Ute INTRODUCTION — HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL INDEX = ‘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 a Most repair operations begin with an overview illustration. It identifies the components and shows how the parts fit together. Example: Exhaust Manifold Stay Oil Cooter Oil Fitter Valve Nim tkghem, fibi ] : Specified torque +# Nor-reusable part prsINTRODUCTION — GENERAL REPAIR INSTRUCTIONS: 9. Use of special service tools (SST) and special ser 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 in the preparation part at the front of each section in this, manual. fiss 10. When replacing fuses, be sure the new fuse has the Hs correct amperage rating . DO NOT exceed the rating ae or use one with a lower rating. cay ( ’ Ww stration Symbol Part Name ‘Abbreviation —~ use FUSE son noses —~—— _| mepium cunnent Fuse Meuse —~Ae— _| ig current Fuse HFUSE aA | rust unk FL ree le 11. Car (a) vere 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.EG-1 ENGINE ENGINE MECHANICAL ~ DESCRIPTION. sues EG— 2 EG- 2 OPERATION = EG- 2 PREPARATION EG- 5 TROUBLESHOOTING - - EG= 10 TUNE=UP + EG-13 IDLE CO/HC CHECK (w/ TWO) EG- 28 IDLE CO CHECK AND ADJUST (w/o TW) EG- 30 COMPRESSION CHECK - EG- 32 TIMING BELT EG- 34 CYLINDER HEAD CYLINDER BLOCK ++ ‘SERVICE SPECIFICATIONS - EG— 50 EG-116 EG-148 EFI SYSTEM «== 6-153, DESCRIPTION swe EG 183 OPERATION vwee EO 155 PREPARATION EG-158, PRECAUTION - EG-160 DIAGNOSIS SYSTEM oe EG-165 ‘TROUBLESHOOTING w/ VOLT, ‘OHMMETER FUEL PUMP FUEL PRESSURE REGULATOR (81202) - FUEL PRESSURE REGULATOR (ST191) - INJECTOR (ST202) =~ INJECTOR (ST191) THROTTLE BODY ISC VALVE «seve EFI MAIN RELAY (ST202) « EFI MAIN RELAY (ST191) ~ CIRCUIT OPENING RELAY « VSV FOR EGR A/C IDLE—UP VALVE: WATER TEMPERATURE SENSOR ~~ INTAKE AIR TEMPERATURE SENSOR VACUUM SENSOR VARIABLE RESISTOR KNOCK SENSOR OXYGEN SENSOR ECU FUEL CUT RPM. SERVICE SPECIFICATIONS: COOLING SYSTEM - EG-292 EG-295 DESCRIPTION-- EG- 295 OPERATION EG-295 PREPARATION ++ EG-207 COOLANT CHECK - EG-208 EG-299 EG-301 EG- 306 EG- 309 EG-316 seseeeees EGH 395 EG- 336 EG- 336 EG- 336 EG-338 EG-340 EG- 341 THERMOSTAT - RADIATOR ELECTRIC COOLING FAN ~ SERVICE SPECIFICATION: LUBRICATION SYSTEM DESCRIPTION. OPERATION PREPARATION «+= OIL PRESSURE CHECK «+--+ OIL AND FILTER REPLACEMENT OIL PUMP seve £G-343 OIL COOLER osseeeerees 5-352 ‘SERVICE SPECIFICATIONS EG- 355, EGEG sat ENGINE — ENGINE MECHANICAL ENGINE MECHANICAL DESCRIPTION The 3S—FE engine is an in—line, 4 cylinder, 2.0 liter DOHC 16—valve engine. OPERATIONjah ENGINE — ENGINE MECHANICAL TROUBLESHOOTING You will find the source of the trouble more easily by correctly using the table shown below. ~ In this table, each number shows the order of priority of the causes of the trouble. Check each part in the order shown. If nesessary, replace the part. EG See page leG-271 EG-273| lec-275 lEG-180] lec-r98 lEG-208 lEG-213 lec-155 \eG-220 IEG-234) leo-257 Suspect area Ie c-s sn Sensor leg 194 Fuel Pressure Regulator Control Valve Fuel Lines Injectors Idle Speed ‘Symptom ‘Vacuum Sensor [Knock Sensor (Cireult Sensor Cireutt NSW Circuit RPM Signal Ignition Circuit Water Ter Setsor Creaie Igtake Air Temp. [A/C Signal eitcit Fuel Pump Circuit Oxyaer Engine does not crank Starter runs ~ engine does not crank ‘No combustion [2 5 : é No complete combustion 4 1 3 EE Engine cranks slowly 2 Engine cranks normally | 12 | 13 4 7 [8 [8 [16 Cold engine Hot engine Incorrect first idle High engine idle speed Low engine idle speed Rough idling 7 Misfire 4 3 Hesitant acceleration wills |s v4 [73 [6 [8 5 8 Does not start Difficult tostart Poor idling Backfire 6 Muffler explosion (after fire) een ee Surging 1 4 Knocking 7 ‘Soon after starting 8 7 3[2[4/s[6 ‘After accelerator pedal depressed 113 s|e]7 After accelerator pedal = ‘ During A/C operation 1 2 When shifting NtoD 7 2 Poor fuel economy 79 | 14 | 20 | 16 | 15 7/18 3 Engine overheat a Engine overcoo! Excessive oll consumption| Low oll pressure High off pressure Starter keeps running Battery often discharges Poor drivability, Engine stall OthersEG EG-14 ENGINE — ENGINE MECHANICAL Recommended Viscosity (SAE) ENGINE OIL INSPECTION 1. CHECK OIL QUALITY Check the oil for deterioration, entry of water, dis- coloring or thinning. If oil quality is visibly poor, replace the oil. Oil grade: API gi SG or SH, or ILSAC multigrade engine oil. Recommended viscosity is as shown in the illus’ tion. 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. BATTERY INSPECTION 1. CHECK BATTERY SPECIFIC GRAVITY AND ELECTROLYTE LEVEL (a) Check the electrolyte level of each cell. If insufficient, refill with distilled (or pu (b) Check the specific gravity of each cell.EG-32 ENGINE — ENGINE MECHANICAL COMPRESSION CHECK HINT: If thera is lack of power, excessive oil consump- tion or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. DISCONNECT DISTRIBUTOR CONNECTORS 3. DISCONNECT HIGH—TENSION CORDS FROM SPARK PLUGS (2) Disconnect the 4 high—ter on the cylinder head cover. (b) Disconnect the high — tension cords at the rubber boot. Do not pull on the high—tension cords. No’ ing on or bending the cords may damage the conductor inside, ion cords from the clamp 4. REMOVE SPARK PLUGS Using SST, remove the 4 spark plugs. SST 09155-16100 5. CHECK CYLINDER COMPRESSION PRESSURE (a) Insert a compression gauge into the spark plug hole. (b) 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 mor (4) Repeat steps (a) through (c) for each cylinder. NOTICE: This measurement must be done in as short» time as possib Compression pressure: w/ TWC: 1.275 kl w/o TWC: 1,226 kPa (12.5 kgf/cm’, 178 psi) or more (13.0 kgf/em*, 185 psi) or more—G ENGINE — ENGINE MECHANICAL 15. DISCONNECT ENGINE WIRE {a) Remove the bolt, and disconnect the engine wire protector from the LH side of the intake manifold. (b) Disconnect the 4 injector connectors. (c) Disconnect the engine wire protector from the 2 bra- ckets on the front side of the intake manifold. @ Remove the 2 bolts, and disconnect the engine wire protector from the alternator bracket and adjusting bar. (0) Disconnect the engine wire protector from the 2 mou- nting bolts of the No.2 timing belt cover in the se- quence shown.EG EG-126 ENGINE — ENGINE MECHANICAL IOS) HINT: Arrange the main bearing caps, bearings and thrust washers in the correct order. CYLINDER BLOCK INSPECTION 1. 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 feeler gauge, mea- sure 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 cylin- der block. 3. INSPECT CYLINDER FOR VERTICAL SCRATCHES Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 4 cylin- ders. If necessary, replace the cylinder block.ENGINE — EFI SYSTEM ae COMPONENTS FOR REMOVAL AND INSTALLATION Rear Seat Cushion Fuel Pump & 3 Sender Gauge: Connector zs 200,20 sTaae 130 10,22) STI8t Fuel Outlet Pipe Nim (kgfem, fibfl | : Specified torque ‘@ Non-reusable part * For use with SSTEG £G-268 ENGINE — EF! SYSTEM A/C IDLE—UP VALVE ‘1202 sT191ENGINE — COOLING SYSTEM. EG-295 COOLING SYSTEM DESCRIPTION i This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a bypass valve mounted on the inlet side. OPERATION Water Outlet To Radiator ‘Water Bypass Pipe Water Pump. Bynes Pips il Cooler (w/ Oil Cooler) The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, electric fan, hoses and other components. Coolant which is heated in the water jacket is pumped to the radiator, through which the electric fan draws 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. EGENGINE — COOLING SYSTEM ee COMPONENTS FOR DISASSEMBLY AND ASSEMBLY (BOSCH) Fan Wire Clamp Fan Shroud Drain Pipe Fan Motor Ring NO.1 COOLING FAN DISASSEMBLY (BOSCH) (See Components for Disassembly and Assembly) 1. REMOVE FAN Remove the C—ring and fan. pr . REMOVE FAN MOTOR {a) Remove the holder and 3 wire clamps, disconnect the wire from the fan shroud. {b) Disconnect the connector from the holder.IGNITION SYSTEM — ON-VEHICLE INSPECTION ON —VEHICLE INSPECTION SPARK TEST = CHECK THAT SPARK OCCURS (a) Disconnect the high—tension cords from the spark plugs. (b) (©) Remove the spark plugs. Install the spark plugs to the each high—tension cord. (d) Ground the spark plug. (©) 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 TNO ‘CHECK CONNECTION OF DISTRIBUTOR AND Connect securely IGNITER CONNECTORS BAD ToK (CHECK RESISTANCE OF HIGH-TENSION CORD Replace the cords). (See page IG-8) Taao'| Maximum resistance: 25 kO per cord ToK ‘CHECK POWER SUPPLY TO IGNITION COIL Check the wiring between ignition switch and 1. Turn ignition switch ON. ignition coi 2. Check that there is battery voltage at ignition coil [BAD positive (+) terminal, “TOK ‘CHECK RESISTANCE OF IGNITION COIL Replace the ignition coil (See page IG-10) Cold Hot 036-0552 045-0650 on 11.4-18.1k2 ‘CHECK RESISTANCE OF SIGNAL GENERATOR Replace the distributor housing assembly. (PICKUP COIL) {See page IG-11) Resistance: Cold Hot BAD G@endGO 185-2752 240-3250 NE@ and NE® 370-5509 475-6500 “Tox ‘CHECK AIR GAP OF DISTRIBUTOR Replace the distributor housing assembly. (See pageIG-10) — Air gap: 0.20.4 mm (0.008 - 0.016 in.) ae ToK (CHECK IGT SIGNAL FROM ECU ‘Check the wiring between ECU , distributor and (See page EG-191) BAD |_igniter,and then try another ECU, ToK TRY ANOTHER IGNITER iaCHARGING SYSTEM — ALTERNATOR(ST191/BOSCH) ae ons Positive (+) Terminal Rectifier Terminal Ohmmeter ers ALTERNATOR INSPECTION AND REPAIR Rotor 1, INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings. ‘Standard resistance: 2.3 — 2.9 Q at 20°C (68°F) If there is no continuity, replace the rotor. 2. INSPECT ROTOR FOR GROUND Using an ohmmeter, check that there is no continuity between the slip ring and rotor. 3. INSPECT SLIP RINGS (a) Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. {b) Using a vernier caliper, measure the slip ring diameter. Standard diameter 12.0 mm (0.472 in.) Minimum diameter: 10.5 mm (0.413 in) If the diameter is less than minimum, replace the rotor. Stator Assembly 1. INSPECT POSITIVE RECTIFIER (a) Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. (b) Reverse the polarity of the tester probes and repeat step (a). (c) Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the stator assembly.