Mazda B3 Engine Service Manual [PDF]

Zitiervorschau

J M O O B 1 0 3 t0 0

Mazda 121

CONTENTS Tirle

Workshop Manual Vofume 1 of 2 FOREWORD This workshopmanualis intendedfor use bv service technicians of AuthorizedMazda D-ealers to help them serviceMazdavehicles. It can also be uselulto ownersand operators of Mazda vehicles in diagnosing some problemsand performinglimitedrepairand maintenanceon Mazda vehicles.

Generallnformation Pre-DeliveryInspection and Scheduled MaintenanceService Engine Lubrication System Cooling System C,onttol SystemI EGI-S FuelandEmission Engine ElectricalSystem Clutch ManualTransaxle Automatic Transaxle Front and Rear Axles

For proper repair and maintenance,a withthismanualis imthoroughlamiliarization portant,and it shouldalwaysbe kept in a handy placefor quick and easy reterence. All the contentsof this manual,including arethe latestavaildrawingsand specifications, able at the time of printing. As modifications affectingrepairor maintenanceoccur,relevant to thisvolumewill informationsupplementary Mazda Authorized at be made available Dealers.This manual should be kept upto-date.

Steering System

Mazda Motor Corporationreservesthe right to alterthe specificationsand contentsof this manualwithoutobligationor advancenotice. All rightsreserved.No part of this book may be reproduced or used in any form or by any means,electronicor mechanical-including photocopying and recording and the use of any kind oJ informationstorage and retrieval system-without permissionin writing.

TechnicalData

Mazda Motor Corporation HIROSHIMA.JAPAN APPLICATION: Thismanualis applicableto vehiclesbeginning with the Vehicle ldentificationNumbers (VlN) shown on the following page.

Secti

Braking Syslem Wheels and Tires Suspension Body Body Electrical System Heater and Aar Conditioner Systems

Special Tools

wiringDiasram Sili:.|Tj|:'"''""'0"'' The section Z is published separatelrom this manual.

o 1990MazdaMotorCorporation ocT. '90 @) 1249-10-90J

(VlN) NUMBERS vEHlcLE IDENTIFICATION JMo D8103100 100001

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GENERALINFORMATION Gl- 2 TMPORTANT TNFORMATION ..................... BAS|CASSUMPT|ONS............................ Gl- 2 ... Gl- 2 sAFEryH1SK............... LOSSOFWARRANry.....,,...... GI- 2 POSSIBLE WARNING ON LUBRICANTS ............. Gl- 2 ANDGREASES. Gt- 3 HOWTO USETH|SMANUAL.................... PREPARATTON ................ Gl- 3 PROCEDURE............................. Gl- 3 REpAtR ............... Gl- 4 SYMBOLS........ GI4 NOTES. AND WARNINGS....... CAUTIONS. FUNDAMENTAL PROCEDURES................. GI- 4 ..,........... GI- 4 PROTECTION OFTHEVEHICLE Gl- 5 A WORDABOUTSAFETY....................... PREPARATION OFTOOLS EQUIPMENT............. GI_ 5 ANDMEASURING .. Gl- 5 SPEC|AL TOO1S............ Gl- s REMOVAL OF PARTS............................. ................ Gl- 5 DTSASSEMBLY REASSEMBLY ................. GI- 6 ..,....,..,,... GI- 7 ADJUSTMENTS ANDTUBING.............,.. GI_ 7 RUBBER PARTS GI- 8 JACKAND SAFETYSTANDPOSITIONS.... TYPE) VEHICLELIFT(2.SUPPORT postTtoNs..... ................. Gl- I ................... Gl- 9 TOW|NG......... NUMBERLOCATIONS.,... GI-10 IDENTIFICATION . . . . . . . . . . . . . . .G. .l .- l 0 uNtTs............. ..................................... Gl-l0 ABBREVTATTONS .... Gl-ll CAUT|ON INSTALLATION OFA MOBILE FAD|OSYSTEM.................... Gl-l1 TWO-WAY KEYON REMOVAL OF IGNITION TRANSAXLE MODE1.......... GI-11 AUTOMATIC TOOLSGI-12 ELECTRICAL TROUBLESHOOTING PARTS........ WITHELECTRICAL GI-13 CAUTION 03uGtx-001

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IMPORTANTINFORMATION

IMPORTANTINFORMATION BASICASSUMPTIONS for the safeandetfiThisworkshopmanualassumesthatyou havecertainspecialtoolsthatarenecessary on Mazdavehiclesandthatyou knowhowto usethemproperly. cientperlormance of serviceoperations You systemsandbasicserviceand repairprocedures. It alsoassumes thatyouarefamiliarwithautomobile you and understand the conseare correcl shouldnotattemptto usethismanualunlesstheseassumptions quencesdescribed below. SAFETYRISK thatyoushouldcarefully information Thismanualcontainscertainnotes,warnings,andotherprecautionary readand iollowto reducethe riskof personalinjuryto yourselfor othersandthe riskof improperservice in regardto anyspectfic thatmay damagethe vehicleor renderit unsafe.lf thereis no suchinformation that personalsafetyor vehiclesafetywill be servicemethod,this does not meanthereis no possibility jeopardized by the use oJincorrectmethodsor tools. POSSIBLELOSSOF WARRANTY Themanufacturer's warrantyon Mazdavehiclesand enginescan be voidedif improperserviceor repairs performed persons by otherthan thoseat an AuthorizedMazdaDealer. are AND GREASES WARNING ON LUBRICANTS Avoidall prolongedand repeatedcontactwith mineraloils,especiallyusedoils.Usedoilscontaminated including effects, (e.g.,enginesumpoils)aremoreirritating andmorelikelyto causeserious duringservice skincancer,in the eventof grossand prolongedskincontact. Washskinthoroughlyafterwork involvingoil. handcleanersmaybe of valueprovidedtheycan be removedfromthe skinwithwater.Do not Protective paraffin,or othersolventslo removeoil fromthe skin. gasoline, use Lubricants and greasesmay be slightlyirritatingto the eyes. Particuclothingif necessary. Bepeated or prolongedskincontactshouldbe avoidedby wearingprotective lead.Do notallowworkclothingto be conlarcareshouldbe takenwithusedoilsand greasescontaining taminatedwithoil. Dry cleanor laundersuchclothingat regularintervals. sMuGrx_oo

Gl-z

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HOWTO USETHISMANUAL

HOWTO USETHISMANUAL matit pro-E operation service Tool(ssT)fortheservice F[rtFf#rtifiirointsouttheneeded speciat

ceeds.Gatherall necessarySST beforebeginningwork. Example: MANUALSTEERING PREPARATION

SST NUMBER

ssT

49 0118850C Pullef,balljoinl

SST NAME

SST ILLUSTRATION 03uGtx-@6

REPAIBPROCEDURE lt identifies the components, showshowthe 1. Mostrepairoperations beginwithan overviewillustration. partsfit together,and visualpartslnspections. lf a damagedor wornpart is found,repairor replaceit as necessary. parts,tightening andsealant areshownin theoverview torques, andsymbols foroil,grease, 2. Expendable illustration. whenserBeferto thisinformation 3. Pagesrelatedto serviceproceduresareshownunderthe illustration. part. vicingthe related Example:

SHOWS TIGHTENING TOROUE UNIT

sHows

RELATED PAGEFOR SERVICE

"1:

17 Spacer 18 Drive pinion page M-2'l Bemoval rpecl splines and leelh fot weat or damage

9MUGIX.O34

(ex.@)showsserviceprocedure. Thenumbering specified. Unitsshownin Nm (m-kg,ftJb)unlessotherwise

Gt-3

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PROCEDURES HOWTO USE THIS MANUAL/FUNDAMENTAL

SYMBOLS Thesesymbolsshowthe pointsof applyingsuch if,er" uresi* symbolsindicatingoil,grease,and sealant. service. during materials Kind

Meaning

Symbol

g

Apply oil

New engine oil or gear oil as appropriate

@

Apply brake fluid

Only brake fluid

E

Apply automatictransmissionfluid

OnlyATF

Applygrease

Appropriategrease

Apply sealant

Appropriatesealant

Apply petroleumjelly

AppropriatepetroleumjellY

€

(@[

e

osuctx005

Note . Whenspecial oil or grease is needed,this is shown in the illustration. AND WARNINGS NOTES,CAUTIONS, Each andWARNINGS. CAUTIONS, youwillcomeacrossNOTES, As you ieadthroughihe procedures, oneis thereforea ipecific purpose.NOTESgiveyou added informationthatwill helpyou to complete procedrire. GAUTIbNSaregivento pri:ventyoufrommakingan errorthatcoulddamagethe a particular cancausePer' carefulinthoseareaswherecarelessness remindyouto beespecially vdhicle.WARNINGS youworkon you when follow general should WARNINGS some lilt contains sonatiniury.Thefollowing a vehicle

olA.,x-oo2

PROCEDURES FUNDAMENTAL OF THEVEHICLE PROTECTION Alwaysbe sureto coverfenders,seats,and floorareasbefore startinowork.

Gt-4

9MUGIX.O37

PROCEDURES FUNDAMENTAL

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A WORDABOUTSAFETY mustbefollowedwhenjackingup Thefollowingprecautions the vehicle. 1. Blockthe wheels. jackingpositions. 2. Useonlythe specified 3. Supportthe vehiclewith safetystands. Starttheengineonlyaftermakingcertaintheenginecompartmentis clearof toolsand people. 9MUGtX-003

9[,{UGtX-038

47UOGX-005

47U0GX-006

SMUGIX,O39

OF TOOLSANDMEASURING PREPARATION EOUTPMENT are equipment toolsandmeasuring Besurethatallnecessary availablebeforestartingany work.

SPECIALTOOLS Use specialtoolswhen they are required.

REMOVAL OF PARTS Whilecorrectinga problem,try alsoto determineits cause. Beginworkonly afterfirstlearningwhichpartsand subassemb es mustbe removedand disassembledfor replacementor repair.

DISASSEMBLY procedureis complex,requiringmanyparts lf the disassembly in a way all partsshouldbe disassembled to be disassembled, that will not affecttheir performanceor externalappearance and identifiedso that reassemblycan be performedeasilyand efficiently.

Gr-5

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PROCEDURES FUNDAMENTAL 1. lnsoectlonof Parts for inspected partshouldbecarefully Whbnremoved,-each problems' other and damage, detormation, malfunctioning,

9MUGtX-040

9MUGIX.O41

2. Arrangementof Parts arrangedior reAlldisJssembled oartsshouldbecarefully assembly. Be sureio separateor otherwiseidentifythe partsto be reolacedfromthosethat will be reused

3. Cleaningparts tor reuse All oarts'iobe reusedshouldbe carefullyand thoroughly method. cleanedin the appropriate

REASSEMBLY Standardvalues,suchas torquesand certainad.iustments' of all parts' mustbe strictlvobservedin the reassembly TORQUE TIGHTENING NUT AND BOLT NEIEr tOSTNUONRD in themain torqueshotmentioned in SectionTDfortightening text. lf removed,thesepartsshouldbe replacedwithnewones: '1. Oil seals 2. Gaskets 4. Lockwashers 3. O-rings 6. Nylonnuts 5. Cotterpins 9MUGIX-OM

)ffi

9MUGIX{42

Gt-6

Dependingon location: 1. Sealantshouldbe appliedto gaskets. of parts' 2. Oil shouldbe appliedto the movingcomponents prescribed the at be applied giease should oilor 3. Specified locations(suchas oil seals)beforereassembly'

PROCEDURES FUNDAMENTAL

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ADJUSTMENTS gaugesand/ortesterswhenmakingadiustments. Usesuitable E

57UoGX-002

RUBBERPARTSANDTUBING or oilfromgettingon rubberpartsortubing. Preventgasoline

9MUGIX.OOs

Gt-7

TYPE)FosmoNs Gl ,oo ANDsAFEw srANDFosmoNsyvEHplEUFT(25UPP6RT

JACKAND SAFETYSTANDPOSITIONS FRONTEND Jack positioni At the frontcrossmember

Satetystand positions: Sidesills

REAREND Jack position: At the centerof the rearcrossmember

Safetystand positions: Sidesills

03uGlx'oog

TYPE)POSITIONS vEHlcLE LIFT (2-SUPPORT REAREND Frame Sidesills

FRONTEND Frame Sidesills

Gt-8

9ltlUGlX-010

TOWING

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TOWING

WHEEL DOLLIES

03uGlx002

is necessary to preventdamageto p Propertowingequipment the vehicle. to vehiclesin tow mustal Lawsand regulations applicable waysbe observed. shouldbe pulledwiththe As a generalrule,towedvehicles damageor other drivingwheels offtheground.lf excessive prevent withthedrivingwheels towingthevehicle conditions offthe ground.usewheeldollies. Witheitherautomaticor manualtransaxle: switchin the ACCposition: 1. Setthe ignition 2. Placethe selectorleveror shiftleverin N (Neutral); the parkingbrake. 3. Release Caution . Do not tow the vehiclebackwardwith drivingwheels on the ground.This may causeinternaldamageto the transaxles. . Do not usethe hookloops underlhe front and rear ol the vehicle tor towing purposes. These hook loops aredesignedONLYtor transporttie-down.It tie.down hook loops are used for towing, the front/rear bumperwill be damaged.

Gt-9

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NUMBER LocATroNs/uNtrs/ABBREVtATtoNS rDENTIFrcATroN

NUMBERLOCATIONS IDENTIFICATION VEHICLE IDENTIFICATIONNUMBER (VIN)

AUTOMATICTRANSAXLEiIODEL AND NUMBER

,'% r(g ' /tYl

.,,/Pk

ENGINEMODELAND NUMBER

UNITS N.m (m-kg or cm-kg, ......Torque ftlb or in-lb).. per minute rpm......... ... . ........Revolutions A . . . . . . . . . . . . . . . . . . . . . . . . .A. m p e r e ( s ) V . . . . . . . . . . . . . . . . . . . . . .V o l t ( s ) Ohm(s)(resistance) . ....... ........... o. . kPa (kg/cm2,psi)..... .. Pressure (usuallyPositive) Pressure mmHg(inHg).... (usuallYnegative) . . . . . .W . att W.......... .... liters (US qt, lmp qt) . . Volume mm (in) ...... ....... .. Length 89U0GX.006

ABBREVIATIONS Atterbottomdead center A / C . . . . . . . . . . . . . . . . . .. A i r c o n d i t i o n e r . ccessories A C C . . . . . . . . . . . . . . . . . . . .A Automatictransaxle ATX. ...... After top dead center ATDC ..... Automatrctransmrssion ATF fluid Bypassair control BAC......... Beforebottomdead BBDC... center BTDC... .... ...... ....Beforetop deadcenter Centralprocessingunit CPU........ ABDC.......

........Electronically-controlled automatictransmission . .n g i n ec o n t r oul n i t E C U. . . . . . . . . . . . .. . . . . . .E gasoline ... Electronic EGI . .............. injection E I L . . . . . . . . . . . . . . . . . . . .E l e c t r i c laol a d .. . Exhaust EX.. circuit Integrated lC........ ....... .. l G N .. . . . . . . . . . . . l g n i t i o n l N . . . . . . . . . . . . . . . . . . . . .I .n. t. a . .k. e . rmftent 1 N T . . . . . . . . . . . . . . . . . . . . .I .n. t. e ldle speedcontrol ISC ............. . .f.th a n d L H . . . . . . . . . . . . . . . . . . . .L. e M....................... tvlotor M I L . . . . . . . . . . . . . . . . . . . . .l .\ .r a l f u n c t i o n i n d i c a t o r lamp Manualtransaxle MTX.......... . Overdrive OD ....... O F F . . . . . . . . .... . . . . . . . . . .S. .w. .i t c ho f f . .i t c ho n O N . .. . . . . . . . . . . . . . . . . .S. .w Positivecrankcase PCV........ ventilatlon PRC.................. Pressureregulator control Powersteering . P/S.-.... .............. P / ! V . . . . . . . . . . . .......... . . . P o w e rw i n d o w . . i g h th a n d R H . . . .... . . . . . . . . .. . . . . . .R Specialservicetool SST.,... . . . t. a r t S T . . . . . ..... . . . . . . . . . . . S . .w . .i t c h S W . . . . . . . . . . . . . . . . .S TDC.......... ............ Top dead center EC-AT.........

03uGtx.004

Gt-l0

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CAUTION

CAUTION INSTALLATIONOF MOBILETWO.WAYRADIOSYSTEM typeis used,the EGIsystem improperly or if a high-powered lf a mobiletwo-wayradiosystemis installed and othersystemsmay be affected. Whenthe vehicleis to be equippedwitha mobiletwo-wayradio,observethe followlngprecaulions: pointlromcontrolunits. 1. lnstallthe antennaal theJarthest (at least30 cm [11.8in]). fromthecontrolunitharnesses feederas far as possible 2. lnstalltheantenna 3. Ensurethat the antennaand feederare properlyadjusted. mobiletwo-wayradiosystem. 4. Do not installa high-powered MOBILETWO.WAYRADIO

EGAT CONTFOL UNIT ENGINECONTROLUNIT

"'o'"*'*J Ll lZ'""-rRoLUN,r

r/rl

AT LEAST 30 cm (11.8 in)

FARTHESTPOINT

05uGlx'013

KEY ON AUTOMATIC REMOVAL OF IGNITION TRANSAXLEMODEL to turntheignitionkey Theselectorlevermustbe in P (PARK) position. to be off butthekey lf the switch seems to the OFF cannotbe removed,the switchmaystillbe in the ACCposilevermaynot be in P (PARK). Shiftthe tion,or the selector and turnthe ignitionkeyto the leverto P (PARK), selector Thekeyshouldnowbe lreefor removal. LOCKposition.

R N D

s L

03UGIX.OOs

Gl-11

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CAUTION TOOLS TROUBLESHOOTING ELECTRICAL Test Light as shownin thefigure,usesa 12Vbulb.The Thetest-light, two leadwiresshouldbe connectedto probes. Thetestlightis usedforsimplevoltagechecksandfor checkingfor shortcircuits. Caution . Whencheckingthe control unit, never use a bulb over 3,4W. 9MUGIX.O19

JumperWire Thelumperwireis usedtortestingby shortingacrossswitch and groundconnections. terminals Caution . Do not connecta iumperwirefromthe powersource line to a body ground; this may cause burning or other damage to harnesses or electronic com' ponents.

9MUGIXO2O

VOLTMETER

Voltmeter is usedto measureof circuitvoltage.A voltTheDCvoltmeter the meterwitha rangeof 15Vor moreis usedby connecting positive(+) probe(redleadwire)to the pointwherevoltage is to be mi;asuredand the negative(-) probe(blacklead wire)to a bodyground.

GFOUNO 9MUGIX.O21

DiagnosisConnector a jumholewhenconnecting theprobeintotheservice Insert per wireto the diagnosisconnector. Caution . Do not insert the jumper wire probe lnto the diag' nosis connectorterminal, which may damagethe terminal.

05uGtx-021

Ohmmeter two between theresistance isusedto measure Theohmmeter anddiagnooointsina circuitandalsoto checkforcontinuity sis of shortcircuits. Caution . Do not attemptto connectthe ohmmeterto any circuit to which voltage is applied;this may burn or otherwisedamagethe ohmmeter.

9MUGIX045

Gl-12

CAUTION

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PARTS CAUTIONWITHELECTRICAL Battery Cable parts, electrical connectors or replacing Beforedisconnecting disconnectthe negativebatterycable.

9MUGIX-022

connectors Removalof connector

conNever pull on the wiringharnesswhen disconnecting nectors.

9MUGIX.O23

9MUGIX.O24

9MUGIX-025

03uGtx,011

Connectorscan be removedby pressingor pullingthe lock leveras shown.

Lockingof connector makesureto listenfor a clickthat Whenlockingconnectors, locked. theyaresecurely willindicate

lnspection orto measure 1. Whena testerisusedto checkforcontinuity side. insertthetesterprobefromthewireharness voltage,

Gr-l3

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CAUTION fromtheconconnectors of waterproof 2. Checktheterminals from thewireharbe accessed cannot nectorside,asthey nessside. Caution . Use fine wire to prevent damageto the terminal. . Do not damageihe terminal when inserting the tester lead.

Terminals lnsoection putitigntly wiresto checkthattheyaresecured on individual in the terminal.

9MUGIX.O27

ReDlacementof terminals as shown' toolsto removetheterminal Us6theappropriate it locks insert it until to be sure theterminal, Wheninstailind securery.

10

20

30

40

50

'

30 :

Engineoil

10w-30

Typicalspecitication:API service SD, SE or SF REPLACEMENT OF ENGINEOIL FILTER 1. Removetheoil filterwiththe SST a suitablewrench. 2. lJsea cleanrag to wipeoff the mountingsudaceon the engine. 3. Applya smallamountof cleanengineoilio therubberseal ol the newfilter. 4. Installthe oilfilterandtightenit by handuntilthe rubber sealcontactsthe base. 5. Tightenthe fllter1 and 1/6turnswitha filterwrench. 6. Startthe engineand checkfor leaks. 7. Checkthe oil levelandadd oil if necessary. Oil filler capaclty 83: 0.17liter(0.18US ql, 0.15lmp qt)

A-7

SERVICES MAINTENANCE SCHEDULED OF COOLINGSYSTEiI INSPECTION Warning . Nevei removethe radialorcap while the engineis hot. . Wraoa thick cloth aroundlhe cap when removingit. . Whdn removingthe radiatorcap, loosen it slowly to the fitst stop until the pressurein the radialoris released.and then removeit. CoolantLevel (Enginecold) 1.Verifvthatthecoolanllevelis nearthe ladiatorf llel neck is be' 2. Verilvthatlhe coolantlevelin the coolantreservior tweenthe FULLand LOWmarks 3. Add coolantif necessary. CoolantOuallty 1.Verffythattheieis no buildupof rustor scalearoundthe radiatorcao or radiatorfillerneck 2. Verilythat coolantis free of oi! Replacethe coolantif necessarv,

CoolantLeakage andthe available) tester(commercially 1. Connecta radiator filler neck. radiator to the SST to the 2. Applyt03 kPa(1.05kg/cmz.15 psi) pressure system. 3. Verifythatthe pressureis held. It not,checkior coolanileakage

?_---z'- .- l,'1,/

' CoolanlProtection Caution . Do not use alcohol-or methanol-basedcoolant' water in the coolant . Useonly soft (deminerallzed) mixlure. andspecificgravitywith temperature thecoolant 1. Measure and a hydrometer' a thermometer to thegraph by referring thecoolantprotection 2. Determine is notproper'addwaterorcoolant lrthecoolantprotectaon Antitreezesolution mixture percentage Gravilyai

Above -16"C (3oF) Above 26oC (-1soF)

Above-a0'C (-40"D COOLANTIEMPEFATUFE'C (.F)

A-8

65 55

coolant 20"c (68"F) 1.054 35 55

1.078

SERVICES SCHEDULEDMAINTENANCE REPLACEi'ENTOF ENGINECOOLANT Warning . Neveropenthe radiatorcapwhilethe engineis hot. . Wrapa thick cloth aroundthe cap whenloosening. . Use caution when draininghqt coolanl.

E

THEDFAINHOSE

Caution . Do nol use alcghol.or methanol-based coolant. . Useonly soft (demineralized) water in the coolanl mixture. '1.Removethe radiatorcapand loosenthe drainplug. 2. Drainthe coolantintoa suitablecontarner. 3. Flushthecoolingsystemwithwateruntilalltracesof color are gone;lhen letthe systemdraincompletely. 4. Installthe drainplug. glycol 5. Fillwiththe properamountand mixtureof ethylene to the tableabove. basedcoolantby referring Coolanlcapacity MTX:5.0 liters (5.3 US qt, 4.4 lmp qt) ATX: 6.0 liters (6.3 US qt, 5.3 lmp qt) 6. Runtheenginewiththeradiatorcapremoveduntiltheupper radiatorhoseis hot. 7. Withthe engineidling,add coolantto the radiatoruntilit reachesthe bottomol the fillerneck. 8. Installthe radialorcap.

A-9

SERVICES SCHEDULEDMAINTENANCE OF IDLE SPEED ADJUSTMENT Preparalion '1.Warmup the engineto normaloperatlngtemperaure. 2. Verityihatthe wat rod e)dendsoutwardiullyandthe idle fromthe roller' cam separates 3. Turnall electricloadsOFF. . BlowerFan . Headlight . RearWindowDelroster 4. Makesurethatthe enginespeeddoesnotchangewnen valve@ connector. lhealr btpasssolenoid disconnecting Note . lf lhe enginesPeeddecleases.the engineis still under the warm-upcondition' waittillthefanslops 5. lftheelectficcoolingfan isoperating, idle in goodcondition6. Verifythatthe engineis runningat connector' 7. Connectthe SSTto the diagnosis lG- terconnector io thediagnosis 8. Connecta tachometer minalas shown.

L Sel switch6) to Position1. 10 SetTESTSW10SELF-TEST. Note . lf the SSTis not used, iump acrossthe TENtelmi' nal and the GND telminal ot the diagnosiscon' nector.

t-\*l

ldle Speed 1. Check the idle speed with a tachometer.

ldle speed:MTX(Neutral) 750 jT rpm ATX(P range)|,100 :'t rpm

adjustthe idlebylurningthe 2. lf notwithinthe specifacalion, throttleadjustingscrewOAS).

A-10

SCHEDULEDMAINTENANCE SERVICES REPLACEMENT OF AIF CLEANEFELEMENT Visually checktheaircleaner elementfor excessive dirt,dam, age or oil, replacelf necessary.

REPLACEMENT OF FUELFILTER Warning . Keepsparksand open flamesaway trom lhe tuel area. . After replacinglhe tuel filter, check ihat the filler ioints are nol leaking. To reolacethe fuelfilter,oroceedas follows: 1. Disconnect the fuelhoses. lheluelli/terwirhrhebrackel 2. Remove 3. lnstalla newfilterin the reverseorderol removal. Note . Wheninstallinglhe fillter makesurelhe hosesare pushedgn as tal as possiblg.Securethe hoseswith clips. INSPECTION OF FUELLINESANOHOSES Checktheiuellinefittings,connections andcomponents for |eaKs, Thereshouldbe no wetness or stalnedareasthatmiohtindicateleaksReplaceany detectivehosesor clips.

A-1 1

SERVICES SCHEDULEDMAINTENANCE OF IGNITIONTIMING ATUUSTMENT Preparation 1. Warmup the engineto normaloperatingtemperature. 2. Verilythatthewaxrod extendsoutwardfullyandthe idle fromthe roller. cam separates loadsOFF. electric 3. Turnall . BlowerFan . Headlight . RearWindowDefroster 4. lvlakesurethatthe enginespeeddoesnotchangewhen valve@ connector' theairbypasssolenoid disconnecting Note . I the enginespeeddecreases,the engineis still u]} der the warm-upcondition. ACHOMETEF

waittillthetanstops. 5. lf theelectriccoolingfanisoperating, in goodcondition. at idle is running 6. Verifythalthe engine connector. the diagnosis to 7. Connectthe SST 8. Connecta timinglight. connector lG- ter' to thediagnosis 9. Connecta tachometer minalas shown.

.--

|N

re

IG-

_--\

GNO

10.Setswitch@ to Position1. 11.SetTESTSWto SELFTEST. Note . lf the SSTis not used,iump acrossthe TENlermi' nal and the GNDterminal gl the diagnosiscon' nector.

GND

.?-.:f-=\,('__',

\r:1.\

lgnition Timing Inspeclion/ Adiustment 1. Checkthatthe idlespeedis withinthe specification. ldle speed: MTX(Neutral) ?50 :l! rPm ATX (P range)1,100 i'! rpm

2. Checkthe ignjtiontimingwitha timinglight lgnition timing: BTDC16 + | "

/1.,"_(V

.:TS r , g 9=9 . . SO

lo

c

@

-

6? qE

n:

JO € d=.u

o o

fi

Q . = ./Jo
. 2

PerformSlep 2 4 a

/)

ll OK, check rgnton system (Referto lroubleshooiing ''Misfke") (r Page G-17 ff not OK, relerio speciJiedcheck seqlence lor displayedcode No. F Page F-?0

ls 00" displayedon SellDiagnosisChecker wlth lgnilLonswilchON? ri page F-67 Maltunctlon code No. displayed Check lor cause(Belerlo specited check sequenceior displayedcode No.) "88" flashes Check ECUlerm nal lF vo tag€

17 Page F-7o r? page F-114

voltage: Approx. 12v (lgnillon switch ON) 4 +

3

Rer.oveair c eanercoveri is fuei iniecledfrom injeclorwhie crankingengine?

1.5-2.0 Nn {15-20 crks,13-17

in-rb)

ll OK. replaceECU ll not OK. check wl.ing belween ECU and SelfDbgnosisChecker and ECUlerm nal 18 vollage Ch€ckiollowng poinls .Spark ptugs . tgnjtionrmrng .Engine compressiof .Warer thermosensor (ECU 20 tem nal vollase) .Fuel pressure (lr njectediuel is smallariounl) .Inlecror (li njecledfuel is smallamounl) Checkfor lnjectoroperatingsound whllecrankng engrne

+ +

ri page F-112

r page c-19 E? pag€ F-63 c? page B-lO -r page F-118 c7 page F-89 17 page F-97

li OK, So lo nexl siep l{ not OK, go ro Slep 6

F-17

F

GUIDE TROUBLESHOOTING ACTION

tNsPECT|Oll F/P.and terminals connector dlagnosis Connect GNDwithiumperwireiis fuelpumpoperarng solnd evidedwilh isnilionswitchON? -7 pege F-92

Check if iuel is iniecledwhib crankng englne n this condftion +

lf injected,check circultopening

4

ll not injecred,check inieclorlof cloggingand if lue is in tank

;)).

GND

5

ls there conllnuilybelweenlLlelpump connecior @ and @?

relay Checkcncuitopenrng

6

at ECU2Vler_ ls thercapprox.12Vmomenlariy m naLwhib crankingengine? (Engrne signalmonitorgreenand red amps ilash)

Try io replace njector(lniectorstuck)

No

F-l8

Checkinjeclorlor continuity +

lf OK,checkwlfinSrelatedto 2Y,2V,2U,and ECUterrninals

+

ll notOK, repaceinjeclor

c7 page F-93

F

TROUBLESHOOTING GUIDE CRANKSNOF ALLY BUT W|LL r,rOTSTART(PART|ALCOtitBUSTtOt{)- U,HENEI{G[{E COLD .Engine at normalsp€edbutshowsonlyparlialcombustion and willnot conlinuelo run DESCN|P.. Batlerycranks in nomal condilion Tto

HtNTsl rrFouBLEsHooTrilc

O Lowensinecompressron

mixtureloo rich O Air/Fuel . Waterlhermosensor malluncllon loo lean O AidFuelrnixture .Fuel njecton controlmallunction (Corectionror coolanltemperature) .Low iuellinepressure .An leakageof inlakeair system INSPECTION 1

ACTION

ls 0O displayedon SellDiagnosisChecker wlth ignilion switch ON?

MallunctionCodeNo. displayed Checklor cause(Reierlo soeciiied checksequence)

17 pageF-m

"88" llashes CheckECUlelmlnal1F voliage

F pageF-114

Voltage:Appror. 12V (lgnltlon switch oN) TESTSWiSELFTEST

a 4

ll OK,replaceECIJ c7 pageF-112 I nol OK.checkwiringbelween ECUand S€lf-Diagnosis Checker

?

/\^\_

/

Checf d sr ouror cdp ard rolor

c:i page G-23

d\ lf notOK,fepairor replacewiins

2

Keep condilionas Step 1 ls there baltery voltage at solenojd valve conneclor lerminalW.e (R/!9?

Repairwiring(R/Vr)

3

ls solenoid valve OK?

Ch€cklor shortor opencircuilin wiringfrommainrelay (FUELINJ relay)to sol€noid valve

F page F-109 NO

Replacesolenod valve

Clrcuit Diagram

VALVE€), SoLENOID FFIOMBATTERY FROMIGNITION SWITCH

VALVE SOLENOIO (PUNGE CONTROL)

SOLENOIDVAIVE

soLENolovAtvE i (PUFGE COMIFOL)ii

F-77

F

FUNCTION SELF-DIAGNOSIS 35 {An AYPASSSOLEI{OIDVALVE@) Dsconneclconnectorfrom ECU ls lhere batleryvoLtageal ECU le|minal2R wrre (F/B)wilh ignilionswilchON?

Ke€ocondilionas StePI ls th;re batteryvoltageat solenoidvalveconnec' tor termina-wie (B/Bf

CheckECUtetminalconneclorlor poor connecron + .t

ll OK,replaceECU lf noi OK,reparror replacewrrrng

PageF-112

Repairwi ng (R/B)

Ct ect tot "lon ot op.n "ircul in wiing fiom malnrelav c? page F-109 Replace soLenod valve

Cllcuit Dlagram

i

AIF BYPASS i VALVEG)i SOLENOID FFOMBATTERY FFOMIGNITION SWITCH

VALVE SOLENOIO CONTFOL) {PURGE

AIFIBYPASS SOLENOID valvE €)

z---F-----rr

ufjl-lJ F-74

FUNCTION SELF-DIAGNOSIS Procedure After-repair '1.Cancelthememoryof mallunctions fromthe ECu by disthe thenegative batterycableanddepressing connecting the brakeoedalfor al least three seconds.Reconnect negativebatterycable.

SST(SystemSeleclor)tothediagnosiscon2. Connectthe nector. 3. Setswitch@ to position1. 4. SetTESTSWto SELF-TEST.

Ff

Checker)to the Sys5. Connectthe SST (Selt-Dlagnosis tem Selectorand a ground. Checkerto posi6. Settheselectswitchof theSelf-Diagnosis tionA. 7. Turnthe ignitionswitchON. 8. Startandwarmup theengine,thenrunitat 2,000tpm tor three minules. 9. Veritythat no code numbersare displayed. "

lEJ.

F-79

F

FUNCTION SELF-DIAGNOSIS

SWITCHiIONITORFUNCTION Checker). switchescan be inspectedby the SST (Selt-Diagnosis Individual Note . itre TEN terminatol the diagnosisconneclormust be groundedand the ignltionswitch oN (enginestopped), . ti e-ntrerof i6e switches remainaclivated,the monilot lamp wlll be illuminated.

ENGINECONTFIOL UNIT NEUTRAL SwlTCH

I

CLUTCHSWTTCH

I

STOPLIGHT SWITCH SWIICH HEADIIGHT

SYSIEM SELECTOB

OEFFOS1EFSWITCH

BLOWEFCONTFOL SwlTCH

INHIBITOB

Self.DiagnoslsChecker(Monitor lamp)

Swilch Clutch switch Neutral swilch Sloplight swilch Headlighlswnch

Lighl Ol{ ([4TX) ([/1X)

Inhibltorswitch

In gear Clulch p€dal released

In gear

lights ON Headlighls/small

ON

Rearwndow defrostersw ch (ATX)

R€mark

Llght OFF

ON ON ON D L, S, or F range

OFF

InspeclionProcedure 1.ionnecllheSST(SystemSelector)to theoiagnosrsconnector. 2 Setsw{ch@ to posttion1. to SELF.TEST, 3 SeITESTSWITCH

F-80

F

FUNCTION SELF.DIAGNOSIS

4. Connectthe SST(Sell-DiagnosisChecker)to the System Selectorand a ground. Checkerto posi5. SettheselectswitchoftheSelf-Diagnosis tion A. 6. Turnthe ignitionswitchON. lampilluminateswhen eachswitchismade 7. Checkif monitor to tunctionas describedbelow. Caution . ll eitherot the switchesremainaclivated.the monitor lamp will be illuminated. . Do not start the engine, Procedure Set conditionsto deactivateeach switch .Ail accessor es OFF .Transmission in neutral Veity lhal monltorlarnpdoesnot illuminate

Checkeach swirchand relaledwting harness .Clurch and Neurralswitch .Felerto pages F 124. 125 .Stoplightswitch :Relerto SeclionT .Headlight swlch Relerto SectionT .Water thefmoswilch Feierto SectionE .Rear delrosler switch :Befer to Section T . Blower swilch Befer lo Section T .lnh brtorswltch :Belerto secfon K

Check each switch as describ€d

Neuiraland Clulch Switches(MTX) Shifltransmissioninto gear ls monilorbmp illurninated wilhclulchpedalreleased?

PC .Neutralor clLrtch switchmallunction {Relerlo pagesF-124, 125) .Openckcuilin relatedwirinSharness . ECUiermlna(1\/)maitunciion (Relerlo pageF-116)

Depress clutch pedal Doesmonitorlamp go out? B€tu.n transmission to neutral

PC . Clulchswitchmalunclion (Relerto page F-124)

Stopllghtswllch Depressbrakepedal ls monitorlampillumlnaled?

Sloplightswilch OK

PC .Sloplight switchmalunction (Beter to Section T) .Open circut in w rlng harnesslrom sloplighl switch to ECU .ECU terminal(1O)maliuncllon (F€ferto pase F 114)

F-81

FUNCTION SELF-DIAGNOSIS Blower switch 'Iun blowerswitchto ON position ls monitorlampilluminated?

PC:.Blowerswitchmalfunclion GeJerto SeclionT) .dpen ctrcurlin ||e wrr'nghanesskom blower swtchlo ECUterm,na(1S) .ECU teminal(1S)maltunciion (Reierto PageF 114)

Headlightswitch Tum ON headllghtswitch ls monrlorlamp illominated?

Headllghlsw(ch oK Tum OFF headlighlswdch

PC:.Headlishtswitchmalfunclion (Reierio SedionT) lromheadlighr .Open crrcuilIn w n19harness swichlo Ecu ieminal(1u) .ECU termrnal (1U)mallunction (Felerto PageF-l16)

Waterthermoswiichcircult (not included in switch insPeclion) Warninq I'iie c'ootinsr"n operateswhenthe diagnoslsconnectortermlnalsTFAtnd GNDare connected with a iumper ttrire' Use caution. ConnectdiagnosisconnectortelminalsTFA and GND V€ritylhat monilorlamp ill'rmlnates

PC. . Felay malfuncton {Beler lo Section E) .Open circlit ln wire harnessfrom watef thermo_ swrlchlo enginecontrolLinrl .Enqrns controlunt lelminal 1R malluncliof

Waterthemoswitchckcuit is OK a jumperwrrc Dlsconnecl

Rea.defrosterswilch Tum ON rear deffoslerswitch ls monitorlampilluminated?

BeardeirosierswitchOK TurnOFF rear deliosterswlch

swichmalfunclion rc: .Fear delroster (Beferto SeclionT) fromfeardefroster .bpen circuitin wldnsharness switchto ECUteminal(1T) .ECU terminal (1T)maliuncton (Reierto pageF-114)

Inhlbitorswitch (ATx) Shitilransmissioninlo gear ls monitorlamplluminated?

lnhilitor swilchOK "P or "N Shlflinto

F-42

range

PC:.hhlbiior switchmalllnct|on iReterto SectionK) .Open ot shol crrcuiln relaledwnng harness (1V)maLfuncton .ECU terminal (Beterlo pageF 116)

F

INTAKEAIR SYSTEM

INTAKEAIR SYSTEM PARTS COMPONENT Removal/ Inspectlon/ Installatlon 1. Removein the ordershownin the figure,referringto RemovalNote. 2. Visuallyinspectthe intakeair systemcomponents and repairor replaceas necessary. 3. Installin the reverseorderol removal 19-25 (1.9-2.5. 1.-r9)

19-25 0,9-2,6, r/r-r9) 7.6-11 nn (40-t10 cn.tg, 6H5In-lb)

REPLACE

11 25 i,9-2.6, 1a-191-

/a :;;s

(3,3-s.3. 27-33)

1.Aircleaner Inspectfor excessive dirt or damage 2. Injectionbody pageF-84 Inspection................................... pageF-85 Disassembly / Assemb1y.............

page F-86 Inspection................................... 4. Intakemanifoldstay

5. Intakemanifold pageF 86 Inspection...................................

RemovalNote Coolant container beforeremovino 1. Drainthecoolantintoa suitable the injectionbody. 2. Retillwilhcoolanlafterinstallation. Cautlon . Belorelooseningthe radialordrainplug verify thai the radiatordraln hose taces stralghl down.

F-83

F

INTAKEAIF SYSTEI' FUELPUMPCOVER

Fuel Pressure Releaae thefuelpressure anyluelhne,release Beloredisconnecting of Injuryor fire. tromthetuelsvstemlo reducethepossibility |. Sladthe en-gine. 2. Removethe rearseatcushton. the fuelpumpconnector' 3. Disconnect 4. Afterthe enoinestalls,turnofi the ignitionswitch rearseat andinstallthe theluelpumpconnector 5. Reconnect cush|on.

PUMPCONNECTOF

BODY INJECTION Inspeclion 1.Checkthe iniectionbodylol wearand deposils withthethrot' 2. Verifythatthethrottlevalvemovessmoothly tle valveleverfromfullyclosedto fullyopen.

Fastldle (On-vehicleInspection) 1.Turnall electricloadsOFF. . Blowerfan . Headlight . Rearwindowdelroster andthatthefastidle 2. Verifythatthe waxrod is contracted cam asin contactwiththe roller.

4-?-2:

3. Connecta tachometer. 4. Starttheengineandverifythattheenginespeedis below 2,500nm. and temperature 5. Warmup theengine1onormaloperating verfy thatthe enginespeeograduallydecreases.

6. AftertheenginewarmsLlp,verifythatthewaxrodextends fromthe roller. fullvand thatthe camsepartes 7. Vdity thatthe idlespeedis withinspecification. ldle speed:MTX (Neutral) 750 :53rpm :1 rpm ATX (P range)1,100 Note . Air bypass solenoid valve @ opens lrom hsll ryanhedup condilion to wamed up condition. . Walertempelaturewhen cam iust separatesis 6l :3"C (142 1!l.R @TX),55 + 8oC (l3l + 46oF) (ATD.

F-A4

F

INTAKEAIR SYSTEM bodyif necessary. 8. Fieplace theinjection Caution . Do not disasasmble ihe iniectionbody. . Do not turn the acrewgshownin lhc ligure.

01E0Faog1

Disassembly/ Aaaembly in the ordershownin the figure. 1. Disassemble 2. Assemblein the reverseorderof disassemblv.

GASKET, FEPLACE 3,4-a.S (35-50, 3O---4:r)

3.4-5.e (35-s0i 30-4t)

;?iil:"ts

7.4-12 t@-12O, 69-1U)

r.2-r.3(12-13, t0-r6)

O8ING,FEPLACE 2.0-2.s (20-30, r7_2G)

rl-22 lln (r.a-2.2 n.l(g,

4. Airflowsensor valve@ 1. Air bypasssotenoid 1 n s p e c t , o n . . . . . . . . . . . . . . . . .page . . . . . .F-121 .......... I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. 0 . .9. . . regulator 5. Pressure 2. Dashpot l n s p e c t i o n . . . . . . . . . . . . . . - . . .page . . . . . F. . . .94 ...... I n s p e c t i o n . . . . . . . . . . . . . . . . . .p. .a. g. .e.F. .-.1. 0 . .4. . . R e p | a c e m e n t . . . . . . . . . . . . . .page . . . . . .F. . . 94 ...... 3. Throttlesensor pageF-122 6. Injector 1nspection................................. pageF- 95 (on-vehicle).............. p Inspection A d j u s t m e n t . . . . . . . . . . . . . . . . . . .a.g. .e.F. .-.1. 2 . .2. . . pageF 96 pageF-I22 Bemoval / lnstallation................ Removal / fnstallation................

F-85

F

INTAKEAIR SYSTEM MANIFOLD BAFFLE/INTAKE Inspection 1 Visuallvcheck for cracks or damageand reolaceif

INTAKEMANIFOLD

z. 8i"ff#

if andreplace oftheintakemanffold ai"tonion

necessary-

PEDAL ACCELERATOR Removal/ Inspection / Installation '1.Removein the ordershownin the fagure pedaland retainerfor cracksor damage' checkthe accelerator 2. Visually of removal. reverse order in the 3. Install

9!-r5

{100-150, t7-r3o)

cable 1.Accelerator ... .. pageF-86 / Adjustment.... lnspection 2. Retainer

3 cliP 4 Fletumspring .. 5 Accelerator Pedal

CABLE ACCELER,ATOR InsD€ction/ Adiustment pedalfully Verifythatthe throttle 1. deoressthe accelerator the throttleleverby hand tirrning by valveis fullyopened cable. play ol the accelerator the 2. lnspect Play: 1-3mm (0.04-0.12 In) 3. Loosennuts@ to adjustthe play if necessary.

F-86

F

FUELSYSTEII/I

FUELSYSTEM DESCRIPTION Thissystemsuppliesthe necessary fuelat a constantpressure to the injector. Fuelis meteredandinjectedintotheintakemanifold according to theinjection conkolsignalkom theECU. Thissystemconsistsof the fuel pump,fuelfilters,pressureregulator, and injector.

PRESSUFE FIEGUFATOB

vFUELFILIER(HIGH.PBESSURE SIDE)

SIOE} FUELFILTER(IOW.PRESSUFE

s

@ \

F-87

F

FUELSYSTEM

22-30 (2.2-3.r, 16-22)

PUMPCONNECTOFI

PRECAUTION Fuel PressuleReleaseand ServicingFuel System whenthe underhighpressure Fuelinthefuelsystemremains engineis not running. anyfuelline'releasethetuel presa) 6eforedisconnecting ot Iniury surelromthetuelsystemto reducethepossrbrlity or ire. 1. Startthe engine. 2. Removethe rearseatcushlon the fuelpumpconnedor' 3. Disconnect 4. Afterthe enginestalls,turn otf the ignitionswitch. the rear and install thetuelpumpconnecior 5. Reconnect seatcushion. tromtuelspraywhendisconnecf b) Usea rag as protection ing the hoses. Pluothe hosesatterremoval. fuelpresthefuelsystem,usea suitable c) Wh;n inspecting suregauge. Caution . Instatl hose clamPsto secure lhe fuel pre$sure gaugeto the fuel lllter and the tuel main hoseto prevent luel leakage. SYSTEMOPERATION Fuel PressureHold lnspection Waming . Beloreperformlngthe followlngoperation,release the tueipEssure tlam the tud systemto .educe the posslbilityot inlury or lire. (Relerlo above')

the negativebatterycable 1. Disconnect pressuregauge. a fuel 2. Install 3. Connectthe negativebatterycable-

. /4,-