Samurai '90-'92 Supplementary Service Manual
Contents
1. Z AZ 0 33u02 uol1o ui jan Aejas duind lend duund jany HJNV3 129 uiv cce ig 4A 13 System Schematic 4A 14 Electronic Control Module ECM ECM is installed under the glove box of the in strument panel ECM is a precision unit consisting of one chip microcomputer A D Analog Digital converter I O Input Output unit and etc It is an essential part of the electronic control system for its functions include not only such a major function as to control fuel injector ISC solenoid valve throttle opener VSV etc but also self diagnosis function fail safe function and back up function as described in the following section 1 ECM 2 Instrument main panel 3 Glove box Fig 4A 14 ECM Location Self diagnosis function When any of such troubles as listed below occurs in Electronic Fuel Injection system ECM acti vates CHECK ENGINE light while engine is running to warn the driver of occurrence of such trouble and stores the data on defective area where trouble occurred in its back up memory The memory is kept as it is even if the trouble was only temporary and disappeared immediate ly And it is not erased unless the power to ECM is shut off for 20 seconds or longer ECM also indicated defective area in memory by means of flashing of CHECK ENGINE light at the time of inspection i e when diagnosis switch terminal is grounded and ignition switch is turned ON e When ECM received2. e First tighten fittings flare nut by hand and then tighten it to specified torque 22 0 28 5 Tightening torque for pipe fitting flare nut FUEL TANK Remove or Disconnect 1 Release fuel pressure in fuel feed line referring to FUEL PRESSURE RELIEF PROCE DURE in p 3 3 2 To release pressure in fuel tank remove fuel filler cap and then reinstall it 3 Negative cable at battery 4 Fuel level gauge and fuel pump lead wire couplers 1 Flare nut 3 Fuel tank 2 To throttle body Fig 4 7 Fuel Pipe Screw Couplings Inspect Visually inspect fuel lines for evidence of fuel leakage hose cracking and deterioration or damage Make sure all clamps are secure Replace parts as needed 2 1 1 Fuel pump coupler de T 2 Fuel levet dulce coupler 4 NN mi j 3 Rear bumper C ay Y Jas l V w Fig 4 9 Fuel Pump and Level Gauge Couplers NV Fi v OO ha IN 5 Breather hose from filler neck and vapor hose N ZA from separator after removing upper protector d 2 Fuel feed hose Fuel return hose Fuel vapor hose Clamp Aan Fig 4 8 Fuel Lines inspection 1 Vapor liquid separator 2 Breather hose 3 Vapor hose Fig 4 10 Vapor Hose and Breather Hose 6 Filler hose from fuel tank after removing lower protector 7 Due to absence of fuel tank drain plug drain fuel tank by pumping fuel out through fuel tank filler Use hand operated pump device to dra
3. filter and lines EMISSION CONTROL SYSTEM IGNITION SYSTEM CHARGING SYSTEM CLUTCH PROPELLER SHAFTS BRAKES BODY ELECTRICAL EQUIPMENT SERVICE DATA SUPPLEMENTARY FOR 2WD MODEL HITTE GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle These general precautions apply to many of the service procedures described in this manual and they will not necessarily be repeated with each procedure to which they apply WARNING Whenever raising a vehicle for service be sure to follow the instructions under STANDARD SHOP PRACTICES on SECTION O of this manual When it is necessary to do service work with the engine running make sure that the parking brake is set fully and the transmission is in Neutral for manual transmission vehicles or Park for automatic transmission vehicles Keep hands hair clothing tools etc away from the fan and beits when the engine is running e When it is necessary to run the engine indoors make sure that the exhaust gas is forced outdoors Do not perform service work in areas where combustible materials can come in contact with a hot exhaust system When working with toxic or flammable materials such as gasoline and refrigerant make sure that the area you work in is well ventilated To avoid gettin
4. 1 5 NOTE For the maintenance items maintenance procedure not found here refer to 88 MODEL SERVICE MANUAL 2 Camshaft timing belt inspection i en 1 5 9 Oxygen sensor replacement see pe RE es eee ee rnnt 1 5 10 Catalytic converter inspection sis ss ss ass Es eee tee eens 1 6 11 Charcoal canister replacement enn nn 1 6 13 EGR system inspection lieet 1 7 14 ECM and associated sensors inspection r 1 7 19 Ignition timing inspection 000 ss ee RR eee eee ee ee eee 1 7 22 Fuel filter replacement 002 c eee ee teen ere rh 1 8 23 Fuel lines and connections inspection 1 8 24 Idle speed inspection hh 1 8 25 Fuel injector inspection EE DE dE NA Ks V RE ERS 1 8 1 3 CHASSIS AND BODY Refer to 88 model SERVICE MANUAL sajaiyan uomneair2ads 120 Aue 40 SWJ uomoadsur jearpouad 40 auo si 1 yBnouije Alessagau J eoerdes S8J2I8A uog 821jJ28dS UEIDEUBID 104 Lal AIUEUBIUIEUI papueululo3a4 e st uonaedsui WEISS YOF 1 ula e 40 1298402 pue 12adsu Ajuo 4aqqna Bununout 1sneuxa 03 ayqeaydde si 4 7 wal e abueyo 40 aoejday y SWJ e2ueuojureui papuauiuto2a4 ase L Wal pue Yyy 9 URI Guia e S310N Buruy uoniuby 6L unim uoniub gI 40101 pue deo 103nquAsIq Z1 suonaeuuoo2 pue ssauJeu uM ur 000 991 saju 000 001 3e 12adsu Suosuas paje
5. 17 7 21 6 in Hg at 800 r min Vacuum specifica tion sea level 6 After checking remove vacuum pump vacuum gauge and hose joint 7 Connect vacuum hoses to throttle opener VSV 3 10 Valve Lash Clearance Valve lash specifications Valve lash refers to gap between rocker arm adjusting screw and valve stern Use a thickness gauge to measure this gap When cold When hot Coolant tempe Coolant tempe rature is 15 use rature is 60 68 C or 59 77 F or 140 154 F 0 13 0 18 mm 0 23 0 27 mm 0 0051 0 0071 in 0 009 Son in 0 15 0 21 mm 0 26 0 30 mm 0 0059 0 0083 in 0 0102 5001 18 in 1 Adjusting screw lock nut 2 Adjusting screw 3 Valve stem Fig 3 19 Checking and adjusting procedures 1 Disconnect negative cable at battery 2 Turn crankshaft pulley clockwise until V mark on pulley aligns with 0 zero on timing belt cover Timing tab belt cover 1 2 O0 mark 3 V mark timing notch on crankshaft pulley Fig 3 20 Aligning Marks 3 Remove distributor cap and check if rotor is 4 f valve lash is out of specification adjust it to positioned as shown in figure i e No 1 specification by turning adjusting screw after piston is at TDC of compression stroke If loosening lock nut After adjustment tighten rotor is out of place turn crankshaft clock lock nut to specified torque while holding ad wise o
6. 2 Start engine and check to ensure that engine runs smoothly as its number of revolutions is increased from idle speed to high speed 3 Stop engine SECTION 2 TROUBLE SHOOTING NOTE For the items not found in this section For trouble shooting other than engine refer to the same section of 88 MODEL SERVICE MANUAL CONTENTS 2 1 ENGINE 2 1 ENGINE Hard Starting Engine cranks OK Possible Cause Ignition system out of order e Blown fuse e Faulty spark plug Leaky high tension cord Loose connection or disconnection of high tension cords or lead wires Faulty ESA system Improper ignition timing e Faulty ignition coil e Cracked rotor or cap in distributor e Faulty noise suppressor Fuel system out of order e Lack of fuel in fuel tank Dirty fuel filter Dirty or clogged fue hose or pipe Malfunctioning fuel pump Air inhaling from intake manifold gasket or throttle body gasket Electronic Fuel Injection system out of order Low compression e Poor spark plug tightening or faulty gasket Incorrect valve lash Compression leak from valve seat Sticky valve stem Weak or damaged valve springs Compression leak at cylinder head gasket Sticking or damaged piston ring Worn piston ring or cylinder Others e Broken valve timing belt e Malfunctioning PCV valve Repair or replace Clean and adjust plug gap or replace Replace
7. Repair or replace Refer to SECTION 8 Adjust Replace Replace Replace Refill Replace Clean Replace Replace Refer to SECTION 4A Tighten to specified torque or replace gasket Adjust Remove cylinder head and lap valves Correct or replace valve and valve guide Replace valve springs Repair or replace Replace piston rings Replace ring and piston Rebore or replace cylinder Replace Replace Condition Possible Cause Engine has no power Correction Low compression Ignition system out of order e Incorrect ignition timing e Faulty spark plug e Worn distributor terminals e Leaks loose connection or disconnec tion of high tension cord e Faulty ESA system Fuel system out of order e Clogged fuel hose or pipe e Dirty or clogged fuel filter e Clogged air cleaner element e Air inhaling from intake manifold gasket or throttle body gasket Electronic Fuel Injection system out of order Others e Loose connection or disconnection of vacuum hoses e Malfunctioning EGR valve e Dragging brakes e Slipping clutch Improper engine idling or engine fails to idle Ignition system out of order e Faulty spark plug e Leaky or disconnected high tension cord e Worn distributor terminals e Improper ignition timing Cracked cap in distributor there being leakage inside e
8. WARNING To avoid danger of being burned do not touch exhaust system when it is still hot This work should be performed when it is cool 1 Disconnect battery negative cable from battery and disconnect oxygen sensor wire at its coupler 2 Remove oxygen sensor from exhaust mani fold 1 Oxygen sensor 2 Exhaust manifold 3 Coupler Fig 1 3 Oxygen sensor 3 Instal new oxygen sensor and tighten it to specification Tiahteni kg Ib ft 4 Connect oxygen sensor wire at the coupler securely and clamp its wire 5 Connect negative cable to battery 6 Start engine and check for gas leak NOTE With Vehicles of Federal specifications except Californian and Canadian specification ones be sure to turn off CHECK ENGINE light with its cancel switch upon completion of service 10 CATALYTIC CONVERTER INSPECTION Inspect exhaust center pipe catalytic converter for leakage ioose connections dents and damages 11 CHARCOAL CANISTER REPLACEMENT WARNING The following cautions should be always observed DO NOT smoke and place NO SMOK ING signs near work area To release fuel vapor pressure in fuel tank remove fuel tank cap and then reinstall it 1 Disconnect negative battery cable at battery 2 Disconnect purge vacuum hose and tank vapor hose from canister 3 Remove canister from vehicle body 4 Install new canister by reversing removal procedure 5 Clamp hoses secu
9. 3 Before installing timing belt to camshaft timing belt pulley and crankshaft timing belt pulley loosen all valve adjusting screws of intake and exhaust rocker arms fully or check to ensure they are loose This is to permit free rotation of camshaft for the reason is when installing timing belt to both pulleys belt should be correctly tensed by tensioner spring force If camshaft does not rotate freely belt will not be correctly tensed by tensioner 1 Valve adjusting screw 2 Lock nut Fig 3 12 Valve Adjusting Screw and Lock Nut 4 After loosening all valve adjusting screws all the way turn camshaft pulley clockwise and align timing mark on camshaft pulley with V mark on the belt inside cover as shown in figure below Camshaft timing pulley Timing mark YE mark Belt inside cover ETE gt Fig 3 13 Timing Marks 5 Turn crankshaft clockwise fitting 17 mm wrench to crank timing belt pulley bolt and align punch mark on timing belt pulley with the arrow mark on oil pump as shown in below figure Crank timing belt pulley bolt Punch mark 1 2 3 Arrow mark 4 Crank timing belt pulley Fig 3 14 Timing Marks 6 With two sets of marks aligned install timing belt on two pulleys in such a way that the drive side of belt is free of any slack and with tensioner plate pushed up by finger NOTE e When installing timing belt match arrow mark lt gt on timing belt with rotating direc
10. Repeated short trips roads C Driving on rough and or muddy roads F Repeated short trips in extremely cold weather D Driving on dusty roads udi Maintenance Maintenance Maintenance Interval Condition Code Operation F I ict Every 3 000 miles R ngine oil and oil filter 5 000 km or 3 months i Every 6 000 miles Exhaust pipes and mountings l 10 000 km or 6 months Every 3 000 miles 5 000 km or 3 months Air cleaner filter element 1 r R Every 15 000 miles 25 000 km or 15 months Every 15 000 miles 25 000 km or 15 months Brake discs and pads Front E I Every 6 000 miles Brake drums and shoes Rear 10 000 km or 6 months Every 6 000 miles 10 000 km or 6 months Every 15 000 miles Transmission transfer and differential 25 000 km or 15 months oil after first replacement at 7 500 miles Every 15 000 miles 25 000 km or 15 months Every 6 000 miles 10 000 km or 6 months Steering wheel free play gear box oil Every 3 000 miles and linkage 5 000 km or 3 months Every 15 000 miles 25 000 km or 15 months Distributor cap and ignition wiring 2 Leaf springs Bolts and nuts on chassis Steering knucle oil seals inspect and correct or replace if neccessary T Tighten to specified torque R Replace or change L Lubricate 1 Inspect more frequently if the vehicle is us
11. Faulty ESA system Fuel system out of order e Shortage of fuel in fuel tank e Clogged air cleaner element Leaky manifold throttle body or cylinder head gasket Electronic Fuel Injection system out of order Engine overheating Low compression Others e Loose connection or disconnection of vacuum hoses e Malfunctioning EGR valve e Malfunctioning PCV valve Previously outlined Adjust Adjust or replace Dress or replace Also check rotor Connect or replace as necessary Refer to SECTION 8 Clean Replace Clean or replace Replace gasket Refer to SECTION 4A Connect securely Check and replace as necessary Repair or replace Adjust or replace Adjust or replace Connect or replace Replace Adjust Replace Refer to SECTION 8 Refill Clean or replace Replace Refer to SECTION 4A Refer to Overheating section Previously outlined Connect securely Check and replace as necessary Check and replace as necessary Condition Engine hesitates Momentary lack of response as accelerator is depressed Can occur at all vehicle speeds Usually most severe when first try ing to make the vehi cle move as from a stop sign Surges Engine power varia tion under steady throttle or cruise Feels like vehicle speeds up and down with no change in the accelerator pedal Excessive detonation Engine makes sharp metallic knocks tha
12. duty through the duty check terminal and CHECK ENGINE light indicates diagnostic code No 71 but it is nothing abnormal FUEL INJECTION CONTROL SYSTEM In this system ECM controls the time amount and timing of the fuel injection from the fuel in jector into the throttle body according to the signals from the various sensors so that suitable air fuel mixture is supplied to the engine in each driving condition Injection Timing e Atstart Fuel is injected at a certain cycle starting immedi ately after the initial CAS signal is inputted Initial CAS signal aol Biter sme iy eer al Injection cycle Fig 4A 28 Injection Timing at Start e In normal driving Standard injection timing Fuel is injected at every ignition s gnal ignition fail safe signal synchronously Ignition signal ON J Injector OF Fig 4A 28 1 Injection Timing in Normal Driving e When accelerating Additional injection timing Fuel is injected in addition to the above standard injection timing whenever the throttle valve opening exceeds the specified opening 4A 21
13. hose Hose III ML amp 20 to 30mm t Clamp 0 79 1 18 in Clamp securely at a position 3 to 7 mm 10 12 0 27 in from hose end Fig 3 2 Hose Connection When installing fue filter union bolt or plug bolt on union bolt always use new gasket and tighten it to specified torque See Section 4 for specified torque When installing injector fuel feed pipe or fuel pressure regulator lubricate its O ring with spindle oil or gasoline When connecting fue pipe flare nut first tighten flare nut by hand and then tighten it to specified torque FUEL PRESSURE RELIEF PROCEDURE CAUTION This work must not be done when engine is hot If done so it may cause adverse effect to catalyst After making sure that engine is cold relief fuel pressure as follows 1 Place transmission gear shift lever in Neutral set parking brake and block drive wheels Disconnect coupler from fuel pump relay Remove fuel filler cap to release fuel vapor pressure in fuel tank and then reinstall it Start engine and run it till it stops for lack of fuel Repeat cranking engine 2 3 times of about 3 seconds each time to dissipate fuel pressure in lines Fuel connections are now safe for servicing Upon completion of servicing connect cou pler to fuel pump relay 1 Fuel pump relay 2 ECM Fig 3 3 Fuel Pump Relay FUEL LEAKAGE CHECK PROCEDURE After performing any serv
14. land pz Aejai ule EZ dund jan ZZ peddinbe J ASA 2 V LZ peddinbe 41 Jerjijduie D v 0Z u91IMs 2IteuBewu 191181S 6 U9u S qoin BL u91MS UIEN ZL AMeaneg OL Ajuo japouw dads eluiop Je9 punoJp SL xOq asnj UI puiuJ81 u911Ms Berg pL Je dnoo aaMUON ui qisnj AO1NAIISIP u SYO LL SSA OL JapowW dads eiu4041 e7 104 10N U31MS UIG 6 1103 uorHub g HUN 480g 1911UDj n Josuas uaB xQ 9 SdL S Josuas aJnssaJd t Ajuo jopouu dads eiuJ0j1 e 2 SLOAY SLM SLV L 4A 13 sef 1sneux3 BANYXIL Jang JAY land diy jeuBis isa e jeubts sisouBeig e 1uau1aBefiua yN e japow dads gluJoJI e2 JO 10u jeuBis uonisod sea UiG e obei o Alaneg e peddinba 41 leubis 2 v e jeuBis yeys auu e paeds a u A e jeu6is Sv e jeubis uoniuB e ysAjeyeo AEM E 3dld YALNAD LSNWHXaA vyf ASA 3NION3 Jouado 323H2 J sisouBeig amoa L HUN 48AAEJ J8911u6 InpONW 023002 21004129 3 W3 SL9JY o sw josuas 8JnssaJg OIOAINVIN ANION3 ex J DIVANI ajea HO aimedadwua seb 3sneuxe u0OIe11ua2 PalelnodloaH e uoo ua Axo ain 1sneuxje e Jada 191844 Burjoo2 auriBu3 e enie4ed LU81 JIE oxe1u e aunoa die ayeu pjojiueuu Josuas HEU UI BANSSEId e usBAXO QTO3INYVIA 1SNYHX3 O41UO2 MOJ 41e ssed g Buiuado 8A 8A nioiul e A A Z K u211 s lp SdL AQqo8 ERAS a1110HHL BAJEA piou 840s OSI
15. result of diagnosis done by ECM s self diagnosis function 1 CHECK ENGINE 5 ECM It also lights under the conditions as described OE d x Wen pukuqa below regardless of Electronic Fuel Injection 3 Diagnosis switch termina 8 Main relay system condition die box i UL When ignition switch is turned ON engine is Fig 4A 15 CHECK ENGINE Light Circuit for at a stop When engine speed is lower than California and Canada spec Model 500 r min and diagnosis switch terminal is ungrounded CHECK ENGINE light turns ON for the purpose of light and its circuit check but turns OFF once engine is started When engine speed is higher than 500 r min as far as Electronic Fuel Injection system is in good condition e Only federal spec model except California and Canada has mileage sensor and cancel switch in its CHECK ENGINE light circuit When mileage reaches 50 000 80 000 and 100 000 miles respectively i e mileage sensor turns ON CHECK ENGINE light turns ON even while engine is running This is to warn the driver that it is time for periodical inspec tion In this case turn OFF CHECK EN GINE light with its cancel switch upon com DOO000 3 jd pletion of inspection ganan 1 CHECK ENGINE tight 8 ECM 2 Cluster 9 Sensed information 3 Diagnosis switch terminal 10 Output 4 Fuse box 11 Main relay 5 Cancel switch 12 Ignition switch 6 Instrument panel 7 Mileage sensor Fig 4A 16 CHECK
16. v Install or Connect Reverse removal procedure for installation using care for the following e Refer to Fig 4 1 for piping and clamp posi tions e Clamp hoses securely e If pipe clamp is broken replace it with new one e Use new gaskets for fuel filter inlet pipe and tighten union bolt to specified torque e Upon completion of installation check fuel system for leakage according to procedure described in p 3 4 4 7 Throttle Body The throttle body consists of the main bore air bypass passage fuel passage vacuum passage for EGR system and canister purge system and the following parts e Injector which injects fuel according to the signal from ECM e Fuel pressure regulator which maintains the fuel pressure to the injector a certain amount higher than the pressure in the intake manifold Throttle valve which is interlocked with the accelerator pedal and controls the amount of the air fuel mixture drawn into the combustion chamber Throttle opener which controls the throttle valve opening so that it isa little wider when the engine is starting than when the engine is idling e TPS which detects the throttle valve opening and sends a signal to ECM e Air valve which supplies the bypass air when the engine is cold e Idle speed adjusting screw which controls the amount of bypass air to adjust engine idle speed Throttle lever Throttle opener Vacuum pipe Fuel injector Fuel pressure regulator TPS
17. 18 Comeingrodberigcs nut 33 37 33 37 M0 285 19 Crankshaft pully bolt 10 13 1 0 1 3 7 5 9 0 i6 1 105 115 1 Timing belt cover bolt and nut 9 12 22 Camshaft timing pully bolt 41 0 46 0 23 Timing belt tensioner bolt 24 30 24 30 175 215 24 Timing belt tensioner stud 9 0 9 1 2 7 0 8 5 25 Oil pump case bolt 0 9 1 2 26 Oil pump rotor plate screw 0 9 1 2 27 Inlet amp exhaust manifold nut 1 8 2 8 28 Engine mounting bracket frame side bolt 4 0 6 0 29 Engine mounting bracket engine side bolt O 0 D 6 30 Engine mounting nut 31 Transmission mounting bracket bolt 32 Transmission mounting bolt 33 Trarismission mounting and frame bolt 18 28 34 Propeller shaft flange bolt and nut 50 60 SECTION 4 FUEL SYSTEM NOTE For the items not found in this section refer to the same section of 88 MODEL SER VICE MANUAL CONTENTS 4 3 FUEL TANK PUMP FILTER AND LINES 4 2 GENERAL DESCRIPTION 22s u rh hh ras 4 2 Fual Tank us ul ls We Tu a GAD vc taped TN EUR HALE XR RR Ee iu eels 4 3 Fuel PUMP is iii iek sesde reses bees Refer to section 4A of this supplement TAS EE EN IE a OP OH Rex oe Dens OR EE OE 4 3 ON VEHICLE SERVICE in AREA Oe Wed aw RR RES ESSET EG oe 4 4 Fuel Pump zs ener RR S Refer to section 4A of this supplement Fuel Filter oe w
18. 9ejday y SOU aoUPUS UIE papuasuluio084 ale EZ Waly pue M ZZ WA Hea OT UDIY e ISILON saGuty 100g y wuaysAs Bbuueelg Ly sinu pue s1 oq Uolsuadsns Buuds ee GE JO e11u849 41p pue 13 SUBJ uoISSIUJSUPJ H 1591 TE 1 s 51eUs 18j adog i sieqiosqe YIOUS s6uijg q jeauM HEE sjeas jo ajonuy BuHaais peddinbe 315 sqny BUiBaUM aai pue sosip jaayAA san a qeo pue 4a a ayxeig mE epad ayeig PINS 94249 EH sedid pue sasoy a xeJg 1624 seous pue suunip ajeg 7 24043 sped pue sosip axe1g I 4an AGOS8 ONV SISSVHO Jo3oefui jany SZ peads p tZ SUOIJOOULIGS pue Saul j6n4 EZ Je Jenj TS jusujoe a 191111 Jaueg 2 diy Lez deo juer jana OZ Iand g7 gzel SL SZ 15414 8Ut02 JaAaYDIY SUQUOW JO BuipeaJ 134 3 C9 Se sc SZL 0001x wa awapo Aq p Bpn aq pinous jeasaqu SIU L GLE CEA ZZi SL S Z 000 x sepu eA181u 1 3 MAINTENANCE RECOMMENDED UNDER SEVERE DRIVING CONDITIONS If the vehicle is usually used under the conditions corresponding to any severe condition code given below it is recommended that applicable maintenance operation be performed at the particular interval as given in the below chart Severe condition code A Towing a trailer E Driving in extremely cold weather and or salted B
19. ASSEMBLY 3 5 3 8 ENGINE MAINTENANCE SERVICE 3 9 3 9 RECOMMENDED TORQUE SPECIFICATIONS 3 12 WARNING The 90 model vehicle is equipped with the Electronic Fuel Injection system As 3 1 GENERAL DESCRIPTION provides important information on it and pre cautions to be taken read it carefully before servicing the engine and make sure to Observe precautions 3 1 3 1 GENERAL DESCRIPTION As the Electronic Fuel Injection system is used for the 90 model vehicle to improve its engine output the 90 model engine differs from 88 and B9 model ones Main differences among others are as follows e Crankshaft Piston stroke is differ ent e Piston Shape of piston head is different e Camshaft Cam height and valve timing are different e Tensioner plate Shape is different GENERAL INFORMATION ON ENGINE SERVICE THE FOLLOWING INFORMATION ON EN GINE SERVICE SHOULD BE NOTED CARE FULLY AS IT IS IMPORTANT IN PREVENT ING DAMAGE AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE When raising or supporting engine for any rea son do not use a jack under oil pan Due to small clearance between oil pan and oil pump strainer jacking against oil pan may cause it to be bent against strainer resulting in damaged oil pick up unit e It should be kept in mind while working on engin
20. ECTION 8 of this supplement for in spection and adjustment procedure 1 7 22 FUEL FILTER REPLACEMENT WARNING This work must be performed in a well ventilated area and away from any open flames such as gas hot water heaters Fuel filter is located at the front part of fuel tank inside the right hand side of chassis 1 Disconnect negative cable from battery 2 Replace fuel filter Be sure to refer to descrip tion under FUEL FILTER REMOVAL and INSTALLATION in SECTION 4 page 4 5 of this supplement for proper procedure 1 Fual filter 2 Inlet pipe 3 Outiet pipe Fig 1 7 Fuel Filter NOTE Torque pipe fastening bolts to specification 3 Connect negative cable to battery 4 After installation start engine and check it for leaks 1 8 23 FUEL LINES AND CONNECTIONS INSPECTION Visually inspect fuel lines and connections for evidence of fuel leakage hose cracking and damage Make sure all clamps are secure Repair leaky joints if any Replace hoses that are suspected of being crack ed 24 IDLE SPEED INSPECTION Check idle speed and adjust it as necessary Refer to ON VEHICLE SERVICE page 4A 78 of SECTION 4A of this supplement for pro cedures to check and adjust idle speed 25 FUEL INJECTOR INSPECTION 1 Check injector for resistance injecting condi tion and leakage For checking procedures refer to Fuel Injection Inspection in SECTION 4A ELECTRONIC FUEL INJECTION SYS TEM
21. ENGINE Light Circuit for Federal Spec Model Except California and Canada 4A 16 Fail safe function When a failure occurs in any of the sensors listed below and their circuits a signal indicating such failure is fed to ECM which judges that signal as such Even then however control over the injector ISC solenoid valve and others is maintained on the basis of the standard signals prestored in the memory of ECM while ignoring that failure signal This function is called fail safe function Thus with this function a certain level of engine performance is available even when some failure occurs in these sensors or their circuits and disability in running is avoided e WTS e TPS e ATS e Pressure sensor Back up function Even when CPU in ECM fails to operate proper ly the back up circuit in ECM controls operation of the injector on the basis of the signals from pressure sensor so as to least impair driving per formance Pressure Intake manifold absolute pressure Sensor PS This sensor senses pressure change in the intake manifold and converts it into voltage change It consists of a semi conductor type pressure con verting element which converts a pressure change into an electrical change and an electronic circuit which amplifies and corrects the electric change The ECM sends a 5 volt reference voltage to the pressure sensor As the manifold pressure changes the electrical resistance of the sensor also chan
22. FOREWORD This SUPPLEMENTARY SERVICE MANUAL is a supplement to SAMURAI 1988 MODEL SERV ICE MANUAL Applicable model 1990 1991 and 1992 SAMURA 4WD MODEL 1991 and 1992 SAMURAI 2WD MODEL It describes single point Electronic Fuel Injection system and different service information of SAMURAI 1990 1991 and 1992 MODEL as com pared with SAMURAI 1988 MODEL Therefore whenever servicing SAMURAI 1990 1991 or 1992 MODEL consult this supplement first And for any section item or description not found in this supplement refer to SAMURAI 1988 MODEL SERVICE MANUAL AM information illustrations and specifications contained in this literature are based on the latest product information available at the time of publi cation approval And used as the main subject of description is the vehicle of standard specifications among others Therefore note that illustrations may differ from the vehicle being actually serviced The right is reserved to make changes at any time with out notice NOTE f When servicing 2WD MODEL consult GROUP 2 first And for any section item or description not found in GROUP 2 refer to GROUP 1 SUZUKI MOTOR CORPORATION TECHNICAL DEPARTMENT AUTOMOBILE SERVICE DIVISION COPY RIGHT SUZUKI MOTOR CORPORATION 1991 TABLE OF CONTENTS _ GENERAL SPECIAL TOOLS AND SERVICE MATERIALS PERIODIC MAINTENANCE SERVICE TROUBLE SHOOTING ENGINE ma SYSTEM ON Fuel oes m
23. FUEL FILTER The fuel filter is installed on the chassis frame and filters the fuel sent under pressure from the fuel pump As it can t be disassembled it should be replaced as an assembly Note that letters indicating the fuel inlet and outlet ports are stamped on the fuel filter Refer to them for proper hose con nection Fuel filter Chassis frame right side Inlet pipe Outlet pipe DOON Fig 4 3 Fuel Filter ON VEHICLE SERVICE WARNING Before attempting service of any type on fuel system following cautions should be always observed e Disconnect negative cable at battery e DO NOT smoke and place NO SMOK ING signs near work area e Be sure to have CO fire extinguisher handy e Be sure to perform work in a well venti lated area and away from any open flames such as gas hot heater e Wear safety glasses To release fuel vapor pressure in fuel tank remove fuel filler cap from fuel filler neck and then reinstall it e As fuel feed line is still under high fuel pressure even after engine was stopped loosening or disconnecting fuel feed line directly may cause dangerous spout of fuel to occur where loosened or discon nected Before loosening or disconnecting fuel feed line make sure to release fuel pressure according to FUEL PRESSURE RELIEF PROCEDURE in p 3 3 A small amount of fuel may be released after the fuel line is disconnected In order to reduce the chance of pe
24. FUEL PRESSURE RELIEF PROCEDURE in p 3 3 CAUTION This work must not be done when engine is hot S4 i 2 Negative cable at battery 3 Fuel filter cap from fuel filler neck to release fuel vapor pressure in fuel tank After releas ing reinstall cap 4 Hoist vehicle Place fuel container under fuel filter 6 Inlet and outlet pipes from fuel filter by using two wrenches On 1 Fuel filter 3 Inlet pipe 2 Outlet pipe 4 Wrenches Fig 4 5 Disconnecting Pipes 7 Fuel filter from chassis frame Install or Connect Reverse removal procedure noting the following e Use new gaskets D e Make sure that gasketed surfaces are free from any damage e Inlet and outlet pipes should come into recess of plate as shown below Gasket Outlet pipe Inlet pipe Recess PWN Fig 4 6 Fuel Filter Installation e Tighten union bolts to specified torque Tightening torque of fuel filter union bolts 30 40 13 0 4 0 22 0 28 5 e Upon completion of installation verify that there is no fuel leakage at each connection according to procedure described in p 3 4 FUEL LINES Due to the fact that fuel feed line is under high pressure this system requires special considera tion for service The feed pipe uses screw couplings Any time these fittings are loosened to service or replace components ensure that e Backup wrench is used while loosening and tightening fitting
25. Idle speed adjusting screw Air valve From fuel pump To fuel tank From ISC solenoid valve To intake pipe Fuel Air Cooling water 90 03g gt Q N B Fig 4A 5 Throttle Body Cross Section 4A 8 Fuel Injector It is an electromagnetic type injection nozzle which injects fuel in the throttle body bore according to the signal from ECM Operation When the solenoid coil of the injector is energiz ed by ECM it becomes an electromagnet and attracts the plunger At the same time the needie valve which is incorporated with the plunger opens and the injector which is under the fuel pressure injects fuel in conic dispersion As the lift stroke of the needle valve of the injec tor is set constant the amount of fuel injected at one time is determined by the length of time during which the solenoid coil is energized injection time Solenoid coil O cing large Filter Ptunger O ring small Needle valve Q oO BUNC Fig 4A 6 Injector Cross Section Fuel Pressure Regulator The fuel pressure regulator keeps the fuel pressure applied to the injector 2 65 kg cm 265 kPa higher than that in the intake manifold at all times The pressure applied to the chamber A of fuel pressure regulator is intake manifold pressure and that to the chamber B is fuel pressure When the fuel pressure rises more than 2 65 kg cm 265 kPa higher than the intake manifold pressure the fuel pushes
26. a defect informing signal from any one of following sensors and circuits or no signal whatever Oxygen sensor ATS Pressure sensor WTS TPS VSS Idle switch CAS bth switch Not for California spec model Ignition circuit Ground circuit California spec model only e When a trouble exists in EGR system or re circulated exhaust gas temperature sensor is defective For California spec model only e When CPU Central Processing Unit of ECM fails to operate NOTE e Even when a trouble occurs in CAS 5th switch circuit or idle switch circuit circuit open ECM does not indicate it or activate CHECK ENGINE light while engine is running And when that troubled circuit regains good condition the memory of defective area will be erased automatically even if the power cir cuit to ECM is not opened as described above 4A 15 Only ignition circuit trouble code No 41 among the above areas is not stored in back up memory of ECM In other words even if ECM has detected a trouble in ignition cir cuit once ignition switch is turned OFF code No 41 will not be indicated even when dia gnosis switch terminal is grounded and ignition Switch is turned ON Therefore to check diagnostic code when engine fails to start crank engine and then ground diagnosis switch terminal with igni tion switch ON CHECK ENGINE light CHECK ENGINE light is located among the instrument cluster It indicates each
27. ay cause dangerous spout of fuel to occur where loosened or disconnected Before loosening or disconnecting fuel feed line make sure to release fuel pressure accord ing to FUEL PRESSURE RELIEF PROCE DURE A small amount of fuel may be released after the fuel line is disconnected In order to reduce the chance of personal in jury cover the fitting to be disconnected with a shop cloth Put that cloth in an approved container when disconnection is completed Never run engine with fuel pump relay dis connected when engine and exhaust system are hot Fuel or fuel vapor hose connection varies with each type of pipe When reconnecting fuel or fuel vapor hose be sure to connect and clamp each hose correctly referring to Fig 3 2 Hose Connection After connecting make sure that it has no twist or kink With short pipe fit hose as far as it reaches pipe joint as shown Hose Ute TALL Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With following type pipe fit hose as far as its peripheral projection as shown AT Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With bent pipe fit hose as far as its bent part as shown or til pipe is about 20 to 30 mm 0 79 1 18 in into the hose ELLE Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With straight pipe fit hose till pipe is about 20 to 30 mm 0 79 1 18 in into the
28. be sure to distinguish its top from bottom as it was instal led before removal and direct topside upward e 1st ring differs from 2nd ring in thickness shape and color of surface contacting cylinder wall Distinguish 1st ring from 2nd ring by referring to figure below e When installing oil ring install spacer first and then two rails Mark if equipped i 1 istring 2 2ndring 3 Oil ring Fig 3 5 Installing Piston Rings Cylinder Head After applying engne oil to cylinder head bolts tighten them gradually with a torque wrench following sequence given in below figure Finally tighten bolts to specified torque Tightening torque for cylinder head 70 75 7 0 7 5 51 0 54 0 ae 1 Camshaft Pulley side 2 Distributor side Fig 3 6 Tightening Sequence of Cylinder Head Bolts NOTE Whenever installing cylinder head to new cylinder block use following procedure to tighten cylin der head bolts Tighten cylinder head bolts to specified torque as previously outlined and loosen them once till tightening torque becomes zero And then torque them to specification again Timing Belt Pulleys Timing Belt and Tensioner 1 Camshaft timing belt pulley Install timing belt guide key and crankshaft timing belt pulley Refer to figure below for proper installation of these parts Install timing beit guide in such a way that its concave side faces oil pump With crankshaft locked tig
29. e that 12 volt electrical system is capa ble of violent and damaging short circuits When performing any work where electrical terminals could possibly be grounded ground cable of the battery should be disconnected at battery e Any time the air cleaner air intake case throttle body or intake manifold is removed the intake opening should be covered This will protect against accidental entrance of foreign material which could follow intake passage into cylinder and cause extensive damage when engine is started e When disconnecting couplers don t pull wire harness but make sure to hold coupler itself With lock type coupler be sure to unlock the lock before disconnection With spring lock type coupler as shown in Fig 3 1 push out 3 2 spring before disconnection but only within the extent that spring is not deformed Attempt to disconnect coupler without un locking may result in damage to coupler When connecting lock type coupler insert it till clicking sound is heard and connect it securely Coupler Lock spring Plane screwdriver Pull AWN Fig 3 1 Disconnection of Spring Lock Type Coupler PRECAUTION ON FUEL SYSTEM SERVICE e Work must be done with no smoking in a well ventilated area and away from any open flames As fuel feed line between fuel pump and fuel pressure regulator is still under high fuel pres sure even after engine was stopped loosening or disconnecting fuel feed line directly m
30. e Position Sensor Output voltage V Low High Small 4 Large Throttle valve opening degree Fig 4A 20 Output Characteristic 4A 18 Air Temperature Sensor ATS Located at the side of intake manifold this sen sor constantly measures the temperature of the air entering there and converts a change in the air temperature into that in resistance through its thermister That is as air temperature lowers resistance increases and as it rises resistance decreases As air density of the intake air varies with variation in temperature ECM by monitoring the resistance adjusts the amount of fuel injection according to the air temperature Water Temperature Sensor WTS Located at the side of intake manifold this sen sor measures the temperature of the engine cool ing water and converts its change into that in resistance through the thermister like the air temperature sensor That is as cooling water temperature lowers resistance increases and as it rises resistance decreases By monitoring the resistance of the water tem perature sensor ECM detects the engine cooling water temperature and that affects most systems under the control of ECM Resistance LOW High Low 4t High Temperature Fig 4A 21 Air Water Temperature Sensor Characteristic Recirculated Exhaust Gas Temperature Sensor REGTS For California spec model o
31. ed under dusty conditions 2 In areas where road salt is used inspect and clean the distributor cap and ignition wiring more frequently 1 4 1 2 ENGINE AND EMISSION CONTROL For maintenance service procedure of any item not found in this section refer to SECTION 1 of 88 MODEL SERVICE MANUAL 2 CAMSHAFT TIMING BELT INSPECTION 1 Disconnect negative battery lead at battery 2 Loosen fan drive belt and remove radiator fan shroud and cooling fan amp clutch at the same time Fig 1 1 Removing Fan Shroud 3 Remove water pump belt and pump pulley 4 Remove crankshaft pulley by removing 4 pulley bolts The crankshaft timing belt pulley bolt at the center needs not be loosen ed 3 1 Key 2 Crankshaft pulley 3 Pulley bolt Fig 1 2 Removing Pulley 5 Remove timing belt outside cover Inspect the belt for damage or wear When any damage or wear is found on the belt replace it NOTE If beit replacement is necessary be sure to install the belt properly referring to page 3 6 to page 3 8 of this supplement for installation procedure 6 Install timing belt outside cover and torque bolts and nut to specification 7 Install crankshaft pulley and torque bolts to specification 8 Install water pump pulley and belt 9 Install radiator shroud and cooling fan amp clutch f 10 Adjust water pump belt tension to specifica tion 11 Connect negative battery lead to battery 9 OXYGEN SENSOR REPLACEMENT
32. from the air conditioner circuit ECM detects whether the air conditioner is ope rating or not through the signal and uses it as one of the signals for controlling ISC solenoid valve operation Battery Voltage The fuel injector is driven by its solenoid coil based upon the ECM output signal There is some delay called as Ineffective injec tion time which doesn t provide fuel between ECM signal and valve action As the ineffective injection time depends on the battery voltage ECM takes voltage information to compensate it in fuel injection time Diagnosis Switch Terminal There are two diagnosis switch terminals one included in the fuse box and the other in the monitor coupler in the engine room When either diagnosis switch terminal is grounded a diagnosis signal is fed to ECM which then out puts self diagnosis code and at the same time outputs ISC duty through duty check terminal 1 Fuse box A 2 Diagnosis switch terminal B Diagnosis switch terminal c D Duty check terminal Ground terminal Test Switch terminal 3 Monitor coupler Fig 4A 27 Diagnosis and Test Switch Terminals Test Switch Terminal The test switch terminal is included in the moni tor coupler When this terminal is grounded ECM sets the ignition timing to the specification and turn CHECK ENGINE light ON even when engine is running When both test switch terminal and diagnosis switch terminal are grounded ECM outputs A F
33. g burned keep away from hot metal parts such as the radiator exhaust manifold tailpipe muffler etc EN a e EE st CAUTION e Before starting any service work cover fenders seats and any other parts that are likely to get scratched or stained during servicing Also be aware that what you wear e g buttons may cause damage to the vehicle s finish When removing parts that are to be reused be sure to keep them arranged in an orderly manner so that they may be reinstalled in the proper order and position When performing service to electrical parts that does not require use of battery power disconnect the negative cable of the battery When removing the battery be sure to disconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal covers Whenever you use oil seals gaskets packing O rings locking washers split pins self locking nuts circlips and certain other parts as specified be sure to use new ones Also before installing new gaskets packing etc be sure to remove any residual material from the mating surfaces Make sure that all parts used in reassembly are perfectly clean When use of a certain type of lubricant bond or sealant is specified be sure to use the specified type Be sure to use special tools when instructed When disconnecting vacuum hoses attach a
34. ges By monitoring the sensor output voltage ECM knows the manifold pressure intake air volume Output voltage Reference voltage fs Ground Semi conductor type pressure converting element Filter Intake manifold pressure Vacuum AUN og Fig 4A 17 Pressure Sensor Output voltage V Low High Low t ba High High vacuum Intake manifold Low vacuum pressure mmHg Fig 4A 18 Output Characteristic ECM uses the voltage signal from the pressure sensor as one of the signals to control fuel in jection time ISC solenoid valve operation EGR VSV operation and ignition timing 4A 17 Throttle Position Sensor TPS The throttle position sensor consisting of a contact point idle switch and a potentiometer is connected to the throttle valve shaft on the throttle body and detects the throttle valve opening The throttle opening in the idle state is detected by means of the contact point which turns ON in that state But beyond that the full opening is detected by the potentiometer as follows A 5 volt reference voltage is applied to the sensor from ECM and as its brush moves over the print resistance according to the throttle valve open ing the output voltage varies accordingly By monitoring the sensor output voltage ECM detects the throttle valve opening and its change 438321 1 Reference voltage 2 Output voltage 3 ON OFF signe 4 Ground Fig 4A 19 Throttl
35. hten crankshaft timing belt pulley bolt to specified torque Tightening torque for crankshaft timing belt pulley boit 1 Timing belt guide 3 Crankshaft timing belt pulley 2 Key 4 Pulley bolt Fig 3 7 Installing Guide Key and Pulley 2 Camshaft timing belt pulley Fit pulley pin on camshaft into slot on cam shaft pulley With camshaft locked tighten the pulley bolt to the specified torque Tightening torque for camshaft timing belt pulley bolt Timing belt inside cover Camshaft pulley Pulley pin Slot Pulley bolt AONO Fig 3 8 Pulley Pin Slot and Pulley Bolt 3 6 1 Camshaft timing belt pulley 2 Proper size rod 3 Camshaft Fig 3 9 Locking Camshaft 3 Tensioner and timing belt 1 insert lug of tensioner plate into hole of tensioner 1 Tensioner plate 4 2 Tensioner 3 Lug 4 Hole Fig 3 10 Lug and Hole 2 Tensioner tensioner plate spring and spring damper Do not tighten the tensioner bolt and stud by wrench yet Hand tighten only at this time Check to ensure that the plate movement in arrow direction as shown in below figure causes the same directional movement of the tensioner If no associated movement between plate and tensioner occurs remove tensioner and plate again and reinsert the plate lug into tensioner hole 1 Tensioner bott 2 Tensioner stud 3 Tensioner plate 4 Tensioner 5 Spring 6 Spring damper Fig 3 11 Tensioner Installation
36. ice on fuel system check to make sure that there are no fuel leaka ges as follows 1 Turn ON ignition switch for 3 seconds to operate fuel pump and then turn it OFF Repeat this ON and OFF 3 or 4 times and apply fuel pressure to fuel line till fuel pressure is felt by hand placed on fuel return hose 2 In this state check to see that there are no fuel leakages from any part of fuel system 3 5 INSPECTION OF ENGINE COMPONENTS NOTE For the inspection not found in this section refer to the same section of 88 MODEL SERV ICE MANUAL Camshaft e Cam wear Using a micrometer measure height H of cam lobe If measured height is less than limits replace camshaft Cam height Standard Limit 38 136 mm 38 036 mm 1 5014 in 1 4975 in Exhaust cam 38 136 mm 38 036 mm i 1 5014 in 1 4978 in Intake cam Fig 3 4 Checking Cam Height 3 6 ENGINE REASSEMBLY NOTE For the assembly procedure not found in this section refer to the same section of 88 MODEL SERVICE MANUAL Piston Ring e As indicated in figure below 1st and 2nd rings have R or T mark When installing these piston rings to piston direct marked side of each ring toward top of piston NOTE There are 2 types of 1st ring marked and un marked When installing a new unmarked 1st ring it is not necessary to distinguish its top from bottom i e either side can face upward but when reinstalling a used one
37. in fuel tank CAUTION Never drain or store fuel in an open con tainer due to possibility of fire or explosion 8 Fuel filter inlet pipe from filter 1 Fuel filter 2 Inlet pipe Fig 4 11 9 Detach fuel pipe clamps from chassis and fuel filter inlet pipe from clamp 1 Clamps 2 Inlet pipe 3 Fuel tank Fig 4 12 Pipe Clamps 10 Fuel return hose from pipe with fuel tank and cover lowered slightly 11 Fuel tank and cover from vehicle Inspect After removing fuel tank check hoses and pipes connected to fuel tank for leaks loose connec tions deterioration or damage Also check fuel pump and level gauge gaskets for leaks visually inspect fuel tank for leaks and damage Replace any damaged or malconditioned parts FUEL TANK PURGING PROCEDURE CAUTION This purging procedure will NOT remove all fuel vapor Do not attempt any repair on tank where heat or flame is required as an explosion resulting in personal injury could occur The following procedure is used for purging the fuel tank 1 After removing fuel tank remove all hoses fuel pump and fuel level gauge from fuel tank 2 Drain all remaining fuel from tank Move tank to flushing area 4 Fill tank with kerosene or trichloro ethylene and agitate vigorously and drain Repeat this washing until inside of tank is clean Replace tank if its inside is rusty 5 Completely flush out remaining fluid after washing
38. ing water temperature reaches about 60 C 140 F the valve is fully closed and the engine speed is back to the normal idle speed 4A 10 1 Thermo wax 4 Water from intake 2 Valve manifold 3 Piston 5 Water to intake pipe Fig 4A 9 Air Valve Close ISC Idle Speed Control Solenoid Valve The ISC solenoid valve opens and closes air by pass passage according to the signal from ECM When it opens the air is supplied to the intake manifold CORR SAVARESE Q S N N Valve Coil Magnet yoke Core G N Fig 4A 10 ISC Solenoid Valve Cross Section ELECTRONIC CONTROL SYSTEM The electronic control system consists of 1 various sensors which detect the state of engine and driving conditions 2 ECM which controls various devices according to the signals from the sensors and 3 various controlled devices Fanctionally it is divided into six sub systems INFORMATION SENSORS CONTROLLED DEVICES 1 Pressure sensor a Injector 2 TPS b ISC solenoid valve 3 ATS c Throttle opener 4 WTS VSV Brown 5 REGTS d EGR VSV Blue California spec model only e CHECK ENGINE light 6 5th switch f Fuel pump relay Not for California spec model g igniter Power unit 7 CAS in distributor 8 Igniter Power unit 9 Oxygen sensor 10 Battery 11 VSS 12 Clutch switch Fig 44 11 Component Parts Location Fuel injection control system ISC solenoid valve contro
39. ioosse 99 ND3 w3 000 991 sell 000 001 pue uri 000 8 sapw OOO OS 18 12edsu waisAs 493 seqn N sesou Pale as uossiug ur 000 991 sajtu 000 001 18 aoerday ABISIUBD LODIEYS w 000 991 s iuu 000 001 Je 158dsul 49148Au02 ONRAJEIED 40suas UaHAxO 9A E ADd sbununow pue sedid 1sneux3 1ug ooo2 u 6u3 SUOI128UU02 pue sasou uiejs s Bui oog 481 t o pue io auiBu3 89uEJe8 9 ysel AJEA aq Buiun yeyswed 1j8q aaup duund 1938 M UE4 TOHLINOO NOISSINW3 3NIDN3 szii sot sze oe Jaze sz sz9 o9 szs se Jozef oe azz st sz stp uou sz Sct peo ost sel sei zuf oor Sie e ste os eze ez fazi ode wy auos ie ecu lo Spee 1 38584 ad JIM 10sues Beaj ay usu L lenuew sty 40 9L Vt d vy NOLLO3S 01 Buti49J84 Yous jeoues 1u ij 3NIDN3 JDIH out Ho uin 03 eins oq aBeayjw Woee 405 peiinbo GZ 8 pL EL LL OL 6 B sway jo aaas e2ueuojuieur jo uonejduioo uod iosu s eau ay Aq pa12a1ap si YSIYM jo U9E2 s jiuu 900 00L pue OOD 08 000 0G JO aBeepus au Je saubi 1838U1 uon euiquioo ay UI IYI 3NION3 NOIHD sut sejoryaA uone91J193dsS ueipeue pue ueiuJ0jrje 1da2xa sapoiuaA Uu0n 31jr2eds je12pa4 104 ALON 31n03H9S 39NYN3JANIVW LL 3 062ugn7 7 anbio1 pauoads ay 01 uay L A1e sa3au 41 a2ejda4 aseaiB 41943 osje ING Jeam pope A uo 10u 01 ajqeoidde s I GE WA e JO 1224400 pue 12edSu GM a2ueuaureur papuaumnuoaa SI HZ WAI e abueyo 40 a
40. ish Use oil of proper viscosity Replace Clean Replace Replace Replace worn parts Engine noise Note Before checking mechanical noise make sure that e Ignition timing is properly adjusted e Specified spark plug is used e Specified fuel is used Possible Cause Valve noise e improper valve lash e Worn valve stem and guide e Weak or broken valve spring e Warped or bent valve Piston ring and cylinder noise e Worn piston ring and cylinder bore Connecting rod noise e Worn rod bearing e Worn crank pin e Loose connecting rod nuts e Low oil pressure Crankshaft noise e Low oil pressure e Worn bearing e Worn crankshaft journal e Loose bearing cap bolts e Excessive crankshaft thrust play Correction Adjust Replace Replace Replace Rebore or replace cylinder Replace piston and r ng Replace Repair by grinding or replace crankshaft Tighten nuts to specification Previously outlined Previously outlined Replace Repair by grinding or replace crankshaft Tighten bolts to specification Replace thrust bearing 2 7 SECTION 3 ENGINE NOTE For the items not found in this section refer to the same section of 88 MODEL SER VICE MANUAL CONTENTS 3 1 GENERAL DESCRIPTION 3 2 3 6 INSPECTION OF ENGINE COMPONENTS 3 4 3 6 ENGINE RE
41. l system Fuel pump control system Throttle opener control system EGR control system ESA control system OTHERS Inmo Roe EGR modulater EGR valve Fuel pressure regulator Throttle opener Canister Monitor coupler ECM Fuse box Diagnosis switch terminal BVSV Main relay 4A 11 191 AI u ggl TNI 10su35 a4nssa4g o19 ut pu Sd L Y31dNOD 3d1 SLYVd 40 NOILISOd 1VNIWNH3aA pu 9 8 18 98 ameer Ya y r Uo w uum O 9 8 19 8 EI py ca 8 OLA Aeto1 JO uonisod jeuruua L Fig 4A 12 System Wiring Diagram 4A 12 enig P9H Ig H De g MOl9A S A AE A SPUMO M MO I8A 19 OIA A A PAA enigAxS 77 as MOIBA PeH A Y u8e49 peu 5D u 3oelg p H g u pay se y 3uld tite 3 MOIaA UaaaB1yBi7 A 5 aiuM ueaJDb1uBr1 w87 xoe g uss451u811 g 67 uaeJB1u81 c ccc Bq MOIBSA AEID A719 pay AeID H 4D uaaaN AP49 9 19 AB sis 19 AAO B A uAA041g PE AS A 48 oelg umoig g g bueiO nlg O Ig OleA en g A Ig eituM enig MIS pay anig 8 18 e g enig 8 l8 ang sre I8 MOJA AAL A G Uaa49 Xoeig D g anig xoeig 1g g 10109 911A IN23 CE 461 3NIDN3 393H2 LE epeue pue PIUJOJI E2 yams 92u82 OF 1d 5x japow 2ads e1epe 10sues eBea tIA 6z Jo1oefu jan4 8z 9A BA PlOUaJOS JS ZZ ASA 4euado epa304u oz ASA H93 SZ Aejas duund
42. lean or replace Adjust Repair or replace Clean adjust or replace Refer to SECTION 8 Refer to SECTION 4A Excessive engine oil consumption Low oil pressure Possible Cause Correction Low compression Others e Poor valve seating e Dragging brakes e Slipping clutch e Thermostat out of order Improper tire pressure Malfunctioning EGR valve Oil leakage Loose oil drain plug Loose oil pan boits Deteriorated or broken oil pan sealant Leaky crankshaft oil seals Leaky cylinder head cover gasket Improper tightening of oi filter Loose oil pressure switch Blown cylinder head gasket Leaky camshaft oil seals Oil entering combustion chamber Sticky piston ring Worn piston and cylinder Worn piston ring groove and ring Improper location of piston ring gap Worn or damaged valve stem seal Worn valve stem Not enough oil Improper oil fiscosity Malfunctioning oil pressure switch Clogged oil strainer Functional deterioration of oil pump Worn oil pump relief valve Excessive clearance in various sliding parts Previously outlined Repair or replace Repair or replace Adjust or replace Replace Adjust Check and replace as necessary Tighten Tighten Replace sealant Replace Replace Tighten Tighten Replace Replace Remove carbon and replace rings Replace or rebore cylinder and replace piston Replace piston and ring Reposition ring gap Replace Replace Replen
43. n with the magnetic Hux as shown below This voltage is wave shaped into the pulse signal sensor signal by the com parator This pulse signal 4 pulses revolution is sent to ECM where it is used to calculate the engine speed and also as one of the signals to control fuel injector and ignition timing 4A 19 1 Signal rotor 2 Magnet 3 Hall element M Threshold Hall element level voltage OV HIGH Sensor signal LOW Fig 4A 25 CAS Ignition Signal ignition fail safe signal This signal is sent from the igniter ECM uses it as one of the signals for controlling fuel injector Engine Start Signal This signal is sent from the engine starter circuit Receiving it ECM judges whether the engine is cranking or not and uses it as one of the signals to control fuel injection timing injection time ISC solenoid valve operation and throttle opener VSV operation 5th Switch Not for California spec model Located on the tansmission it turns ON when the gear shift lever is shifted to the Sth gear position and OFF when it is at any other position The ON OFF signa from this switch is one of the signals that ECM uses to control EGR VSV 4A 20 Fig 4A 26 5th Switch Clutch Switch Located above the clutch pedal it turns ON when clutch pedal is depressed and OFF when released ECM uses it as one of the signals for controlling fuel injector Air Conditioner Signal For vehicle with A C This signal issent
44. nce 360 justing screw stationary with screwdriver and In this state check valve lashes at valves 1 then make sure again that valve lash is within 2 6 and 2 specification Tightening torque for adjusting screw lock nut 15 19 1 5 1 9 11 0 13 5 5 After checking and adjusting valve lashes at valves D and 2 rotate crankshaft exactly one full turn 360 and check the same at valves 6 and 8 Adjust them as necessary 6 After checking and adjusting all valves install 1 Distributor rotor cylinder head cover and distributor cap Fig 3 21 Checking Rotor Position EX 1 Thickness gauge Fig 3 23 Checking Valve Lashes 3 9 RECOMMENDED TORQUE SPECIFICATIONS s Tightening torque Fastening parts Nm kem bt 1 Cylinder head bolt 70 75 7 0 7 5 51 0 54 0 2 Cylinder head cover bolt 4 5 0 4 0 5 3 0 3 5 D O M 8 3 Spark plug 20 30 2 0 3 0 14 5 21 5 4 Distributor gear case 8 12 0 8 1 2 6 0 8 5 b Rocker arm shaft screw 9 12 09 12 6 Valve adjusting screw lock nut 15 19 1 5 1 9 7 Crankshaft main bearing cap bolt 50 57 5 0 5 7 8 Oil filter stand 20 25 20 25 9 Oil filter Ass y 9 0 11 5 11 Oil drain plug 30 40 12 Oil pan bolt and nut 9 12 0 9 12 7 0 8 5 13 Oil pump strainer bolt 9 12 0 9 1 2 7 0 8 5 14 Water pump bolt and nut OR m 09 12 70 88
45. nly This sensor is located at the EGR valve Like the air and water temperature sensors described previously it measures the temperature of the gas which was recirculated through the EGR valve and converts a change in the exhaust gas temperature into that in resistance to send it to ECM ECM uses it for diagnosing a trouble in the EGR system 1 EGR valve 2 REGTS Fig 4A 22 REGTS Oxygen Sensor The oxygen sensor is located on the exhaust manifold to detect the concentration of oxygen in the exhaust gases Graphite ring Zirconia element Atmosphere Element cover Exhaust gases OAN Fig 4A 23 Oxygen Sensor Vehicle Speed Sensor VSS The VSS consisting of the lead switch and magnet is built in the speedometer As the magnet turns with the speedometer cable its magnetic force causes the lead switch to turn ON and OFF Such ON OFF frequency increases or decreases in proportion with the vehicle speed and is sent to ECM as pulse signals ECM uses it as one of the signals to control the SC solenoid valve 1 Reed switch 2 Magnet 3 Speedometer ass y Fig 4A 24 VSS Crank Angle Sensor CAS The crank angle sensor located in the distributor consists of the signal generator hall element and magnet and signal rotor As the signal rotor turns it causes the magnetic flux from the magnet to be applied to the hall element intermittently The hall element genera tes the voltage in proportio
46. rely 1 Bracket 2 Canister 3 Vacuum hose 4 Vapor hose 5 Clamo Fig 1 4 Canister 13 EXHAUST GAS RECIRCULATION EGR SYSTEM INSPECTION Check EGR valve for proper operation For checking procedures refer to SECTION 4A of this supplement 14 ECM AND ASSOCIATED SENSORS INSPECTION WARNING Apply parking brake without fail before this work With manual transmission vehicle shift gear shift lever to NEUTRAL position 1 Start engine and warm it up normal operating temperature NOTE With vehicles of Federal specifications except Californian and Canadian specification ones be sure to turn off CHECK ENGINE light with its cancel switch 2 Stop engine 3 Connect ground spare fuse to diagnosis switch terminal 1 Fuse box 2 Diagnosis switch terminal Fig 1 6 Diagnosis Switch Terminal 4 Run engine at idle speed and check CHECK ENGINE light on meter panel as to which number of diagnostic code it indicates Fig 1 6 CHECK ENGINE Light 5 If CHECK ENGINE light indicates No 12 of diagnostic code ECM and associated sen sors are in good condition but if it indicates any other diagnostic code number refer to DIAGNOSIS of SECTION 4A 6 Stop engine and disconnect spare fuse con nected to diagnostis switch terminal in fuse box 19 IGNITION TIMING INSPECTION Check to make sure that ignition timing is set properly If out of specification adjust it Refer to S
47. replace as necessary Refer to the section Overheating Replace Adjust Connect securely Overheating Fuel system out of order e Clogged fuel filter and fuel lines e Air inhaling from intake manifold or throttle body gasket Electronic Fuel Injection system out of order Others e Excessive combustion chamber deposits e Malfunctioning EGR valve Insufficient coolant Loose water pump belt Inoperative thermostat Poor water pump performance Improper ignition timing Clogged or leaky radiator Improper engine oil grade Clogged oil filter or oil strainer Not enough oil Poor oil pump performance Oil leakage Dragging brakes Slipping clutch Blown cylinder head gasket Poor gasoline mileage Fuel system out of order e Fuel leakage from fuel tank and lines e Clogged air cleaner element Ignition system out of order Improper ignition timing Leaks or loose connection of high ten sion cord Faulty spark plug improper gap heavy deposits and burned electrodes etc e Faulty ESA system Electronic Fuel Injection system out of order Replace or clean Replace Refer to SECTION 4A Remove carbon Check and replace as necessary Replenish Adjust Replace Replace Adjust Flush repair or replace Replace with proper grade oil Replace or clean oil strainer Replenish Repair or replace Repair Repair or replace Adjust or repair Replace Repair or replace C
48. rsonal injury cover the fitting to be disconnect ed with a shop cloth Put that cloth in an approved container when disconnection is completed e Note that fuel hose connection varies with each type of pipe Be sure to connect and clamp each hose correctly referring to the following With short pipe fit hose as far as it reaches pipe joint as shown Hose DER Pipe I Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end 4 4 With following type pipe fit hose as far as its peripheral projection as shown AA Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With bent pipe fit hose as far as its bent part as shown or till pipe is about 20 to 30 mm 0 79 1 18 in into the hose D LLL Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end With straight pipe fit hose till pipe is about 20 to 30 mm 0 79 1 18 in into the hose Hose 2010 30 mm clamp 0 79 1 18 in Clamp securely at a position 3 to 7 mm 0 12 0 27 in from hose end e When connecting fuel feed hose to throt tle body lubricate its O ring with spindle oil or gasoline e When connecting fuel pipe flare nut first tighten flare nut by hand and then tighten it to specified torque FUEL FILTER Remove or Disconnect 1 After making sure that engine is cold release fuel pressure in fuel feed line referring to
49. s tara Ds n aa q Ia ee Ge GE Sundae inte ie EUR RC Rp RE Pa 4 5 Fuel Lines cc oce ke ca a ak xoxo E Ro gor ed EE EE dw MEAE XC KR 4 5 TINT AR NR ET eA TR EE HE wm m eR RUE RUN RI e aa 4 6 RECOMMENDED TORQUE SPECIFICATIONS 4 8 CAUTION THE ENGINE OF THIS VEHICLE REQUIRES THE USE OF UNLEADED FUEL ONLY USE OF LEADED AND OR LOW LEAD FUEL CAN RESULT IN ENGINE DAMAGE AND REDUCE THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEMS 4 3 FUEL TANK PUMP FILTER AND LINES GENERAL DESCRIPTION The main components of the fuel system are fuel tank fuel pump fuel filter and fuel level gauge and it includes three lines fuel feed line fuel return line and fuel vapor line For the details of fuel flow and fuel vapor flow refer to SECTION 4A ELECTRONIC FUEL INJECTION SYSTEM and SECTION 5 EMISSION CONTROL SYSTEM respectively Fuel tank Fuel pump Fuel filter Fuel level gauge Vapor liquid separator Breather hose Fuel feed line Fuel return line Fuel vapor line To throttle body From fuel pressure regulator Tocanister OONOM KON N ao Fig 4 1 Fuel Lines 4 2 FUEL TANK The fuel tank is located under the rear of the vehicle The fue pump and fuel level gauge are installed on the upper part of the fuel tank 1 Fuel filter element 2 Fuel Fig 4 4 Fuel Filter Element 1 Fuel tank 2 Fuel pump 3 Fuel level gauge Fig 4 2 Fuel Tank
50. t change with throttle opening Sounds like pop corn popping Possible Cause Correction Ignition system out of order e improper ignition timing e Spark plug faulty or plug gap as out of adjustment e Leaky high tension cord Fuel system out of order e Clogged air cleaner element e Clogged fuel filter hose or pipe Electronic Fuel Injection system out of order Engine overheating Low compression Others e Malfunctioning EGR valve Ignition system out of order e Improper ignition timing e Faulty ESA system e Leaky or loosely connected high tension cord e Faulty spark plug excess carbon deposits improper gap and burned electrodes etc e Cracked rotor or cap in distributor Fuel system out of order e Clogged fuel filter e Kinky or damaged fuel hose and lines Electronic Fuel Injection system out of order Others e Malfunctioning EGR valve Engine overheating Ignition system out of order e Faulty spark plug e Improper ignition timing e Loose connection of high tension cord Adjust Replace or adjust gap Replace Clean or replace Clean or replace Refer to SECTION 4A Refer to Overheating section Previously outlined Check and replace as necessary Adjust Refer to SECTION 8 Check and repair or replace Check and clean adjust or replace Replace Replace Check and replace as necessary Refer to SECTION 4A Check and
51. tag describing the correct installation position so that the hoses can be reinstalled correctly After servicing fuel oil water vacuum exhaust or brake systems check all lines related to the system for leaks Be careful not to touch the electrical terminals of parts which use microcomputers e g electronic control unit The static electricity from your body can damage these parts When taking measurements at electrical connectors using a tester probe be sure to insert the probe from the wire harness side backside of the connector For vehicles equipped with a catalytic converter be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged Conduct a spark jump test oniy when necessary make it as short as possible and do not open the throttle Conduct engine compression checks within the shortest possible time Avoid situations which can result in engine misfire e g starting the engine when the fuel tank is nearly empty For vehicles equipped with fuel injection systems never disconnect the fuel line between the fuel pump and injector without first releasing the fuel pressure or fuel can be sprayed out under pressure SECTION 1 PERIODIC MAINTENANCE SERVICE CONTENTS 1 1 MAINTENANCE SCHEDULE 1 2 Maintenance recommended under severe driving conditions 1 4 1 2 ENGINE AND EMISSION CONTROL
52. the valve in the regula tor open and excess fuel returns to the fuel tank via the return pipe Chamber A Chamber B Spring 7 Diaphragm Valve From fuel pump To fuel tank Intake manifold pressure TEE Fig 4A 7 Pressure Regulator Cross Section 4A 9 Air Valve The air valve consists of thermo wax springs and valve When the engine is cold it sends the air from the air cleaner to the intake manifold without letting it pass through the throttle valve to increase the engine speed and thus the engine is warmed up Operation When the engine is cold or engine cooling water is lower than about 60 C 140 F the thermo wax contracts In this state the valve is pushed to the left by the spring force and opens the air passage allow ing the air from the air cleaner to be drawn into the intake manifold Thus the amount of intake air increases even when the throttle valve isat the idle position and the engine speed rises to the fast idle state which is higher than the idle speed 8 5 Air to intake manifold 1 Throttle body 6 Air from air cleaner 2 Thermo wax 7 Water from intake 3 Springs manifold 4 Valve 8 Water to intake pipe Fig 4A 8 Air Valve Open As the engine is warmed up the thermo wax expands gradually then the piston is pushed to move the valve to the right gradually and the amount of air passing through the air passage decreases and so does the engine speed When the engine cool
53. tion of crankshaft e In this state No 4 piston is at top dead center of compression stroke Direction of crankshaft 1 Drive side of belt Fig 3 15 Installing Timing Belt 7 To take up slack of timing belt turn crank shaft two rotations clockwise after installing it After making sure that belt is free from slack tighten tensioner stud first and then tensioner bolt to each specified torque Then confirm again that two sets of marks are aligned respectively Tightening torque for tensioner stud 70 85 Tightening torque 17 5 21 5 for tensioner bolt 1 Tensioner stud 2 Tensioner bolt Fig 3 16 Tensioner Bolt and Stud 3 8 ENGINE MAINTENANCE SERVICE NOTE For the maintenance service procedure not found in this section refer to the same section of 88 MODEL SERVICE MANUAL Compression Pressure Measurement Check compression pressure on all four cylinders as follows Warm up engine Stop engine after warming up Disconnect CAS coupler 1 2 3 WARNING Failure in disconnecting CAS coupler can 4 5 cause spark to occur in engine room possibly resulting in a dangerous explosion Remove all 4 spark plugs Install special tool Compression gauge into spark plug hole 1 Special tool Compression gauge 09915 64510 Fig 3 17 Installing Compression Gauge 6 Disengage clutch to lighten starting load on engine and depress accelerator pedal all the way to make thro
54. ttle fully open 7 Crank engine with fully charged battery and read the highest pressure on compression gauge NOTE For measuring compression pressure crank engine at least 250 r min by using fully charged battery Compression pressure at sea level 14 0 kg cm pts 12 0 kg cm t Max difference 1 0 kg cm between any two 14 2 psi 100 kPa cylinders 8 Carry out steps 5 thr ugh 7 on each cylinder to obtain four readings 9 After checking install spark plugs high tension cords and connect CAS coupler Vaccum Measurement The engine vacuum that develops in the intake line is a good indicator of the condition of the engine The vacuum checking procedure is as follows 1 Warm up engine to normal operating tempera ture and make sure that engine idle speed is within specification 2 Stop engine and disconnect vacuum hoses from throttle opener VSV 3 Connect vacuum pump to vacuum hose of opener side 4 Connect special tools vacuum gauge and hose joint to vacuum hose of intake manifold side 1 Throttle opener VSV 4 Vacuum pump 2 Vacuum hose of opener 09917 47910 side 5 Vacuum gauge 3 Vacuum hose of intake 09915 67310 manifold side 6 Hose joint 09918 08210 Fig 3 18 Installing Vacuum Gauge 5 Start engine and apply 40 cmHg vacuum to throttle opener to run engine at specified idle speed and read vacuum gauge Vacuum should be within specification 45 55 cm Hg
Download Pdf Manuals
Related Search