0 kef/om, 114 psi) Difference of pressure borweeneach oylinder 98 KPa (1.0 Igf/om’, 14 psi or less Ttoke at idle speed : 13 KPa (478 mmHg, 18.6 ina) manifold Gylinder head | Warpage — Cylindor block eld (Limt) 10.18 ram (0.0088 in) Warpage ~ Manifold side (Limit) 0.10 mm {0.0088 in) 200t — Refacing ongle (intake) 30°, 45°, 75° Valve scat — Refacing angie (Exhaust) 45°, 75° Valve seat ~ Contacting angle as Valve seat — Contecting width (Intake) 1.2 — 1.6 mm (0.047 ~ 0.083 in) Valve seat ~ Contscting width (Exhaust) 1.0 - 14 mm (0.089 ~ 0.055 in) Cylinder head bolt outside diamete STD | 10.85 ~ 11.00 mm (0.4272 ~ 0.4991 in) Limit_|_ 10.6 mm (0417 iny Valve guide Inside diameter ~~ 7.010 — 7.030 mm (0.2780 — 0.2768 in) bushing Outside diameter (for repair part) sD | 11.492 ~ 11.513 mm (0.4524 ~ 0.4533 in) 0/8005 | 11.542 ~ 11.563 mm (0.4544 — 0.4552 in) Protusion height 8.2 — 86 mm (0.323 ~ 0.339in) ___ | Replacing temperature (Gylinder head side) 80 = 100°C (176 ~212"F) } GEG:EG-170 ENGINE — ENGINE MECHANICAL Valve Valve overall length 1FZ—FE STD (Intake) | 984 mm (3.874 in) (€xnaus) | 97.9 mm (3.854 in) Limit (intake) | 97.9 mm (3.854 in) (exnaust) | 97.4 mm (3.835 in) Valve overall length 1FZ—F ‘STD (Intake) | 98.7 mm (3.889 in) {Exhaust | 98.1 mm (9.862 i Limit intake) | 98.2 mam (8.886 in.) (Exhaust) | 97.6 mm (2843 in} Valve face angi 445° ‘Stem diameter (Intake) | 6.970 ~ 6.985 mm (0.2744 ~ 0.2750 in) | (Exhaust) | 6.985 ~ 6.980 mm (0.2742 ~ 0.2748 in) ‘Stem oil clearance STD (Intake) | 0.025 — 0,060 mm (0.0010 ~ 0.0026 in) | (Exhaust) | 0.030 — 0,065 mm (0.0012 ~ 0.0026 in) | Limit (ntake) | 0.08 mm (0.0031 in) (Exhaust) | 0.10 mm (0.0039 in) Margin thickness 1F2—FE STD. | 1.2 mm (0.047 in) Limit] 1.0 mm (0.038 ing Margin thickness 1F2—F STD (intake) | 1.5 mm (0.058 in.) (@xhaus) | 1.4 mm (0.058 in) Lieit 1.0 mm (0.039 in.) Valve spring | Deviation Limit [2.0 mm (0.079 in) Free lenath 43,94 ~ 45.08 mm (1.7299 ~ 1.7740 in} Installed tension at 98.6 mm (1.437 in) 214 ~ 2381N (21.8 ~ 24.2 kot, 48.1 — 53.4 tof) Valve lifter (iter diameter 33.866 — 33.976 mm (1.3372 — 1.3376 in} Lifter bore diameter 34,000 ~ 34.021 mm (1.3385 ~ 1.3394 in, Oil clearance: STD | 0.024 ~ 0.085 mm (0.0009 ~ 0.0022 in) Limit_| 0.07 mm (0.0028 in) Manifold warpage Limit_[ 0.80 mm (0.0118 in) Air intake 0.80 mm (0.0118 in) Loo Werpage Limit Camshatt Thrust clearance ‘STD | 0.080 — 0.080 mm (0.0012 ~ 0.0031 in) Limit | 0.10 mm (0.0039 in) Journal ol clearance 81 | 0.0025 ~ 0.082 mm (0.0010 ~ 0.0026 in} Limit | 0.10 mm (0.0039 in} Journal diameter 26.959 ~ 26.975 mm (1.0614 — 1.0820 in Circle rouncut Limit | 0.06 mm (0.0024 in) Cam lobe height, STD | 80.61 ~ 60.71 mm (1.9928 ~ 1.9868 in) Limit} $0.51 mm (1.9886 in.) Camshaft aeer becklesh STD} 0.020 ~ 0.200 mm (0.0008 ~ 0.0072 in) Limit | 0.30 mm (0.0188 in) Camshaft gear spring end free distance 18,2 — 18.8 mm (0.717 ~ 0.740 in) Spark plug Protusion 455 mm (1.791 in) | tubeENGINE ~ ENGINE MECHANICAL EG-171 Oil pune ‘870 | 0.050 ~ 0.150 mm (0.0020 — 0.0059 in drive shatt Limit | 0.90 eum (0.04 18 in) gear Chain and ‘Chain elongation at (6 links Limit [146.6 mm (8.772 in) timing gear | Crankshatt timing gear wear (w/ chain) Limit | 126.0 mm (4.981 in) Camshaft timing gear wear (w/ chain) Limit_| 65.4 mm (2.575 ind ‘chain ‘Wear Timit | 1.0 ram (0.088 in) tensioner slipper anc vibration damper Cylinder block | Cylinder head surface warpage ‘Limit. | 0.05 mam (0.0020 in) Cylinder bore diameter STD (Mark 1) | 100.000 ~ 100.010 mm (3.9370 ~ 2.9374 in.) (mark 2) | 100.010 — 100.020 mm (3.9374 ~ 3.9878 in) (Mark 3) | 100.020 — 100.080 mm (3.9378 — 3.9882 In) Limit (STO) | 100.28 mm (3.9461 in) (0/8080) | 100.73 mm (3.9688 in) Main bearing bolt outside diameter STD | 10.86 = 11.00 mm (0.4271 ~ 0.4931 ny Limit | 10.8 mm (0.47 in) Piston and Piston diameter ‘STD (Mark 1) | 99.950 — 98,960 mm (3.9350 — 3.9354 in) piston ring (mark 2) | 99.980 - 99.970 mm (3.9354 ~ 3.8388 in) (mark 3) | 99.970 ~ 99.980 mm (3.9358 — 3.9362 in) 0/8 0.50 | 100.486 ~ 100.480 mm (3.9547 — 3.9559 in) 3,00 | 100.950 ~ 100.980 mm (3.9744 ~ 3.9756 in) Piston oil clearance STD | 0.040 ~ 0.080 mm (0.0016 ~ 0.0024 in, Piston ring groove clearance Not} 0.040 ~ 0.080 mm (0.0016 ~ 0.0031 in) No2 | 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) Piston ring end gap STD (No.1) | 0.300 ~ 0.520 mm (9.0118 ~ 0.0208 in) (No.2) | 0.450 ~ 0.870 mm (0.0177 ~ 0.0264 in) (a1) | 0.150 ~ 0520 mm (0.0089 ~ 0.0208 in.) Lie (0.1) | 1.12 mm (0.0441 ny (No.2) | 1.17 mm (0.0481 in) (oy | 1.12 mm (0.044t in} Piston pin installing temperature 80 = 90°C (178 - 194°F) reeEG-172 ENGINE — ENGINE MECHANICAL Crank pin tape and out—of—round (Limit) ‘Connecting Thrust clearence STD | 0,160 — 0.262 mm (0.0063 ~ 0.0108 in) vod Limit | 0.362 mm (0.0143 in.) Connecting rod beating center wall thickness STD (Mark 2) | 2.489 — 2.492 mm (0.0980 — 0.0981 in} STD (Mark 3) | 2.492 ~ 2.495 mm (0.0981 ~ 0.0982 in) STD (Mark 4) | 2.495 ~ 2.498 mm (0.0982 ~ 0.0883 in} ‘STO (Mark 5) | 2.498 ~ 2.5601 mm (0.0983 ~ 0.0985 in) STD (Mark 6) | 2.601 ~ 2.604 mm (0.0985 ~ 0.0986 in} Connecting rod oil clearance STD STO) | 0.032 — 0.050 mm (0.0013 ~ 0.0020 in) (U/S.0.25) | 0.033 ~ 0.073 mm (0.0013 — 0.0029 in) Limit | 0.10 mm (0.0038 in) Rod bending Limit per 100 mm (8.94 inj. | 0.05 mm (0.0020 in) Rod twist Limit per 100 mm (3.94 in} | 0.18 mm (0.0059 in} Bushing inside dismeter 28,008 - 26.020 mm (1.0289 ~ 1.0244 in) Piston pin diameter 26.000 ~ 26.012 mm (1.0238 ~ 1.0241 in Piston pin oil elearance st} 0.004 ~ 0.012 mm (0.0002 — 0.0008 in) Limit | 0.05 mm (0.0020 in) Connecting rod bolt outside diameter STD | 8.40 ~ 8.60 mm (0.3307 — 0.3386 in} Limit_| 80 mm (0.318 in) Crankshaft Thrust clearanoe Stp_| 0.020 — 0.0220 mm 0.0008 — 0.0087 in) Limit | 0.30 mm (0.0118 iny Trust washer thiskness (STD) | 2.440 — 2.490 mm (0.0861 ~ 0.0880 in} (0/8 0.125) | 2.803 — 2.553 mm (0.0986 ~ 0,105 in) (0/8 0.250) | 2.565 — 2.618 mm (0.1010 ~ 0,1030 in) Main journal ol elearance STD (STD) | 0.042 — 0.080 mm (0.0017 — 0.0026 in} (U/S.0.25) | 0.041 — 0.081 mm (0.0016 — 0,0032 in} Limit} 0.10 mm (0.0039 in) Main journal diameter STD | 68.982 ~ 69.000 mm (2.7158 ~ 2.7168 in.) us8 028 | 68.745 — 68.755 mm (2.7086 — 2.7068 in) ‘Main bearing center wall thickness ‘STD (Mark 2} | 2.480 — 2.492 mm (0.0980 ~ 0,0981 in) STD (Mark 3) | 2.492 ~ 2.485 mm {0.0981 ~ 0.0862 in) ‘STD (Mark 4) | 2.495 — 2.498 mm (0.0982 — 0.0983 in) STD (Mark 6) | 2.498 ~ 2.501 mm (0.0983 — 0.0985 in) STD (Mark 6) ) 2.501 ~ 2.504 mm (0.0985 — 0.0886 in) Crank pin diameter stb | 56.982 ~ 57.000 mm (2.2434 — 2.2441 in.) U/8.0.26 | 86.745 ~ 56.755 mm (2.2341 — 2.2344 in) Cieole eunout Limit | 0.08 rom (0.0024 in} ‘Main journal taper and out—of—round (Limit) | 0.02 mmm (0.0008 in) 0.02 mm (0.0008 in}ENGINE — ENGINE MECHANICAL EG-173 TORQUE SPECIFICATIONS Part tightened Nm kotom feibe Ar intake connector x Cylinder head 20 200 4 Air intake connector x Carburetor ay 88 48 in-ibt Distributor x Gylinder head 2 210 15 Throttle body x Air intake chambor 21 210 15 ‘Spark piug x Cylinder head 20 200 14 Fuel filter x intake manifold 21 210 18 intake manifold x Gylinder head 2 210 18 Heater iniet pipe x Intake manifold 2 210 15 EGR pipe x Cylinder head 2 210 1s Cylinder head x Gylinder block (1st) 38 400 29 Gylinder head x Oylinder block (2st) Turn 80° Tura 90° Tarn 80° Oylinder head x Gylinder block (8ra) Turn 80° Turn 90° Turn 90° Oylinder head x Taming chain cover 2 210 16 Camshaft bealeng cap x Cylinder head 16 160 2 Camshaft timing gear x Camshaft 74 750 54 Chain tensioner x Cylinder head 2 210 8 2 210 18 7 an "420 30 id x Cylinder 38 400 29 | Heat insulator x Exhaust manifold 18 195, 14 PAIR reed valve x Cylinder head 20 200 | Air pipe x PAIR reed valve 2 210 + Air pipe x Exhaust manifold a4 210 15 Air pipe x Gylinder head 20 200 14 Heater pipe x Timing chain cover a 210 1s Heater pipe x Oylinder head 20 200 4 Front exhaust pipe x Exhaust manifold 2 630 46 Intake manifold x Gyinder head 21 210 15 ‘Noct support bracket x Transmission 38 400) 28 No. support bracket clamp bolt 18 198 4 Front exhaust pipe x No.3 front exhaust pipe 38 ‘400 20 Fuel inlet hose x Fuel fter 28 300, 2 i Delivery pipe x Intake manifold 2 210 8 } No.1 fuel pipe x Delivery pipe (Union bolt 28 300 22 | Not fa pipe (Bolt) 20 200 14 No.1 fuel pipe x Fue! filter 28 300 22 Fuel return pipe x Intake manifold 20 200 14 | Emission control valve sot assembly x intake maniford 20 7200 14 | Air intake chamber x Intake manifold 21 210 15 Oli dipstick guide x Inteke manifold 20 200 14 Oil dipstick guide x Not oll pan 20 200 4 Heater inlet pipe x Ar intake chamber 20 200 14 EGR pipe x EGR valve 64 650 a7 | No.2 water by—pass pibe x Cylinder head 20 200 14 | No.2 water by—pass pipe x Engine hanger 20 200 14 Water outlet x Cylinder heed 21 210 is ‘Alternator bracket x Cylinder head cS 440) 32EG-174 ENGINE — ENGINE MECHANICAL Distributor x Cylinder bes 2i 210 15 PS reservoir tank x Gylinder head 20 200 4 Oil jot x Cylinder block 20 200 4 Chain tensioner slipper x Cylinder biock 68 700 51 Vibration damper x Gylinder block 20 200 4 Timing ehain caver x Gylinder block 21 210 18 ‘Drive balt idler pulley x Timing chain cover 43 440 32 SEG [_Cronkshottpuley x Crankshaft a2 4200 304 “ ‘Not oil pan x Cylinder block (14 mm head bolt) a 440 32 Nat oil pan x Cylinder block (12 mm head bolt) 20 200 4 Nat oil pan x Timing chain cover 20 200 is No oil pan x No.1 cil pan (Bolt 78 80 69 incibf ‘No oil pan x No.t oil pan (Nut), a8 90 78 inatot ‘Transmission housing x No.1 oil pan 72 730 53 (Oil level sensor x No.1 oil pan’ 34 85 48 inotbh Radiator pipe x Not oil pan 21 210 15 ‘A/G compressor bracket x No.1 oll pan a7 35 2 [A/C compressor bracket x Cylinder block 37 375 27 ‘A/6 compressor x A/C compressor bracket 25 250 18 Water pump x Timing chain cover 21 210 18 Main bearing cap x Cylinder block (1st) 7 750 Ba ‘Main bearing cap x Cylinder block (2nd) Tum 90" Tum 90° Turn 80" ‘Gonnesting rod cap x Conneating ro (st) 4 490 35 Connecting rod eap x Gonnecting rod (2nd) Tum 90" Tum 80" Tum 90° Oil nozzle x Cylinder bracket 25 250 18 Rear oll seal retainer x Gylinder block 20 200 a Oil cooler cover x Cylinder block 21 210 15 LH engine mounting bracket x Gylinder blook 68 700 eI [LH Insulator x LH engine mounting bracket 72 730 ry [RH engine mounting bracket x Cylinder block 08 700 31 [RH insulator x RH engine mounting bracket 72 730 a PS pump x Cylinder block 36 370 27 Knock sensor x Gylinder block a4 450) 33 Oil filter union x Cylinder block 44 450 33 Drive plate x Crankshaft 100 1,000 74 “Transmission x Gylinder block 7 730 48 Transmission x No.1 oll pan 72 730 a Torque converter clutch x Drive plata 55 850 a [A/T oil cooler pipe x Union (Transmission) a4 350 25 Starter x Transmission 38 400, 28 Frame crossmomber x Frame ol 620 a Frame crossmember x Engine roar mounting insulator 7 750 3a Engine front mounting insulator x Frame 74 750 8a Transfer under cover x Frame crossmember 28 290 21 Traneter shift lever x Transmission 18 185 73 “Transmission shift lever assembly x Body ba 58 48 in.tbt Tranamission control red x Gontrol shaft lover 13 130 8 Front propeller shaft x Front differential 74 780 5a Front propeller shaft x Transfer 74 750 84ENGINE — ENGINE MECHANICAL EG-175, oar propeller chaft x Rear differontial 88 ‘800 6 Rear propeller shaft x Tranet 38 ‘800 65 Stabilizer bar brackot mounting bolt 18 186 8 Stabilizer bar x Axle carrior 25 260 18£G-176 ENGINE — MEMO —ENGINE — EFI SYSTEM EFI SYSTEM DESCRIPTION EG-177 VSV for EVAP*? vev Charcoal Canistor Air Cleaner ‘crow [| TP Sensor Dashpor heuer Incako Ale ‘emp. Sensof fFuct Fitter VSV for Fuel Pressure Control Silencer Distributor ty an Fuel Tank |{A*,, Injector FP Resistor Twer! Water Temp. Sensor’ FP Relay EFI Main Relay Pa © yeti eed Sensor = Check Connector = Only for Europe Ex. GCC and General Only for AT JVSV for AS*? Newtral Start Switch*? Battery EGR*" Vacuum Modulator Vsy for EGR" | Stop Light ‘Switch=e) Fons, ENGINE — EF! SYSTEM The EFI (Electronic Fuel Injection) system is composed of three basic sub—systems: Fuel, Air Induction and Electronic Control Systems. FUEL SYSTEM Fuel is supplied under constant pressure to the EFI injectors by an electric fuel pump. The injectors inject a metered quantity of fuel into the intake port in accordance with signals from the ECU (Electronic Control! Unit). AIR INDUCTION SYSTEM The air induction system provides sufficient air for engi ELECTRONIC CONTROL SYSTEM 1e operation. The 1FZ—FE engine is equipped with a TOYOTA Computer Controlled System (TCCS) which centrally controls the EFI, ESA, ISC diagnosis systems etc. by means of a Engine Contro! Unit (ECU)—formerly EFI computer) employing a microcomputer. The ECU controls the following functions: 1. Electronic Fuel Injection (EF!) The ECU receives signals from various sensors indicating changing engine operation conditions such as: Intake air volume Intake air temperature Water temperature Engine speed Acceleration / deceleration Exhaust oxygen content ete. The signals are utilized by the ECU to determine the injection duration necessary for an optimum air—fuel ratio. 2, Electronic Spark Advance (ESA) The ECU is programmed with data for optimum ignition timing under any and all operating conditions, Using data provided by sensors which monitor various engine functions (engine speed, coolant temperature, ete), the micro computer (ECU) triggers the spark at precisely the right instant. Idle Speed Control (ISC) The ECU is programmed with target idling speed values to respond to different engine conditions (coolant temperature, air conditioning (A/C) ON/OFF, ete.). Sensors transmit signals to the ECU which controls the flow of air through the by—pass of the throttle valve and adjust idle speed to the target value. 4. Diagnosis The ECU detects any malfunctions and abnormalities in the sensor network and lights a “CHECK” engine warning light on the combination meter. At the same time, trouble is identified and a diagnostic code is recorded by the ECU. The diagnostic code can be read by the number of blinks of the “CHECK” engine warning light when terminals TE1 and E1 are connected. The diagnostic trouble codes are referred to the later page. (See Diagnostic Code Chrat 5. Fail—Safe Function In the event of the sensor malfunction, a back—up circuit will take over to provide minimum drivability, and the “CHECK” engine warning will illuminate.ee ENGINE — EFI SYSTEM EG-179 SYSTEM CIRCUIT +H Ignition Switch ecu CHECK" engine warcing light TEE. fr Rey) oe Opening Roley os \Woter temp, Sensor amt BOA ‘AM2 FL 0.3 No.1 No.2 No.3 No.4 No.6 No.6 aw stor FL 1.258, - Thal ‘Stop Light Switch ‘stop 60 ight Battery igt 1GF lonition Coit w/ Igniter Oniy for Europe Bx. Goo and Ga "Ont for AITEG-180 ENGINE — EFI SYSTEM PREPARATION SST (SPECIAL SERVICE TOOLS) 7 Gears, 09268-41045 Injection Measuring Tool Set “ee, (C8208 62010) ‘nection Measuring Actchment (90405-09015) No.1 Union (09968=45012 EFI Fuel Posture Gauge {09631=72020 Power Storing Hose Nut Fuel ine fore et 14 17 mm Weoneh Set OBELE=GODID 08 Pressure Switch Soccee, Kock soar 09842-90070 Wising“F*EFI inspection = QBEA3— 16020 Disgnosie Check Wie ae i RECOMMENDED TOOLS oe (09082-00015 RS =e <9 ‘08200-00010 ‘TOYOTA Electrical Testor Engine Adjust Kit (09258-00030 i rv, < s 7 l Hote Plog Set lug for the vacuum hose, fuel, hose eteENGINE — EFI SYSTEM EG-181 EQUIPMEMT | Graduated cylinder Injeetor Carburetor cleaner Throttle body ‘Sound scope Injector Tachometer Torque wrench Vacuum gauge 7 EEE ‘Soft brush Throttle bodyEG-182 ENGINE — EFI SYSTEM 1 PRECAUTION Before working on the fue! system, disconnect the cable from negative (—) terminal of the battery. HINT: Any diagnostic trouble code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before removing the terminal. Do not smoke or work near an open flame when working on the fuel system. Keep gasoline away from rubber or leather parts. MAINTENANCE PRECAUTIONS (a) (b) (e) (d) fa) (b) CHECK CORRECT ENGINE TUNE—UP. [See page EG—11 PRECAUTION WHEN CONNECTING GAUGE Use battery as the power source for the timing light, tachometer, etc. Connect the tester probe of a tachometer to the ter- minal IGO of the check connector. IN EVENT OF ENGINE MISFIRE, FOLLOWING PRECAUTIONS SHOULD BE TAKEN Check proper connection of battery terminals, etc. Handle high— tension cords carefully. After repair work, check that the ignition coil termi- nals and all other ignition system lines are reconne- cted securely. When cleaning the engine compartment, be especially careful to protect the electrical system from water. PRECAUTIONS WHEN HANDLING OXYGEN SEN- SORS Do not allow oxygen sensor to drop or hit against an object. Do not allow the sensor to come into contact with water.ENGINE — EFI SYSTEM eae IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION (HAM, CB, ETC.) For vehicles with mobile communications systems such as two — way radios and cellular telephones, observe the following precautions. 1. Install the antenna as far as possible away from the ECM, ECU and sensors of the vehicle's electronic systems. 2. Install the antenna feeder at least 20 cm (7.87 in) away from the ECM, ECU and sensors of the vehicle's electronics systems. For details about ECM, ECU and sensor locations, refer to the section on the applicable component. 3. Do not wind the antenna feeder together with any other wiring. As much as possible, also avoid running the antenna feeder parallel with other wire harnesses. 4, Confirm that the antenna and feeder are correctly adjusted. 5. Do not install powerful mobile communications sys- tems. AIR INDUCTION SYSTEM 1. Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of turn. 2. Disconnection, looseness or cracks in the parts of the air induction system between the air flow meter and cylinder head will allow air soution and cause the engine to run out of tune. ELECTRONIC CONTROL SYSTEM 1. Before removing EFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the battery ter- minals. HINT: Always check the diagnostic trouble code before disconnecting the battery terminal.EG-184 ose cos F609 ze ENGINE — EFI SYSTEM 2. When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (-) cables. 3. Do not permit parts to receive a severe impact during removal or installation. Handle all EFI parts carefully, especially the ECU. 4. Do notbe careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can further troublles. 5. Do not open the ECU cover. 8. When inspecting during rainy weather. take care to prevent entry of water. Also, when washing the ‘engine compartment, prevent water from getting on the EFI parts and wiring connectors. 7. Parts should be replaced as an assembly. 8. Care is required when pulling out and inserting wiring connectors. {a) Release the lock and pull out the connector, pulling on the connectors. (b) Fully insert the connector and check that it is locked. 9. When inspecting a connector with a volt/ohmmeter. (2) Carefully take out the water—proofing rubber if it water—proof type connector.EG-186. ENGINE — EFI SYSTEM (b) Insert the test probe into the connector from wiring side when checking the continuity, amperage or vol- tage. () Do not apply unnecessary force to the terminal. (4) After checking, install the water—proofing rubber on the connector securely. 10. Use SST for inspection or test of the injector or its wiring connector. SST 09842-30070 FUEL SYSTEM 1. When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (a) Puta container under the connection. (b) Slowly loosen the connection. {c) Disconnect the connection. (d)_ Plug the connection with a rubber plug. 2. When connecting the flare nut or union bolt on the high pressure pipe union, observe the following pro- cedures: (Union Bolt Type) (2) Always use a new gasket. (b) Tighten the union bolt by hand. (c)_ Tighten the union bolt to the specefied torque. Torque: 29 N-m (300 kgf-cm, 22 ft-lbf) (Flare Nut Type) (2) Apply a light coat of engine oil to the flare and tighten the flare nut by hand, {b) Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 30 N.m (310 kgf-em, 22 ft-Ibf) HINT: Use a torque wrench with a fulerum length of 30 em (11.81 in).ee EG-186 ENGINE — EF! SYSTEM > 9 New O-ing CORRECT i Grommet i th > 2 2 noe Ld sas (b) (c) Observe the following precautions when removing and installing the injectors, Never reuse the O—ring. When placing a new O-ring on the injector, take care not to damage it in any way. Coat a new O—ring with spindle oil or gasoline before installing —never use engine, gear or brake oil. Install the injector to the delivery pipe and intake manifold as shown in the illustration. Check that there are no fuel leaks after performing any maintenance on the fuel system. Using SST, connect terminals +B and FP of the check connector. ‘SST 09843-18020 Turn the ignition switch ON. NOTICE: Do not start the engine. When the fuel return hose is pinched, the pressure within high pressure line will rise to approx. 392 kPa (4 kgf/cm*, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid ben cause the hose to crack.ENGINE — EFI SYSTEM ache {d)_ Turn the ignition switch OFF. (e) Remove SST from the check connector. SST 09843-18020Eevee ENGINE — EFI SYSTEM DIAGNOSIS SYSTEM DESCRIPTION The ECU contains a builtin, self—diagnosis system by which troubles with the engine signal network are detected and a “CHECK” engine werning light on the combination meter lights up. By analyzing various signals as shown in the later table the ECU detects system malfunctions relating to the sensors or actuators. The self—diagnosis system has two modes, a normal mode and a test moode. If a malfunction is detected when in the normal mode, the ECU lights up the “CHECK” Engine warning light to inform the driver of the occurrence of a malfunction. (For some codas the light does not come on.) The light goes off automatically when the malfunction has been repaired. But the diagnostic trouble code(s) remains stored in the ECU memory. The ECU stores the code(s) until it is cleared by removing the EF/ fuse with the ignition switch OFF. The diagnostic trouble code can be read by the number of blinks of the “CHECK” Engine warning light when TE1 and E1 terminals on the check connector are connected. When 2 or more codes are indicated, the lowest number (code) will appear first. If a malfunction is detected when in the test mode, the ECU lights up the “CHECK” Engine warning light to inform the technician of the occurrence of a malfunction (except for code Nos. 43, 51 and 53), In this case, TE2 and E1 terminals on the check connector should be connected as shown later. ([See page EG— 192]. In the test mode, even if the malfunction is corrected, the malfunction code is stored in the ECU memory even when the ignition switch is OFF (except code Nos.43, 51 and 53). This also applies in the normal mode. The diagnostic mode (normal or test) and the output of the “CHECK” Engine warning light can be selected by connecting the TE1, TE2 and E1 terminals on the check connector, as shown later. A test mode function has been added to the functions of the self—diagnosis system of the normal mode for the purpose of detecting malfunctions such as poor contact, which are difficult to detect in the normal mode. This function fills up the selt—diagnosis system. The test mode can be implemented by the technician following the appropriate procedures of check terminal connection and operation described later.ENGINE — EFI SYSTEM veneer engine warning {C1 igh \ F2s70 =I ight ‘Check Connector Sst EG-189 “CHECK” ENGINE WARNING LIGHT 1. The “CHECK” engine warning light will come on when the ignition switch is placed at ON and the engine is not running. 2. When the engine is started, the “CHECK” engine warning light should go off. If the light remains on, the diagnosis system has detected a malfunction or abnormality in the system. DIAGNOSTIC CODES OUTPUT (Normal mode) To obtain an output of diagnostic trouble codes, proceed as follows: 1. Initial conditions (a) Battery voltage 11 V or more (b) Throttle valve fully closed (throttle position sensor IDL points closed) (©) Transmission in neutral position (d)_ Accessories switched OFF (e) Engine at normal operating temperature 2. Turn the ignition switch ON. Do not start the engine. 3. Using SST, connect terminals TE1 and E1 of the check connector. SST 09843-18020 4. Read the diagnostic code as indicated by the number of flashes of the “CHECK” engine warning light.EG-190 No Matfunetion 0.26 ON ON ON ON OFF OFF OFF (Seconds) 0.28 poze 2001 Code No.13 Code No. 31 as2 ~—TFaxonon onanonon lore OFF. = 28 45 (Seconds) oss ese ENGINE — EFI SYSTEM Diagnostic Codes (a) Normal System Operation (no malfunction) @ = The light will alternately blink ON and OFF at 0.26 seconds intervals. (b)_ Malfunction Code Indication * in the event of # malfunction, the light will blink every 0.52 seconds. The first number of blinks will equal the first digit of a 2—digit diagnostic trouble code and, after a 1.5 seconds pause, the 2nd number of blinks will equal the 2nd. if there are two or more codes, there will be a 2.5 sec- onds pause between each code. * After all the codes have been output, there will be a 4.5 seconds pause and they will all be repeated as long the terminals TE1 and E1 of the data link connector 1 are connected. HINT: In the event of a number of trouble codes, indication will begin from the smaller value and con- tinue to the larger. (c) (2 Trip Detection Logic) Diagnostic code No. 25 use “2 trip detection logic”. With this logic, when a malfunction is first detected, the malfunction is temporarily stored in the ECU memory. If the same case is detected again during the second drive test, this second detection causes the ” CHECK’ engine warning light to light up. The 2 trip repeats the same mode a 2nd time. (How- ever, the ignition switch must be turned OFF between the 1st time and 2nd time.) In the Test Mode, the “CHECK” engine warning light lights up the 1st time a malfunction is detected.ENGINE — EFI SYSTEM EG-191 5. After the diagnosis check, remove SST. SST 09843-18020EG-192 ‘Check Connector zi Flashing UU or JUL 0.131 Seconds 1 Check Connector ENGINE — EFI SYSTEM (Test mode) HINT: * Compared to the normal mode, the test mode has high sensing ability to detect malfunctions. © It can also detect malfunctions in the starter signal circuit, air conditioning signal and neutral start switch signal. * Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the test mode. To obtain an output of diagnostic trouble codes, proceed as follows: 1. Initial conditions (a) Battery voltage 11 volts or more (b) Transmission in neutral position (c) Accessories switched OFF (d) Engine at normal operation temperature 2. First using SST, connect terminals TE2 and 1 of the check connector. SST 09843-18020 3. Turn the ignition switch ON. HINT: To confirm that the test mode is operating, check that the "CHECK" engine warning light flashes when the ignition switch is turned ON. 4, Start the engine and drive the vehicle at a speed of 10 km/h (6 mph) or higher. 5. Simulate the conditions of the malfunction decribed by the customer. 6. Using SST, connect terminals TE1 and E1 of the check connector. SST 09843-18020 7. Read the diagnostic code as indicated by the number of flashes of the “CHECK” engine warning light. (See page EG— 194)ENGINE — EFI SYSTEM EG-193 8. After the diagnosis check, remove SST. SST 09843~ 18020 HINT: © The test mode will not start if terminals TE2 and E1 are connected after the ignition switch is turned ON. The starter signal and vehicle speed signal will be diagnosed by the ECU as malfunctions, and code "ee Nos.42 and 43 will be output. if the operation in“ step 4 is not performed. © When the automatic transmission shift lever is in the “D", "2°, "L" or “R” shift position, or when the air conditioning is turn ON or when the accel- erator pedal is depressed, code No.51 (Switch condition signal) is output, but this is not abnor- mal. DIAGNOSTIC CODE CANCELLATION 1, After repair of the trouble area, the diagnostic code retained in memory by the ECU must be cancelled out by removing the EFI fuse (15A) for 30 seconds or more, depending on ambient temperature (the lower ‘the temperature, the longer the fuse must be left out) with the ignition switeh OFF, HINT: * Cancellation can also be done by removing the battery negative (—) terminal, but in this case, other memory systems (clock, radio ETR etc.) will also cancelled out. * If the diagnostic code is not cancelled out, it will be retained by the ECU and appear along with a new code in the event of future trouble. * If it is necessary to work on engine components requiring removal of the battery terminal, a check must first be made to see if a diagnostic code has been recorded. 2. After cancellation, perform road test of the vehicle to check that a normal code is now read on the "CHECK" engine warning light. If the same diagnostic code appears, it indicates that the trouble area has not been repaired thoroughly.aa ENGINE — EFI SYSTEM. DIAGNOSIS INDICATION (1) When 2 or more codes are indicated, the lowest number (code) will appear first. (2) All detected diagnostic codes, except for code Nos.51 and 53 will be retained in memory by the ECU from the time of detection until canceled out. (3) Once the malfunction is cleared, the “CHECK” engine warning light on the combination meter will go off but the diagnostic code(s) remain stored in ECU memory (except for code Nos.43, 51 and 53). DIAGNOSTIC CODES HINT: © If a malfunction is detected during the diagnostic code check, refer to the circuit indicated in the table, and turn to the corresponding page. * Your readings may vary from the parameters listed in the table, depending on the instru- ments used. umber of 2 Code “CHECK” engine | System sea all ae ng ight Blinks Diag ‘Trouble aor = [SULUUL] norma — | = | Ne mettunerions derectes eI 7 Mo "NE" or "61". "G2" signal | $ Distnbutor circuit 2 rem signal | ON | NA. | LOECM within 2 seconds attr” | ¢ Distrbvtor ° ae euaee $ Stator sal cou Firs06| wl eI ECU No “NE” sonal is 1 €6U for 0.1 | + Ditrbutor cet 13 |__JLIUMT_| rem sions} ow | on | See. orm wnen engine spews) | * Bitter ° 1S sbove 600 om peal soe cies No "IGE" sina to ECU 6 tinas | * [QnA an anton sat 1 UL | etn ow | wa. | insuesession and'no sonal ins | SRE cay | O Dut wth 250 mass ra Torna ang sees Bsn 100 Eamon sope peed Shue | « onon sensor cheat wt oysen WHat Beis sates | ¢ Steen ever cea | Sensor Signat sensor signal (OX1) is reduced to - tel? at mn con | ow | betwteon 0.35 — 0.70'V continu ously for 60 seconds ar mare. Not Oxygen ++ Oxygen sensor circuit Satie perso sierinonaen | 3 BURY 7 ‘temp. sensor signal for 0.5 sec. erat | AUIUI_| Eryn | OF | OF | teceesentier eee | re wne sewn | x | ULI | rzisce | ov | on | SRSENRAIR MOS | amp emer | © enn] 20" S902 ECUENGINE — EFI SYSTEM DIAGNOSTIC CODES (Cont'd) EG-195 Code | nc tanec | HECK engine | System etal fetal aie No | warning light Blinks Normal | Test — re 7 Mote = Sota © Engine ground bolt loose (1) Heated oxygen sensor autout | + Open in Et eu 800 ren bleetor eve ss ‘ictal Ratio ange unan warmed up AD: pressure 2s |__|} tes ‘on | on ‘lies onty to code 25 and for | * VAF meter ° Mauneion ESttomis moss, excepting WR system |, hansioe bese. 5 ete Syaen sor {2 tip drection logic) (1) - | + Hosted oxygen vonsore & 3 hpaion vio sen 2 1 ‘Rinora aig speed below 700 | found arent 008 | | 7 "760 Tm ample of beatea | + Oxygen sensor ckeut | No.2 Ory | 20a. moe ated | > Qrvgn sree | Seat redusosrovetneen 350,100 | + ECU 3° | on | on. | Continuously for 80 seconds or ° 2 | JULIAN, a No. 2 Oxygen A 1+ Oxygen sensor chet 268 oF short ert im heated ¥ elle ‘oxygen sensor heater. HT2) 1 Oxygen sensor | saune| #2 Sana ie When iis contacts ae cased 1 he tow meter ereut Ae Flow a | Suu ier Signa | ON | ON At tow meter ° \ Mitr i ra! | pate Sat betwoon VS and EE + ie How meter chet Ac Flow en cit in €2 oF shor cheat 32 |_ JULIAN} Baers | on | om | Soerccnive a TAGflow mater ° Nott Si Stereen ve and VS. tau pen 0 short ttn Vacuum Vecwum Sen- | ag 7 se |_Aamnni] eens" | og? | on | Seto" sanal er ses! ecu ° Ptetaic reall Open or shot ckeut in totte | # TP sensor cet ton Sensor Dostion encor signal tor O.5.) | + TP sensor ° Signa! he (ON | ‘ec. oF mare. * ECU a When angie aoe’ 2,700spm or | _eacuts so Speed Sen. | OFF | OFF | More and with vehi nok + ehide specs sensor | © moving ree No "STA" signal to £CU unt en | + Igniton sien eet starter signat | nA. | OFF | Sine spend reaones 800 rom with | + ignition sweeh x atnde no moving 1a Koen sea, foe eae santo |” Ug Tater Ne ongor Si SEuir econ ravetuene wits |, KOCK sensor cui 7 rartion” | O% | 8A | Speed Cecran 00mm | * Rex erat ‘ i acaeos| 2) snd 5260 rpm weeEG-196 ENGINE ~ EFI SYSTEM DIAGNOSTIC CODES (Cont'd) Code warning gh «| No, Stem Diagnosis “Tovbie ea Memory as Wioge.|_ ode No ac coo ga to ECU Knack Con- j for To cen reveutone nth ew | : sa LIUIUUTLIIUL. | wePsinet” | ON | NA. | ging sped between 7,600 mm” | * EU nd 61200 rom i 0s _t 2 Knook fia No.2 knock sensor signal to | * OPeR. sort in No. 2 or 6 rank tvolosone with se ULI on | NA. | Sng spoed bstweon 1-860 pm | * NO. 2 krack sensor 263995] ree secu core | ai? Inno, — | Comment | on | nia, | SPmmin sett creator 22 | 4 cor cro ° ECT ECU \ 1 ost lammannacnan, | Comes | ow | nua, | Speransoayereuto08 | «esa crown 5 ec eou ’ cou ‘pen in BAZ crest 0.5 | « esr cue eF [ruven | Some ON | NA. | sec, after 0.5 sec. at idle. BAZ cout ° ect ecu 2 Open in E9A8 circuit for 0.6 i 98? [rneunnmuaminin. | Commun: ON | NAL | Seer ater 0.5 soo. le + E843 cteuit 1° osz0 L rch ove We 0" Sarat NSH" gral ait. : Switch Con Cea" Sigal FEM, ith tho reuit a st LULL aice’soeai | MA) OFF | Sicttmaae et and fet eon | 2 SW = * Acceleration pedal snd aise es oa REMARKS “1: "ON" displayed in the diagnosis mode column indicates that the “CHECK” engine warning light is lighted up when a malfunetion is detected. “OFF” indicates that the “CHECK” does not light up during malfunction is detected. *2: "©" in the memory column indicates that a diagnostic trouble code is recorded in the ECU memory when a malfunction occurs. "X” indicates that a diagnostic trouble code is not recorded in the ECU memory even if a malfunction occurs. Accordingly, output of diagnostic results is performed with the ignition switch ON. The malfunction indicator lamp comes on if malfunction occurs only for California specifications. Codes No.21 and 25 are used only for Europe and Australia specifications. Code No.28 is used only for Europe specifications. Codes No.81, 83, 84, 85, are used only for ECT specifications. °2 trip detection logic” [See page EG—1EG-197 ENGINE — EF! SYSTEM DIAGNOSTIC TROUBLE CODE DETECTION DRIVING PATTERN Purpose of the driving pattern. (a) To simulate diagnostic code detecting condition after diagnostic code is recorded. {b) To check that the malfunction is corrected when the repair is completed, confirming that diagnostic code is no longer detected. Code No.| 21, 28 | Oxygen Sensor Circuit Malfunction: Deterioration of Oxygen Sensor Iehicte speed) 7 @ Detection 80 km/h (50 mph) 4— 64 kmh (40 mph} {~ Disconnect the EFI fuse (15 A) for 10 seconds or more, with ignition swith OFF. Initiate test mode: Connect terminals TE2 and E1 or Check Connector with ignition switch OFF. Start the engine and warm the engine up with all accessory switches OFF. After the engine is warmed up, let it idle for 3 minutes. Accelerate graduslly and maintain at approximately 1,500 rpm, or within the 1,300 to 1,700 tpm range. Turn the A/C ON, and drive in “D”’, upshift appropriately. Shift carefully so that the engine speed would not fall below 1,200 rpm. Depress the accelerator pedal gradu- ally and maintain a steady speed to avoid engine braking. Maintain the vehicle speed at 64 — 80 km/h (40 ~ 50 mph). Keep the vehicle running for 1 — 2 minutes after starting acceleration. f any malfunction is detected, the malfunction indicator lamp will ight up during step (2). If this procedure is not strictly followed, you cannot detect the malfunction. eo ® @ ® wombali ENGINE — EFl SYSTEM. DIAGNOSTIC CODE DETECTION DRIVING PATTERN (Cont'd) Purpose of the driving pattern. (a) To simulate diagnostic code detecting condition after diagnostic code is recorded. (b) To check that the malfunction is corrected when the repair is completed, confirming that diagnostic code is no longer detected. Code No. 25 Air-Fuel Ratio Lean Malfunction Malfunction: Open or Short in Oxygen Sensor (Engine speed ® 4,000 rpm} =~ = © 2,000 rpm =~ == fp} ft op ft © @® teling bs Oel a ee min, 80566. | rime) @ Disconnect the EF! fuse (15 A) for 10 seconds or more, with ignition switch OFF. @ ae test mode; Connect terminal TE2 and E1 of Check connector with ignition switch @ Start the engine and warm the engine up, with all accessory switches OFF. @® After the engine is warmed up, let it idle for 3 minutes. © Accelerate rapidly to 4,000 rpm three times. © _ Maintain 2,000 rpm for 90 seconds. HINT: Ifa malfunction is detected, the “CHECK” engine warning light will light up during step NOTICE: If this procedure is not strictly followed, you cannot detect the malfunction.ENGINE — EFI SYSTEM eee DIAGNOSIS CIRCUIT INSPECTION ECU Ignition Switch GAUGE “CHECK” engine warning light EFI Main Relay 1. [Does “CHECK™ engine warning fght come YES [os ‘on when ignition switch is at ON? 7 Two Does “CHECK” engine warning light come Check wiring betweon ox | try anctner con when ECU terminal W is grounded tothe LY®SL| ECU conminal Et and body |X| Te 9m body? ground. 7 [Ro [pao Check bulb, fuse and wiring between ECU tnd ignition switch io Repair or replace. Repair or replace. 2. | Does “CHECK” engine warning light go off LYES | So normal when the engine is started? [xo Check wring between EOU ond “GREGK” | Ban [> |242-L pai. engine warning Tight Tox Check wiring between ECU terminal TET and check connector terminal TE1, and ECU terminal Et and check connector terminal €1. Is there diagnostic code output when check | NO ‘connector terminals TE1 and E1 connected? [es [oe Does "CHECK engine warning Toh oo ot | NO ; Try anc after repair according to malfunction code? Further repair required. ECU. [vs ‘System OK |---| Cancel out diagnostic code,Ferane ENGINE — EF| SYSTEM TROUBLESHOOTING W/VOLT,OHMMETER (A/T) HINT: © The following troubleshooting procedures are designed for inspection of each separate system, and therefore the actual procedure may vary somewhat. However, troubleshooting should be performed while referring to the inspection methods described in this manual. Before beginning inspection, it is best to first make a simple check of the fuses, H—fuses, fusible links and the condition of the connectors. © The following troubleshooting procedures are based on the supposition that the trouble fies in either a short or open circuit within the computer. * If engine trouble occurs even though proper operating voltage is detected in the computer connector, then it can be assumed that the ECU is faulty and should be replaced. EFI SYSTEM CHECK PROCEDURE PREPARATION (a) Disconnect the connectors from the ECU. (b) Remove the locks as shown in the illustration so that ‘the tester probe(s) can easily come in. NOTICE: Pay attention to sections “A” and “B’ illustration which can be easily broken. 7 szoa | (€) Reconnect the connectors to the ECU. {d)_ Using a voltmeter with high impedance (10 kQ/V minimum), measure the voltage at each terminal of the wiring connectors. HINT: © Perform all voltage measurements with the con- nectors connected. © Verify that the battery voltage is 11 V or more when the ignition switch is in “ON" position. in the ro1266 80ENGINE — EFI SYSTEM EG-201 ECU Terminals (For A/T) Symbol Connection Symbol Connection ‘Symbol Connection |) |NO.2 HEATED OXYGEN £01 |POWER GROUND - #12" |Sogon 02__|POWER GROUND e11_[Ecu GROUND = W410 [INJECTOR (No.1) TEI _|Check Connector ‘STA_|NSW SWITCH ¥30_ [INJECTOR (No.3) TE2_|Check Connector NSW_[IGNITION sWiTcH #20 [INJECTOR Wo.2) KNK1_[NO.1 KNOCK SENSOR neo [ECT ECU #1 [ecu GRouno KNK2 [NO.2 KNOCK SENSOR = #40. | INJECTOR (No.4) 0x1 |No.1 oxYGEN seNson | va |ecT ECU ist ficnirer x2" |No.2 oxYGEN sensor | ect? |ecT ecu PV_|VSV FOR EVAP THW_ [WATER TEMP, SENSOR | SPD |VEHICLE SPEED SENSOR gr” |vsv For EGR ox+ JoxvGeN sensors ect2 |ecT ecu AS * [VSV FOR AS THA_|AIa FLOW METER AIC [AIC AMPLIFIE VSv FOR FUEL PRESSURE Feu | veyron ro. {TP sensor ect lect ecu TSC VALVE ain FL 7 'SC1 | (No.1 Motor Coil) hea miei VTA |1P SENSOR Esai [ECT ECU iSC VALVE wsc2 |SCVAWE vec |1P sensor 7 7 £2 [SENSOR GROUND ESA2 [ECT ECU iSC VALVE “CHECK” ENGINE 1s: 6 |oisrta 3 |ino.3 Motor Coib OA |PEn eur W __|warNine LGHT 7 NE [DISTRIBUTOR Esaa [ECT ECU iSC VALVE Be Ne cold - MEL | EFI MAIN RELAY (COIL) 1GF_|IGNITER G1_|pistaRUTOR Si _ [STOP LIGHT SwiTCH FPR_ [FUEL PUMP RELAY = BATT [BATTERY B+ VF2_|Check Connector G2_[pistaBUTOR Tesw [IGNITION SWITCH 450 [INJECTOR (No.5) = $¥B1_[EFIMAIN RELAY VE1_[Check Connector = +8 _[EFIMAIN RELAY NO.1 OXYGEN #60. INJECTOR (No. “Only for Europe. WECTOR (No.6) HTT [eo ton Only for Europe. LT = ECU Terminals Lun, UL,Be 202, ENGINE — EFI SYSTEM ECU Wiring Connectors Voltage (For A/T) esW a Mine El 1G SW ON, 7 +B1 as 2 Throttle valve fully closed i VTA ~ €2 (Throttle opener must be cancelled first) Pret 3 VS — E2 leasuring plate fully open 0.2- 0.5 ating 12-24 3,000 rpm 0.8 — 1.3 ne _ gos [E209] 4 io — £02 IG SW ON, 9-14 |EG-209 5 | tan e2 Intake ar temp. 20°C (68°F) 34 SzOT | IG sw ON ce ai 1D. 05 — 3. a 7 | STA~€1 | Cranking 6 or more 8 IGT - £1 | Idling Pulse generation 4EG-213 | 9 t —E€1 |iGSWON 9-14 /EG-214 | Eom Terminals oomENGINE — EFl SYSTEM EG-203 No. | Terminale Trouble Condition STD voltage BATT — 1 | No voltage = 9-14 IG sw - £1 7 M-REL — £1 | No voltage IG SW ON 9-14 +B(+B1) ~ £1 fF ECU rt att et |@ There is no voltage between ECU terminals BATT and E1. | [@ Check that thore is voltago botweon ECU torminal BATT and body ground, fate lee rere [@ Cheek wiring between ECU terminal ET and boa stun ox mao (ir anenareoa aparece ‘Check fuse and fusible link. | BAD Replace. y Check wiring between ECU BAO a | terminal and battery Repai ot replace.EG-204 ENGINE ~ EFI SYSTEM 1G sw - £1 fay Thetis no voltage between ECU terminals 1G SW and E7. AG SW ON) Voter T Exe Check that there is voltage between ECU terminal |G SW lol 1 sno body ground. (IG SW ON) Ss Two ox 790780) ‘Check wiring between ECU terminal E1 and body ground. Tex [ea Ty another E00, Tepair or replace Voltmeter ‘Check fuses, fusible link and ign |_BAD_ tion switch, Roplair or replace. + M-REL — E1 [op There is no vonage between ECU terminals M-REL and €7. (iG sw ON) I lq Check that there is voltage between ECU terminal M-REL and body ground. (IG SW ON) wo‘ oK a Check wiring between EGU ternal 1 an bog around Tox [exo Try snot EU. Tapa or vesiace E Replace. Shack ain yan wins nares Boe page €6-27 Tox Try soto 860ENGINE — EF! SYSTEM EG-205 © +8 (+81) — £1 ep There is ne voltage between ECU terminals +B (+81) end £1, WG SW ON) q [q@ Cheek that there ie valtage between ECU torminal +B {+B1) and body ground. (1G SW OND NO Tox ‘Check wiring between ECU terminal £1 and body ground. Tok Tea Ty another EU Repair or replace. ‘Check fuse, fusible link and wiring | BAD harness. [+] Repair or replace. Tox Check main ay. ea Replace.EG-206 ENGINE — EF! SYSTEM, No. | Terminals Trouble Condition STD voltage IDL — £2 Throttle valve open 9-14V vec — €2 - 45 -5.5V 2 No voltage Ie swon | Throttle valve fully closed (Throttle opener must be | 0.3 - 0.8V VTA — €2 cancelled first) Throttle valve fully open 32-49V | | + IDL-£2 @ Thee is Ho voltage between ECU terminals WOL and £2 (IG SW ON) (Throttle valve open) @ Check thet there fs voltage between ECU terminal +6 (+81) and body ground. WG SW ON) NO oK ‘Check wiring between ECU terminal E1 and body ground. OK BAD Tey another ECU. =| Repair or replace. BAD [Refer to Not) [See page EG-203} OK ‘Check TP sensor. Bree page £6-259 TP Sensor | BAD | ox Reps oF replace, BAD Repair or replace TP sensor. Check wiring between ECU and TP sensor |x Try another ECU.EG.207 ENGINE — EFi SYSTEM * Ve - £2 Gp THEW I no voTtage betwen ECU terminals VEE and £2 (iG Sw ON) ‘Check that there is voltage between ECU terminal +B (=Bi) and body ground. (IG SW ON} [ox NO Shack Tenor fel [See ooe 709 7 [BA0 TK f Check witing between ECU and TP @| [Repsirorrepiace, | [Cheek witna | TP Sensor TOK TRAD Ohmmeter, ve Try another ECU, Repair or replace wiring, vt tot 2 ro0te: + VTA -E2 There i no apacitiod voltage at ECU terminals VTA and E2 ® te sw ont T 1 @ Check tha there is Voltage between ECU terminals VEC and £2. 1G SW ON) NO OK Rafer to VOC — E2 trouble section. ce) (eee Ecu vec! & Try another ECUENGINE — EFI SYSTEM rouble Condition STD voltage vee — €2 ! See “45-55V | vs — €2 1eSWON | Measuring plate fully closed | 3.5 — 4.5 V VS — £2 No voltage. Measuring plate fully open | 0. 2-0.5V i “vs —&2 Idling 12-24V vs — 2 3,000 rpm 08 -13V cou 3 AirFiow Meter OD | @errasswom There is no voltage between ECU terminals VCC or VS and Check that there is voltage between ECU terminal +B (+61) and body ground. {IG SW ON) t | ok oe ' [no Roofer to No. [See page €G-203] Check wiring between ECU terminal £7 and body ground, oK t i Bee page E6-267] Check Air Flow meter. @ Repair or replace. [eno [ox t sows] [Replace Ai Thock wig between ECU and Air Flow mote Flow meter Ohmmeter Air Flow Meter je BAD Gaspzes) Try another ECU. Repair or replace.ENGINE — EFI SYSTEM EG.209 Voltmeter #30 #40 #50 No. | Terminals Trouble Condition STD voltage W710 E01 : alow No voltage IG sw ON -14Vv #60 £02 Ignition Switch Ev AM? FL ose ¥ Battery 00208 @|_ | @ Theres no voltage betwoon ECU terminals #10 ~ 60 ond £01 and/or E02. (IG SW ON) am #10 420 #60 £01 ECU of @ ‘Check that there is voltage between ECU terminal #10 ~ Voltmeter] 4 ? #60 and body ground. No OK eo: #30 #40 #50 Check {and body ground, wiring between ECU terminal E01 andlor E02 oK BAD Try another ECU. Repair or replace. (Check fusible link and ignition switch. Repair or replace. oK @ cheek resistence of each inector. oe STD resistance: Approx. 13.8 2 Sena) eee [eno Pee Ca5 Replace injector.ate EG-210 ENGINE — EFI SYSTEM (Air Flow Meter) No. | Terminals Trouble Condition STD voltage 5 | THA-—£2 | Novoltage | IGSWON | Intake air temperature 20 °C (68 °F) | 0.6 ~ 3.4V Intake Air Temp. Sensor cu Voltmeter G sw ON) ‘There fs no voltage between EGU terminals THA and E2 @ @ Check that there is voltage between ECU terminal +B (FBT) and body ground. (16 SW ON) ok [Check wiring between ECU terminal E1 and body ground No Rater to No.1 OK BAD © Bee pans (O25 ‘Check Intake air temp. sensor Repair or replace. BAD Replace Air Flow meter. oK ‘Check wiring between ECU and In- ‘take air temp. sensor Air Ftow Motor ©} oK BAD “Try another ECU. Repair oF replace.ENGINE — EFI SYSTEM EG-211 No. | Terminale | Trouble Condition ‘STD voltage 6 | THW-£2 | Novoltage | 1G SWON | Engine coolant temperature 80 °C (176 °F) | 0.2 — 1.0 Woter Temp. Sensor THW There i no volage between EOU terminals THW and E2, | @asswon ‘Check that there is voltage between ECU terminal +8 (+B1) ‘and body ground. W@ SW ON) Voltmeter co ch ok [xo Refer to Not Check wiring between ECU terminal E1 and body ground ox [= Shack Water feng: eaor , sa0 Te = eros 7 [ox = Water Temp. Sensor ‘Onmmeteralii ENGINE — EFI SYSTEM No. | Terminals Trouble Condition STD voltage 8 | STA-E1 No voltage Cranking 6Vormore | ecu Ignition Switch Neutral Start Switch STA (Terminal 601 To Circuit Opening Relay | There is no voltage between ECU terminals STA end ET ug sw start) | Check wiring between ECU Vottmeter Sleek etree OK terminal STA and ignition switch operation. terminal ST1 BAD OK BAD 200749 Ropair or replace. | Cheek wiring between ECU terminal ET and ® boay ground: Te ms (Check H-fuse, fusible link, battery, wiring. ignition switch and neutral start switch, BAD _| Repair or replace. 00799 @| ok heck that there fs voltage at starter terminal 60. ® (ig sw staRt) STD voltage: 6 V or mote oK No ‘Check wiring between ignition | Starter | | Check starter. switch terminal ST1 and starter terminal 50.£G-213 ENGINE — EFI SYSTEM No. Torminals Trouble Condition ‘STD voltage Iet ~ £1 No voltage tating Palse generation ECU There is no voltage between ECU terminals IGT and E1 | tating) I @ Check that there is voltage between ECU terminal IGT and body ground (Idling) No [ox Check wiring between | ECU terminal E1 and | BAD} Repair or body ground. replace. [ox Try another ECU BAD fusible link and ignition ‘Check fusible link and ignit flpale ahead switch, ]=« 210 Check distributor (See IG section) |PAP.T Repair or replace. cE Check wiring between ECU and |_BAD battery. Repair or replece. Jo« Check igniter. (See IG section) | BAT Repair or replace.£G-214 ENGINE — EFI SYSTEM No. | _ Terminals Trouble Condition STD voltage 9 | Isci~isca—e1 | No voltage Ig SW ON 9-14Vv EFI Main Relay ISC Valve Eu 09908 £1. (1G SW ON} a The*e is ne voltage between ECU terminals ISCt ~ 1SC4 and [@ Check thar there is voltage betweon ECU terminal +8 (+81) and body ground (IG SW ON) 0K No Refer to No. 1 ‘Chack wiring between ECU terminal E1 and body ground. ok BAD }@ Ghsck isc vale, Repair or replace. BAD ok Replace ISC ‘Check wiring between ECU and EFL valve main relay ok BAD 4 Try another ECU. Repair or replace.ENGINE — EF! SYSTEM £G-215 To Ignition ‘Switch (IG 1) Indicator Lamp Malfunction Combination Meter No. | Terminale Trouble Condition STD volt eet No voltage | Ne trouble (melfunction indicator lamp Hight off and oaay engine running. ECU Aldting) ‘There is no voltage between ECU terminals W and £1 @ Check that there is voltage between ECU terminal W and bor dy ground, No 0K roars @ Check wiring betwean ECUtorminel E1 and body ground. OK BAD ‘Try another ECU. Repair or replace. Check GAUGE fuse (10A) and maifun indicator lamp. OK |»0 Repair or replace, [rse tows ‘Check wiring between ECU terminal W and fuse. BAD [Repair or replace.EG-216 ENGINE — EFI SYSTEM No.1 Oxygen Sensor Check Connector ECU ‘Oxygen Sensor To EFI Main Relay: 80 ee wing baton FOU WET ond Boy Bd Tox [exo ‘Check for at svetion of sic into exhaust system. }®A2T Repair air suction. Tox Check tor air igak trom air induction system. BART Repair air look. Toe ‘Check spark plugs. }EAQT Repair or replace. ox Check distributor and ignition system. [BART Repair or replace. Tox Check fuel pressure. [BA2T Repair or replace. Tox ‘Chock injectors. }BARL Repair or replace. OF Cheek sir flow meter [BART repair or replace Tox [cheek open ot onygen tener }2X.[ Sistem normal Teno ‘Cheok wiring between oxygen sensor and ECU }BAQT Repair wiring. To« Repair oxygen sensorEG-218 ENGINE — EFI SYSTEM. TROUBLESHOOTING W/VOLT,OHMMETER (M/T) HINT: © The following troubleshooting procedures are designed for inspection of each separate system, and therefore the actual procedure may vary somewhat. However, troubleshooting should be performed while referring to the inspection methods described in this manual. * Before beginning inspection, it is best to first make a simple check of the fuses, H—fuses, fusible links and the condition of the connectors. * The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit within the computer. © If engine trouble occurs even though proper operating voltage is detected in the computer connector, then it can be assumed that the ECU is faulty and should be replaced. EFI SYSTEM CHECK PROCEDURE PREPARATION (a) Disconnect the connectors from the ECU (b) Remove the locks as shown in the illustration so that the tester probes) can easily come in, NOTICE: Pay attention to sections “A” and “B" in the illustration which can be ily broken. rave | (€) Reconnect the connectors to the ECM. (4) Using a voltmeter with high impedance (10 kQ/V minimum), measure the voltage at each terminal of the wiring connectors. HINT: * Perform all voltage measurements with the con- nectors connected. © Verify that the battery voltage is 11 V or more when the ignition switch is in “ON” position.ENGINE — EF! SYSTEM Engine ECU Terminals (M/T) EG-219 SENSOR Syms | Comosion | Sra [toon | typo [Soman cor [Pon Grouno ne BSTHBTTOR Tha | TARE A Tow. SOR fo | iyector 16F | IGNITER vs | AIRFLOWMETER #20 | msecron we [av Fon var ia _[twrerTuerosmion smison 1 | een OUR ww nevinasTanTawiTow | #2 | son aroun ise? [ise waive #20 [miecton iesw_[ oumion swTow i0[woecron iso muecTon 7 ist IGNITER et ‘SENSOR GROUND ‘SPD SPEED SENSOR = : ran Ne ROOK NOR 7 cou wevronrorcessune Tox. [ower enson sant earrnr ct DISTRIBUTOR THW | WATER TEMP. SENSOR +eT EFI MAIN RELAY G2 DISTRIBUTOR WL Serene Foe +8 ‘EF| MAIN RELAYEeeee ENGINE — EFi SYSTEM ECU Wiring Connectors Voltage (M/T) wo: Terminal Condon STD voltage WT See pave gar = = IG Sw —€1 1 7 9-14 [ REL EF ig ew on +3 +81 Et ior = €2 Toe valve aren ania vec = #2 E a5= 55 2 ‘Throttle valve fully closed Heceae VTA — £2 {Throttle opener must be cancelled first) 7 ie ew on Throttle valve fully open 32-49 &2 = 45-55 iesorng plat Fly led a4 a Measuring nite fly open 02-08 [foa6 vs —E2 ig plat lly op iar 12-24 2,000 7m oe = 18 #10 a) "2-1 leswon ont #60 e [tia =e intake a tomp. 2000 68°F Osa 3a IG SW ON P | Taw ~e2 Engine coolant tmp, 60°C (76% 02-10 7 [Sta = 81 | Ganiing Gormere @ | et 81 ang False generation weet e] oy! -e1 jioswon o-u [eae isc i W — £1 |N@ trouble (matfunetion indicator lamp light off) and engine ag running ECM Terminals Sus tT, c 5|ENGINE — EFI SYSTEM No. |__Terminate | Trouble Condition STD voltage BATT — £1 | No voltaue = g-14v Ig sw —E1 7 M-REL — E1 | No voltage Ic SwON 9-14V +B (+81) — £1 MAIN Battery] pose * BATT — 1 [@ There is no voltage between ECU terminals BATT and ET, ody ground, [@ Check that there is voltage between ECU terminal BATT and No cE ‘Check wi © ‘ground. between ECU terminal E1 and body [x [eo Try another ECU Repair or replace. terminal and battery. Check fuse and fusible lr | BAD_T Replace. OK Check wiring between ECU BAD 7 [eAO + Repair or replace. porre?|Fears ENGINE — EFI SYSTEM So 1G sw-e1 Thee iso votage betweon ECU terminals 16 SW and EY, {ig sw ony ] Voltmeter [gp Check a theres voltage between ECU terminal iG SW and body ground, (16 SW ON) no ox rouse Check wing baton ECU erin EY nd body aoa Tx Tea Tey avator FOU Rapa or eae ‘Check fuses, fusible fink and igni- | BAD. Sen aah Roplair or replace. 0300 * MREL ~ Et [a Thre is no voltage between ECU terminals M-REL and E1. (Is sw ON) I Vottmeter = [a Sheek har hers votege Between ECU terminal EL and body ground. (1G SW ON) Oger NO Jox 080 Check wiring between ECU termine! Et and body ground. [ox [pao Try another ECU. Repair or replace. ‘Check EFL main rel ing [BAD [BAD | replace. harness. [ee pag tear] 72] eee [ox “Try another ECU. Proson|ENGINE — EFI SYSTEM Voltmeter a 2 +B (+B1 ~ ET EG-223 [G There is no voltage between ECU terminals +8 (+81) and E1. (1G SW ON) i [@ Check that there is voltage between ECU terminal +B (+81) and body ground. (1G SW ON) NO _Jox ‘Check witing between ECU terminal E1 and body ground. Tox [pao Try another ECU. [Besar orp, Check fuse, fs nk ond wine | BAD_[ poor ov eooo enerhs Repair or reslace. Tox ‘Check EFI main relay. BAD. Peers Tor Rafer to MEL — E1 trouble section.EG-224 ENGINE — EFI SYSTEM ve [tems [ en conn TO vate ne Tet a oe 2 vovenge | sew ow | Fae ae Thetis aonwimat oe | 03 o8y wae ae * IDL -E2 ©] pane wera aaa SN wna BSS Won ane oo T Voltmeter @ Check that tere is votoge between ECU terminal +B (=Bi) and body ground. (IG SW ON) poze OK wo fox heck wirig between ECU terminal ET and Body aroun Jo BAD Ty snatner FOU. Repair or Tsar Teter Nod BA Repair or replace. ‘Check TP sensor. @ [See page £6-259 BAD ok BAD Repair or roplace TP sensor. Check wiring between ECU and TP sensor. roszea ok Try another ECU.ENGINE — EFI SYSTEM EG-225 + vec - £2 "There fs no voltage betwaen ECU terminals VCC and E2. ® tg sw on Volmetsr (Check that there is voltage between ECU terminal +8 (¥BT) = and body ground. (1G SW ON) lO; Tox © CRE sensor, [Bao ]o« Repair or replace. | [Check wiring between ECU and TP sensor. @ [OK [BAD TP Sensor Ropair or replace Onmmeter -— ve | | TY another Ecu. wiring. cml ae VTA on tol i £2 VTA -£2 There is no specified voltage at ECU terminals VTA and E2. ® te swon Voltmeter | Check that there fe voltage botween ECU torminale VEC and £2. (IG SW ON} [No OK Refer to VEC — ED vores} [touble section, [ox B sensor. @ peese TP ser | 242 Tepito enace, poK Voltmeter Check wiring between ECU and BAD. aml [SAD | Repair or replace. OF [ox Try another ECU @ TP Sensor Onmmeter ve ea VTA iL e2eee, ENGINE — EFI SYSTEM No. | Terminals Trouble Condition STD voltage vec — E2 | - 45—-5.5V vs —&2 IGswon | Measuring plate fully closed | 3.5 — 4.5V 3 vs— 2 | Novoltage Measuring plat fully open 02-05 vs — €2 ‘dling 12-24 vs — €2 3,000 rpm 08-13 foo Air Flow Meter @ Tei®s ho voltage between ECU terminals VEC oF VS and E2, (IG SW ON) I (@ Cheek that tere is voltage between ECU terminal +B (FBT) and body ground. (1G SW ON) oK ‘Check wiring between ECU terminal E1 and body ground, ok [no Kai flow meter. © ws 7 Repair of replace. BAD | ok roses] [Replace ai Tiheck wiring between ECU and air flow meter. flow moter. == Try another ECU. Repair or replace. Ohmmeter Ca}ENGINE — EFI SYSTEM lanl Terminals | Trouble Condition STD voltage 710 E01 alee No voltage Ie sw on =v #60 £02 Ignition Switch Fou FL. Injector Battery rons @ Thais le vokage between ECU Terminale FTO ~ FO and £01 andor £02. 1G SW ON) heck that there is voltage between ECU terminal #10 — #60 end body ground. NO | OK (Check wiring between ECU terminal EDT rou and/or E02 and body ground. oK BAD e | ecu Tiy snother ECU. Repair or replace. Vottme eo) ‘Check fusible link and BAD. Repair fi log Neva0 eo ee pir or replace ox Ee Shack veance oF each not. STD resistance: Approx. 13.8 2 onmmeter @) ox BAD Teplace ijector | heck wing between ECU terminal | BAD I Tee eae | 240 | pepair or replace, | Injeotor verselee: EG-228 ENGINE — EFI SYSTEM Condition STD voltage 5 No | Terminals Trouble THA —E2 | No voltage 1G SWON | Intake air temperature 20 °C (68 °F) | 0.5 —3.4V Intake Air Temp. Sensor (Air Flow Matar) Voltmeter row (iG sw ON) @ {here's no vokage between ECU Terminals THA and E2. 2 Check that there is voltage betwean ECU terminal +B (+B1) and body ground, (16 SW ON) oK No Refer to Not [See page EG-221] (Check wiring between ECU terminal Et and body ground. BAD air temp. sensor. Ohmmeter bap | oK Check wing between ECU and Intake air temp, sensor. [ox BAD iy anathor ECU ] [Repair orresiocs-ENGINE — EFI SYSTEM aaiomie No. | Terminals | Trouble Condition STD voltage 6 | THW—E2| Novoltage | 1G SWON | Engine coolant tomperature 80 °C (176 °F) | 0.2 — 1.0 Water Temp. Sensor HEo-~ @ THe®e is no voltage between ECU terminals THW and Ez. (4G Sw ON) | Check that thore ls volkago between ECU tarminal +B ® (4-81) and body ground. 1G SW ON) Voltmeter ox No Hofer to No.i soxs7 Check wiring between ECU terminal E7 and body ground. Vattnater [ox Jeo @ Bas engy: sensor Ropair or replace BAD OK vosn| [Replace water temp. Check wiring between ECU sensor. and ECT sensor. ® oK |e Try enother ECU, Repair or replace ‘Sensor OhmmeterEG-230 ENGINE — EFI SYSTEM No. Trouble Condition ‘STD voltage 7 | sta—e1 No voltage Cranking [Vor more Ecu Ignition Switch STA (Terminal 50} To Circuit Opening Relay OD] [q Thee 8 no vottge between ECU terminots STA and ET. (1G SW START) Chesk wiring between ECU ok Voltmeter fepeck siattey terminal STA and ignition pperations switch terminal ST1 BAD OK | BAD Repair or replace. @ Ceo wiring Detwaen ECU terminal EV and body ground, OK | BAD Try another ECU. Repair or replace. Check H-fuse, fusible ink, battery, BAD ‘wiring, ignition awitch and neutral start |""2| Repair or replace. switch. pox ‘Ohmmeter ‘Voltmeter ® Terminal 50) ‘Check that there is voltage at starter terminal 50. {NG SW START) STD voltage: _6 V or more [o« NO. ‘Check wiring between ignition Check sterter, switch terminal ST? and starter terminal 50. woEG-231 ENGINE — EFI SYSTEM No.| Terminals: Trouble Condition STD voltage © ior — £1 No voltege lang Palse generation Ignition Switch ECU © dciings There is no voltage between ECU terminals IGT and £1. T Check that there is voltage between ECU terminal IGT and |® body ground ting) No [ox ‘Check wiring between a |® ECU terminal E1 and BAD. ses body ground, : [ox ‘Try another ECU. switch. ible 7 BAD Check fusible link and ignition esate tasters oK Check distributor (See IG section) BAD Repair or replace. [ox battery. Check wiring between ECU and BAD [+ Repair or replace. [ox Check igniter. (See IG section) BAD Repair or replace,reas ENGINE ~ EFI SYSTEM No. Terminals Trouble Condition STD voltage 9 | Isc1~isca—e1 | No voltage 1G SW ON o-14Vv EFI Main Relay Isc Valve ECU 709908 Q a There is no voltage between ECU terminals SC1 ~ 1SC4 and EI. {IG SW ON) I Voltmeter [@ Check that there is voltage between ECU termine! +B (+81) ind body ground. 1G SW ON) =v i ground. OF Ok | NO. ree Refer to No.1 ‘Check wiring between ECU terminal £1 and body ground. ok | BAD a ecco Repair or replace ar BAD [ox Replace ISC Check wiring between ECU and EFI vane, tain relay. [ox [ex ‘Try another ECU. Repair or replace.ENGINE — EFI SYSTEM EG-233 No.| Terminals Trouble Condition STD voltage wo] weer No voltage No rouble (natinton Indicator lamp light off) and Tay ECU To Ignition ‘Switch (IG 1) Aldting) | There is no voltage botwoen ECU terminals W and E1. I body ground. Check that there is voltage between ECU terminal W and NO ok ronrr Check wiring between ECU terminal E1 and ® bo. dy ground. 0K BAD Try another ECU. Repair or replace. 1 Check GAUGE fuse (104) and malfunction icator lamp. OK BAD Repair or replaci Fuse blows again Check wiring between ECU a terminal W and fuse. Repair or replace.fea ENGINE — EF! SYSTEM ‘Oxygen Sensor ECU Check Connector To EFI Main Relay ones. [OD There is no vortage between ECU VET and E71) ‘Check that thar le epocifod voltage betwoon ECU erminal VFI end body ground vo or Check wing betweon ECU terminal ET end body ground Tox [uo Tey evother ECU. Repair or repioes ‘Check frei austin of er into exhoveteyetem. }®A2[ Repair suction. Tox ‘Check fo wi leek fom ir ndueton system. Tox ‘Check spark plugs. BART Repair or reiace. Tox ‘Check distributor and ignition system. }BA2 Repair or replace. Tox ‘Check fuel pressure. | BA2[ Repair or replace. Tox ‘hack injectors }®42[ nepar or repece. ~ [ox Check ai flow meter ]242[ Repair or reece, Tox [© check operation of oxygen sensor, LOKL System normal. "20 heck we Deweon waver soar on €00 YEAR pa wing OKENGINE — EFI SYSTEM FUEL PUMP SYSTEM CIRCUIT EG-235 Battery ICheck Connector Fuel Pum Relay Neutral Start Switch Fuel Pump Switch {Air Flow Meter) Pump Resistor ECU connector. SST 09843-18020 aoe BE ON-—VEHICLE INSPECTION 1. CHECK FUEL PUMP OPERATION {a) Using SST, connect terminals +B and FP of the check (b) | Turn the ignition switch ON. NOTICE: Do not start the engine.ENGINE — EFI SYSTEM | <=] (©) Check that there is pressure in the hose from the fuel filter. ff A i A HINT: At this time, you will hear fuel return noise. If there is no pressure, check the following parts: (4 * Fusible links (MAIN 2.0L, AM2 0.3P) M b= BS) SQ, © Fuses (EFI 15A, IGN 7.5A) eee : a © EFI main relay On Lf G © Fuel pump Salty DM) ot © Wiring connections {d)_ Turn the ignition switch OFF. {e) Remove SST. SST 09843-18020 2. CHECK FUEL PRESSURE (a) Check that the battery voltages is above 12 volts. (b) Disconnect the cable from the negative (—) terminal of the battery. {c) Remove the union bolt and two gaskets, and discon- nect the No.1 fuel pipe from the delivery pipe. HINT: © Puta suitable container or shop towel under the delivery pipe. * Slowly loosen the union bolt. (d) Install the No.1 fuel pipe and SST (pressure gauge} to the delivery pipe with three new gaskets and SST (union bolt). SST 09268-45012 Torque: 29 N.m (300 kgf-cm, 22 ft-Ibf) (0) Wipe off any splattered gasoline.£G-237 ENGINE — EFI SYSTEM (f) () th) a) a Using SST, connect terminals +B and FP of the check connector. SST 09843-18020 Reconnect the battery negative (—-) cable. Turn the ignition switch ON. Measure the fuel pressure. Fuel pressure: 265-304 kPa (2.7—3.1 kat/em*, 38-44 psi) If pressure is high, replace the fuel pressure regulator. If pressure is low, check the following parts: * Fuel hoses and connections Fuel pump Fuel filter Fuel pressure regulator Fuel pume relay Fuel pump resistor Injectors ee ceee Remove SST from the check connector. SST 09843-18020EG-238 ENGINE — EFI SYSTEM (FP) 265 - 304 kPa Plug Se on NEN yo For 5 Minutes After Engine Stops 147 kPa or more (ky a (m) (n) (0) (p) (a) ) (s) () (u) Start the engine, Disconnect the vacuum sensing hose from the fuel pressure regulator, and plug the hose end. Measure the fuel pressure at idle, Fuel pressure: (265-304 kPa (2.7—3.1 kgf/cm*. 38-44 psi) Reconnect the vacuum sensing hose to the fuel pre- ssure regulator. Measure the fuel pressure at idle. Fuel pressure: 206~265 kPa (2.1—2.6 kaf/em*, 31~37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. Stop the engine. Check that the fuel pressure remains as specified for 5 minutes after the engine is stops. Fuel pressure: 147 kPa (1.5 kgf/cm’, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. After checking fuel pressure, disconnect the battery negative (—) cable and carefully remove SST to pre- vent gasoline from splashing. SST 09268-45012 Reconnect the No.1 fuel pipe to the delivery pipe with two new gaskets and the union bolt. Torque: 29 N-m (300 kgf-cm, 22 ft-Ibf) Reconnect the cable to the negative (—) terminal of the battery. Check for fuel leakage.EG.239 ENGINE — EFI SYSTEM je =o Battery rosa FUEL PUMP INSPECTION A. Inspect fuel pump resistance Using an ohmmeter, measure the resistance between the terminals 5 and 6. Resistance (Cold): 0.2- 300 If the resistance is not as specified, replace the fue! pump. B. Inspect fuel pump operation Connect the positive (+) lead from the battery to terminal 6 of the connector, and the negative (—) lead to terminal 5. Check that the fuel pump operates. NoTic! © These tests must be performed quickly (within 10 seconds) to prevent the coil from burning out. © Keep the fuel pump as far away from the battery as possible. © Always perform switching at the battery sid If operation is not as specified, replace the fuel pump. ie)EG-240 ENGINE ~ EFI SYSTEM COMPONENTS FOR DISASSEMBLY AND ASSEMBLY Fuel Pump Bracket Fuel Sender Gauge Fuel Pump: Rubor Cushion EP scp SO Fuel Pump Filter Non-rousable part esa FUEL PUMP DISASSEMBLY 1, REMOVE FUEL PUMP FROM FUEL PUMP BRACKET (2) Pulloff the lower side of the fuel pump from the pump bracket. {b) Disconnect the fuel pump connector. {) Disconnect the fuel hose from the fuel pump, and remove tthe fuel pump. (4) Remove the rubber cushion from the fuel pump. 2. REMOVE FUEL PUMP FILTER FROM FUEL PUMP. {a)_ Using a small screwdriver, remove the clip. {b) Pull out the pump filter.ENGINE — EFI SYSTEM Pelee 3. REMOVE FUEL SENDER GAUGE FROM FUEL PUMP BRACKET (a) Remove the three screws and diconnect the lead wires from the pump bracket. {b) Remove the three screws and sender gauge. rs FUEL PUMP ASSEMBLY 1, INSTALL FUEL SENDER GAUGE TO FUEL PUMP. BRACKET (a) Install the sender gauge with the three screws. {b) Connect the three lead wires to the pump bracket with the screws as shown, 2. INSTALL FUEL PUMP FILTER TO FUEL PUMP Install the pump filter with a new clip. 3. INSTALL FUEL PUMP TO FUEL PUMP BRACKET (a) Install the rubber cushion to the fuel pump. (b) Connect the fuel hose to the outlet port of the fuel pump. (c) Install the fuel pump connector. (d) Install the fuel pump by pushing the lower side of the fuel pump.GC. bin ENGINE — EFI SYSTEM FUEL FILTER ON—VEHICLE INSPECTION INSPECT FUEI (See step 2 01 COMPONENTS FOR REMOVAL AND INSTALLATION oa No.1 Fuel Pipe B20, 18) Fuel Filter NO Q0 Nein (ighem, TIBET] + Specified torque © Non-reusable part Gasket Fuet inlet HoseENGINE ~ EFI SYSTEM. EG-243 FUEL PRESSURE REGULATOR Vacuum Sensing Hose a Fuel Pressure Regulator Delivery Pipe ON-—VEHICLE INSPECTION INSPECT FUEL PRESSURE (See step 2 on|page EG—236| COMPONENTS FOR REMOVAL AND INSTALLATION Vacuum Sensing Hose Fuel Pressure Regulator s_ Fuel Return Hose v \ \(, eZ 7, O-Ring a CA. / + Specitied torque, | / SA my NNENGINE — EFI SYSTEM FUEL PRESSURE REGULATOR REMOVAL — 1. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 2. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR HINT: Put a suitable container or shop towel under the pressure regulator. 3. REMOVE FUEL PRESSURE REGULATOR Loosen the lock nut, and remove the fuel pressure regulator. FUEL PRESSURE REGULATOR INSTALLATION 1, INSTALL FUEL PRESSURE REGULATOR (a) Fully loosen the lock nut of the fuel pressure regula- tor. (b) Apply a light coat of gasoline to a new O-ring and install it to the fuel pressure regulator. (c) Thrust the fuel pressure regulator completely into the delivery pipe by hand. () Turn the fuel pressure regulator counterclockwise until the outlet faces in the direction indicated in the illustration. (0) Torque the lock nut. 5 N-m (250 kgf-cm, 18 ft-Ibf)ENGINE — EFI SYSTEM EG-245 2. CONNECT FUEL RETURN HOSE TO FUEL PRES- SURE REGULATOR 3. CONNECT VACUUM SENSING HOSE TO FUEL PRESSURE REGULATOR cd 4, START ENGINE AND CHECK FOR FUEL LEAKAGEEG-246 ENGINE — EFI SYSTEM INJECTOR Fuel Inlet PipeENGINE — EFI SYSTEM Leite ON~—VEHICLE INSPECTION 1, INSPECT INJECTOR OPERATION Check operation sound from each injector. (2) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine speed. (b) If you have no sound scope, you can check the in- jector transmission operation with your finger. If no sound or unusual sound is heard, check the wiring connector, injector or injection signal from the ECU. 2. INSPECT INJECTOR RESISTANCE (a) Remove the throttle body. {b) Disconnect the injector connectors. {c)_ Using an ohmmeter, measure the resistance between the terminals. Resistance: 1210169 If the resistance is not as specified, replace the in- jector. (d) Reconnect the injector connectors (e) Reinstall the throttle body. {See page EG—265)re2e ENGINE — EFI SYSTEM COMPONENTS FOR REMOVAL AND INSTALLATION ate 6S ‘Vacuum Sensing Hose ' Delivery Pipe Spacer 29 1300, 22 Gasket 1. -Ring Grommet ac insulator (Rim kef-em, IBA] : Specified torque ‘@ Non-reusable part ff gam) ®. Fuel Return Pipe @ EGR Valve and Vacuurn Modulator EGR Pipe No.1 Water By-Pass Hose ‘@GasketEG-249 ENGINE — EFI SYSTEM. INJECTORS REMOVAL ros 1 2. (a) (b) () (d) a DISCONNECT CABLE FROM NEGATIVE TERMINAL, OF BATTERY DRAIN ENGINE COOLANT (For Europe) REMOVE EGR VALVE AND VACUUM MODULATOR Disconnect three vacuum hoses. Loosen the EGR pipe union nut. Remove the two nuts holding the EGR valve and air intake chamber. Remove the two stud bolts, EGR valve and vacuum modulator assembly and gasket. REMOVE BOLT HOLDING HEATER INLET PIPE AND AIR INTAKE CHAMBER DISCONNECT NO.1 AND NO.2 PCV HOSES. DISCONNECT VACUUM HOSES DISCONNECT NO.2 WATER BY~PASS HOSE DISCONNECT EVAP HOSE9. 10. 11. 12, (a) (b) (o) 13. (a) (b) (e) fa) (b) 14, 15. ENGINE — EFI SYSTEM DISCONNECT THROTTLE POSITION SENSOR CONNECTOR DISCONNECT IDLE SPEED CONTROL VALVE CONNECTOR DISCONNECT CONNECTOR FOR EMISSION CONTROL VALVE SET ASSEMBLY REMOVE ENGINE OIL DIPSTICK AND GUIDE Remove the two mounting bolts. Pull out the dipstick together with dipstick guide. Remove the O—ring from the dipstick guide. DISCONNECT GROUND STARP REMOVE AIR INTAKE CHAMBER Disconnect the two vacuum hoses from the BVSV. Disconnect the No.1 water by—pass hose from the cylinder head. Remove the four bolts, four nuts, air intake chamber and two gaskets. REMOVE RETURN PIPE Disconnect the fuel hose from the fuel pressure reg- ulator. Remove the two bolts and fuel return pipe.EG-251 ENGINE — EF! SYSTEM fa) (b) () (d) (e) 16, 17. REMOVE NO.1 FUEL PIPE Remove the two union bolts, bolt, four gaskets and No.1 fuel pipe. REMOVE DELIVERY PIPE AND INJECTORS Disconnect the six injector connectors. Remove the three bolts and delivery pipe together with the six injectors. NOTICE: Be careful not to drop the injectors when rem- coving the delivery pi Remove the six insulators and three spacers from the intake manifold. Pull out the six injectors from the delivery pipe. Remove the O-ring and grommet from each injector.hbase ENGINE — EFI SYSTEM INJECTORS INSPECTION Pressure Regulstor {From Vehicie! sgt 1, INSPECT INJECTOR INJECTION sst CAUTION: Keep injector clean of sparks during the test. ( Fuel Fitter sst {On Vehicle) Injector (a) Connect SST (union and hose) to the fuel filter outlet with two new gaskets and the union bolt. sst SST 09268-41045 (90405-09015) Ti Hose} Torque: 29 N-m (300 kgf-em, 22 ftlbF) S sst f & (Union! Fuel @ Finer de Rp Union Gasket Bolt rs (b) Remove the fuel pressure regulator. ual (c) Install a new O-ring to the fuel inlet of pressure Pressure Regulator regulator, (4) Connect SST (hose) to the fuel inlet of the pressure ‘SST (Union) regulator with SST (union). Fos petuan tices SST 09268-41045 (09268-52010) Torque: 25 N-m (250 kgf-em. 18 ftlbf) SST (Hose} (2) Connect the fuel return hose to the fuel outlet of the rs pressure regulator. Seer (f) Install the grommet and a new O-ring to the injector. Lb (Hose) | (9) Connect SST (union and hose) to the injector, and hold the injector and union with SST (clamp). SST 09268-41045 (bh) Put the injector into the graduated cylinder. 0-Ring JDos HINT: Install a suitable vinyl hose onto the injector to. ws (Clamp) prevent gasoline from splashing out. Vinyt Tube une () Using SST, connect terminals +B and FP of the check connector. SST 09843-18020 (i) Reconnect the battery negative (—) cable.ENGINE — EFI SYSTEM tk) ()) swe 2 (a) (b) {e) (d) te) EG-253 Turn the ignition switch ON. NOTICE: Do not start the engine. Connect SST (wire) to the injector and battery for 15 seconds, and measure the injection volume with a graduated cylinder. Test each injector two or three times, SST 09842-30070 Volume: 66 — 82 cm’ (4.0 — 5.0 cu i Difference between each inject 5 cm’ (0.3 cu in.) or less. If the injection volume is not as specified, replace the injector. 1.) per 15 seconds INSPECT LEAKAGE In the condition above, disconnect the test probes of ‘SST (wire) from the battery and check the fuel leakage from the injector. SST 09842~30070 Fuel drop: ‘One drop or less per minute Turn the ignition switch OFF. Disconnect the battery negative (—) cable. Remove SST. SST 09268-41045, 09843-18020 Reinstall the fue! pressure regulator to the delivery pipe.ENGINE — EF! SYSTEM. INJECTORS INSTALLATION (See Components for Removal and Installation) 1. INSTALL INJECTORS AND DELIVERY PIPE {a)_ Install a new grommet to the injector. {b) Apply a light coat of gasoline to a new O=ring and install it to the injector. (c) While turning the injector left and right, install it to the delivery pipe. Install the six injectors. Uy rd (d) Position the injector connector upward. es (d)_ Position the inj ctor up) A ae Turn Push Os {e) Place six new insulators and the three spacers in position on the intake manifold. (f) Place the six injectors together with the delivery pipe in position on the intake manifold. (a) Temporarily install the three bolts holding the delivery pipe to the intake manifold.ENGINE — EFl SYSTEM. EG-255 (h) Check that the injectors rotate smoothly. LA é < ores ey HINT: If injectors do not rotate smoothly, the probable Spring Idle Speed Adjusting Screw 1, Praimary Main Jet 2) Secondary Main JetENGINE ~ FUEL SYSTEM ees CARBURETOR DISASSEMBLY HINT: The following instructions are organized sothat you will work only one component group at a time. This will help you avoid confusion between similar looking parts from different subassemblies being on your workbench at the same time. (a) To facilitate reassembly, arrange parts in order. (b) Be careful not to mix up or lose balls, clips or springs. (c) Use SST (carburetor driver set). SST 09860-11011 Air Horn Disassembly EG—31 UNION (See JRETOR STUD BOLT AND NIPPLE 2, REMOVE ACCELERATION PUMP ARM (2) Remove the snap ring from the pump connecting link, (b) Remove the pivot bolt. (@) Disconnect the pump arm from the pump plunger. () Disconnect the pump connecting link from the throt- tle lever and remove the pump arm and pump con- necting link. 3. DISCONNECT FAST IDLE CAM BREAKER (FICB) LINKEG-314 ENGINE — FUEL SYSTEM 4. fe) (b) REMOVE AIR HORN ASSEMBLY Remove the seven screws and following parts: (1) Number plate (2). Wire clamps (3) Vacuum hose clamp Lift off the air horn assembly together with the air horn gasket. REMOVE FLOAT AND NEEDLE VALVE Remove the float pivot pin, float and needle valve subassembly. REMOVE ACCELERATION PUMP PLUNGER Remove the pump plunger and boot. REMOVE AIR HORN GASKET REMOVE NEEDLE VALVE SEAT Remove the needle valve seat and gasket. REMOVE POWER PISTON Remove the screw, retainer, power piston and spring.ENGINE — FUEL SYSTEM all 10, REMOVE PRIMARY UPPER SLOW JET ze 11. DISCONNECT WIRES FROM CARBURETOR CONNECTOR Pry up the locking lugs with a screwdriver and pull out the terminal. 12. REMOVE OUTER VENT CONTROL VALVE (OVCV) Remove the three screws, wire clamp, OVCV and gasket. 13, REMOVE COIL HOUSING Remove the three screws, retainer, coil housing and gasket. 14, REMOVE CHOKE LEVER Remove the screw and choke lever.EG-316 ENGINE — FUEL SYSTEM (a) (b) 18. 17. REMOVE CHOKE BREAKER (CB) Remove the three screws, cover and spring. Remove the E—ring, stopper, spring collar and dia- phragm. . REMOVE FUEL CUT SOLENOID VALVE Remove the solenoid valve and gasket. REMOVE THERMOSTAT HOUSING Remove the two screws and thermostat housing. |. REMOVE FAST IDLE CAM BREAKER (FICB) LINK Remove the screw and FICB link.ENGINE — FUEL SYSTEM (a) (b) {c) (d) (a) (b) (a) (b) Carburetor Body Disassembly (See page EG~312; REMOVE CHECK BALLS FOR ACCELERATION PUMP Remove the pump discharge weight, spring and large ball. Remove the plunger spring. ieee Using tweezers, remove the ball retainer. Remove the small ball. REMOVE SLOW JETS Remove the primary slow jet. Remove the secondary slow jet. REMOVE CHECK BALLS FOR AUXILIARY ACCELERATION PUMP (AAP) Remove the plug, spring and ball. Remove the plug and ball. REMOVE POWER VALVEEG-318 ENGINE — FUEL SYSTEM fom 5. fa) (b) (a) (b) (c) REMOVE DASH POT (DP) Remove the three screws and DP. REMOVE PRIMARY AND SECONDARY MAIN JETS Remove the two passage plugs and gaskets. Remove the primary and secondary main jets and gaskets. REMOVE SMALL VENTURIES Remove the passage ring. Remove the two screws, primary small venturi and gasket. Remove the two screws, secondary small venturi and gasket.£G-319 ENGINE — FUEL SYSTEM saris Re SS ce 8. fa) {b) () 10, fa) (b) (c) M1, REMOVE AUXILIARY ACCELERATION PUMP (AAP) Remove the three screws, pump housing, spring and diaphragm. ie REMOVE SECONDARY THROTTLE VALVE DIAPHRAGM. Remove the snap ring and disconnect the diaphragm link. Remove the two screws, throttle valve diaphragm assembly and gasket. If necessary, remove the four screws and disassembly the throttle valve diaphragm. REMOVE FAST IDLE GAM BREAKER (FICB) Remove the snap ring. Remove the two screws. Disconnect the link, and remove the FICB. REMOVE THROTTLE POSITIONER (TP) Remove the two screws and TP.EG-320 ENGINE — FUEL SYSTEM 12. REMOVE FAST IDLE CAM 13. REMOVE SIGHT GLASS Remove the two screws, retainer, sight glass and O— ring. 14, SEPARATE CARBURETOR BODY AND FLANGE (a) Remove the passage screw and spring washer. {b) Remove the two bolts. {c) Separate the body and flange. (d)_ Remove the insulator.ENGINE — FUEL SYSTEM ‘air EG-321 GENERAL CLEANING PROCEDURE CLEAN DISASSEMBLED PARTS BEFORE INSPECTION (a) With a soft brush wash and clean the cast parts in carburetor cleaner. (b) Clean off the carbon around the throttle valve. (c) Wash the other parts thoroughly in carburetor clean- er. (4) Blow all dirt and other foreign material from the jets, fuel passages and restrictions in the body. INSPECTION OF CARBURETOR 1, INSPECT FLOAT AND NEEDLE VALVE (a) Inspect the pivot pin (1) for scratches and excessive wear. (b) Inspect the float (2) for broken lips and wear in the pivot pin holes. {c) Inspect the spring (3) for breaks and deformation. (@)_ Inspect the needle valve (4) and plunger (5) for wear or damage. (0) Inspect the strainer (6) for rust and breaks. 2. INSPECT POWER PISTON Check that the power piston moves smoothly. 3. INSPECT POWER VALVE Check for faulty opening and closing action.EG-322 ENGINE — FUEL SYSTEM AA oe © Battery 4. (a) (b) (a) (b) () (a) INSPECT FUEL CUT SOLENOID VALVE Connect the connector terminals to the battery ter- minals. You should feel a “click” from the solenoid valve when the battery power is connected and disconnected. If the solenoid valve is not operating properly, replace it, INSPECT CHOKE HEATER (COIL HOUSING) Using an ohmmeter, measure the resistance between the terminals. istance (Cold): 1,7-1.8 Q at 20°C (68°F) If a problem is found, replace the choke heater. INSPECT OUTER VENT CONTROL VALVE (OVCV) Check the valve and seats for damage. Check the valve rod moves smoothly. Using an ohmmeter, measure the resistance between the wire terminal and body. Rosistance (Cold): 32-380 If the resistance is not within specification, replace the OVCV. Connect the OVCV body and wire terminal to the battery terminals and check that the valve is retra- cted. If the OVCV is not operating properly, replace it.ENGINE — FUEL SYSTEM. lalate CARBURETOR ASSEMBLY HINT: Use new gaskets and O—rings throughout. Carburetor Body Assembly 1. ASSEMBLE CARBURETOR BODY AND FLANGE (a) Assemble the flange and body together with a new insulator. (b) Install the two bolts. (c) Install the passage screw together with the spring washer. 2, INSTALL SIGHT GLASS Install anew O-ring, the sight glass and retainer with the two screws. 3. INSTALL FAST IDLE CAMENGINE — FUEL SYSTEM. 15) New Gasket 4, INSTALL THROTTLE POSITIONER (TP) Install the TP with the two screws. 5. INSTALL FAST IDLE CAM BREAKER (FICB) (a) Connect the link, and install the FICB with the two screws. (b) Secure the link with the snap ring. 6. INSTALL SECONDARY THROTTLE VALVE DIAPHRAGM (2) Assemble the housing (1), a new gasket (2), the phragm (3), spring (4) and cover (6). (b) Install the four screws. {c) Place a new gasket in position on the carburetor body.ENGINE — FUEL SYSTEM (9) fe) (a) (b) (co) 9 (a) EG-325 Install the throttle valve diaphragm with the two screws, Connect the diaphragm link with the snap ring. we INSTALL AUXILIARY ACCELERATION PUMP (AAP) Install the following parts with the three screws. (1) Diaphragm (2) Spring (3) Cover INSTALL SMALL VENTURIES Install a new gasket and the primary venturi with the two screws. Install a new gasket and the secondary venturi with the two screws. Install the passage ring. INSTALL PRIMARY AND SECONDARY MAIN JETS Install the primary and secondary main jets with new gaskets.EG-326 « iSmal Hole a ao. Marge Hole 7 mr ENGINE — FUEL SYSTEM (b) Install the primary and secondary passage plugs with new gaskets. 10. INSTALL DASH POT (DP) Install the DP with the three screws. 11. INSTALL POWER VALVE 12. INSTALL CHACK BALLS FOR AUXILIARY ACCELERATION PUMP (AAP) {a) Install the ball, spring and plug. {b) Install the ball and plug. 13, INSTALL SLOW JETS (2) Install the primary slow jet. (b) Install the secondary stow jet.ENGINE — FUEL SYSTEM bist 14, INSTALL CHECK BALLS FOR ACCELERATION (a) _ Install the plunger small ball. {b) Using tweezers, install the ball retainer. re {c) Install the plunger spring, {d) Install the pump discharge large ball, spring and weight. Air Horn Assembly INSTALL FAST IDLE CAM BREAKER (FICB) LINK Install the FICB link with the screw. 2. INSTALL THERMOSTAT HOUSING Install the thermostat housing with the two screws. 3, INSTALL FUEL CUT SOLENOID VALVE {a) Install a new O—ring to the solenoid valve. (b) Install the solenoid valve together with a new gasket,EG-328 ENGINE — FUEL SYSTEM. 4. fa) (b) (c) (c) (d) INSTALL CHOKE BREAKER (CB) Insert the diaphragm into the thermostat case, and install the collar, spring and stopper with the E—ring. Insert the shaft of the diaphragm into the hole of the thermostat case. Install the following parts with the three screws: (1) Spring (2) Cover INSTALL CHOKE LEVER Install the choke lever with the screw. INSTALL COIL HOUSING Install the gasket to the thermostat case. Align the bi—metal spring with the wire spring and install the coil housing, aligning the choke lever as shown in the illustration. Align the scale center line of the thermostat case with the coil housing line, and install the plate with the three screws. Check the choke valve action.EG-329 ENGINE — FUEL SYSTEM Bone Coll Housing Fuel Cut Solenoid Valve ovev % {a) (b) 10. 1. INSTALL OUTER VENT CONTROL VALVE (OVCV) Install a new gasket, the wire clamp and OVCV with the three screws. CONNECT WIRES TO CONNECTOR Push in the terminal until it is securely locked in the connecting lug. Pull on the wire to check that it is securely locked. INSTALL PRIMARY UPPER SLOW JET INSTALL POWER PISTON Install the spring and power piston with the retainer and screw. INSTALL NEEDLE VALVE SEAT Install the valve seat together with a new gasket, ieENGINE — FUEL SYSTEM. 12. fa) (b) {e) (4) () ADJUST FLOAT LEVEL Insert the needle valve, spring and plunger into the needle valve seat. HINT: After adjusting the float level, install the clip ‘onto the needle valve. Install the float with the pivot pin. Allow the float to hang down by its own weight. Using SST, measure the clearance between the float tip and air horn. SST 09240-00014 Fioat level (Raised position): 7.0 mm (0.276 in.) HINT: This measurement should be made without a gasket on the air horn. Adjust by bending the portion of the float lip marked A Lift up the float. Using SST, measure the clearance between the needle valve plunger and float lip. SST 09240-00020 Float level (Lowered position): 0.9 — 1.1 mm (0.035 — 0.043 in.)EG-331 ENGINE — FUEL SYSTEM (f) (9) (h) fa) (b) 13, 14, 15. Adjust by bending the position of the float lip marked B. After adjusting the float level, remove the float, plung- er, spring and needle valve. Assemble the clip onto the needle valve. INSTALL NEW AIR HORN GASKET Place the air horn gasket on the air horn. INSTALL ACCELERATION PUMP PLUNGER Install a new boot and the pump plunger. INSTALL NEEDLE VALVE AND FLOAT Hook the needle valve clip to the lip portion of the float. Install the float and secure it with the pivot pin. eeEG-332 ENGINE — FUEL SYSTEM 16, a) (b) (ce) 17. 18, (a) (b) (c) (a) 19, 20. INSTALL AIR HORN ASSEMBLY Install the wire clamp in position. Place the air horn in the carburetor body. Install the following parts with the seven screws: (1) Number plate (2) Wire clamps (3) Vacuum hose clamp CONNECT FAST IDLE CAM BREAKER (FICB) LINK INSTALL ACCELERATION PUMP ARM Connect the pump connecting link to the throttle lever. Connect the pump arm to the pump plunger. Install the pump arm with the pivot bolt. Secure the link with the snap ring. INSTALL NIPPLE UNION Install a new gasket and nipple union CHECK FOR SMOOTH OPERATION OF EACH PARTENGINE — FUEL SYSTEM. EG-333 CARBURETOR ADJUSTMENT HINT: Use SST 09240-00014 to make adjustment. 1, CHECK AND ADJUST THROTTLE VALVE OPENING (a) Check the full opening angle of the primary throttle valve. Standard angle: 90° from horizontal (b) Adjust by bending the primary throttle stop lever. ‘eons (c) Check the full opening angle of the secondary throttle valve. Standard angle: 90° from horizontal (d) Adjust by bending the secondary throttle stop lever. \y WenTSee Secondary Throttle ™~ iE ‘Stop Lever P=EG-334 ‘Secondary Throttle Kick-Up Lever 2. (a) {b) (a) (b) fa) (b) ENGINE — FUEL SYSTEM CHECK AND ADJUST KICK—UP SETTING With the primary throttle valve fully opened, check the opening angle of the secondary throttle valve, ‘Standard angle: 23° from horizontal Adjust by bending the secondary throttle kick—up lever. CHECK AND ADJUST SECONDARY TOUCH ANGLE Check the primary throttle valve opening angle at the same time the primary kick lever just touches the secondary kick lever. ‘Standard angle: 67° from horizontal If the angle is not within specification, replace the carburetor flange. SET AUTOMATIC CHOKE Set the coil housing line so that it is aligned with the center line of the thermostat housing, HINT: The choke valve becomes fully closed when the atmospheric temperature reaches 30°C (86°F). Depending on vehicle operating conditions, turn the coil housing and adjust the engine starting mixture. {f too rich ....... Turn clockwise If too lean ...... Turn counterclockwiseENGINE — FUEL SYSTEM EG-335 Vacuum 5. CHECK AND ADJUST FAST IDLE SETTING * (2) Apply vacuum to the dash pot (DP). i esse AQ (b) Position the fast idle lever onto the 4th step as shown. (©) Check the primary throttle valve angle. Standard angle: G.c.c. 15.5 — 17.5° from horizontal Others 17.0 — 19.0° from horizontal ses (d) Adjust by turning the fast idle adjusting screw. S Fast Adjusting Screw 6. CHECK AND ADJUST UNLOADER (2) With the primary throttle valve fully opened, check the choke valve angle. Standard angle: 36 — 39° from horizontalENGINE — FUEL SYSTEM q Ist Step in SEP & (b) (a) {b) (ce) (d) Adjust by bending the unloader lever. CHECK AND ADJUST FAST IDLE CAM BREAKER (FICB) Set the fast idle cam. (1) While holding the throttle slightly open, push the choke valve closed, and hold it closed as you release the throttle valve. (2) Chock that the fast idle lever is a set in the Ist step of the fast idle cam as shown. Apply vacuum to the FICB and release it. Check that the choke linkage moves, and that the fast idle cam is released to the 4th step. Adjust by bending the FICB lever.ENGINE — FUEL SYSTEM bated 8. CHECK AND ADJUST CHOKE BREAKER (CB) {a) Set the fast idle cam, (See step 8) (b) Apply vacuum to the CB. (c) Check the choke valve angle. Standard an 44 — 48° from horizontal (d) Adjust by turning the CB adjusting screw. 9, CHECK AND ADJUST DASH POT (DP) (a) Open the throttle valve and then close it with the choke valve fully open. HINT: Check that fast idle is not operating. (b) Check the primary throttle valve angle. Standard angle: 19 — 21° from horizontal (©) Adjust by turning the DP adjusting screw.EG-338 10. (a) (b) (c) We (a) (b) (c) (a) (b) {c) 12. ENGINE — FUEL SYSTEM CHECK AND ADJUST THROTTLE POSITIONER (TP) Apply vacuum to dash pot (DP), fast idle cam breaker (FICB) and throttle positioner (TP). Check the primary throttle valve angle. Standard angle: 17.5 — 19.5° from horizontal Adjust by turning the TP adjusting screw. CHECK AND ADJUST ACCELERATION PUMP Apply vacuum to dash pot (DP), fast idle cam breaker {FICB) and throttle positioner (TP). Rotate the throttle shaft and check that the length of the stroke. Standard stroke: 10.9 mm (0.429 in.) Adjust the pump stroke by bending the connecting link. PRESET IDLE SPEED ADJUSTING SCREW Apply vacuum to dash pot (DP) and fast idle cam breaker (FICB). Check the primary throttle valve angle. Standard angle: 14° from horizontal Adjust turning the idle speed adjusting screw.ENGINE — FUEL SYSTEM. eee 13. PRESET IDLE MIXTURE ADJUSTING SCREW If the idle mixture adjusting screw has been removed, fully screw it in and then unscrew it the following amount. ‘Standare Return 2 1/4 turns from fully closed position HINT: Use SST if necessary. SST 09243-00020 ieee NOTICE: Use care not to screw it in too tightly and damage the screw tip. 14. CHECK FOR SMOOTH OPERATION OF EACH PART 15. INSTALL CABURETOR STUD BOLTENGINE — FUEL SYSTEM. 1 fa) (b) (c) fa) {b) (ce) (d) 4. 6. 7 10. CARBURETOR INSTALLATION [See page EG—309] INSTALL CARBURETOR Place the insulator and new gaskets on the intake manifold. Place the carburetor on the insulator. Install the four carburetor mounting nuts. Torque: 13 N-m (130 kgf-cm, 9 ft-Ibf) CONNECT FOLLOWING HOSES Emission control hoses Fuel inlet hose Outer vent control hose No.1 water bypass hose CONNECT CARBURETOR CONNECTOR CONNECT ACCELERATOR CABLE INSTALL INTAKE AIR CONNECTOR FILL WITH COOLANT ADJUST IDLE SPEED AND IDLE MIXTURE ADJUST FAST IDLE SPEED ADJUST DASH POT (DP) SETTING SPEED ADJUST THROTTLE POSITIONER (TP) SETTING SPEEDENGINE — FUEL SYSTEM fee FUEL PUMP FUEL PUMP REMOVAL Outlet Hose: Inlet Hose \ , Return Hose Insulator Fuel Pump. Nii Tkgh-em, f16f] : Specitied torque # Non-reusable part aay 1. DISCONNECT FUEL HOSES FROM FUEL PUMP 2, REMOVE FUEL PUMP Remove the three bolts, fuel pump and insulator.£G-342 ENGINE — FUEL SYSTEM FUEL PUMP INSPECTION (Airtight Test)” CUTAWAY VIEW Retumn Pipe Outlet Valve Outlet Pipe Diaphragm ae on Seat Vent Hole Inlet Pipe Inlet Valve Outlet Valve Rocker Arm rosa PRECHECKS (a) {b) Before performing the following checks on the fuel pump: Run some fuel through the pump to insure that the check valves seal tightly (a dry check valve may not seal properly). Without blocking off any pipes, operate the rocker arm and check the amount of force necessary for operation and the amount of arm play. This same amount of force should be used in the checks. CHECK INLET VALVE Block off the outlet and return pipes with your finger and check that there is an increase in rocker arm play and that the rocker arm moves freely (no reaction force).ENGINE — FUEL SYSTEM Insulator EG-343 2. CHECK OUTLET VALVE Block off the inlet pipe with your finger and check that the rocker arm locks (does not operate with same amount of force used in the precheck above). HINT: Never use more force than that used in the precheck. This applies to checks 3 and 4 also. 3. CHECK DIAPHRAGM Block off the inlet, outlet and return pipes and check ‘that the rocker arm locks. HINT: If all three of these checks are not as speci- fied, the caulking (sealing) of the body and upper casing is defective. 4, CHECK OIL SEAL Block off the vent hole with your finger and check that the rocker arm locks. FUEL PUMP INSTALLATION 1. INSTALL FUEL PUMP Install a new insulator and fuel pump with the three bolts. Torq 1. N-m (210 kof-cm, 15 ftbf) 2. CONNECT FUEL HOSES TO FUEL PUMP 3. START ENGINE AND CHECK FOR LEAKS fee)i EG.344 ENGINE — FUEL SYSTEM SERVICE SPECIFICATIONS SERVICE DATA Part. No. 21100-68010 Carburetor 21100-68020 21100-68030 Float level (Raised position) 7.0 men (0.278 in.) Float level (Lowered position) 0.9 ~ 1.1 mm (0.080.043 in) Throttle valve closed angle (Primary) 9° from horizontal Throttle valve closed angle (Secondary) 20° from horizontal Secondary throtto valve full open angie (Primary) | 90° from horizontal Secondary throttle valve full open angle (Secondary) | 90° from horizontal Secondary throttlo valve kickup angle 23° from horizontal Secondary touch angle '58° from horizontal Fast idle angle (Pre—setting)~G.C.C. 155 ~ 178° from horizontal Fast idle angle Pre~setting)— Others 17 ~ 19° from horizontal Choke valve closed angle 20" from horizontal Unioder anale 35 ~ 99° from horizontal Choke breaker angle 44 ~ 46° from horizontal DP angle 19 ~ 21° from horizontal Throttle positioner angle 17.5 — 18.8% from horizontal Idle speed angle (Pre—setting) 14° from horizontal Idle mixture adjusting screw (Pr Serow out approx. 2 1/4 tums Acceleration pump stroke 1.08 mm (0.428 in.) « Choke heater resistance 17-199 COVEY resistance 32-389 TORQUE SPECIFICATIONS Part tightened Nn kote fib Garbulator x Intake manifold “13 130 . Fuel pump x Ovlinder heed L 2 210 15ENGINE — COOLING SYSTEM Eeean COOLING SYSTEM DESCRIPTION This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by—pass valve mounted on the inlet side. OPERATION 41FZ-FE 7 Throttle Body Water Outlet TO RADIATOR ‘Water By-Pass. Outlet Water Inlet ‘Water Pump Water Outlet Throttle Body Water By-Pass Outlet ‘Thermostat Radiator Cap {e 4 Cylinder Head < Reservoir Tank ~ ~ Cylinder Block Radiator Water Inlet Heater Heater Valve Water PumpEG-346 ENGINE — COOLING SYSTEM. 4EZF FROM HEATER To HEATER Carburetor Water Outlet Water inlet 3 “TO RADIATOR Wator By-Pass Outlet ‘Water Pump So FROM RADIATOR SS Thermostat Water Outlet Water By-Pass Outlet Carburator Reservoir Tank Cylinder Block Radiator opt Water Inlet Water Pump “Heater Heater Valve The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, cooling fan, hoses and other components. Coolant which is heated in the water jacket is pumped to the radiator, through which an cooling fan blows air to cool the coolant as it passes through. Coolant which has been cooled is then sent back to the engine by the water pump, where it cools the engine. The water jacket is a network of channels in the shell of the cylinder block and cylinder head through which coolant passes. It is designed to provide adequate cooling of the cylinders and combustion chambers which become heated during engine operation.ENGINE — COOLING SYSTEM Feet RADIATOR The radiator performs the function of cooling the coolant which has passed through the water jacket and become hot, and it is mounted in the front of the vehicle. The radiator consists of an upper tank and lower tank, and a core which connects the two tanks. The upper tank contains the inlet for coolant from the water jacket and the filler inlet. It also has a hose attached through which excess coolant or steam can flow. The lower tank has an outlet and drain cock for the coolant. The core contains many tubes through which coolant flows from the upper tank to the lower tank as wall as to cooling fins which radiate heat away from the coolant in the tubes. The air sucked through the radiator by the cooling fan, as well as the wind generated by the vehicle's travel, passes through the radiator, cooling the coolant. An automatic transmission fluid cooler is built into the lower tank of the radiator. A cooling fan with fluid coupling is mounted behind the radiator to assist the flow of air through the radiator. RADIATOR CAP The radiator cap is a pressure type cap which seals the radiator, resulting in pressurization of the radiator as the coolant expands. The pressurization prevents the coolant from boiling even when the coolant temperature exceeds 100°C (212°F). A relief valve (pressurization valve) and a vacuum valve (negative pressure valve) are built into the radiator cap. The relief valve opens and lets steam escape through the overflow pipe when the pressure generated inside the cooling system exceeds the limit (coolant temperature: 110—120°C (230—248°F), pressure; 59-103 kPa (0.6—1.05 kgf/cm’, 8.5 — 14.9 psi). The vacuum valve opens to alleviate the vacuum which develops in the cooling system after the engine is stopped and the coolant temperature drops. The valve’s opening allows the coolant in the reservoir tank to return to the cooling system. RESERVOIR TANK The reservoir tank is used to catch coolant which overflows from the cooling system as a result of volumetric expansion when the coolant is heated. The coolant in the reservoir tank returns to the radiator when the coolant temperature drops, thus keeping the radiator full at all times and avoiding needless coolant loss. Check the reservoir tank level to learn if the coolant needs to be replenished. WATER PUMP The water pump is used for forced circulation of coolant through the cooling system. It is mounted on the front of the cylinder block and driven by two drive belts.EGraS ENGINE — COOLING SYSTEM THERMOSTAT The thermostat has a wax type by—pass valve and is mounted in the water inlet housing. The thermostat includes a type of automatic valve operated by fluctuations in the coolant tempera- ture, This valve closes when the coolant temperature drops, preventing the circulation of coolant through the engine and thus permitting the engine to warm up rapidly. The valve opens when the coolant temperature has risen, allowing the circulation of coolant. Wax inside the thermostat expands when heated and contracts when cooled. Heating the wax thus generates pressure which overpowers the force of the spring which keeps the valve closed, thus opening the valve. When the wax cools, its contraction causes the force of the spring to take effect once more, closing the valve. The thermostat in this engine operates at a temperature of 82°C (180°F).ENGINE — COOLING SYSTEM EG-349 PREPARATION aH SST (SPECIAL SERVICE TOOLS) © 2 (08231-00060) Nos Pius OD This Part No. i 8 component part of 03290-01010 COOLANT CAPACITY (Reference) EQUIPMENT ot Heater Thermostat Radiator cap tester ‘Thermometer Thermostat "Torque wrench item TFZ—FE (iters (US ais, Imp.ats) 1ZF—F Gitors (US ats, mp.ats) w/e Heater 12.2128, 10.7) 125 (132, 11.0) W/ Front Hester 13.2 (140, 51.6) 135 (14.2, 11.9) L_w/_Front and Rear Heater 142 (15.0, 128) 145 (18.3. 12.8) * Classification: Ethylene—glycol base.EG-350 ENGINE — COOLING SYSTEM Zo AEE drain Plug Drain Cock COOLANT CHECK AND REPLACEMENT 1. CHECK ENGINE COOLANT LEVEL AT RESERVOIR TANK The coolant level should be between the “LOW” and “FULL’ lines. If low, check for leaks and add coolant up to the “FULL line. 2. CHECK ENGINE COOLANT QUALITY (a) Remove the radiator cap. CAUTION: To avoid the danger of being burned, do not remove it while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) There should not be any excessive deposits of rust or scales around the radiator cap or radiator filler hole, and the coolant should be free from oil, If excessively dirty, replace the coolant, (c) Reinstall the radiator cap, 3. REPLACE ENGINE COOLANT {a) Remove the radiator cap. CAUTION: To evoid the danger of being burned, do not remove it while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. (b) Drain the coolant from the radiator drain cock and engine drain plug. (Engine drain plug at the left of engine block.) (c} Close the drain cock and plug. Torque (Engine drain plug): 29 N-m (300 kaf-cm, 22 ft-lbf)ENGINE — COOLING SYSTEM. EG-351 (4) Slowly fill the system with coolant. - © Use a good brand of ethylene~glycol base coo- lant and mix it according to the manufacturer's directions. © Using coolant which includes more than 50 % ethylene—glycol (but not more than 70 %) is SS EES recommended. SSS notice: Peete * Do not use @ alcohol type coolant. ¢ The coolant should be mixed with demineralized water or distilled water. Capacity (w/ Hi 14.2 liters (15.0 US ats, 12.4 Imp. ats) (e) Reinstall the radiator cap. (f) Warm up the engine and check for leaks. (a) Recheck the coolant level and refill as necessary.eae ENGINE — COOLING SYSTEM ‘WATER PUMP COMPONENTS FOR REMOVAL AND INSTALLATION — a Water Pump Pulley Drive Belt Nem tkaf-om, ft-ibil] : Specified torque ‘@ ‘Non-reusable part rie WATER PUMP REMOVAL DRAIN ENGINE COOLANT DISCONNECT NO.3 WATER BY—PASS HOSE DISCONNECT RADIATOR INLET HOSE REMOVE DRIVE BELTS, FAN WITH FLUID COUPLING, WATER PUMP PULLEY AND FAN SHROUD (a) Stretch the belts and loosen the water pump pulley mounting nuts. (b) Loosen the lock, pivot and adjusting bolts of the generator, and remove the drive belts. (c)_ Remove the two bolts holding the fan shroud to the radiator. ()_ Remove the four water pump pulley mounting nuts, (e) Pullout the fan with fluid coupling, water pump pulley and fan shroud. () Remove the fan from the fluid coupling. Pepe y Lock BottEG- ENGINE ~ COOLING SYSTEM ibid 5. REMOVE WATER PUMP Remove the four bolts, two nuts, water pump and gasket. WATER PUMP COMPONENTS INSPECTION 1. INSPECT WATER PUMP Turn the pulley seat and check that the water pump bearing is not rough or noisy. If necessary, replace the water pump. 2. INSPECT FLUID COUPLING Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. WATER PUMP INSTALLATION {See Components for Removal and Installation) 1. INSTALL WATER PUMP Install a new gasket and water pump with the four bolts and two nuts. Torque: 21 N-m (210 kgf.cm, 15 ft-lbf) 2. INSTALL WATER PUMP PULLEY, FAN SHROUD, FAN WITH FLUID COUPLING AND DRIVE BELTS. {a)_ Install fan to the fluid coupling. (b) Place the fan with fluid coupling, water pump pulley and fan shroud in position. {c) Temporarily install the fan pulley mounting nuts. (d)_ Install the fan shroud with the two bolts.(e) (f) (9) PaPe ENGINE — COOLING SYSTEM Install the drive belts with the adjusting bolt and pivot bolt. Stretch the belts tight and tighten the four water pump pulley mounting nuts. Adjust the drive belts. (See CH section) CONNECT NO.3 WATER BY-PASS HOSE CONNECT RADIATOR INLET HOSE FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKSENGINE — COOLING SYSTEM EG-355 THERMOSTAT COMPONENTS FOR REMOVAL AND INSTALLATION Nem ikgt-em, ftibhh ‘* Non-reusable part Water Inlet 21210, 18) 1 Specified torque ‘Thermostat #Gasket THERMOSTAT REMOVAL HINT: Removal of the thermostat would have an adverse effect, causing a lowering of cooling effi- ciency. Do not remove the thermostat, even if the engine tends to overheat. 1. DRAIN ENGINE COOLANT . REMOVE WATER INLET AND THERMOSTAT {a) Remove the three nuts holding the water inlet to the housing, and disconnect the water inlet from the inlet housing. (b) Remove the thermostat. (c)_ Remove the gasket from the thermostat.EG-356 ENGINE — COOLING SYSTEM ‘mm oem THERMOSTAT INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. {a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature Valve opening temperatur 80 — 84°C (176 — 183°F) If the valve opening temperature is not as specified, replace the thermostat. (c)_ Check the valve lift. Valve lift: 10 mm (0.39 in.) or more at 95°C (203°F) If the valve lift is not as specified, replace the ther- mostat. (d) Check that the valve spring mostat is fully closed. If not closed, replace the thermosta’ ight when the ther-ENGINE — COOLING SYSTEM EG-367 THERMOSTAT INSTALLATION {See Components for Removal and Installation) 1. PLACE THERMOSTAT IN WATER PUMP (a) Install a new gasket to the thermostat. - Now Gasier ee {b) Align the jiggle valve of the thermostat with the pro- trusion of the water inlet housing, and insert the thermostat in the water inlet housing. HINT: The jiggle valve may be set within 15° of either side of the prescribed position. 2. INSTALL WATER INLET Install the water inlet with the three nuts. Torque: 21 N-m (210 kgf-cm, 15 ftibf) FILL WITH ENGINE COOLANT START ENGINE AND CHECK FOR LEAKS aeEG-358 ENGINE — COOLING SYSTEM RADIATOR RADIATOR CLEANING 1. fro SSS 016 2. aviator Cap cooiae zoe 3. @ (b) rc) Using water or a steam cleaner, remove any mud and dirt from the radiator core. NOTICE: If using a high pressure type cleaner. be car- ful not to deform the fins of the radiator core. If the cleaner nozzle pressure is 2,942 — 3,432 kPa (30 — 35 kgf/cm’, 427 — 498 psi), koop a distance of at least 40 — 50 cm (15.75 ~ 19.69 in.) between the radiator core and cleaner nozzle. RADIATOR INSPECTION REMOVE RADIATOR TANK CAP CAUTION: To avoid the danger of being burned, do not remove it while the engine and radiator are still hot, as fluid and steam can be blown out under pressure. INSPECT RADIATOR CAP Using a radiator cap tester, pump the tester and measure the relief valve opening pressure. Standard oponing pressure: 74 — 103 kPa (0.75 — 1.08 kgf/cm’, 10.7 — 14.9 psi Minimum opening pressure: 59 kPa (0.6 kaf/em’, 8.5 psi) If the opening pressure is less than minimum, replace the radiator cap. INSPECT COOLING SYSTEM FOR LEAKS Fill the radiator with coolant and attach a radiator cap tester. Warm up the engine. Pump it to 118 kPa (1.2 kgf/cm’, 17.1 psi), and check that the pressure does not drop. If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block and head.ENGINE — COOLING SYSTEM EG-359 SZ = SSeLEEE Ee OS 4, REINSTALL RADIATOR CAPEG-360 SERVICE SPECIFICATIONS SERVICE DATA ENGINE — COOLING SYSTEM Thermostat | Valve opening tom ‘Valve lift at 95°C (203°F) 80 — 84°C (176 — 18°F) 10 mm (0.39 in) oF more Radiator eap | Relief valve opening pressure (STO) Reliet valve opening pressure (Limit) 74 — 103 kPa (0.78 — 1.08 kaf/om*, 10.7 — 149 esd 59 kPa (0.8 kof/em*, 8.5 psi) TORQUE SPECIFICATIONS Part tightened Nm Khem feibe Oyfinder block x Drain plug 28 300 2 Water pump x Gylindor block 21 i 210 18 Water inlet x Water inlet housing 2 210 18 Radiator support x Radiator tank 13 130 2 Radiator x Bracket 2 120 2 Radiator mounting bott 18 188 13 Radiator mounting nut 12 720 3 Radiator lower tank x Nut (for Oll cooler) 10 100 7 Radiator lower tank x Pipe (for Olt cooler) 15 150 WENGINE — LUBRICATION SYSTEM £G-361 LUBRICATION SYSTEM DESCRIPTION A tully pressurized, fully filtered lubrication system has been adopted for this engine. OPERATION ~~ fistoxs 1 orien == Cama] Ta} a err t Surv cen wae urT@s |__| sean Lites /- I 1 ' ' CSA ==) [0 t i (Conner rensionen ~~ { Sona }ie) EG-362 ENGINE — LUBRICATION SYSTEM A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this ‘engine, The lubrication system consists of an oil pan, oil pump, oil filter and other external parts which supply oil to the moving parts in the engine block. The oil circuit is shown in the illustration at the top of the previous page. Oil from the oil pan is pumped up by the oil pump. After it passes through the oil filter, it is through the various oil holes in the crankshaft and cylinder block. After passing through the cylinder block and performing its lubricating function, the oil is returned by gravity to the oil pan. A dipstick on the center left side of the cylinder block is provided to check the oil level. OL PUMP The oil pump pumps up oil from the oil pan and feeds it under pressure to the various parts of the engine. An oil strainer is mounted in front of the inlet to the oil pump to remove impurities. The oil pump itself is a trochoid type pump, inside of which is a drive rotor and a driven rotor. When the drive rotor rotates, the driven rotor rotates in the same direction, and since the axis of the drive rotor shaft is different from the center of the driven rotor, the space between the two rotors is changed as they rotate. Oil is drawn in when the space widens and is discharged when the space becomes narrow. OIL PRESSURE REGULATOR (RELIEF VALVE) At high engine speeds, the engine oil supplied by the oil pump exceeds the capacity of the engine to utilize it. For that reason, the oil pressure regulator works to prevent an oversupply of oil During normal oil supply, a coil spring and valve keep the by—pass closed, but when too much oil is being fed, the pressure becomes extremely high, overpowering the force of the spring and opening the valves. This allows the excess oil to flow through the valve and return to the oil pump. inlet. OIL FILTER The oil filter is a full flow type filter with a relief valve built into the papor filter element. Particles of metal from wear, airborne dirt, carbon and other impurities can get into the oil during use and could cause accelerated wear or seizing it allowed to circulate through the engine. The oil filter, integrated into the oil line, removes these impurities as the oil passes through it. The mounted outside the engine to simplify replacement of the filter element. A relief valve is also included ahead of the filter element to relieve the high oil pressure in case the filter element becomes clogged with impurities. The relief valve opens when the oil pressure overpowers the force of the spring. Oil passing through the relief valve by—passes the oil filter and flows directly into the main oil hole in the engine.ENGINE — LUBRICATION SYSTEM. EG-363 PREPARATION SST (SPECIAL SERVICE TOOLS) aa [9082-00160 01 Pan Seal Cuter a =e TO219S E0012 Cranhals Pulley Holding Too! = ee ae (821360017 crankaate Paley & Gear Pur ——— ‘Set ae (09213-00020) Body With Bolt — (09213-00030) Handle 2 (€8213-00060) Bolt Sex 09223-46011 Crankshaft Front Oil Seal Ee 7 7 Roplcer 08228-44011 01 Fiter Wench 0831660010 Trantmision & Transfer Bearing Roplacer (8516-00010) Repiacer Five ‘Crankshaft tant ol seal (8816-00060) Repiacer “O° ‘Crankshaft front il seal ‘08890-00021 Companion Fange Holding Too! Crankshatt puley 5 ‘0985020017 Universal Pulor Bae, cae SSEG-364 RECOMMENDED TOOLS ENGINE — LUBRICATION SYSTEM. : (09200-00010 Engine Adjust Kit ——— —— EQUIPMENT Oil pressure gauge | Precision straight edge Oi pump Torque wrench LUBRICANT em Capacity Gasification 8.0 liters (85 US ats, 7.0 Imp. ats) Drain and ref ‘w/ 01 fter change 74 ltrs (7.8 US ats, 85 Imp. ats) ‘w/o Oil fiter change 6.9 liters (7.8 US ate, 6.1 Imp. ats) API grade 86 or better. Hit is impossible to get SG or better, you may uso SF grade. SSM (SPECIAL SERVICE MATERIALS) (08828-00080 Seal packing or equivalent 01 pump i pan (Timing chain cover) ‘08833-00080 Adhesive 1244, THREE BOND 1344, LOCTITE 242 or equivalent ‘Ot pressure awitenENGINE — LUBRICATION SYSTEM EG-365 OIL PRESSURE CHECK Recommended viscosity (SAE: com Ct 1. CHECK ENGINE OIL QUALITY “I Prt Check the oil for deterioration, entry of water, disco- Ect T loring or thinning. Sooo | If the quality is poor, replace the oil. pet Duiyieded Cee Pee Eee eet API grade $G or better, recommended viscosity is as oss shown. If it is impossible to get SG or better, you may use ze SF grade. 2. CHECK ENGINE OIL LEVEL The oil level should be between the “L” and “F” marks on the dipstick. If low, check for leakage and add oil up to “F* mark. 3. REMOVE OIL PRESSURE SWITCH, AND INSTALL OIL PRESSURE GAUGE 4. WARM UP ENGINE Allow the engine to warm up to normal operating temperature. 5. CHECK OIL PRESSURE Oil pressure: At idle 29 kPa (0.3 kgf/cm’, 4.3 psi) or more At 3,000 rpm (246 — 490 kPa (2.5 — 5.0 kgt/em*, 36 — 71 psi) Adhesive 6. REMOVE OIL PRESSURE GAUGE AND REINSTALL OIL PRESSURE SWITCH 7 (a) Remove the oil pressure gauge. Lo (b) Apply adhesive to two or three threads of the oil pressure switch. Adhesi Part No, 08833-00080, THREE BOND 1344, vata! LOCTITE 242 or equivalent (©) Reinstall the oil pressure switch. 7. START ENGINE AND CHECK FOR LEAKSEG-366 ENGINE ~ LUBRICATION SYSTEM OIL AND FILTER REPLACEMENT eT y fy syd a co) 2 @) (b) CAUTION: © Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, \ to dryness, irritation and dermatitis. In ad- dition, used engine oll contains potentially harmful contaminants which may cause skin cancer. © Gare should be taken, therefore, when changing engine, oil to minimize the frequency and length of 1@ your skin is exposed to used engine oil. Pro- tective clothing and gloves that cannot be pen rated by oil should be worn, The skin should be thoroughthly washed with soap and water, or use water — less hand cleaner, to remove any used ‘engine oll. Do not use gasoline, thinners, or solvents. © In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites. DRAIN ENGINE OIL Remove the oil filler cap. Remove the oil drain plug, and drain the oil into a container. REPLACE OIL FILTER Using SST, remove the oil filter. SST 09228-44011 Check and clean the oil filter installation surface,ENGINE — LUBRICATION SYSTEM oer (c) Apply clean engine oil to the gasket of a new oil filter. Ee (d) Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. (e) Using SST, tighten it an additional 3/4 turn. SST 09228-44011 3. FILL WITH ENGINE OIL (2) Clean and install the oil drain plug with a new gasket. Torque: 25 N-m (250 kgf-om, 18 ftibf) (b) Fill with new engine oil, Oil grade: filter change 7.4 liters (7.8 US qts, 6.5 Imp. ats) w/o Oil filter change 6.9 liters (7.3 US qts, 6.1 Imp. ats) Dry fill 8.0 liters (8.5 US qts, 7.0 Imp. ats) Reinstall the oil filler cap. START ENGINE AND CHECK FOR LEAKS RECHECK ENGINE OIL LEVEL oesEG-368 ENGINE — LUBRICATION SYSTEM OIL PUMP COMPONENTS FOR REMOVAL AND INSTALLATION Sette, EEF TQ oe GY to orig & O-Ring il Pump {timing Chain Cover) Crankshaft Front Oil Seal Crankshaft Pulley eGasket Drive Belt ‘Adjusting Bar Drive Belt idlor Pulloy Nem tkahem, febil] + Specified torque ‘@ Non-reusable partEG-369 ENGINE — LUBRICATION SYSTEM. OIL PUMP REMOVAL (b (b) fa) ) ) HINT: When repairing the oil pump, the oil pan and strainer should be removed and cleaned. DRAIN ENGINE OIL {Ee REMOVE WATER PUMP. Remove the four bolts, two nuts, water pump and gasket. REMOVE CYLINDER HEAD (Europe) REMOVE OIL LEVEL SENSOR Remove the four bolts and level sensor. Remove the gasket from the level sensor. REMOVE NO.2 OIL PAN Remove the 17 mounting bolts and two nuts. Insert the blade of SST between the No.1 and No.2 oil pans, cut off applied sealer and remove the No.2 oil pan. SST 09032-00100 NOTICE: ‘* Be careful not to damage the No.2 oil pan contact surface of the No.1 oil pan. © Be careful not to damage the oil pan flange.EG-370 ENGINE — LUBRICATION SYSTEM 6. REMOVE NO.1 OIL PAN (a) Remove the 21 mounting bolts and two nuts. {b) Remove the No.1 oil pan by prying the portions (A) between the cylinder block and No.1 oil pan with a screwdriver. NOTICE: Be careful not to damage the contact surfacos the cylinder block and No.t 7. REMOVE CRANKSHAFT PULLEY {2) Using SST, remove the pulley bolt. SST 09213-58012, 09330-00021 (b) Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST. SST 09213-60017 (09213-00020, 09213-00030, 09213-00060), 09950-20017ENGINE — LUBRICATION SYSTEM. fa) (b) (c) (d) £G-371 REMOVE DRIVE BELT IDLER PULLEY Remove the bolt and idler pulley. lee REMOVE OIL PUMP (TIMING CHAIN COVER) Remove the nine mounting bolts, two mounting nuts and drive belt adjusting bar. Remove the oil pump by prying the portions betweeen the cylinder block and oil pump with a screwdriver. NOTICE: Be careful not to damage the contact surfeces of the cylinder block and oil pump. Remove the O—rings from the oil pump. Remove the gasket from the oil pump.Fest ENGINE — LUBRICATION SYSTEM. COMPONENTS FOR DISASSEMBLY AND ASSEMBLY Qi! Pump (Timing Chain Cover) @ Crankshaft Front Oil Seal g . q Spring ASS y Pug e f ce (600,36) AP Relief Valve f yy sonia cata Driven Rotor ° Drive Rotor il Pump Cover [Nem tigf-em, TDA] : Specified torque @ Non-reusable part a OIL PUMP DISASSEMBLY 1. REMOVE DRIVE AND DRIVEN ROTORS Remove the seven screws, pump cover, drive rotor, driven rotor and gasket. 2. REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve.£G-373 ENGINE — LUBRICATION SYSTEM OIL PUMP INSPECTION 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it does not, replace the relief valve. If necessary, replace the oil pump assembly. 2. INSPECT DRIVE AND DRIVEN ROTORS A. Inspect rotor body clearance Using a thickness gauge, measure the clearance be- tween the driven rotor and body. ‘Standard body clearance: 0.100 — 0.170 mm (0.0039 ~ 0.0067 in.) Maximum body clearance 0.30 mm (0.0118 in.) If the body clearance is greater than maximum, re- place the rotors as a set. If necessary, replace the oil pump assembly. B. Inspect rotor side clearance Using a thickness gauge and precision straight edge, measure the clearance between the rotors and pre: sion straight edge. Standard side clearance: 0.030 — 0.090 mm (0.0012 — 0.0036 in.) um side clearance: 0.15 mm (0.0059 in.) If the side clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly. C. Inspect rotor tip clearance Using a thickness gauge, measure the clearance be- tween the drive and driven rotor tips. ‘Standard tip cle nce: 0.030 — 0.160 mm (0.0012 — 0.0063 in.) Maximum tip clearance: 0.25 mm (0,0098 in.) If the tip clearance is greater than maximum, replace the rotors as a set.ENGINE — LUBRICATION SYSTEM CRANKSHAFT FRONT OIL SEAL REPLACEMENT HINT: There are two methods (A and B) to replace the oil seal which are as follows: EG-374 REPLACE CRANKSHAFT FRONT OIL SEAL ‘A. If oll pump is removed from cylinder block: (2) Using a screwdriver and a hammer, tap out the oil seal. (b) Using SST and a hammer, tap in a new oil seal until its surface is flush with the oil pump case edge. SST 09316-60010 (09316-00010, 09316-00050) (c) Apply MP grease to the oil seal lip. B. If oil pump is installed to the cylinder block: (a) Using a screwdriver, pry out the oil seal. NOTICE: Be careful not to damage the crankshaft. Tape ‘the screwdriver tip. (b) Apply MP grease to a new oil seal lip. (c) Using SST and a hammer, tap in the oil seal until its surface is flush with the oil pump case edge. SST 09316~60010 (09316-00010, 09316-00050)ENGINE ~ LUBRICATION SYSTEM. EG-375 OIL PUMP ASSEMBLY (See Components for Removal and Installation) 1. INSTALL RELIEF VALVE {a) Insert the relief valve and spring into the pump body hole. {b) Install a new gasket to the plug. (ce) Install and torque the plug. Torque: 49 N-m (500 kaf-cm, 36 ftibf) 2, INSTALL DRIVE AND DRIVEN ROTORS {a) Place the drive and driven rotors into the pump body. NOTICE: Apply engine oil to drive and driven rotors. (b) Place a new gasket on the pump body. {c) Install the pump cover with the seven screws.ENGINE — LUBRICATION SYSTEM. rae OIL PUMP INSTALLATION (See Components for Removal and Installation) 1. SET CRANKSHAFT Turn the crankshaft until the set key on the crankshaft facing downward. 2. INSTALL TIMING CHAIN AND CAMSHAFT TIMING GEAR (a) Install the timing chain on the camshaft timing gear with the bright link aligned with the timing mark on the camshaft timing gear. (b) Install the timing chain on the crankshaft timing gear with the other bright link aligned with the timing mark on the crankshaft timing gear. (c) Tie the timing chain with a cord as shown in the illustration and make sure it doesn’t come loose. 3. INSTALL OIL PUMP (TIMING CHAIN COVER) (2) Remove any old packing (FIPG) material and be car- eful not to drop an oil on the contact surfaces of the oil pump and cylinder block. Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. © Thoroughly clean all components to remove all the loose material.ENGINE — LUBRICATION SYSTEM Seai Packing (b) (c) (a) (e) ( EG-377 * Using a non—residue solvent, clean both sealing surfaces. Apply seal packing to the oil pump as shown in the illustration. Seal packing: Part No. 08826—00080 or equivalent Install a nozzle that has been cut toa 2 — 3 mm (0.08 — 0.12 in) opening. HINT: Avoid applying an excessive amount to the surface. @ Parts must be assembled within 5 minutes of application. Otherwise the material must be re- moved and reapplied. ‘© Immediately remove nozzle from the tube and reinstall cap. Place two new O-ring in position on the oil pump. Engage the gear of the oil pump drive rotor with the gear of the oil pump drive gear, and slide the oil pump. Install the oil pump and drive belt adjusting bar with the nine bolts and two nuts. ‘Torque: 21 N-m (210 kgf-cm, 15 ftlbf) HINT: Each bolt length is indicated in the illustration, A 30 mm (1.18 in) B50 mm (1.97 in) C 60 mm (2.38 in.) Remove the cord from the chain. aENGINE — LUBRICATION SYSTEM 4, INSTALL DRIVE BELT IDLER PULLEY Install the pulley with the bolt. Torque: 43 N.m (440 kaf-cm, 32 ftbf) 5. INSTALL CRANKSHAFT PULLEY (@) Align the pulley set key with the key groove of the pulley, and slide on the pulley. (b) Using SST, install and torque the pulley bolt, SST 09213-58012, 09330-00021 Torque: 412 N-m (4,200 kgf-cm, 304 ft-Ibf) 6. INSTALL NO.1 OIL PAN {a) Remove any old packing (FIPG) material and be car- eful not to drop any oil on the contact surfaces of the oil pan, oil pump and cylinder block. © Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves. * Thoroughly clean all components to remove all the loose material. © Using a non—residue solvent, clean both sealing surfaces. (b) Apply seal packing to the No.1 oil pan as shown in the illustration. me Seal Width 3-4mm Seal packing: Part No. 08826—00080 or equivalent 8 © Install a nozzle that has been cut toa 3 — 4mm. & (0.12 — 0.16 in) opening. HINT: Avoid applying an excessive amount to the surface. © Parts must be assembled within 5 minutes of application. Otherwise the material must be re- moved and reapplied. © Immediately remove nozzle from the tube and reinstall cap.New Gasket (ce) (d) (e) (a) (b) EG-379 ENGINE — LUBRICATION SYSTEM. Install a new gasket in position. Pour in approximately 15 cm* (0.9 cu in.) of engine oil in position. Install the No.1 oil pan with the 21 bolts and two nuts. 14 mm head Torque: 43 N-m (440 kgf-cm, 32 ftibf) 12 mm head Torque: 20 N-m (200 kgf-cm, 14 ftbF) INSTALL NO.2 OIL PAN Remove any old packing (FIPG) material and be car- ‘eful not to drop any oil on the contact surface of the No.1 oil pan. © Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves, ¢ Thoroughly clean all components to remove all the loose material. ¢ Using a non—residue solvent, clean both sealing surfaces. Apply seal packing to the No.2 oil pan as shown in the illustration. NOTICE: Do not use a solvent which will affect the painted surfaces. Seal packi Part No. 08826—00080 or equivalent reEG-380 ENGINE — LUBRICATION SYSTEM A Y seat width 3-4mm 7 Seal Width 2— 3mm (c) (a) (b) © Install a nozzle that has been cut toa 2 — 3mm (0.08 — 0.12 in.) opening or 3 — 4 mm (0.012 — 0.016 in.) opening. HINT: Avoid applying an excessive amount to the surface, © Parts must be assembled within 5 minutes of application. Otherwise the material must be re- moved and reapplied. © Immediately remove nozzle from the tube and reinstall cap. Install the No.2 oil pan with the 17 bolts and two nuts. Torque: 7.8 N.m (80 kgf-cm, 6 in..Ibf) for Bolt Torque: 8.8 N.m (90 kgf-cm, 78 in.-Ibf) for Nut (Europe) INSTALL OIL LEVEL SENSOR Install a new gasket to the level sensor. Install the level sensor with the four bolts. Torque: 5.4 N-m (55 kgf-em, 48 in.-Ibf)ENGINE — LUBRICATION SYSTEM EG-381 9. INSTALL CYLINDER HEAD [See page EG—70]or[108] 10. INSTALL WATER PUMP Install a new gasket and water pump with the four bolts and two nuts. 1 Nem (210 kgf-em, 15 ftbf)a ees ENGINE — LUBRICATION SYSTEM. OIL COOLER COMPONENTS FOR REMOVAL AND INSTALLATION No.1 Heat Insulator No.1 Exhaust Manifold #Gasket Air Pipe 21210, I} B——Reliet Valve Spring S—#Gasket @— Pruglas 1600, 36) Olt Pressure Switch Tem ikghom, fbf] : Specified torque ‘@ Non-reusable partENGINE — LUBRICATION SYSTEM. eat OIL COOLER REMOVAL (See Components for Removal and Installation) 1. DRAIN ENGINE COOLANT Ee 2. (Europe) REMOVE AIR PIPE Remove the two bolts, six nuts, air pipe and three gaskets. |. REMOVE NO.1 EXHAUST MANIFOLD (a) Remove the three bolts and No.1 heat insulator. (b) Remove the six nuts, exhaust manifold and gasket. 4. (1FZ—FE) REMOVE OIL PRESSURE SWITCHENGINE — LUBRICATION SYSTEM 5. REMOVE OIL COOLER AND OIL COOLER COVER ASSEMBLY Remove the ten bolts, two nuts, oil cooler and oil cooler cover assembly and gasket. 6. SEPARATE OIL COOLER AND OIL COOLER COVER Remove the four nuts, oil cooler and two gaskets from the oil cooler cover. 7. REMOVE RELIEF VALVE Remove the plug, gasket, spring and relief valve. OIL COOLER INSPECTION 1. INSPECT RELIEF VALVE Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesn’t, replace the relief valve. If necessary, replace the oll cooler cover. 2. INSPECT OIL COOLER Check the oil cooler for damage or clogging. If necessary, replace the oil cooler.EG-385 ENGINE — LUBRICATION SYSTEM. Adhesive —— OIL COOLER INSTALLATION (See Components for Removal and Installation) 1. INSTALL RELIEF VALVE Install the relief valve, spring and a new gasket with the plug. Torque: 49 N.m (500 kgf-cm, 36 ft-Ibf) 2. ASSEMBLE OIL COOLER AND OIL COOLER COVER Install two new gaskets and the oil cooler to the oil cooler cover with the four nuts. Torque: 17 N-m (170 kgf-cm, 12 ftibf) 3. INSTALL OIL COOLER AND OIL COOLER COVER ASSEMBLY Install a new gasket, the oil cooler and oil assembly with the ten bolts and two nuts. Torque: 21 N-m (210 kgf-cm, 15 ftbf) ‘ooler cover 4. (1FZ—FE) INSTALL OIL PRESSURE SWITCH (2) Apply adhesive to two or three threads of the oil pressure switch. Adhesive: Part No. 08833—00080, THREE BOND 1344, LOCTITE 242 or equivalent (b) Install the oil pressure switch.5. (a (b) ) ENGINE — LUBRICATION SYSTEM. INSTALL NO.1 EXHAUST MANIFOLD Install a new gasket and the exhaust manifold with the six nuts. Torque: 39 N-m (400 kaf-cm, 29 ft-lbf) Install the heat insulator with the three bolts. Torque: 20 N-m (195 kgf-om, 14 ft-lbf) INSTALL AIR PIPE Install three new gaskets and air pipe with the two bolts and six nuts. Torque: 20 N-m (200 kgf-cm, 14 ft bf) for Bolt Torque: 21 N-m (210 kgf-cm, 15 ftlbf) for NutENGINE — LUBRICATION SYSTEM hati OIL NOZZLE COMPONENTS FOR REMOVAL AND INSTALLATION Crankshaft Rem tkghem, febhl] : Specified torque OIL NOZZLES REMOVAL 1, REMOVE CRANKSHAFT See pages EG— 105) 2. REMOVE OIL NOZZLES Remove the six check valves and oil nozzles.£G-388 ENGINE — LUBRICATION SYSTEM. 1. 1. fa) (b) OIL NOZZLES COMPONENTS INSPECTION INSPECT CHECK VALVES Push the valve with a wooden stick to check if it is stuck. If stuck, replace the check valve. INSPECT OIL NOZZLES Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle. OIL NOZZLES INSTALLATION (See Components for Removal and Installation) INSTALL OIL NOZZLES Align the pin of the oil nozzle with the pin hole of the cylinder block. Install the oil nozzle with the check valve. Install the six oil nozzles. Torque: 25 N-m (250 kgf-cm, 18 ft-lbf) INSTALL CRANKSHAFT ise jes EG— 161)EG-389 ENGINE — LUBRICATION SYSTEM SERVICE SPECIFICATIONS SERVICE DATA Oil pressure | Atidle speed (normal operting temperature) 28 WPa (03 kat/on, 43 pad or more {At 3000 rpm inarmal operating temperature) 245 ~ 490 kPa (25 — 5.0 kat/om 36 ~ 71 pe Oi pump Body clearance (STD) (0.108 — 0.170 mm (0.0039 — 0.0087 in) Body clearance (Maximum) 0.30 mm (0.0118 in.) Tip cletance (S70) 0.030 ~ 0.180mm (0.0012 ~ 0.0063 in) Tip clearance (Maximum 0.25 mm (0.0088 in) Sie cloarance (STD) 0.030 ~ 0.080 mm (0.0012 ~ 0.0035 in) Side cloranco (Meximum) 0.15 mm (0.0059 in) TORQUE SPECIFICATIONS Part tightened a Nem kgf-om felt Oil pan x Brain plug 2 250 8 Oil pump x Relief vaive plug 49 500 | 36 Oil pump cover x Oil pump z 10 105, 8 Oil pump x Cylinder block 24 210 16 Driv bel ilo pulley x OF pump a 440 2 Oil svainor x No.t oll pan 20 200 14 Baffle plate x No.1 oil pan 78 80 | Not ol pan x Gyindor Bock (14 mm head bolt) “a uo 2 No ol pan x Grindor book (12 mm head bot) 20 300 14 Not ol pan x Oi pump (Timing chain cover) 20 200) 14 [No of pan xNost oll pan Gold 78 2 @9 instbt ‘No. oi pan x No.t oll pan (Nut) a8 20 78 inslbt No. ol pan x Transmission housing w 720) 8 Oil feel sensor x No.t ol pan Ba 5 48 nibh Faciaterpipo x Nast ol pan 2i 210 18 'A/G comprestor bracket x Not oll pan 7 375; 27 ‘A/G compressor bracket x Cylinder block 7 35 7 'A/G compressor x A/C compressor bracket 25 250 i Oi oer x Ol cooler cover 7 170 2 Oi cooler cover x Gvlider block 2i 210) 5 Tos exhaust manifold x Gyindor heed 3 400) 29 Nos exhaust manifold x Heat insulator 20 196 14 | Ricpioe x Gvinder heed 20 200) 14 Air pie x Exhoort manifold zi 210 15 ‘ir pipe x PAIR reed valve 2 210 15 Front exhaust pipe assembly x Exhavet manifold 62 620 46 No] euuport bracket x Transmission hovting 39 400) 29 Front exhaust pipe assombly x No. front oxhevet pipe 3 400) 29 Oi check valve x Cylinder block 25 250) 8 a1¢-2 (1FZ—FE) DESCRIPTION The ECU is programmed with data for optimum ignition timing under any and all operating conditions. Using data provided by sensors which monitor various engine functions (Engine RPM, intake air volume, engine coolant temperature, ete.), the microcomputer (ECU) triggers the spark at precisely the right instant. The ECU monitors the engine condition by signals from each sensor, calculates the ignition timing and sends an ignition signal to the igniter. High voltage from the ignition is distributed to each spark plug in the appropriate order to generate a spark between the electrodes, which ignites the air—fuel mixture. IGNITION SYSTEM — (1FZ—FE) IGNITER The igniter temporarily interrupts the primary current with the ignition signal (IGT signal) from the ECU and generates sparks at the spark plug. Also, as a fail—safe measure, when ignition occurs an ignition confirmation signal (IGF signal) is sent to the ECU. IGNITION COIL The ignition coil uses a closed core coil with the primary coil wrapped around the core and the secondary coil wrapped around the primary coil. This allows the generation of a high voltage sufficient to cause a spark to jump across the spark plug gap. DISTRIBUTOR This correctly distributes high voltage to the spark plug of each cylinder in the specified ignition order. PICKUP COILS The NE coil detects the crankshaft position, and the G1 and G2 coils detect the camshaft position.IGNITION SYSTEM — (1FZ—FE) IG-3 PRECAUTIONS 1. Donot leave the ignition switch on for more than 10 minutes if the engine does not start. 2. With a tachometer connected to the system, con- nect the test probe of the tachometer to the IGO of the check connector. 3. As some tachometers are not compatible with this ignition system, we recommend that you confirm the compatibility of your unit before use. 4, NEVER allow the tachometer terminals to touch ground as it could result in damage to the igi and/or ignition coil. 5. Do not disconnect the battery while the engine is running. 6. Check that the igniter is properly grounded to the body.'c-4 IGNITION SYSTEM — (1FZ—FE) SYSTEM CIRCUIT Ignition Switch Ignition Coil TOUOTN TOON Spark Plug Distributor tS awn 1.288 $ — | lonite eee sues Scheme l OPERATION fate ignition timing, the ECU sends a control signal so that the ion coil and the spark plugs produce a spark. To maintain the most approp! igniter sends current to the iIGNITION SYSTEM — (1FZ—FE) 16-5 PREPARATION a SST (SPECIAL SERVICE TOOLS) 08185~16100 _ Spark Plug Wrench ae 7 09843-18020 Diagnosis Check Wire RECOMMENDED TOOLS ot = 09082-00015, loctrical Testor “| x TOYOTA lacked T. = =e (08200-00010 Enpine Adjust Kit ese EQUIPMENT a Spark plug cleaner Tachometer ~ Torque wrench Timing light | Tonton timing(a) (b) () IGNITION SYSTEM — (1FZ—FE) ON—VEHICLE INSPECTION SPARK TEST CHECK THAT SPARK OCCURS Disconnect the high—tension cords (from the ignition coil) from the distributor cap. Hold the end approx. 12.5 mm (0.50 in.) from the body ground. Check if spark occurs while engine is being cranked. HINT: To prevent gasoline from being injected from injectors during this test, crank the engine for no more ‘than 1 — 2 seconds at a time. If the spark does not occur, perform the test as fol- lows (SPARK TEST {No ‘CHECK CONNECTION OF IGNITION COIL, |___.[ Connect securely. IGNITER AND DISTRIBUTOR CONNECTOR BAD 1oK ‘CHECK RESIST F HIGH-TENSION Replace the cords). CORD _.| Maximum resistance: 25 k2 per cord BAD | {0K 7 SEE ‘CHECK POWER SUPPLY TO IGNITION CO Check wiring between ignition switch AND IGNITER 10 ignition coil and igniter. 4. Turn ignition switch to ON. beac” 2. Check that there is battery voltage at | ignition coil positive (+) terminal I 10K HECK ANGE OF IGNITION COIL [Replace the ignition coil, Resistance: (Cold) (Hot) teas'| Primary 036-0552 0.45 - 0.65.2 Secondary 90-154kQ 114~ 18.1 ko __1_OK ‘CHECK RESISTANCE OF SIGNAL Replace the distributor housing ICKUP COIL) assembly, oat istance: (Cold) (Hot) — GiandGS 185-2750 240-3252 © | BAD GrandGS 185-275 Q 240-325. NEandGO 185-2750 240-325 0 I 19K OF DISTRIBUTOR Replace the distributor housing fos-e| assembly. Air gap: 0.2 - 0.4 mm {0.008 - 0.016 ind BAD 7 POK 7 7 ‘CHECK IGT SIGNAL FROM ECU ‘Check wiring between ECU, distributor BAB and igniter, and then try another ECU, }_OK FRY ANOTHER IGNITER varsIGNITION SYSTEM — (1FZ—FE) a HIGH— TENSION CORDS INSPECTION 1. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. 2. DISCONNECT HIGH—TENSION CORDS FROM ‘SPARK PLUGS (a) Remove the two mounting bolts of the No.1 and No.2 cord clamps. {b) Disconnect the high — tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor insi 3. DISCONNECT HIGH—TENSION CORDS FROM DISTRIBUTOR CAP AND IGNITION COIL (a) Using a screwdriver, lift up the lock claw and dis- connect the holder from the distributor cap (ignition coil). (b) Disconnect the high—tension cord at the grommet. DO NOT pull on the cord. NOTICE: * Pulling on or bending the cords may damage the conductor inside. * Do not wipe any of the oil from the grommet after the high— tension cord is disconnected.1G-8 IGNITION SYSTEM — (1FZ~FE) lohmmeter estan fo connecr won foe 4. INSPECT HIGH—TENSION CORD RESISTANCE Using an ohmmeter, measure the resistance. Maximum resistance: 25 kQ per cord If the resistance is greater than maximum, check the terminals. If necessary, replace the high — tension cord. 5. RECONNECT HIGH—TENSION CORDS TO DISTRIBUTOR CAP AND IGNITION COIL (2) Assemble the holder and grommet. HINT: Connect the high—tension cords to the dis- tributor cap as shown in the illustration. (b) Align the spline of the distributor (ignition coil) with the spline of the holder, and push in the cord. NOTICE: Check that the holder is correctly installed to ‘the grommet and distributor cap as shown in the illus-IGNITION SYSTEM ~ (1FZ—FE) IG-9 (c)_ Check that the lock claw of the holder is engaged by lightly pulling the holder. 6. RECONNECT HIGH—TENSION CORDS TO SPARK PLUGS Secure the high—tension cords with the clamps see ‘the illustration on the next page. (@) (b) Install the No.1 and No.2 cord clamps with the two bolts.IG-10 IGNITION SYSTEM — (1FZ—FE) 7. INSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the four bolts. SPARK PLUGS INSPECTION 1. REMOVE NO.2 AND NO.3 CYLINDER HEAD COVERS Remove the four bolts and head covers. 2. DISCONNECT HIGH—TENSION CORDS FROM SPARK PLUGS (2) Remove the two mounting bolts of the No.1 and No.2 cord clamps. (b) Disconnect the high — tension cords at the rubber boot. DO NOT pull on the cords. NOTICE: Pulling on or bending the cords may damage the conductor insi 3. REMOVE SPARK PLUGS Using a 16 mm plug wrench, remove the spark plug.1G-11 IGNITION SYSTEM — (1FZ—FE) 4. fa) (by CLEAN SPARK PLUGS Using a spark plug cleaner or wire brush, clean the spark plug. VISUALLY INSPECT SPARK PLUGS Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND K16R-U NGK BKR5EYA ADJUST ELECTRODE GAP Carefully bend the outer electrode to obtain the cor- rect electrode gap. Correct electrode gay 0.8 mm (0.031 in.) INSTALL SPARK PLUGS Using a 16 mm plug wrench, install the spark plug. Torque: 20 N-m (200 kgf.em, 14 ft-lbF) RECONNECT HIGH—TENSION CORDS TO SPARK PLUGS Reconnect the high—tension cords to the spark plugs. Install the No.1 and No.2 cord clamps with the two bolts. ie1G-12 IGNITION SYSTEM — (1FZ—FE) 9. INSTALL NO.2 AND NO.3 CYLINDER HEAD COVERS Install the head covers with the four bolts. IGNITION COIL INSPECTION NOTICE: “Cold” and “Hot” in the following sentences express the temporature of the coils themselves. “Cold” is from —10°C (14°F) to 50°C (122°F) and "Hot Is from 50” © (122°F) to 100°C (212°F). 1. DISCONNECT IGNITION COIL CONNECTOR 2. DISCONNECT HIGH—TENSION CORD 3. INSPECT PRIMARY COIL RESISTANCE Using an chmmeter, measure the resistance between the positive (+) and negative (—) terminals. Primary coil resistance (Cold): 0.36 — 0.55 Q Primary coil resistance (Hot): 0.45 — 0.650 If the resistance is not as specified, replace the igni- tion coil. 4, INSPECT SECONDARY COIL RESISTANCE Using an ohmmeter, measure the resistance between the positive (+) and high—tension terminals. Secondary coil resistance (Cold): 9.0 — 15.4 kO Secondary coil resistance (Hot): 11.4 ~ 18.1k2 If the resistance is not as specified, replace the igni- tion coil. RECONNECT HIGH—TENSION CORD RECONNECT IGNITION COIL CONNECTOR tanaIGNITION SYSTEM — (1FZ—FE) NE Pickup DISTRIBUTOR INSPECTION NOTICE: “Cold” and “Hot” in the following sentences ‘express the temperature of the coils themselves. “Cold” is from — 10°C (14°F) to 50°C (122°F) and “Hot” is from 50° C (122°F) to 100°C (212°F). 1, DISCONNECT DISTRIBUTOR CONNECTOR 2. REMOVE DISTRIBUTOR CAP WITHOUT ; DISCONNECTING HIGH—TENSION CORDS 3, REMOVE ROTOR 4, INSPECT AIR GAPS Using a thickness gauge, measure the gap between the signal rotor and the pickup coil projection. Air gap: .016 in.) |, replace the distributor housing.IGNITION SYSTEM — (1FZ—FE) 5. INSPECT SIGNAL GENERATOR (PICKUP COIL) RESISTANCE Using an ohmmeter, check that the resistance of the pickup coil. Pickup coil resistance (Cold): G1 and GO 185 - 2750 G2 and GO 185 — 275.9 NE and GO 185 ~ 2759 Pickup coil resistance (Hot): G1 and GS 240 - 3259 G2 and GO 240 - 3259 NE and GO 40 — 3250 If the resistance is not as specified, replace the dis- tributor housing. 6. REINSTALL ROTOR 7. REINSTALL DISTRIBUTOR CAP 8. RECONNECT DISTRIBUTOR CONNECTOR IGNITER INSPECTION (See procedure Spark Test on|page IG—6}IGNITION SYSTEM — (1FZ—FE) Latte DISTRIBUTOR COMPONENTS FOR REMOVAL AND INSTALLATION Connector Distributor Cap (with High-Tension Cord) Distributor Packing Nem ikgf-om, fetbA)] = Specified torque @ Non-reusable pert DISTRIBUTOR REMOVAL 1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY 2. DISCONNECT DISTRIBUTOR CONNECTOR 3. REMOVE DISTRIBUTOR CAP WITHOUT DISCONNECTING HIGH—TENSION CORDSIGNITION SYSTEM — (1FZ—FE) 4 (a) (b) fa) (b) SET NO.1 CYLINDER TO TDC/COMPRESSION Turn the crankshaft pulley until the timing mark is aligned with “0” mark on the timing chain cover. Check that the distributor rotor direction is as shown. if not, turn the crankshaft pulley one complete revo- lution, REMOVE DISTRIBUTOR Remove the hold—down bolt and pull out the dis- tributor. Remove the O-ring from the distributor housing.1G-17 IGNITION SYSTEM ~ (1FZ—FE) liga, DISTRIBUTOR INSTALLATION (See Components for Removal and Installation) 1 fa) (b) {e) (d) (e) CHECK NO.1 CYLINDER TO TDC/COMPRESSION If nescessary, remove the cylinder head cover, and check the following conditions: © Turn the crankshaft pulley and align its groove with the timing mark “0” of the timing chain cover. ¢ Verify taht the timing marks with one and two dots are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft one revolution (360°) and align the mark as above. INSTALL DISTRIBUTOR Install a new O—ring to the distributor. HINT: Always use a new O—ring when installing the distributor. Align the groove of the distributor housing with the protrusion on the driven gear. Apply a light coat of engine oil on the O—ring. Insert the distributor, aligning the center of the flange with that of the bolt hole on the cylinder head. Lightly tighten the hold—down bolt, eIGNITION SYSTEM ~ (1FZ—FE) Check Connector aco Tachom ve oF rote en Check Connector 4 (b) INSTALL DISTRIBUTOR CAP CONNECT DISTRIBUTOR CONNECTOR CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY WARM UP ENGINE Allow the engine to warm up to normal operating temperature. CONNECT TACHOMETER AND TIMING LIGHT Connect the test probe of a tachometer to terminal 1G © of the data link connector 1. NOTICE: © NEVER allow the tachometer terminal to touch ground as it could result in damage to the igniter and/or ignition coil. © As some tachometers are not compatible with this ignition system, we recommend that you confirm ‘the compatibility of your unit before use. ADJUST IGNITION TIMING Using SST, connect terminals TE! and E1 of the data link connector 1. SST 09843-18020 3° BTDC @ idle (Transmission in neutral position and A/C OFF)