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EFI SYSTEM — Troubleshooting EFI Electronic Circuit with EFI

1. Filter Rubber Cushion B5769 B5435 1G GE Service Service EFI Main Rela Connector ee 15A EFI Main Relay Connector i F FJ Circuit Opening Fuel Pump AM Fusible Link 2 0L 1 Battery Fuel Pump Switch i FIDS6 7 EFI SYSTEM Fuel System FI 87 ON VEHICLE INSPECTION 1 CHECK FUEL PUMP OPERATION a Turn the ignition switch ON NOTE Do not start the engine b Short Fp and B terminals of the fuel pump service connector for diagnosis c Check that there is a pressure in the pressure regula tor fuel return hose NOTE At this time you will hear fuel return noise from the pressure regulator d Remove the service wire e Turn the ignition switch OFF lf there is no pressure check the following parts Fusible link Fuse EF 15A IGN 7 5A Circuit opening relay Fuel pump Wiring connections 2 CHECK FUEL PRESSURE 1G E Se coe ae a Check that battery voltage above is 12 volts N Pies f wan cold Start Injector ON b Disconnect the battery ground cable c Disconnect the wiring connector from the cold start injector Cold Start Injector Connector FI 88 Cold Start Injector Pipe aw EFI SYSTEM Fuel System FIO360 d Place a suitable container or shop towel under the cold start injector pipe e Remove the cold start injector pipe f Drain the fuel in the delivery pipe g In
2. FI 96 EFI SYSTEM Fuel System Pressure Regulator 1G GE Pressure Regulator Vacuum Sensing SS SS TZ Hose FROM DELIVERY PIPE ON VEHICLE INSPECTION CHECK FUEL PRESSURE See page FI 87 REMOVAL OF PRESSURE REGULATOR 1 DISCONNECT VACUUM SENSING HOSE B0482 FI0372 2 DISCONNECT FUEL HOSE a Place a suitable container or shop towel under the pressure regulator b Disconnect the fuel hose from the pressure regulator 3 REMOVE PRESSURE REGULATOR Loosen the lock nut and remove the pressure regulator INSTALLATION OF PRESSURE REGULATOR 1 INSTALL PRESSURE REGULATOR a Fully loosen the lock nut of the pressure regulator b Thrust the pressure regulator completely into the delivery pipe by hand c Turn the pressure regulator counterclockwise until the outlet faces in the direction indicated in the figure d Torque the lock nut Pressure Regulator Torque 300 kg cm 22 ft lb 29 N m Front lt Et Delivery Pipe Out let 2 CONNECT FUEL HOSE 3 CONNECT VACUUM SENSING HOSE EFI SYSTEM Fuel System FI 97 Injector Wiring Terminal Plunger Needle Valve INJECTION ON VEHICLE INSPECTION 1 CHECK INJECTOR OPERATION Check the operating sound from each injector a With the engine running or cranking use a sound scope to check that there is normal operating noise in proportion to engine rpm b If a sound scope is not quailable you can check th
3. Lj CHAMBER CLEANER CHAMBER SIDE SIDE Air By pass FROM AIR Passage Measuring Plate CLEANER Measuring Plate Air By pass Passage FIO448 FI0449 1G E ON VEHICLE INSPECTION FoF E VeVcVsTHAl MEASURE RESISTANCE OF AIR FLOW METER a Unplug the wiring connector from the air flow meter Ohmmeter HA b Using an ohmmeter measure the resistance between E VcE VsT each terminal 1G GE Resistance Terminals Temperature Vs E 20 100 Q 20 6000 K Ve E 100 300 2 200 400 Q _ 10 20 KQ 20 C 4 F o c 32 F 20 C 68 F 40 C 104 F 60 C 140 F ate ea tse wel THA E If not within specification replace the air flow meter FI 106 EFI SYSTEM Air Induction System REMOVAL OF AIR FLOW METER 1 DISCONNECT AIR FLOW METER CONNECTOR 2 DISCONNECT AIR CONNECTOR HOSE 3 REMOVE AIR FLOW METER Remove the four nuts and one bolt and remove the air flow meter INSPECTION OF AIR FLOW METER MEASURE RESISTANCE OF AIR FLOW METER Using an ohmmeter measure the resistance between each terminal by moving the measuring plate Resistance Q Measuring plate 1G GE opening Infinity Fully closed Zero Other than closed position Terminals 20 100 20 600 Fully closed Fully colsed 20 1 000 20 1 200 to fully opek position NOTE Resistance between Vs and E will change in accordance with the measuring plate openin
4. closed Measuring plate fully open intake air temperature 20 C 68 F 140 180 Ne G ISC ISC ISC ISC B 10 30 EFI SYSTEM Electronic Contro System FI 129 Fuel Cut RPM INSPECTION OF FUEL CUT RPM a Start and warm up the engine b Disconnect the throttle position sensor connector from the throttle position sensor c Short circuit terminals E and IDL on the wire connec tor side d Gradually raise the engine rpm and check that there is fluctuation between the fuel cut and fuel return points NOTE The vehicle should be stopped A C S W Fuel Cut rpm Fuel Return rpm OFF 1 600 rpm ON 2 100 rpm 1 700 rpm fees Wess 1 600 rpm 1 000 rpm Sal aranan aa aka a nv noah AKAN E ENEAN MEMO m iia igat
5. gasoline to the O rings and install the injectors into the delivery pipe Injector Delivery Grommet Pipe 2 ay jo wT 2 INSTALL DELIVERY PIPE WITH INJECTORS a Install the six insulators and two spacers to the cylinder head Insulator N S X Vaan n b install the injectors together with the delivery pipe to the cylinder head c Make sure that the injectors rotate smoothly d Install and torque the bolts Torque 75 kg cm 65 in Ib 7 4 N m Fl 104 EFI SYSTEM Fuel System 3 10 CONNECT FUEL INLET PIPE a Install the fuel pipe and clamps with the nuts b Install and tighten the pulsation damper and n bolt with new gaskets Torque Pulsation damper 300 kg cm 22 ft lb 29 N m Union bolt 170 kg cm 12 ft Ib 17 N m c Tighten the nuts CONNECT INJECTOR CONNECTORS INSTALL COLD START INJECTOR PIPE See page FI 96 INSTALL COLD START INJECTOR AND THROTTLE BODY CONNECT FOLLOWING HOSES a Fuel return hose to the pressure regulator b Vacuum sensing hose to the pressure regulator c PCV hose to the cylinder head cover FILL WITH COOLANT CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY CHECK FOR LEAKAGE See page FI 9 EF SYSTEM Air Induction System FI 105 AIR INDUCTION SYSTEM Air Flow Meter NG Plate POTENTIONMETER Damping Chamber Compensation Plate Return Spring Es ee TO AIR AIR Sensor y INTAKE AIR INTAKE
6. the fuel hose b Instali the rubber cushion to the lower side of the fuel pump c Push the lower side of the fuel pump together with the rubber cushion into the fuel pump bracket INSTALL FUEL PUMP BRACKET a Place the bracket with a new gasket on the fuel tank b Install and torque the seven screws Torque 40 kg cm 35 in lb 3 9 N m INSTALL FUEL TANK CAUTION Tighten the fuel tank mounting bolts etc to the specified torque e Tighten the pipe and flare nut type hose to the specified torque Push in the pipe and insert type hose to the specified position and instali the clip to the specified location If reusing the hose reinstall the clip at the original location REFILL WITH GASOLINE FI 92 EFI SYSTEM Fuel System Cold Start Injector Wiring Connector Solenoid Coil Injection ignition Switch Cold Start Start Injector Injector Time Switch Fusible AM Link 40A 80A 2 0L 1G E ON VEHICLE INSPECTION Ohmmeter 1G GE Ohmmeter ae Cold Start Injector 1G E Cold Start Injector Pipe 2 MEASURE RESISTANCE OF COLD START INJECTOR al Disconnect the cold start injector connector b Using an ohmmeter check the resistance of injector Resistance 3 5 0 c Connect the cold start injector connector REMOVAL OF COLD START INJECTOR 1 DISCONNECT COLD START INJECTOR CONNECTOR REMOVE COLD START INJECTOR PIPE a Put a suitable
7. two collars to the cylinder head O Ring b Install the injectors together with the delivery pipe to Grommet the cylinder head Va BE Spacer Delivery Pipe Cylinder Thicker Spacer c Make sure that the injectors rotate smoothly d Install the three thinner spacers and bolts Torque the bolts Torque 130 kg cm 9 4 ft lb 13 N m FI 102 EFI SYSTEM Fuel System 3 4 No 2 Fuel Pipe 5 6 7 INSTALL AIR INTAKE CHAMBER a Connect the two No 2 water by pass pipe hoses to the air valve b Install the air intake chamber and gasket with two nuts and five bolts Torque 230 kg cm 17 ft lb 23 N m c Connect the cold start injection and throttle position sensor connectors d Install two air intake chamber stays INSTALL NO 1 AND NO 2 FUEL PIPES WITH PULSATION DAMPER Torque Pulsation damper 400 kg cm 29 ft lb 39 N m INSTALL COLD START INJECTOR PIPE Install the cold start pipe with the gaskets and union bolts Torque 180 kg cm 13 ft lb 18 N m INSTALL PCV HOSE AND VACUUM HOSES CHECK FOR FUEL LEAKAGE al With the ignition switch ON use a service wire to short both terminals of the fuel pump check connec tor b Check for fuel leakage a r t EFI SYSTEM Fuel System FI 103 INSTALL OF INJECTORS 1G GE 1 INSTALL INJECTORS INTO DELIVERY PIPE a Replace the O ring on the injector b Apply a thin coat of
8. EFI SYSTEM Troubleshooting EFI Electronic Circuit with EFI Checker FI 85 7 1 jection son O wowi raking Check injection signal with checker Depress the computer injection signal check switch and confirm that light 10 blinks while cranking engine NO BLINK BLINK 2 Check voltage at resistor B terminal STD 10 13 V IG S W ON Check and repair the following as required Poor electrical connection at connector e B wire open from connector to G terminal of ignition switch Check wires No 10 and No 20 individually between each in jector and harness computer connector for a short circuit ZERO V OK 3 Check voltage of each resistor terminal STD 10 13 V IG S W ON ALL LOW VOLTAGE ALL OK Check wires No 10 and No 20 individually between each in jector and harness computer connector for an open circuit o Q Repair wiring as required INFINITE ZERO Q Try another computer Check the resistance of wires Eo1 and E02 individually between the harness connector and the vehicle frame Solenoid gt oi Voltmeter Solenoid lt Resistor t Resistor f rw gt lZ Og Wg fh FI 86 EFI SYSTEM Fuel System FUEL SYSTEM Fuel Pump Check Valve WD Relief Valve Bearing Brush OUTLET INLET Armature Magnet Bearing impeller
9. F SOLENOID RESISTOR Using an ohmmeter measure the resistance between B and other terminals Resistance 2 each FI 122 EFI SYSTEM Electronic Control System Start Injector Time Switch Ignition Switch ST Cold Start Injector Start Injection Time Switch FIG363 1G E INSPECTION OF START INJECTOR TIME Ohmmeter SWITCH MEASURE RESISTANCE OF START INJECTOR TIME SWITCH a Disconnect the connector l b Using an ohmmeter measure the resistance between each terminal escaneo O STA STJ 25 50 below 15 C 59 F 60 85 above 30 C 86 F ee Oy k LR 7 EL Ohmmeter 1G GE Ohmmeter RESISTANCE k Q EFI SYSTEM Electronic Control System FI 123 Water Thermo Sensor 20 0 20 40 60 80 100 120 4 32 68 104 140 176 212 248 TEMPERATURE C F INSPECTION OF WATER THERMO SENSOR MEASURE RESISTANCE OF WATER THERMO SENSOR a Disconnect the connector b Using an ohmmeter measure the resistance between both terminals Resistance Refer to chart FI 124 EFI SYSTEM Electronic Control System Computer 1G E INSPECTION OF COMPUTER 1 MEASURE VOLTAGE OF COMPUTER NOTE The EF circuit can be checked by measuring the resistance and voltage at the wiring connectors of the computer Check the voltages at the wiring connectors Remove the glove box Turn the ignition switch ON Voltmeter Measure the voltage at each terminal EFI Co
10. NSOR CONNECTOR 5 DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY 6 DISCONNECT THROTTLE CABLE FOR AUTOMATIC TRANSMISSION 7 REMOVE THROTTLE BODY Remove the two bolts nuts and the throttle body and gasket INSPECTION OF THROTTLE BODY 1 CLEAN THROTTLE BODY BEFORE INSPECTION a Wash and clean the cast parts with a soft brush and craburetor cleaner b Using compressed air blow through all passages and apertures in the throttle body CAUTION To prevent deterioration do not clean the throttle position sensor 2 CHECK THROTTLE VALVE a Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed Throtie Lever Throttle Stop No Clearance AIR INTAKE CHAMBER SIDE EFI SYSTEM Air Induction System FI 171 Vacuum Advancer Port 50 mm 1 97 in AIR CLEANER SIDE 39 b When the throttle valve is fully closed check that advancer port is located on the air cleaner side as shown in the figure lf not adjust the throttle valve closing angle NOTE Do not adjust the throttle valve closing angle unless necessary IF NECESSARY ADJUST THROTTLE STOP SCREW a After loosening the lock nut of throttle stop screw loosen the stop screw until is about to touch the lever NOTE Make sure that the throttle valve is fully closed and the vacuum advancer port is positioned at the air cleancer side b Have the
11. ONNECT THROTTLE SENSOR CONNECTOR 5 CONNECT FOLLOWING HOSES a No 2 water by pass pipe hoses b Vacuum control hoses c Air valve pipe hose 6 INSTALL AIR CONNECTOR HOSE 7 FILL WITH COOLANT EFI SYSTEM Air Induction System FI 113 Throttle Body 1G GE fel Throttle Position raat Sensor a gt Fi fi JN f FIO394 IH 1 6 2 IH 2 2 FIO416 ON VEHICLE CHECK 1 CHECK THROTTLE BODY Check that the throttle linkage moves smoothly 2 CHECK THROTTLE POSITION SENSOR a Check the continuity between the terminals Unplug the connector from the sensor Insert a wire gauge between the throttle stop screw and stop lever Using an ohmmeter check the continuity between each terminal FIG425 FIO321 FI 114 EFI SYSTEM Air Induction System Clearance between lever and Continuity of termina eas stop screw IDL E Psw E IDL Psw Acc Acco F _ 0 30 mm 0 0118 in Continuity No continuity No continuity 0 50 mm 0 0197 in No continuity No continuity No continuity Throttle valve fully closed to Continuity fully open three times REMOVAL OF THROTTLE BODY 1 REMOVE AIR INTAKE CONNECOTR a Remove the four bolts and air intake connector b Remove the O ring from the throttle body 2 DRAIN COOLANT 3 DISCONNECT FOLLOWING HOSES a No 1 and No 3 water by pass hoses b PCV hose 4 REMOVE ACCELERATOR CONTROL CABLE B
12. OSITION SENSOR a Loosen the screws of the sensor b Insert SST 0 40 mm 0 0157 in between the throt tle stop screw and lever and connect the ohmmeter to terminals IDL and E Gradually turn the sensor counterclockwise until the ohmmeter deflects and secure the sensor with two Screws SST 09240 00020 FI 116 Ohmmeter EFI SYSTEM Air Induction System c Using SST recheck the continuity between terminals IDL and E SST 09240 00020 Sy Clearance between tag lever and stop screw Continuity IDL E 0 30 mm 0 012 in Continuity INSTALLATION OF THROTTLE BODY 1 INSTALL THROTTLE BODY a Install a new gasket to the intake manifold b Install the throttle body with two bolts and nuts CONNECT THROTTLE SENSOR CONNECTOR INSTALL ACCEL CONTROL CABLE BRACKET CONNECT FOLLOWING HOSES a PCV hose b No 1 and No 3 water by pass hoses INSTALL AIR INTAKE CONNECTOR a Install the new O ring to the throttle body b Instali the air intake connector with four bolts Torque the bolts Torque 65 kg cm 56 in lb 6 4 N m FILL WITH COOLANT EFI SYSTEM Air Induction System FI 117 Air Valve 1G E only Thermo Wax Coolant FIO569 ON VEHICLE INSPECTION CHECK OPERATION OF AIR VALVE Check the engine rpm by fully screw in the idle speed adjusting screw At low temp Coolant temp below 80 C or 176 F When the idle speed adjusting screw is in t
13. RACKET 5 DISCONNECT THROTTLE SENSOR CONNECTOR 6 REMOVE THROTTLE BODY C a Remove the two nuts and bolts b Remove the throttle body and gasket INSPECT OF THROTTLE BODY 1 CLEAN THROTTLE BODY BEFORE INSPECTION a Wash and clean the cast parts with a soft brush in carburetor cleaner b Using compressed air blow through all passages and apertures in the throttle body CAUTION To prevent deterioration do not clean the throttie position sensor 2 CHECK THROTTLE VALVE a Check that there is no clearance between the throttle stop screw and throttle lever when the throttle valve is fully closed Throttle No Clearance Stop Screw FIO399 EFI SYSTEM Air Induction System FI 115 b With the first throttle valve fully closed check the clearance between the secondary throttle valve stop screw and secondary lever Standard clearance Less than 1 mm 0 0394 in c Using SST check the first throttle valve opening at the same time the second throttle valve just starts to open SST 09240 00014 Standard angle 18 26 from horizontal plane NOTE Itis not necessary to adjust the secondary touch angle dh Using an ohmmeter check the continuity between each terminal Throttle valve angle IDL E IDL Psw Less than 16 3 re No 70 from vertical No N i ra continuity continuity continuity 80 from vertical NO Continuity i continuity continuity 3 IF NECESSARY ADJUST THROTTLE P
14. b Install the ISC valve with two bolts and one nut Torque 65 kg cm 56 in lb 6 4 N m 2 CONNECT TWO ISC VALVE CONNECTORS 3 FILL WITH COOLANT EFI SYSTEM Air Induction System FI 109 Throttle Body 1G E 7D Vehicle Throttle Adjusting Screw Power Point Throttle Position Throttle Sensor Moving Point Position Sensor Guid lt lt Gui e Cam Throttle Position Sensor Throttle Linkage FIO456 FIO387 Flo4ag 1 2 Idle Point ae FIO570 FIO451 FIOS88 FI0452 ON VEHICLE INSPECTION CHECK THROTTLE BODY a Check that the throttle linkage moves smoothly b Check the vacuum at each port Start the engine Check the vacuum with your finger At idling Other than idling Vacuum 3 RHD Vechicles only CHECK THROTTLE POSITION SENSOR al Check the continuity between the terminals Unplug the connector from the sensor Insert a thickness gauge between the throttle stop screw and stop lever Using an ohmmeter check the continuity between each terminal FI 110 EFI SYSTEM Air induction System 0 44 mm 0 0173 in Continuity No continuity No continuity 0 66 mm 0 0260 in No continuity REMOVAL OF THROTTLE BODY Vacuum Hose DRAIN COOLANT N REMOVE AIR CONNECTOR HOSE 3 DISCONNECT FOLLOWING HOSES a Air hose b Vacuum hose s c No 1 and No 2 water by pass pipe hoses 4 DISCONNECT THROTTLE SE
15. container or shop towel under the c start injector pipe K b Remove the two union bolts and the cold start injec tor pipe with the gaskets NOTE Slowly loosen the union bolts EFI SYSTEM Fuel System FI 93 3 REMOVE COLD START INJECTOR Remove the two nuts and cold start injector with the gasket ross INSPECTION OF COLD START INJECTOR CHECK INJECTION OF COLD START INJECTOR spion pot a _ Install the gasket SST two unions another gasket SST Union and two union bolts to the delivery pipe and injector b Connect the SST hose from the unions SST 09268 41045 c Connect the SST wire to the injector SST 09842 30050 SST Wire WARNING Position the injector as far away from the battery as possible SST Hose d Put a container under the injector e Turn the ignition switch ON NOTE Do not start the engine f Short Fe and B terminals of the fuel pump service connector for diagnosis g Connect the test probes of the SST to the battery and check that the fuel spray is as shown SST 09842 30050 NOTE Perform this check within the shortest possible time FI 94 EFI SYSTEM Fuel System h Disconnect the test probes from the battery and check that fuel does not leak from the injector Fuel drop Less than one drop of fuel per minute i After checking restore the following to the previous state SST SST Fuel pump check connector Ignition switc
16. e injector operation with your finger If no sound or an unusual sound is heard check the wiring connector injector resistor or injection signal from the computer 2 MEASURE RESISTANCE OF INJECTOR a Unplug the wiring connector from the injector b Using an ohmmeter check the continuity of both ter minals Resistance 1 5 3 0 0 FI 98 1G E Cold Start Injector Pipe Cover Fi0221 2 EFI SYSTEM Fuel System REMOVAL OF INJECTOR 1G E 1 REMOVE PCV HOSE AND VACUUM HOSES REMOVE COLD START INJECTOR PIPE Remove two union bolts pipe and gaskets REMOVE NO 1 AND NO 2 FUEL PIPES WITH PULSATION DAMPER REMOVE AIR INTAKE CHAMBER a Remove two air intake chamber stays b Disconnect the two connectors from the cold start injection and throttle position sensor c Disconnect the No 2 water by pass pipe hose froin the air valve d Remove the two nuts and five bolts and remove the air intake chamber and gasket REMOVE DELIVERY PIPE WITH INJECTORS a Remove the three bolts and thinner spacers and then the delivery pipe with injectors b Remove the six insulators three thicker spacers and two collars from the cylinder head NOTE When renoving the delivery pipe be careful not to drop the injectors Do not remove the injector cover REMOVE INJECTORS Pull out the injectors from the delivery pipe NOTE Do not remove the injector cover EFI SYSTEM Fuel Sys
17. g INSTALLATION OF AIR FLOW METER 1 INSTALL AIR FLOW METER Install the air flow meter with four nuts and one bolt 2 CONNECT AIR CONNECTOR HOSE 3 INSTALL AIR FLOW METER CONNECTOR EFI SYSTEM Air Induction System FI 107 idle Speed Control ISC Valve 1G GE S B Sa VT S By S4 A3888 CHECK FOR OPERATING SOUND FROM ISC VALVE Confirm that there is a clicking sound immediately after stopping the engine REMOVAL OF ISC VALVE 1 DRAIN COOLANT 2 DISCONNECT TWO ISC VALVE CONNECTORS 3 DISCONNECT TWO WATER BY PASS HOSES FROM ISC VALVE 4 REMOVE ISC VALVE a Remove the two nuts and bolt b Remove the ISC valve and gasket FI 108 IH 4 1 IC 2 2 a Resistance B S or S EFI SYSTEM Air Induction System INSPECTION OF ISC VALVE 1 CHECK RESISTANCE OF ISC VALVE Using an ohmmeter measure the resistance between i minal B S or and B S or S4 10 30 Q B S or S 10 r 30 Q 2 INSPECT OPERATION OF ISC VALVE Apply battery voltage to terminals B and B and while repeatedly grounding S S S S S in sequence check that the valve moves toward the closed position Apply battery voltage to terminais B and B and while repeatedly grounding S S S in sequence check that the valve moves toward the open position INSTALLATION OF ISC VALVE 1 INSTALL ISC VALVE a Install the new gasket to the intake manitold
18. h e SST Cold start injector Injector wiring INSTALLATION OF COLD START INJECTOR 1 INSTALL COLD START INJECTOR Place on a new gasket and instail the cold start injector with the two nuts Torque 55 kg cm 48 in lb 5 4 N m 2 INSTALL COLD START INJECTOR PIPE Using new gaskets connect the cold start injector pipe to the delivery pipe and cold stary injector Install the union bolts Torque 180 kg cm 13 ft lb 18 N m 3 CONNECT COLD START INJECTOR CONNECTOR 4 CHECK FOR FUEL LEAKAGE See page FI 9 EFI SYSTEM Fuel System FI 95 Pressure Regulator 1G E TO RETURN PIPE DELIVERY 2 No 2 Fuel Pipe Fuel Return Pipe Vacuum Sensing Hose Fi0443 FIO584 ON VEHICLE INSPECTION CHECK FUEL PRESSURE See page FI 87 REMOVAL OF PRESSURE REGULATOR 1 DISCONNECT VACUUM SENSING HOSE DISCONNECT NO 2 FUEL PIPE a Place a suitable container or shop towel under the pressure regulator b Disconnect the fuel hose from the pressure regulator REMOVE PRESSURE REGULATOR Remove the two bolts and the pressure regulator INSTALLATION OF PRESSURE REGULATOR 1 INSTALL PRESSURE REGULATOR a Install the pressure regulator with two bolts Torque 75 kg cm 65 ft lb 7 4 N m CONNECT NO 2 FUEL PIPE Install a new gasket pipe another gasket and union bolt to the pressure regulator Torque the union bolt Torque 180 kg cm 13 ft lb 18 N m CONNECT VACUUM SENSING HOSE
19. he engine RPM should drop After warm up When the idle speed adjusting screw is in check that the engine RPM drops less than 600 rpm or the engine stops REMOVAL OF AIR VALVE 1 REMOVE THROTTLE BODY See page FI 110 2 REMOVE AIR VALVE a Remove the four screws air valve and gasket INSTALLATION OF AIR VALVE 1 INSTALL OF AIR VAVLE a Place a new gasket on the air valve b Install the air valve with the four screws FI 118 EFI SYSTEM Electronic Control System ELECTRONIC CONTROL SYSTEM Location of Electronic Control Parts 1G E EFi Computer RHD Vehicle only EFI Computer LHD Vehicle only Circuit Opening Relay LHD Vehicle only Throttle Position Sensor Solenoid Resistor Air Flow Meter Cold Start Injector Fuel Pump Maan Water Thermo Sensor Cold Start Injector DIS Stor Time Switch EFI Main Relay lgnition Coil 4 Circuit Opening Relay RHD Vehicle only my 10405 1G GE Cold Start Injector ECU Time Switch Water Thermo Sensor Air Flow Meter Throttle Position Sensor VER eg AH N a r 7 sK Fuel Pump X s ISC Valve X Solenoid Resistor Cold Start injector Circuit Opening Relay Ignition Coil EFI Main Relay FI0406 EFI SYSTEM Electronic Control System FI 119 EFI Main Relay 30A Fusible Link 2 0L F Battery Ignition Switch Solenoid Resistor Fuse 7 5A EFI Main Relay IGN Lr Computer Te
20. hose onto the injector to prevent gasoline from splashing out e Connect the ground cable to the battery f Turn the ignition switch ON NOTE Do not start the engine g Using a service wire short both terminals of the fuel pump check connector NOTE The fuel pump will operate P atta S h Connect the SST to the battery for 15 seconds and measure the injection volume with a graduated cylinder Test each injector two or three times If not within specified volume replace the injector SST 09842 30020 Volume 1G E 30 40 cc 15 sec 1 8 2 4 cu in 1G GE 40 50 cc 15 sec 2 4 3 1 cu in Difference between each injector Less than 6 cc 0 37 cu in CHECK LEAKAGE a In the condition above disconnect the SST from the battery and check for fuel leakage from the injector nozzle SST 09842 30020 PoR Fuel drop Less than one fuel drop of fuel per mik e b Disconnect the battery ground cable ic Remove the SST and disconnect the service wire from the fuel pump service connector SST 09268 41045 EFI SYSTEM Fuel System FI 101 INSTALLATION OF INJECTORS 1G E 1 INSTALL INJECTORS INTO DELIVERY PIPE a Replace the O ring on to the injector b Apply a thin coat of gasoline to the O rings and install the injectors into the delivery pipe _ Delivery Pipe Injector M Grommet 2 INSTALL DELIVERY PIPE WITH INJECTORS a Install the six insulators three thicker spacers and
21. mputer NOTE 1 Perform all voltage measurements with the connectors connected 2 Verify that the battery voltage is 11 V or above when the ignition switch is ON Connectors of EFI Computer IG A C A C MAGNET SWITCH Vs TL THROTTLE SWITCH ve INJECTOR B Eoi MAIN RELAY ENGINE GROUND STA STARTER SWITCH THW WATER TEMP SENSOR ENGINE GROUND IDL THROTTLE SWITCH Eos ENGINE GROUND g FIO426 EFi SYSTEM Electronic Control System FI 125 Condition 8 13 IG S W ON Throttle valve open Throttle vaive fully closed TL E IG S W ON Vo E 8 eama a ee en 0 5 2 5 Measuring plate fully closed Measuring plate fully open IG S W ON IG S W ON Coolant temperature 80 C 176 F Intake air temperature 20 C 68 F IG S W ST position No 10 E 10 13 iG S W ON O g e oee wswon 2 MEASURE RESISTANCE OF COMPUTER CAUTION 1 Do not touch the computer terminals 2 The tester probe should be inserted into the wir ing connector from the wiring side Check the resistance between each terminal of the wiring connector Remove the glove box Unplug the wiring connectors from the EFI computer Measure the resistance between each terminal of the wiring connectors Resistances at Coputer Wiring Connectors Resistance 0 Throttle valve fully closed 20 400 Vs E Measuring plate fully closed 0 Measuring plate fully
22. open 20 100 ee 200 400 Intake air temperature 20 C 68 F 2000 3000 Fl 4126 y H paa amp H Ares llo y NOTE 1 EFI SYSTEM Electronic Control System Electronic Controlled Unit ECU 1G GE INSPECTION OF ECU 1 MEASURE VOLTAGE OF ECU NOTE The EFI circuit can be checked by measuring the resistance and voltage at the wiring connectors of the ECU Check the voltages at the wiring connectors Remove the glove box Turn the ignition switch ON Measure the voltage at each terminal Perform all voltage measurements with the connectors connected 2 Verify that the battery voltage is 11 V or above when the ignition switch is ON Connectors of ECU Terminal Name ENGINE GROUND ENGINE GROUND INJECTOR INJECTOR VF G w mis gt 9 m 5 z z 919 Ni j O o p 4 gt STARTER SWITCH syns Terminal Name CHECK CONNECTOR NGINE REVOLUTION SENSOR CHECK CONNECTOR ENGINE REVOLUTION SENSOR THROTTLE SWITCH Symbol Terminal Name f F aan C manev Wie macner swrn C oom WARNING LAMP E M REL A C SPD 8 IGt IGNITER Ne ENGINE REVOLUTION SENSOR THA AIR THERMO SENSOR E THROTTLE SWITCH Vs AIR FLOW METER S TH THROTTLE SWITCH Vc AIR FLOW METER ISC THROTTLE SWITCH Batt BATTERY B ENGINE GROUND IDL C semon Ae a ae ae ise moron Tw sc sewon e G ENGINE REVOLUTION SENSOR Ess ISC n
23. p IGNITER ATER THERMO SENSOR SENSOR GROUND SENSOR GROUND IG S W B IGNITION SWITCH W EFI MAIN RELAY eae bap Flt rs PPS Yaels es nef exo JKK Pro ra ve vole BT bowler fee Although this position is connected if is not related to the computer s function Ex E PPID PDD FlOurd EFI SYSTEM Electronic Control System F1 127 BE H 10 14 IG S W E IG S W ON M REL eT Pow e E Throttle valve fully closed Tr IG S W ON Intake air temperature 20 C 68 F THW E 0 1 0 5 IG S W ON Coolant temperature 80 C 176 F 9 14 IG S W ON Idling IG S W ON 2 3 secs after engine off IG S W ON Service connector T E not short FI 128 EFI SYSTEM Electronic Control System 2 MEASURE RESISTANCE OF ECU CAUTION ECU Wiring if 1 Do not touch the ECU terminals 2 The tester probe should be inserted into the wir ing connector from the wiring side Check the resistance between each terminal of the wirning connector 9 Remove the glove box Unplug the wiring connectors from the ECU Measure the resistance between each terminal of the wiring connectors Resistances at ECU Wiring Connectors Terminals Condition Resistance Q Throttle valve open bor Throttle valve fully closed Throttle valve open Psw E Throttle valve fully closed Measuring plate fully
24. rminal B FI0407 EFI Main Relay INSPECTION OF EFI MAIN RELAY 1 CHECK EFI MAIN RELAY OPERATION a Turn the ignition switch ON b At this time an operation noise will occur from the relay MEASURE RESISTANCE OF EFI MAIN RELAY a Remove the EFI main relay from the relay block b Measure the resistance between each terminal Between terminals Resistance Q 1 3 40 60 2 4 infinity FI 120 EFI SYSTEM Electronic Control System Circuit Opening Relay FFI Main Relay Ignition Switch ST Circuit Fuel Pump Opening Check Connector Relay SR Near the No 2 junction block Air Flow Meter l FIOS76 INSPECTION OF CIRCUIT OPENING RELAY 1 CHECK CIRCUIT OPENING RELAY OPERATION al Remove the cowl side trim driver s side b Remove the circuit opening relay with the connec from No 1 relay block c Using a voltmeter check that the meter indicates voltage at Fp terminal during engine cranking and running d Stop the engine 2 MEASURE RESISTANCE OF CIRCUIT OPENING RELAY a Disconnect the connector b Measure the resistance between each terminal Resistance 0 STA E 30 60 IG Fe 80 120 B Fp Infinity EFI SYSTEM Electronic Control System FI 121 Solenoid Resistor Ignition Switch IG Solenoid Resistor injectors Computer No 10 Computer No 20 INSPECTION OF SOLENOID RESISTER MEASURE RESISTANCE O
25. sconnect the battery ground cable and carefully remove the SST to pre vent gasoline from splashing u Using new gaskets reconnect the cold start injector hose to the delivery pipe v Connect the wiring connector to the cold start injec tor w Check for fuel leakage FI 90 EF SYSTEM Fuel System REMOVAL OF FUEL PUMP Clip Fuel Hose Fuel Hose Fuel Pump Gasket a Fuel Pump Bracket ED IE gt Fuel Pump Filter xX j C gt Rubber Cushion TT FO217 Clip Non reusable part WARNING Avoid smoking and open flame when working on the fuel pump 1 DRAIN GASOLINE FROM FUEL TANK TI 2 REMOVE FUEL TANK 3 REMOVE FUEL PUMP BRACKET FROM FUEL TANK a Remove the seven screws b Pull out the fuel pump bracket 2 4 REMOVE FUEL PUMP FROM FUEL PUMP BRACKET v HONEY al Remove the two nuts and disconnect the wires from the fuel pump b Puil off the lower side of the fuel pump from the bracket c Remove the fuel pump from the fuel hose Torque 385 kg cm 28 ft lb 38 N m R 2 7 mm 0 08 0 28in EFI SYSTEM Fuel System FI 91 FIO102 5 REMOVE FUEL PUMP FILTER FROM FUEL PUMP a Remove the rubber cushion b Remove the clip and pull out the filter INSTALLATION OF FUEL PUMP See page FI 90 1 2 INSTALL FUEL PUMP FILTER TO FUEL PUMP INSTALL FUEL PUMP TO FUEL PUMP BRACKET a Insert the outlet port of the fuel pump into
26. stall a gasket SST another gasket and union bolt to the delivery pipe as shown in the figure SST 09268 45011 h Wipe off any splattered gasoline i Reconnect the battery cable k j Short terminals Fp and B of the service connector NOTE The service connector is located near the No 2 injection block k Turn on the ignition switch ll Measure the fuel pressure Fuel pressure 2 3 2 7 kg cm 33 38 psi 226 265 kPa lf high pressure replace the pressure regulator if low pressure check the following parts Fuel hoses and connection Fuel pump Fuel filter Pressure regulator m Remove the service wire from the service connector n Start the engine o Disconnect the vacuum sensing hose from the pressure regulator and pinch it p Measure the fuel pressure at idling Fuel pressure 2 3 2 7 kg cm 33 38 psi 226 265 kPa EFI SYSTEM Fuel System FI 89 a Reconnect the vacuum sensing hose to the pressure regulator r Measure the fuel pressure at idling Fuel pressure 1 8 2 2 kg cm 26 31 psi 177 216 kPa lf not pressure check the vacuum sensing hose and pressure regulator s Stop the engine Check that the fuel pressure remains above 1 5 kg cm 21 psi 147 kPa for 5 minutes after the engine is turned off lf not with in specification check the fuel pump pressure regulator and or injectors t After checking fuel pressure di
27. tem FI 99 REMOVAL OF INJECTOR 1G GE 1 FIO375 DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY DRAIN COOLANT DISCONNECT FOLLOWING HOSES a PCV hose from cylinder head cover b Vacuum sensing hose from pressure regulator c Fuel return hose from pressure regulator REMOVE AIR INTAKE CONNECTOR AND THROTTLE BODY REMOVE COLD START INJECTION PIPE See page FI 92 DISCONNECT INJECTOR CONNECTORS DISCONNECT FUEL INLET PIPE a Remove the two clamp nuts b Remove the pulsation damper union bolts gasket and fuel pipe REMOVE DELIVERY PIPE al Remove the two bolts and then remove the delivery pipe with the injectors NOTE When removing the delivery pipe be careful not to drop the injectors b Remove the six insulators and two collars from the cylinder head REMOVE INJECTORS Pull out the injectors from the delivery pipe NOTE Do not remove the injector cover FI 100 EFI SYSTEM Fuel System Origin 1 Pipe M Service Connector aa Wire zA Pressure Regulator INSPECTION OF INJECTOR TEST INJECTION OF INJECTORS WARNING Keep ciear of sparks during the test al Connect the SST to the fuel filter outlet SST 09268 41045 b Connect the SST to the pressure regulator and the injector SST 09268 41045 c Hold the injector and hose with SST SST 09842 30020 d Put the injector into the graduated cylinder NOTE Install a suitable vinyl
28. throttle stopper screw touch the lever Then screw it in 1 4 turn and lock it with the lock nut c After installation of the throttle body make sure that engine rpm does not change even if the vacuum hose Part No J to the vacuum advance port is pinched CHECK THROTTLE POSITION SENSOR a Make an angle gauge as shown in the figure b Set the throttle valve angle to 51 or 61 from a ver tical plane ic Using an ohmmeter check the continuity between each terminal Throttle valve Continuity opening angle E TL IDL Psw Less than 7 5 ae No No from vertical Continuity continuity 51 from No No No vertical continuity continuity continuity 61 from No FY No FI 172 EFI SYSTEM Air Induction System 5 IF NECESSARY ADJUST THROTTLE POSITION SENSOR a Loosen the two screws of the sensor b Insert a thickness gauge 0 55 mm or 0 0216 in between the throttle stop screw and lever and con nect the ohmmeter to terminals IDL and TL Gradually turn the sensor counterclockwise until the ohmmeter deflects and secure the sensor with two screws Thickness Gauge c Using a thickness gauge recheck the continuity bet ween terminals IDL and TL Clearance between lever and stop screw 0 44 mm 0 0173 in Continuity Continuity IDL TL INSTALLATION OF THROTTLE BODY 1 INSTALL THROTTLE BODY CONNECT THROTTLE CABLE For A T 2 3 CONNECT ACCELERATOR CABLE 4 C

EFI SYSTEM — Troubleshooting EFI Electronic Circuit with EFI

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EFI SYSTEM &mdash; Troubleshooting EFI Electronic Circuit with EFI

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EFI SYSTEM — Troubleshooting EFI Electronic Circuit with EFI