Toyota Engine 7M-GE 7M-GTE

TOYOTA
7M-GE , 7M-GTE
. '
.ENGINE
REPAIR MANUAL
TOYOTA 7-M�·GE, . 7M.�GTE
ENG·1NE .REPA·tR· MANUAL
.-----·--· .
.:..11\iTROoucTI. ON
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✓- ENGINE MECHANICAL
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/;.TURBOCHARGER SYSTEM
V EFI SY_illM
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C00Lt�G SYSTEM E
LUB.RICATI0N SYSTEM 0
. l�NITI0N SYSTEM ID
STARTING SYSTEM Iii
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SERVICE:SPECIFICATIONS
STANDARD BOLT TORQUE SPECIFICATIONS E
,, SST AND SSM Ill
© 1996 TOYOTA MOTOR CORPORATION

All rights reserved. This book may not be re
produced or copied, in whole or in part, with·
out the written permission of Toyota Motor
Corporation.
INTRODUCTION
p~•o•·•··
HOW TO USE THIS MANUAL ............. , . , , ... IN-2
.•:
IDENTIFICATION INFORMATION • • • •. • . • ••• • . .... IN-4
GENERAL REPAIR INSTRUCTIONS ••••.• ,", , •.• , , , IN-4
PRECAUTIONS FOR VEHICLES EQUIPPED WITH
A CATALYTIC CONVERTER .................... IN-6
ABBREVIATIONS USED IN THIS MANUAL IN-7
INTRODUCTION - How to Use This Manual
HOW TO USE THIS MANUAL

To assist you in finding y our way through this manual, the Sec
tion Title and major heading ar:e given at the top of every page.
An INDEX is provid ed on t he 1st page of each section to guide
you to the item to be repaired.
At the beginning of each section, PRECAUTIONS are given
that pertain to all repair operations contained in that section.
Read these precautions before starting any repair task.
TROUBLESHOOTING tables are included for each system to

help you diagnose the system problem and find the cause. The
repair for each possible cause is referenced in the remedy col-
umn to quickly lead you to the solution.
REPAIR PROCEDURES
Most repair operations begin with an overview illustration. It
identifies the components and shows how the parts fit
together.
Example:
<iw----Snap Ring
@----Spacer
Key---0
W--Oil Pump Shaft Drive Gear
e ♦
�Union Bolt
--
\) � 1 350 t25. 341 I
QI "�.____._,,.._-_,._.._,,,_...,,,---
Oil Pump Outlet Pipe
----Oil Pump Body
Oil Pump Strainer
Oil Pump
Drive Shaft
Oil Pump
Plug-----<112� Dri\en Gear
©:
Spring------,
Relief Valve-e----�
-
175 (66 ln.-lb, 7.4) !1----:13

\ kg-cm (ft-lb, N·m! : Specified torque
♦ Non-reusable part Ll/0553
INTRODUCTiON - How to Use This Manual IN-3
The procedures are presented in a step-by-ste format:

• The illustration shows what to do and wher, to do it.
• The task heading tells what to do.
• The detailed text tells how to perform the task and gives
other information such as specifications an warnings.
Example:
� Task heading: w at to do
2. IF NECCES§ARY, REPLACE DRIVE SH FT BEARING
Using SST, replace the No.1 bearing by sing No. 2 bear
ing as a guide.
SST 09215-00100 (09215-00120, 09 15-00150,
Illustration:
what to do and where /09215-00160, 09215-00210, 09 14-00220)
Set part No. �Compone t part No.
Detail text: how to do it
(i) Tighten the No. 3 and No. 7 bearing cap bolt a little at
a time and in the sequence shown n the figure.
Torque: 500 kg-cm (36 ft-lb, 49 N· )
Specification
This format provides the experienced techni ian with a FAST

TRACK to the information needed. The upper ase task heading
can be read at a glance and only when n cessary, the text
below it provides detailed information. lmpo ant specifications
and warnings always stand out in bold type.
REFERENCES
References have been kept to a minimum. H wever, when they
are required you are given the page to go t
SPECIFICATIONS
Specifications are presented in bold type th ughout the text in
the applicable step. You never have to lea the procedure to
look up your specifications. All specificatio s are also found in
Appendix A, Specifications, for quick refer nee.
WARNINGS, CAUTIONS, NOTE

• WARNINGS are presented in bold type, nd indicate there is
a possibility of injury to you or other pe pie.
• CAUTIONS are also presented in bold t pe, and indicate the
possibility of damage to the componen s being repaired.
• NOTES are separated from the text but o not appear in bold
type. They provide additional informati n to help you effi
ciently perform the repair.
Identification Information,
IN-4 INTRODUCTION - General Repair Instructions
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
The engine serial number is stamped on the right side of the
cylinder block.
IN0083
GENERAL REPAIR INSTRUCTIONS

1. Use fender, seat and floor covers to keep the vehicle clean
and prevent damage.
2. During disassembly, keep parts in order to facilitate

reassembly.
3. Observe the following:

(a) Before performing electrical work, disconnect · the
negative (-) cable from the battery terminal.
(b) If it is necessary to disconnect the battery for inspec
tion or repair, always disconnect the cable from the
negative (-) terminal which is grounded to the vehi
cle body.
(c) To prevent damage to the battery terminal post,
loosen the terminal nut and raise the cable straight up
without twisting or prying it.
(d) Clean the battery terminal posts and cable terminals
with a shop rag. Do not scrape them with a file or
other abrasive object.
\
(e) Install the cable terminal to the battery post with the
nut loose, and tighten the nut after installation. Do
not use a hammer to tap the terminal onto the post.
(f) Be sure the cover for the positive (+) terminal is pro
perly in place.
4. Check hose and wiring connectors to make sure that they

are secure and correct.
5. Non-reusable parts
(a) Always replace cotter pins gaskets, 0-rings, oil seals,
'
etc. with new ones.

(b) Non-reusable parts are indicated in the component
illustrations by the "♦" symbol.
6. Precoated Parts
Precoated parts are the bolts, nuts, etc. which are coated
with a seal lock adhesive at the factory.
(a) If a precoated part is retightened, loosened or caused ·
to move in any way, it must be recoated with the
specified adhesive.
Seal Lock Adhesive
INTRODUCTION - General Repair Instructions IN-6
(b) Recoating of Precoated Parts
( 1) Clean off the old adhesive from the part·s
threads.
(2) Dry with compressed air.
(3) Apply the specified seal lock adhesive to the
part's threads.
illustrations by the "*" symbol.

(c) Precoated parts are indicated in the component
7. When necessary, use a sealer or gaskets to prevent leaks.

8. Carefully observe all specifications for bolt torques.
Always use a torque wrench.
9. Use of special service tools (SST) and special service

materials (SSM) may be required, depending on the nature
of the repair. Be sure to use SST and SSM where specified
and follow the proper work procedure. A list of SST and
SSM can be found at the back of this manual.
1 0. When replacing fuses, be sure the new fuse is the correct
amperage. DO NOT exceed the fuse amp rating or use one
of a lower rating.
11. Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the
proper locations.
(a) If the vehicle is to be jacked up only at the front or
rear end, be sure to block the wheels in order to
ensure safety.
(b) After the vehicle is jacked up, be sure to support it on
stands. It is extremely dangerous to do any work on
the vehicle raised on a jack alone, even for a small job
that can be finished quickly.
12. Observe the following precautions to avoid damaging the
parts:
(al Do not open the cover or the case of the ECU unless
absolutely necessary. (If the IC terminals are touched,
the IC may be destroyed by static electricity.)
(b) Be careful not to drop electrical components, such as
sensors or relays. If they are dropped on a hard floor,
they should be replaced and not reused.
(c} When disconnecting vacuum hoses, pull on the end

of the hose. not the middle.
(d} When separating electrical connectors, pull on the
connector itself, not the wires.
p .. p
WRONG CORRECT
001
EM-1
ENGINE MECHANICAL
Pile• ..
DESCRIPTION . • • ... • • .. . • . • • • • . • . • • • • • • • • • . • • EM:2
··,
TROUBLESHOO TING • .•• • .••• • • • • • .••• • • • • • • • EM-4.
. ENGINE TUNE-UP .••••••••••••.•••••.., •••• , , • EM
COMPRESSION CHECK .. .. • • .. .. .... .. • . • .. .. EMi1·•2 6.
� <m
TIMING B ELT .••• ,.•.•• • .••• ••• .•• • • •••.• • •••• •• • EM-28
CYLINDER H EAD' ..•• • • . .•••• • ••.•• .• • • . . •• ..• EM-37
CYLINDER BLOCK .. .. .. ••• • .. ..• • • •• • • • • • .. • • EM-65
EM-2 ENGINE MECHANICAL - Description
DESCRIPTION
The 7M-GE and 7M-GTE engines are an in-line 6-cylinder 3.0 liter DOHC 24 valve engine.
7M-GE (MS)
7M-GTE
ENGINE MECHANICAL - . Description EM-S
The 7M-GE, 7M-GTE engines are an in-line 6- ders is closed off by the cylinder head and the
cylinder engine with the cylinders numbered 1-2- lower end of the cylinders becomes the cra·nkcase,
3-4-5--6 from the front. The crankshaft is sup in which the crankshaft is installed. In addition, the
ported by 7 bearings specified by the inside of the cylinder block contains a water jacket,. through
crankcase. These bearings are made of kelmet. which coolant is pumped to cool the cylinders.
The crankshaft is integrated with 8 weights The oil pan is bolted onto the · bottom of the
which are cast along with it for balancing. Oil holes cylinder block. The oil. pan is an oil. reservoir made
are b�ilt into the crankshaft for supplyirig oil to the of pressed steel sheet. A dividing plate'is included
connecting rods, pistons and other components. · inside the oil pan to keep sufficient oil in the bot
These engine's ignition order is 1-5-3-6-2"'.4 . tom of the pan even when the vehicle is tilted. This
The cylinder head is made of aluminum alloy, with dividing plate also prevents the oil from making
a cross flow type intake and exhaust layout and waves when the vehicle is stopped suddenly and
with pent roof type combustion chambers. The thus shifting the oil away from the oil pump suc
spark plugs are located in the center of the com tion pipe.
bustion chambers.
. , Exhaust and intake valves are equipped with
irregular pitch springs with symmetrical ends
made of oil tempered silicon chrome steel wire
'which are capable of following the valves even at
•high engine speeds.
Both the exhaust side cam shaft and the. intake
side cam shaft are driven by a single timing belt.
The cam journal is supported at 7 places between
the valve lifters of each cylinder and on the
cylinder head of front end. Lubrication of the cam
journal and cam is accomplished by oil being sup
plied through the oiler port in the center of the
camshaft.
Adjustment of the valve clearance is done by
means of an outer shim type system, in which
valve adjusting shims are located above the valve
lifters. This permits replacement of the shims
without removal of the camshafts.
The resin timing belt cover is made in 2 pieces.
Pistons are made of highly temperature-resis
tant aluminum alloy, and depressions are built into
the piston head to prevent interference with
valves.
Piston pins are the full-floating type, with the
pins fastened to neither the piston boss nor the
connecting rods. Instead, snap rings are fitted on
both ends of the pins, preventing the pins from
falling out.
The No. 1 compression ring is made of stainless
steel and the No. 2 compression ring is made of
cast iron. The oil ring is made of a combination of
stainless steel. The outer diameter of each piston
ring is slightly larger than the diameter of the
piston and the flexibility of the rings allows them
to hug the cylinder walls when they are mounted
on the piston. Compression rings No. 1 and No. 2
work to prevent the leakage of gas from the
cylinder and the oil ring works to scrape oil off the
cylinder walls to prevent it from entering the com�
bustion chamber.
The cylinder block is made of cast iron. It has 6
cylinders which are approximately 1.6 times the
length of the piston stroke. The top of the cylin-
£M-4 ENGINE MECHAN ICAL -· Troubleshooting
1----------------------------.....-------------
TROUBLESHOOTING
Problem Possible cause Remedy Page
Engine overheats Cooling system faulty Troubleshoot cooling system C0-4
Incorrect ignition timing Reset timing EM- 1 7
Engine will not crank or., Starting system faulty Troubleshoot starting system ST-2
cranks slowly ,'
Engine will not start/ Vacuum leaks Repair as necessary

hard to start • PCV hoses .,
(cranks OK) • (w/ EGR)

EGR valve
• Intake manifold
• Air intake chamber
• Throttle body
• ISC valve
Pulling in air between air flow meter and Repair as necessary Fl-96, 98
throttle body
Ignition problems Perform spark test IG-5, 1 2,,·
• Ignition coil
• Igniter ..
• (7M-GE)
Distributor
(7M-GTE)
Cam position sensor
High-tension cord disconnected or broken Inspect cord IG-6, 1 3
No fuel sup.ply to injector Troubleshoot EFI system Fl-1 2
• No fuel in tank
• Fuel pump not working
• Fuel filter clogged
• Fuel line clogged or leaking
EFI system problems Repair as necessary
ISC system problem Check ISC .system F l-1 08
Spark plugs faulty Inspect plugs IG-7
Low compression Check compression EM-26, 27
Rough idle, stalls or Vacuum leaks Repair as necessary
misses • PCV hoses
• (w/ EGR)
EGR valve
• Intake manifold
• Air intake chamber (
• T hrottle body I
• ISC valve
Pulling in air between sir flow meter and Fl-96, 98
throttle body
Incorrect idle speed Check ISC system F l- 1 08
Ig nition problems Perform spark test IG-5, 1 2
• Ignition coil
• Igniter
• (7M-GE)
Distributor
(7M-GTEl
Cam position sensor
High-tension cord faulty Inspect cord IG-6, 1 3
ENGINE MECHANICAL - Troubleshooting · EM-6
TRO UBLESHOOTING (Cont'd)

Rough idle, stalls or Spark plu gs faulty Inspect plugs IG-7
misses (cont'd) Engine overheats Check cooling system · C0-4
Engine hesitates/ Vacuum leaks Repair as necessary
poor acceleration • PCV hoses
• (w/ EGR}
EGA valve
• Intake manifold
• Air intake chamber '
• Throttle body
• ISC valve
Pulling in air between air flow meter and Repair a s necessary Fl-96, 98
throttle body
Incorrect ignition timing Reset timing EM-1 7
Emission control system problem
(cold engine)
• (w/ EGR)
EGA system alvvavs on Check EGR system
High-tension cord faulty Inspect cord IG-6,
Fuel system clogged Check fuel system Fl-73
Air cleaner clogged Check a ir cleaner EM-7
Spark plugs faulty Inspect plugs IG-7
Engine overheats Check cooling system C0-4
Low compression Check compression EM-26, 2 7
Engine diesels EFI system problems Repair as necessary
(runs after ignition
switch is turned off)
Muffler explosion Deceleration fuel cut system always off Check EFI (fue l cut) system Fl-1 28
(after fire) on
deceleration only
Muffler explosion Air cleaner clogged Check air cleaner EM-7
(after fire) all the time EFI system problem Repair as necessary
Incorrect ignition timing Reset timing EM- 1. 7
Engine backfires Vacuum leak Check hoses and repair as
• PCV hoses necessary
• (w/ EGR)
EGR valve G
• Intake manifold
• Th rottle body
• ISC valve
Pulling in air between air flow meter and Repair as necessary Fl-96, 98
throttle body
EFI system problem Repair as necessary
Insufficient fuel flow Troubleshoot fuel system
Carbon deposits in combustion chambers Inspect cylinder head EM-37
EM-6 ENGINE M ECHANICAL - Troubleshooti n g
TROUBLESHOOTING (Cont'd)
Excessive oil Oil leak Repair as necessary
consumption
PCV line clogged Check P CV system
Piston rings worn or damaged Check rings EM-65
Valve stem and guide worn Check valves EM-37
"
Valve stem seal worn Check seals EM-37
Poor fuel economy Fuel leak Repair as necessary
Air cleaner clogged Check air cleaner EM-7
• I njector faulty
• Deceleration fuel cut system faulty
Idle speed too high Check ISC system Fl- 1 08
/:,
,,
;: Spark plugs faulty Inspect plugs IG-7
EGR system always on Check EGR system
Tires improperly inflated Inflate tires to proper pressure
Clutch slips Troubleshoot clutch
Brakes drag Troubleshoot brakes
Unpleasant odor Incorrect idle speed Check ISC system Fl- 1 08

Vacuum leaks Repair as necessary
• PCV hoses
• (w/ EGR)
EGR valve
• Intake m anifold
• T hrottle body
(
ENGINE M ECHANICAL ...: Engine Tune-up EM-7
ENGINE TUNE- U P
INSPECTION OF ENG I N E COOLANT
(See page C0-5)
I NSPECTION OF ENG INE OIL

(See page LU-5)
INSPECTION OF. AIR FILTER

(a) Visually check that . the air cleaner element is not
exc.essively dirty, damaged or oily.
(b) Clean the element with compressed air. < ,
First blow from back side thoroughly. Then blow off
the front side of the element.
MA0293
INSPECTION OF BATTERY
(See page CH-3)
INSPECTION OF HIGH-TENSION CORDS

(See pages IG-6, 1 3}
I NSPECTION OF SPARK PLUGS

(See pages •�-7 to 9)
INSPECTION OF DRIVE BELT

(See page CH-4)
ENGINE M ECHANICAL - Engine Tune-up
. '
INSPECTION AND ADJUSTMENT OF VALVE

CLEARANCE.
NOTE: Check and adjust the valve clearance while the
·,
l'
, engine is cold.
, (7M-GE)
1. REMOVE AIR INTAKE CONNECTOR ..
(a) Remove the PCV pipe.
,
, {b) (ex. MS RHO)

Disconnect the accelerator connecting rod.
(c) Disconnect the water by-pass h oses from the throt
tle boµy.
(d) Disconnect following hoses:
· • (w/ EGR)
VSV h ose (for EGR)
• (w/ TWC)
BVSV hose
• (w/ EGA)
EGA vacuum modulator hoses
• Np. 7 air hose
(e) · Disconnect the th rottle position sensor connector.
(f) Remove the throttle body bracket (s).
EM3008
(g) Remove the air intake connector bracket mounting

bolts.
(�
(h) Remove the four bolts, two nuts, air intake connector
and gasket.
2. REMOVE CYLINDER HEAD COVERS

(See pages EM-69 , 60)
ENGINE M ECHAN ICAL -- Engine Tune-up
3. MEAS URE VALVE CLEARANCI:

(a) Set No. 1 cylinder to TDC/compression.
• Tum the crankshaft pulley and align its groove
with the "Q" mark on the No. 1 timing belt cover.
• Check that the valve lifters on the No. 1 cylinder
are loose and valve lifters on the No.6 cylinder are
tight.
If not, tum the crankshaft pulley one complete revolution.
(b) Measure the clearance of No. 1 (IN) and No.4 (IN) and
No. 1 (EX) and No.5 (EX) valves.
• Measure only those valves indicated in the figure.,
EX • Record · the measurements which are . out of
specification. They will be used later to determine
the required replacement shims.
IN
Valve clearance (Cold) :
Intake 0. 1 5 - 0.25 mm (0.0069 - 0.0098 �
Exhaust 0.20 - 0.30 mm (0.0079 - o.01 1 sti1J
EM2890
(c) Turn the crankshaft pulley 2/3 revolution (240° ) and

;: · ,3 · 6 6 · measure the clearance of No.3 (IN) and No.6 (IN) and
No.3 (EX} and No.6 (EX) valves.
;� ·.. · . . . . • Check that the valve lifters on the No. 3 cylinder

are l oose.
• Measure only those valves indicated in the fi gure.
IN
• Record the measurements which are out of
3 3 5 5 the required replacement shims.
EM2991
{d) Turn the crankshaft pulley 2/3 revolution (240 °) and

2 2· 44 measure the clea rance of No. 2 ON) and No.6 (IN) and
No.2 (EX) and No.4 (EX) valves.
EX • Check that the valve lifters on the No.2 cvlir{)
are loose. . ·
• Measure only those valves indicated in the figure.
IN
• Record the measurements which are out of
the req uired replacement shims.
2892
4. ADJUST VA LVE CLEARANCE ·

(a) Remove the adjusting shim.
• Tum the cranksh aft· (J ulle,y to. position the lobe on
the adjusting valve camshaft upward.
• Using S ST (A), press down the valve lifter and
place SST (8) between the camshaft and valve
lifter. Remove SST (A).
SST 09 248- 55 0 1 0
NOTE: Before pressing down the valve lifter, position the
notch toward the spark plug.
EM- 1 0 ENGINE M ECHAN ICAL - Engine Tune-up
• Remove t h e a dj u st i n g s h i m with a s m a l l
screwdriver and magnetic finger.
(b) Determine the replacement shim size by using the

following (Formula or Chart).
..
• Using a micrometer, measure the thickness of the
shim which was removed.
• Calculate the thickness of the new shim so the
valve clearance comes within specified value.
T ........ Thickness of shim used
A ........ Valve clearance measured
N ........ Thickness of shim new
Intake N = T + (A - 0.20 mm (0,0079 in.))
Exhaust N = T + (A - 0.25 mm (0.0098 in.))
• Select a new shim with a thickness as close as
possible to the calculated value.
NOTE: Shims are available in 1 7 sizes, in increments of .�
0.050 mm (0.0020 in.), from 2.500 mm (0.0984 in.) to
.
3.300 mm (0. 1 299 in.).
(c) Install a new adjusting shim.

• Place a new adjusting shim on the valve lifter.
• Using SST (A), press down the valve lifter and
r remove SST (B).
l:; >
.
- ;,,..
SST 09248-550 1 0 (
5. RECHECK VALVE CLEARANCE
6. INSTALL CYLI N DER HEAD COVERS

(See pages EM- 59, 60)
EM4537
7. INSTALL AIR INTAKE CONNECTOR

(a) Install a new gasket and air intake connector with the
four bolts and two nuts.
Torque : 1 80 kg-cm ( 1 3 ft-lb, . 1 8 N·m)
E N G I N E M ECHANICAL i-.' En'g ine Tune-.o p
(b) Install the air intake connector bracket mounting

bolts
. , (c) .: Install the throttle body bracket(s).

(cl) Connect the throttle position sensor connector.
(e) 1 Connect following hoses:
• No. 7 air hose
• (w/ EGa)
'EGR vacuum modulator hoses
• (w/ TWC) .
BVSV hose
• (w/ EGR)
VSV hose (for EGR)
(f) Connect the water by-pass hoses.
..
(gl (ex. MS RI-ID)
Connect the accelerator connecting rod.
(h) . Install the; PCV p.ipt:1: ,
\ -;��
C
EM- 1 2 ENGINE MECHAN ICAL - Engine Tune-up
(7M-GTE)
1. REMOVE ISC PIPE
{a} Disconnect the hoses from the ISC pipe.
(b) Rem ove 'the two bolts and ISC pipe.
2. REMOVE PCV PIP! WITH HOSES

(a) Disconnect the oxygen sensor wire from the two
clamp.
(b) Disconnect the No.4 PCV hose from the PCV pipe.
(t) Remove the two bolts.
(d) Disconnect the PCV pipe with hoses from the
cylinder head co.vars and thr�ttle body.
311
3. REMOVE INTAKE AIR CONN ECTOR

(a) Disconnect the air valve h ose from the intake air con
n ector.
(b) Loosen the clamp and remove the two bolts.
{c) Remove the intake air connector.
4. REMOVE IGN ITION COVER

(a) Remove the oil filler cap.
(b) Remove the five nuts and ignition coil cover.
5. REMOVE IGNITION COIL WITH BRACKET

(a) Disconnect the connector and ground strap.
(b) Remove the nut.
(c) Remove the No. 1 and No.2 high-tension cords from
the ignition coil and clamp.
(d) Remove the ignition coil with bracket and high-ten
sion cords.
(e) Remove the No. 1 and No.2 high-tension cords from
the spark plugs.
312
ENGINE MECHANICAL .:.:.,.:, Engine Tune-up EM-1 3
6. REMOVE CYLIND ER HEAD COVERS

(a) Remove the accelerator link.
(b) Disconnect the . No.3 PCV hose.
.· (c) Remove the cylinder head covers.
·· 7. M EASURE VALVE CLEARANCE

.(See step 3 ori page E M- 9)
8. · ADJ UST VALVE CLEARANCE

-csee •itep 4 on pages EM.1.9, 1 0)
9, flECH"ECK. VALVE CLEARANCE
1 0. INSTALL CYLIN DER H EAD COVERS

(See pages EM- 69, 60)
. '.1 ; 1'·1 . . INSTALL IGNITION COIL WITH BRACKET

·< c :c!a) · Install the· No. 1 and No.2 high-tension cords to spark
. p;lugs.
(b) Install the ignition· coil with' bracket and high-tension(
cord. (Se�"page IG- 1 -5) .
-
•"/
(c) Install the; No. 1 and No.2 high-tensiQn·tords to igni

tion coil �hd clamp.
(d) Install and torque the nut

Torque : 56 Kg-cm (48 in._- lb, 6.4 N·m)
NOTE: Do not over tighten the nut
(e) Connect the ground strap and connector.
1 2. INSTALL IGN ITION COIL COVER

(a) Install the ignition coil cover with the five nuts.
(b) Install the oil filler cap.
EM35tl1
EM- 1 4 _ ENGINE Ml:CHAN ICAl "".'" Engine. Ti.Jhe..;up .
1 3. INSTALL INTAKE AIR CONNECTOR

(a) Install ttie intake air connector to throttle body.
(b} Install and tighten the two nuts.
(c) Tighten the clamp.
(d) Connect the air valve hose to intake air connector.
1 4� INSTALL PCV PIPE WITH HOSES

(a) ·. · ·· install the PCV pipe with hoses to the throttle body
. and cylinder head covers.
(b) • Install and tighten the two bolts.
(c} Cpnnect the No.4 P CV h ose to the PCV pipe.
. . '(d) . C�nnect the oxygen sensor wire to the· two clamps.
EM33 1 1
•
1 5. INSTALL ISC PIPE
(a) Install the ISC pipe with the two bolts.
(b) Connect the hoses to the ISC pipe.
ENGINE M ECHANICAt.· � '·Erigirie Tune.;i.Jp'. EM-1 5
"Adjustin'g 'Slltm Selection Using Chart

INTAKE
Shim thickness mm (in.)

Shim Shim
Thickness Thickness
No. No.
02 2.500 (0.0984) 20 2.950 (0. 1 1 6 1)
04 2.550 (0. 1 004) 22 3.000 (0.1 1 8 1 )
06 2.600 (0.1 024) 24 3.050 (0. 1 20 1 l
08 2.650 (0. 1 043) 26 3 . 1 00 (0. 1 220)
10 2.. 700 (0. 1 063) 28 3.1 50 (0. 1 240)
Intake valve clearance (cold) :
0.1 5 - 0.26 mm (0.006 - 0.0 1 0 in.) 12 2.750 (0. 1 083) 30 3.200 (0.1 260)
Example: A 2.800 mm shim is Installed and the 14 2.800 (0. 1 1 02) 32 3.250 (0. 1 280)
measured clearance is 0.450 mm
16 2.850 (0. 1 1 22) 34 3 .300 (0. 1 299)
Replace the 2.800 mm shim with
shim No. 24 (3.050 mm). 18 2.900 ·(0. 1 1 42)
EM- 1 6 ENGINE M ECHANICAi,. - Engine Tune-up
Adjusting S him Selection U sing Chart

EXHAUST
. Mep,.,,ed
Cleef'lllll:e
Imm!
0.000 - 0.009
0.010 - 0.025
0.028 - 0.040
0.041 - 0.050
0.051 - 0.070
0,071 - 0.0110
0.091 - 0.100
0.101 - 0.120
0. 1 2 1 - 0.140
0.1'1 - 0.150
0.428 - o.
0.441 - 0.4
0.451 - 0.4
0.471 - 0.4
0.476 - 0.4
0.491 • 0.5
0.501 - O.!i
0.521 - 0.5
0.528 - 0.5
0.541 - 0.5
Shim thickness mm (in.}

Shim Shim Thickness
No. Thickness No.
02 2.500 (0.0984) 20 2.950 (0. 1 1 6 1 )
04 2.5 50 (0. 1 004) 22 3.000 (0. 1 1 8 1 )
06 2.600 (0.1 024) 24 3.050 (0.1 201 l
08 2.650 (0. 1 043) 26 3.1 00 (0.1 220)
10 2. 700 (0. 1 063) 28 3.1 50 (0. 1 240)
Exhaust valve clearance (cold) :
0.20 - 0.30 mm (0.008 - 0.012 in.) 12 2. 7 50 (0. 1 083) 30 3.200 (0.1 260)
Example : A 2.800 mm shim is Instal led and the 1 4 2.800 (0. 1 1 02) 32 3.250 (0. 1 280)
measured clearance is 0.450 mm 1 6 2.850 (0. 1 1 22) 34 3.300 (0. 1 299)
Replace the 2.800 mm shim with
shim No. 22 (3.000 mm). 18 2.900 (0. 1 1 42)
ENGINE MECHANICAL .;.;. Engine Tune-up'
I NSPECTION AND ADJUSTMENT OF

IGNITION TI M ING
1. WARM. UP ENGINE
Allow the engine to reach normal ope.rating temperature.
2. CONNECT TACHOMETER AND TIMING LIGHT TO

ENGINE
Connect the tachometer positive terminal to the check
connector terminal IG e.
CHECK CONNECTOR LOCATION:
• ·See pages Fl-1 1 0, 1 1 1
CAUTION:
• Never allow the tachometer terminal to touch
ground as it could result in damage to the igniter
and/or Ignition coil.
• As some tachometers are not compatible with this
ignition system, we recommend that you confirm
the . compatlbUity of your unit before using.
NOTE (7M-GTE) : Connect the timing light pickup to t
No.6 cylinder high-tension corcl.
3. CHECK IGNITION TIMING

(a) Using a service wire, short terminals T{MA) or
TE 1 (MS) and E1 of the check connector.
CHECK CONNECTOR LOCATION.:
See pages Fl- f 1 0, 1 1 1 .
(b) Check the idle speed.
Idle speed:
7M-GE w/ TWC 700 rpm
w/o TWC 800 rpm
7M-GTE 800 rpm
(c} Using a timing light, check the ignition timing.
Ignition timing: 1 0° BTDC @ idle
[w/ short-circuited T (TE1) and E1
and Transmission in "N" range] {
If necessary, loosen the distributor (7M-GE) or cam pos't�/
tion sensor (7M-GTE) bolt and turn the distributor (cam
position sensor) to align the marks. Recheck the timing
- after tightening the distributor (cam position sensor).
Torque: 1 40 kg-cm (1 0 ft-lb, 1 4 N·m)
IG0808
(d) Unshort the check connector:..

EM- 1 8 ENGINE MECHAN ICAL - Engine Tune-up
4. FURTHER CHECK IGNITION TIM ING

Check that the ignition timing advances.
Ignition timing :
7M-GE .. 1 0 -· ·1 3" BTDC @ idle
7M-GTE More than 1 2 ° BTDC @ idle
6. DISCONNECT TACHOMETER AND TIM ING LIGHT

FROM ENGIN E
�INSPEC:T IO·N. AN D ADJUSTM ENT OF--·I DLE
M IXTURE (w/o TWC)
1. INITIAL CONDITIONS
(a) Air cleaner ,installed
.. (b) Normal engine operati ng temperature
(c) All pipes and hoses of air intake system connected
(d-) All accessqries switched off
'(e) All vacuum lines properly connected
(f ) EFI system -'w1rih{f connectors f�lly plugged ·
:·· "(g ) i.g njtip� timing �et correctly
(h) Transmission.Jn..N ran g e
2. WARM · UP ENGINE ·
Allow · the engine i& iV�'� f rio�mal operating temperature.
k
CON Nl:CT TACHOM ETER TO ENGINE

(See page E M.- 1 7)
- � CH ECK IDLE SPEED

Idle speed: 800 rpm
5. INSPECT AN D ADJUST IDLE CO CONCENTRATION

. CAUTIO N :
• Alw ays use a C O met�r., when adju.sting the idle mix
ture. It is not necessary to adjust with the idle · mix
ture adjusti ng screw - in. most vehicles if they are in
good condition. If a CO meter is not available, DO
NOT ATTEMPT TO ADJ UST WITH THE SCREW.
• If a CO meter is not available and it is absolutely
necessary to adjust with the idle mixture adjusting
screw, or if the air flow meter is replaced, use the
alternative method.
A. METHOD WITH CO METER

Tachometer
(al Check that the· CO meter ts properly calibrated.
(b) Race the engine for approx. 1 20 seconds at appr<r '-
2, 500 rpm before measuring the concentration. �" .;1
(c) Wait 1 - 3 minutes after racing the engine to allow

rpm_
the concentration to stabilize.
1 20 Seconds
EC0163
(d) Insert a testing probe at least 40 cm (1 .3 ft) into the

tailpipe, and measure the concentration with a short
time.
Idle CO concentration : 1 .0 ± 0.6 %
EM2883
EM-20 ENGINE M ECHANIC.AL ....; . Engine Tune-up
If the CO concentration is not as specified, adjust the idle

mixture by turning the idle mixture adjusting screw with
SST.
SST 09243:00020
· • If the CO concentration is within specification , thi s
adjustment· is complete.
• If the CO concentration cannot be corrected by idle
mixture adjustment, see the table below for other possi
. . ble causes.
EM2884
Troubleshooting
, . .,
HC co SYMPTOMS CAUSES
: ' .
High Normal Rough idle · 1 . Faulty ignition :

• Incorrect timing
..- 1 �· • Fouled, shorted or i mproperly gapped plugs
,.
• Open or crossed high-tension cords
• Cracked distributor cap
2. Incorrect valve clearance
3. Leaky EGR valve
4. Leaky intake and exhaust valves
5. Leaky cylinder
High Low Rough idle 1 . Vacuum leak:
• Vacuum hose
(Fluctuating HC reading) • EGR valve
• Intake manifold (Air intake chamber)
• Throttle body
• Cylinder head gasket .
• Brake booster line
2. Lean mixture causing misfire
High High Rough idle 1 . Restricted air filter
2. Faulty .EFI system ;
(Black smoke from exhaust) • Faulty pressure regulator
• Clogged fuel return line
· • Faulty air flow meter
• Defective water temp. sensor
• Defective air temp. sensor
• Faulty ECU
• Faulty injector
• Faulty cold start injector
• Faulty throttle position sensor
ENGINE MECHANICAL - Engine Tune-up
(e)
.
Reinstall .t he rubber plug into the hole of the idle mix
ture adjusting screw.
EM288
B. ALTERNATIVE METHOD
NOTE:
• This method is to be used ONLY .when it is absolutely
necessary to adjust the idle mixture screw or If the air
flow meter is replaced without the aid of a CO meter. ·
• The ·inscribed number shows the depth of the idle mix
ture screw positioned for prese"-1ng.
Example: Inscribed number depth
83 - 8.3 mm (0,326 in.)
Depths over 1 0 mm with a decimal point are abbreviated.
Example: Inscribed number depth
1 & - 1 1 .6 mm (0.4&3 In.)
8.3 mm
l:M2881.1
87
(a) Remove the rubber plug from the air flow meter.
. (b} Measure the depth of
the idle mi�l.ifljt adjustin9
screw with vernier calipers;
(cl Adjust the depth of idle mixture adjusting screw by

turning the screw With SST.
SST 09243-00020
(d) Reinstall the rubber plug into the hole of the idle mix
ture adjusting screw.
EM-22 ENGINE MECHANICA L - E'n gine Tune-up
I NSPECTION OF I DLE HC/CO

CONCENTRATION (w/ TWC)
NOTE: This check method is used only to determine
whether or not the idle HC/CO complies with regulations.
1. INSTALL CON DITIONS

(a) Air cleaner installed
(b) Normal engine operating temperature
(c) All pipes and hoses of intake system connected
(d) All accessories switches off
(e) All vacuum lines properly connected
NOTE: All vacuum hoses for EGA system etc. should be
properly connected
(f) EFI system wiring connectors fully p!ugged
(g) Ignition timing set correctly
(h) Transmission in "N" range
0) Tachometer and HC/CO meter at hand and calibrated
2. WARM UP ENGINE
Allow the . engine to reach normal operating temperature.
3. CONNECT TACHOMETER TO ENGINE

(See page EM- 1 7)
4. CH ECK IDLE SPEED

Idle speed :
. 7M-G E 700 rpm
7M-GTE 800 rpm
5. CH ECK OXYGE N SENSOR OPERATION .

(a) Using a service wire, sh ort terminals T and E1 of the
check connector.
CHECK CONNECTOR LOCATI O N : S e e page Fl- 1 1 0
(b) Connect the positive (+) probe of a voltmeter to ter

minal VF of the check conne.ctor, and negative ( - )
probe to terminal E 1 .
(c) Hold the engine speed at 2,500 rpm for approx. 2
m inutes.
(d) Then, maintaining engine at 2,500 rpm, count how
many times needle of voltmeter fluctuates between O
and 5 V.
Minimum needle fl uctuation :
8 times for every 1 0 seconds
If the fluctuation is less than minimum, check the air
induction system for leakage. If necessary, see EFI
SYSTEM.
ENGINE .MECHANICAl. � Engi'ne Tune-t.lp
6. , RACE ErJ.GINE AT 2, 500 RPM APPROX. 2 MINUl'ES.·,
. 7. INS�RT TESTING PROBE OF HC/CO METER INTO TAIL

PIPE AT 40 cm (1.3 ft)
8. MEASVRE HC/CO CONCENTRATION AT IDLE

Wait ·'at lest one minute before measuring to allow the
concentration to $tabilize.
Complete the measuring within .three minutes.
Idle CO concentration : 0 - 0.6 %
If the. CO/H C concentration does not conform to your
regulations, see the table in page EM- 20 for possible
cause,.
I .
.
f
EM-24 ENGINE M ECHANICAL - Engine Tune-up

' .
I NSPECTION AND ADJUSTM ENT OF DASH

POT ,(DP) SYSTEM
1 . WARM UP ENGINE
2. CONNECT TACHOMETER TO ENGINE

(See page EM- 1 7)
3. CHECK IDLE SPEED
7M-GE 4. INSPECT AND A DJUST DP SETTING .SPEED

DP Diaphragm
(a) Maint1:1in the engine speed at 3,000 rpm.
(b) Pinch the vacuum hose between the DP and VTV.
7M-GTE
rottle Valve
IIP Diaphragm
�
EM.2889
351
(c) Release the throttle valve.

(d) Check that the DP is set.
DP setting speed : 2,000 rpm
7M-GTE
ENGINE M ECHANICAL . - Engine Tune.;.up
7M-GE Jf not at specified speed, adjust with· the DP aajustirig1

screw.
7M�GTE
EM2896
EC 362
5, ·. CHECK OPERATION OF VTV

(a) Set the DP speed in the same procedure as above; (a)
to (c).
(b} Release the pinched hose and check that the engine
returns to idle speed in a pprox. 1 second.
,7M-GTE
EM289
EC23
/
EM-26 ENGINE MECHAN ICAL - Compression Check
COM PRESSION CHECK

NOTE: If there is lack of power, excessive oil consump
tion or poor fuel mileage, measure the cylinder compres
sion pressure.
(7M-G E)
1. WARM UP ENGINE
2. DISCONNECT COLD START INJECTOR CONNECTOR
3. DISCONN ECT SOLENOI D RESISTOR CONNECTOR
4. D ISCONNECT DISTRIBUTOR CONNECTOR
5. REMOVE THROTTLE BODY

(a) Remove the PCV hose.
(b) Disconnect the water by-pass hoses and plug the
hose end.
(c) Disconnect following hoses :
• {w/ EGR)
VSV hoses
• (w/ TWC)
BVSV hoses
• (w/ EGR)
EGR vacuum modulator hoses
• No. 7 air h ose
{d) Disconnect the throttle position sensor connector.
{e) Remove the throttle body bracket (s) .
(f) Remove the four bolts, throttle body and gasket.
6. REMOVE SPARK PLUGS (See page IG-7)
7. CHECK CYLINDER COMPRESSION PRESSURE

(a) Insert a compression gaug e into the spark plug hole.
(b) While cranking the engine with the starter motor,
measure the compression pressure.
NOTE: Always use a fully charged battery to obtain an
engine revolution of more tharl 250 rpm.
(c) Repeat steps (a) through (b) for each cylinder.
Compression pressure:
1 1 .0 kg/cm2 ( 1 56 psi, 1 ,079 kPa} or more
M inimum pressure :
9.0 kg/cm2 (1 28 psi, 883 kPa)
Difference between each cylinder:
1 .0 kg/cm2 (1 4 psi, 98 kPa) or less
(d) If cylinder compression in one or more cylinders is
low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat steps
(a) through (b) for the cylinder with low compression.
• If adding oil helps the compression, chances are
that the piston rings and/or cylinder bore are worn
or d amaged.
• If pressure stays low, a valve may be sticking or
seating improperly, or there may be l eakage past
ENGINE M ECHANICAL --: CofTlpression Cl:)eck
(7M -GTE)
1. WARM UP ENGINE
2. DISCONNE�T SOLENOID RESISTOR CONNECTOR
3. DISCONNECT CAM POSITION SENSOR CON NECTOR
F5129
4. REMOVE NO. 1 AIR CLE·ANER HOSE
5. REMOVE PCV PIPE
6. REMOVE IGNITION COIL

(See steps 41 6 on page E�-1 2)
7, REMOVE SPARK PLU GS (See page IG- 1 2)
8. . CHECK CYLINDER COMPRESSION PRESSURE

(See step 7 on page EM-26)
Compression pressure:
1 0.0 kg/cm2 ( 1 42 psi, 981 kPa) or more
Minimum pressure:
9.0 · kg/cm2 ( 1 28 psi, 883:,.kPa)
Difference between each cylinder:
1 .0 kg/cm2 ( 1 4 psi, 98 kPa) or less
EM-28 ENGINE M ECHAN ICAL; ..:. Timing Belt
T I M I NG e·e·LT
COM PONENTS
Timin Belt
Camshaft Timing Pulley
No. 3 Timing Belt Cover
Oil Pump Drive Pulley

Crankshaft T ming Pulley
2,700 {1 96, 265)

Crankshaft Pulley
I kg-cm (ft-lb, N·m� : Specified torque EM300I
REMOVAL OF TIMING BELT

1. REMOVE SPARK PLUGS
2. REMOVE WATER OUTLET

Remove the · two bolts, water outlet and . thermostat with
gasket.
3. (with A/CJ
REMOVE A/C BELT
4. REMOVE FAN AND ALTERNATOR D RIVE BELT

5. REMOVE PS BELT
ENGINE M ECHANICAL , ;... Timi"ng Belt
6, REM OVE N0.3 TIMING BELT COVl:R

Remove the five bolts, nut and No.3 timing belt cover with.
the gasket.
EM4578
7. SET N0.1 CYLINDER TO TDC/COM PRESSION

(a} Turn the crankshaft pulley and align its groove with
the "O" mark on the No. 1 timing belt cover.
(b) Check that the matchmarks on the camshaft timing

pulleys an� No.2 timing belt cover are align�d.
If not, turn t he crankshaft pulley one complete revolution.
llM3018
8, . REMOVE TIM I N G . BELT FROM CAMSHAFT TIMING

PULLEYS
NOTE: If reusing the timing .belt draw a direction arrow
on the belt On direction of engine revolution).
(a) Loosen the idler pulley bolt a.nd shift it left as far as it
will g o with a screwdriver and wrench.
(b) Temporarily tighten the set bolt and then relieve the
timing belt tension.
(c) Remove the belt from the camshaft timing pulley.
EM 004
EM- 30 ENGINE MECHANICAL - Timing Belt
NOTE:
• Support the belt so the meshing of the crankshaft tim
ing pulley and timing belt does not shift.
• Be careful not to drop anything inside the timing belt
cover.
• Do not allow the · belt to come into contact with oil,
water and dust.
EM3032
9. REMOVE CAMSHAFT TIMING PULLEYS

Using SST to hold the pulley, remove the pulley bolt, tim
ing pulley and match pin.
SST 09278-540 1 2
CAUTION: Do not make use of the timing belt ten
sion when removing and installing the pulley set bolts.
1 0. REMOVE CRANKSHAFT PULLEY

(a) Using SST to hold the crankshaft pulley, loosen the
pulley bolt.
SST MA 092 1 3-700 1 0 and 09330-000 2 1
M S 092 1 3-540 1 4 and 09330-0002 1
(b) Remove SST and pulley bolt.
(c) Using SST, remove the pulley.

SST 092 1 3-31 021
1 1 . REMOVE PS AIR PIPE
1 2. REMOVE NO.1 TIMING BELT COVER

(with A/C)
Remove the nine bolts, nut, A/C idler pulley bracket, com
pressor bracket and No. 1 timing belt cover.
(without A/C)
Remove the six bolts, No. 1 timing belt cover.
1 3 . REMOVE TIMING BELT
1 4. REMOVE IDLER PULLEY AND TENSION SPRING

ENGINE MECHAN ICAL - Timing Belt
1 5. REMOVE CRAN KSHAFT TI MING .PULLEY

Using SST and a . socket wrench, remove the crankshaft _
timing pulley.
SST 092 1 3-600 1 7
1 6. REMOVE OIL PUMP D RIVE PULLEY

Using a screwdriver to hold the pulley, remove the pulley
bolt and pulley.
F5823
I NSPECTION OF COMPONENTS
1; INSPECT TIMING BELT
CAUTION :
• Do not bend 1 twist or turn the belt inside out.
• Do not allow the belt to come into contact with oil,
water or steam.
• Do not utilize belt tension when installing or remov
in'g the set bolt of the camshaft timing pulley.
EM0128
If there are defects as shown in the figures. Check the

following points and replace the timing belt if necessary.
(a) Premature parting
• Check for pro per installation.
• Check the . timing belt cover gasket for damage
and proper insta llation.
�
EM0127
(b} If the belt teeth are cracked or damaged, check to

see if the camshaft is locked.
E.M0128
EM-32 ENGINE M ECHANICAL - Timing Belt
(c) If there is noticeable wear of cracks on the belt face,

check to see if there are nicks on one side of the idle r
pulley lock.
EM0129
(d) If there is wear or d amage on only one side of the

belt, check the belt guide and the alignment of each
pulley.
EM0130
{e) If there is noticeable wear on the belt teeth, check the

.timing belt cover gasket for damage and check for
foreign materials on the pulley teeth.
EM0131
2. IN SPECT IDLER PULLEY

Check the turning smoothness of the timing belt idler
pulley.
lf necessary, replace the idler pulley.
t,
3. INSPECT TENSION SPRING
Check the free length of the spring.
-
69 mm � Free length: 69 mm (2. 72 in.)
If not as specified, replace the spring .
EM29 10
ENGINE M ECHANICAL - Timing Belt
I N STALLATION O F TIMING BELT

(See page EM- 28)
1. INSTALL O I L P U M P PULLEY
· Using a screwdriver to hold the pulley, i nstall and torque
the pulley bolt.
Torque: 220 kg-cm (1 6 ft-lb, 22 N•m)
F5623
2. INSTALL CRAN KSHAFT TIMING PULLEY

Using SST and a hammer, drive in the pulley.
SST 092 1 4- 600 1 0
EM2912
3. TEMPORARILY I NSTALL I D LER P ULLEY AND

TENSION SPRING
(a) Install the idler pulley and tension spring.
(b) Pry the pulley toward the left as far as it will go and
temporarily tighten it.
NOTE: Remove any . oil or water on the idler pulley and
keep it clean.
EM2913
4. TEM PO RARILY INSTALL TIMING BELT

CAUTIO N : The engine should be cold.
NOTE: If reusing the timing belt, install it with the rota
tion direction m ark pointing in the same direction as
before disassembly.
Install the timing belt on the crankshaft timing pulley, oi l
pump drive pulley and idler pulley.
EM3037
6. I NSTALL NO.1 TIMING BELT COVER

(with A/C)
Install the No. 1 timing belt cover, A/C compressor bracket
and idler pulley bracket with the nine bolts and nut.
(without A/C)
Install the No. 1 ti ming belt cover with the six bolts.
6. INSTALL PS AIR PIPE

EM- 34 ENGINE M ECHANICAL --. Timing Belt
7. INSTALL CRAN KSHAFT PU LLEY

(a) Align thQ pulley · set key with the key groove of the
pulley.
(bl Install the pulley.
(c) Using SST to hold the crankshaft pulley, install and
torque the pulley bolt.
SST MA 092 1 3-700 1 0 and 09330-0002 1
MS 092 1 3-540 1 4 and 09330-0002 1
Torque: 2,700 kg-cm (1 95 n-lb, 265 N·m)
8. SET NO. 1 CYLINDER TO TDC/COMPRESSION OF

CRAN KSHAFT
Turn the crankshaft pulley and align its groove with the
"O" mark on the No. 1 timing belt cover.
9. INSTALL CAMSHAFT TIMING PU LLEYS

(a) Align the timing pulley matchmark with the No.2 tim-
ing belt cover matchmark.
(b) Install the timing pulley.
(c) Install the pin into the middle hole.
NOTE :
• When replacing the camshaft or the · camshaft timing
pulley:
Align the center holes of the camshaft and timing
EM3023 pulleys, as shown in the illustration and insert the
straight pin.
• When reusing the camshaft or camshaft timing pulleys:
C heck that the straight pin hole position is in the same
position it was at disassembly, insert the straight pin.
(d) Install the pulley bolt.
(e) Using SST to hold the pulley, torque the pulley bolt.
SST 09278-540 1 2
Torque : 500 kg-cm {36 ft-lb, 49 N·m)
(f) Check that the matchmarks on the camshaft timing
pulley are aligned with those on the No.2 timing belt
cover.
EM3024
ENGINE M ECHANICAL - Timing Belt
1 0. INSTALL TIMING BELT

(a} Install the timing belt to the IN side and EX side.
(b} Loosen the idler pulley bolt, and torque the idler
pulley bolt.
Torque: 500 kg-cm (36 ft-lb, .49 N ·m)
EM3005
NOTE: Make sure that the timing belt tension at A is

equal to that at B.
If not, readjust with the idler pulley.
(c} Tum the crankshaft pulley two revolutions clockwise
frorn TDC to TDC.
(d} Check that the matchmark on the camshaft timing
pulley are aligned with those on the No.2 timing belt
cover.
EM29l6
1 1 . CHECK TIMING BELT TENSION

(al Tum both the intake and exhaust camshaft pulleys
inward at the same time to slacken the timing belt at
position A.
Turning torque : 200 kg-cm (1 4 ft-lb, 20 N·m)
.,.
(b} Measure the timing belt deflection as show,n.
2 - 3 kg �
1 Belt deflection at 2 - 3 kg (4.4 - 6.6 lb, 20 - 29 N) :
Cold Used belt 5 - 7 mm (0.20 - 0.28 in.)
--� New belt 4 - 6 mm (0. 1 6 - 0.24 in.)
Hot (Reference) 3 - 6 mm (0. 1 2 - 0.20 in.)
If the measurement is not within specification, adjust by
the idler pulley.
EM3046
1 2. INSTALL NO.3 TIM IN G BELT COVER

Install a gasket and the belt cover with the five bolts and
nut.
1 3. INST ALL PS BELT
EM4S78
EM-36 ENGINE MECHANICAL -:- Timing Belt
1 4. INSTALL ALTERNATOR DRIVE BELT AND FAN

· Torque : Fan 66 kg-cm (48 ln.-lb, 6.4 N·m)
Ad}usting bolt 1 30 kg-cm (9 ft-lb, 1 3 N•m)
1 6. (with A/C)
INSTALL A/C BELT
1 6. INSTALL WATER OUTLET

Install the thermostat with a new gasket and water o utlet
with the two bolts.
1 7. INSTALL SPARK PLUGS

(See page IG• 7)
1 8. ADJUST D RIVE BELTS

Install and adjust the drive belts.
· Alternator Drive belt deflection with 1 0 kg or 22 lb :
New belt
Water A 1 0 - 1 2 mm (0.39 - 0.47 in.)
Pump B 7 - 8 mm (0.28 - 0.31 in.)
C MA 7 - 9.5 mm (o.2s· - 0.374 in.)
MS 7 .5 - 9.5 mm (0.295 - 0.374 in.)
Used belt
A 1 5 - 1 7 mm (0.59 - 0.67 in.)
B 9 - 1 1 mm (0.36 - 0.43 in.)
C MA 1 0.6 - 1 2 mm (0.41 3 - 0.47 in.)
000
MS 1 0 - 1 3 mm (0. 39 - 0.51 in.)
(Reference)
SST B Using SST, check the drive belt tension.
SST A 0921 6-00020
SST B 09 2 1 6-00030
Drive belt tension :
New belt A 70 - 80 kg
B 66 - 65 kg
C 53 - 7 7 kg
Used belt A 30 - 45 kg
B 25 - 40 kg
EC0003 EC0004 C 30 - 40 kg
NOTE:
• "New belt" refers to a belt which has been used less
than 5 minutes on a running engine.
• "Used belt" refers to a belt which has been used on a
running engine for 5 minutes or more.
• After installing the drive belt, check that it fits properly
in the ribbed grooves.
CORRECT WRONG WRONG • Check by hand to confirm that the belt has not slipped
out of the groove on the bottom of the crank pulley.
CH0088
• After installing the belt, run the engine for approx. 6
minutes and then recheck the deflection.
. ENGINE MECHANICA� -- . Cyli!1d$r .Head .
CYLINDER HEAD
COMPONENTS
7M-GE
No. 2 Cylinder Head

Cover
No. 3 Cylinder Head---- 1-----No. 1 Cylinder Head Cover

Cover
· --------Camshaft Bearing Cap

�....
ifold . · . -------Camshaft
♦ Oil Seal --Q) · Adjusting· Shim
l'llll.1,L,_�..,-
N_
· Seal � · ==Valve Lifter
--- ···· Valve Keepers
--
i1',._---Valve Spring Retainer
::..✓.:.�
· Valve Spring
ii-
♦ Valve Stem Oi l Seal
!'
@}----- Valve Spring Seat
�'-------Valve Guide Bushing
♦ Snap Ring
800 (1$8, 78) ------Valve
' 1-----------....,,.-~No. 2 Engine Hanger
�
Wot"! Outlet
Housing . @ ---EGR Cooler
I
♦ Gasket
♦ Gasket
No. 2 Timing Belt
Cover
Air Intake Chamber

with Connector
♦ Gasket
Alternator Bracket -------�
�
♦ Gasket ----------�
I kg-cm (ft-lb. N•m)! : Specified torque Intake Manifold

♦ Non-reusable part 1 80 (13, 1 81
EM-38 ENGINE MECHANICA L - Cylinder Head
COM PONENT$ (Cont'd)
7M-GTE
ISC Pipe
PCV Pipe
No. 2 Cylinder Head Cover

--- Heater Hose Clamp
-\----No. 1 Cylinder Head Cover

No. 3 Cylinder Head ----4i�
Cover
Turbocharger
Exhaust
Manifold
Heat ---
lnsulator
' 'C
�,J
7
�
Auxiliary
Exhaust Air Pipe
Manifold
Stary
Water Outlet
Housing
No. 2 Timing � ♦ Gasket

Belt Cover _
v
/
Alternator Bracket
♦ Gasket
Air Intake Chamber

with Connector
Intake Manifold
I kg-cm (ft.lb, N·mll : Specified torque 1 80 (1 3, 1 8)
♦ Non-reusa ble part

M3!l59
EN GIN E MECHAN ICAL - Cylinder Head EM-39
REMOVAL OF CYLIN DER HEAD

(See pages EM-37. 38)
1. REMOVE A LTERNATOR
(a) Disconnect the No.3 PCV hose.
(b) Remove the drive belt.
(c) Remove the alternator and adjusting bar.
2. (7M-GTE)
REMOVE PS RESERVOIR TAN K
Remove the two bolts, nut and. reservoi r tank with bracket.
3. (7M-GTE) .
REMOVE CAM POSITION SENSO R
4. · REMOVE AIR INTAKE CHAM BER WITH CONNECTOR

(a) Remove the PCV pipe. ·
(b) Disconnect following connectors:
• (7M-GE)
Cold start injector connector
• Th rottle p osition sensor connector
• ISC valve connector
(c) Disconnect following hoses:
• BVSV h ose from throttle body
• EGR hoses from throttle _ij_pdy ··
• Vacuum transmitting pipe hose from intake cham-
ber
• P ressur� regulator hose
• VSV (for · fuel . press�re up) h?ses
• (7M-GE)
Diaphragm hose
( (d) Disconnect following hoses:
• (7 M-GTE)
Auxiliary air pipe hose from vacuum transmitting
pi pe hose
• No. 1 water by-pass hose from ISC valve
• (7M-GE)
No.3 water by-pass hose from throttle body
• (7M-GTE)
No.3 water by-pass hose from water by-pass pipe
(e) (w/ EGR)
Remove the EGR pipe m ounting bolts.
(f) Remove the manifold stay mounting bolts.
EM-40 ENGINE MECHANICAL -· Qylinder Head
(gl (7M-GE)
Removt!. the throttle body bracket(s).
(7M-GTE)
Remove the ISC pipe.
(h) (7M-GTE)
Remove the air intake connector m ounting bolt.
(i) {7M-GE)
Remove the air intake connector bracket mounting
bolts.
(j) Remove the cold start injector tube.
(k} Remove the EGR vacuum modulator from the
bracket.
0) Disconnect the engine wire from the clamps of intake
chamber.
(m) Remove the two nuts, five bolts, vacuum transmitting
pipes and intake chamber with connector and gasket.
(n) (7M-GTE)
Disconnect the cold start injector connector.
5. (7M-GTE)
REMOVE IGN ITION COIL WITH BRACKET
(See steps 6 and 6 on pages EM- 1 2, 1 3)
\
ENGINE M ECHANICAL - Cylinder Head
6, REMOVE ENGINE WIRE

(a) Disconnect following wires:
• (w/ TWC)
Oxygen sensor connector
• Oil pressure sender gauge connector
• Water temp. sensor connector
• Water temp. send.er gauge con�_ector
• Cold start injector time switch connector
• Distributor connector
• Injector connectors
• Three VSV connectors
• Knock sensor connectors
• Ground strap from intake manifold
(b) Remove the engine wire from the each clamps.
7. REMOVE PULSATION DAMPER, VSV AND NO, 1 FUEL

PIPE
8. · REMOVE N O.2 FUEL PIPE

(a) Disconnect the fuel hose from the No.2 fuel pipe.
( (b) Remove the bolt, · union bolt, No.2 fuel pipe and
gaskets.
9. (7M•GTE)
REMOVE AUXILIARY AIR PIPE
1 0. (7M-GE}
REMOVE HIGH-TENSION CORDS AN D DISTRIBUTOR
1 1 . (7M-GE}
REMOVE OIL DIPSTICK
1 2. (7M-GTE}
REMOVE TURBOCHARGER
------�------:2
EM::=.:
au =2 (See steps 6 to 7 and 9 to 1 6 on pages TC- 1 0 -to 1 2)
E M-42 ENGINE M ECHANICAL - Cylinder Head
1 3. REMOVE EXHAUST MANIFOLD

(a) (7M-GTE)
Remove the five nuts and heat i nsulators.
(b) (7M-GTE)
Remove the three bolts and exhaust manifold stay.
(c) Remove the seven nuts, exhaust manifold and

gasket.
1 4. REMOVE WATER O UTLET HOUSING

(a) (7M-GE)
Remove the union bolts, union with No.4 water by
pass hose and gaskets.
(b) Disconnect the No.6 water by-pass hose from the
water by-pass pipe.
(c) Remove the bolt, two nuts, water outlet housing and
gasket.
EM3025
ENGINE MECHANICAL - Cylinder Head
1 6. REMOVE CYLIN DE R HEAD COVERS

(a} (LHD}
Remove the accelerator link.
(b) (MA) .
Remove the heater hose clamp.
(c) Remove the No. 1 and No. 2 cylinder head covers.
(d) Using SST, remove the No.3 cylinder head cover.

SST 09923-000 1 0
1 6. REMOVE SPARK PLUGS

(See page IG-7)
1 7. REMOVE TIMING BELT AND CAMSHAFT TIMING
PULLEYS
(See steps 4 and 6 to 9 on pages EM-28 to 30)
1 8. REMOVE CYLINDER H EAD

(a) Using SST, uniformly loosen and remove th�" ;ylinder
head bolts in several passes, in the sequence shown.
SST 09043-38 1 00
CAUTION : Head warpage or cracking could result
from removing in incorrect order.
EX
lN
EM2921
EM2922
(b) lift the cylinder head from the dowels on the cylinder
block.
(c) Place the head on wooden blocks on a bench.
If the cylinder head is difficult to lift off, pry with a
screwdriver between the cylinder head and block projec
tion.
CAUTION :
• Be careful not to damage the cylinder head and
b lock surface on the cylinder and head gasket side.
• Be careful not to damage the VSV.
DISASSEMBLY O F CYLI N DER HEA D
(See pages EM R31,. 38)
1. REMOVE N0.2 TIMING BELT COVER
2. REMOVE ALTEJINATOR BRACKET
3. REMOVE DELIVERY PIPE WITH INJECTORS

(a) Remove the three bolts, and then remove the delivery
pipe with the injectors.
NOTE: When removing the delivery pipe, be careful not
to drop the injectors.
(b) t=lemove .the six insulators and three spacers from the
cylinder head.
EM2924
. 4. REMOVE INTAKE MANIFOLD

(w/ EGR)
· Remove the four nuts, seven bolts, EGR valve, VSV, intake
manifold and gasket.
(w/o EGR)
Remove the four nuts, seven bolts, VSV, intake manifold
and gasket. ·
5. REMOVE N0.2 .ENGINE HANGER AND GRO U N D

STRAP
6. REMOVE HEATER U N IO N
7. (w/ EGR)
REMOVE EGR COOLER
8. REMOVE BEARING CAPS AND CAMSHAFTS

(a) Uniformly loosen and remove the bearing cap bolts in
several passes, in the sequence shown.
(b) Remove the camshaft bearing caps, oil seal and
camshaft.
EM2921
ENGINE MECHANICAL - . Cylinder' Head
9. REMOVE VALVE LIFTERS WITH SHIMS

Arra_nge the valve litt:ers and shims in ord�r.
ex o o o o o o o o o o o o
9 9 9 9 9 9 -99 9 9 9 9
es
IN O O
es ee ee
00 00 00 00 00
0 0 00
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
-11
1 O. REMOVE VALVES
(a) Using SST, press the valve spring and remove the
two keepers.
SST 09202-7001 0
(b) Remo.vs the spring retainer, valve spring, seat and
valve.
(c) Pry out the oil seal.
NOTE: · Arrange the valves, seats. valve springs and
retainers i n order.
INSPECTION, CLEANING AND REPAI R OF

CYLI N DER H EAD COM PONENTS
1. CLEAN TOP OF PISTONS AND TOP OF CYLIN DER
BLOCK
"·
(a} Tum the crankshaft and bring each piston to top
dead center. Using a gasket scraper, remove all the
' carbon from the piston tops.
(b} Using a gasket scraper, remove all gasket material
from the top of the block. Blow carbon and oil from
the bo lt holes.
WARNING : Protect your eyes when using high
pressure air.
2. REMOVE GASKET. MATERIAL
Using a gasket scraper, remove all gasket material from
the head and manifo ld surfaces.
CAUTION : Be ca reful not to scratch the surfaces.
ENGINE MECHANICAL -, Cylinder Head
3. CLEAN COMBUSTION CHAMBER

Using a wire..brush, remove all the carbon from the com
bustion chambers.
CAUTION: Be careful not to scratch the head gasket
contact surface.
4. CLEAN VALVE GUIDE BUSHINGS

Using a valve guide brush and solvent, clean all the valve
guide bushings.
l EM002S
5. CLEAN CYLINDER HEAD

Using a soft brush and solvent, thoroughly clean the head.
EM293
6. INSPECT CYLINDER HEAD FOR FLATINESS

Using a precision straight edge and feeler gauge, measure
the surface contacting the cylinder block and manifold for
warpage.
Maximum warpage : 0.1 0 m m (0.0039 in.)
If warpage is greater than maximum, replace the c;ylinder
head.
EM2933
EM2934
EM2935
EM2936
ENGIN E M ECHAN ICAL - Cylinder Head EM- 4 7
7. I NSPECT CYLIN DER H EAD FO R CRACKS

Using a dye penetrant, check the combustion chamber,
intake and -exhaust ports, head surface and the top of the
head for cracks.
If cracked, replace the head.
8. CLEAN VALVES
(a) Use a gasket scraper to chip any carbon from the
valve head.
(b) Using a wire brush, thoroughly clean the valve.
9. INSPECT VALVE STEMS AND GUIDE BUSHINGS

(a) Using a caliper gauge, measure the inside diameter of
the valve guide.
Guide inside diameter: 6.0 1 0 - 6.030 mm
(0.2366 - 0.2374 in.)
(b) Using a micrometer, measure the diameter of the

valve stem.
Stem diameter :
Intake 5.970 - 5. 985 mm
(0. 2350 - 0.2356 in.)
Exhaust 5.965 - 5.980 mm
(0.2348 - 0.2354 in.)
(c) Subtract the valve stem diameter measurement from
the valve guide bushing inside diameter measure
ment.
Standard stem oil clearance:
I ntake 0.025 - 0.060 mm
(0.001 0 - 0.0024 in. )
Exhaust 0.030 - 0.065 mm
(0.001 2 - 0.0026 i n.)
Maximum stem oil clearance:
I ntake 0.08 mm (0.003 1 in.)
Exhaust 0. 1 0 mm (0.0039 in.)
If the clearance is greater than maximum, replace the valve
and guide busing.
EM-48 ENGINE MECHANICAL .:... Cylinder Head
1 0. IF N ECESSARY, REPLACE VALVE GUIDE BUSHINGS

(a} Insert an old valve wrapped with tape into · the valve
guide bushing and break off the. valve guide bushing
by hilting .jt with a hammer.
CAUTION : Be careful not to damage the l ifter hole.
B6085
(b) Gradually .. heat th e cyli nder head to approx.

90 ° C(1 94° F).
EM2939
(c) Using SST and hammer, drive out valve guide bush
- ing.
SST 0920 1 - 700 1 0
ST
EM0630
(d) Using a caliper gauge, measure the valve. g uide bore

of the cylinder head.
EM2940
(e) · Select a new valve guide bushing.

If the valve guide bushing bore of the cylinder head is
Both intake and exhaust
. • ··, r· more than 1 1 .027 mm (0.4341 inJ, machine the bore to
Bushing bore mm (in.) Bushing size the following dimensions.
1 1 .000 - 1 1 .027 Rebored valve guide bushing bore dimension :
.. .:
(0.433 1 - 0.434 1 )
Use STD
1 1 .060 - 1 1 .077 mm (0.4360 - 0.4361 in.)
Over 1 1 .027
(0.434 1 )
Use 0/S 0.05
ENGII\IE MECHANICAL - Cylinder Head
(f) Gradually heat the cylinder head to approx'. "'90° C

(1 94°F).
SST (g) Using SST and hammer, drive in a new valve guide
bushing until the snap ring makes contact with the
cylinder head.
SST 0920 1 -700 1 0
Snap Ring
EM0632
(h) Using a sharp 6 mm (0.23 in.) reamer, ream the valve

guide bushing to obtain standard specified clearance
(See page EM-47) between the .valve guide bushing
and new _ valve.
EM0633
1 1 . INSPECT AN D GRIND VALVES

(a) Grind the valve only enough to remove pits and car
bon.
(b) Ch�ck that the valve are ground to the correct valve
face angle.
Valve face angle : 44. 5 °
- EM0254 EM0,80
(c) Check the valve head margin thickness.

Standard margin thickness : 1 . 3 mm (0.05 1 in.)
- Mi11imum margin thickness : 0. 5 mm (0.020 in.)
If the valve head margin thickness is less than minimum,
replace the valve.
EM01 8 1
(d) Check the valve overall length.

Standard overall l ength : 98. 1 5 mm (3.8642 in.)
Minimum overall length : 97. 75 mm (3.8484 in.)
If the valve overall length is less than minimum, replace
Overall Length the valve.
26062
EM-50 ENGINE MECHANICAL - Cylinder Head
(e)
.
Check the· surface of the valve stem tip for wear.
If the valve stem tip is worn, regrind it with grinder or re
place the valve if necessary.
CAUTION : Do not grind off more than minimum over
all le ngth (See page E M-49).
EM0373
1 2. INSPECT AN D CLEAN VALVE SEATS

(a) Using a 45 ° carbide cutter, resurface the valve seats.
Remove only enough metal to clean the seats.
(b) C heck the valve seating position.

Apply a thin coat of prussian blue (or white lead) to
the valve face. Install the valve. Lightly press the
valve against the seat Do not rotate the valve.
(c) Ch eck the valve face and seat for the following:
• If blue a ppears 3 6 0 ° around the face, the valve is
concentric. If not, replace the valve.
• If blue appears 360 ° around the valve seat, the
gu ide and seat are concentric.
If not, resurface the seat.
• C heck that the seat contact is on the middle of the
EM3026
valve face with the following width.

1 .0 - 1 .4 mm (0.039 - 0.065 in.)
If not, co rrect the valve seat as follows:
• If seating is too h ig h on the valve face use 30 ° a nd
45 ° c utters to correct the seat.
• If seating is too low on the valve face, use 60 °, and

45 ° cutters to correct the seat
ENGINE MECHANICAL - Cylinder Head
{d) Hand-lap the valve and valve seat with an abrasive

compound.
EM2942
1 3. INSPECT VALVE SPRINGS

Squareness
(a) Using a steel square, measure the squareness of the
valve springs.
Maximum square ness : 1 .6 mm (0.059 in.)
If squareness is greater than maximum, replace the valve
spring.
EM2590
{b ) Using calipers, measure the free length of the valve

spring.
Free length : 4 1 . 64 mm (1 .6394 in.) ·
If the free length is not within specification, replace the
valve spring.
81713
{c) Using a spring tester, measure the tension of the

valve spring at the specified installed length.
Installed tension :
1 6.0 kg (35 lb, 1 5 7 N) at 36.0 mm (1 .378 in.)
If the installed tension is not as specified, replace the valve
spring.
EM0281
1 4. INSPECT CAMSHAFT AND BEARING CAPS

(a) Place the camshaft on V-blocks and, using a dial
gauge, measure the circle runout at the center jour
nal.
Maximum circle runout : 0.03 mm (0.001 2 in.)
If the circle runout is greater than maximum, replace the
camshaft
EM2943
cM-52 ENGINE MECHANICAL - Cylinder Head
(b) Using a micrometer, measure the cam lobe height.

Standard ca,n lobe height:
I ntake
7M-GE MA 38.36 mm (1 .6 1 02 in.)
.MS 38.1 6 mm (1 .6024 in.)
7M-GTE 38.36 mm (1 .6098 In.)
Exhaust
7M-GE MA 38.36 mm (1 .&1 02 In.)
MS 38.3& mm (1 .6098 in.)
7M-GTE 38.36 mm (1 .&098 in.)
EM2101 Minimum cam lobe height:
Intake.
7M-GE MS 37 .86 mm ( 1 .4906 in.)
Others 38.00 min (1 .4961 in.)
Exhaust 38.00 mm (1 .4961 in.)
If the cam lobe height is less than minimum, replace the
camshaft.
(c) Using a micrometer, measure the journal diameter.

Standard diameter:
No. 1
26.949 - 26.966 mm (1 .06 1 0 - 1 .061 6 in.)
No.2 - No.7
26.888 - 26.976 mm (1 .0686 - 1 .0620 in.)
If the journa l diameter is less than specified, replace the
camshaft.
EM2591
1 6. I NSPECT CAMSHAFT OIL CLEARANCE

(a) Clean the bearing caps and camshaft journal.
(b) Place the camshaft in the cylinder head.
(cl Lay a strip of plastigage across each journal.
(d) Place the bearing caps with the top of the number on
4 the cap pointing toward the front and in numerical
7 6 3 5 2
order from the front side.
(e) Install and torque the cap bolts gradually in the
sequence shown in the figure.
Torque : 200 kg-cm ( 1 4 ft-lb, 20 N·m}
NOTE: Do not turn the camshaft while the plastigage is
i n place.
(f) Remove the caps and measure the plastigage at its
EM2927 widest point.
ENGIN'; "'1 ECHANICAL - Cylinder H�a.d
Standard oil clearance:

. No.1
0.035 - 0.072 mm (0.00 1 4 - 0.0028 In.)
No.2 .:. No. 7
0.025 - . 0.093 mm (0.001 O - 0.0037 In.)
Maximum ·oll clearance: .0 . 1 3 mm (0;0061' in.)
If clearance is greater than maximum, replace the cylinder
head and/or camshaft.
(g) Clean out the pieces of plastigage from the bearing
caps and journals.
1 6. INSPECT ·CAMSHAFT THRUST CLEARANCE

(a) Clean and install the camshaft and bearing caps.
(b) Using a dial gauge, measure ,the thrust clearance
while moving the camshaft back and forth.
Standard thrust clearance : 0.08 - 0.1 9 mm
(0.003 1 - 0.0076 In.)
Maximum thrust clearance : O.�O mm (0.01 1 8 In.)
If clearance is greater than· rriaxirrium, replace the
I' .•
camshaft and/or cylinder head.
1 7 . INSPECT VALVE LIFTER OIL CLEARANCE

· (a) Using a micrometer, measure the diameter of the
valve lifter.
Valve lifter diameter: 27 .976 - 27 .985 mm
(1 . 1 0 1 4 - 1 , 1 .0 1 8 In.)
(b) Using a dial indicator, measure the inside diameter of

the cylinder head bore.
Lifter bore diameter: 28.000 - 28,021 mm
(1 . 1 024 - 1 ,1 03Z In.)
(c) Subtract the valve lifter measurement from the
cylinder head bore.
St�ndard oil clearance: 0.01 6 - 0.046 mm
(0.0006 - 0.001 8 In,)
M aximum oil clearance : 0.1 mm (0.004 In.)
If clearance is greater than maximum, replace the cylinder
EM2947 head and/or valve lifter.
1 8, INSPECT INTAKE, EXHAUST MAN IFOLD AND

INTAKE CHAM BER
Using a precision straight edge and feeler gauge, check
the surfaces contacting the cylinder head · or irttake
manifold for warpage.
Maximum warpage:
Intake manifold 0. 1 0 mm (0,0039 in.)
Exhaust manifold 7 M-GE 0. 76 mm (0.0296 In.)
EM2948
7M -GTE 0.60 (0:01 97 Ir,.) mm
EM3570
EM2950
Intake chamber 0.1 0 mm (0,0039 i�.)
... .. ._ . . _,.._,.. ,, .._. . ",... ,..,, w ..,.. ,.,.,.,,d
EM-54 ENGINE MECHANICAL - Cylinder Head
INSPECTION OF I NTAKE AIR CONTROL

· SYSTEM (7M-GE only)
1. CHECK AIR CONTROL VALVE OPERATION
With 400 m mHg ( 1 5. 75 i n.Hg, 53.3 kPa} of vacuum
applied to the actuator, check ·that the control valve
moves smoothly to the fully closed position.
If not adjust with the adjusting screw.
2. C H EC K VACUUM TAN K BY BLOWING AIR I NTO

EACH PIPE
· (a} Check that air flows from pipe B to A.
(b) Check·that air does not flow from pipe A to B.
(c} Apply 500 mm Hg (1 9.6 9 i n.Hg, 66. 7 kPa) of vacuum

to pipe B and check that there is no change in
vacuum after one minute.
If there is a change, replace the vacuum tank.
EM::!95
3. CHECK VAC U U M CIRC U IT CONTIN U ITY I N T H E VSV

BY BLOWING AIR INTO PIPE
(a) Connect the VSV terminals to the battery terminals
as illustrated.
lb) Blow into pipe E and check that air comes out of the
pipe G.
<f>
Battery
e
EM:2954
(c) Disconnect the battery.

(d) Blow into pipe E and check that air comes o ut of the
air filter.
If a problem is found, replace the VSV.
EB
Battery
EM2955
ENGINE M ECHANICA.L - Cyllnder Head
ASSEMBLY OF CYLINDER HEAD

(See pages E M-37, 38)
NOTE:
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil to all
sliding and rotating surfaces.
• Replace all gaskets and oil seals with new ones.
1. INSTALL VALVES
(a) Insert the valves in the cylinder head valve guide
bushing. Make sure the valves are installed in the cor
rect order.
(b) Using SST, install new oil seals on the valve guide
bushings.
SST 09201 -41 020
(c) Install spring seats, springs and spring retainers.
EM2956
(d) Using SST, compress the valve retainers and place

two keepers around the valve stem.
SST 09202-700 1 0
(e) Tap the stem lightly to assure proper fit.
2. INSTALL VALVE LIFTERS WITH SHIMS

Make sure the valve l ifters with their shims are installed in
the correct order.
00 00 00 00 00
EX O O
99 9 9 9 9 9 9 9 9 9 9
00 00 00 00 0 0 00
IN 99 99 99 99 99 09
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
EM06 1 ?
3. INSTALL CAMSHAFTS AND OIL SEALS

(a) Apply engine oil to the lip of a new oil seal.
(b) Install the oil seal to the camshaft.
EM0050 EM2957
EM-66 . ENGINE MECHANICAL . - Cylinder Head
(c) Coat all bearing journals witt, engine oil.

(d) Place the camshafts on the cylinder head as shown in
the figur�!'
NOTE: The exhaust camshaft has a distributor (7M•GE)
or cam position sensor (7M-GTE) drive gear.
EM2999
(e) Apply seal packing to the areas indicated in the

figure.
C
�
Seal packing : Part No.08826-00080 or equivalent
NOTE: Install the No.1 beari ng cap immediately after
applying · the . seal packing.
EM2958
I : Intake (f) Place bearing caps on each journal with the front
No. 2 - No. 7
E: Exhaust marks pointing toward the front.
I: lntake
Front Mark E: Exhaust
EM2959
(g ) Tighten each bearing cap bolt a tittle at a time and in

the sequence shown in the figure.
7 6 1 4 3 5 2
EM2927
(h) Using SST� drive in a new camshaft oil seat.

SST 09223-500 1 0
NOTE: Be careful not to install the oil seal slantwise.
EM2960
ENGINE MECHANICAL - Cylinder Head EM-15.7
{I) Tighten the No.3 and No. 7 bearing cap bolts a little at
1 2 a time and in the sequence s hown in the figure.
(No. 3) (No. 7) Torque : 20.0 kg-cm (1 4 ft-lb, 20 N•m)
-- EM2927
ij ) Torque each bearing cap bolt a little at a time and in

the sequence shown In the figure.
5 4 2 1 3
Torque : 200 kg-cm ( 1 4 ft-lb, 20 N·m)
(k) Check the camshaft thrust clearance.
EM2927
4. (w/ EGR)
INSTALL EGR COO LER
Install a new gasket and EGR cooler with the eight bolts.
Torque : 1 40 kg-cm (1 0 ft-lb, 1 4 N·m)
(w/o EGR)
INSTALL EGR HOLE PLATE
Install a new gasket and EGR hole plate with the two bolts.
5. INSTALL H EATER UNION

(a) Install a new gasket, union, another gasket and union
bolt to the cylinder head.
(b) Torque the union bolt.
Torque : 600 kg-cm (43 ft-lb, 59 N•m)
6. INSTALL N0.2 ENGINE HANGER AND GROUND

STRAP
Torque: 400 kg-cm (29 ft-lb, 39 N•m)
7. INSTALL INTAKE MANIFOLD

(a) Position a new gasket o n the cylinder head.
(b) (w/ EGR)
• I nstall the intake manifold and VSV with the two
nuts and seven bolts.
• Install the EGR valve with the two nuts.
• Torque the bolts and nuts.
EM-58 ENGINE M ECHANICAL - Cylinder Head
(w/o EGR}
• Install ..the intake manifold · four nuts and seven
bolts.
• Torque the bolts and n uts.
Torque : 1 80 kg-cm ( 1 3 ft-lb, 1 8 N·mJ
8. INSTALL DELIVERY PIPE W ITH INJECTORS

(a) Install the six insulators into the injector hole of the
cylinder head.
(b) Install the black rings on the upper portion of each of
the three spacers. Then install the spacers on the
delivery pipe mounting holes of the cylinder head.
(c) Place the injectors together with delivery pipe on the

cylinder head.
(d} Make sure that the injectors rotate smoothly.
{e) Install the three thinner spacers and bolts.

Torque the bolts.
EM2924
9. INSTALL ALTERNATOR BRACKET

Torque : 400 kg-cm (29 ft-lb, 39 N·m)
1 0. INSTALL NO.2 TIMING BELT COVER

ENGINE M ECHAN.ICAL - Cylinder· Head
I NSTALLATION · o f CYLI N DER HEAQ . . .. .

(See pages EM--37, 38)
"'
:>::.;}
·. ,.· .. •F · ·· ·));i.•
1. INSTALL CYLINDER H EAD :-�;, · .
(a) Apply seal packing to the two lo t1oh; shown.
Seal packing: Part No. 08826-00080 or equh�alent
EM2961
(b) Place a new cylinder head gasket on the cylinder

block.
CAUTION: Be careful of the installation direction.
• Front
EM2962
(c) Place the cylinder head on the cylinder head gasket,

and connect the No.5 water by-pass hose to the
union.
(d) Apply a light coat of the. engine oil on the threads and
under the cylinder head· bolts.
(e) Using SST, install and uniformity tighten the fourteen
cylinder head bolts . in several passes and in the
sequence shown.
SST 09043-38 1 00
Torque: 800 kg-cm (58 ft-lb, 78 N·m)
12 8 4 2 5 9 13 2. INSTALL CAMSHAFT TIM ING PULLEYS AND TIM ING

BELT
(See steps 8 to 1 2 and 1 4 on pages E M-34 to 36)
EX
3. INSTALL SPARK PLUGS
(See page IG-7)
IN
14 10 6 1 3 7 11
EM2963
EM2922
4. INSTALL CYLINDER H EAD COVERS

(a) Using SST, install the No. 3 cylinder head cover and
heater hose clamp.
SST 09923-000 1 0
EM-60 E N G I N E M ECHANICAL "!"'" Cy.tinder Head
(b) Apply , seal packing to the cylinder head as shown in

the figure.
Seal packing: ·· Part No.08826-00080 or equivalent
(c) Install the No. 1 and No.2 cylinder head covers.
Torque : 26 kg-cm {22 ln.-lb, 2.15 N·m)
EM2902
(d) (MA)
Install the heater hose clamp.
(e) (7M-GTE)
Install the accelerator link.
6. INSTALL WATER OUTLET HOUSING

(a) Install a new gasket and water outlet housing with
the bolt and two nuts.
(b) Connect the No.6 water by-pass hose.
(c) (7M-GE)
Install a new gasket, union, another g asket and union
bolt to the water outlet housing.
6. I NSTP.LL EXHAUST MANIFOLD

(a) Face a new exhaust gasket so the protrusion is facing
Protrusion the rear and install on the cylinder head.
Front ..,
EM2949
ENGINE MECHANICAL. - . Cyli_n der Head
(b) Install the exhaust manifold with the seven nuts.

Torque: 400.kg-cm ·(29 ft-lb, 39 N·m)
EM301 1
(c) (7M-GTE)
Install the exhaust manifold stay with the three bolts.
(d) . (7M-GTE)
Install the heat insulators with the five bolts.
7. (7M-GTE)
INSTALL TU RBOCHARGER
(See steps 4 to 8 and 1 0 to 1 2 on pages TC-1 5 to 1 7)
8. (7M-GE)
INSTALL OIL DIPSTICK
9, (7M-GE)
INSTALL DISTRI BUTOR AND HIGH-TENSION CORDS
(See page IG-22)
1 0. (7M-GTE)
INSTALL AUXILIARY AIR PIPE
EM-62 ENGINE MECH.ANICAL + C,y linder tiead
1 1 . I NSTALL N0.2 FUEL PIPE
(a) Install a f1�W gasket, No.2 fuel pipe, another gasket
and union bolt to the pressure regulator.
Torque: 260 kg-cm (1 8 ft-.lb, 2& N·m)
{b) Install the No.2 fuel pipe to the delivery pipe with the
bolt.
1 2. INSTALL N0.1 FUEL PIPE AND PULSATION DAMPER

· (a) Install a new gasket, No. 1 fuel pipe; another gasket
and pulsation damper to the delivery pipe.
Torque : 400 kg-cm (29 ft-lb, 3 9 N·m)
(b) Install the No. 1 fuel pipe and VSV to the intake
manifold.
(c) Connect the No.1 fuel pipe to the fuel support (MA)
or fuel filter (MS).
1 3. INSTALL ENGINE WIRE

(a) Install the engine wire to the each clamps.
{b) Connect following wires:
• Three VSV connectors
• Knock sensor connector
• Ground strap to i ntake manifold
• Injector connectors
• Distributor connector
• Cold start injector time switch connector
• Water temp. sender gauge connector
· • Water temp. sensor connector
• Oil pressure sender gauge connector
• (w/ TWC)
Oxygen sensor connector
1 4. (7M-GTE)
INSTALL IGNITION COIL WITH BRACKET
(See steps 1 1 , 1 2 on page EM-1 3)
1 5� INSTALL AIR INTAKE CHAM BER WITH CONNECTOR

(a) Position a new gasket on the intake manifold.
(b) {7M-GTE)
Connect the cold start injector connector
ENGINE MECHAN ICAL - Cylinder Head EM-63
(c) Install the intake chamber with connector and

vacuum transmitting pipes with the two n uts and five
bolts.
Torque: 1 80 kg-cm ( 1 3 ft-lb, 1 B N·m}
(d) Connect the engine wire to the clamps of the intake
chamber.
(e) Install new gaskets and cold start injector tube.

Torque: To delivery pipe
. 300 kg-cm (22 ft-lb, 29 N•m) .
To cold start injector
1 80 kg-cm (1 3 ft-fb, 1 8 N:m}
(f) (w/ EGR}
Install the EGR vacuum modulator to the bracket.
(g) (7M-GE)
Install tne air intake connector bracket mounting
bolts.
(h) (7M-GE}
Install the throttle body bracket{s).
(i) (7M-GTE)
Install the ISC pipe and connect the hoses.
�MiJl!§tMiQ.HAI\U.C,�1:. ;� CyUnd�r H�ad
' l �l.:li!��m=:t!!).;.��:,11•;1('U\1J;�\.+i.-;.:,,;;.♦,." ' ,�;, \>"4" •
ij ) lr:,stall the EGR pipe mounting bolts.

(k) Install the mJ:!nifold stay mounting bolt.
(I) Connect following hoses :
• - (7M-GE)
No.3 water by-pass hose to throttle . body
(7M-GTE)
• Auxiliary air pipe hose to vacuum transmitting pipe
• No. 1 water by-pass hose to ISC valve
(m) Connect following hoses :
• (7M-GE)
Diaphragm hose
• VSV (for fuel pressure up) hoses
• Pressure regulator hose
• EGR hqses to throttle body and vacuum transmit
ting pipe.
• Vacuum transmitting pipe hose fo Intake chamber
• BVSV hose to throttle body
(n) Connect following wires :
• !SC valve connector
• Throttle position sensor connector
• (7M-GE)
(o) Install the PCV .pipe.
1 6. (7M-GTE)
INSTALL CAM POSITION SENSOR
(See steps 1 , 2 on page IG-26)
1 7. (7M-GTE)
INSTALL PS RESERVOIR TANK
Install the PS reservoir tank with bracket.
E1 881i
1 8. INSTALL ALTERNATOR AND ADJUSTING BAR

(a) Install the alternator and adjusting bar.
(b) Install the drive belt.
(See page EM-36)
(c) Connect the No.3 PCV pipe.
ENGINE MECHANICA'- -:- Cylinder Block
CYLI NDER BLOCK

COM PONENTS
�------- Piston Ring
Piston------- n--------- ♦ Snap Ring

Piston Pin-----0
----------1C onnecting Rod Bushing
�--------Connecting Rod Bearing

� ♦ Gasket
Connecting Rod Capo------ ♦ Oil Seal
1 680 147, 64) 1-1------------w 4

♦ Gasket
Rear Oil Seal Retainer
" c
ii Nozzle (7M-GTE)
g 1 210 11a, 2s1 1

l f0-.�------Crankshaft Thrust
A
(l1lP I
" xfU Washer
I
Timing Belt Case I
Crankshaft
r:JiF'
Oil Pump Drive Shaft
AM,-----1 1 ,040 176, 1 02) l
I kg-cm (ft-lb, N·mJ : Specified torque

♦ Non-reusable part EM467 1
I"
EM-66 ENGINE M ECHANICAL - Cylinder Block
.. DISASSEMBLY OF CYLINDER BLOCK

(See page EM-65)
1. REMOVE FLYWHEEL OR DRIVE PLATE AND REAR
END PLATE
2. INSTALL ENGINE STAND FOR DISASSEMBLY
3. REMOVE TIM ING BELT
(See steps 2 to 8 and 1 0 to 1 8 on pages EM-28 to 3 1 )
4. RE MOVE CYLINDER H EAD

(See steps 1 to 1 5 and 1 8 on pages EM-39 to 43)
5. REMOVE WATER BY-PASS PIPE AND HOSES
(a) Remove. the two nuts from the timing belt case.
(b) Remove_ the three bolts from the cylinder block and
the water by-pa�s pipe and hose with gasket.
6. REMOVE G ROUND STRAP FROM CYLINDER BLOCK
7. (7M-G E)
REMOVE VACUUM CONTROL VALVE SET
8. REMOVE FUEL RETURN PIPE S UPPORT

Remove the two nuts, fuel pipe support and insulator.
9. REMOVE ENGINE MOUNTING BRACKETS
1 0. (7M.:GE)
REMOVE OIL FILTER
(See page LU-6)
(7M-GTE)
REMOVE OIL FILTER BRACKET
(See step 1 on page LU-1 8)
1 1 . (7 M-GE w/ Oil cooler)

REMOVE OI L HOLE COVER PLATE
(7 M-GE w/o Oil cooler)
REMOVE O I L HOLE COVER PLATF
1 2. REMOVE PS PU MP BRACKET
1 3. REMOVE OIL PAN
(See page LU-9)
14. REMOVE TIMING BELT CASE WITH WATER PUMP

Remove the seven bolts and three nuts, and remove the
timing belt case and gaskets.
EM2969
ENGINE MECHANICAL - Cylinder Block
1 5. REMOVE OIL P U M P DRIVE SHAFT

(a) Remove the bolt and oil pump d rive shaft.
(b) While turning oil pump drive shaft, slowly pull out so
as not to damage the bearing.
1 6. REMOVE OIL PUMP

(a) Loosen the union nut.
(b) Remove the two bolts and oil pump.
1 7. REMOVE REAR OIL SEAL RETAINER

Remove the five bolts, rear oil seal retainer and gasket.
1 8. CHECK CON N ECTING ROD THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while
moving the rod back and forth.
Standard thrust clearance: 0. 1 60 - 0.296 mm
(0.0063 - .0.01 1 7 in.)
Maximum thrust clearance: 0.3 mm (0.01 2 in.)
If clearance is greater than maximum, replace the connect
ing rod assembly. If necessary, replace the crankshaft.
1 9. REMOVE CONNECTING ROD CAPS A N D CHECK OIL

CLEARANCE
(a) Using a punch or numbering stamp, place the
matchmarks on the rod and cap to ensure correct
reassembly.
ENGINE MECHANICAL � Cylinder Block
(b) Remove the connecting rod cap nuts.
(c) Using a plastic-faced hammer, lightly tap the con

necting rod bolts and lift off the connecting rod cap.
NOTE: Keep the lower bearing inserted with the .con
necting rod _c ap.
(d) Cover the connecting rod bolts with a short piece of

hose to protect the craflkshaft from damage.
(e) Clean the crank pin and bearing.

(f) Check the crank pin and bearing for. pitting and
scratches.
If the crank pin or bearing are damaged, replace the bear-:
ings. If necessary, grind or replace the crankshaft.
(g) Lay a strip of Plastigage across the crank pin.

ENGINE M ECHANIC�L .� · Cylinder Block
(h) Install the coi:-inecting rod cap.

(See step 7 on page EM-90)
Torque: 850 kg-cm (47 fi-lb, 84 N•m)
NOTE: Do not turn the crankshaft.
(i) Remove the connecting rod cap.

Q) Measure the Plastigage at its widest point.
Standafd oil clearance: 0.021 - 0.0&3 mm
{0.0008 - 0.0021 In.)
Maximum oil clearance: 0.07 mm {0.0028 In.)
If the oil clearance is greater than maximum, replace the
bearings. If necessary, g rind or replace the crankshaft.
U ndersized bearing : U/S 0.25
(k) Completely remove the plastigage.
N OTE: If using a standard size bearing, replace with one

No. 4 - No. 6 Crank Pin having the same number. If the number of the bearing can
No. 1 - No. 3 Crank Pin not be determined, select a bearing from the table below
Mark according to the numbers imprinted on the connecting rod
0, 1 or 2
------
cap and crankshaft. There are five sizes of standard bear
ings, marked " 1 ", "2", "3", "4" and "5".
Number marked
..._ Front Rod cap 1 1 2 1 2 3 2 3 3
Crankshaft 0 1 0 2 1 0 2 1 2
Bearing 1� . 2 2 3 3 3 4 4 5
Example: Rod cap "2", Crankshaft " 1 " = Bearing "3"

(Reference)
mm (in.)
Big End Inner Crank Pin Bearing Center
Mark
-
Diameter Diameter Wall Thlcknesa
5 1 .993 - 5 2.000
0
(2.04 70 - 2/04 72)
55.0 1 5 - 5 5.025 5 1 .985 - 5 1 .992 1 .490 - 1 .495
1
(2. 1 6 5 9 - 2. 1 663) (2.0446 - 2.0469) 10,0687 - 0.0 589)
5 5.026 - 5 5.035 6 1 .976 - 5 1 .984 1 .496 - 1 .500
2 10.058 9 - 0.059 1 )
-
(2. 1 664 - 2. 1 667) (2.0463 - 2.0466)
5 5.036 - 55.045 1 . 501 - 1 . 505
3 (0.059 1 - 0.0593)
-
(2. 1 668 - 2. 1 6 7 1 )
1 .506 - 1 . 5 1 0
4 10.0593 - 0.0594)
5 - - 1 .5'1 1 - . 1 . 5 1 5
10.0595 - ·o.0596l
U/S 55.0 1 5 - 5 5 .045 6 1 .725 - 5 1 .735 1 .e22 -,,1 .632

I
0.25 (2. 1 659 - 2. 1 67 1 ) (2.0364 - 2.0368) (o.oa·a e - 0.06431
;
20. REMOVE PISTON AND CONNECTING ROD

ASSEMBLIES ..
(a) Remove all the carbon from the top of the cylinder.
(b) Cover the rod bolts with a short piece of hose to pro
. tect the .crankshaft from damage.
(c) Push the piston, connecting rod assembly and the
upper bearing through the top . of the cylinder block.
NOTE:
• Front • Keep the bearing insert with the connecting rod and
cap.
• Arrange the piston and connecting rod assemblies in
order.
1 2 3 4 5 6
EM1471
2 1 . CHECK CRANKSHAFT THRUST CLEARANCE

Using a dial indicator, measure the thrust clearance while
prying the crankshaft back and forth with a screwdriver.
Standard thrust clearance : 0.05 - 0.25 mm
(0.0020 - 0.0098 in.}
Maximum thrust clearance: 0.30 mm (0.0 1 1 8 in.)
If the clearance is greater than maximum, replace the
th rust washers as a set.
Thrust washer thickness:
STD size 2.925 - 2.975 mm
(0.1 1 52 - 0.1 1 7 1 in.}
0/S 0.1 25 2.988 - 3.038 mm
(0.1 1 76 - 0. 1 1 96 in.)
22. REMOVE MAIN BEARIN G CAPS AND CH ECK OIL

CLEARANCE
(a) Uniformly loosen and remove the main bearing cap
bolts in several passes, in the sequence sh own.
EM1482
EN(;I�� MECHANICAL :-:-- . C:y(in�er . Block-
' (b) Usi·ng th� removed main bearing cap bolts,·'wiggiel

the cap back and forth, . and remove the caps, lower
bearings an'd lower thrust washers (No. 4 cap only). :
. NO.TE:
• Keep the lower bearing inserted • with the cap.
• Arrange the caps and lower thrust washers in correct
o�e� ·
(c) Lift out the crankshaft.
NOTE: Keep the upper bearings and upper thrust
EM363 washers insert with the cylinder block.
(d) Clean each journal and bearing.
(e) Check each journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings.
If necessary, g rind or replace the crankshaft,
E'M3764
(f) · Place the crankshaft on the cylinder block.

(g) Lay a strip of P lastigage across each journal.
(h) Install the main bearing caps. (See step 5 on page

EM-89)
Torque: 1 ,040 kg-cm (75 ftwlb. 1 02 N·m)
NOTE: Do not turn the crankshaft.
G) Remove the main bearing caps.

ij) Measure the Plastigage at its widest point.
Standard oil clearance: 0.030 - 0.048. mm
(0.00 1 2 - ().001 9 in.)
Maximum oil clearance : 0.07 mm (()�0028 in.)
If the oil clearance is greater than maximum, r�place the.
bearings. If necessary, replace the crank�tl,i:ift
U nder size bearing : U/S 0.25
EM3928
(k) Completely remove the P l�st!.��(.., . . ,, ..",� -"· ,,..,... .....,.•,�""'
EM-72 ENGINE MECHANICAL - Cylinder Block
N OT E : If using a standard size bearing, replace with one

having the same number. If the number of the bearing can
not be determined, select a bearing from the table below
according to the numbers imprinted on the cylinder block
and crankshaft.
There are five sizes of . standard bearings, marked " 1 " ,
°
" 2 , "3",· "4" afld "5".
--------
ont
No. 7 ark
No. 5 , No. 6 , 1 or 2 Number marked
No. 3, No. 4
No. 1 , No. 2 Journal Cylinder Block 1 1 2 1 2 ' 3 2 3 3
Crankshaft 0 1 0 2 1 0 2 1 2
Bearing 1 2 2 3 3 3 4 4 5
Mark
1 , 2, 3, 4 or 5 Example : Cylinder Block " 2", Crankshaft " 1 " = Bearing "3"
Mark (Reference)
No. 5 - No. 7 Journal 1 , 2, or 3 mm On.)
No. 1 -:- No. 4 Journal
Bearing Center
Mark Cylinder Block Main · Main Journal
Journal Bore Diameter Wall Thickness
0 - 60.007 - 60.0 1 2
(2.3625 - 2.3627)
-
1 64.024 - 64.030 60.00 1 - 60.006 1 .988 - 1 .991
.(2.5206 - 2.5 209) (2.3622 - 2.3624) (0.0783 - 0.0784)
64.03 1 - 64.036 5 9.994 - 60.000 1 .992 - 1 .994
2
(2.5209 - 2.5 2 1 1 ) (2.3620 - 2.3622) (0.0784 - 0.0785)
3 64.037 - 64.042 1 .995 - 1 .997

(2.52 1 1 - 2.5 2 1 3) (0.0785 - 0.0786)
4 - - 1 .998 - 2.000
(0.0787 - 0.0787)
5 - - 2.001 - 2.003
(0.0788 - 0.0789)
UIS 64.022 - 64.046 5 9.730 - 5 9.740 2.1 23 - 2.1 33
0.2 5 (2.5205 ...: 2.5 2 1 5) (2. 35 1 6 - 2.3520) (0.0086 - 0.0840)
Upper
23. REMOVE CRANKSHAFT
(a) Lift out the crankshaft.
(b) Remove the upper bearings and upper thrust
washers.
NOTE:
• Arrange the caps, bearings and thrust washers in cor
rect order.
• The pilot bearing in the crankshaft rear end is perma
nently lubricated and requires no cleaning or lubrication.
24. (7M-GTE)
REMOVE OIL NOZZLES
ENGINE MECHANICAL -·�ylinder Block
INSPECTION OF CYLIN DER BLOCK

1. REMOVE GASKET MATERIAL
Using a gasket scraper, remove all the gasket material
from the cylinder block surface.
2. CLEAN CYLINDER B LOCK

Using a soft brush and solvent, clean the block.
4622
3. INSPECT TOP OF CYLINDER B LOCK FOR FLATNESS

Using a precision straight edge and thickness gauge,
measure the surfaces contacting the cyli nd er h ead gasket
for warpage.
Maximum warpage: 0.06 mm (0.0020 In.)
If warpage is greater than maximum, replace the cyfinder
block.
4. INSPECT CYLINDERS FOR VERTICAL SCRATCHES

Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all six cylinders. If
necessary, replace the cylinder block.
6. INSPECT CYLINDER BORE DIAMETER

Using a cylinder gauge, measure the cylinder bore
diameter at positions A, B and C in the thrust and axial
directions.
Standard diameter:
STD size 82.99 - 83.04 mm
(3.2673 - 3.2893 in.)
Maximum diameter:
STD size 83.24 mm (3.2772 in.)
0/S 0.50 83. 74 mm (3.2968 In.)
If the diameter is greater than maximum, rebore all six
·EB
cyrinders. If necessary, replace the cylinder block.
CD Thrust
Direction
Front
@ Axial
Direction
I
.)
3. fs�n
.1
B=t Middle
A
C 1 0 mm
(Q.39 jn.) EMOOB6
EM0366
EM�74 ENGINE J\IIECHAN ICAL - Cylinder Block
6. REMOVE CYLINDER RIDGES

If the wear is less than 0.2 mm (0.008 in.), use a ridge
reamer to machine the top of the cylinder.
DISASSEMBLY OF PISTON AND

CONNECTING ROD ASSEMBLIES
(See page EM-65)
1. CHECK FIT BETWEEN PISTON AND PIN
Try to move the piston ba�k a nd forth o� the piston pin.
If any movement is felt, replace the piston and pin as a set.
EM2978
2. REMOVE PISTON RINGS

{a) Using a piston ring expander, remove the compres
sion rings.
EM2977
(b) Remove the two side rails and oil ring expander by
hand.
NOTE: Arrange the rings in correct order.
3. DISCONN ECT CONNECTI NG ROD FROM PISTON

(a) Using needle-nose pliers, remove the snap rings from
the piston.
EM3667
EM02.84
(c) · Using a plastic-faced h ammer and brass bar, lightly

tijp out the piston pin and remove the connecting
rod.
NOTE:
• The piston and pin are a matched set.
. • Arrange the pistons, pins, rings, connecting rods and
bearings i n correct order.
6
EM4544
' I NSPECTIO N OF PISTON AND CON N ECTING

, ROD .ASSEM B LIES
1. CL.�AJ\I PISTONS
(a) Using a gasket scraper, remove the carbon from the
piston top.
(b) Using a groove cleaning tool or broken ring, clean the

ring grooves.
EM-78 E N GIN� M ECHAN ICAL - Cyli nder Block
(c) Usi ng a soft bru�h and solvent, thoroughly clean the

piston.
CAUTION : Do not damage the piston.
2. . INSPECT PISTON DIAM ETER AND OIL CLEARANCE

(a) Using a micrometer, measure the piston diameter at a
rig ht angle to the piston pin hole center line, 2 2 mm
(0. 87 i n.) from the piston h ead.
Standard diameter:
7M-GE STD size82.90 - 82.96 mm
(3.2638 - 3.2868 in.)
0/S 0.&0 83.40 - 83.4& mm
(3.283& - 3.2864 in.)
7M-GTE STD size 82.91 - 82.96 mm
(3.2642 - 3 .2861 in.)
0/S 0.60 B3.41 - 83.46 mm
(3. 2839 - 3.2868 In.}
(b) Measure the cylinder bo_re diameter in thrust direc
tions.
(See step 5 on page EM- 73)
(c) Subtract the piston diameter measurement from the
cylinder bore diameter measurement.
Standard oil clearance :
7M-G E 0.08 - 0. 1 0 mm (0.003 1 - 0.0039 in.)
7M-GTE 0.07 - 0.09 mm (0.0028 - 0.0036 in.)
M aximum oil clearance : 0. 1 3 mm (0.0061 in.)
If the oil clearance is g reater than maximum, replace the
pi ston. If necessary, rebore all six cylinders and replace all
six pistons. If necessary, replace the cylinder block. :
3. I NSPECT CLEARANCE BETWEEN WALL OF RIN G

G ROOVE A N D N EW PISTON RING
Using a thickness gauge, m easure the clearance between
new piston ring and the wall of the piston ri.ng groove.
Ring groove clearance : No. 1 0.03 - 0.07 . m m
(0.00 1 2 - 0.0028 In.)
EM4641
No. 2 0.02 - 0.06 mm
(0.0008 - 0.0024 in.,
Cylinder Block If the clearance is not within specification, replace the
Surface piston.
4. INSPECT PISTON RING E N D GAP
(a) Insert the pisto n ring into the cylind er bore.
1 1 0 mm (b) Using a piston, push the piston ring a littl� beyond
the bottom of the ring travel.
(1 1 0 mm (4. 3 3 i n.) from top surface of cylinder
block)
EM0224
.
ENGINE MECHANICAL - Cylinder Block
(c) Using a thickness gauge, measure the end gaJt"" ···

__
Standard end gap:
No. 1
7M-GE (w/o TWC) and 7M-GTE
0.29 - 0.44 mm (0.01 1 4 - 0.01 73 In.)
7M-GE (w/ TWC)
0.23 - 0.38 mm (0.0091 - 0.01 60 in.)
No. 2 0.26 - 0,53 mm (0.0098 - 0.0209 in.)
Oil (Side rail) .,
EM2552
0.10 -· 0.44 mm (0.0039 - 0.01 73 in.)
7M-GE (w/ TWC)
0.1 0 - 0.40 mm (0,0039 - 0.01 67 in.)
Maximum end gap:
No. 1
0.74 mm (0.0291 in.)
7M-GE (w/ TWC)
0.88 mm (0.0268 In.)
No. 2 1 . 1 3 m m (0.0446 in.)
Oil (Side rail)
1 .04 mm (0.0409 in.)
7M-GE (w/ TWC)
1 .00 mm (0.0394 in.}
· 1f the gap is greater than maximum, replace the piston
ring. If the gap is greater than maximum, even with a new
piston ring, rebore the cylinder and use an 0/S piston ring.
5. CHECK PISTON PIN FIT

At 60° C (140 ° F) you should be ·able to push the pin into
the piston with your thumb.
If the pin can be installed at a lower temperature, replace
the piston.
6. INSPECT CONNECTING RODS

(a) Using a rod aligner and thickness gauge, check the
connecting rod alignment.
• Check for bend.
Maximum bend:
0.05 mm (0.0020 In.) per 1 00 mm (3.94 in.) .
If bend is greater than maximum, replace the connecting
rod· assembly.
EM0287 EM02SS
EM-78 ENGINE MECHANICAL - Cylinder Block
• Check for..twist.
Maximum twist:
0. 1 5 mm (0.0059 in.) per 1 00 mm (3.94 in.)
If twist is greater than maximum, replace the connecting
rod assembly.
eM0289 EM0290
(b) Inspect the oil clearance between the rod bushing

and piston pin.
• Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter: 22.005 - 22.01 7 m m
(0.8663 - 0.8668 in.)
EM0226
• Using a micrometer, measure the piston pin

diameter.
Piston pin diameter: 21 .996 - 22.009 mm
(0.8660 - 0.8665 in.)
• Subtract the piston pin diameter measurement

from the bushing inside diameter measurement.
Standard oil c learance: 0.005 - 0.0 1 1 mm
(0.0002 - 0.0004 in.)
Maximum oil c learance: 0.02 mm (0.0008 in.)
If the oil clearance is greater than maximum, replace the
bushing. If necessary, replace the piston and piston pin
assembly.
7. IF N ECESSARY, REPLACE CONNECTING ROD

BUSHINGS
(a) Using SST and a press, press out the bushing.
S ST 09222-300 1 0
i---- EM1321
ENGINE MECHANICAL - 'Cylinder Block
(b) Align,,the oil holes of a new bushing and connecting

rod .
(c) Using SST and a press, press in the bushing.
SST 09222-300 1 0
Oil Hole .
EM2983
(d) Using a pin hole grinder, hone the bushing to obtain

the · specified clearance between the bushing and
piston pin.
(e) . Check the piston pin fit at normal room temperature.

Coat the piston pin with engine oil and push it into
the connecting rod with your thumb.
BORING OF CYLIND ERS

NOTE:
· • Bore all six cylinders for the oversized piston outside
diameter.
• Replace the piston rings with ones to match. the over-
sized pistons.
1. SELECT OVERSIZED PISTON

Oversized piston diameter:
0/S 0.50 7M-GE 83.40 - 83.45 mm
(3.2835 - 3.2854 in.)
7M-GTE 8�.�1., - 83.46 mm
(3.2839 - 3.2868 in.)
2. CALCU LATE AMOUNT TO BORE CYLINDER

(a) Using a micrometer, measure the piston diameter at a
right angle to the piston pin hole center line, 22 mm
(0.87 in.) from the piston head.
(b) Calculate the amount each cylinder is to be rebored
as follows :
Size to be rebored = P + C - H
P = Piston diameter
C = Piston clearance
7M-GE 0.08 - 0.1 0 mm
{0.0020 - 0.0028 in.)
7M-GTE 0.07 - 0.09 m m
(0.0028 - 0.0035 in.)
=
H Allowance for honing
0,02 mm (0,0008 In.) or less .
3. BORE AND HONE CYLINDERS TO CALCULATED
DIMENSIONS
Maximum honing : 0.02 mm (0.0008 in.)
CAUTION: Excess honing will destroy the finished
roundness.
ENGINE M ECHANICAL - Cylinder Block EM-81
I NSPECTION OF CRANKSHAFT
1. INSPECT CRANKSHAFT FOR RUNOUT
(a) Place the crankshaft on V-blocks.
(bl Using a dial i ndicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the ·
crankshaft.
EM29!14
NOTE: Use a long spindle on the., dial gauge.
2. I NSPECT MAIN JOURNALS AND CRANK PINS ·
(a) Using a micrometer, measure the diameter of each
main journal and crank pin.
Journal diameter:
STD size · 69.994 - 60.0 1 2 mm
(2.3620 - 2.3627 i n.)
U/S 0.26 69. 730 - 59. 740 mm
· (2.35 1 6 - 2.3520 . in.)
Crank pin diameter:
STD si.ze 61 .976 - 62,000 mm
EM3765 EM3780
(2.0463 - 2.0472 In.)
U/S 0.26 6 1 .726 - 6 1 .735 mm
(2.0364 - 2.0368 In.)
If the diameter is not withi n specification, check the oil
clearance. If necessary, grind or replace the crankshaft.
(b) Check each main journal and crank pin for taper and
out-of-round as shown.
Maximum taper a nd out-of-round: 0.02 mm
(0.0008 in.)
If taper or out-of-round is greater tha n maximum, replace
the crankshaft.
3. I F NECESSARY, GRIND AND HONE MAIN JOURNALS

AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the
finished undersized diameter (See procedure step 2).
Install new main journal and/or crank pin undersized bear
ings.
E M-82 ENGINE M ECHANICAL - CyUnder Block
..
INSPECTION AND REPAIR O F OIL PUMP
DRIVE SHAFT, .1:5 EARINGS AND . BUSHI NG ''
1. INSPECT OIL PUM P DRIVE SHAFT
(a) Using a micrometer, measure the journal diameter of
pump drive shaft,
Standard journal diameter :
Front 40.959 - 40.976 mm
(1 .61 26 - 1 .6 1 32 in.)
Rear 32.959 - 32.975 mm
(1 .2976 - 1 .2982 in.)
(b) Using a cylinder gauge, measure the inside diameter
of the pump drive shaft bearing.
Bear i ng inside diameter :
Front 41 .000 - 41 .025 mm
(1 .61 42 - 1 .6 1 62 in.)
Rear 33.000 - 33.025 mm
(1 .2992 - 1 .3002 in.)
(c) Subtract the journal diameter measurement from the

bearing inside diameter measurement.
Standard o i l c l e.arance: 0.025 - 0.066 mm
(0.001 0 - 0.0026 i n.)
Maximum oil c learance: 0.08 mm (0.0031 in.)
If the clearance is greater than maximum, replace the
bearing. If necessary, replace the drive shaft.
IF N ECESSARY, R EPLACE Oil PUMP D RIVE SHAFT

No. 1 Bearing Replacement 2.
BEARING
No. 1 Bearing No. 2 Bearing
(a) Using SST, replace the No. 1 bearing by using No. 2
bearing as a guide.
SST 0921 5-00 1 00 (092 1 5-001 20, 0921 5-00 1 30,
092 1 5-001 40, 092 1 5-001 60, 092 1 5-002 1 0,
0921 5-00220)
EM1475
(b) Using SST, replace the No. 2 bearing by using the No.
No. 2 Bearing Replacement
1 bearing as a guide.
No. 1 Bearing No. 2 Bearing
SST 092 1 5 -00 1 00 (09 2 1 5-00 1 20, 092 1 5-00 1 30,
092 1 5-00 1 40, 092 1 5-002 1 0, 092 1 5-00220)
EM1476
ENGINE MECHAN IC:AL -' Cylinder Block
CAUTION : Whe n . inserting the bearings, align·-eacli'�

pil hole.
3 . . IN$PECT OIL PUMP DRIVE SHAFT THRUST

CLEARANCE
Using a thickness gauge, measure the drive shaft thrust
clearance· between the thrust plate and collar.
Standard thrust clearance:0.06 - 0.1 3 mm
(0.0024 � C:[006 1 in.)
Maximum thrust clearance: 0.30 mm (0.01 1 8 in.}
If clearance . is greater than maximum, replace the thrust
plate and/or collar.
EM2987
4. IF NECESSARY, REPLACE THRUST PLATE AND

COLLAR
(a) Using SST, remove the thrust plate and collar.
SST 09950-200 1 7
EM2988
(b) Install the thrust plate and coltar in the direction as

shown.
(c) Using a press, install the thrust plate and collar.
EM29 EM2989
6. IF N ECESSARY, REPLACE OIL PUMP GU IDE BUSH ING

{a) Drive out the bushing from the outer side of the
block.
EM2991
EM-84 ENGINE MECHANICA� -- Cylinder Block .
(b) Drive in the bushing from the inside of the block with
a suitable tool.
NOTE: The oil liole should be positioned toward the
crankshaft side.
(c) Make sure the front mark of bushing is positioned
toward the front of block.
Axial
Directio
..f, ii Hole
Thrust Direction EM147 2992
REPLACEM ENT OF OIL SEALS

· NOTE: There are two methods (A and B) of oil seal rep
lacement.
1. REPLACE CRANKSHAFT FRONT OIL SEAL

A. If the timing case is removed from the cylinder
block:
(a) Using a screwdriver and hammer, tap out the oil seal.
(b) Using SST and a hammer, tap in a new oil seal.

SST 092 1 4-600 1 0 and 09506-3501 0
(c) Apply MP grease to the oil seal lip.
l::M4566
B. If the timing case is Installed to the cylinder

block:
(a) Using SST, remove the oil seal.
SST 09308-5501 0
EM2993
(b) Apply MP g rease to a new oil, seal lip; ··
(c), Using .SST and a hammer, tap in lhe oil seal.
SST 09 2 1 4-6001 0 and 09606-3501, 0 ; ·
2. . REPLACE CRANKSHAFT REAR OIL SEAL ·

· A. If the rear oil seal retainer is removed from the.
cylinder block:
EM3787
(b) Using SST and a h ammer, tap in a new oil seal .

SST 09223-41 020
(cJ Apply MP grease to the oil seal lip.
B. If the rear oil seal retainer i s installed to the

. cylinder
. block:
(a) Using a knife, cut off the lip of the oil seal as shown.
(bl Using a screwdriver, pry out the oU seal.
CAUTION: Be careful not to damage . the crankshaft.
Tape the screwdriver tip.
., ta
Cut PQsition (c) Check the oil seal lip contact surface of the
crankshaft for cracks or damage.
EM0282 EM1751
(d} Apply MP grease to a new oil seal lip.

(el Using SST and a hammer, tap in the oil seal.
SST 09223-41 020
EM-86 . . ENGIN� Ml;�i-tANI.CAL - Cylinder Block
3. REPLACE PU MP DRIVE SHAFT OIL SEAL

A. If the timing belt case is .removed from the
cylinder block:
M-4554
(b) Using SST and a hammer, tap in a new oi l seal.

SST 092 1 4-4
.
1010
..
.,,,,
(c) Apply MP grease to the oil seaUip .
.....
B. If the timing belt case is Installed to the cylinder

block:
(a) Using a knife, cut off the lip of the oil seal as shown.
{b) Using a screwdriver, pry out the oil seal.
CA.UTION : Be careful not to damage the crankshaft.
Tape the screwdriver tip.
Cut Position (cl Check the oil seal lip contact surface of the pump
� tu Tape
EM02.82 9/11 160
drive shaft for crack� or damage.
(d) Apply MP grease to a new oi l seal lip.

(e) Using SST and a hammer, tap in the oil seal.
SST 0921 4-41 0 1 0
l!M1797
ENGINE MECHANICAL � Cylinder Bl_oc;:�
ASSEMBLV O F PISTON AND CONN ECTING·� �-�

ROD . . . . · .:• ,_ :
-- ;P
· (See page EM-6 5)
1. ASSEM BLE PISTON AND CONNECTIN G ROD
(a) Install a new snap ring on one side of the pisfori· pin
· ·
hole.
(b) Gradually heat the piston to approx. 60 ° C (1 40 ° F).
(c) Coat the piston p)n with engine oil.

(d) Align the front marks of the piston and the connect
ing rod, and push in the piston pin with your thumb.
(e) Install a new snap ring on the other side of the pin
hole.
Front Mark Front Mark

(Protrusion) (Protrusion)
2. INSTALL PISTON RINGS

(a) Install the oil ring expander and two side rails by
hand.
(b) Using a piston ring expander, install the two com

pression rings with the code mark facing upward.
EM2977
CompressiQfl (c) Position the piston rings so that the ring ends are as
Upper Side
Rail Ring No. 1 shown.
CAUTION : Do not align the ends.
Front
-4---
Compression Lower Side

Ring No. 2 Rail EM4549
3. INSTALL BEARINGS
(a) Align the bearing claw with th,e claw groove of the
connecting rod or connecting .rod cap.
(b) Install the bearing in the connecting rod and rod cap.
CAUTION: · I nstall the bearings with the oil hole in the:
connecting rod.
ASSEMBLY OF CYLIN DER BLOCK

(See page E M-65)
NOTE:
• Thoroughly clean all parts to be assembled.
• Before installing the parts, apply new engine oil to all
sliding and rotating surfaces.
• Replace all gaskets, O-rings and oil seals with new
parts.
1. (7M-GTE)
INSTALL OIL NOZZLES
Torque: 250 kg-cm (1 8 ft- lb, 25 N·m)
2. INSTALL MAIN BEARINGS

No. 1 Ex. No. 1 NOTE: Different the bearing are used for the No. 1 and
ex. No. 1 .
Upper
�
. Lower-w
2 5 mm (0.98 in.) 22 mm (0.8 7 in.)

EM0770
ENGINE MECHANICAL ..:.. Cylinder Block
· (a) Align the bearing claw with the the claw groove of
the main bearing cap or cylinder block.
• (b} Install the bearing in the cylind�r block and bearing
caps.
�AUTION: Instal l the bearing with the oil hole in the
block.
· 3. INSTALL UPPER THRUST WASHERS

Install the thrust washers under the No. 4 main journal
position of the block with the oil grooves facing outward.
4. PLACE CRAN KSHAFT ON CYLINDER BLOCK
5. INSTALL MAIN BEARING CAPS AND LOWER TH RUST

WASHERS
NOTE: Each bearing cap has a number and front mark.
840
(a) Install the thrust washers on the No. 4 bearing cap

with the g rooves facing outward.
(b) Install the bearing caps in numbered order with

arrows facing forward.
(c) Install and uniformly tighten the fourteen cap bolts in
several p asses, in the sequence shown.
Torque: 1 ,040 kg-cm (75 ft-lb, 1 02 N·m)
{d) Check that the crankshaft turns smoothly.
(e) Check the crankshaft thrust clearance.
(See step 2 1 on page EM-70)
EM1 482
EM-90 ENGINE MECHAN ICAL . - Cylinder Block
6. INSTALL PISTON AND CONNECTIN G ROD

ASSEMBLIES
(a) Cover the·connecting rod bolts with a short piece of
hose to protect the crankshaft from damage.
I
(b) Using a piston ring compressor, push the correctly
numbered piston and connecting rod assemblies i nto
each cylinder with the front mark (delta for 7M-GE
and arrow for 7M-GTE) of the piston facing forward.
7. INSTALL CONNECTING ROD CAPS

(a) Match the numbered cap with the numbered con
necting rod.
(b) Install the cap with the protrusion facing forward.
(cl Install and alternately tighten the cap nuts in several

passes.
Torque: 660 kg-cm (47 ft-lb, 64 N·m}
(dl Check that the crankshaft turns smoothly.
(el Check the con necting rod thrust clearance.
(See step 1 8 on page EM-67)
8. INSTALL OIL PUMP ASSEMBLY

(a) Clean the oil pump.
(b) Install the oil pump with the two bolts and union n ut
Torque the bolt and union nut.
Torque: Bolt (A) 220 kg-cm (1 6 ft-lb, 22 N·m)
Solt (B) 60 kg-cm (62 in.-lb, 5.9 N ·m)
Union nut 360 kg-cm (25 ft-lb, 34 N·m)
ENGINE M ECHANICAL � Cylinder Block
.
.. '
9. INSTALL OIL PU M P DRIVE SHAFT

(a) While turning the drive shaft, insert slowly to avoid
damaging the drive shaft bearing.
EM2997
(b) Install the bolt.

Torque: 1 45 kg-cm (1 0 ft-lb, 1 4 N ·m)
1 0. INSTALL REAR OIL SEAL RETAINER

Install a new gasket and rear oil seal retainer with the five
bolts.
Torque: 1 30 kg-cm (9 ft-lb, 1 3 N ·m)
EM3038
1 1 . INSTALL TIM ING BELT CASE WITH WATER PUM P

(a) Position new gaskets on the cylinder block.
20 (b) Apply sealant to two or three threads of the 1 0 mm
bolt end.
20 Sealant: Part No. 08833-00070, THREE BOND 1 324
or equivalent
(c) Install the timing belt case with the seven bolts and
three nuts.
1 2. INSTALL OIL PAN
(See page LU-1 4)
1 3. INSTALL PS PUMP BRACKET

EM-92 ENGINE MECHANICAL �, Cylinder Block
· · ,. ·
·1 4, (7M.::Gi: w/ O11 Cooler)
INSTALL OIL REGULATOR
Install a new gasket and oil regulator with. the two bolts.
(7M-GE w/o Oil Cooler and 7 M-GTE)
INSTALL OIL HOLE COVER, PLATE
Install a new gasket and oil hole cover plate with the two
bolts.
1 5. {7M-GE)
INSTALL N EW OIL FILTER
(See page LU-6)
1 6. INSTALL ENGINE MOUNTING BRACKETS
1 7. INSTALL FUEL RETU RN PIPE SUPPORT

Install a new insulator and fuel pipe ·support with the two
n uts.
Torque: 1 30 kg-cm (89 ft-lb. 1 3 N·m)
1 8. (7 M-GE)
INSTALL VACU U M CONTROL VALVE SET
1 9. INSTALL G RO U N D STRAP TO CYLIN DER BLOCK
20. IN.STALL WATER BY- PASS PIPE

(a) Install a new g asket and water by-pass pipe to the
timing belt case with the two nuts.
Torque: 1 40 kg-cm (1 0 n.:n,. 1 4 N·m)
(b) Install the water by-pass pipe to.:the cylinder block
with the three bolts.
Torque : 1 30 kg-cm (9 ft-lb, 1 3 N·m)
2 1 . INSTALL CYLINPER HEAD

{See steps 1 and 4 to 1 8 on pages EM-59 to 64)
22. INSTALL TIMING BELT

(See step 1 to 8 and 1 O to 1 5 on pages E M:'33 to 36)
'
23. REMOVE ENGINE STAND
'
24. INSTALL REAR END PLATE

Torque: 1 30 kg-cm (9 ft-lb, 1 3 N·m)
25. INSTALL FLYWHEEL OR D RIVE PLATE O N

CRANKSHAFT
(a) Install the flywheel or d rive plate on crankshaft.
(b) Install and uniformly tighten the bolts in several
passes, in the sequence shown.
Torque : 750 kg-cm (54 ft-lb, 74 N • m)
1486
TU RBOCHARGER SYSTEM
Page
DESCRIPTION . . • , • • • . • • . . • • . • • • . • • • . • , • • . • , • • • • TC-2·
PRECAUTIONS ' .. - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..,,, ,,I =
..
,· ' . . :·· :.-.�.;: -�·;:;,
TROUBLESHOOTING • . • . . • • • • . • • . • . . • • • • • • • • • • • , i t
TURBOCHARGER • • • • • • • • • • I • • • • I • • • • • • • • • • • • • • : ' TC�
TURBOCHARGER SYSTEM - Description
DESCRIPTION
Turbine Wheel
Oxygen Sensor
Oil Passage
From Oil Inlet Pipe lntercooler Pipe Arrangement

Coolant
To Oil Outlet Pipe lntercooler

TCOOSO
CSOl 15 Ft29 1 7
The turbocharger is a device which increases than usual, engine output can be increased by
engine output by sending a greater amount of air i ncreasing the average combustion pressure with
fuel mixture to the engine than under normal con out increasing the engi ne speed.
ditions. Engine output depends upon the amount Superchargers are either turbocharger type
of the air-fuel mixture ignited per unit of time. {using exhaust gas to turn the turbine) or
Therefore, to increase engine output, the most supercharger type {using the engine crankshaft,
effective method is to send a greater amount of etc. to mechanically turn the pump, etc.). For the
air-fuel mixture into the cylinder. Supra 7M-GTE engine, the turbocharger type has
In other words, by installing a special tur been adopted.
bocharger and providing more air-fuel mixture
TU RBOCHARGER SYSTEM - Description
Air Flow
Turbocharger Meter
Air
<:= C>
Cleaner
Turbine
Wheel
Actuator lntercooler
Air Intake
Chamber
TC001 1
Operation of the Turbocharger lntercooler

Exhaust gas. acts on the turbine wheel inside the The intercooler cools the turbocharged air
turbine housing, causing it to revolve. When the (intake air) put out by the turbocharger, thereby
turbine wheel revolves, the impeller wheel which i s increasing the air density. As the air intake efficien
located on the same shaft also revolves, com cy increases, the gas temperature in the combus
pressing the intake air which has passed throug h tion chamber falls and the occurrence of knocking
the air flow meter from the air cleaner. When is suppressed, giving an increase in engine output.
expelled from the compressor housing the com The Supra 7M-GTE intercooler is an air cooling
pressed air is supplied to the cylinders. When the type located at the front of the vehicle, utilizing the
engine speed increases, the exhaust gas volume vehicle windstream to cool the turbocharged air.
increases and the turbine wheel revol utions
increase (approx. 20,000 rpm - 1 1 0,000 rpm),
thus the turbocharged air pressure grows greater
and engine output increases.
:, Waste Gate Valve

Although on the one hand high output is
achieved by turbocharging, if the turbocharged air
pressure becomes too h igh, knocking occurs and
on the contrary, a reduction in engine output is
caused. If the turbocharged air pressure exceeds
the prescribed air pressure, the flow of exhaust
gas bypasses the turbine, controlling turbine wheel
revolutions and turbocharge air pressure. This by
pass valve which controls the quantity of exhaust
gas flowing to the turbine is called the waste gate
valve.
When the supercharged air pressure exceeds
the prescribed pressure, the actuator operates, the
waste gate valve opens and part of the exhaust
gas by-passes the turbine. This causes a drop in
the turbine · revolution rate and controls the
supercharged air within the prescribed limits.
. -- -· · .... r a I t:
M .;;_ ,. P rec autions
Do. n ot st p
tra der or h?19h the .f!lnglne imm edlaltely after PU
spe-d, (f l n ,
- 1 20 seconds, de or uphill dri ving. Idle the en g 111 e8
ing co nd ition pending on th e sev
. eri ty of th e Cl�
2. Avoid aud · ·. ·· i
lle n ra cing or ac
starting a c celeration Imm ediatel
old e ngine . . y <l ff
3. If thi, eng
ine la r�n With
foreign lliat8rla the air clean er remo ,,
Which ru n'' at 1 ;. 8 nterln9 livlU 9
extr'3me1y high damage th e W fl ee
4. If the turb speed.
ocharetr is ·c:tefe
first ch eck f ctive and mu st be rep lac
or e
the fo ilowin tM. c!ause of t he d efect in refere nc
g ftetit,.' and repla e t
· • E rigine· ou ce parts if nece ssary :
leire f and quality
• · co;;;;1t1.;�; �nd
er which the turboc
used harge r \/Va
• OU Hnea leading
to the tu rbocharge r
s. Use ca ution
Wh
bo c harg e r a ss e n �em ovl ng a nd reinstal lin g the tu_
an ythi ng or g r e m b ly. D o not d r op it or bang it again
asp ft by easily�
the a ctu ator d eformed parts, such
or rod, v,,he n
6. Before r emov mo vi ng ft.
ing 'the turboc
e xha u st port ha rg er, plug the intake a
s a n d "otfJ nJat
other foreig to p rev ent entry of dirt .,
n mateHat
EM3271
7. ff rep la ci n g
the t urbocharg
of slu dg e pa e r,
rticl es in the oil che ck for accumulati
r eplac e the pipes and , If neces a
o n p ipes . a r
8. Co mp lete ly re
move the gas
tion o il pipe ke t adhe red to the lubric
flang e a nd tur
9. If repla clng bo b o c h a rg e r o il flan ge.
lts or nuts, do
n e w o ne s to
g u a r d. 11g a inst so o nly with the ap<ic iil
bre a kage o r deformat o,
!
1 0. If re pl aci
n g the tu rb ocfl
o ff into the tur arg e r, p ut 20 cc (1 ,2 cu In.)"<
boc harger o i l
whe e l by h a nd inl e t a nd turn the impelf.
to spr e a d on
1 1 . If over h a u lli to t he bearing,
i�'o
ply a fter reas f r8p iai: i ng th e e n g ine, cut the fuel
se
s e co nds to dls m b l y a nd cra nk the engine for · .. !fa
trlb(lti, o i l thr
allow th e e ng i oug h out the engine. .. ;
n e to i d le for �
6 0 s e c onds. · �·:
TURBOCHAR GE R SYSTEM - Troubleshooting TC-6
TRO UBLESHOOTING
NOTE: Before troubleshooting the turbocharger, first
check the engine itself. (Valve clearance, engine compres
sion, ignition timing etc.)
.
INSUFFICIENT ACCELERATION, LACK OF POWER OR
EXCESSIVE FUEL CONSU M PTION
(Possible Cause) (Check Procedure and Correction Method)

1. TURBOCHARG ING PRESSURE TOO I-
Check turbocharging pressure. (See page TC-8)
LOW Turbocharging pressure:
M/t 0.39 - 0.53 kg/cm2
{5.6 - 7 .5 psi, 38 - 62 kPa)
A/T 0.34 - 0.42 kg/cm2
(4.8 - 6,0 psi, 33 - 41 kPa)
If the pressure is below �pecification, begin
diagnosis from item 2.
2. RESTRICTED INTAKE AIR SYSTEM Check intake air system, and repair or replace
parts as necessary. (See page TC-7)
3. LEAK IN INTAKE AIR SYSTEM Check intake air system, and repair or replace
parts as necessary. (See page TC- 7)
. 4. RESTRICTED EXHAUST SYSTEM Check exhaust system, and repair or replace parts
as necessary. (See page TC-7)
6. LEAK I N EXHAUST SYSTEM C heck exhaust system, and repair or replace parts
as necessary. (See page TC-7)
6. ERRATIC TURBOCHARGE R ,-.

C heck rotation of impeller wheel. If it does not turn
OPERATION or turns with a heavy drag, replace the turbocharger
assembly.
Check axial play of bearing shaft. (See page TC- 1 4)
Axial play: 0. 1 3 m m (0.0051 in.) or less
If not withi n specificatior:i, replace the turbocharger
assembly.
TC4S TURBOCHARGER SYSTEM :' ' ·:Troobleshooting·
{Possible Cause) (Check Procedure and Correction Method}
1. TURBOCHARGER INSULATOR C heck for loose, improperly installed or· deforme�

...- . RESONANCE insulator 'ni ourit bolts and nuts, and repair or replace
as necessiiy. . ,·, ,, F ,> _.' •
,,,.-
·,r,.,• ;>,'¼ ,:-,� >: so;. ,., h , ,;,,, •..
'.
'
:•" :: ...( ''' <..,;'!;' '.. : .. ,
2. EXHAUST PIPE LEAKING O R Check .foMtJ<l\l,aust:�ipe deformation, loose mount

VIBRATING bolts or a dijmag�d gasket, and repair_ or replace as
necessary.
3. E RRATIC TURBOCHARGER Refer to item �6 qfJNS.U F,FICIENT ACCELERATION,

. .
OPERATION LACK OF POWER OF EXCESSIVE FUEL : ··
CONSUMPTION
e�,·-=======================================
EXCESSIVE OIL CONSIJM PTION OR WHITE EXHAUST
(Possible Cause)
t
FAULTY TU RBOCHARGER OIL SEAL Chedk' f6' oil · 1iitea{Je' tiftxnatit1:. syslefu.
• Remove the turbine elbow from the turbocharger
a nd , pheck fofaf,:,�pt!s�\�� c.art-;,fm,deposits on the
turbine wheeh;,,��,s1)1�i.t;it�q,;I);, dep�$its would
. Jndicate a ·faultv'"turboeharger; ,,. · -
Check for oil leakage in intake air system.
• Check for axial,,,,pt,av.JoJmpJ1Uer .wheel, and replace
. th'.e' turbocfiat:g�': ifine�sSBf¥f ..,
(�ee page rc;::f¢)"·· ·· -· --.--�-
.
Axial play: 8.13° mm '.(0�0051 in.} or less
··. C�UJION:·· ''Dcr:�ft· .
�l<.epl )' �! a911ose o·r dinary
.on: mist ftom ttte!'ic: "' by gas as an oil �tfie•bfow
leak from the turbocharger.
1i
TURBOCHARGER';SYS:T EM�,:Turbo'.c h�g ett
TU RBOCHA RGER: _ ,_ . _
ON�VEHICLE I NSPECTIOl\ft>F - . , ., .. .,
•
" ·' ,v "'•:· - , :� ,..,,.• ,••. �- ; \·.• _;.:t f'l
TU RBOCHARG ER
1. I N SPE CT INTAKE AIR SYST�� ' - - , - . --
CheckJpr leakage or clogging befWeen'
':;t:.>-;:�..�;}" ---- ,
tqe ciif 9_lean.er and
·;<,
-
turbocharger inlet and between the turb,:pgh�irg�r
· · outlet
anlt cylinder head.
• CIOgged air cleaner .... Clean or replace· the element
• Hoses collapsed or deformed .... Repair or replace
��ti��--,
••• • ••• ••• ••• '"" ••�......M,� "•0v' -•••'' '"• • L.....
4
r f
l..�akage from connecti�ns .... Check each
and· repair
• Cracks in compqnents .... Check. and r�pla�e
• . , ·· 1 · .:,;
,
i:'.
2. INSPECT EXHAUST $)'STEM

Check for leakage or clogging betw�en · the cylinder head
and turbocharger inlet and between the turbocharger out
let and exhaust pipe.
• Deformed components .... Repair or replace
• FOreign materi.a l in passages .... Remove
• Leakage from components .... Repair or replace
__ • Cracks in components .... Check and replace
3. iNSPECT OPERATION OF ACTUATOR AND WASTE

GATE VALVE
(a) Remove the No.4 air cleaner pipe with No. 1 and No.2
air cleaner hoses.
(b) D1sconnecfthe air hoses .

. (c) Disconnect the air flow meter connector.
EM3527
(d) Loosen the clamps and remove the bolt· · ·

(e) Remove the No. 7 air cleaner hosewith air flow meter
__ and air cleaner cap.
(f) Disconnect the PS idle µp air hose.
EM3528
TU flBOCHARGER SYSTEM Turbocharger
\
0
-.
(g) Disconnect the actuator hose.

f :·
(h} Using SST (turbocharger pressure gauge), apply
approx. 0.52 kg/cm 2 (7.4 psi, 6 1 kpa) of pressure to
· the actuator and check that the rod moves.
SST 09992'."00241
If the rod does not move, replace the turbocharger assem
bly.
CAUTION : N ever apply more than 0.8 kg/cm2 (1 1 .4
SST psi 78 kPa) of pressure to the actuator.
EM352 9
4. CHECK TURBOCHARGING PRESSU RE

(a) Install SST (turbocharger pressure gauge) to the
pressure regulator with a three way.
SST 09992-0024 1
(b) (MIT models)
Accelerate the vehicle with . the throttle valve· fully
open after driving at 3-speed at 1 ,000 rpm.
Meausure the turbocharging pressure when the
engine speed is over 2,500 rpm .
coo
29
_____,
.______________T Standard pressure: 0.39 - 0.53 kg/cm2
(5.6 - 7 .5 psi, 38 - 62 kPa)
(c} (A/T models}
From a stationary state accelerate the vehicle in "L"
range with the throttle valve fully open. Measure the
turbochargining pressure when the engine speed is
over 3,500 rpm.
Standard pressure: 0.34 - 0.42 kg/crn 2
(4.8 - 6.0 psi, 33 - 41 kpa)
If the pressure is less than that specified, check the intake
air and exhaust systems for leakage. If there is •no leakage,
replace the turbocharger assembly.
If the pressure is above specification, check if the actuato_r
hose is disconnected or cracked. If not, replace the tur
bocharger assembly.
6. INSPECT IMPELLER WHEEL ROTATION

Grasp the edge of the impeller wheel and turn it.
Check that it turns smoothly.
If it does not turn or if it turns with a drag, replace the tur
bocharger assembly.
TURBOCH ARGER SYSTEM ...,.. TurbQcharger
COMPO NENT$
No. 1 Turbo Water Hose
No. 1 Turbo Water Pipe
No. 2 Turbocharger Stav-----'""
♦ Gasket
e -- ---
Turbine Outlet Elbow

♦ Gasket Turbo Oil Pipe
Turbo Heat Insulator
360 (26, 34)
Turbocharger Stay
jkg-cm (ft-lb, N•mij : Specified torque

♦ Non-reusable part TC001 3
TC-1 0 TU RBOCHARGER SYSTEM , - Turbocharger
REMOVAL OF TU RBOCHARGER
(See page TC-9L
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY
2. DRAIN COOLANT
3. REMOVE NO.4 AIR CLEANER PIPE WITH NO.1 AND

N O.2 AIR CLEANER HOSES
4. REMOVE NO.7 AIR CLEAN ER HOSE WITH AIR

FLOW M ETER AN D AIR CLEANER CAP
(a) Disconnect the three air hoses and PCV hose.
(b) Disconnect the air flow meter connector.
(c) Disconnect the PS idle up air hose.
EM3527
(d) Loosen the clamps and remove the bolt. A

(el Remove the No. 7 air cleaner hose with air flow meter
and air cleaner cap.
EM3528
5. REMOVE TURBO H EAT INSULATOR

(al Disconnect the oxygen sensor connector.
(bl Remove the three nuts, plate washer and turb o he
insulator.
EM3531
· ··· . ... - ... ··-- · · · ... · ··••····· · ·
, 6. · RE Mo vE O 1 L 0·1 psfic K: ouT0 f :.
(a) Remove th� oil .d i�s�i�k., ·:.&:
,. .. - :' . .
';< ,;, .
. ..,_i:-·,;:1. \? ;k ·\:r t:·<·. i . r-':'·
.. : .
(b) Remove the bolt. and • tjil :�y:fstlq�:ggjg_�."
(c) Remove the O-ring f.r<>�':t�c{i1i•J.tij�ti(: g�ide. k.
''·��;; , ' 4! "

\
7. REMOVE N0.1 AIR CLEANER PIPE WITtfNo:i·

.- -AIR_.,_,
CLEANER HOSE
(a) loosen the No.5 arid No.6 air cleanef htis;\�Jamp�. :
,�°".". C 1 •. •• i
(b) Remove the No. 1 air cleaner pipe mounting bolt. ·
(c) Remove the No. 1 air deaner . pipe· ,with No.6 ai� ·
cleaner hose.
$; · 1"blSCONNECT FRONT EXHAUST PIPE

(a) Remove the three nuts.
(ll) Remove the front exhaust pipe clamp.

(c) D1sconne9t the front exhaust
· pipe
· · the exhaust
from ' ·· · ·. '
manifold.
(d) Remove the gasket.
9. REMOVE 'TURBO OIL PIPE MOUNTING NUTS .
1 o. REMOVE TURBO OIL PIPE MOU �Il�,- 4J\l!ON BOLT

1'.:Q'7�ta;:
'-.�i''+1 , • �,"-. •j•:� f,_r_h,'•/"'0"V4' '/":<\"I��-�� ...,��•
lYfllQ�AffGl;fl\.S}'/$.JiM:1�.:Tvrl:>�•.Qqharger
,.a<_;;;s;::_;;;-..<.,.,,,�.,,.•••'"•''"�•-2-.,,h•, ... ,J • >-.g�.J. •'
1 1 . .. REMOVE TURBOCHARGER STAY
637
1 2. REMOVE N0,2 TURBOCHARGER STAY
1 3. DISCONNECT N0. 1 TURBO WATER HOSE FROM

WATER OUTLET HOUSING
1 4. DISCONNECT UNION PIPE

Remove the union bolt and gaskets.
1 5;; �EMOVE TURBOCHARGER

Remove �ti four nuts, turbocharger and gasket.
EM3566
1 7. REMOVE TURBO OIL PIP!; .
Remove the ..two nuts, turb� "«sir'pipe and gasket.
. JS: REMOVE TURBINE OUTLET ELBOW

Remove the four nuts, turbine outlet elbow and gasket.
TC- 1 4 TURBOCHARGER SYSTEM - · Turbocharger
I NSPl:CTION OF TU RBOCHARGER
..
1. INSPECT IMPELLER WHEEL ROTATION
Grasp the edge of the turbine wheel and turn it. Check that
the impeller wheel turns smoothly.
If the impeller wheel does not tum or if it turns with a drag,
replace the turbocharger assembly.
2. INSPECT AXIAL PLAY OF S HAFT BEARING

Insert a dial gauge into the intake side hole the turbine
wheel edge by and check the a�ial play.
Standard clearance: 0.1 3 mm (0.0051 i n.) or less
If not within specification, replace the turbocharger
assembly.
INSTALLATION O F TU RBOCHARGER
(See page TC-9)
CAUTION : After replacing the turbocharger assemb
ly, pour approx. 20 cc ( 1 .2 cu in.) of new oil i nto the oil
inlet and turn the impeller wheel by hand to splash oil
on the bearing.
1. I NSTALL TU RBINE OUTLET ELBOW

Install a new gasket and the turbine outlet elbow with the
four nuts.
EM3541
2. INSTALL TU RBO OIL PIPE

Install a new gasket and the turbo oil pipe with the two
nuts.
Torque : 1 30 kg-cm (9 ft-lb, 1 3 N•m)
EM3540
TURBOC�ARGER SYSTEM - Turbocharger TC-1 5
3. INSTALL N0.1. TURBO WATER PIPE

Install a new gasket and the No. 1 turbo water pipe with
the two nuts.
Torque : 75 kg-cm (65 in.-lb, .7.4 N·m)
EM353
.....
4. INSTALL TURBOCHARGER
Front
(a) Face the new gasket so the protrusion is facing the
rear and install on the exhaust manifold.
0 0 (b) Place a new gasket on the oil return hole of the
cylinder block.
EM3277
(c) Install the turbocharger through the turbocharger

stud bolts and turbo oil pipe stud bolts,
(d) Temporarily i nstall the four nuts holding the exhaust
manifold and turbocharger.
(e) Temporarily install the turbo oil pipe flange nuts.
(f) Temporarily install the union bolt with two new
gaskets.
(g) Torque the turbocharger mounting nuts.

(h)Torque the turbo oil pipe union bolt and flange nuts.
Torque : Bolt 350 kg-cm (25 ft-lb, 3 4 N·m)
Nut 1 30 kg-cm (9 ft-lb, 1 3 N•m)
TC-1 6 T URBOCHARGER SYSTEM - Turbocharger
6. CONNECT UNION PIPE

Connect .. the union pipe with the union bolt and new
gaskets.
6. CONNECT NO.1 TURBO WATER HOSE TO WATER

OUTLET HOUSING
7. INSTALL NO.2 TURBOCHARGER STAY
8. INSTALL TURBOCHARGER STAY

Torque:
To turbocharger
8 1 0 kg-cm (59 ft-lb, 79 N•m)
To engine mounting bracket
590 kg-cm (43 ft-lb, &8 N·m)
9. CONNECT FRONT EXHAUST PIPE

(a) Install a new gasket to the front exhaust pipe.
(b) Connect the front exhaust pipe to the exhaus
manifold with three new nuts.
Torque: 630 kg�cm (46 ft-lb, 62 N·m)
TURBOCHARGER SYSTEM - Turbocharger TC- 1 7
(c) Install the front exhaust pipe clamp.
l!M3634
1 O. INSl;ALL NO.1 AIR CLEANER PIPE WITH NO.6 AIR

. ..\CtEANER HOSE
(a) Install the No. 1 air cleaner pipe with No.6 air cleaner
hose to the No.5 air cleaner hose and turbocharger'.
(b) Connect the No. 1 air cleaner pipe to bracket with the
��
Torque: 1 30 kg-cm (9 ft-lb, 13 N•ml
(c) Tighten the No.5 and No.6 air hose clamps.
EM3582
· 1 1 . INSTA:U. :OIL DIPSTICK GUIDE

·· (�) ·•·· ;l�stall a new 0-ring to the oil dipstick g uide.
(b) 'Insert, the oil dipstick guide to the No.2 oil dipstick
guide.
(c) tc mnect the oil dipstick guide to the turbocharger
with the bolt.
(d) Install the oil dipstick.
EM3632
1 2. INSTALL TURBO HEAT INSULATOR

(a) Install the turbo heat insulator and plate washer with
the three nuts.
(b) Connect oxygen sensor connector.
EM353
1 3. INSTALL NO.7 AIR CLEANER HOSE WITH AIR

FLOW METER AND AIR CLEANER CAP
(a) Install the No. 7 air cleaner hose with air flow meter
(b) Install the bolt and tighten the clamps.
EM3528
TC;;1'8 TU RBOCHARGER SYSTEM - Turbocharger
(c) · Connect the PS idle up air hose.

(d) Connect the air .flow meter. connector.
(e) Connect·the PCV hose and three air hoses.
14. INSTALL N0.4 AIR CLEANER PIPE WITH N0.1

AND N0.2 AIR CLEANER HOSES
II
t
1 5. FILL WITH COOLANT
(See page C0-5)
1 6. CONNECT CABLE TO NEGATIVE TERMINAL OF

BATTERY
1 7. START ENGINE AND CHECK FOR LEAKS

Fl-1
·EFI SYSTEM
Page
SYSTEM DESCRI PTION Fl-214-f;
, \\$,f;'.;�
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl-7 , ., ·
INSPECTION PRECAUTIONS • , • • • . . . • . • • • • • • . . . Fl-7
TROUBLESHOOTING • • • • • . . . • • • • • • • . . . • • • • . • • • Fl-1 2 ·
DIAGNOSIS SYSTEM • • • . • . • . , , • • • • . . . • . . ,. . . . • F l-25
TROUBLESHOOTING WITH
VOLT/OHMMETER (MA) F l-34
TRO U BLESHOOTING WITH
VOLT/OH M M ETER (MS) Fl-57
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl-7 3 •
Fuel Pump . . .. . ·. . . . . . . . . . . . . . - . . . . . . . . . . . ..• . . _ . . Fl•73
Cold Start I njector · . . . • • • • • • ; • • • • , • . , , • • • • • • • F1�ao
Pressure Regulator • • • . • . . • , . • • • • • , • • • • • • . . • • F l�'84
I �jectors .· . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,. . . Fl-86
AI R IND UCTION SYSTEM . . . . . . . . . . . . . . . , . . . . . Fl-96
Air Flow Meter (7M-GE} .................... Fl-96
Air Flow Meter (7M-GTE) ,.................. Fl-98
Throttle Body .............................. Fl-1 02
Idle Speed Control (ISC) Valve • . • • • • . . . . • • • • , Fl-1 08
E LECTRONIC CONTROL SYSTEM . . . . . . . . . . . . . . Fl-1 1 0 1i
Location of Electronic Control Parts • • • • . • • . . . Fl-1 1 0

i'
,. EFI Main Relay . . . . . . . . . . . . . . . ·. . . . . . . . . . . . . . Fl-1 1 2
r
1,
Circuit Opening Relay • . • . • • • • • • . . . • • • • • • • • • • Fl-1 1 3 �i]
i'!
Solenoid Resistor • . • • • . • . . . • • . . • . . . • . • . . • • • • Fl-1 1 4 l

Fl-1 1 5 i
Cold Start Injector Time Switch . . • . • • . • . • . • . •
11
h,l1
Water Temperature Sensor . . . . • • . • • • • • • . • . . . Fl-1 1 6
Fuel Pump Relay and Resistor . . • • • • . . • • • • • . . Fl- 1 1 7
H igh Temperature Line Pressure
�!,.,'
Up System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl-1 1 9
it'.
H igh Altitude Compensation (HAC}
System (7M-GTE) . . . . . . . . . . . . . . . . . . . . . . . . Fl-1 21
Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fl- 1 22
Electronic Controlled U nit (ECU} • • . . . • • • . . . . . Fl- 1 25
Fuel Cut RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . Fl-1 28
!·
:?!
.... N
•
i:
Circuit
Opening
Relay Fuel Pump Relay
Fuel Tank .. · · · · · .... .. •..
Fuel Pulsation VSV (FPU)
Pump
Resistor "--1�---' Damp er
"CHECK
ENGINE"
Warning : '
Light ECU
r;:=======
,! :
Air Temp. Sensor

Electronic Air Flow ......
Meter a, m
Load
-< �
I
a,
�
EGR
m ....
fA
(1)
Vacuum ·� 3
Check Connector Modulator
C Ill
EGR Valve
m ::i. '
u, "C
-:a
=:r.
0 0
:::::,
A/C Compressor
Cold Start Injector Time Switch

Water Temp. Sensor
-
�
0
Speed Sensor To Charcoal Canister
TWC vsv 2
Neutral Start
Switch IA/T)
Circuit
Opening
Fuel Tank .... ---- .. - · ........ . . .. ·
VSV .(FPU)
Pump Fuel Pulsation
Resistor Damper
"CHECK
ENGINE"
Warning
Light ECU
rn
::!!
UJ
Air Temp. Sensor -<
UJ
Electronic Air Flow Cold Start en m
Load Meter Injector
-< 3:
en I
Check Connector -----.irr----- ��: �i H
t::J l!1 J I -I en
i- -rr m -<
Pressure
s: 0
C
;m
Regulator
en :::!.
2
r
.,,--I
(') ::::I
:D
-0
A/C Compressor
Oxygen Sensor
-
Water Temp. Sensor
To Charcoal Canister
2
TWC vsv
(')
0
,.....
-
:::,
Neutral Start a.
Switch WT)
::!!I
w
Circuit
Opening
Fuel Pulsation VSV (FPU)
Re$istor Damper
"CHECK
ENGINE"
Warning
Light ECU
m
To Charcoal Canister ::?!
U)
(Saudi Arabia only) <
Air Temp. Sensor
0 U)
Cl)
Electronic Load
<
Cl)
�
I
-I . en
m ....
s:
C heck Connector er,
Cl)
3
0
m
Cl)
er,
0
::!.
Cl)
-.,,:a
"O
Q'.
(") 0
:::s
A/C Compressor
-0....
Water Tern . Sensor
vsv
-z
(")
-
0
..
::s
,+
a.
..., I
s:
......
Circuit
G)
Fuel Tank
-f
Opening Fuel Pump
m
Battery
�- Ignition S/W Relay
......
I
Relay
ro:t
L:. _.
I !LJ .
,1 1 I
Resistor --..; 1
1
i;:;i�=============;)
mp
·
Pulsation Damper Speed Sensor
�
-=- 8 EB
.------ 1 -----4 I
l===::::!.=========:;)11 I
Electronic L�ad (M/T)
"'
ECU
A/C Compressor
'---
"CHECK ENGINE"
Warning Light
Air By-pass Valve
l_[Jm
r I
V
Igniter Neutral Start Switch (A/T) .,,
m
Ln11
L..IW----�
�
J�\ +
C/)
Pressure r-
a
-<
- Check Connector
1 Regulator
en
C/)
.,_ ia;; I Air Flow Meter

-t
-<
m
�
'I
,... en
Oxygen Sensor l\
�..... ji / === "
-I
J
IS �alve
G- L �I i Ifl l- ,/4p□�\J
TWC � �
BVSV
m
s
� Actuator
1 rl= ;
�o�r,
rl::l I � � - § =�E:::
) ]q - --
.n�;'I�
.....
I
VSV (EG A)
C
_ ��
• ll '" 1(� '- - - -
!-. C ol d Start en
: ffl
"'-.II Injector J d
Cam Positi on
Sensor
-
1 /
I•
0
l"�, >====�1
"- Injector -
n
:D
-_-:_-_-:_-_
.__'-:_-_ -_-_-_---i _-...._
---:i- -_
-_
--
�
Water
Temp. /
1,,t:P �VJ\l\-11 I Il l\
�\I l!m� :::
I\ -. . -= � vsv
�
-::' ...
r:
EGR Vacu um
Modulator -
-I
"tJ
0
-z
I\ IFPU/
( J ill/ TWC 1�• Cold S::•��rit-1

Injecto r Time
�
�
\
�] EGR Vahle
(")
Switch '\ 0
Knock ::,
.,,
Sensor
-..
r+
Q.
:!!
<O I
(JI
-.J
1-6 EFI SYSTEM - System Description
lle . EFI system is composed of 3 basic sub 3. Idle Speed Control {ISC)
;ystems; Fuel Induction, Air Induction and The ECU is programmed with. target idling
:lectronic Control. speed values to respond to different engine
conditions (coolant temperature, air condi
FUEL SYSTEM tioner on/off, etc.). Sensors transmit signals
to the ECU which control the flow of air
An electric fuel pump supplies sufficient fuel, through the bypass of the throttle valve and .
under a constant pressure, to the injectors. These adjust idle speed to the target value.
injectors inject a metered quantity of fuel into the (See pages Fl-53, 7 1 , 1 08) ,.
intake manifold in accordance with signals from
the ECU (Electronic Control Unit). 4. Diagnosis
The ECU detects any malfunctions or abnor
AIR INDUCTION SYSTEM malities i n the sensor network and lights the
"CHECK ENGINE" warning light on the instru
The air induction system provides sufficient air for ment panel. At the same time, the trouble is
engine operation. identified and a diagnostic code is recorded
/�;,) by the ECU.
b.. ECTRONIC CONTROL SYSTEM
5. Fail-Safe Function
The 7M-GE, 7M-GTE engines are equipped with a
Toyota Computer Control System (TCCS) which In the event of computer malfunction, a back
centrally controls the EFI, ESA, Diagnosis systems, up circuit will take over to provide minimal
etc. by means of an Electronic Control Unit (ECU - d rivabil ity. S i m u lta neously, the "CHECK
for-merly EFI computer) employing a microcom ENGINE" warning light will come on.
puter.
By means of the ECU, the TCCS controls the
following functions :
1 . Electronic Fuel Injection (EFI)
The ECU receivers signals from.various sen
sors indicating changing engine operating
conditions such as:
Exhaust oxygen content {w/ TWC)
Intake air volume
Intake air temperature
Coolant temperature
Engine rpm
Vehicle speed
Acceleration/deceleration etc.
These signals are utilized by the ECU to
determine the injection duration necessary for
an optimum air-fuel ratio.
2. Electronic Spark Advance {ESA)

The ECU is programmed with data for
optimum ignition timing under any and all
operating conditions. Using data provided by
sensors which monitor various engine func
tions (rpm, A/C signal, coolant temperature,
etc.), the microcomputer (ECU) triggers the
spark at precisely the right instant. (See IG
section)
EFI SYSTEM - Precautions, Inspection Precautions Fl-7
PRECAUTIONS
1. Before working o n the fuel system, disconnect the
negative terminal from the battery.
NOTE: Any diagnosis code retained by the computer will
be erased when the battery terminal is removed.
Therefore, if necessary, read the diag nosis before
removim g the battery terminal.
2. Do not smoke or work near an open flame when work
ing on the fuel system.
3. Keep gasoline off rubber or leather parts.
I NSPECTION PRECAUTIONS
MAINTENANCE .PRECAUTIONS
1. INSURE CORRECT ENGINE TUNE-UP
2. PRECAUTIONS WHEN CONNECTING GAUGE

(a) Connect the tachometer test probe to the terminal
IG 8 of check connector. .
See pages Fl-1 1 O, 1 1 1
(b) Use the battery as the power source for the timing
light, tachometer, etc.
3. IN EVENT OF ENGINE MISFIRE FOLLOWING

PRECAUTIONS SHOULD BE TAKEN
(a) Insure proper connection of battery terminals, etc.
(b) Handle high tension cords carefully.
(c) After repair work, insure that the ignition coil ter
minals and all other ignition system lines are recon
nected securely.
(d) When cleaning the engine compartment, be especial
ly careful to protect the electrical system from water.
IG0591l
4. PRECAUTIONS WHEN HANDLING OXYGEN SENSOR

(w/ TWC)
(a) Do not allow oxygen sensor to drop or hit against an
object.
(b} Do not allow water to come into contact with the
sensor or attempt to cool it.
-8 EFI SYSTEM ..- Inspection Precautions
I F VEHICLE IS EQUIPPED WITH MOBILE

RADIO SYSTEM (HAM, CB, ETC) .
The ECU h as been designed so that it will not be affected by
outside interference.
However, if your vehicle is equipped with a CB radio
transceiver, etc. (even one with about 1 0 W output), it may. at
times, h ave an affect upon ECU operation, especially if the
antenna and feeder are installed nearby.
Therefore, observe the following precautions:
1. Install the antenna as far as possible from the ECU. The
ECU is located behind the glove box (MA) or passenger's
kick panel {MS), so the antenna should be installed in the
rear of the vehicle.
2. Keep the antenna feeder as far away as possible from the
ECU wires at least 20 cm (7.87 in.), and especially, do not
wind them together.
3. Insure that the feeder and antenna are properly adjusted.
4. Do not equip your vehicle with· a powerful mobile radio
system,
5. Do not open the cover or the case of the ECU unless
absolutely necessary. (If the IC terminals are touched, the
I C may be destroyed by stati c electricity.)
AIR INDUCTION SYSTEM

1. Separation the engine oil dipstick, oil filler cap, PCV hose,
etc.. may cause the engine to run out of tune.
2. Disconnection, looseness or cracks in the parts of the air
induction system between the air flow meter and cylinder
head will allow air suction and cause the engine to run out
of tune.
7M-GTE
EFI SYSTEM - Inspection Precautions Fl-9
ELECTRONIC CONTROL SYSTEM

1. Before removing EFI wiring connectors, terminals, etc.,
first disconnect the power by either turning the ignition
switch OFF or disconnecting the battery terminals.
2. When installing a battery, be especially careful not to
incorrectly connect the positive and negative cables.
3. Do not permit parts to receive a severe impact during
removal or installation. Handle all EEi parts carefully.
especially the ECU.
Fl1066
4. Do not be careless during troubleshootin g as there are
numerous transistor circuits and even slight terminal con
tact can cause further troubles.
5. Do not open · the ECU cover.
6. When inspecting during rainy weather, take care to pre
vent entry of water. Also, when washing the engine com
partment, prevent water from getting on . the EFI parts and
wiring connectors.
7. Parts should be replaced as an assembly.
8. Care is requ ired when pulling out the inserting wiring con
nectors.
{a) Release the lock and pull out the connector, pulling
on the connectors.
Lock Spring
Fl0092 FI0093
(b) Fully insert the connector and insure that it is locked.
9. When inspecting a connector with a circuit tester.

(a) Carefully take out the water-proofing rubber if it is a
water-proof type connector.
FI0095 FI0095
Fl- 1 0 EFI SYSTEM - Inspection Precautions
(b} Insert the tester probe i nto the connector from the
wiring side when checking the continuity,, amperage
or voltage.
(c) Do not apply unnecessary force to the terminal.
(d) After checking, install the water-proofi ng rubber on
the connector securely.
FI0097 FI0098
1 0. Use SST for inspection or test of the injector, cold start

injector or its wiring connector.
SST 09842-30060 and 09842-30060
Ft1596
FU E L SYSTEM
1. When disconnecting the high fuel pressure line, a large
amount of gasoline will spill out, so observe the following
procedure.
Plug � (al Put a container under the connection.
(bl Slowly loosen the connection.
(c) Disconnect the connection.
(d) Plug the connection with a rubber plug. ·
Fl0419 FI0421
2. When connecting the flare nut or union bolt on the high

pressure pipe union, observe the following procedure :
(Union bolt type)
(a) Always use a new gasket.
(bl Hand tighten the union bolt.
(c) Tighten the bolt to the specified torque.
Torque: 300 kg-cm (22 ft-lb, 29 N ·m)
Fl1 067 Fl1068
(Flare nut type)

Fulcrum Length
(a) Apply a thin coat of oil to the flare and tighten the
ao CIJ? flare nut.
(b) Then using SST, tighten the nut to the specified tor-
que.
SST 0963 1 - 22020
Torque: 31 0 kg-cm (22 ft-lb, 30 N·m)
NOTE: Use a torque wrench with a fulcrum length of 30
cm (1 1 .8 1 in.) .
EFI SYSTEM - Inspectio n Precautions Fl-1 1
3. Observe the fo!lowing precautions when removing and

installing the injectors.
(a} Never reuse a 0-ring.
(b) When placing an 0-ring on the injector, use care care
not to damage it in any way.
(c) Lubricate the 0-ring with spindle oil or gasoline
before installing - never use engine, gear or brake oil.
F11598
4. Install the injector to the delivery pipe and cylinder head as

Black Ring shown in the figure.
Delivery
Spacer---==�� ,..__, Pipe NOTE: Install the spacer with the black ring side facing
---O-Ring upward.
�� _:-
-___Grommet
Cylinder '-. )'::;__--- Injector
Head
.41r----- lnsulator
5. Check that there are no fuel leaks after performing any

maintenance on the fuel system.
(a} With engine stopped, turn the ignition switch ON.
(b) Short circuit the fuel pump check terminal +B and FP
of the check connector with the service wire.
See pages Fl-1 1 0, 1 1 1
(c) When the fuel return hose is pinched, the pressure

within the high pressure line will rise to about 4 kg/
cm (57 psi, 392 kPa). In this state, check to see that
there are no leaks from any part of the fuel system.
CAUTION : Always pinch the hose. Avoid bending as
it may cause the hose to crack.
1- 1 2 EFI SYSTEM - Troubleshooting·
TROU BLESHOOTIN·G
TROU BLESHOOTING HINTS
1. Engine troubles are usually not caused by the EFI system.
When troubleshooting, always first check the condition of
the other systems.
(a) Electronic source
• Battery
• Fusible links
• Fuses
(b) Body ground
(c) Fuel supply
• Fuel leakage
• Fuel filter
• Fuel pump
(d) Ignition system .
• Spark plug
• High-tension cord .
• Distributor (7M-GE) · or cam position sensor (7M
GTE)
• Igniter and ignition coil
(e) Air induction system
• Vacuum leaks
(f) Emission control system
• PCV system
• EGR system (w/ EGR)
(g) Others
• Ignition timing (ESA system)
• Idle speed (ISC system)
2. The most frequent cause of problems is simply a bad con

tact in wiring connectors. Always make sure that connec
tions are secure.
When inspecting the connector, pay particular attentiQn to
the following points:
(a) Check to see that the terminals are not bent.
(b) Check to see that the connector is pushed in com
pletely and locked.
{c) Check to see that there is no signal change when the

connector is slightly tapped or wiggled.
3. Sufficiently troubleshoot for other causes before replac

ing the ECU. The ECU is of high quality and it is expensive.
EFI SYSTEM ,- Troubleshooting Fl- 1 3
4. Use a volt/ohmmeter .with high impedance (1 0 k. !l N

Digital Type
Analog Type minimum) for troubleshooting of the electrical circuit.
I�
TOYOrA ILIC'l'IIC.lt � I'. / (See pages Fl-34, 5 7)
0· �
- ~
I/ \
+ @
D{ l)
� 1 . --@
Fl0889
TROUBLESHOOTING PROCEDURES
SYMPTOM - DIFFICULT TO START OR NO START
(EN(j lN,E WILL NOT CRANK OR CRANKS SLOWLY)
CHECK ELECTRIC SOURCE BAD 1 . Battery

(1 ) Connection
(2) Gravity - Drive belt - charging system
(3) Voltage
2. Fusible links
toK
CHECK STARTING SYSTEM BAD 1 . Ignition switch

2. Starter relay (MS)
3. Starter
4. Neutral start switch (A/T)
5. Wiring/Connection
EFI SYSTEM - Troubleshooting
SYM PTOM - DIFFIC U LT TO START O R NO START (CRANKS OK)
CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic code (s) (See pages Fl-30, 3 1 , ·32)
Check for output of diagnostic code. code(s)
(See page Fl-26)
i Normal code
,,
DOES ENGINE START WITH OK ISC system

ACCELERATOR PEDAL DEPRESSED? ( 1 ) ISC valve
(2) Wiring connection
l No
CHECK FOR VACUU M LEAKS IN AIR BAD 1 . Oil filler cap

INTAKE LINE 2. Oil dipstick
3. Hose connections
I
4. PCV hose
5. (w/ EGR)
EGR system - EGR valve stays open
! oK
CHECK IGNITION SPARK BAD 1 . High-tension cords
7M-GE {See page IG-5) 2. Distributor (7M-GE) or cam position
7M-GTE (See page IG-1 2} sensor (7M-GTE)
3. Ignition coil
4. Igniter
! oK
CHECK SPARK PLUGS NO 1 . S park plugs
Plug gap: 2. Compression pressure
7M-GE Conventional Tipped Type Limit: 9.0 kg/cm2 (1 28 psi, 883 kPa)
0.8 ·mm {0.031 In.) at 260 rpm
7M-GE Platinum Tipped Type 3. Valve clearance (Cold)
1 .1 mm (0.043 in.) STD: I N 0.1 8 - 0.25 m m
7M-GTE (0.006 -- 0.01 0 in.)
0.8 mm (0.031 In.) EX 0.20 - 0.30 m m
NOTE: Check compression pressure and (0.008 - 0.0 1 2 in.)
valve clearance if necessary.
BAD 1 . Injector - shorted or leaking

I
2. Injector wiring between resistor and
� J
�Plugs
ECU shorted
WET 3. Cold start injector - leakage
(See page Fl-80)
4. Cold start injector time switch
!
(See page Fl- 1 1 5)
OK CONTINUED ON PAGE Fl- 1 5

EFI SYSTEM - Troubleshooting Fl-1 5
CONTINUED FROM PAGE Fl- 1 4
CHECK F U EL SUPPLY TO INJECTOR BAD 1 . Fuel line - leakage - deformation

1 . Fuel in tank 2. Fuse
2. Fuel pressure in fuel line 3. Fuel pump (See age Fl-73)
(1 ) Short terminals +B and FP of the 4. Fuel filter
check connector. 5. Fuel pressure regulator (See page Fl-84)
(2) You can feel · fuel pressure in fuel 6. Circuit opening relay (SeE;' page Fl- 1 1 3)
return hose.
3. Check circuit opening relay
CHECK FUEL PUMP SWITCH IN AIR BAO Air flow meter {See page Fl-96)
FLOW METER (7M-GE)
Check continuity between terminals FP and
E1 with measuring plate of. air flow meter
open.
CHECK IGNITION TIMING NO Adjust ignition timing {See page EM- 1 7)

1 . Short terminals T (MA) or TE1 (MS) and
E1 of the check connector.
2. Check ignition timing.
STD : 1 0° BTDC @ Idle
(w/ short circuited T(MA) or'!
lTE1 (MS) - E1 j
l oK
CHECK EFI ELECTRONIC C IRCUIT BAD 1 . Wiring connection
USING VOLT/OHMMETER 2. Power to ECU
(See pages Fl-34, 5 7) (1 ) Fusible links
(2) Fuses
(3) EFI main relay
3. Air flow mete r
4. Water temp. sensor
5. Air temp. sensor
6. Injection signal circuit
( 1 ) Injector wiring
(2) Resistor
(3) ECU
1-1 6 EFI SYSTEM - Troubleshooting
SYMPTOM - ENG I NE OFTEN STALLS
CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic code(s) (See pages Fl- 30, 3 1 , 32)
Check for output of diagnostic code. code (s)
, (See page Fl-26)
l Normal code
CHECK FOR VACUU M LEAKS IN AIR BAD 1 . Oi! filler cap

INTAKE LINE 2. Oil level gauge .
3. Hose connections
4. PCV hose
l OK
CHECK FUEL SU PPLV TO INJECTOR

·" BAD 1 . Fuel line - leakage - deformation
Fuel in tank 2. Fuse
<L. Fuel pressure in fuel line 3. Fuel 'pump (See' page Fl-7 3)
(1 ) Short terminals +B and FP of the check 4. Fuel filter
connector. 5. Fuel pressure regulator (See page Fl-84)
(2) You can feel fuel pressure in fuel 6. Circuit opening relay (See page Fh 1 1 3) ·
return hose. ,
3. Check circuit opening relay

l OK
. Element -- Clean or replace
CHECK AIR FILTER ELEMENT BAO
l oK
CHECK IDLE SPEED BAD ISC system
STD: 7M-GE w/ TWC 700 rpm (1 ) Wiring connection
7M-GE w/o TWC 800 rpm (2) ISC valve
7M-GTE · 800 rpm (3) ECU
•·
l oK
,.
CHECK IGNITION TIMING NO Adjust ignition timing. (See page EM- 1 7)

1 . Short terminals T(MA)or TE1 (MS) and
E1 of the c heck connector.
STD: 1 0° BTDC @ Idling
w/ short circuited T(MA} oj
(
TE1 (MS) - E 1
! oK
CHECK SPARK PLUGS BAO 1 . Spark plugs
7M-GE Conventional Tipped Type Limit: 9.0 kg/cm2 (1 28 psi, 883 kPa)
0.8 mm (0.031 in.) at 250 rpm
1 . 1 mm (0.043 in.) STD: IN 0. 1 5 - 0.26 mm
7M-GTE (0.08 - 0.01 O in.)
0.8 mm (0.031 in.} EX 0.20 - 0.30 mm
NOTE: C heck compression pressure and (0.008 - 0.01 2 in.}
-t - - - - - - - ;" lrl''U!'\ l"lOCC�r\/
EFI �YSTEM - Troubleshooting Fl- 1 7
l oK CONTINUED FROM PAGE Fl- 1 6

..
CHECK COLD START INJECTOR BAO 1 . Cold start injector

(See page Fl-80) 2. Cold start injector time switch
l
i oK
CHECK FUEL PRESSU RE BA.0 1 . Fuel pump (See page Fl-73)

(See page Fl- 7 4) 2. Fuel filter
3. Fuel pressure regulator (See page Fl-84)
1 OK
CHECK INJECTORS BAO I njection condition

(See page Fl-86)
···•
! OK
CHECK EFI ELECTRONIC CIRC U IT BAO 1 . Wiring connection

(See pages Fl-34, 5 7) ( 1 ) Fusible links
(2) Fuses
(3} EFI main relay
3. Air flow meter
5. Air temp. sensor
6. I njection signal circuit
(2) Resistor
(3} ECU
SYMPTOM - ENGINE SOMETIMES STALLS
I CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic code(s) (See pages Fl-30, 3 1 , 32)
Check for output of diagnostic code. code (s)
. (See page Fl-26)
l Normal code .
CHECK AIR FLOW METER · BAD Air flow meter

(See pages . Fl-96, 98)
! oK
CHECK WIRING CONNECTORS AND BAO 1 . Connector '

RELAYS 2. EFI main relay (See page Fl- 1 1 2)
Check for a signal change when the connec- 3. Circuit opening relay (See page Fl- 1 1 3)
tor or relay is slightly tapped or wiggled.
8 EFI SYSTEM - Troubleshooting
SYMPTOM - ROUGH I DLIN G AND/OR M ISSING
iECK DIAGNOSIS SYSTEM Malfunction Diagnostic code(s) (See pages Fl-30, 3 1 , 32)
1eck for output of diagnostic code. code (s)
ee page Fl-26)
Normal code
'
HECK FOR VACUUM LEAKS I N AIR BAD 1 . Oil filler .cap

\JTAKE LINE 2. Qil level gauge
3. Hose connections
4. PCV hose
6. EGR system - EGR valve stays open (EGR)
OK
-
I
:v· .':K AIR FILTER ELEMENT BAD Element - Clean or replace
OK
CHECK I DLE SPEED BAD ISC system

STD : 7M-GE w/ TWC 700 rpm (1 } Wiring connection
7M-GE w/o TWC 800 rpm (2) ISC valve
7M-GTE 800 rpm (3) ECU
OK

1. Short terminals T(MA) or TE 1 (MS) and
E 1 of the check .connector.
STD : 1 0° BTDC @ Idling
w/ short circuited T(MA} o r]
( .
TE1 (MS) - E1
OK
(
CHECK SPARK PLUGS BAD 1 . Spark plugs
7M-GE Conventional Tipped Type Limit: 9.0 kg/cm2 ( 1 28 psi, 883 kPa)
0,8 mm (0.031 in.) at 250 rpm
1 .1 mm (0,043 In.) STD: I N 0,1 5 - 0.26 m m
7M-GTE (0.06 - 0.01 O in.)
0.8 mm (0.031 In.) EX 0.20 - 0.30 m m
NOTE: Check compression pressure and (0.008 - 0.01 2 i n.)
OK CONTINUED ON PAGE Fl- 1 9

'
EFI SYSTEM - Troubleshooting Fl-1 9
l oK CONTINUED FROM PAGE Fl- 1 8 ..
CHECK COLD START INJ ECTOR BAD 1 . Cold start injector

l oK
CHECK FUEL PRESSU RE BAD 1 . Fuel pump (See page Fl- 73)
(See page Fl-7 4) 2. Fuel filter
! oK
CHECK INJECTORS BAD Injection condition
(See page Fl-86)
! oK
J>
·.- , �HECK EFI E LECTRONIC CIRCUIT BAD 1 . Wiring connection
(See pages Fl-34, 5 7) . (1) Fusible links
(2) Fuses
(3) EFI main relay
3. Air flow meter
5. Air temp. sensor
6. Throttle position sensor
(1 ) Injector wiring
(2) Resistor
(3) ECU
20 EFI SYSTEM - Troubleshooting
SYM PTO M - H IGH E N G I N E I D LE SPEED (NO DROP)
;HECK ACCELERATOR LINKAGE BAD Linkage - Stuck
OK
CHECK, POWER STEERING IDLE�UP BAD Air valve

SYSTEM
OK
CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic code(s) (See pages Fl-30, 3 1 , 32)
Check for output of diagno�1ic code. code(s)
(See page Fl".' 26)
Normal code
CHECK ISC SYSTEM BAD 1 . Wiring connection

(Air con, Throttle position sensor - ECU)
2. ISC valve
3. Air conditioner switch
OK
CHECK THROTTLE POSITION SENSOR BAD Throttle body
OK
CHECK FUEL PRESSU RE BAD Fuel pressure regulator - High pressure

(See page Fl-7 4)
OK
CHECK COLD START INJ ECTOR BAD Cold start injector - Leakage
,ee page Fl-80)
OK
CHECK INJECTORS (See page Fl-86) BAD I njectors - Leakage, Injection quality
OK
CHECK EFI ELECTRON IC CIRCUIT USING BAD 1 . Wiring connection

VOLT/OHMMETER 2. Power to ECU
(See pages Fl-34, 57) ( 1 ) Fusible links
(2) Fuses
{3) EFI main relay
3 . Air flow meter
5. Air temp. sensor
(2) Resistor
{3) ECU
EFI SYSTEM - Troubleshooting Fl-21
·. SYM PTOM - ENGINE BACKFIRES-Lean Fuel M ixture
CHECK DIAGNOSIS SYSTEM Malfunction Diagnostic code(s) (See pages Fl-3O, 3 1 , 32)
Check for output of diagnostic code .code (s)
(See page Fl-26)
! Normal code
..
CHECK FOR VACUUM LEAKS IN AIR BAD 1. Oil filler cap
INTAKE LINE 2. Oil dipstick
3. Hose connections
4. PCV hose
! oK

1. Short terminals T (MA) or TE1 (MS) and
E 1 of the check connector.
> � . Check ignition timing.
(wf short circuited T(MA) or)
TE1 (MS) - E 1
! oK
CHECK COLD START INJECTOR BAD 1 . Cold start injector

(See page Fl-8O) 2. Cold start injector time switch
(See page Fl- 1 1 5 )
..
! OK
CHECK FUEL PRESSURE BAD 1 . Fuel pump (See page Fl-73)

(See page Fl-7 4) 2. Fuel filter
3. Fuel pr�ssure regulator (See page Fl-84)
! oK
I
. ":HECK INJECT()RS BAD Injectors - Clogged
\ !\See page Fl-86)
! OK· ":
" '
CHECK EFI ELECTRON IC CIR.C U IT BAD 1 •. VViring connection
USING VOLT/OHMME:r�R 2. Power to ECU
(See pages Fl-34, 5 7) (1 ) Fusible links
(2) Fuses
(3) EFI main relay
3. Air flow meter
4. Water temp •. sensor
5. Air temp. sensor
(1 ) Injector wiring
(2) Resistor
(3) ECU
(4) Fuel cut signal
8. Oxygen sensor
..
EFI SYSTEM - Troubleshooting
SY MPTOM - MU FFLER EXPLOSION (AFTER FIRE)

-Rich Fuel Mixture-Misfire
CHECK D IAGNOSIS SYSTEM Malfunction Diagnostic code (s) (See pages Fl-30, 3 1 , 32)
Check for output of diagnostic code code(s)
(See page Fl-26)
! Normal code

1 . Short terminals T (MA) or TE1 (MS) and
w/
short circuited T (MA) o �
! G
TE1 (MS) - E 1
l oK
CHECK COLD START INJECTOR BAD 1 . Cold start injector

! OK
I
CHECK INJECTORS BAD Injector - Leakage
! OK
CHECK SPARK PLUGS NO 1 . Spark plugs

7M-GE Conventional _Tipped Type Limit: 9.0 kg/cm2 ( 1 28 psi, 883 kPa)
0.8 mm (0.031 In.) at 260 rpm
1 .1 mm (0.043 in.) STD: IN 0,1 5 - 0.25 m m
EX 0.20 - 0.30 mm
7M-GTE (0.08 - 0.01 0 In,)
0.8 mm (0.031 in.)
NOTE: Check compression pressure and (0.008 - 0.0 1 2 In.)
l OK
CHECK EFI ELECTRONIC CIRCUIT USING BAD 1 . Throttle position sensor

VOLT/OHMMETER 2. Injection �ignal circuit
(See pages Fl-34, 57) ( 1 ) Injector wiring
(2) Resistor
(3) ECU
3. Oxygen sensor
EFI .SYSTEM - Troubleshooting Fl-23
SYMPTOM - ENG I N E HESITATES AND/O R POOR ACCELERATION
CHECK CLUTCH AND BRAKE BAD 1 . Clutch - Slips

2. Brakes - Drag
l oK
CHECK FOR VACUUM LEAKS IN AIR BAD 1. Oil filler cap
INTAKE LINE 2. Oil level gauge
3. Hose connections
4. PCV hose
5. EGA system - EGA valve stays open {EGR)
! oK
Element - Clean or replace
I I·
CHECK AIR FILTER ELEMENT BAO
l oK
CHECK DIAGNOSIS SYSTEM M alfunction Diagnostic code(s) {See pages Fl-30, 3 1 , 3 2)
Check for output of diagnostic code. code
(See page Fl-26)
i Normal code
CHECK IGNITION SPARK BAD 1. High-tension cords

7M-GE (See page IG-5) 2. Distributor (7M-GE) or cam position
7M-GTE (See page IG-1 2) sensor (7M-GTE)
3. Ignition coil
4. Igniter
t oK
CHECK IGNITION TIMING NO Adjust' ignition timing. (See page EM- 1 7)
1. Short terminals T (MA) or TE 1 (MS) and
STD: 1 0° BTDC @ Idling
�
w/ short circuited T (MA) oj
l'E1 (MS) - E1
l OK
CHECK FUEL PRESSURE BAD 1 . Fuel pump (See page Fl-73)

(See page Fl-7 4) 2. Fuel Filter
! oK
CHECK INJECTORS BAD Injection condition
(See page Fl-86) -
i oK CONTINUED ON P AGE Fl- 24
Fl-24 EFI SYSTEM .,... Troubleshooting
OK . . CONTINUED FROM PAGE Fl-23
CHECK SPARK PLUGS BAD 1 . Spark plugs

Plug gap: 2. Compression pressu re
7M-GE Conventional Tipped Type Limit: 9.0 kg/cm2 ( 1 28 psi, 883 kPa}
0�8 mm (0�03 1 'in;) · at 260 rpm
1 .1 mm (0.043 in.) STD : IN 0.1. 5 - 0.25 mm
7M-GTE (0.06 ·- .0.01 0 in.)
0.8 mm (0.031 in.) EX 0.20 - 0.30 mm
NOTE: Check compression pressure and (0.008 - 0.0 1 2 in.)
valve �learance if neceSJElry.
,C.H ECK EFI ELECTRONIC'CIRCUIT BAD 1 . Wiring connection

. .. JING VOLT/OHMMETER 2. Power to ECU
(See ·pages F1.;;34:;sn· (1 ) Fusible links
{2) Fuses
{3) EFI main relay
3. Air flow meter ·
5. Air temp. sensor
{1 ) Injector wiring
{2) Resistor
(3) ECU
EFI SYSTEM - Diagnosis' System Fl-25
DIAGNOSIS SYSTEM
D ESCRIPTIQJ\Jti-
��ir::i·_ -: -. :.:�
,'�', � ,_•, I :
(MA)
The ECU contains a built-in self-diagnosis system by which
troubles with the engine signal network are detected and a
"CHECK ENGINE" warning light on the instrument panel
flashes.
By analyzing various signals as shown in the later table (See
pages Fl-30, 3 1 l the Electronic Control Unit (ECU) detects
system malfunctions which are related to the various operating
parameter sensors or to the actuator. The ECU stores the
failure until the d iagnosis system is cleared by removing the EFI
fuse with the ignition switch off.
A "CHECK ENGINE" warning light_ on the instrument panel
informs the d river that a malfunction has been detected.
The light goes out automatically when the malfunction has
been cleared.
The diagnostic code can be read by the number of the blinks of
the "CHECK ENGINE" warning l ig ht when T and E 1 are short-
circuit
(MS)
The ECU contains a built-in self-diagnosis system by which
troubles with the engine signal network are detected and a
"CHECK ENGINE" warning light on the instrument panel
flashes.
By analyzing various signals as shown in the later table (See
page Fl-32) the Electronic Control Unit (ECU) d etects system
malfunctions which are related to the various operating
parameter sensors or to the actuator. The ECU stores the
failure until the diagnosis system is cleared by removing the EFI
fuse with the ignition switch off.
In the ECU, a test mode function has been added to the func
tions of the self-diagnosis system of the previous diagnosis
mode (normal mode) for the purpose of detecting malfunctions
such as poor contact which are difficult to detect in the normal
mode. This function fills up the self-diagnosis system. The test
mode can be i mplemented by the technician to follow the pro
cedures of appropriate check terminal connection and opera
tion described in later (See page Fl-28).
In the normal mode, the self-diagnosis system monitors 1 4
items, indicated by the codes except for code No. 5 1 as shown
in Fl-32. A "CHECK ENGINE" warning light on the instrument
panel informs the d river that a malfunction has been detected.
The light goes out automatically when the malfunction has-
been cleared.
The diagnostic code can be read by the number of the blinks of
the "CHECK ENGINE" warning l ight when T E 1 and E1 are
short-circuited.
Fl-26 . EFI SYSTEM - Diagnosis System
I n the test mode, seven items, indicated by code N

24, 4 1 , 42, 43, and 5 1 , its s hown in Fl-32 are mo
malfunction is detected in any one of the systems i n .. by
code Nos. 1 3, 22, 24, and 41 the ECU lights the "CHECK
ENGINE" warning light to warm the technician that the mal
function has been detected. In this case, TE2 and E 1 terminals
on the check connector should be connected as shown later
(See page Fl-28)
In the test mode, for all seven conditions shown above in code
Nos. 1 3 - 5 1 , even if the malfunction is corrected, the mal
function is stored in the ECU memory while the ignition switch
remains on. Also, when a malfunction occurs for the four con
ditions from code Nos. 1 3 - 4 1 , the "CHECK ENGINE" warning
light remains on. However, once the ignition switch is turned to
OFF, the ECU erases all of the malfunctions in the memory. The
diagnostic mode (normal or test) and the output of the "CH ECK
· ENGINE" warning light can be selected by the TE 1 , TE2 and E 1
terminal connections o n the .c heck connector, a s shown i n the
later.
i''
.,CHECK ENGINE" WARNING LIGHT CHECK

1. The "CHECK ENGINE" warning light will come on when
the ignition,tY;'..!!ch is placed at ON and the engine is not
running.
�-.
2. When tht:1 engine is &"tarted, the "CHECK ENGINE" warning
light should go out. ·
"CHECK ENGINE" Warning Light If the light remains on, the diagnosis system has detected
a malfunction or abnormality in the system.
Fl2552
OUTPUT OF DIAGNOSIS CODES

(MA)
To obtain a n output of diagnostic codes, proceed as follow�: ,:_,,�t
1. Initial conditions
(a) Battery '(Oltage about 1 1 volts
(b) Throttle valve fully closed (throttle position sensor
IDL points closed)
(cl Transmission i n neutral position
(d) Accessory switches OFF
2. Turn the ignition switch to ON. Do not start the engine.

�� W 1/,r, NL{W
EFI �:VSTEM - Diagnosis System
�V\ _kf:_ Fl-27
3. Using a service- wire, short terminals T (MA) or TEf(MS)

and E 1 of the check connector.
CHECK CONNECTOR LOCATION :
See pages Fl- 1 1 0, 1 1 1
4. Read the diagnosis code as indicated by the number of

flashes of the °CHECK ENGINE" warning light.
" CHECK ENGINE" Warning Light

FI0293
Diagnosis code (See pages Fl-30, 3 1 , 3 2)

(a) Normal System Operation
0.2 5 • The light will alternately brink on ancJ off for 0.26
second intervals.
ON ON ON ON
{Seconds)
0.25
FI0294
(b) Malfunction Code Indication

Code No. 3 2
• The light will blink the number of times equal to
the malfunction code indication with pauses as ·
follows: ..
1. Between the first digit and second digit, 1 . 6
seconds.
3
4.0 2. Between code and code, 2.6 seconds.
2.5 4.5 \�;
3. Before repeating all malfunction codes, 4.5
. .
1 .5 {Seconds) seconds.
FI0296 • The diagnostic code series will be repeated as long
as the "CHECK ENGINE" connector terminals
T (TE 1 ) and E 1 are shorted.
NOTE: In event of a number of trouble codes, indication
will begin from the small value and continue to the larger
in order.
6. After the diagnosis check, remove the service wire.

28 EFI SYSTEIVI_ - Diagnosis System
(MS)
Normal mode
(See procedure MA)
-�_ ________,_/v k /4 hL t,�e--
Test mode
To obtain an output of diagnostic codes, proceed as follows :
1 . Initial conditions
(a) Battery voltage about 1 1 volts
(b) Throttle valve fully closed (throttle position sensor
IDL points closed) .
(c) Transmission in neutral position
(d) Accessory switches OFF
a
2. Using a service wire, short terminals TE2 and E1 of the
.•o/
check connector.
Service Wire
the engine and run the vehicle at a speed of 1 0 km/h
(6 mph) or higher.
0 re(
0 �
E1� 4. Simulate the conditions of the malfunction described by
/ /
Check Connector
; /
the user.
// 5. Using a service wire, short terminals TE 1 and E 1 of the
check connector.
NOTE:
Fl2814
• The test mode will not start if terminals TE2 and E 1 are con
nected after the ignition switch is turned on, or terminals TE2
and E1 are connected after terminals TE1 and E1 are con
nected.
• The starter signal and vehicle spee_d signal will be diagnosed
by the ECU as malfunctions, and codes No. 42, and 43 will
be output, if_ the operation in 3. above is not performed.
6. Read the diagnosis code as indicated by the number of

flashes of the "CHECK ENGINE" warning light.
(See page Fl-27)
7. After the diagnosis check, remove the service wires.
EFI SYSTEM - Diagnosis System Fl-29
. CANCELLI NG OUT DIAGNOSTIC CODE

..
1. After repair of the trouble area, the diagnostic code
retained in memory by the ECU must be _c ancelled out by
removing the EFI fuse 1 5A for 30 seconds or more,
depending on ambient temperature (the lower the tem
perature, the longer the fuse must be left out} with the
ignition switch off.
NOTE:
• Cancellation can also be done by removing the battery ·
EFI 1 5A
MS negative (-} terminal, but in this case other memory
LHD EFI 1 5A systems (clock etcJ will also be cancelled out.
• If the diagnostic code 1s not cancelled out it will be
retained by the ECU and appear along with a new code
in event of future trouble.
• If it is necessary to work on engine components requir
ing removal of the battery terminal, a check must first
be made to see if a diagnostic code has been recorded.
2. After cancellation, road test the vehicle to check that a
"normal" code is now read on the "CHECK ENGINE"
warning light.
If the same diagnostic code is stiU indicated, it means that
the trouble area has not been repaired thoroughly.
EFI 1 5 A
1'11 603
Fl2822
DIAG NOSIS INDICATION

(1} When 2 or more codes are indicated, the lowest number
(code} will appear first.
However, no other code will appear along with code No.
1 1.
(2) All detected diagnostic codes, except 5 1 and 53, will be
retained in memory by the ECU from the time of detection
until cancelled out.
(3) Once the malfunction is cleared, the "CHECK ENGINE"
warning light on the instrument panel will go out but the
diagnostic code (s) remain stored in ECU memory (except
for codes 5 1 and 53).
1-30 .EFI SYSTEM - Diagnosis System
DIAGNOSTIC CODES (MA)

Number of
iCode Check engine System Diagnosis Trouble area See
1 No. blinks page
- JlJlilJlJ1_
F111!04
Normal This appears when none of
the other codes area identified. ·
- -
• Ignition switch circuit
Momentary interruption in • Ignition switch
11 _fl_fl__ ECU (+B)
power supply to ECU. •
•
Main relay circuit
Main relay
Fl-41
Fl1 605
• ECU
N o "NE" or "G" signal to • Distributor circuit

• Distributor
12
-1l.IlfL_ RPM Signal ECU within 2 seconds after
engine has been cranked. • Starter signal circuit
IG-3
Flf608
• ECU
:Cf No "NE" signal to ECU when •. Distributor circuit
. .J
__fLfU1fL_ RPM Signal engine speed is above
1 ,000 rpm.
• Distributor .
• ECU
IG-3
Fl1607
• Ignition and ignition coil
14 -1Lf1illUl Ignition Signal No "IGF" signal to ECU
6 - 8 times in succession.
circuit
• Igniter and ignition coil
Fl-5 1
FIH\08
• ECU
•1 Oxygen Sensor Oetectio!:' of oxygen sensor • Oxygen sensor circuit

21 ___fUUL_ Signal deterioration. • Oxygen sensor
• ECU
Fl-1 22
F11tl09
• Water temp. sensor

Water Temp. Open or short circuit in water . .1 �irelJit
22 .
Sensor Signal temp. sen_sor signal. • Water temp. sensor
Fl-49
:',•,.:-�:,.
Fl1 610
• ECU
• Intake air temp. sensor
24 --1UUU1J1fL ln_take Air Temp Open or short circuit in intake
Sensor Signal air temp. sensor signal.
circuit
• Intake air temp. sensor
Fl-48
''; . Flt81 I
• ECU
. ·.
r ;
(7M-GE)
Open circuit in VC signal or
short circuit between VS and • Air flow meter circuit
Air-flow
31 -1UlflJL_ Meter Signal
E2 when idle contacts are
closed.
• Air flow meter Fl-44
• ECU
(7M-GTE)
Open or Short circuit in air
Fl1 6 1 2
flow meter signal.
(7M-GE) (7M-GE) • Air flow meter circuit
Air Flow Open circuit in E2 or short • Air flow meter Fl-44
Meter Signal circuit between VC and VS. • ECU
32 _flfUlfUL_ (7M-GTE) (7M-GTE) • HAC sensor circuit
HAC Sensor .Open or short circuit in HAC • HAC sensor Fl-56
Signal sensor signal • ECU
Fl1 813
-
•3 • Turbocharger
•2
34 -11flJlJU1IUl Turbocharger
Pressure
Turbocharger pressure is
abnormal.
•
•
•
Air flow meter
lntercooler system
ECU
Fl281 8
Throttle • Throttle position sensor

Open or short circuit in circuit
41 -11fUlJlJL_ Position
Sensor Signal throttle position sensor signal. • Throttle position sensor
Fl-42
i:11A"14
• ECU
DIAG NOSTIC CODES (MA) (Cont'd)

-
Number of
Code See
Check engine System Diagnosis Trouble area
No. page
blinks
No "SPO" signal for 5
42
-1lJ1fUUUL
Vehicle Speed
Sensor Signal
seconds when engine speed
is between 2,500 rpm and
4,500 rpm and coolant temp.
• Vehicle speed sensor
circuit
-
is below 80 °C (1 76 ° F) except • ECU .
when racing the engine.
,
FIHl 1 5
No "ST A" signal to ECU until • Ignition switch circuit

43 _flfU1fl_fUlfL Starter Signal engine speed reaches 800 • Ignition switch Fl-50
Fl1 6 1 8 rpm with vehicle not moving. • ECU
• Knock sensor circuit
52 �
Knock Sensor
Signal
O pen or short circuit in knock
sensor signal.
• Knock sensor -
• ECU
-
Fl1 1118
Knock Control
53 Jl.fU1fUUlfUL Fl11119
signal in ECU
Knock control in ECU faulty. • ECU
• A/C switch circuit

• A/C switch
• A/C amplifire
-
No "IDL" signal, "NSW" • Neutral start switch
51 .JUlMflJL Switch Signal
signal or "A/C" signal to
ECU, with check terminals •
circuit
Neutral start switch
E1 and T shorted. • Throttle position sensor
circuit
• Throttle position sensor
Ft1 11 1 7 • ECU
• 1 w/ TWC vehicles only
*2 7M-GTE only
*3 Abnormalities in the air flow meter may also be detected.
DIAGNOSTIC CODES (MS)
Number of
Code See
Check engine System Diagnosis Trouble area
No. page
blinks
- �1104
Normal
This appears when none of
the other codes are identified.
- -
• Ignition switch circuit
Momentary interruption i n • Ignition switch
11 __fLfL_ ECU (8) • Main relay circuit Fl-62
power supply to ECU.
• Main relay
FIHIOS • ECU
• Distributor circuit
No "NE" or "G" signal to
• Distributor IG-3
RPM Signal ECU within 2 seconds after
12 -1Ul.fl_ engine has been cranked.
• Starter signal circuit
FIHl06 • ECU
No "NE" signal to ECU when • Distributor circuit
13 _JlJWL_ RPM Signal engine speed is above • Distributor IG-3
Fl1 607 1 ,000 rpm. • ECU
. • Igniter and ignition coil
No. "IGF" signal to ECU circuit
14 --1lflJ1JUl Ignition Signal
6 - 8 times in succession. • Igniter and ignition coil
Fl-70
Fii 608 • ECU

Fl-32 EFI SYSTEM - Diagnosis System
DIAG NOSTIC CODES (MS) (Cont'd)
Number of
Code See
Check engine Svstem Diagnosis Trouble area
No. page
blinks
22 -1UlJlfl_ Water Temp.
Sensor Signal
Open or short circuit in water
temp. sensor signal.
circuit
Fl-68
Fl1610
• ECU
• Intake a i r temp. sensor

Intake Air Temp. Open or short circuit in intake circuit
24 __flILfUlflfL Sensor Signal air temp. sensor signal. • Intake air temp. sensor
Fl-67
A1 S1 1
• ECU
Open circuit in VC signal or

• Air flow meter circuit
. Air-flow short circuit between VS and
,:
31 _fifUUL_ Meter Signal E2 when idle contacts are
• ECU
closed.
Fl1 6 1 2 ;
.
• Air flow meter circuit
Air-flow Open circuit in E2 or short
32 -11fUlJUL_ Meter Signal circuit between VC and VS.
Fl1 6 1 3
• ECU

Throttle
Open or short circuit in circuit
41 --11J1JlJlJl_ Position
throttle position sensor signal. • Throttle position sensor
Fl-63
Sensor Signal
Fl1 614
• ECU
No "SPD" signal for 5

seconds when engine speed
42 -1l.flfUlflJL Vehicle Speed

Sensor Signal
is between 2,500 rpm and
4,500 rpm and coolant temp.
circuit -
is below 80 °C ( 1 7 6 °F) except
Fl1 615
when racing the engine.
No "STA" signal to ECU until • Ignition switch circuit

43 _JlJlJ1JUlflf1_ Starter Signal engine speed reaches 800 • Ignition switch Fl-69
Fl1 616 rpm with vehicle not moving. • ECU
52 .JUlJ1fU1J1JL Knock Sensor

Signal
Open or short circuit i n knock
sensor signal.
• Knock sensor circuit
• Knock sensor -
Fl 1619
• ECU
53 .JU1flllJUU1JL Knock Control

signal i n ECU
Knock control in ECU faulty. • ECU -
F11 619
• A/C compressor relay
72
JUlfUUUlJLJlfl
A/C Com-
pressor
Open or short circuit in
A/C compressor relay signal.
circuit
• A/C compressor relay
-
Relay Signal
Fl281 1
• ECU
• A/C switch circuit

• A/C switch
• A/C amplifire
No ''IDL" signal, "NSW" • Neutral start switch
51 Jl.fUl.fUlJl_ Switch Signal signal or "A/C" signal to
ECU, with check terminals
circuit
• Neutral start switch
-
E1 and TE1 shorted. • Throttle position sensor
circuit
INSPECTION O F DIAG NOSIS CIRCUIT

Fuse l G N
Ignition (MA) 7.5A
ECU
Fusible Link Switch (MS) 1 5A
IG S/W
AM2 30A B A TT
EFI Main Relay
+ B 1 (B 1 )
Fusible Link Fuse
+ B ( B)
MAIN 1 .0Y (MS} EFI 1 5A
M-REL
Ignition
Fusible Link Switch Fuse
Fusible ALT AM 1 AM 1 IG 1 GAUGE .

Link (MA/7M-GE}40A 7 .5A " CHECK ENGINE"
MAIN 2.0L 1 .2 5 8 Warning Light
E1
(MA/ 7M-GTE)
� OOA
B attery T (MS) · 1 OOA Check
l
Connector .----□ El
(MA) T
(MS) T E 1
F129 t5
1. Dose " CHECK ENGINE" warning light come YE s

on when ignition switch is at ON ? ___ System Normal
NO
Does "CHECK ENGINE" warning light come Check wiring between
Try another
on when ECU terminal W is grounded to the Y ES ECU terminal E 1 and body OK
i-----..i ECU
body? ground.
NO BA D
Check bulb, fuse and wiring between ECU and
Repair or replace
ignition switch.
B AD
Repair or replace.
2. Does "CHECK ENGINE" warning light go off ES

Y_
when the engine is starte d? 1-- -.1 S ystem Normal
NO
Check wiring between ECU and 1--_ D
Repair
BA
" CHECK ENGINE" warning light. .,...
OK
Is there diagnostic code output when check Check wiring between E C U terminal T and check
NO connector terminal T(MA) or TE 1 (MS), and ECU
_______________
connector terminals T (MA) or TE1 (MS) and
E 1 are short circuited? 1----i terminal E1 and check connector terminal E 1 .
.__ ___,
YES OK
Does "CHECK ENGINE" warning light go out N
__o_ Further repair required.
after repair according to malfunction code?
YES
System OK
i..-..;.._________,
1-------------.� Cancel out diagnostic code.
.34 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
VOLT/OHMMETER (MA)
OTE: The following troublesh ooting p ro The following troubleshooting procedures are
edures are designed for inspection of each separ based on the supposition that the trouble lies in
te system, and therefore the actual procedure either a short or open circuit in a component out
1ay vary somewhat. However, troubleshooting side the computer or a short circuit within the
hould be performed refering to the inspection computer.
1ethods described in this manual. If engine trouble occurs even though proper
3efore beginning inspection, it is best to first make operating voltage is detected in the computer con�
3 simple check of the fuses, fusible links and the nectar, then it can be assumed that the ECU is
:ondition of the connectors. faulty and shQuid be replaced.
LOCATION OF FUSES AND FUSIBLE LINKS
No. 1 Relay Block (RHO) No. 1 Relay Block (LHD)
USI e m
ALT
Fuse IGN 7 .5A (7M-GE) 1 .
(7M-GTE) 1
Fusible link
MAIN 2.0L
No. 2
Relay Block �
c::::J CJ
Fusible Link Fuse EFI 1 5A

AM2 30A
Fl2787
EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA) Fl-36
EFI SYSTEM CHECK PROCEDURE

NOTE:
• Perform all voltage measurements with the connectors
connected.
• Verify that the battery voltage is 1 1 V or above when
the ignition switch is at "ON .
°
Using a voltmeter with high-impedance (1 0 k fi /V .

minimum), measure the voltage at each terminal of the
wiring connectors.
Voltmeter
FI0299
Terminals of ECU (7 M-GE)

Symbol Terminal Name Symbol Terminal Name Symbol Terminal Name
E0 1 POWER GROUND T CHECK CONNECTOR L3 ECT COMPUTER
E02 POWER GROUND G2 DISTRIBUTOR EGA VSV (EGR}
No. 1 0 INJECTOR (No. 1 and 4} VTA THROTTLE POSITION SENSOR A/C A/C MAGNET SWITCH
. No. 20 INJECTOR (No. 2 and 6) NE DISTRIBUTOR SPD SPEEDOMETER
STA STARTER SWITCH IDL THROTTLE POSITION SENSOR w WARNING LIGHT
No. 30 INJECTOR {No. 3 and 5) IGT IGNITER FPR FUEL PUMP RELAY
STJ COLD START INJECTOR DFG DEFOGGER RELAY
E1 COMPUTER GROUND IGF IGNITER THA AIR TEMP. SENSOR
NSW NEUTRAL START SWITCH WT) ECT ECT COMPUTER
N/C •CLUTCH SWITCH (M/T) THW WATER TEMP. SENSOR vs AIR FLOW METER
KNK KNOCK SENSOR LP HEADLIGHT RELAY
ISC 1 ISC MOTOR NO. 1 COIL ox OXYGEN SENSOR vc THA01'i,l;,E PO�ION SENSOR
AIR FLO MET
ISC 3 ISC MOTOR NO. 3 COIL E2 SENSOR GROUND
ISC 2 ISC MOTOR NO. 2 COIL vsv 1 VSV IAIR CONTROL) BATT BATTERY
ISC 4 ISC MOTOR NO. 4 COIL L1 ECT COMPUTER +B EFI MAIN RELAY
G6 DISTRIBUTOR VSV2 VSV (FPU) IG S/W IGNITION SWITCH
VF CHECK CONNECTOR L2 ECT COMPUTER +81 EFI MAIN RELAY
G1 DISTRIBUTOR M-REL EFI MAIN RELAY (COIL)
ECU Terminals
- -
vsv M- EGA
I I I ........., I I I
EO 1 ��§STJ ".re ISC ISC

2 G6 G1 G2 NE !GT IGF THW ox vsv
1 2 REL $PO FPR THA VS vc IG
SAlT S/W
E02 N20
o . o. E1
30 3
!SC !SC VF
4 T VTA IDL KNK E2 A/C w OFG LP +B +81
FI0514
Fl-36 E FI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
Terminals of ECU (7 M -GTE)

Symbol Terminal Name Symbol Terminal Name Symbol Terminal Name
E0 1 POWER GROUND G2 C A M POSITION SENSOR A/C A/C MAGNETIC SWITCH
E02 POWER G ROUND VTA THROTTLE POSITION SENSOR SPO SPEEDOMETER
No. 1 0 INJECTOR (No. 1 and 4) NE CAM POSITION �ENSOR w WARNING LIGHT
No. 20 INJECTOR {No. 2 and 6) IDL THROTTLE POSITION SENSOR FPR FUEL PUMP RELAY
STA STARTER SWITCH IGT IGNITER OIL OIL PRESSURE SWITCH
No. 30 INJECTOR (No. 3 and 5) IGdA IGNITER THA AIR TEMP. SENSOR
STJ COLD START INJECTOR IGF IGNITER ECT ECT COMPUTER
E1 COMPUTER GROUND KNK1 KNOCK SENSOR HAC m[5'Re COMPENSATION
NSW NEUTRAL START SWITCH WT) THW WATER TEMP. SENSOR FC CIRCUIT OPENING RELAY
N/C "CLUTCH SWITCH (MIT) KNK2 KNOCK SENSOR VC THROTTLE POSITION SENSOR
AIR FLOW METER
IGdB IGNITER OX OXYGEN SENSOR KS AIR FLOW METER
ISC 1 ISC MOTOR NO. 1 COIL E2 SENSOR GROUND BATT BATTERY
· ISC 3 ISC MOTOR NO. 3 COIL vsv VSV (FPUl +B EFI MAIN RELAY
lSC 2 ISC MOTOR NO. 2 COIL Ll ECT COMPUTER IG S/W IGNITION SWITCH
ISC 4 ISC MOTOR NO. 4 COIL HT OXYGEN SENSOR +81 EFI MAIN RELAY
G8 CAM POSITION SENSOR L2 ECT COMPUTER TIL TURBO INDICATOR
VF CHECK CONNECTOR M-REL EFI MAIN RELAY (COIL) DFG DEFOGGER RELAY
G1 CAM POSITION SENSOR L3 ECT COMPUTER LP HEADLIGHT RELAY
T CHECK CONNECTOR EGR VSV (EGA)
ECU Termi nals
- I I - I I - I
- 1o1
D - DFG
E01 No.
, 2 � G1 G2 NE IGT IGF TIM OX V�\I GR SP□ FPRTHAHAC VC BATT s'J.v
s
NS\/\ ISC ISC
No. E1 IGdB ISC ISC VF T -r,1n IOL IG<jA !CNK KNK E2 L1 �L2 L3 IAJc w 01L ecr FC KS +a +a1
STA STJ iN%
TIL i
E02 No.
10
LP
20 30 3 4 1 2
FI0574 Fl1 998
*For cruise control

EFI SYSTEM - Troubleshooting with' Volt/Ohmmeter {MA) Fl-37
Voltage at EClJ Wiring .C onnectors (7M-GE)

No. Termina l s Condition STD Voltage See page
BATT - E 1 - 10 - 14 Fl-39
IG S/W - E 1
1 Fl-40
M-REL - E 1 Ignition S/W ON 10 - 14
.,. .
+B (+8 1 ) - E 1 Fl-41
IDL - E2 Throttle valve open 10 - 14 Fl-42
vc - E2 - 4 - 6
Ignition S/W ON
Throttle valve fully ·closed 0 . 1 - 1 .0 Fl-43
VTA - E 2
e::
Throttle valve fully open 4 - 5
VC - E2 - 4 - 6
Ignition S/W ON Measuring plate fully closed 4 - 5
3 Measuring plate fully open 0.02 - 0.08 Fl-44

VS - E 2
Idling 2 - 4
3,000 rpm 0.3 - 1 .0
No. 1 0 E0 1
5 No. 20 - Ignition S/W ON 9 - 14 Fl-47
No. 30 E02
6 THA - E2 Ignition S/W ON Intake air temperature 20° C (68 °F) 1 - 3 Fl-48
7 THW - E2 Ignition S/W ON Coolant temperature 80 °C ( 1 7 6 °F ) 0. 1 - 1 .0 Fl-49
8 STA - E 1 Cranking 6 - 14 Fl-50
9 IGF, IGT - E 1 Idling 0.7 - 1 .0 Fl-5 1
1Sf 1
11 _ E1 Ignition S/W O N 9 - 14 Fl�5 3
ISC4
No trouble (" CHECK ENGINE" warning light off) and

12 w - E1 8 - 14 Fl-54
engine running
13 A/C - E 1 Air conditioning ON 10 - 14 Fl- 5 5
ECU Terminals
I ....._. I I ...,__, I I - I
EO1 No.
1 0 STA STJ
NSW
0(
N/C
ISC ISC G 0 G 1 G2 NE IGT IGF
1 2
THW ox vsv
1
VS\/ M• IG
2 REL EGR SPD FPR THA vs vc BATT S/W
EO2 No. No. E1 ISC ISC VF T VTA IDL KNK E2 A/C w DFG LP +B +81
2030 3 4
FI0574
Fl-38 EFI SYSTEM - Troubleshooting with Vblt/Ohmmeter (MA)
Voltage at ECU Wiring Connectors (7M-GTE)
Terminals <=ondition STD Voltage See page

-
No.
BATT - E 1 10 - 14 Fl-39
IG S/W - E 1
1 Fl-40
+B (+81 ) - E 1 Fl-4 1
IDL - E2 Throttle valve open 10 - 14 Fl-42
vc - E2 - 4 - 6
2 Ignition S/W ON
Throttle valve fully closed 0.1 - 1 .0 Fl-43
VTA - E2
, , ,;'O
Ignition S/W ON 4-6

Body
KS - Fl-45
ground Cranking or running 2-4
4
Body
vc - ground
Ignition S/W ON 4-6 Fl-46
No. 1 0 E0 1
5 No. 20 - Ignition S/W O N 9 - 14 Fl-47
No. 30 E02
6 THA - E2 Ignition 5/W ON Intake air temperature 20 ° C (68 ° F) 1 - 3 Fl-48
7 THW - E2 Ignition S/W ON Coolant temperature 80° C (1 7 6 ° F) 0 .1 - 1 .0 Fl-49
9 IGF, IGT - E 1 Idling 0.7 - 1 .0 Fl-5 1
10 IGdA, IGdB - E 1 Idling 1 -3 Fl-5 2
l �C 1
11 E1 Ignition S/W O N 9 - 14 Fl-53
ISC4
N o trouble ("CHECK ENGINE" warning light off) and

12 w - E1
engine running
8 - 14 Fl-54
13 A/C - E 1 Air conditioning ON 10 - 14 Fl- 5 5
5 40 m mH g (2 1 .26 in.Hg. 7 2.0 kPa} Approx. 2.8

14 HAC - E2 Ignition S/W ON Fl-66
750 mmHg (29.53 in.Hg, 1 00.0 kPa) Approx. 3.6
ECU Terminals
-
No. STA STJ NSVI
I I - I I � -.
E01 10 1 .Bi;..
ISC ISC GE>
1 2 G1 G2 NEIGT IGF THY. ox V�\/ HT IM•
DCI EGR SPD fPF THA HAC vc llATI
1!:11�
11:02 No. No.

20 30
E1 IGdB
ISC ISC VF
3 4 T VTA IDL lGdA 1 2 E2 L1 L2 L3 A/C w OIL ECT FC KS +B 1+81
KNK KNK
�
p
EFI SYSTEM - Troubleshooting with ·Volt/Ohmmeter {MA) Fl-39
-
No. Terminals Trouble Condition STD Voltage
BATT - .E1 No voltage 10 - 14 V
IG S/W - E1 No voltage Ignition switch ON 10 - 14 V
1
M•REL - E1 No voltage Ignition switch ON 10 - 14 V
+B (+BU - E1 No voltage Ignition switch ON 10 - 1 4 V
ECU
BATT
r
EFI Main Relay
Fusible Link Fuse +B1
- - � +B
AM2 30A EFI 1 5A ( _- } M-REL
Fusible
, MAIN 2.0L
f "C:-1/
Ignition Switch Fuse
Link
- -
-- IG S/W
E
> 1
�IG2 IGN 7.5A
Battery T
r
Fl1 823
• BATT - E1
(D There is no voltage between ECU terminals BATT and E 1 •
!
(ID Check that there is voltage between ECU terminal BATT and
body ground.
NO OK
FI0309 ® Check wiring between ECU terminal E 1

ground.
and body
ECU BATT
l OK l BAD
Try another ECU. Replace or repair.
BAD
Check fuse and fusible link. Replace.
OK
Check wiring between ECU terminal BAD

FI03 10 Repair or replace.
and battery.
®
E1 ECU
103 1 1
Fl-40 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
CD • 18 S/W - E 1
CD There i s n o voltage between ECU terminals I G S/W and E 1 .
ECU IG S/W (IG S/W ON)
Voltmeter
® Check that there is voltag e between ECU terminal IG S/W and
body ground. UG S/W ON)
Fl0313
NO .·l OK
Check wiring between ECU terminal El and body

ground.
l OK l BAD
Check fuse, fusible links and BAD

Repair or replace.
ignition switch.
• M-REL - E 1
CD
CD There is n o voltage between ECU terminals M-AEL and E 1 .
(IG 5/W ON)
® Check that there is voltage between ECU terminal M-REL and

body ground. (IG S/W ON)
NO i OK
FI0315 Check wiring between ECU terminal E1 and body
ground.
l OK l BAD
Check EFI main relay and wiring BAD

Replace.
harness.
FI031 6
OK
Try another ECU.

• +B l+B 1 ) - E1
CD
There is no voltage between ECU terminals +B (+B 1 l and E 1 .
(D
(IG S/W. ON)
@ Check that there is voltage between ECU terminal +B (+B 1 )

and body ground. (IG S/W ON)
I
NO !oK ,
R0299
Check wiring between ECU terminal E 1 and body ground.
I
loK i BAD
Check fuse, fusible links and wiring BAD

Repair or replace.
harness.
OK
Check EFI main relay. BAD _
Replace.
(See page Fl- 1 1 2}
OK
Refer to M�REL - E1 trouble .

section.
.=t-42 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
No, Terminals Trouble Condition

·•
STD Voltage
IDL - E2 Throttle valve open 10 - 14 V
vc - E2 4-6V
No voltage
Ignition
switch ON
2
Throttle valve fully closed 0.1 - 1 .0 V
VTA - E2
Throttle valve fully open 4-6V
ECU
+B
Throttle Position Sensor (+B 1 )
E2
....-..--o-+-,-,::-:------------o E 2
--- IDL _________
o-�""',',,- --o IOL
'l:!4------0--1-VT
.:...:..;A..;.__________-o VTA
'----O--J'---'v�c'------------� vc
E1
1'11366
CD • IDL - E2
CD There i s no voltage between ECU terminals IOL and E2.
UG S/W ON) (Throttle valve open)
® Check that there i s voltage between ECU terminal +B {+B 1 )

- and body ground. (IG S/W ON)
NO OK
Check wiring between ECU terminal E 1 and body ground.

Fl1 62.4
OK BAO
Try another ECU. Repair or replace.
Refer to No. 1 . BAD

,__________ Replace or repair.
(See page Fl-4 1 )
OK
@ Check throttle position sensor. BAD

FI031Z
BAO OK
Replace or repair Check wiring between ECU and

throttle position sensor. throttle position sensor.
Ohmmeter OK
ckness
uge
Try another ECU.
• VC - E2 .
CD
There is no voltage between ECU terminals VC and E2 .
(D
. oo �w o�
l
Check that there is voltage between ECU terminal +B (+B1 ) and
! OK ,
l NO
Fltll28
® Check throttle position sensor. Refer to No. 1 .
(See page Fl- 1 02) (See page Fl-4 1 )
E2 ! BAD ! OK
Check wiring between ECU and throttle

Repair or replace.
position sensor.
! l
.
Ohmmeter ckness OK BAD

uge
Repair or replace
Try another ECU.
[91+---- 1'11628
wiring.
• VTA - E2
CD
CD There is no specified voltage at ECU terminals VTA and E2.
(IG S/W ON)
!
® Check that there is voltage between E C U terminal VC and E2 .
. UG S/W ON)
i NO OK
Refer to VC - E2 trouble
Ft11128
section.
i OK
BAD _
@ Check throttle position sensor. Repair or replace.
l OK
Check wiring between ECU and BAD

Repair or replace.
throttle position sensor.
t OK
Fl1 !l28
T ry another ECU.
E2
VTA
Fl1627
EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
No. Terminals Trouble Condition ·-

STD Voltage
vc - E2 4-6V
Ignition
vs - E2 S/W ON Measuring plate fully closed 4-5V
vs - E2 No voltage Measuring plate fully open 0.02 - 0.08 V
vs - E2 Idling 2-4V
vs - E2 3,000 rpm 0.3 - 1 .0 V
•1M -GE only ECU

+B
{+B 1 )
E2
,............-0--1-------------------Q EZ
VS
�->-1--
v-c------------------<>
'---<----------------------.i vs
VC
Air flow meter .-----o E 1
Fl1269
CD
(D There is no voltage between ECU terminals VC or VS and E2.
UG S/W ON)
Check that there is voltage between ECU terminal +B (+B l )

@
OK NO
Refer to No. 1 .
(See page Fl-4 1 )
Fl2444
Check wiring between ECU terminal E l and body ground.
OK BAD
Check air flow meter.

@ Repair or replace.
(See page Fl-96)
BAD OK
Replace air flow Check wiring between ECU and air

meter. flow meter.
OK BAD

Ohmmeter
n.
0
0 0
EFI SYSTEM - Troubleshooting wit'11 Volt/Ohmmeter (MA)
No. Terminals Troubl e Condition STD Voltage

..
Body Ignition S/W ON 4-6V
KS
-
ground Cranking or running 2 -4V
"4 No voltage
Body
vc ground Ignition S/W ON 4-GV
•?M-GTE only
ECU.
+B
Air Flow Meter 0 (+B 1 )
-- vc vc
-- KS KS
�) ·
....� E2 El '
e1, --: -�
Fl2560
• KS - Body ground
CD
(D There is no voltage between ECU terminals KS and body
ground. (IG S/W ON)
® Check that there ls voltage between ECU terminal +B (+B 1 )

!
OK NO
Refer to No. 1 .
(See page Fl�4 1 )
!
@ Check wiring between ECU terminal E1 and body
ground.
OK BAD
Check air flow meter.

Repair or replace.
(See page Fl�98}
BAD i oK
@ meter. flow meter.
! oK l BAD
Fl031 1
48 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
• VC - Body ground
(D There is no voltage between ECU terminals VC and body

ground. (IG S/W ON)-
@ Check that there is voltage between ECU terminal +B (+B 1 ) an

body ground. {IG S/W ON)
OK NO
Refer to No. 1 .
(See page Fl-41 )
+81
Check wiring between ECU terminal E1 and body ground.
OK BAD
@ Check air flow meter. Repair or replace.
(See page Fl-98)
BAD OK
FI031 2
Air Flow Meter @ meter. flow meter.
Ohmmeter OK BAD
00 0
F12006
EFI SYSTEM - Troubleshooting with .Volt/Ohmmeter (MA} Fl-47

No. 1 0 E0 1
No. 20 No voltage Ignition switch ON 9 - 14 V
No. 30 E02
ECU
-:x::::1b-------...--,,,-------c,.._o---0 1G S/W
AM2 IG2 +B IGN 7.5A
Fusible AM2 30A
Link
Fusible
Link MAIN 2.0L
.__------o No. 1 0
----------a No. 20
Battery 1 -------------nNo. 30
E01
E02
Fl2995
No. 1 0
G) There is no voltage between ECU terminal No. 1 0, No. 20
and/or No. 30 and EO 1 or E02. UG S/W ON)
@ Check that there is specified voltage between resistor terminal

+B and body ground. STD voltage: 9 - 1 4 V
QK ! No
Check fuse, fusible links BAD

Repair or replace.
F!1633
and ignition switch.
l oK
Check wiring between BAD
Repair or replace.
resistor and battery.
Check that there is specified voltage between resistor terminal

@ (No. 1 0, No. 20 or No. 30) and body ground.
i
STD voltage: 9 - 1 4 V
OK BAD
@ Check resistance of magnetic coil in Replace resistor.

each injector.
OK l BAD
l
Check wiring between ECU and
Replace injector.
injector.
I I
OK BAO

I
Fl-48 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter . (MA)
No. Terminals · Trouble Condition STD Voltage

No voltage °
6 THA - E2 IG S/W ON I ntake air temperature 20 c (68"FI 1 -3V
7M-GE 7M-GTE
ECU ECU
+B +B
(+B 1 ) (+B 1 )
---c>-1--'-�--'------o T H A
TH A
[ii: I
:;
TH A
E2
TH A
E2
1
E1
.-----o E l
Air Temp. Sensor Air Temp. Sensor
(Air Flow Meter) (Air Flow Meter}
Fl2665
CD There is no voltage between ECU terminals Ti-IA and E2.

(D
(IG S/W ON)
Check that there is voltage between ECU terminal +B (+B 1 ) and

body ground. (IG S/W ON}
OK i NO
Refer to No. 1 ,
(See page Fl-4 1 )
l · 7M-GE
Air Flow Meter
Check wiring between ECU terminal El and body ground. \
OK .! BAD
® Check air temp. sensor. Repair or replace.

(See pages Fl-96, 98}
BAD ! OK

meter. temp. sensor.
7M-GTE
Ohmmeter
Air Flow Meter
! OK i BAD
co
T ry another ECU. Repair or replace.
FI0330
F12569
No. Terminals Trouble . Condition STD Voltage

Ignition switch Coolant temperature· 80°C
7 THW - E2 No voltage 0.1 - 1 .0 V
ON (1 76 ° F}
ECU
Water Temp. Sensor

1 +B (+B1 )
THW
I . ... - '
E2
'---
E1
"'"
"';...
F10487
CD (D There is no voltage between ECU terminals THW and E2.

(IG S/W ON)
@ Check that there is voltage between ECU terminal +B· (+B 1 ) and
body ground. UG S/W ON) .
OK l No
Refer to No. 1 .
A 1 637
(See page Fl-4 1 )
'
Check wiring between ECU terminal E1 and body ground. I
OK ! BAD
@ Check water temp. sensor. Repair or replace.

BAD ! oK
Replace water Check wiring between ECU and water
temp. sensor. temp. sensor.
i oK ! BAD
Fl1638
-.
1-50 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)

8 STA - E 1 No voltage Cranking 6 - 14 V
(MIT)
ECU
Fusible Ignition
Link Switch
Fusible Link
ALT AM 1 40A AM 1 ST 1
7M-GE Neutral Start S/W
1 .2 5 B . {A/T)
7 M-GTE
Starter
1 00A
MAIN 2.0L
Battery T
I To Circuit Opening Relay (STAl
E1
FIH.139
CD © There is no voltage between ECU terminals STA and ·E 1 .

(IG S/W START}
Check starter Check wiring between ECU terminal STA
!
OK
operation. and ignition switch terminal ST1 .
BAD OK BAD
Repair or replace.
Fl0335
® Check wiring between ECU �erminal E 1 and body

!
ground.
OK BAD
Chec k fusible links, battery, wiring,

BAD _
ignition switch and neutral start Repair or replace.
switch.
Voltmeter @ OK
Check that there Is voltage at ST A (50) terminal of starter.

@
(IG S/W START) STD voltage: 6 - 14 V
OK NO
Check wiring between ignition switch

Check starter.
terminal ST 1 and starter terminal STA (50).
EFI SYSTEM -- Troubleshooting with Volt/Ohmmeter (MA) Fl-51

9 IGT, IGF - E 1 N o voltage Idling 0.7 - 1 .0 V
ECU
Fusible Link Ignition Switch
AM2 30A AM2 IG2 To

Tachometer
,------t•
Fusible Igniter w/
Link MAIN 2.0L
Ignition Coil
____,,...
T
Battery I -----------o IGF
..L
'-----------o lGT
....---o E 1
Flt64t
CD
(D There is no voltage between ECU terminals IGT and E 1 .
(Idling)
Voltmeter CV Check that there is voltage between ECU terminal IGT and
body ground. (Idling)
NO i OK
Check wiring between ECU BAD Repair or

@
terminal E 1 and body ground. replace.
F11642
l OK
Try another ECU.
Check fusible links and ignition BAD Repair or replace.

switch.
OK
Check distributor or cam position BAD Repair or replace.

sensor. (See pages IG- 1 1 , 1 8)
@ OK
Check wiring between ECU and BAD Repair or replace.

battery.
OK
Check igniter.
BAD Repair or replace.
Fl-62 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
IGdA
·10 _ E1 No voltage ldllng 1 -3V
IGdB
*7M�GTE only
ECU
Fusible Ignition
Link
AM2
-
AM2
- --
Switch
IG2
.
- To
30A Tachometer
Fusible 1 )
Link MAIN 2.0 L 1 ,gnit;,. I
--
Battery l IGdA
IGdB
El
1 Fl1991
There is no voltage between ECU terminals IGdA or IGdB and

(D
E1 . (Idling)
® Check that there is voltage between ECU terminal IGdA or

IGdB and body ground. (Idling)
NO .i OK
Check wiring between ECU BAD Repair or
@
terminal E 1 and body g round. replace.
Fll 958
! OK
Try another ECU.
Check fusible links and ignition BAD

Repair or replace.
switch.
OK
Check cam position sensor. BAD

Repair or replace.
Fll 951
(See page IG- 1 8)
OK

Repair or replace.
battery.
OK
BAD
Check igniter. (See page I G • 1 7} Repair or replace.

11 ISC 1 ~ ISC4 - E 1 N o voltage Ig nition switch ON 9 - 14 V
EFI Main Relay ISC Valve ECU

Fuse
.-------0,-....,0,...------1--<Y""" o-+-----..-to..-J1�>1---� ISC 1
EFI 1 5A t--t0-tt-1"00'-o+--...--6 ISC2
'-+-'"llll�:>-+----0 ISC3
Fusible ...,.oi,'-<>-1,,,-----0 ISC4
AM2 30A
Link
Fusible
---------o
MAIN 2.0L --------..o +B
link
-------------0 M-REL
+81
T ·
Battery 1
..l..
.....---o E l
Fl2994
(D There is no voltage between ECU terminals ISC 1 ~ ISC4 a nd

(D
E 1 . (IG S/W ON)
® Check that there is voltage between ECU terminal +B (+B 1 )

OK l NO
Refer to No. 1 .
(See page Fl-4 1 l
Fl0344
Check wiring between ECU terminal E 1 and body ground. ,
OK l BAD
@ Check ISC valve. Repair or replace.

(See page .Fl- 1 08)
BAD l OK
Replace ISC Check wiring between ECU and EFI
valve. main relay.
® l OK ! BAD
Try another ECU. I Repair or replace.

I
EB e
Flt 643
54 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MA)
Jo. Terminals Trouble Condition STD Voltage

No trouble ("CHECK" engine warning
12 W - E1 No voltage
light off)
and engine running
8 - 14 V
ECU
FUSE
--o......,J:>.--0----' '-----0-.;.,_------------.; W
GAUGE 7.5A " CHECK ENGINE"
Warning Light
Combination Meter .----o E 1
FI0728
(D
(D There is no voltage between ECU terminals W and E1 .
· O�i��
@ Check that there is voltage between ECU terminal W and

body ground.
NO ! OK
@ Check wiring between ECU terminal E1 and body

Fl1251
ground.
! OK ! BAD
Chec k GAUGE fuse (7.5A) and "CHECK

ENGINE" warning light.
OK ! BAD
I Repair or replace.
!
Fl125O
Fuse blows again

Repair or replace.
W and fuse.

..
13 A/C - E 1 N o voltage Air conditioning O N 10 - 14 V
ECU
A/C
Amplifier A/C
.. E1
A/C Compressor
:;-,..
I Fl0922
CD CD There is no voltage between ECU terminals A/C and E 1 .

(Air conditioning ON)
.
Voltmeter ® Check that there is voltage between ECU terminal A/C and
body ground.
NO l OK
Fl1 256 @ Check wiring between ECU terminal E 1 and body

ground.
1 OK l BAD
Try another ECU; Repair or replace.
OK
Check compressor running. Check wiring
between ECU
BAD terminal A/C an.d
amplifier.
l BAD
Repair or replace.
@
ECU
Check that there is voltage between BAD
Repair or replace.
amplifier terminal and body ground.
OK
Check wiring between amplifier and BAD
Repair or replace.
ECU or compressor.
FI031 1
EFI SYSTEM .;._ Troubleshooting with Volt/Ohmmeter (MA)
o. · Terminals Trouble Condition STD Voltage ·

540 mmHg !21 .26 in,.Hg, 72;0 kPa} Approx. 2.8 V
:4 HAC - E2 No voltage
760 mmHg (29.53 in.Hg, 1 00.0 kPa) Approx. 3.6 V
7M-GTE only
ECU
To Air Flow
-- - -- -7r
-- :
Q)
C>
.,...,...--- -
---- -o VC
ca
......,,,T-o�T=h�r-0 � 3.6
o,-,-P�o� si=
ti=
o=-=--:;
n �"'f:+
------o HAC
From - I
ri--=- Po=s=iti=·:c=...==�----o
E2
� 2.8 --- ---/
•-
I
From Air E ,' :
I
I
HAC Sens o r
Flow Meter {::. 1 .2. ---<!
I
l :
I
U l I
I I I
·....,._--o E1
<(
1 50 540 750 Atmo spheric
____...._._.__-'-
Pressure (mm Hg)
2,000 0 Alitude (m)
1 ,000
Fl1995 l'11 996
There is no yo itage between ECU t�rmi�al HA.c and E2.

·(D
•. (IG S/W ON} .
® Check that there is v ltage between ECU t�rminal ye and

o
• · body ground. (IG S/W ON}
OK ! NO
Refer to No. 2.
(See page Fl-43)
Check wi.ri ng between ECU termi�al E1 and body gro und. I
...
OK l BAD
@ Check HAC senso r. Repair o r replace.

· (Seel)age Fl-1 2 1 )
··:,r
BAD i OK
A1628 Replace HAC Check wiring between ECU and HAC

sensor. senso r.
E2 vc
l OK ! BAD
. Try an other ECU. Repair or replace.

., ,._ ·. · ·,-,
Fl 1 997
EFI SYSTEM - Tro ubleshooting with Volt/Ohmmeter {MS) Fl-57
VOLT/OHMMETER (MS)
N OTE: T h e following troubleshooting pro The following troubleshooting procedures are
cedures are designed for inspection of each separ based on the supposition that the trouble lies in
ate system, and therefore the actual procedure either a short or open circuit in a component out
may vary somewhat. However, troubJe�hooting side the computer or a short circuit within the
should be performed refr:,ring to the insp�ction computer.
methods described i n this manual. If engine trouble occurs even though proper ·
Before beginning·inspection, it is best to first make operating voltage is detected i n the computer con
a simple check of the fuses, fusible links and the nector, then it can be assumed that the ECU is
condition of the connectors. faulty and should be replaced.
LOCATION OF FUSES AND FUSI BLE LINKS
Junction Block and Relay Block Cassettes
LHD
r ,........_____
GAUGE
7.5A
IGN 1 5A
GAUGE 7.5A
Fl2821
58 EFI SYSTEM - T roubleshooting with Volt/Oh.mmeter (M S)
"A " EFI SYSTEM CHECK PROCEDURE

PREPARATION
(a) Disconnect the connectors from the ECU.
(b) Remove the locks as shown in the illustration so that
the tester probe(s) can easily come in.
CAUTION: Pay attention to sections "A" and "B" in
the illustration which can be easily broken.
(c) Reconnect the connectors to the ECU.
NOTE:
R2944
• Perform all voltage measurements with the connectors

connected.
• Verify that the battery voltage is 1 1 V or above when
the ignition switch is at "ON".
iltmeter Using a voltmeter with high-impedance ( 10 kil/V minimum),
:::::EJ measure the voltage at each terminal of the wiring con
nectors.
Fl2798
Terminals of ECU
rmbol Terminal Name Symbol Terminal Name Symbol Terminal Name
E01 POWER GROUND NE DISTRIBUTOR ACPS A/C P RESSURE SWITCH
502 POWER GROUND El COMPUTER GROUND SPD SPEEDOMETER
o. 1 0 INJECTOR (No. 1 and 4) VF CHECK CONNECTOR ECT ECT COMPUTER
o. 30 INJECTOR (No. 3 and 5) G8 DISTRIBUTOR ACR A/C COMPRESSOR
o. 20 INJECTOR (No. 2 and 6) TE2 CHECK CONNECTOR L1 ECT COMPUTER
DEFOG ER SWITCH
ELS HEADLl�HT SWITCH TEl CHECK CONNECTOR L2 ECT COMPUTER
FPU VSV (FPU) KNK KNOCK SENSOR FPR FUEL PUMP RELAY
ACV VSV (A/R CONTROL) THW WATER TEMP. SENSOR L3 ECT COMPUTER
SC 1 ISC MOTOR NO. 1 COIL IDL THROTTLE POSITION SENSOR w WARNING LIGHT
�.-
IGT IGNITER THA AIR TEMP. SENS()R M-REL EFI MAIN RELAY (COIL)
ISC MOTOR NO. 2 COIL VTA THROTTLE POSITION SENSOR IG S/W IGNITION SWITCH
ISC3 ISC MOTOR NO. 3 COIL vs AIR FLOW METER B1 EFI MAIN RELAY
AIR FLOW ETER
1SC4 ISC MOTOR NO. 4 COIL vcc THROTTLJ1POSITION SENSOR BATT BATTERY
IGF IGNITER E2 SENSOR GROUND B EFI MAIN RELAY
G2 DISTRIBUTOR STA ST ARTER SWITCH
G1 DISTRIBUTOR NSW NEUTRAL START SWITCH
:CU Terminals
1J1J '1l'
'-'
uu ru ...... U 'UU '\I' 1..n.J
1:0 1 1 �8" 1 �· 1
1
I I'\
5c
IFPUIAcvl 5P 1 2 I
I 'i I I GF I G2 NE
'-' VF IT1:2I IKNK!THWITHAI lvcc ST*c�sPolARcl ! FPR ! w ! �. I l�JW►An
:eo 2I �8· I ELSI I I l 1GT I I I I I G 1 I E 1 G8ITE 1 ! I I 10L !vuJ vs I e2 �sw! lecTI L1 I L2 I LS I I I I 8 1 I B
Fl291 1
EFI SYSTEM - T(publeshooting with .Volt/Ohmmeter (MS) Fl-69
Voltage at ECU - W iring Connectors
-
No. Terminals Condition STD Voltage See page
BATT - E 1 10 - 1 4 Fl-60
IG S/W - E l
Fl-6 1
B (8 1 } - E 1 Fl-6 2
IDL - E2 Throttle valve open 10 - 1 4 Fl-63
vcc - E2 - 4 - 6
2 Ignition S/W ON
Throttle valve fully closed 0. 1 - 1 .0 Fl-64
VTA - E2
-
,· �-
VCC - E2 4 - 6
Ignition S/W ON Measuring plate fully closed 4 - 5
3 Measuring plate fully open 0.02 - 0.08 Fl-65

VS - E2
Idling 2 - 4
3,000 rpm 0.3 - 1 .0
No. 1 0 E0 1
4 No. 20 - Ignition S/W ON 9 - 14 Fl-66
No. 30 E02
5 THA - E2 Ignition S/W ON Intake air temperature 20 °C (68 ° F) 1 - 3 Fl-6,7
6 THW - E2 Ignition S/W ON Coolant temperature 80° C ( 1 76 ° F) 0. 1 - 1 .0 Fl-68
,, 8 IGF, IGT - E l Idling 0.7 - 1 .0 Fl-70
1sp 1 _
9 El Ignition S/W ON 9 - 14 Fl-7 1
ISC4
No trouble {"CHECK ENGINE" warning light off) and

10 w - El 8 - 14 Fl�72
engine running
ECU Terminal&
Lru "U" vu u -u- u n.ru "V' uu

IFPulAcvl 1�c;I •�cl 1�fl 'l I IGF I a2 I NE vF he2I lvcc STAj'lc�sPo!Ac� I FPRI w l � I I 'G �AT
1 ,.,. IKNJqTH\MTHAI
i::011 �8· 1�0· 1
1:02j �?i h,LS ( I I liarl I I I I G1 i e1 ae1 re11 I I 10L lvrAl vs I e2.riswl leer L1 I I I I I I B1 I B
L2 L3
Fl-60 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MS)
No. Terminals Trouble Condition .. STD Voltage

BATT - E1 No voltage 10 - 14 V
IG S/W - E1 No voltage Ignition switch ON 1 0 - 14 V
1
M-REL - E1 No voltage Ignition switch ON 10 - 14 V
B (81 ) - E1 N o voltage Ignition switch ON 1 0 - 14 V
r-------------o BATT '

EFI Main Relay
Fusible Link ,---------0 B 1
Fuse
.-----ei=�>----0.......0---+----f-o- o-------o B
MAIN 1 .0Y EFI 1 5A r---+-CY�!D'O--#------l) M-REL
IGN 1 6A
E1
A:1.916
CD • BATT - E 1
ECU CD There is no voltage between ECU terminals BATT and E 1 .

Voltmeter
® Check that there is voltage between ECU terminal BATT and
body ground.
NO ! OK
@ Check wiring between ECU terminal E 1 and body

A:1.753
ground.
ECU
® l OK ! BAD

oltmeter
BAD
Check fuse and fusible link. Replace.
0 0
OK

Fl:1.754 Repair or replace.
and battery.
@
ECU
Ohmmeter
0
0
EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MS) Fl-6 1
• IG S/W - E 1
CD There i s n o voltage between ECU terminals IG S/W and E 1 .

UG S/W ON)
l
@ Check that there is voltage between ECU terminal IG S/W and
NO OK
!
Fl2758
Check wiring between ECU terminal E 1 and body
ground.
ECU l OK BAD

Voltmeter
CD
Check fuse, fusible link and BAD

Repair or replace.
ignition switch.
Fl2759
• M•REL - E 1
ECU CD There is no voltage between ECU terminals M-REL and E 1 .

(IG S/W ON)
Voltmeter
i
(ID Check that there is voltage between ECU terminal M-REL and
O JOH---- . body ground. (IG S/W ON) ·
NO OK
A2760
ground.
ECU l oK ! BAD

Voltmeter
CD
Check EFI main relay and wiring BAD

Replace.
harness.
OK
Fl271ll
Try another ECU.

• B (81 ) - E 1
here is n o voltage between E C U terminals B (B l ) and E 1 .

(D T
(IG S/W ON)
® Check that there is voltage between ECU terminal B (B 1 ) and

F1291 1
NO l OK

ground.
.! OK ! BAD
Check fuse, fusible link and wiring BAD

Repair or replace.
harness.
OK
FI2767
Check EFI main relay. BAD
Replace.
OK
Refer to M-REL - E 1 trouble

section.
EFI SYSTEM - Troubleshooting with Volt/Ohmmeter (MS) Fl-63

IDL - E2 Throttle valve open 10 - 14 V
vcc - E2 Ignition
- 4-6V
. No voltage
switch ON Throttle valve fully closed 0.1 - 1 .0 V
VTA - EZ
Throttle valve fully open 4- 5V
ECU ..
r
Throttle Position Sensor

◄1 B
(B1 l
-
Q E2 E2
1 IDL
vc
IDL
vcc
t. j_ ; I VTA VTA
v
,....- > E1
--- Fl1368
(j)
• IDL - E2
(D There is no voltage between ECU terminals IDL and E2.

(IG S/W ON) (Throttle valve open)
@ Check that there is voltage between ECU terminal B (B 1) and

K
NO
1O
Fl271!2
ground.
ECU
l OK BAD
Try another ECU.

:gt::::::==:..------·
Voltmeter
CD
0 Refer to No. 1 . BAD

Replace or repair.
(See page Fl-62)
0
OK
I
Fl2167
@ Check throttle position sensor. BAD

@
E2
BAD
l oK
IDL Replace or repair Check wiring between ECU and
throttle position sensor. throttle position sensor.
Ohmmeter kness l oK
uge
DO Try another ECU.
0
0 10!+------
CD • VCC - E2
ECU CD There is no voltage between ECU terminals VCC and E2.

(IG S/W ON)
Voltmeter
Cu
!
Check that there is voltage between ECU terminal B (B 1 ) and
l OK ! NO
Fl2784
® Check throttle position sensor. Refer to No. 1 .
(See page Fl- 1 02) (See page Fl-62.l
l BAD l OK
Check wiring between ECU and throttle

Repair or replace.
position sensor.
! OK ! BAD
Repair or replace
Try another ECU.
wiring.
Fl 1 629
CD • VTA - E2
CD There is no specified voltage at ECU terminals VTA and E2..

(IG S/W ON)
!
Check that there is voltage between ECU terminal VCC and E2.
@
(IG S/W ON)
Fl2783
! NO OK
Refer to VCC - E2 trouble

section.
! OK
BAD
@ Check throttle position sensor. Repair or replace.
1
Voltmeter
! OK

Repair or replace.
throttle. position sensor.
F12764
! OK
Try another ECU.

@
1ckness
uge
fl!627
-
No. Terminals Trouble Condition __ STD Voltage
vcc - E2 4-6V
Ignition
vs - E2 S/W ON Measuring plate ful ly closed 4-6V
-
3 vs - E2 No voltage Measuring plate fully open 0.02 - 0.08 V
-
vs - E2 Idling 2 -4V
vs - E2 3,000 rpm 0.3 - 1 .0 V
,,
. --
ECU
iB
(81 )
4- vs
E2 E2
.. -
vc
VS
vcc
1-
Air Flow Meter E1
Fl1269
CD There is no voltage between ECU terminals VCC or VS and E2.

G)
(IG S/W ON)
Voltmeter
@ Check that there is voltage between ECU terminal B (81 ) and
OK l NO
Refer to No. 1 .
Fl2817
(See page Fl-62)
Voltmeter
Check wiring between ECU terminal El and body ground.
OK !
I BAD
LL]
@ Check air flow meter. Repair or replace.
(See page Fl-96)
BAD ! OK
Fl2767 Replace air flow Check wiring between ECU and air
!
meter. flow meter.
l
I
Air Flow Meter @ OK BAD
Ohmmeter
Try another ECU.
n
0
0 0
Fl1283
Fl-66 EFI SYSTEM - Troubleshooting with Volt/Ohmmeter {MS)

No. 1 0 E01
4 No. 20 No voltage Ignition switch O N 9 - 14 V
No. 30 E02
Ignition Switch ECU

Fuse
IG S/W
AM2 IG2 +B IG N 1 5 A
No. 1 0
T ,.__________-('\ No. 20
Battery 1 ,__________;_____0 No. 30
E01
E02
Fl2941
There is no voltage between ECU terminal No. 1 0, No. 20

(D
and/or No. 30 and E0 1 or E02. (IG S/W ONI
® Check that+Bthere
!
is specified voltage between resistor
terminal and body ground. STD voltage: 9 - 1 4 V
OK NO
i
Repair or replace.
Solenoi OK
Repair or replace.
+B
¼.4_
No.
� ® Check that there is specified voltage between resistor terminal
(No. 1 0, No. 20 or No. 30) and body ground.
No. 20 STD voltage: 9 - 14 V
N
Fl2.812 OK ! BAD
@ Check resistance of magnetic coil in
l
Replace resistor.
each injector.
OK BAD
!
Replace injector.
injector.
I I I
OK BAD
F11635
Ignition switch Intake air temperature 20°C

5 THA - E2 No voltage
(68 ° F)
1 -3V
ON
-
ECU
-- (B l )
-
y c B
,.
=.•,.·
E2
E2
-
'• . �
-- THA
THA
Air Temp. Sensor

(Air Flow Meter) El
C --
F11 272
CD There is no voltage between ECU terminals THA and E2.

(IG S/W ON)
Check that there is voltage between ECU terminal B (B1 ) and

@
OK .! NO
Refer to No. 1 .
(See page Fl-6 2)
FI2787

Voltmeter
OK .! BAO
Check air temp. sensor.

@ Repair or replace.
(See page Fl-96)
BAD ! OK
F12757 Replace air frow Check wiring between ECU and air
meter. temp. sensor.
Air Flow Meter

@ l OK ! BAD

Ohmmeter
.n
0 1a+----
0
F11253
Ignition switch Coolant temperature 80 ° C

6 THW - E2 0.1 - 1 .0 V
(1 76 °F)
.No voltage
ON
ECU
B (B 1 )
Water Temp. Sensor
-o--4--------------o THW
-....-.:_-__.
'-'VIMr-o--+-------------o E2
----� E 1
Fl0487
There is no voltage between ECU terminals THW and E2.

G)
·.··· (IG .• 5/'N ON)
Voltmeter
ED ® Check that there is voltage between ECU terminal B (B 1 l and
•· · body ground. (IG 5/W ON) �
!
0
0 OK NO
Refer to No. 1 .
(See page Fl-62)
A2768
®
(_ Check wiring between ECU terminal E 1 and body ground. I
Voltmeter l BAD
OK
CY]
@ Check water temp. sensor. Repair or replace.
.
.,
BAD l OK
A2757 Replace water Check wiring between ECU and water

temp. sensor. temp. sensor.
! OK ! BAD
Ohmmeter Try another ECU. Repair or replace.

[J:[J
0 0
EFI SYSTEM - Troubleshooting with Volt/Ohmmeter {MS) Fl-69
No. Terminals Trouble Cori,Htion _STD Voltage

7 STA - E1 No voltage Cranking 6 - 14 V
To Circui..__ _u
ec __
Neutral Start
Ignition Switch .------Opening
Switch (A/T)
Relay
AM1 40A
(MIT)
Starter
Relay
....----o E1
F\2.943
(D There is no voltage between ECU terminals STA and E 1 .

UG S/W START)
Check starter Check wiring between ECU terminal STA
!
OK
operation. and ignition switch terminal ST1 .
BAD OK BAD
Fl2.768
Repair or replace.
® Check wiring between ECU terminal E 1 and body

!
ground. ..
Ohmmeter l OK BAD
T ry another ECU. Repair or replace.
Check fusible links , battery, wiring,

BAD
Fl27511 ignition switch and neutral start Repair or replace.
switch.
Voltmeter @ OK
@ Check that there is voltage at STA (50) terminal of starter.

(IG S/W START) STD voltage: 6 - 14 V
OK NO
Check w iring between ignition switch

Check starter.
terminal ST 1 and starter terminal STA (50).
1/
E F I SYSTEM - Troubleshooting with Volt/Ohmmeter (MS)

8 IGT, IGF - E1 No voltage Idling 0.7 - 1 .0 V
ECU
Ignition Switch
AM2 IG2
.--_..... To
Tachometer
Fusible
Link
· T
Battery .J_
--------o IGF
._________--o IGT
..---o El
Fl2438
There is no voltage between ECU terminals IGT and El .

ECU (D
(Idling}
Voltmeter �:§::::::::�=�r==:=!1-�===�
Check that there is voltage between ECU terminal IGT and
!
@
· body ground. (Idling)
NO OK
Check wiring between ECU Repair or
!
@
BAD
terminal E1 . and body ground. replace.
Fl2770
OK
Try another ECU.
Voltmeter
0 ::g�===�"
CY]
Check fusible link and ignition BAD
Repair or replace.
switch.
OK
BAD
Check distributor. (See page IG- 1 1 ) Repair or replace.
1
Fl2771
OK
@
!
BAD
Repair or replace.
battery.
Ohmmet
OK
DL]
BAD
Check igniter. Repair or replace.

9 ISC1 ~ ISC4 - E 1 No voltage Ignition switch ON 9 - 14 V
EFI Main Relay ECU

ISC Valve
Fuse
.-----<l"--....C>-------+-� o-�--......-tc...,_roo-,.-o+----Q ISC 1
EFI 1 5A ._-k>H-l'l!l!'-4>t----o lSC2
"-+"llll'-0..,._---o lSC3
'-'l!ll'--cM....----o lSC4
Fusible
link MAIN 1 .0Y
..---------Q B
'-----------0 8 1
'-------------9M-REL
Battery
.-----o E1
Ff2913
CD ~ ISC4
(D There is no voltage between ECU terminals ISC 1
and E1 . (IG S/W ON)
Voltemter
Check that there ls voltage between ECU terminal B (B 1 ) and
rv-1 @
821!+----- F127tll!
OK ! NO
Refer to No. 1 .
(See page Fl-62)

Voltmeter
CTI
OK ! BAO
@ Check ISV valve. Repair or replace.

(See page Fl-1 08)
BAD ! OK
!'121&i Replace ISC Check wiring between ECU and EFI

valve. main relay.
@ ! OK i BAD
Fl1643
72 EFI SYSTEM � Tr�>UbfeshQoting with Volt/Ohmmeter (MS)
,0. Terminals Trouble Condition STD Voltage

Ne:, tr:ouble ("CHECK engine warning
:o W - E1 N.9 voltage
·nght offt a nd engine running
8 ".'"" 1 4 V
ECU
FUSE
--�
Y
�E�
GA U G 7 .-�►.-
5A ,C-H�
E-
CJK·. �eNGl-N-
== ' . �----------� w
E�
Warning' Light
Combination Meter .----o E1
FI072
. © There is no voltage between ECU ierminals W and E 1 .

· . Udling)
..
® Check that th�re is voltage between ECU terminal W and
body ground.
0 0 .-----
1()1,
NO l OK
F12772 @ Check wiring between ECU terminal E1 and body

. ground. · · ·
! OK !' BAD
Voltmeter .
Try another ECU.
L Repair or replace.
!
Check GAUGE fuse (7 .5A) and "CHECK
ENGINE" warning light.
OK BAD
> Fl2773 I Repair or replace.
J Fuse blows again

Repair or replace.
W and fuse.
Ohmmeter
ClLJ
Fl2755
EFI SYSTEM - Fuel System Fl-73
FUEL SYSTEM
Fuel Pump
Check Valve---".'"""..
Relief Valve---��
Bearing------tt:-:-::
Brush -----i1i!'r:
Armature-----:-
Filter
Rubber Cushion
ECU
Fusible Link Ignition Switch Fuse
,------<�o-......,...,...._--u;;. lb----0--....0-------------y lG S/W
AM2 30A
r-----:::=:-::7"-;--=:--:-------yBATT
EFI Main Relay
.------v +B i (B i )
Fu
-_ s ible Lin k
__.,___-o...,, F us e
+- O'lt::�,- ----- - -- v- ""'--<>-;.-- -,...--� +B (B l
,
MAIN 1 .0Y (MS) EFI 1 5A
..J.)-
r-"T<:>-' OOOIW'<>-t----:r--� M-REL

Ignition
Fusible Link Switch
ALT "A" AM 1 ST 1
A M 1 40A Check
(MS) Connect
Circuit
ST Opening
Fuse
(MA) 7.5A Relay Fuel Pump Relay
Fusible (MA)
Link (MS)
MAIN 2.0
FC
.....__---u FC
(7M-GTE) (7M-GTE)
Fuel Pump
Neutral Resistor
Start S/W Fuel Pump Switch
(A/T) !Air Flow Meter)
l
BatteryJ_
ALT "A" (M/T)
!MA/ 7M-GE) E1
1 .258
(MA/7M-GTE)
1 00A
!MS)
1 00A = Fl 0491 FU479
'1-74 -
ON-VEHICLE INSPECTION
EFI SYSTEM Fuel System
FP
1. INSPECT FUEL PU M P OPERATION
(a) Turn the ignition switch to ON.
NOTE: Do not start the engine.
(b) Using a service wire, short circuit the fuel pump
check terminals +B and FP of the check connector.
See pages Fl- 1 1 0, 1 1 1
(cl Check that there is pressure i n the fuel return hose.

. NOTE: At this time, you will hear fuel pressure noise.
(d) Remove the service wire.

(el Turn the ignition switch OFF.
If there is no pressure, check the following parts.
• Fusible links
• Fuse
• EFI main relay
• Fuel pump
• Wi ring connections
2. · INSPECT FUEL PRESSU RE

(a) Check that battery voltage is above 1 1 bolts.
(b) Disconnect the cable from the negative (-} terminal
of the battery.
{c} Remove the cold start injector tube.

(7M-GE)
• Disconnect the wiring connector from · the cold
start injector.
• Place a suitable container or shop towel under the
cold start injector tube.
• Slowly loosen the union bolt of the cold start injec
tor tube and remove the bolt and two gaskets from
the delivery pipe.
(7M-GTE)
• Place a suitable container or shop towel under the
cold start injector.
• Slowly loosen the union bolt of the cold start injec
tor tube and remove the bolt and two gaskets from
the cold_ start injector.
• Remove the union bolt, fuel tube and two gaskets.
• Remove the two bolts and disconnect the cold

start injector with gasket.
• Disconnect the cold start injector connector.
• Install the gasket and cold start injector with the
bolts.
Torque: 55 kg-cm (48 in.-lb, 5.4 N·mt
(d) Install SST (pressure gauge) to the delivery pipe with

new gaskets and union bolt, as shown in the figure.
SST 09268-4501 2
Torque: 300 kg-cm (22 ft-lb, 29 N•m) ·
(e) Wipe off any splattered gasoline.
(f) Reconnect the battery negative (-) cable.
Fl1&48
Fl•76 EFI SYSTEM - Fuel System
I I (g) Using a service wire, short circuit the fuel pump

FP Service Wire check terminals FP and +B of the check connector.
+B CHECK CONNECTOR LOCATION:
See pages Fl- 1 1 O, 1 1 1
Fl1597
(h) Tum the ignition switch ON.

(i) Measure the fuel pressure.
Fuel pressure: 2.3 - 2.8 kg/cm2
(33 - 40 psi, 226 - 276 kPa)
If pressure is high, replace the pressure regulator.
If pressure is low, check the following parts:
• Fuel hoses and connection
• Fuel pump
1'11Jl49 • Fuel filter
• Pressure regulator
lj) Remove the service wire from the check connector.
(k) Start the engine.
0) Disconnect the vacuum sensing hose from the

pressure regulator and plug hose end.
(m) Measure the fuel pressure at idling.
Fuel pressure: 2.3 - 2.8 kg/cm2
(33 - 40 psi, 226 - 275 kPa)
Fl1650
(n) Reconnect the vacuum sensing hose to the pressure

regulator.
(o) Measure the fuel pressure at idling.
Fuel pressure: 1 .6 - 2. 1 kg/cm2
(23 - 30 psi, 1 67 - 206 kPa)
If pressure is not as specified, check the vacuum sensing
hose and pressure regulator.
EFI s
1sTEM - Fuel System Fl-77
(p) Stop the engine. Check that the fuel pressure

remains �bove 1.5 kg/cm2 (2 1 psi, 1 47 kPa) for 5
minutes after the engine is turned off.
If pressure is not as specified, c heck the fuel pump,
pressure regulator and/or i njectors.
(q} After checking fuel pressure, d iscon nect the battery
negative (-) cable and carefully remove the SST to
prevent gasoline from splashing.
SST 09268-4501 2
{r) Install cold start injector tube.

(7M-GE)
• Reconnect the cold start injector tube with new
gaskets and union bolt to the d el ivery pipe.
Torque: 300 kg-cm (22 ft-lb, 29 N•m)
• Connect the wiring connector to the cold start
injector.
(7M-GTE)
• Remove the two bolts and cold start injector with
gasket.
• Connect the cold start injector connector.
• Install the cold start injector tube with new four
gaskets and two union bolts.
Torque :
Delivery pipe side 300 kg-cm
(22 ft-lb, 29 N·m)
Cold start injector side 1 80 kg-cm
( 1 3 ft-lb, 1 8 N •m)
Fl1993
(s) Check for fuel leakage.

i=l-78 EFI SYSTEM - Fuel System
REMOVAL OF FU EL PU MP
MA
Fuel Tube� .
♦ Non-reusable part Fl1662
1, DISCONNECT CABLE FROM NE.GATIVE TERMINAL

OF BATTERY
2, DRAIN GASOLINE FROM FUEL TANK

WARNING: Do not smoke or work near an open
flame when working on the fuel pump.
3. REMOVE FUEL TANK
4. REMOVE FUEL PU MP BRACKET FROM FUEL TANK

(a) Remove the screws.
(b) Pull out the fuel pump bracket.
FI0933
5, REMOVE FUEL PUMP FROM FUEL PUMP BRACKET

(a) Remove the two nuts and disconnect the wires from
the fuel pump.
(b) Pull off the l ower side of the fuel pump from th e
bracket.
(c) Remove the fuel pump from the fuel hose.
EFI SYSTEM - Fuel System
6. REMOVE FUEL P U M P FILTER FROM FUEL PUMP

(a l Remove the rubber cushion.
(b) Using a.. small screwdriver, remove the clip.
(c) Pull out the pump filter.
fll6113
I NSTALLATION OF FUEL PU MP
(See page Fl-78)
1. INSTALL FUEL PU M P FILTER TO FUEL PU MP
(a) Install the pump filter with the clip.
(bl Install the rubber cushion.
2. INSTALL FUEL PUM P TO FUEL PU M P BRACKET

(a) Insert the outlet port of the fuel pump into the fuel
'--______
,..
________F10
=e=34 hose.
(bl Push the lower side of the fuel pump and install the
fuel pump. ·
3. INSTALL FUEL PU MP BRACKET

Install a new gasket and the pump bracket with the
screws . .
Torque: 36 kg-cm (30 in.-lb, 3.4 N•m)
4. INSTALL FUEL TANK

::..
(a) Apply a thin coat of oil to the flare and tighten the
�§�::'::��===�-::--::--:::-
__e.......,
._______________oo 33 flare nut.
(b) Then using SST, tighten the nut to the specified tor-
Fulcrum length que.
SST 0963 1 ;.22020
Torque: 3 1 0 kg-cm (22 ft-lb. 30 N·m)
NOTE: Use a torque wrench with a fulcrum length 30 cm
(1 1 . 1 8 1 in.) .
2 - 7 mm (0.08 - 0.28 inJ CAUTION :
Pipe Hose • Tighten the fuel tank mounting bolts, etc. to the
specified torque.
• Tighten the pipe union and flare nut (hose) to the
specified torque.
• Push In the p ipe and insert-type hose to the
,---'-l 1Ui..&--Clip specified position, and install the cllp to the
0 - 3 mm (0 - 0. 1 2 in.) speclfiecd location.
• If reusing the hose, reinstall the clip at the original
location.
6. REFILL GASOLINE
6. CON NECT CABLE TO NEGATIVE TERMINAL OF

Fl ! 654
FU0041 BATTE RY
F/0494
Fl-80 EFI SYSTEM - Fuel System
Cold Start Injector

7M-GE
Ignition
Switch
Cold Start Start Injector
ST 1 Injector Time Switch
7M-GTE
ECU (STJ) ....

Point
Fl:2981
Fl:2980 F12482
ON-VEHICLE I NSPECTION (7M-GE Only)

INSPECT RESISTANCE OF COLD START I N JECTOR
(a) Disconnect the cold start injector connector.
(b) Using an ohmmeter, measure the resistance of the
injector.
Resistance: 2 - 4 0
If the resistance is not as specified, replace the cold start
injector.
(c) Connect the cold start injector connector.
REMOVAL OF COLD START I N JECTOR

1. DISCONNECT CABLE FROM N EGATIVE TERMINAL
OF BATTERY
2. (7M-GE)
DISCON NECT COLD START INJECTOR CON N ECTOR
3. REMOVE COLD START INJECTOR TUBE

(7M-GE)
(a) Place a suitable container or shop towel under the
cold start injector tube.
(b) Slowly loosen the two union bolts of the cold start
injector tube and remove the bolts, four gaskets and
injector tube,
(7M•GTE)
(al Place a suitable container or shop towel under the
cold start injector.
(b} Slowly loosen the union bolt of the cold start injector
tube and remove the bolt and two gaskets from the
Fl\993 cold start injector.
(c) Remove the un"ion bolt, fuel tube and two gaskets.
4. REMOVE COLD START INJECTOR

(7M-GE}
Remove the two bolts and cold start i njector with the
gasket.
(7M-GTE}
Remove the two bolts and cold start injector with the
gasket, and disconnect the cold start i njector connector.
I NSPECTION OF COLD START I NJECTOR

Ohmmeter 1. (7M-GTE)
D'.CJ INSPECT RESISTANCE OF COLD START INJECTOR
Using an ohmmeter, check the resistance of the injector.
0 1o++--
o
Resistance: 2-4 0
If the resistance i s not as specified, replace the cold start
injector.
Fl2979
2. I NSPECT INJECTION OF COLD START INJECTOR

i--union Bolt WARN ING: Keep clear of sparks during the test.
(a) Install SST (two unions) to the injector and delivery
SST {Hose} Gasket pipe with new gaskets and the union bolts.
SST (Union) SST 09268-41 045
(b) Connect the SST (hose) to the unions.
SST 09268-41 045
SST (Wire) (c) Connect the SST (wire) to the i njector.
Fl2984 SST 0984?.'.
:UlOl:.:n
(d) Put a container under the injector.

(e) Reconnect the battery negative (-) terminal.
(f) Turn the ignition switch ON.
NOTE : Do not start the engine.
(g)Using a service wire, short terminals +B and FP of

the check connector.
See pages 'Fl- 11 0, 1 1 1
(h) Connect the test probes of the SST (wire) to the bat-
tery, and check that the fuel spray is as shown.
SST 09842-30050
CAUTION : Perform this check within the shortest
possible time.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of
SST (wire) from the battery and check fuel leakage
from the injector.
SST 09842-30050
Fuel drop: One drop or less per minute
(b) Disconnect the battery negative (-) cable.
(c) Remove SST and the service wire.
SST 09 268-41045 and 09842-30050
INSTALLATION OF COLD START INJECTOR

1. INSTALL COLD START INJECTOR
(7M-GE)
Install a new gasket and the the cold start injector with the
two bolts.
Torque: 55 kg-cm (48 in.-lb, 5.4 N·m)
(7M-GTE)
(a) Connect the connector to the cold start injector.
(b) Install a new gasket and the the cold start injector
with the two bolts.
Torque: 55 kg-cm (48 in.-lb, 5.4 N·m)
2. INSTALL COLD START INJECTOR TUBE

Using new gaskets, connect the cold start injector tube to
the delivery pipe and cold start injector. Install the union
bolts.
Torque:
Delivery pipe side 300 kg-cm
(22 ft-lb, 29 N·m)
Cold start injector side 1 80 kg-cm
(1 3 ft-lb, 1 8 N·m)
3. (7M-GE)
CONN ECT COLD START INJECTOR CONNECTOR
4. CON NECT CABLE TO N EGATIVE TERMINAL OF

BATTERY
5. CH ECK FOR FUEL LEAKAGE

t-84 EFI SYSTEM - Fuel System
Pressure Regulator.
Pressure Regulator
TO RETURN
PIPE
FROM DELIVERY
PIPE
No. 2 Fuel Pipe ·

Fl1659 F11660
ON-VEH ICLE INSPECTION

INSPECT FUEL PRESSU RE (Se e page Fl-74)
REMOVAL OF PRESSURE REGU LATOR

1. DISCONNECT PCV HOSE
2. DISCONNECT VACU U M SENSING HOSE
3. DISCONNECT NO.2 FUEL PIPE

(a) Place a suitable container or shop towel under the
pressure regulator.
(b) Remove the union bolt and two gaskets.
(c) Remove the clamp bolt of the No.2 fuel pipe.
Fl1 661
4. REMOVE PRESSU RE REGULATOR

loosen the lock nut, and remove the pressure regulator.
Pressure Regulator
I NSTALLATION OF PRESSU RE REGULATOR
1. INSTALL PRESSURE REGULATOR
(a) Fully l oosen the lock nut of the pressure regulator.
(b) Thrust the pressure regulator completely into the
Front • delivery pipe by hand.
(c) Turn the pressure . regulator counterclockwise until
the outlet faces in the directi.on indicated in the
Delivery Pipe figure.
R1883
(d) Torque the lock nut.

Torque: 260 kg-cm (1 8 ft-lb, 26 N·m)
2. CONNECT NO. 2 FUEL PIPE

{a) Using new gaskets, connect the No. 2 fuel pipe to the
pressure regulator. Install the union bolt.
Torque: 260 kg-cm {1 8 ft-lb, 25 N·m)
(b) Install the clamp bolt.
Fl1861
3. CONNECT VACU U M SENSING HOSE
4. CONN ECT PCV HOSE

Fl-86 EFI SYST.EM - Fuel System
I njectors
..
FUEL
Coil
F12661
1. CHECK INJECTOR OPERATION
Cheqk operation sound from eac_h 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 you have no sound scope, you can check the injec-
tor transmission operation with your finger.
If no sound or an unusual sound is heard, check the wiring
connector, injector, resistor or i njection signal from the
ECU.
Fl1666
2. INSPECT RESISTANCE OF INJECTOR

(a) Disconnect the injector connector.
(b) Using an ohmmeter, measure the resistance of both
terminals.
Resistance:
7M-GE 1 .8 - 3.4 0
7M-GTE 2.0 - 3.8 0
'-----'-' If the resistance is not as specified, replace the i njector.
�
�F l SYSTEM - Fuel 5Ystem Fl.,87
1
REMOVAL OF. INJECTOR
1. DISCONN ECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY
2. DRAIN COOLANT
3. DISCONNECT FOLLOWING HOSES:

• Water hoses from throttle body (7.M-GE) o r water by-
pass pipe (7M-GTE)
• Vacuum hoses from throttle body
• I S C valve hoses from throttle body
• Vacuum sensing hose from pressure regulator
4. DISCONNECT FOLLOWING CONNECTORS:

• (7M-GE)
5. REMOVE AIR INTAKE CONNECTOR

(7M-GE)
(a) Disconnect the air cleaner hose from the throttle
body.
(b) Remove the throttle body and air intake connector
brackets.
(c) Remove the four bolts and two nuts, intake connec
tor a nd gasket.
(7M-GTE)
(See steps 1 to 3 on page EM- 1 2)
6, (7M-GTE)
REMOVE THROTTLE BODY (See page Fl-1 04)
--------------t I 7. REMOVE ISC VALVE

·1 (a) Disconnect the No. 2 water by-pass hose from the
ISC valve.
(p) Remove the two bolts, ISC valve and gasket.
Fll670
8. DISCONNECT INJECTOR CONNECTORS
9. DISCONNECT COLD START INJECTOR TUBE FROM

DELIVERY PIPE (See page Fl-80)
1 0. REMOVE N0.1 FUEL PI PE

(a) · Remove tile pulsation damper and two gaskets.
(b) Remove the union bolts and two gaskets from the
fuel pipe support (MA) or fuel filter (MS).
(c) ·Remove the clamp bolt, No. 1 fuel pipe and VSV (w/
EGR).
ti {.1,-,
l Fl1671
1 1 . ,REMQVE N0.2 FUEL PIPE ·

(a) Remove the union bolt and two gaskets from the
. pressure regulator.
(b) Pisconnect the fuel hose from the No.2 fuel pipe.
(c) .Remove the clamp bolt and No.2 fuel pipe.
v .1 2; · REMOVE PRESSURE REGULATOR

(a) Loosen the look nut.
(b) Remove the pressure regulator and two gaskets.
1 3. REMOVE DELIVERY. PIPE

(a) Remove the three bolts, and then remove the delivery
pipe with injectors.
CAUTION : Be careful not to drop the Injectors, when
removing the delivery pipe.
(b) Remove the six insulators and three spacers from the
cylinder head.
R1B72
1 4. REMOVE. INJECTORS
(a) Pull out the injectors from the delivery pipe.
(b) Remove the 0-ring from the injector.
1-90 EFI SYSTEM - Fuel System ·
MA Pressure Regulator INSPECTION OF INJECTOR

(From v,hiclel
O� '. TEST INJ ECTION OF INJECTORS
� 01/1 :WARN ING: Keep clear of sparks during the test.
SST (Union) 1
MS Pressure Regulator
!From Vehicle) ssr
�:;A
' {Hose)
i
(' (Union)
1 F12570
(a) Disconnect the No. 1 fuel pipe from the fuel return
i
MA
pipe support (MA) or fuel filter (MS).
(b) Connect SST (hose) to the fuel pipe support (MA) or
fuel filter (MS) outlet with SST (union), new gaskets
� � and union bolt.
SST ® _,,, Disconnect
SST 09268- 4 1 045
Fuel Suppo rt NOTE: Use the vehicle's fuel support (MA) or fuel filter
(MS).
Fl1976
Fl2572
(c) Remove the pressure regulator (See page Fl-84).
h
New Gasket Pressure (d) Connect the fuel return hose to 1:he pressure regula
I
I Regulator
Union
Bolt
� tor with SST (union), new gasket and union bolt.
Q
�� SST 092 68-41 045
tfl--ssr (Union)
(el Connect SST (hose) to the pressure regulator with
Fuer
Return
Hose 1I J SST (union).
SST 092 68-4 1 045
SST (Hose)
�
(f) Connect the SST (hose) to the injector.

SST 09268-4·1 045
[}-SST
(Hose) (g) Put the injector into the graduated cylinder.
•
c:::a
NOTE: I nstall a suitable vinyl tube onto the injector to
prevent gasoline from splashing out.
(h) Connect the battery cable.
(i) Turn the ignition switch ON.
.----Vinyl Tube NOTE: Do not start the eng_i ne .
Fl1674
Using a service wire, short circuit the fuel pump

lj )
check terminals +B and Fp of the service connector.
See pages Fl- 1 1 0, 1 1 1
. ,. (k} Connect SST (resistor wire) to the injector and bat

� SST (Resistor Wire) tery for 1 5 seconds and measure the injection
volume with a graduated cylinder.
Test each injector two or three times.
SST 09842-30060
Volume:
7M-GE
Graduated 65 - 80 cc (4.0 - 4.9 cu in.) per 1 5 sec.
Cylinder
Vinyl Tube 7M-GTE
Fl1876
1 0 1 - 1 1 4 cc (6.2 - 7.0 cu in.) per 1 5 sec.
Difference between each injector:
9 cc (0.6 cu in.) or less.
If the injection volume is not as specified, replace the
injector.
2. INSPECT LEAKAGE
(a) In the condition above, disconnect the test probes of
SST (wire) from the battery and check for fuel
leakage from the injector nozzle.
SST 09842-30060
1'11 676 Fuel drop: One drop or less per minute
(b) Disconnect the battery negative (-) cable.
(c) Remove the SST and service wire.
SST 09268-4 1 045
EFI SY�_TEM - Fuel System
I NSTALLATION Of. INJ ECTORS

1. I NSTALL INJECTORS I NTO DELIVERY PIPE
(a) Install a new grommet to the injector.
Grommet
Fl1817
{b) Apply a light coat of gasoline to a 0-ring and install it

to the injector.
Fl1596
(c) While turning the injector l eft and right, install it to

the delivery pipe. Install the six injectors.
Fl1678
Black Ring 2. INSTALL DELIVERY PIPE WITH INJECTORS

(a) Install the six insulators into the injector hole of the
cylinder head.
{b) Install the black rings on the upper portion of each of
the three spacers. Then install the spacers on the
delivery pipe mounting hole of the cylinder head.
A1679
(c) Place the injectors together with the delivery pipe on

the cylinder head.
(d) Check that the injectors rotate smoothly.
NOTE: If the injectors do not rotate smoothly, the proba
ble cause is incorrect installation of 0-rings. Replace 0-
rings.
(e) Install the three spacers and bolts.

Torque the bolts.
Fl1672
3. INSTALL PRESSURE REG ULATOR

Pressure Regu lator Delivery Pipe (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
Front • the outlet faces in the directiQn indicated in the
figure.
Fl1!163
(d) Torque the lock nut.

4. INSTALL NO. 2 FUEL PIPE

(a) Install the No. 2 fuel pipe and clamp bolt.
(b) Connect the fuel hose.
·.. �
{c) Install the union bolt and new two gaskets to the
pressure regulator. Torque the union. bolt.
Torque: 250 kg�cm ( 1 8 ft-lb, 25 N·m)
6. INSTALL NO. 1 FUEL PIPE

(a) Install the No. 1 fuel pipe, VSV (w/ EGR) and clamp
bolt.
(b) Install the union bolt and two new gaskets to the fuel
pipe support. Torque the union bolts.
(c) Install the pulsation damper and two new gaskets.
Torque the pulsation damper.
--.
0 ,,, Torque: 400 kg-cm (29 ft-lb, 39 N·m)
, Fl1 6 7 1
94 EFI SYSTEM - Fuel System
&. . CONNECT INJECTOR CONN�CTORS
7. CONNECT COLD START INJECTOR TUBE TO

DELIVERY PIPE
{See page Fl-83)
8. INSTALL ISC VALVE

(a) Install a new gasket and ISC valve with the two bolts.
Torque: 1 30 kg-�m (9 ft-lb; 1 3 N·m)
(b) Connect No. 2 water by-pass hose to the ISC valve.
9. (7M-GTE)
INSTALL THROTTLE BODY
{See step 1 on page Fl-1 06)

(7M-GE)
(a) Install a new gasket and air intake connector with the
four bolts and two nuts.
Torque : 1 80 kg-cm (1 3 ft�lb, 1 8 N•m)
(b) Install. the air intake connector and throttle body

brackets.
(c) Connect th.a air cleaner hose to the throttle body.
{7M-GTE)
(See page EM-1 4)
1 1 . CO,N N ECT FOLLOWING CON N ECTORS:

• (7M-GE)
1 2. CON N ECT FOLLOWING HOSES:

• Water hoses from throttle body (7M-GE)
·· or water by-
pass pipe (7M-GTE)
• Vacuum hoses from throttle body
• ISC valve hoses from throttle body
• Vacuum sensing hose from pressure regulator
1 3. REFILL CQOLANT (See page CO_-5} ·
1 4. CON NECT CABLE TO NEGATIVE TERMI NAL O F

BATTERY .
1 5. CHECK FOR FUEL LEAKAGE (See page Fl-1 1 )

EFI SYSTEM - Air Induction System
. .
AIR IN DUCTION SYSTEM

Air Flow Meter (7M -GE)
POTENTIONMETER
Compensation Plate
... -
Damping Cham ber
Return Spring
Air Temp.
Sensor
TO AIR
INTAKE
...
AIR AIR
,
CLEANER I NTAKE
CHAMBER
SIDE CHAMB E R
SIDE
Air By-pass
C FROM AIR Passage Measuring Plate
C LEANER Measuring Plate Air By-pass Passage
Fl1 681 FI0449
Ohmmeter INSPECT RESISTANCE O F AIR FLO W METER
(a) Disconnect the air flow meter connector.
(b) Using an ohmmeter, measure the resistance between
each terminal.
Terminals Resistance Temperatu re
VS - E2 20 - soo o -
FI0618
VC - E2 200 - 400 o -
10 - 20 K O - 20 °c t 4 F)
°
4- 7 KO 0 °C ( 3 2 F)
°
THA - E2 ·· 2- 3 KO 20 °C ( 6 8 F)
°
-
0.9 - 1 .3 K O 40 °C (1 04°F)
0.4 - 0.7 K O 60 °C ( 1 40 °f )
FC - E 1 Infinity
If the resistance is not as specified, replace the air flow

meter.
(c) Reconnect the air flow meter connector.
FI0622
EFI SYSTEM - Air Induction System Fl-97
REMOVAL OF -AI R l=LOW M ETER

1. D ISCONNECT AIR FLOW METER CONNECTOR
2. DISCONN ECT NO. 2 AIR CONNECTOR HOSE
3. REMOVE AIR CLEANER CAP

Remove the two bolts and cap.
4. REMOVE AIR FLOW METER

____________
.__ F11.........,
ss2 Pry off the lock plates, and remove the four nuts, and air
flow meter.
INS PECTIO N OF AIR FLOW METER

INSPECT RESISTANCE OF AIR FLOW METER
FC E l E2 vs . Using an ohmmeter, measure the resistance between each
I CJI u:::::JI CJI a::::::::11 u:::::JI a::::::::D a::::::::I
I
terminal by moving the measuring plate.
Measuring plate
Terminals Resistance (n l
opening
Infinity Fully closed

FC - E 1 Other than
Zero
closed position
20 - 600 Fully closed

VS - E2
20 - 1 ,200 Fully open
Measuring NOT E : Resistance between terminals E2 and VS will

Plate change in a wave pattern as the measuring plate slowly
opens.
FI0480
FI0449
meter.
INSTALLATION OF AI R FLOW M ETER

1. INSTALL AIR FLOW METER
Install the air flow meter with the two lock plates and four
nuts. Pry the lock plates on the nuts.
2. INSTALL AIR CLEANER CAP

Install the cap with the two bolts.
3. CONNECT NO. 2 AIR CONNECTOR HOSE

• F11 682
4. INSTALL AIR FLOW METER CONNECTOR
8 EFI .SYSTEM - Air Induction System
Air ,flow Meter {7M -GTE)
Leaf S prin
Luminous Diode 3
Pressure
blrectihg
Vortex Hole
Generating
O bjectives
MS0001 F111177
Air .Flow Meter O N -VEH ICLE I NSPECTION

Ohmmeter E 1 VC KS THA E2
INSPECT RESISTANCE OF AIR FL(;)W.. M ETER
(a) Disconnect the air flo�.ri!er·con ector.
CD
�
(b) Using an ohmmeter (analgg typEI), measure the resis-
tance between each termUial.
,· i . . ...
Terminals Resi�taoce Temperature
n
·"'-.° V•f'· ·. ,-..
KS - E 1 co
-
Fl2006
E1 - KS 5 - 1 0 kO
VS - E 1 1 0 - 1 5 kO
. E1 - vc 5 - 1 0 kO
1 0 - 20 k O - 20 ° C ( 4° F)
4 - 7 kO 0°C ( 3 2 °F)
THA - E2 2 - 3 kO 20°C ( 6 8 ° F)
0.9 - 1 .3 k O 40° C { 1 04° F)
0.4 - 0.7 k O · . 60° C ( 1 40 ° F)

meter.
(c) Reconnect the air flow meter connector.
REMOVAL .O F AIR FLOW M ETER

1, REM OVE NO. 4 AIR CLEANER PIPE WITH NO. 1 AND
NO. 2 AIR CLEANER HOSES
2. REMOVE AIR FLOW M ETE R WITH AIR CLEANER

CAP
(a) Disconnect th e connector.
Fl197S
(b) Remove the three clamps and bolt.
(c) Loosen the clamp and remove the air flow meter with
air cleaner cap.
Fl1 980
3. REMOVE AIR FLOW METER

(a) Remove the two screws and bracket.
Fl1981
- 1 00 EFI SYSTEM - Air Induction System
(b) Pry off the lock plate.

(c) Remove the four nuts, lock plates, No.
· 1 air
· cleaner
cover and air cleaner cap.
Fl1 982
I NSPECTION O F AIR FLOW METER

INSPECT AIR FLOW M ETER
C J
Check that the hony-combed mesh is neither deformed
0
0
0-
0
nor damaged.
If necessary, replace the air flow meter.
0 0
C .. J
F\1983
INSTALLATION OF AIR FLOW M ETER

1. INSTALL AIR FLOW .METER
(a) Install the air cleaner cap, No. 1 air cleaner cover and
lock plates to the air flow meter with the four nuts.
(b) Pry the lock plates on the nuts.
Fl1982
(c) Install the bracket with the two screws.
Fl1 981
2. INSTALL AIR FLOW M ETER WITH AIR CLEANER

CAP
(a) Install the air flow meter with air cleaner · cap, and
tighten the clamp.
F11980
(c) Connect the connector.
R1978
3. I NSTALL NO 4 AIR R P I PE W ITH NO. 1 . AND

NO. 2 AIR C LEAN E RC��:::
EM3526
Fl-1 ()2 EFJ SYS"l):M . - Air tnductiori Sys�em
Throttle Body
7M-GE 7M-GTE
Throttle Position Throttle Position

Sensor Sensor
.O N -VEHICLE I NSPECTION
FIH l83 Fl0604 Fl1984
1 . INS PECT THROTTLE BODY

{a) C heck that the throttle linkage moves smoothly.
(b) Check the vacuum at each port.

• Start the engine.
• Check the vacuum with your finger.
Port At Idling Other than Idling

Purge No vacuum Vacuum
EGR No vacuum Vacuum
R No vacuum No vacuum
Fl1B86
7M-GE 2. INSPECT THROTTLE

.. POSITION SENSOR
E2 (a) Disconnect the connector from the sensor.
IDL (b) Insert a thickness gauge between the throttle stop
screw and stop lever.
(c) Using an ohmmeter, measure the resistance between
each terminal.
l=========::_,,
Ohmmeter
Cl[]
0 .
0 !g
Clearance between
lever and stop screw Between
Resistance
terminals
7M-GE 7M-GTE
O mm (0 in.) VTA - E2 0.3 -:- 8.3 k O
Thickness Gauge 0.4 mm 0.6 mm Less than
IDL - E2
(0.01 5 7 In.) (0.0 1 97 in.) 2.3 kO
0.75 mm 0.9 mm
IDL - E2 C0
(0.0295 in.) (0.0354 In.)
Throttle valve fully
VTA - E2 3.6 - 1 0.3 kO
opened position
Flt8:t5
- VC - E2 4.25 - 8.26 kO
Fl1986
- ..---....-7
Ir--
(d) Reconnect the sensor connector.
IOL
VTA
vc i f
�- IDL VT� VC i
l
FIi t211
REMOVAL OF THROTTLE BODY

(7M-GE)
1. DRAIN COOLANT FROM THROTTLE BODY
2. REMOVE ACCELERATOR CONN ECTING ROD

3. DISCOI\IN ECT VAC U U M HOSES
4. DISCONNECT NO. 2 AND NO. 3 WATER BY-PASS

HOSES
6. DISCONNECT THROTTLE POSITION SENSOR

CONNECTOR
8. DISCONNECT AIR CLEANER HOSE
7. REMOVE TH ROTTLE BODY B RACKET(S)

Remove the four · bolts and throttle body with the gasket.
FlH:188
Fl- 1 04 EFI SYSTEM - Air Induction System
..
(7M.:GTE)
..
1. DRAIN COOLANT FROM THROTTLE BODY
2. DISCONNECT ACCELERATOR CONNECTING ROD
3. REMOVE AIR INTAKE CONN ECTOR

(See steps 1 to 3 on page EM-1 2)
4. DISCONNECT VACU U M HOSES
5. DISCONNECT THROTTLE POSITION SENSOR

CONNECTOR

( a) Disconnect the t�o water by-pass hoses from the
ISC valve and water pipe.
F5508
(b) Remove the four bolts, throttle body and gasket.

(c) Remove the two water by-pass hoses.
INSPECTION OF THROTTLE BODY

1. CLEAN THROTTLE BODY
(a) Using a soft brush and carburetor cleaner, clean the
cast parts.
(d) Using compressed air, clean all passages and aper
tures;
CAUTION : To prevent deterioration, do not clean the
throttle position sensor and dash pot.
2. INSPECT THROTTLE VALVE

Check that there is no clearance between the throttle stop
screw and throttle lever when the throttle valve is fully
closed.
C
G Throttle Lever
Trottle Stoo Screw

EFI SYSTEM - Air Induction System Fl-1 06
3. INSPECT THROTTLE POSITION SENSOR

(See step 2 ·on page Fl-1 03)
4. IF N ECESSARY, ADJUST THROTTLE POSITION

SENSOR
(a) Loosen the two screws of the sensor.
fl1689
(b) Insert a 0.58 mm (0.0228 i n.} (7M-GE) or 0.70 mm

(0.0276 in.) (7M-GTE) thickness gauge, between the
throttle stop screw and lever.
(c) Connect the test probe of an ohmmeter to terminals
. IDL and E.
fl1625
(d) Gradually tum the sensor clockwise until the ohm

meter deflects, and secure the sensor with th e two
screws.
Fl1690
(e) Recheck th e continuity between terminals IDL and

E2 E2.
IDL
Clearance between
lever and stop screw Continuity (IDL - E2)
7M-GE 7M-GTE
0.40 mm 0. 50 mm
Continuity
(0.0 1 57 in.} (0.0 1 97 in.)
0.75 mm 0.9 0 mm
F11 625 No continuity
(0.0295 in.l (0.0354 in.)
EFI SYSTEM - Air Induction System
INSTALLATION
( � '' "
OF�.. TH ROTTLE
. - '
BODY
(7M-C3E)
1, INSTALL THROTTLE BODY
Install the gasket and throttle body with the four bolts.
Torque: • 1 30 kg-cm (9 ft-lb, 1 3 N·m)
2. CONNECT THROTTLE BODY BRACKET(�)

Fl1888 3, CONN ECT AIR CLEANER HOSE
4. CONNECT THROTTLE POSITION SENSOR

CONNECTOR
6. CONNECT VACUUM HOSES
8. CON NECT WATER HOSES
7. CONNECT ACCELERATOR CONNECTING ROD
8, REFILL WITH COOLANT
(7M-GTE)
1. INSTALL THROTTLE BOl;)Y
(a) Install the two water by-.pass hoses.
(b) Install a new gasket and throttle body with the four
bolts.
. (c ) Connect the two water by-pass hoses to the ISC

valve and water pipe.
EFI SYSTEM - Air Induction System Fl- 1 07
2. CONNECT THROTTLE POSITION SENSOR

CONN ECTOR ..
3. CONNECT VACUU M HOSES

(See steps 1 3 to 1 6 on page EM•1 4)
6. INSTALL ACCELERATOR CONNECTING ROD
6. REFILL WITH COOLANT
Fl-1 08 EFJ SYSTEM - Air Induction System
Id le Speed Control (ISC) Valve
Rotor
Rotor
B2 S2 S4
Fl188t FI1692
ON-VEH ICLE INSPECTION

CH ECK FOR OPERATING SOUND FROM ISC VALVE
Check that there · is a clicking sound immediately after
stopping the engine.
Flt683
REMOVAL OF ISC VALVE

1. D RAIN COOLANT
2. DISCONNECT ISC VALVE CONNECTOR
3. DISCONNECT TWO WATER BY-PASS AND AIR

HOSES FROM ISC VALVE
R1669
4. REMOVE ISC VALVE

(a) Remove the two bolts.
(b) Remove ISC valve and gasket.
(cl (7M-GTE)
Remove the seal washer and check valve from the
intake chamber.
EFI SYSTEM - Air lnductio'n System Fl-1 09
INSPECTION O F I SC .VALVE
1. INSPECT RESISTANCE OF ISC VALVE
Using an ohmmeter, measure the resistance between ter
S4 B2 S2 minal 8 1 - S 1 or S3 and 82 - S2 or S4.
S3 B 1 S 1 Resistance: B1 - S1 or S3 1 0 - 30 n
B2 - S2 or S4 1 0 - 30 0
If resistance is not as specified, replace the ISC valve.
Fl\694
2. INSPECT OPERATION OF ISC VALVE

(a) Apply battery voltage to terminals 8 1 and B2 and
while repeatedly grounding S 1 - S 2 - S3 - S4 -
S 1 in sequence, check that the valve moves toward
the closed position.
EB e
Battery
Fll643
(b) A pply batterY, voltage to terminals B 1 and B2 and

while repeatedly grounding S4 - S3 - S2 - S 1 -
S4 in sequence, check that the valve moves toward
the open position.
INSPECTI ON OF CHECK VALVE (7M-GTE only}

EB e INSPECT CHECK VALVE
Battery Inspect the check valve for damage and the diaphragm for
cracks.
Ftl843
If necessary, replace the check valve.
7M-GTE onl�eck Valve INSTALLATION O F ISC VALVE

1. INSTALL ISC VALVE
SeaJ Wa,(!.o
(a) {7M-GTE)
Install the check valve and the seal washer as shown
in the illustration, to the intake chamber.
(b) Install a new gasket to the intake .manifold.
(c) Install the ISC valve with the two bolts and one nut.
1....----------------' F1zooe Torque: 1 30 kg-cm (9 ft-lb, 1 3 N·m)
2. INSTALL AIR AND TWO WATER BY-PASS HOSES TO
ISC VALVE
3. CONNECT ISC VALVE CONNECTOR
4. REFILL WITH COOLANT
F11669
EFI SYSTEM ;... Electronic Control System
ELECT RONIC CONT ROL SYSTE M

Locatio n of Electro nic Contro l Parts
MA
7M-GE
Fuel Pump_ Relay
Fuel Pump· Solenoid
Resistor
Cold Start Injector
Time Switch
Oxyg en Sensor
(w / TWC)
VSV . (for FPU)
- EFI Main Relay
7M-GTE
O �g,n
Fuel Pum '· ·
Fuel Pump Solenord
Re•l�tor
Cold Start lnjectpr
Time Switch
EFI SYSTE� - Electronic Control System Fl-1 1 1
Location of Electronic· Control Parts (Cont'd)

MS
EFI Main Relay
LHD Fuel Pump Relay
Check Connector --
Circuit Opening
Relay
Cold Start Injector

Time Switch
VSV (for FPU)
RHD
�
Check Conne ctor�
Circuit Opening Relay;::--
//
EFI Main Relay
. Cold Start Injector II
Time Switch Fuel Pump Relay
1/;?
Fuel Pump. Solenoid Resistor
Solenoid Resistor
12 EFI SYSTEM - Electronic Control System
EFI Main Relay ..
ECU
EFI Main Relay

Fusible Link Fuse
r----O::::::-<:>--�--o,...-cr---------,-.� ·--..c)-4.'=---�i.-----r >+B (B)
AM2 EFI 1 5A
. (MA) ....--=��OOllOO'o-J,_______-v M-REL
(MS)
Fusible (MA) MAIN 2.0L

Link (MS) MAIN 1 .0Y
..---c 1 E 1
T
Battery 1
Fl2912
Jo continuity Continuity INSPECTION O F EFI MAIN RELAY

CJD
1. INSPECT RELAY CONTINUITY
CJD
(al Using an ohmmeter, check that there is continuity
between terminals 1 and 3:
(bl Check that there is no continuity between terminals 2
and 4.
If continuity is not as specified, replace the relay.
BE0009
2. INSPECT RELAY OPERATION

(al Apply battery voltage across terminals 1 and 3.
(bl Check that there is continuity between terminals 2
and 4.
If operation is not as specified, replace the relay.
BE00 1 0
· EFI SYSTEM - Electroni c Control System Fl-1 1 3
Circuit Openi!lg Relay
---..- To E C U (STA)
�------------ To ECU +B (B)
B To EFI Main Relay STA
Check Connector
.___ ..... FP FC E1
Fuel Pump Switch
(Air Flow £\..'leter)
(7M-GE)
To Fuel Pump
.-----.
ECU o----------
Relay
(7M�GTE)
INSPECTION OF CIRCUIT OPENING RELAY

Fl1992
1. I NSPECT RELAY CONT I N UITY

(a) Using an ohmmeter, c heck that there is continuity
between terminals STA and E 1 .
(b) Check that there is continuity between terminals B
and FC.
(c) Check that there is no continuity between terminals B
and FP .
.______________... 1 s=-
A.;..;.os If continuity is not as specified, replace the relay.
2. I N SPECT RELAY OPERATIO N

(a) Apply battery voltage across terminals STA and . E 1 .
(b) Using an ohmmeter, check that there is continuity
between terminals B and FP.
Continuity
e �
Battery
Fl1909
(c) Apply battery voltage across terminals B and FC.

(d) Check that there is continuity between terminals B
and FP.
If operation is not as specified, replace the relay.
Continuity
e ®
Battery
·1 1 4 EFI SYSTEM - Electronic Control System
Solenoid Resistor
Ignition Switch ECU

Fuse IGN
..----,..,,..,,.,:,f,-C.,.- o4--o,...,,--------.."'.'"::"-----<T"-o---u l G S/W
AM2 __..,.IG2 +B (MA) 7.5A
Solenoid (MS) 1 5A
Fusible AM2 30A Resistor
Link
(MA)
Fusible MAIN
Link 2.0L (MS) Injector
,__-------nNo. 1 0
· Battery :
.,. '-------------oNo. 20
'---------------nNo. · ao
E01
E02
1'12914
INSPECTION OF SOLENOI D RESISTOR

INS PECT RESISTANCE OF SOLENOID RESISTOR
+B g 10 Using an ohmmeter, measure the resistance between +B
and other terminals.
Resistance: 3 n each
If the resistance is not as specified, replace the resistor.
No. 20 No. 30
Fl2574
EFI SYSTEM - Electronic Coritrol System Fl-1 1 5
To Ignition Switch _-+------------------4�---To ECU (STA)

(ST 1 l
STA STJ STJ STA
I
. I
To ECU (STJl
l_ _ Cold Start Injector
Time Switch .
F11 374
I NSPECTION OF COLD START INJ ECTOR

TIME SWITCH
1. INSPECT RESISTANCE OF COLD START INJECTOR
TIME SWITCH .
(a) Disconnect the connector.
each terminal.
Resistance:
w/ TWC
STA - STJ 25 - 60 !l below
1 s0 c (59 ° F>
n
60 - 85 above
30°c (86 °F>
STA - Ground 2s - 8& n
w/o TWC
STA - STJ 20 - 40 !l below
30°c (s& ° F>
n
40 - 60 above
40° c (1 04°F>
STA - Ground 20 - 80 n
If the resistance is not as specified, replace the switch.
2. IF N ECESSARY, REPLACE COLD START INJECTION
TIME SWITCH
(a) Drain the coolant.
(b) Using SST, replace the switch with a new gasket.
SST 0981 4-2001 0
(c) Refill with coolant.
Fl1 703
Fl-1 1 6 EFI SYSTEM - Electronic Control System
Water Temp_erature Sensor
40
20
10
8
WATER TEMP. SENSOR 6
C: 4
� 2
<( 1
ffi
(/) 0.8
1-
0.6
a: 0.4
0.2
Thermistor
- 20 0 20 40 60 80 1 00 1 20
(-4l (32l (68H1 04) (1 40){1 76)(2 1 2) (248l
TEMPERATURE ° C (° F) F10515 F10709
I NSPf;CTION OF WATER TEMPERATU RE

SENSOR
INSPECT RESISTANCE OF WATER TEMPERATURE
SENSOR
Using an ohmmeter, measure the resistance between both
terminals.
Ohmmeter Resistance: Refer to chart.
If the resistance is not as specified, replace the water tem -
Fl1 638 perature sensor.
EFI SYSTEM - Electronic Control System Fl-1 1 7
Fuel Pump Relay and Resistor
Fuel Pump Relay
F11 704
MA Continuity Continuity I NSPECTION OF PUMP RELAY AND

00 RESISTOR
1. INSPECT FUEL PUMP RELAY
A. Inspect Relay Continuity
(a) Using an ohmmeter, check that there is continuity
between terminals +B and FP.
(b) Check that the.re is continuity between terminals +B
and FPR.
No continuity (c) Check that there is no continuity between terminals
Continuity +B and PR.
MS Continuity
C:JCJ If continuity is not as specified, replace the relay.
FP
PR
R2575
R2669
B. Inspect Relay Operation

MA
(a) Apply battery voltage across terminals +B and FPR.
(b) Using an ohmmeter, check that there is continuity
between terminals +B and PR.
(c) Check that there is no continuity between terminals
B and FP.
If operation is not as described, replace the relay.
Continuity Fl2576
118 EFI SYSTEM - Electronic Control System
3
No continuity
D:D
2. INSPECT FUEL PUMP RESISTOR

DC!
Inspect Resistance of Fuel Pump Resistor
Using an ohmmeter, · measure the resistance between both
terminals.
Resistance: · Approx. O. 7 n
If the resistance is not as specified, replace the fuel pump
resistor.
EFl SYSTEM - Electronic Coritrol System Fl-1 1 9
H igh Temperature Line ·Pressure U p �ystem
ECU
To Circuit Opening Relay ----------o STA

To EFI Main Relay +B (B)
Air Temp. Sensor (Fuel Pressure Up)

(Air Flow Meter) ..--0-,--------Q THA
"'-O---------o e2
L'"""!c��t-------------� THW
Water Temp. Sensor E1
Fl1709
Ohmmeter INSPECTION OF HIGH TEMPERATU RE LINE

PRESSURE UP SYSTEM
INSPECT VSV
n. A. Inspect VSV for Open Circuit
Using an ohmmeter, check that there is continuity be
tween terminals.
Resistance: 30 - 60 .0
If there is no continuity, replace the VSV.
B. Inspect VSV for Short Circuit

Using an ohmmeter, check that there is no continuity be
tween each terminal and the body.
If there is continuity, replace the VSV.
C. Inspect VSV Operation

(a) Apply battery voltage across the terminals.
(b) Check that air flows from pipe E to air filter.
e �
Battery
Flt!ll 9
·120 EFI SYSTEM - Electronic Control System
(c) Di�connect the battery.
(d) Check that air, flows from the pipe E and pipe G.
If operation is not as specified, replace the VSV.
e EB
Battery
Fl1920
EFI SYSTEM - Electronic Control System Fl- 1 2 1
H igh Altitude Compensation {HAC)

System {7 M-- GTE)
ECU
C--=-::::----:-,-:------T--',__-o V
c-��......,,�:'r------o HAC
�i,.,.
n---;f.;,<ro=m=A
Flow Meter
r
==--.--.......--0 E2 -----·
--- ---{·71i I
,/' I
HAC Sensor
I
--<f ; I
I l
---a E 1
I I
I I
Atmospheric
___1 50 540 7 50
...........___Pressure (mm Hg)
· 2,000 0 ·
__,_
AUtude (m)
1 ,000
Fl1995 A1996
I NSPECTIO N OF HAC SENSOR

INSPECT RESISTANCE OF HAC SENSOR
(a) Remove the glove box.
each terminal.
Terminals Resistance
vc - p 700 - 860 !l
VC - E2 2.2 - 3.3 !l
n
Flt 939
P - E2 2.9 - 4.2
If the resistance is not as specified, replace the HAC sen
vc sor.
F11 997
22 EFI SYSTEM - Electronic Control Syste·m
Oxygen Sensor (w/ TWC)

: INS.PECTION OF OXYGEN SENSOR
1. WARM UP ENGINE
Allow the engine to reach normal operating temperature.
2. INSPECT FEEDBACK VOLTAGE (VF)

Connect the positive (+) probe of a voltmeter to terminals
_
_____________ VF of the check connector, and negative (-) probe to ter-
___
Fl"""
1 7.;.;.i
11
minal E 1 . Perfom the test as follows.
Narm up Oxygen sensor with the · engine at

2,500 rpm for approx. 90 seconds. ...
-
5hort terminals T and E 1 of the check connector. ( Replace the ECU )
\nd maintain ·engine speed at 2,S-do fpni. t
l After replacing
Zero 89ain
I the oxygen sensor
::'.:heck the number of �ime,s th.e yolt"!eter meedle fluctuates in 1 0 -seconds. I

' .. Zero
8 times
. Less· than 8 times
or more
·:
(
..
Warm up the oxygen sensor with the, �ngine at

2,500 rpm for approx. 90 seconds. Andmaintain
Normal )
· · ' · · · ,"
engine at 2,500 rpm.
..
8 times or more
Check that the number of times the voltmeter
needle fluctuates in 1_0 sec()nQ!;i!
Zero
Less''than 8 times
'
Unshort terminals T and E 1 of the check connector.
And maintain engine speed at 2,500 rpm.
Measure voltage between terminals VF and E 1 .
ov
i
More than O V I Read and record diagnostic codes. (See page Fl-30) I
Normal code Malfunction code(sl
and code 2 1 (ex. code 2 1 )
( Repair the relevant diagnostic code. )

EFI SYSTEM - Electronic Control System Fl-1 23
CONTINUED FROM PAGE Fl- 1 22
©
(Repair the relevant diagnostic code.
Malfunction code(s)
(ex. code 2 i )
Read and record diagnostic codes. (See. page Fl-30)
Normal code
and code 2 1
Unshort terminals T and E1 of the check connector.

And maintain engine at 2,500 rpm.
M_easure voltage between terminals VF and E 1 .

5V
av
I Disconnect the PCV hose. I
I Measure voltage between terminals VF and E 1 . I
More than O V
( Repair {Over rich)
Disconnect the water temp. sensor connector and

connect resistor with resistance of 4 - 8 k O or
another coded water temp. sensor.
Short terminals T and E 1 of the check connector.
Warm up the oxygen sensor with the engine at

2,500 rpm for approx. 90 seconds. And maintain
engine speed at 2,500 rpm.
Measure voltage between terminals VF and E 1 .
av 5V
Replace the oxygen sensor ) ( Repair (Over lean) )

\.
Fl-1 24 EFI SYSTEM - Electronic Control System
Ohmmeter 3. (7M-GTE)
INSPECT HEATER.RESISTANCE OF OXYGEN
S ENSOR
. Using an ohmmeter, measure the resistance between the
terminals 2 and 3.
Resistance: 3.0 - 3.6 n
If the resistance is not as specified, replace the sensor.
2
l'l3030
(
EFI SYSTEM - Electronic Control System Fl-1 25
MA E lectronic Controlled U nit (ECU)

INSPECTION OF ECU
NOTE: The EFI circuit can be checked by measuring the
Voltmeter resistance and voltage at the wiring connectors of the
ECU.
1. (MS)
PREPARATION
(See page Fl-58)
MS 2. INSPECT VOLTAGE OF ECU
Check the voltage between each terminal of the wiring
ECU
connectors.
• Turn the ignition switch ON.
Voltmeter
· • Measure the voltage at each terminal.
CD
0 NOTE:
(· • Perform all voltage measurements with the connectors
connected.
FI0299
• Verify that the battery voltage is 1 1 V or more when the
A291 1 ignition switch is ON.
Voltage at ECU Wiring Connectors
- -
Terminals STD Voltage Condition
BATT E1
I G S/W - E 1
10 - 14
M-REL - E 1 Ignition S/W ON
+B (+ 8 1 )
E1
B (8 1 )
IDL - E2 4 - 6 Throttle valve open
VC (VCC) -. E2 4 - 6 -
Ign ition S/W ON
0.1 - 1 .0 Throttle valve fully closed
VTA - E2
4-5 Throttle valve fully open
4-5 Measuring plate fully closed

Ignition S/W ON
0.02 - 0.08 Measuring plate fully open
* 1 vs - E2
2 - 4 Idling
0.3 - 1 .0 3,000 rpm
4-6 Ignition S/W ON

* 2 KS - E2
2 - 4 Cranking or running
vc - E2- 4 - 6 Ignition S/W ON
THA - E2 1 - 3 Ignition S/W ON Intake air temperature 20 ° C (68 ° F)
THW - E2 0 . 1 - 1 .0 Ignition S/W ON Coolant temperature 80 ° C (1 7 6 ° F)

EFI SYSTEM - Electronic Cont.rol System
. Voftag e at E9U Wjring Con nectors (Cont'd)

Terminals STD Voltage Condition
No, 1 0 E0 1
No. 20 - 9 .:.. 1 4 \. Ignition S/W ON
No. 30 E2
STA - E 1 6 - 14 Cranking
ISC1
I - E1 9 - 14 Ignition S/W ON
ISC4
Idling
* 2IGdA, IGdB - E 1 Idling
Approx. :fa 540 mm Hg (2 1 .26 in.Hg, 72.0 kPa)

Ignition S/W ON
Approi ·3.6 7 50 mm Hg (1 29.53 in.Hg, 1 00 .0 kPa)
No tro1.1ble ("CHECK ENGINE" warning light off) and

W - E1
engine running.
Air conditioning ON
Check connector T (TE 1 ) - E1 not short

T - E1 Ignition S/W ON
0 Check connector T (TE 1 ) - E 1 short
* 3NSW (A/T)
0 Shift position P or N range
- E1 Ignition S/W ON
10 - 14 Ex. P or N range
* 3N/C (MIT)
0 Clutch pedal not depressed
- E1 Ignition S/W ON
1 0 - 14 Clutch pedal depressed
Defogger S/W OFF

Ignition S/W ON
0 Defogger S/W ON
10 - 14 Headlight S/W OFF
Headlight S/W ON
* 1 7M-GE only
*2 7M-GTE only
*3 MA only
EFI SYSTEM - Electronic Control. System Fl-1 27
MA 3. INSPECT RESISTANCE OF ECU

CAUTION:
• Do not touch the ECU terminals.
• The tester probe should be Inserted into the wiring
connector from the wiring side.
Check the resistance between each terminal of the wiring
connectors.
• Disconnect the wiring connectors. from the ECU.
• Measure the resistance each terminal.
MS
E
I
Ohmmeter
�t=========-
OLJ
0o
{
1'11728
Fl2788
Resistance of ECU Wiring Connectors

Terminals Condition Resistance (0 )
Throttle valve open

IDL -:- E2
Throttle valve fully closed Less than 2,300
Throttle valve fully open 3,500 - 1 0, 300

VTA - E2
-
Throttle· valve fully closed 300 - 6,300
VC (VCC) - E2 200 - 400
Measuring plate fully closed 20 - 600

* 1 vs - e2
-
Measuring plate fully open 20 - 1 ,200
* 2 KS - E2
-
00
* 2 e2 - Ks
-
5,000 - 1 0,000
* 2 vc - e2
-
1 0,000 - 1 5,000
*2 e2 - vc 5,000 - 1 0,000
°
THA - E2 Intake air temperature 20 C (68 F)
°
2,000 - 3,000
-
THW - E2 Coolant temperature B0 ° C (1 76 °F) 200 - 400
-
G 1 , G2 - G 8
1 40 - 1 80
NE - G S
ISC 1 , ISC2
_ +B (B) - 1 0 - 30
-
ISC3, ISC4
*2 HAC - E2 2,900 - 4,200
* 1 7M-GE only
*2 7M-GTE onlv
EFI SYSTEM � . Electroni.c Con.trol System
F1Jel Cyt RPM -

.INSPECTIO N O F FUEL CUT RPM
E2--t..;;..Hi-flJI
1; WARM U P ENGINE
IDL------;n-tt
VTA --in-iLJ.JI
VC ---r<+---H 2. INSPECT FUEL CUT RPM
(a) Disconnect the connector from the throttle position
1 FI0547
sensor.
(b) Short circuit terminals IDL and E1 on the wire con
nector side.
(c) Gradually raise the engine rpm and check that there
is fluctuation the fuel cut and fuel return points.
NOTE: The vehicle should be stopped.
Fuel cut rpm: 1 ,800 rpm .
Fuel return rpm: 1 ,200 rpm
Tachometer
Fl1 142.
COOLING SYSTEM - DescriptiQn
DESCRIPTION
This engine utilizes a pressurized water forced circulation cooling system which includes a thermostat equip
ped mounted on the outlet side.
7M·GE
Throttle Body
To Radiator
By-pass Pipe
RHO
From Heater
7 M-GTE
ISC Valve
To Radiator
cocc
COOc
· COOLING SYSTEM - Descript1on
The cooling system is composed of the water RESERVOIR TANK

jacket · (inside the cylinder block and cylinder head), The reservoir tank is used to catch coolant
radiator, water pump, thermosta t, cooling fan, which overflows the cooling system as a result of
hoses and other components. volumetric expansion when th e coolant is heated.
Coolant which is h eated in the water jacket is The coolant in the reservoi r tank returns to the
pumped to the radiator, through which a cooling radiator when the cool ant temperature d rops, thus
fan blows air to cool the coolant as it passes keeping the radiator full at all times and avoiding
through. Coolant which has been cooled is then needless coolant loss. Check the reservoir tank
sent back to the engine by the water pump, where level to learn if the coolant needs to be rep
it cools the engine. lenished.
The water jacket is a network of channels in the
shell of the cylinder block and cylinder head WATER PUMP
through which coolant p asses. It is designed to
The water pump i s used for forced circulation of
provide adequate cooling of the cylinders are com
coolant through the cooling system. It is mounted
bustion c hambers which become the h ottest d u r
on the front o f the cylinder block and driven by a
ing engi n e operation.
!
V-ribbed belt
F(... - !ATOR
l
THERMOSTAT
The radiator performs the function of cooling
The thermo stat has a wax type and is mounted
the coolant which has passed through the water
in the water outlet housing. The thermostat
jacket and become hot, and is mounted in the front
includes a typ e of automatic valve operated by
of the vehicle. The radiator consists of a n u pper
fluctuations in the coolant temperature. This valve
tank and lower tank, and a core which connects
closes when the coolant temperature drops, pre
the two tanks. The upper tank co ntains the i nlet for
venting the circulation of coolant th rough the
coolant from the water jacket and the filter inlet. It
engine and thus permitting the engine to warm up
also has a h ose attached through which excess
rapidly. The valve opens when the coolant tem
coolant or steam can flow. The lower tank contains
perature has risen, allowing the circulation of coo•
the outlet for coolant and the drain cock. The core
lant. Wax inside th e thermostat expands when
contains many tubes throug h which coolant flows
heated and contracts when cooled. Heating the
from the upper tank to the lower tank as well as
wax thus generates pressure which overpowers
cooling fins which radiate heat away from the c o o
_ the force of the s p ring which keeps the valve ; I
lant ln the tubes. The air sucked thro ugh the rad ia
closed, thus opening the valve. When the wax
tor by cooling fan, as well as the wind genereted
cools its contraction causes the force of the
by the vehicle's travel, passes through the radia
spring to take effect once more, c losing the valve.
tor, cooling it. Models with autom atic transmission
The thermostat in this engine operates at a tem
incl"-te an automatic transmission fluid cooler built
perature of 88 ° C ( l 90 ° F).
im:, .,e lower tank o f the radiator.
RADIATOR CAP
The radiator cap is a pressure type can which
seals the radiator, resu lting i n p ressurization of the
radiator as the coolant expands. The p ressu rize�
tion prevents the coolant from boiling even when
the coolant temperatu re exceeds 1 00 ° C. A relief
valve (pressurization valve) and a vacuum � alve
(negative p ressure valve) a re built into the radiator
:ap, The relief valve opens a nd lets steam esca pe
:hrough the overflow pipe w h en the pressure
Jenerated i nside the cooling system exceeds the i i
im it (coolant temperature : 1 1 0 - 1 20 ° C, (230
- 2 4 8 ° F), pressure; 0.3 - 1 .0 kg/cm 2, (4.3 - 1 4.2
)Si, 2 9.4 - 98. 1 kPa). The vacuum valve opens to
il levi ate the vacu um which develops i n the coolant
,yste m after the engine is stopped and the coolant
emperature d ro ps. The valve's opening allows the
i res sure in the cooling system to return to the
:oo! ant in the reservoir tank.
C0-4 C.O OLING SYSTEM - Troubleshooting
TROUBLESH·o oTING
Engine overheats Alternator drive belt loose or missing Adjust or replace belt CH-4
Dirt, leaves or insects in radiator or Clean radiator or condenser
condenser
Hoses, water pump, water outlet Repair as necessary
housing, radiator, heater, core plugs
or head gasket leakage
Thermostat faulty Check thermostat C0-8
Ignition timing retarded Set timing EM- 1 7
Fluid coupling faulty Replace fluid coupling C0-6
R adiator hose plugged or rotted Replace hose
Water pump faulty Replace water pump C0-6
Radiator plugged or cap faulty Check radiator C0-9
Cylinder head or block cracked or Repair as necessary
plugged
..
COOLIN G SYSTEM - C heck and Replacement of Engine Coolant C0-5
CHECK AND REPLACEM ENT OF

ENGINE COOLANT
1. CHECK ENGINE COOLANT LEVEL AT RESERV E TANK
The coolant level should be between the "LOW" and
"FU LL" lines.
If low, check for lea ks and add coolant u p to the "FULL"
line.
C00350
2. CHECK ENGINE COOLANT QUALITY

There should riot be any excessive deposits of rust or
scales around the radiator cap or radi ator filler hole, and
the coolant should also be free from oil.
If excessively d irty, replace the coolant.
3. REPLACE ENGINE COOLANT

{a) Remove the radiator cap.
(b) Drain the coolant from radiator and engi ne drain
cocks. (Engine drain is at right rear of cylinder block.)
(c) Close the drain cocks.
{d) Fill system with coolant.
Use a good brand of ethylene-glycol base coolant, mixed
according to manufactuer's directions.
C00340 Capacity:
MA
w/ Heater or air conditioner
M/T 8. 1 liters (8.5 U S qts, 7.1 Imp. qts)
A/T 8.0 liters (8.5 U S qts, 7 .O I mp. qts}
w/o Heater or a ir conditioner
MIT 7.5 liters (7.9 U S qts, 6.6 Imp. qts)
A/T 7 .4 liters (7 .8 US qts, 6.5 Imp. qts)
MS
w/ Heater or air conditioner
GCC Countries*
8.5 l iters (9.0 U S qts, 7 .5 Imp. qts)
Others
7.8 l iters (8.2 US qts, 6.7 Imp. qts)
w/o H eater or a i r conditioner
GCC Countr ies"
Others
(e) Install th e radiator cap.
(f) Start the engine and check for leaks.
(g) Recheck the coolant level and refill as necessary.
• G C C Countries : Saudi Arabia, Sultanate of Oman,
Bahrain, United Arab Em irates, Qatar, Kuwait.
C0-6 COOLING SYSTEM Water P ump
WATER PU M P
CO M PONE NTS
♦ Gasket
Fluid Coupling Water Pump Pulley Water Pump
♦ Non-reusable part C00341
REMOVAL OF WATE R PU MP
1. REMOVE ALTERNATOR DRIVE BELT, FLU ID
COU PLING AND WATER P U M P PU LLEY
(a) Loosen the water pump pulley set n uts.
(b) Loosen the pivot bolt, adjusting bolt and n ut, and
remove the drive belt.
(c) Remove the four n uts, fluid coupling a n d wate;
pump.
(d} Remove the fan from the fluid coupling.
2. REMOVE PS AIR PIPE
3. REMOVE WATER PU M P
Remove the eight bolts and two nuts, and remove wate
pump and gasket.
C00342
COOLING SYSTEM - Water Pump
INSPECTION O F WATER PUM P

1 , INSPECT WATER PUMP BODY AND TIMINC
. · -L ···BELT
CASE
Check the water pump body and timing belt case for
cracks and damaged g asket surfaces.
If necessary, replace the water pump or timing belt case.
C00343
2. I NSPECT WATER P U M P BEARING

Tum the pulley and check that the water pump bearing
moves smoothly and quietly.
If necessary, replace the water pump.
3. INSPECT FLUID COUPLING

Check that the fluid coupling is not damaged and that no
silicon oil leaks.
If necessary, replace the fluid coupling.
C002l6
INSTALLATION OF WATER PU MP
(Se e page C0-6)
1. I NSTALL WATER PUMP

Install water pump on new g asket with the eight bolts and
two nuts.
Torque: 1 80 kg-cm (1 3 ft-lb, 1 8 N•m)
2. I NSTALL PS AIR PIPE

FS534
3. INSTALL WATER PUM P PU LLEY, FLU I D COUPLING

AND ALTERNATOR DRIVE BELT
(a) Install the water pump pulley and fluid coupling with
the four nuts.
(b) Place the drive belt on to each pulley.
(c) Stretch the belt tight and tighten the four nuts.
4. ADJUST ALTERNATOR DRIVE B E LT TENSION

(Se e page EM-36)
I
!I I
COOLING SYSTEM .:.. Thermostat
THERMOSTAT
REMOVAL OF THERMOSTAT
REMOVE WAl.ER OUTLET AND THERMOSTAT
(a) Remove two bolts, water outlet and thermostat with
gasket from the water outlet. housing.
(b) Remove the gasket from the thermostat.
INSPECTION O F TH ERMOSTAT
NOTE: Thermostat is numbered according to the valve
opening temperature.
(a) Immerse the thermostat in water and heat the water
gradually.
(b} Check the valve opening temperature.
Valve opening temperature:
86 - 90° C ( 1 87 - 1 94° F)
C00227 C00228 If the valve opening temperature is not withi n specifica
tion, replace the thermostat.
le) Check the vatve lift.
Valve lift:
8 mm (0.31 in.) or more at 1 00°c (21 2° F}
If the valve lift is less than specification, replace the ther
mostat.
(d) Check that the valve spring is tight when the ther•
mostat is fully closed.
If necessary, replace the thermostat
C00229
Jiggle Valve
INSTALLATIO N O F THERMOSTAT
INSTALL THERMOSTAT AND WATER OUTLET
{a) Place a new gasket to the t hermostat.
(b) Install the thermostat with the jiggle valve facin
upward as shown in the illustration, and water outh
with the two bolts.
\
C00345
COOLING SYSTEM - Radiator
..
RADIATOR
CLEANING OF RADI ATOR
Using water or steam cleaner, remove mud and dirt from
the radiator core.
CAUTION: If using· high-pressure, type cleaner, be
careful not to deform the fins of the radiator core. Keep
a distance of more than 40 - 50 c m ( 1 5. 75 - 1 9.69 in.)
between the radiator core and cleaner nozzle when
the cleaner nozzle pressure is 30 - 35 kg/cm2 (427 -
498 psi, 2,942 - 3,432 kPa) .
INSPECTION · OF RADIATO R
1. CHECK RADIATOR CAP
Using a radiator cap tester, pump tester until relief valve
opens. Check that valve opens between 0.75 kg/cm2
(1 0.7 psi, 74 kPa) and 1 .05 kg/cm2 (1 4.9 psi, 1 03 kPa).
Check that pressure gauge d oes not dro p rapidly when
pressure on cap i s below 0.6 kg/cm2 (8.5 psi, 59 kPa).
If either check is not within limits, replace cap.
2. CHECK COOLING SYSTEM FOR LEAKS

(a) Fill the radiator with coolant and attach a rad iator cap
tester.
(bl Warm up the engine.
(c) Pump it to 1 .2 kg/cm 2 ( 1 7 . 1 psi, 1 1 8 kPa), c heck
that pressure does not drop.
If the pressure drops, check for l ea ks from the hoses,
radiator or water pump. If no external leaks are found,
check the heater core, cylinder block and head.
r
;- l
1
:I
. t.
C0-1 0 COOLING SYSTEM - Radiatpr
COMPONENTS
MA (A/T)
MS (A/T) 1------£:ore
-.;;�----.. 0-Ring
�?!!-::J-----• Tank Plate
Oil Cooler
�------Lower Tank
♦ Non-reusable part coose
DISASS EMBLY OF RADIATOR

(i) 1, REMOVE TANK PLATE
{a) Raise the claws of the tank plates with SST in tr
numerical order shown in the figure.
@{�-
_____,v�
____,______,}@
SST 09230-000 1 0
NOTE: Be careful not to damage the core plate.
Tank
Tank Plate
C0031!2
C00353 C0004l
COOLING SYSTEM - Radfotor C0-1 1
(b) Pull the tank plate s outward.
C:00354
2. REMOVE TANK AND 0-RING

(a) Pull the tank upward.
(b) Remove the 0-ring.
C00351
3. (A/T}
REMOVE OIL COOLER FROM LOWER TANK
(a) (MS}
Remove the pipes.
NOTE: Make a note of the direction the pipes face.
(b) Remove the nuts, plate washers and oil cooler.
(c) Remove the 0-rings from the oil cooler.
C00348 C00362
ASSEMBLY OF RAD IATOR

(See page CO-1 0)
1. (MA with A/T)
INSTALL OIL COOLER TO LOWER TAN K
(a} Clean the 0-ring contact surface of the l ower tank
and oil cooler.
(b) Install new 0-rings ( 1 ) to the oil cooler (2).
(c) Install the oil cooler (2) with 0-rings ( 1 ) to the lower
tank (3}.
(d) Install the plate washers (4), and nuts ( 5). Torque the
nuts (5).
C00348
-------------�
C0- 1 2 COOLI N G SYSTEM - Radiator
(MS with A/T)

INSTALL OIL COOLER TO LOWER TAN K
(a) Clean the 0-ring contact surface of the lower tank
and oil cooler.
(b) Install new 0-rings ( 1 ) to the oil cooler (2) .
(c) Install the oil cooler (2) with the 0-rings (1 ) to the
lower tank (3).
(d) Install the plate washers (4), spring washers (5) and
nuts (6). Torque the nuts (6).
Torque: 220 kg-cm ( 1 6 ft-lb, 22 N ·m)
(e) Install the pipes (7).
Torque : 1 60 kg-cm (1 1 ft-lb. 1 5 N·m)
NOTE: Face the pipes in the same direction they were
before disassembly.
C5\B2
2. INSPECT CORE PLATE

Core Plate Core Plate Inspect the core plate for damage.
NOTE :
• If the sides of the core plate groove are deformed,
reassembly of the tank will be impossible. Therefore,
first correct any . deformation with pliers.
• Water leakage will result if the bottom of the core plate
groove is damaged or dented. Therefore, repair or re
place if damaged.
C00355
3. INSTALL N EW 0-RING AND TAN K

NOTE:
• Clean the tank and core plate.
C00356
@ �
• Inspect the 0-ring for twists.
O Normal XTwisted
0-Ring ij
XTwiste
27555
..
COOLING SYSTEM - Radiator
4. INSTALL TANK PLATE

Insert the tank plates from both ends in the dir��;l�n of
... the arrows. Insert to where the portions by the arrows

contact with the tank.
C00357
SST
5. STAKE CLAW OF TANK PLATE
(a) Set the punch on SST to "LOW."
�� L]B
�� □
SST 09230-000 1 0
CS186
(b) Stake the claws of the tank plates with SST in the
numerical o rder shown in the figure.
....
® (D @
•
SST 09230-000 1 0
cv{ ' �.J®

"----v---'v
... 1=l
®
�
@
C00352
Tank Plate CAUTIO N : If the bottom of the core plate is staked

(
with the SST on the guide block stopper. it may result
't•unch
in water leakage.
SST 09230-000 1 0
Guide Block st0PPer CO0043 C00045
NOTE:
• Stake with just enough pressure to leave a mark on the
claw. the staked plate height "B" should be as follows:
Plate height: 9.1 8 - 9.53 mm (0.361 4 - 0.37 52 in.)
C0- 1 4 COOLING SYSTEM· - Radiator
• Do not stake the areas protruding around the pipes,

brackets or tank ribs.
• The points shown in the illustration cannot be staked

with the SST. Use a pliers and be careful not to damage
the core plate.
f,. .'
C00352
C00359
,o(
I
..
J
6. INSPECT FOR WATER LEAKS
(al Tighten the drain plug.
Plug the oil cooler pipes to prevent any water leakage
1 ,
SST
I
I
J
I (bl
into the oil cooler.
I I
(cl Plug the inlet and outlet pipes of the radiator with
SST.
SST 09 230-000 1 0
(dl Using a radiator cap tester, apply pressure to the
radiator.
Test pressure : 1 .5 kg/cm2 (21 psi, 1 47 kPa)
(el Inspect for water leaks.
NOTE : On radiator with resin tanks, there is a clearance
between the core plate and tank plate where a minute
amount of air will remain, giving the apperance of an air
leak when the radiator is submerged in water.
Therefore, before performing the water leak test, first
Clearance swish the radiator around in the water until all air bubbles
disappear.
7. PAINT TANK PLATES

NOTE: If the water leak test checks out okay, allow the
radiator to completely dry and then paint the tank plates.
LU BRICATION SYSTEM
Page
DESCRIPTION • • • • • • • • • • • • • • • • • • • • , • • • • • • • • • • • LU-2
TROUBLESHOOTING , • , , • • • • • • • • • • • • • • • • • • • • • • LU-4
OIL PRESSURE CHECK • • • • • • • • • • • • • • • . • • • • . • • • . LU-5
REPLACEMENT OF ENGINE OIL
AND OIL FilTER • • • • • • • . • • • . , • • . . • • • • • . • • • • . LU-6
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . LU-8
OIL COOLER AND OIL PRESSURE
REGULATOR (7M-GE) • • • • . . • • • • • • • • • • • • . • • • • LU-1 6
OIL COOLER AND OIL PRESSURE
REGULATOR (7M-GTE) • • • • • • • • • . • • • • • • • • • • • LU- 1 8 1111D
\
i
LU-2 --LU BRICATIO N SYSTEM - Description
DESCRI PTION
A fully pressurized, fully filtered lubrication system has been adopted for this engine.
7M-GE (MA)
Oil Cooler
Oil Cooler
7M-GTE (A/T)
ainer
Oil Cooler Oil Pump
VALVE__,,
.____ ____, -,l
GUIDES
r-----
.-----------------, I
r- - - - - PISTONS VALVE L!FTERS -;
·1
I
:
CONNECTING ROOS *OIL NOZZLES CAMSH AFTS
�-- - - -
*CHECK VALVE CAMSHAFT JOURNALS
·1
r.
I
I
*TURBOCHARGER CYLINDER HEAD
I
1
I
I
I BYPASS VALVE OIL FILTER

I
I
I *OIL FILTER BRACKET RELIEF VALVE
i
I
I
I
l RELIEF VALV E
I
I Oil COOLER
! •7M-GTE only
OIL STRAINER
OIL PAN
LU0589 LUO!
lU0588 LUO!
LUBRICATION SYSTEM - Description
A pressure feeding lubrication system has been OIL FILTER

ad opted to supply oil to the moving parts of this The oil filter is a full flow type filter with a built
engine. The lubrication system consists of an oil in paper filter element. Particles of 'm�tal from
pan, oil pump, oil filter and other external parts wear, afrborn dirt, carbon and other impurities can ·
which supply oil to the moving parts in the engine get in the oil during use and could cause acceler
block. The oil circuit is shown in the illustration at ated wear or siezing if allowed to circulate through
the top of the previous page. Oil from the oil pan is the engine. The oil filter, integrated into the oil line,
pumped up by the oil pump. After it passes removes these impurities as the oil passes through
through the oil filter, it is fed through the various it. The filter is mounted outside the engine to
oil holes in the crankshaft and cylinder block. After simplify replacement of the filter element. A relief
passing through the cylinder block and performing valve is also included ahead of the filter element to
its lubricating function, the oil is returned by gra relieve the high oil pressure in case the filter ele
vity to the oil pan. A dipstick on the side of the ment becomes clogged with impurities. The relief
cyli nder block is provided to check the oil level. valve opens when the oil pressure overpowers the
force of the spring. Oil passing through the relief
OIL P U MP
valve bypasses the oil filter and flows directly into
The oil pump pumps up oil from the oil pan and the main oil hole in the engine.
sends it under pressure to the various parts of the
eng i ne. An oil strainer is mounted in front of the
inlet to the oil pump. The oil pump itself is a gear
pump, which uses a drive gear and driven gear
inside the pump body. When the drive gear
rotates, the driven gear rotates in the opposite
direnion. When the gear teeth disengage oil is
dra,\ n in, and when the gear teeth engage oil is
discha rg ed .
O I L PR ES SURE REGU LATOR

At hi gh engine speeds, the engine oil supplied
by t h t> oil p ump exceeds the capacity of the engine
to ut1 1 i ze it. For that reason, the oil pressure regula
tor \\ ,.., rks to prevent an oversupply of oil. During
norm ,, 1 oil supply, a coil spring and valve keep the
by p,1 $ s closed, but when too much oil is being fed,
the p1 es sure becomes extremely high, overpower
ing t h :? force of the spring and opening the valves.
T hi s -� !lo ws the excess oil to flow through the
val vn ;, n d return to the oil pan.
I
'
LU-4 LUBRICATION SYSTEM - Troubleshooting
TROU BLESHOOTING
Oil leakage Cylinder head, cylinder block or oil pump Repair as necessary
body damaged or cracked
Oil seal faulty Replace oil seal EM..:a4
Gasket faulty Replace gasket
Low oil pressure Oil leakage Repair as necessary

Relief valve faulty Repair relief valve LU-8
Oil pump faulty Repair oil pump LU-8
Engine oil poor quality Replace engine oil LU-6
Crankshaft bearing faulty Replace bearing EM-85
Connecting rod bearing faulty Replace bearing EM-66
on filter clogged Replace oil filter LU-8
High oil pressure Relief valve faulty Repair relief valve LU-8
..vgn1vA rlON SYSTEM - Oil P ressure Check :·. ' ; ? ; .. 1
(
OIL PR.E SSURE CHECI "•
Recommended Viscosity (SAE) :
1. CHECK ENGINE OIL QUALITY
C hec k the oil for deterioration, entry of water, discoloring
or thinning.
If oil quality is poor, replace the oil.
°C-29 -1S -7 · 4 Europe (7M-GE} and Australia
Of-20 Q 20 40 6Q 80 100
TEMPERATURE RANGE ANtlCtPATEO BEFORE NEXT 011. CHANGE Use API grade SE, SF or better and recommended
viscosity oil.
LU0310 Europe (7M-GTE)
Use API grade SF or better and recommended
viscosity oil.
Others
Use API grade SC, SD, SE, SF or better and recom
mended viscosity oil.
2. CHECK ENGINE Oil LEVEL

The oil level should be between the "L" and "F" marks on
the dipstick.
If low, check for leakage and add oil up to the "F" mark.
EM1759
3. REMOVE OIL PRESSURE SENDER GAUGE
4. INSTALL OIL PRESS URE GAUGE
6. START ENG I NE
Start engine and warm it up to normal operating tem
perature.
6. M EASURE OIL PRES S U RE

Oil pressure:
At idle 0.3 kg/cm2 (4.3 psi, 29 kPa)
or more
At 3,000 rpm 2.5 - 5.0 kg/cm
(36 - 71 psi, 245 - 490 kPa)
NOTE: Check for oil leakage after reinstalling the oil
pressure sender gauge.
LUBRICATION SYSTEM - Replacement . of Engine Oil and Oil Filter
(d) lightly screw i n the oil filter to where you feel resis
tance.
(e) Then, using SST, tighten . the oil filter an extra 3/4
turn.
SST 09228-07500
LU0490
3. FILL WITH E N G I N E OIL

(a) Clean and install the oil drain plug with a new gasket.
(b) Fill the engine with new oil.
Oil capacity:
Ory fil l
7 M-GE MA (GCC Countries")
5.0 liters (5.3 US qts, 4.4 Imp. qts)
7M-GE M A (Others)
LU0626 4.9 liters (5.2 US qts, 4.3 I mp. qts)
7M-GE M S
5 . 3 liters (5.6 U S qts, 4 . 7 I mp. qts)
7M -GTE (A/T)
5.0 liters (5.3 US qts, 4.4 I mp. qts)
7M-GTE (M/T)
5.1 liters (5.4 US qts, 4.5 I mp. qts)
Drai n and refil
w/o oil filter change
MA
3.9 titers (4. 1 US qts, 3.4 I mp. qts)
MS
4.1 liters (4.3 US qts, 3.6 Imp. qts)
w/ oil filter change
MA
4.2 liters (4.4 US qts, 3. 7 Imp. qts)
MS
4. START E N G I N E AND CHECK FOR LEAKS
5. RECHECK E N G I N E OIL LEVEL (See page LU -5)

• GCC Countries : Soudi Arabia, Sultanate of Oman,
Bahrain, United Ara b Emi rates, Qatar, Kuwait.
LU-6 LUBRICATION SYSTEM - Replacement·-of Engine Oil and Oil Filter
REPLACEM E NT O F ENGINE OIL

AN D OIL FILTER
1. DRAIN ENGINE OIL
(a} Remove th e oil f iller cap.
(b} Remove the oil drain plug and drain the oil into a con
tainer.
LU0526
2. REPLACE OIL FilTER

(a) Using SST, remove th e oil filter (located on right side
of the engine block}.
SST 09228-07500
7M-GTE NOTE ( 7M-GTE) : Remove the oil filter taking it over the
engine mounting bracket and do.wn between the bracket
and No. 1 suspension crossmember.
LU0406
(b) Clean and check the oil filter installation surface.
05 58
•
(c) Apply clean engine oil to the gasket of the new oil
filter.
LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filter
(d) lightly screw in the oil filter to where you feel resis
tance.
(e) Then, using SST, tighten . the oil filter an extra 3/4
turn.
SST 09228-07 500
LlJ0490
3. FILL WITH ENGINE OIL

(a) Clean and i nstall the oil drain plug with a new gasket.
Torque: 350 kg-cm (25 ft- lb, 3 4 N · m)
(bl Fill the engine with new oil.
Oil capacity:
Dry fil l
7 M - G E M A (GCC Countries•)
5.0 liters (5.3 U S qts, 4.4 Imp. qts)
7M-GE M A (Others)
26 4.9 l iters (5.2 US qts, 4.3 I mp. qts)
7M-GE M S
5 . 3 l iters (5.6 U S qts, 4 . 7 Imp. qts)
7M-GTE (A/T)
5.0 l iters (5.3 U S qts, 4.4 Imp. qts)
7M-GTE (M/T)
5.1 l iters (5.4 U S qts, 4 . 5 Imp. qts)
Drain and refil
w/o oil filter change
MA
3.9 l iters (4.1 U S qts, 3.4 Imp. qts)
MS
4.1 liters (4. 3 U S qts, 3.6 I mp. qts)
w/ oil filter change
MA
4.2 liters (4.4 US qts, 3. 7 Imp. qts)
MS
4.4 l iters (4. 7 U S qts, 3.9 Imp. qts)
4. START ENGINE A N D C H E CK FOR LEAKS
5. RECHECK E N G I N E O I L LEVEL (Se e page LU -5)

* G C C Countries : Saudi Arabia, S ultanate of Oman,
Bahrain, United Arab Emirates, Qatar, Kuwait.
LU-8 L UBRICATION SYST_E M - Oil Pump
OIL PU M P
COMPONENTS
MA
!
<1ni-------Snap Ring
e Spacer
Key'---e>
ftt!)------Oil Pump S haft Drive Gear
® ♦.
�Union Bott
--
�f ♦ 0-Ring
Oil Pump Strainer
Oil Pump Outlet P ipe
---- Oil Pump Body
Oil Pump------1
Drive Shaft MS
.
Oil Pump
Plug ----� Driven Gear
� ---- Snap Ring
Spring----\ >--------Spacer
1----- Key
Relief Valve ----c;, Oil Pump Shaft
Drive Gear
'
Oil Pump Cover�
r-----1---- 0il Pump
Body
r
'
I
Union Bolt
Oil Pump Outlet Pipe
Oil Pump Drive Shaft

Oil Pump
Driven Gea
Relief Valve
Oil Pump Cover

♦ Non-reusable part
LUBRICATION SYSTEM - Oil Pump
REMOVAL· OF 011:: PU M P
(See page LU·B)
1. DRAIN ENGINE OIL
(b} Remove the oil drain plug and drain the oil into a con
tainer.
2. REMOVE OI L PAN
{a) Remove the dipstick.
w�� (b} Remove the bolts and nuts.
�-�=� (c) Insert the blade of SST between the cylinder block
and oit pan, cut off applied sealer and then remove
the oil pan.
SST 09032�00 1 00
CAUTION: Se careful not to damage the oil pan
. )
LU0465 t\J0466
flange.
3. REM OVE OIL PU M P

(a) Loosen the union nut o f the oil pump outlet pipe.
(b} (MA)
Remove the mount bolt of the oil pump strainer stay.
(c) Remove the bolt and oil pump.

a.v· 1 v LUtsfUCATION SYSTEM - Oil Pump
DISASSEMBLY OF OIL PU M P
(See page LU-8)
1. REMOVE OIL P U M P OUTLET PIPE

(al Unstake tht:1 lock washer.
(b) Remove the union bolt. lock washer, oil pump outlet
pipe and gasket.
2. (MA)
REMOVE OIL PUM P STRAINER
Remove the two bolts, oil pump strainer and 0-ring.
LU0533
3. REMOVE RELIEF VALVE

Unscrew the relief valve plug, and remove the spring and
relief valve.
e LU0531
4. REMOVE OIL PU M P COVER

Remove the five bolts and oil pump cover.
5. REMOVE OIL PUMP DRIVEN GEAR
LU0536
6. REMOVE OIL PU M P DRIVE SHAFT

Using snap ring pliers, remove the snap ring, spacer, shaft
drive gear, key and oil pump drive shaft.
LU0535
LUBRICATION S YSTEM - Oil Pump
I NSPECTION OF OIL P U M P
1. I NSPECT RELIEF VALVE
Coat the valve with engine o i l and check that it falls
smoothly into the valve h ole by its own weight.
If it does not, replace the relief valve., If necessary, replace
the oil pump assem b ly.
2. INSPECT BODY CLEARANCE

Using a thickness g auge, measure the clearance between
the driven gear and pump body.
Standard clearance : 0.1 05 - 0.1 76 mm
(0.0041 - 0.0069 in.)
Maximum clearance: 0.2 mm (0.008 in.)
If the clearance is greater than maximum, replace the gear
or oil pump assembly.
3. INSPECT GEAR BACKLASH

Using a thickness gauge, measure the backlash as shown
in several places.
Standard backlash: 0.6 - 0.6 m m
{0.020 - 0.024 in.)
Maximum backlash: 0.9 mm (0.035 in.)
If the backlash is greater than maximum, replace the oil
pump drive shaft and driven gear.
I.IJ()3
4. INS PECT S IDE CLEARANCE

Using a thickness gauge and prec1s1on straight edge,
measure the clearance between the gears and precision
straight edge.
Standard clearance : 0.03 - 0.09 mm
(0.00 1 2 - 0.0035 in.)
Maximum clearance; 0.1 5 mm (0.0059 in.)
If the clearance is greater than maximum, replace the drive
shaft and driven gear. If necessary, the oil pump assembly.
L 355
:f
LU- 1 2 LUBRICATION SYSTEM - OiJ Pump .
ASSEMBL V AND OPERATION CHECK OF OIL

PU MP
(See page LU-8)
1. INSTALL OIL PUM P DRIVE SHAFT
Install the oil pump drive shaft, key, s haft drive gear,
spacer, and using snap rin g pliers, install the snap ring.
2. INSTALL OIL PUMP DRIVEN GEAR

LUO 35
3. INSTALL OIL PUM P COVER

Install the oil pump cover with the five bolts.
Torque the bolts.
( Torque: 76 kg-cm (65 in.-lb, 7.4 N•m)
LU0536
4. INSTALL RELIEF VALVE

Install the relief valve and spring with the relief valve plug.
Torque the plug.
Torque: 375 kg-cm (27 ft-lb, 37 N · m)
LU0531
5. CHECK PUMP O PERATION

(a) Immerse the suction end of the pump into clean
engine oil and turn the shaft counterclockwise. Oil
should come o ut of the discharge h ole.
LU0368
(b) Close the discharge hole with your thumb, and turn
the shaft as before. The shaft should be difficult to
turn.
LU0359
LUBRICATION SYSTEM ..- Oil Pump LU-1 3
6. (MA) .
INSTALL OIL P U M P STRAIN E R
(a) Install a new 0-ring to oil pump strainer.
(b) Install the oil pump strainer with the two bolts.
U0533
7. INSTALL. OIL PU M P OUTLET PIPE

Install the oil pump outlet pipe with a new lock
washer,gasket and the union bolt. Fi nger tighten the union
bolt.
LU0540
. . I NSTALLATION OF Oil PUMP

f �y ,..(
" \ '-......,,I
I / \ /
.,... ,.
;
(S e e page LU-8)
,., 1. INSTALL OIL PU M P
(a) Install the o i l p u m p with the bolt. Torque the bolt.
Torque: 220 kg-cm (1 6 ft-lb, 22 N · m)
(b) Install the mount bolt holding the o i l pump strainer

stay to block.
Torque : 60 kg-cm (52 in.-lb, 6.9 N • m)
(c) Connect the outlet pipe with the union bolt.

Torque the union bolt and nut.
Torqu e : 360 kg-cm (26 ft-lb, 34 N·m}
(d) Stake the lock washer.
..
LU- 1 4 L U B RICATION SYSTEM - Oil Pump
2. INSTALL OIL PAN

(a) Remove any old packing (FIPG) material and be care
ful not to drop any oil on the contact surfaces of the
oil pan and cylinder block.
• Using a razor blade and gasket scraper, remove all
the packing (FIPG) material from the gasket sur
faces
. • Thoroughly clean all components to remove all the
loose material.
• Clean both sealing surfaces with a non-residue
solvent.
CAUTION : Do not use a solvent which will affect the
painted surfaces.
(b) Apply seal packing to the oil pan as shown in the

fig ure.
Seal packing : Part No. 08826-00080 or equivalen t
• I nstall a nozzle that has been cut to a 5 m m (0.20
B
in.) opening.
(c) I nstall the oil pan with the bolts and nuts.
3. FILL W IT H ENGINE O I L (Se e st e p 3 on page LU-7)
4. START ENG INE AND CH ECK FOR LEAKS

LU0093
5. RECH ECK OIL LEVEL (See step 2 on page LU -5)

O I L COO L E
RE G U LATORR A N D O I L P R
CO M PO N E N T ( 7 M · G EJ
S
MA
650 {47, 64)
Bracket
Oil Pipe
Unio n
Oil Cooler H ose
♦ Gasket
-....� ��---:
' . I
I
� ffD
I
I
I
Oil Cooler Hose
GCC C ou n
tn� s. •
Oil Cooler _________
I
Oil C ooler
jkg-cm (ft-lb, N·m� : Specified

torq ue
♦ Non-reusabl e part • GC C Coun trie
s: 'hudi Arabi
Bahrain, U nited a, S Itana te of Oman,
h-sb Emirates, u
Oata r, Kuwait .
LU0543
..
COM,:,QNE"'TS (Cont'd)
MS
376 127, 37)
♦ Gasket
860 147, 84)
Spring
♦ Gasket
• Relief Valve
Pressure Regulator
♦ Gasket
Oil Pipe
Union
♦ Gasket
Oil Cooler Hose
Oil Cooler Hose
I kg-cm (ft-lb, N·mX : Specified torque

♦ Non-reusable part LOO!;
L U BRICATION SYSTEM - Oil Cooler and Oil Pressure. Regulator (7M•GE) LU-1 7.
R EMOVAL AND DISASSEMBLY OF OIL

PRESSURE REGU LATOR
(See pages LU-1 6, 1 6)
1. DISCONNECT OIL HOSE

2. REMOVE OIL PRESSU RE REGU LATOR
Remove the two bolts, oil pressure regulator and gasket.
3. REMOVE RELIEF VALVE

Unscrew the plug, and remove the spring, relief valve and
gasket.
LU0458
I N SPECTION OF O I L PRES S U RE REGU LATOR

I NSPECT RELIEF VALVE
Coat the valve with e ngine oil and check that it falls
smoothly into the valve hole by its own weight.
If it does not, replace the relief valve. If necessary, replace
the oil pressure regulator assembly.
LU0488
ASSEM BLY AND I NSTALLATION OF OIL

PRESSURE REG U LATOR
(See pages LU- 1 6, 1 6)
1. I N STALL RELIEF VALVE

Install the relief valve and spring with the plug and a new
gasket. Torque the plug.
LU0459
2. I NSTALL OIL PRESS U RE REGU LATOR

Install the oil pressure regulator with the two bolts. Torqu e
the bolts.
Torque : 1 45 kg-cm ( 1 0 ft-lb, 1 4 N·ml
3. CONNECT O I L HOSE
O I L COOLER AND OIL PRESSU RE
REGU LATOR (7M -GTE)
COMPONENTS
Union Bolt
7
�� y�ket
@_,-,_
o
Plug ------Oil Filter Bracket
♦ Gasket ' -- - {OU Pressure Regulator}
Spring - , ♦ 0-Ring
Relief Valve : - - - - - ·-;
0-
No. 1 Oil Cooler Bracket
� .t - Oil Filter
... � Bracket €3 rt,.....
' ·6':l
�1!:/1 -
a
�/ .._ � @ ♦ Gasket
Oil Cooler Hose � ,i,y
l __ l
Oil Pipe
♦ Non-reusable part LU05 72 LU05S2
REMOVAL AN D D ISASSEMBLY OF O I L
FILTER BRACKET
1. REMOVE OIL FILTER BRACKET
Remove the union bolt, g asket, oil filter bracket and 0-
ring.
2. REMOVE OIL FILTER

(See page LU-6)
3. REMOVE RELIEF VALV E

Unscrew the plug, and remove t h e spring, relief valve and
gasket.
LU0534
LU BRICATION SYSTEM - Oil Cooler and Oil Pressure Regulator (7M:Gle)___:,_.:��' LU- 1 9
INSPECTIO N OF RELIEF VALVE

Coat the valve with engine oil and check that it falls
smoothly into the valve bole by its own weight.
If it does not, replace the relief valve. If necessary, replace
the oil filter bracket assembly.
LUO 41
ASSEM B LY AND I NSTAL LATIO N OF OIL

FI LTER BRACKET
(See page LU- 1 8)
1. INSTALL RELIEF VALVE
(a) Install the relief valve and spring.
lU0532
(b} Install and torque the plug with a new gasket.

Torque: 375 kg-cm {27 ft-lb, 37 N·m)
2. INSTALL OIL FILTER

(See page LU-6)
3. INSTALL OIL FilTER BRACKET

(a) Install a new O-ring to bracket.
(b) Install a new gasket to union bolt.
(c) Put the oil filter bracket hole over the cylinder block
stud bolt and i nstall the oil filter bracket with the
union bolt.
(d} Torque the union bolt.

IGNITl·6�N SYSTEM
Pa ge
PRECAUTIO NS • • • , , . • • • . , , • , • • • , • • , , • , • • • • • • , . IG- 2
TROU BLESHOOTIN G • • • • • • . • , • • • ,.• , • • , • , • • , , • • • IG-3
IGNITION SYSTEM CIRCUIT • • . , • • , • • . • • . • • • , • . • IG-4
ON-VEHICLE INSPECTION (7M-GE) • • . . • • • . • . • . • IG-6
ON-VEHICLE I NSPECTION (7M-GTE) . • • • • • . . • • • • IG- 1 2
DISTRIBUTOR (7M-GE) • . . . . . • • • • . . • . . • • • • • • • • • • I G- 1 9
CAM POSITION SENSOR (7M-GTE) • • • • • • . • • • • • • IG-23
I
IG-2 IGNITION SYSTEM - Precautions
PRECAUTIONS
1• Do not l eave the ignition switch o n for more than 1 0
minutes i f the engine does not start.
2. When a tachometer is connected to the system, con�

nect the tachometer test probe to the check connector
terminal IG 8 .
See pages Fl- 1 1 0, 1 1 1
3. As some tachometers are not compatible with this

ignition system, we recommended that you confirm
the compatibility of your unit before using.
4. N EVER allow the tachometer terminals to touch

ground as it could result in damage to the igniter and/
or ignition coil.
5. Do not disconnect the battery while the engine is run�

ning.
6. Make sure that the igniter is properly grounded to the

body.
IGNITION SYSTEM - TroubleshoQting 1<3-:3 .
� 'S, ,,.....,.,,;,. ,#'f,:....
......._ _ ...._.�..,.,.,••
TROUBLESHOOTING
, 10
Problem Possible causes Remedy Page� ·
Engine will not start/ Incorrect ignition timing Reset timing EM- 1 7
hard to start Ignition problems
(cranks OK)
• Ignition coil Inspect coil IG- 1 0 or 1 4
• (7M-GTE)
Igniter Inspect igniter IG- 1 7
• {7M-GE)
:on- Distributor Inspect distributor IG-1 1
::tor OM-GTE)
Cam position sensor Inspect cam position sensor IG- 1 8
• High-tension cords Inspect high-tension cords IG-6 or 1 3
Ignition wiring disconnected Inspect wiring
or broken
Rough idle or stalls Spark plugs faulty Inspect plugs IG-7

Ignition wiring faulty Inspect wiring
Inco rrect ignition timing Reset timing EM-1 7
Ignition problems
this
:irm • Ignition coil Inspect coil IG-1 0 or 1 4
• (7M-GTE)
Igniter Inspect igniter IG - 1 7
uch
ind/
• {7M-GE)
Distributor Inspect distributor IG- 1 1
{7M-GTE)
�un- Cam position sensor Inspect cam position sensor I G- 1 8
• High-tension cords Inspect high-tension cords IG-6 or 1 3
the Engine hesitates/ Spark plugs faulty Inspect plugs IG-7

poor acceleration Ignition wiring faulty Inspect wiring
I ncorrect ignition timing Reset timing EM-1 7
\L
Muffler explosion I ncorrect ignition timing Reset timing EM- 1 7

(after fire) all the
time
Engine backfires Incorrect ignition timing Reset timing EM- 1 7
Poor fuel economy Spark plugs faulty Inspect plugs IG-7

Engine overheats Incorrect ignition timing Reset timing EM� 1 7

IG-4 IGNITION SYSTEM - Ignition System Circuit
IGN IT10N SYSTEM CIRCUIT

7M•GE
Ignition Switch
AM2 IG2
AM2 30A
Fusible Link Distributor
MAIN 2.0L (MS)

(MA)
Spark Plug
Igniter u---- To Tachome:
Battery I
...J_ 0 0
G1 G2 G 8 NE IGT IGF
� ECU
Ignition Switch
AM 2 IG2
D-_;....._____________..,...___.....,......,
To Tachometer
am Position Spark Plug
---,
� I�
Sensor
AM 2 30A
---�G 1
Fusible Link IGF
� 1r:
' I'
MAIN 2.0l ECU
Igniter
Battery
'.
-1-
ELECTRO NIC SPARK ADVANC E (ESA)
The ECU is programmed with d ata for optimum ignitio
timing under any a nd all operating conditions. Using d at
provided by sensors which monitor various engine func
tions (rpm, intake air volume, eng. temperature, etc.) th
microcomputer (ECU) triggers the spark at precisely th
right instant.
I G N ITION SYSTEM - O n-Vehicle Inspection (7M-GE)
ON-VEHICLE IN SPECTION (7 M..:G E)

SPARK TEST
CHECK THAT SPARK OCCURS
(a) Disconnect high-tension cord from the d istributor.
(b} Hold the end about 1 2.5 mm (0.49 i n.) from body of
vehicle.
(c) See if spark occurs while engine is being cranked.
NOTE: To prevent gasoline from being injected from
injectors d uring this test, crank the engine for no more
than 1 -2 seconds at a time.
If the spark does not o ccur, perform the test as follows:
I S PARK TEST
. CHECK CON N E CTIO N OF I G N ITION COIL, BAD Connect securely.
l
I IGN ITER AND D ISTRI BUTO R CONNECTORS
OK
CHECK RESISTANCE OF H I G H -TENSION BAD Replace the cord (s).
CORDS (See page IG-6)
! OK
CHECK POWER SU PPLY TO I G N ITION COIL Check wiring between Igniti o n switch to
1 . Ignition switch turn to ON. BAD switch to i gnition coil.
2. Check that there i s battery voltage at
ignition coil positive (+} terminal.
CHECK RESISTANCE OF I G N ITION CO IL BAD Replace the ignition coil.
l
(Se e page IG- 1 0}
OK
CH ECK RESISTANCE OF D I STRI BUTOR BAD Replace the distributor.

SIGNAL G E N E RATOR (PICK UP COIL)
!
Resistance: 1 40 - 1 so n
OK
CHECK AIR GAP OF D I STRI BUTOR BAD Replace the distributor.

-
Air Gap: Each 0.2 - 0.4 mm
(0.008 - 0.0 1 6 in.}
i OK
CHECK IGt S IGNAL FROM ECU BAD C h eck wiring between ECU and d istributor,
only then try another EC U.
l
(See pages Fl-6 1 , 70)
OK
TRY ANOTHE R I G N ITER

IG-6 IGNITION SYSTEM - On-Vehicle Inspection (7M-GE)
INSPECTION OF H IGH-TENSION CORDS

1. REMOVE HIGH-TENSION CORDS
(a) Disconnect the throttle body.
• Disconnect the air cleaner hose.
• Remove the throttle body bracket.
• Disconnect the throttle cables or accelerator con
necting rod.
Air Cleaner Hose • D isconnect the PCV hose.
• Remove the four bolts and pick up the throttle
body.
(b) Carefully remove the high-tension cords by their rub
ber boots from the spark plugs.
CAUTION: Pulling on or bending the cords may
damage the conductor inside.
IG0596
2. INSPECT HIGH-TENS ION CORD RESISTANCE

Using an ohmmeter, measure the resistance without dis
connecting the cap.
Maximum resistance: 25 kO per cord
If resistance exceeds maximum, check the terminals.
If necessary, replace the high-tension cord and/or dis
tributor cap.
I 0597
3. INSTALL H IGH-TENSION CORDS

(a) Install high-tension cords.
(b) Install the throttle body.
• Install the throttle body with the four bolts.
• Connect the PCV hose.
• Connect the throttle cables or accelerator con
necting rod.
• Install the throttle body bracket.
• Connect the air cleaner hose.
IGNITION SYSTEM - On-Vehicle Inspection (7M-GE)
INSPECTION OF SPARK PLUGS

{Conventional Tipped Type Spark Plug)
(a) Remove the high-tension cords.
(See page. IG-6)
(b) Using S ST, remove the spark plug.

SST 09 1 5·5- 1 6 1 00
IG0598
2. CLEAN SPARK PLUGS

Using a spark plug cleaner or wire brush, clean the spark
plug.
IGOt52
3. VIS UALLY INSPECT SPARK PLUGS

Check the spark plug for electrode wear, threads damage
and insulator damage.
If abnormal, replace the plugs.
Recommended spark plugs :
ND Q20R- U
NGK BCPR8EY
160148
4. ADJ UST ELECTRODE GAP

Carefully bend the outer electrode to obtain the c orrect
electrode gap.
Correct electrode gap : 0.8 mm (0.031 in.)
5. INSTALL SPARK PLUGS

(a) Using S ST, install and torque the spark plug.
SST 09 1 55- 1 6 1 00
IG00.04
IG-8 IGNITION. SYSTEM - On-Vehicle Inspection l7M-GE)
(Platinum Tipped Type Spark Plug)

CAUTION :
• Never use a wire brush for cleaning.
• Never attempt to adjust gap on used plug.
• Spark plugs should be replaced every 60,000 miles
(1 00,000 km) .
1. INSPECT E LECTRODE
Megger
(a) If using a megger (insulation resistance meter) :
00 0
• Remove the high-tension cords. (See page IG-6)
• Measure the insulation resistance.
M fi
Correct insulation res ista nce: 1 0 M U or more
If less than 1 0 M n . proceed to step 2.
IG0147
{b) If not a megger:

• Quickly race the engine ta 4, 000 rpm five times.
• Usi ng SST, remove the spark plug. (See p rocedure
below)
SST 091 5 5 - 1 6 1 00
IG0598
• Visually inspect the spark plugs.

If the electrode is dry ..... Okay
If the e lectrode is wet ..... Proceed to step 3
IG014S

(al Remove the high-tension cords. (See pag e IG-6)
(b) Using SST, remove the spark plug.
SST 09 1 5 5- 1 6 1 00
IGNITION SYSTEM - On-Vehicle Inspection (7M-GE) '.IG-9
3. VISUALLV INSPE CT SPARK PLUGS

Check the spark plug for thread or insulator damage.
If abnormal, replace the plug.
Recommended spark plugs :
7M-GE. ND PQ 1 6R
N G K BCPR5 EP 1 1
7 M.. GTE N D PQ20R-P8
NGK BCPR6EP-N 8
03HI
4. IN SPECT ELECTRODE GAP

Maximum electrode gap :
7M-GE 1 .3 m m (0.06 1 in.)
7M-GT E 1 , 0 m m (0.039 In.)
; 0.8 mm (7M-GTE)
1 . 1 m m (7M-GE) j If the g ap is greater than maximum, replace the plug.
it l S:7 Correct electrode gap of n ew plug :

7M-GE 1 . 1 mm (0. 043 In.)
7M-GTE 0. 8 mm (0.031 in.)
If adjusting the gap of a new plug, bend only the base of
) the ground electrode, do not touch the tip.
5. CLEAN SPARK PLUGS

If the electrode has traces of wet c·a rbon, allow it to d ry
and then clean with a spark plug cleaner.
Air pressure : Below 6 kg/cm 2 (85 psi, 688 kPa)
Duration : 20 seconds or l ess
NOTE: If there are traces of oil, remove it with gasoline
before using the spark plug cleaner.
IG0182
6. IN STALL SPARK PLU GS

(a} Using SST, install and to rque the spark pl ug.
SST 09 1 5 5 - 1 6 1 00
Torque : 1 80 kg-cm {1 3 ft-lb, 1 8 N·m)
IG0598
(b) Install the high-tension cords.

IG- 1 0 IGNITION SYSTEM - On-Vehicle Inspection (7M-GE)
MA INSPECTION OF i'O N ITION COIL

1. DISCONN ECT HIGH-TENSION CORD
(See page IG-6)
2. INSPECT PRIMARY COIL RESISTANCE

Using an ohmmeter, measure the resistance between the
positive (+} and negative (-} terminals.
Primary coil resistance (cold) :
MA 0.24 - 0.30 fi
MS 0.41 - 0.60 0
MS If the resistance is not as specified, replace the ignition
coil.
IG0599
IG0854
3. INSPECT SECON DARY COIL RESISTAN CE

MA
positive (+} termi nal and high-tension termi nal.
Secondary coil resista nce (cold) :
MA 9.2 - 1 2.4 k.0
MS 1 0.2 - 1 3.8 kO.
If the resistance i s not as specified, replace the ignition
coil.
4. RECONNECT H IGH-TENSION CORD

(See page IG-6)
MS
IG080
!00853
INSP ECTION OF IGNITER

(See procedure IG-5)
IGN ITION SYSTEM - On-Vehicle Inspection (7M-GE) IG- 1 1
INSPECTION OF DISTRI BUTOR

1. INSPECT AIR GAPS
NE Pickup G 1 Pickup G2 Pickup Using a thickness gauge, measure .the gap between the
signal rotor and pickup coil projection.
�@ @
Air gap : 0.2 - 0.4 mm (0.008 - 0.01 6 in.)
If the gap is not as specified, replace 'the distributor.
IG0601
2. INSPECT PICKU P COILS

Using an ohmmeter, check resistance of the pickup coil.
G1 pickup coil resistance:
G 1 - G 0 1 40 - 1 80 !l
G2 pickup coil resistance:
G2 - G 0 1 40 - 1 80 !l
NE pickup coil resistance:
N E - G 0 1 40 - 1 80 !l
If the resistance is not as specified, replace the distributor.
1S-4-2-A
IG- 1 2 IGNITION ..SYSTEM - On-Vehicle Inspection (7M-GTE)
(7M-GTE)
S PARK TEST
NOTE: Perform this test to check that voltage is coming
from the ignition coil to spark plug.
1, DISCONNECT NO.1 AIR CLEANER HOSE

2. DISCONNECT FO LLOWING CABLES AND ROD:
(a) Accelerator link w/ cable
(b) Accelerator rod
(c) (A/T)
Throttle cable
3. REMOVE ISC PIPE

(a) Disconnect the six hoses from ISC pipe.
(bl Remove the two bolts and ISC pipe.
4. REMOVE PCV PIPE WITH HOSES

(a) Remove the oxygen sensor wire from two clamps.
(b) Disconnect the No.4 PCV hose from the PCV pipe.
(cl Remove the two bolts.
(d) Disconnect th e PCV pipe with hoses from the
cylinder head covers and throttle body.
EM331 1
5. REMOVE INTAKE AIR CONNECTOR

(al Disconnect the air valve hose from the intake air con
nector.
(b) loosen th e clam p and remove the two bolts.
(cl Remove the intake air connector.
· 1GNITION SYSTEM - On-Vehicle lnspectic;m (7M-GTE)
6. REMOVE IGNITION COIL COVER

{a) Remove the oil filler cap.
(b) Remove t h e five nuts and ignition coil cove
7. REMOVE IGNITION COI.L WITH BRACKET

{a) Remove the nut.
(bl Discon nect the No. 1 a nd No.2 high-tension cords
from the ignition coil and clamp.
(c) Remove the ignition coil with bracket and high-ten
sion cords.
(d) Remove the No. 1 and No.2 high-tension cords from
the spark plugs.

Using SST, remove the spark plug .
SST 09 1 5 5 - 1 6 1 00
9. PERFORM SPARK TEST

(a) Install the oil filler cap.
(b) Install the spark plug s to each high-tension cord.
(c) Ground the spark plug.
IG059S (d) Disconnect the solenoid resistor and cold start i njec
tor connectors.
(e) See if spark o c curs while engine is being c ranked.
I NSPECTION OF HIGH-TENSION CORDS

INSPECT HIGH-TENSION CORD RESISTANCE
Using an ohmmeter, measure the resistance.
Maximum resistance : 25 kfi per cord
If resistance exceed s maximum, check the terminals.
If necessary, replace the hig h -tension cord.
IG0667
INSPECTION OF SPA RK PLUGS

(Se e pages IG-7, 8)
IG- 1 4 IGNITION· SYSTEM - On-Vehicle Inspection (7M-GTE)
INSPECTIO-N OF IGNITION COIL ·

1. INSPECT POWER SOURCE LINE
(a) Disconnect the high-tension cord from the ignition
coil.
(b) Disconnect the ignition coil connectors.
(c) Turn the ignition switch O N .,
(d) Using a voltmeter, measure the voltage between ter

Voltmeter minal 1 and body ground.
Voltage: Approx. 1 2 V
IG0668
INSPECT PRIMARY COIL RESISTANCE

Ohmmeter
2.
positive (+) and negative (-) terminals.
Primary coil resistance (cold) : 0.3 - 0.5 fl
NOTE: Because is inside the coil, it is impossible to
measure secondary coil resistance.
IG0670
3. INSPECT IGNITION COIL GROUND

No continuity ,.-,,.._..,..s:,, Using an ohmmeter, check that there is no continuity be
tween the ignition coil terminal and body g round.
!G0671
4. IF NECESSARY, REPLACE IGNITION COIL

Using a hexagon key wrench 3 mm {0. 1 2 in.), replace the
ignition coil.
..
IGNITION SYSTEM - On-V�hicle Inspection {7M-GTE) IG- 1 5
5. INSTALL IGNITION COIL WITH BRACKET

(a) Connect the ignition coil connector.
(b) Install the high-tension cords as shown in the illustra- ·
tion; No.5 and No.6, No.3 and No.4, and No. 1 and
No.2.
180085
{c) Install and torque the nut.

Torque : 55 kg-cm (48 in.-fb, 5.4 N ·m)
CAUTION : Do not over tighten the nut.
6. INSTALL IGNITION COIL COVER

(b) Install the ignition coil cover with the five nuts.
le) Install the oil filler cap.
7. INSTALL I NTAKE AIR CONNECTOR

(a) Install the intake air connector.
(b) Install and tighten the two bolts.
(c) Tighten th e clamp.
(d) Connect the air valve hose.
IG- 1 6 IGNITION SYSTEM - On-Vehicle Inspection (7M-GTE)
8. I NSTALL PCV PIPE W ITH HOSES

(a) Instal l the PCV pipe with hoses to th rottle body and
cylinder head cover.
(b) Install and tighten the two bolts.
(c) Connect the No.4 PCV hose.
(d} Install the oxygen sensor wire to the two PCV pipe
clamps.
EM331 '
9. INSTAL L ISC PIPE

(a) Install th� ISC pipe with the two bolts.
(b} Connect the six h oses to ISC pipe.
1 0. CON N ECT FOLLOWI NG CABLES A N D ROD:

(a) {A/T)
Th rottle cable
(b) Accelerator rod
{c) Accelerator link w/ cable
1 1 . CO N N ECT N0. 1 AIR CLEANER HOSE

IGNITION SYSTEM - On-Vehi cle Inspection. (7M-GTE)
I NSPECTION OF IGNITER
1. CHECK POWER SOURCE LINE VOLTAGE
{a) Disconnect the connector 6-P.
(b) Turn the ignition switch ON.
(cl Using a voltmeter, connect the positive (+) probe to
the terminal 3 o f harness side and negative (-) probe
to the body gro und.
Voltage: Approx. 1 2 V
(d) Connect the connector 6-P.
2. CHECK POWER TRANSISTO R IN IGNITER
(a) Disconnect the connector 4-P.
(b) Disconnect each ignition coil from its connector.
(c) Turn the ignition switch ON.
Ohmmeter (d) Using an ohmmeter, connect terminal 2 of the igni

tion coil C and body ground.
{e) Using a 3 V dry cell battery, apply voltage to terminal
2 of the connector 4-P.
As voltage is applied, check that there is momentary
continuity.
IG0679
(f) Using an ohmmeter, connect terminal 2 of the igni

tion coil A and body g round.
(g) Using a 3 V dry cell battery, apply voltage to terminal
4 of the conn ector 4-P.
(h) With terminal 4 connected apply voltage to terminal
2 of connector 4-P.
As you apply voltage, c heck that there is momentary
continuity.
Ohmmeter (i) Using an ohmmeter, connect terminal 2 of th e igni

tion coil B and body g round.
UlJ Q) Using a 3 V dry cell b attery, apply voltage to terminal
!) 3 of the connector 4-P.
(k) With terminal 3 connected apply voltage to terminal
2 of connector 4-P.
As you apply voltage, check that there is mo mentary
continuity.
IG- 1 8 IGNITION SYSTEM - On-Vehicle Inspection (7M-GTE}
. .
INSPECTION OF -CAM POSITION SENSOR ·
NE Pickup G 1 Pickup G2 Pickup 1. INSPECT AIR GAP
Using a thickness gauge, measure the gap between the
signal rotor and pickup coil projectio n.
Air gap : 0.2 - 0.4 mm (0.008 - 0.01 8 in.)
If the gap is not within specification, replace the cam posi
tion sensor.
F54S8
2. INSPECT PICK U P COILS

Using an ohmmeter, c heck resistance of the pickup coil.
61 pickup coil resistance :
G1 - G e 1 40 - 1 80 n
62 pickup coil resistance:
G2 - G e 1 40 - 1 so n
N E pickup coi l resistance:
NE - G 8 1 40 - 1 80 0
If the resistance is not as specified, replace the cam posi
tion sensor.
IGNITION SYSTEM - Distributor (7M-GE) IG7 1 9
DISTRIBUTOR (7M-GE)
COM PO NENTS
Packing
----'Distributor Cap
<§)--- ♦ O-Ring
c;:::::::r-- •
Straight Pin
♦ Non-reusable part IG0002
REMOVAL OF DISTRIBUTOR
1. DISCONNECT H IGH-TENSION CORDS FROM
DISTRIBUTOR CAP
2. D ISCONN ECT DISTRIBUTOR CONNECTOR
3. REMOVE DISTRIBUTOR CAP AND PACKIN G
4. SET N0. 1 CYLIN DER TO TDC/COMPRESSION

(bl Look through oil fil l er hole and turn the crankshaft
clockwise until the cam nose can be seen.
IG-20 IGNITION SYSTEM - Disfributor (7M-GE)
(cl Turn°the crankshaft counterclockwise approximate

1 20 .
(d) Tum the crankshaft again approximately 1 0 ° to 4C
clockwise so that the timing belt cover TDC mark an
the crankshaft pulley TDC mark are aligned.
IG0880
6. REMOVE Dl�TRIBUTOR
(a) f:lemove the hold-down bolt,
IG0605
(b) Pull out the distributor from the cylinder head .
6. REMOVE O-RING
IG0 1 36
I G N ITION SYSTEM - Distributor (7M-GE)
REPLACEM ENT OF DISTRI BUTORl:Jii'

GEAR
Groove 1, GRIND DRIVEN GEAR A N D PIN
(a) Align the drilled mark o n the driven ge� r with · the
groove of the housing.
{b} Place a matchmark on the distributor shaft that
aligns with the groove of the housing.
Drilled Mark
100601
(c) Using a grinding wheel, grind the gear and pin .

CAUTION : Se careful not to damage the ahaft.
!G061 0
2. REMOVE PIN AND DRIVEN G EAR

(a} Using a punch and h am mer, drive out the pin.
(b) Remove the driven gear and discard it.
IG061 1
3. INSTALL NEW DRIVEN G EA R AND PIN

(a l Align the matchmark with the g roove of the housing.
{b} Align the drilled m ark o n the new driven gear with the
Groove groove of the housing.
Drilled Mark
IG0607
(c) Using a punch and hammer, peen both ends of the

pin.
IGOBS:Z
IG-22 IGN ITION SYSTEM - Distributor (7M-GE}
· t NSTALLATION O F DISTRI BUTOR

1. CHECK NO. 1 CYLI NDER TO TDC/COM PRESSION
2. I N STALL DISTRIBUTOR
(a} Install a new 0-ring to the distributor.
NOTE: Always use a new 0-ring when installing the dis-
tributor.
IG01 6
(b) Align the drilled mark · on the driven gear with the
(c) Insert the distributor, aligning the center of the flange
with that of the bolt hole on the cylinder head.
(d) Lightly tighten the hold-down bolt.
Groove
Drilled Mark IG0607 IG0606
3. I N STALL D ISTRIBUTO R CAP

4. CONN ECT DISTRIB UTOR CONN ECTOR
5. CONN ECT H IGH-TENSION CORDS TO DISTRIBUTOR
CAP
6. ADJUST IGN ITION TIMIN G (See page EM- 1 7)

IGNITION S-VSTEM - Cam Position Sensor (7M-GTE)
CAM POSITIO N SENSOR._(71\11.;

',,
COMPONENTS
♦ 0-Aing
♦ Gear
Position Sensor Housing
Packing
Dust Proof Cover
♦ Non-reusable part 0 74
REMOVAL OF CAM POSITION SENSOR

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL
OF BATTERY
2. DISCONNECT CAM POSITION SENSOR CO NNECTOR
3. SET N0. 1 CYLINDER TO TDC/COM PRESSION

{a) Remove the oil filler cap.
(b) look through oil filler hole and turn the crankshaft
1·
clockwi se until the cam n ose can be seen.
I'
I[
10-24 IGN ITION SYSTEM - Cam Position Sensor (7M-GTE)
(c) Turn the crankshaft counterclockwise �pproximately

· 1 2o·s. · ·· - ,
(d) Turn the crankshaft again approximately 1 0 ° to 40"

clockwise so that the timing belt cover TDC mark and
the crankshaft pulley TDC mark are aligned.
IGOll80
4. REMOVE N0.4 AIR CLEA N E R PIPE WITH N0.1 AND

N0.2 AIR CLEA N E R HOSES
5. REMOVE N0.7 AIR CLEA N E R HOSE WITH AIR FLOW

METER AND AIR CLEA N E R CAP
(a) Disconnect the three air h o se s and PCV hose,
(b} Disconnect the air flow meter connector.
(c) Disconnect the PS idle u p air h ose.
EM3527
(d) Loosen the clamps and remove the bolt.

(e) Remove the No.2 air cleaner hose with air flow meter
EM352S
6, REMOVE PS RESERVOIR TAN K

Remove the two bolts, nut and reservoir tank with bracket.
IGN ITION SYSTEM - Cam Position Sensor {7M-GTE) IG-215,
7. REMOVE CAM POSITIO N SENSOR

(a} Remove the hold-down b olt.
(b} Pull out the cam positio n sensor from the cylinder
head.
8. REMOVE O-RINO
REPLACEMENT OF CAM POSITION SENSOR

DRIVEN GEAR
1. GRIND DRIVEN GEAR A N D PI N
(a) Align the drilled mark o n the d riven g ear with the
g roove of the h ousing.
(b} Place a matchmark on the cam positio n shaft that
aligns with the g ro ove of the h o using.
Drilled Mark
100875
(c) Using a g rinding wheel, g rind the gear and pin.

CAUTIO N : Be careful not to damage the shaft.
IG0878
2. REMOVE PIN AN D D RIVEN GEAR

(a) Using a punch and h ammer, drive out the pin.
(bl Remove the driven g ea r and discard it.
IG0877
3. INSTALL N EW D RIVEN G EA R A N D PIN

(a) Alig n th e match mark with the g roove of the housing.
(bl Align the dri lled mark on the new d riven gear with the
Drilled Mark
F�A'17
I
I
i . .. .
IG-26 IGNITION SYSTEM - Cam Position Sensor (7M-GTE)
(c) Using a:: punch,,��d,·�;��t� -peen both ends of the

pin.
f48 3
INSTALLATION OF CAM POS ITION ..SENSOR

1. CHECK N0. 1 CYL I N DER TO TDC/COM PRESSION
2. IN STALL CAM POSITION SENSOR

ta) Install a new 0-ring to the cam position sensor.
NOTE: Always use a new 0-ring w hen installing the cam
position sensor.
(b) Alig n the drilled mark on the driven gear with the
Groove groove of the h ousing.
(c) Insert the cam position sensor. aligni ng the center of
the flang e with that of the bolt hole on the cylinder
head.
(d) Lightly tighten the hold-down bolt.
Drilled Mar�
3. INSTALL PS RES E RVOIR TANK

Instal l the PS reservoir tank with bracket with the two
bolts and nut.
4. I N STALL NO. 7 AIR CLEAN E R HOSE WITH AIR FLOW

METER AND AIR CLEANER CAP
(a) Instal l the No. 7 a i r cleaner hose with air flow meter
(b) Install the bolt and tighten the c lamps.
IGNITION SV:�TEM - Cam Position Sensor {7M-GTE) IG-27
{c) Connect the PS idle up air hose.

(d) Connect the air flow meter connector.
(el Connect the PCV hose and three air hoses .
. EM3S27
5. INSTALL N O.4 AIR CLEANER PIPE WITH NO.1 AND

NO.2 AIR CLEANER HOSES
6. CONNECT CAM POSITION SENSOR CONNECTOR
7. WARM UP ENGINE
8. ADJUST IGNITION TIMING (See page EM- 1 7}

:CHARG-I NG SYSTEM
Page
PRECAUTIONS • •. • • • • • • • . . • . . • ·• • • • • • • • • • . . • • • . • • CH-2
TROUBLESHOOTING . . . . . . . . . . . . . . .'. . • . . . . • • • • • CH-2
CHARGING SYSTEM CIRCUIT . . . . . • • • • • • • • • • • • • • CH-3
ON-VEHICLE INSPECTION • • • • • • • • • • : • • • • • , • • • • • CH-3
ALTERNATOR • • • • • • • . • • • • • • • • • • • • • • . . • • • • • • • • • • CH- 7
CH-2 CHARGING SYSTEM - Precautions, Troubleshooting
PRECA�TIONS
1. Check that the battery cables are connected to the
correct terminals.
2. Disconnect the battery cables when the battery Is
g iven a quick charge.
3. Do not perform tests with a high voltage Insulation

resistance tester.
4. N ever disconnect the battery while the engine is run

n ing.
TRO U B LESHOOTING
( ·.·.•·
Problem P01&ible cause Remedy Page
Discharge warning Fuse blown Check "CHG" and

light does not light "IGN" fuses
with Ignition ON and Light burned out Replace light
engine not running
Wiring connection loose Tighten loose connections
IC regulator faulty Replace IC regulator CH-7
Discharge warning Drive belt loose or worn Adjust or replace drive belt CH-4
light does not go out Battery cables loose, corroded or worn Repair or replace cables
with engine running
(battery requires fre- Fuse blown Check " ENG" fuse
quent recharging Fusible link blown Replace fusible link
IC regulator or alternator faulty Check charging system CH-3
Wiring faulty Repair wiring
CHARG ING SYSTEM - Charging System -Circuit, On-Vehicle Inspectio
n
CHARG I N G SYS TEM CIRC U I

ENGINE
1• -----
AM 1 IG1
Fusible B
Link
AM 1
40A
Fusible
Link
ALT
Link
Fuse IGN
7M-GE)
(MA/ Fusible
(MA} 7.5A
AM2 30A (MS) 1 5A
1 .25B
'MA/
7M-GTE) Discharg e
1 00A Warning
(MS) 1 OOA..,.____--i Light
Link
Fusible
(MA) IMS)
L __
MAIN 2.01.:
I
T Battery Fuse
..I-
CHG 7.5 A
Alternator
CH0600
ON-V EHICL E INS PECT ION

1. CHECK BATTERY SPECIFIC GRAVITY
(a} Check the specific gravity of each cell.
Standard specific gravity
pper level When fully charged at 20 ° C (68° Fh 1 .25 - 1 .27
wer Level If not within specifications, charge the battery.
(b) Check the electroJyte quantity of each cell.
CH0002 If insufficient , refill with distilled (or purified) water.
2. CHECK BATTERY TERMINAL S, F U S I B LE LINKS AN O

FUSES
(a) Check that the battery terminals a re not loose o r cor•
roded .
(b) Check the fusible links and fuses for continuity.
CH0211�
I
CH-4 CHARGING SYSTEM - On-Vehicle Inspection·
3. I NSPECT DRIVE BELT

(a) Visually check the belt for separation of th e adhesive
rubber above and Qelow the core, separation from
the belt side, severed core, separation of the rib from
the adhesive rubber, cracking or separation of the
ribs, torn of worn rib s or cracks in the
., in ner ridges of ·
the ribs.
If the belt has any of the above defects, replace it
CH0004 CH0039
(b) Check the drive belt deflection by pressing on the

belt at the points indicated in the fig u re with 1 0 kg
(22,0 lb,98 N) of pressure.
D rive belt deflection:
New belt 10 - 1 2 mm (0.40 - 0.47 in.)
U sed belt 1 5 - 1 7 mm (0. 59 - 0.67 in.)
If necessary, adjust the drive belt deflection.
C rankshaft Pulley
CH0230
(Reference)
SST B l
Using SST, check the d rive belt tension.
SST" A 092 °1 6-00020
SST B 092 f6 -00030
Drive belt tension:
N ew belt 70 - 80 kg
SST A Used belt 30 - 45 kg
If necessary; a djust the drive belt tension.
EC0003 EC0004
NOTE:
• "New belt" refers to a belt wh ich h as been u sed less
than 5 minutes on a running engine.
• " Used belt" refers to a belt which has been used on a
running eng ine for 5 minutes o r more.
• After installing the d rive belt, check th at it fits properly
in the ribbed grooves.
CORRECT WRONG WRONG • Check with your hand to confirm that the belt has not
slipped out of the groove on the bottom of the crank
CH0086 pulley.
• After installing the belt, run the engine for about 5
minutes and recheck the deflection o r tension.
4. INSPECT FUSES FOR CONTI N U ITY

• CHG 7 . 5 A
• IGN 7.5 A
• ENGINE 1 5 A
.C HARGING SYSTEM - On-Vehicle {nspection
· ·wIRiN cr*iNo
·:·_",'·".._ '• 1;f\�_: • .· :
5. VISUAL LY C H E� K A LTERNATOR
LISTEN FOR ABNORMAL NOISES · . .
.
(a) Check that the �wiring is in g ood conditio n:·- .
(b) Chec k that there are no abno rmal noises fro m · the
alternator while ·the engine is running.
6.
t
CHECK DISCHARGE WARN ING LIGHT CIRCUIT
(a) Warm u p the engine and turn it off.
(b) Turn off all accessories.
CH0464
(c) Turn the ignition switch to "ON". C heck that the
charge light is lit.
(d) Start the engine. C heck that the light goes out.
If the light does not operate as specified, troubleshoot the
charge light circuit.
Disconnect Wire 7. CH ECK CHARGING CIRCUIT WITHOUT LOAD

from 8 Terminal NOTE: If a battery/ alternator tester is available, connect
Alternator the tester to the charging circuit according to the
- r+--- manufacturer's i nstructions.
B
(a) If a tester is not available, connect a voltmeter and
ammeter to the c harging circuit as follows:
BatterY.i_ • Discon nect the wire from term inal B of the alterna
tor and connect the wire to the negative (- ) ter
.I minal of the ammeter.
CH0008
• Connect the test lead f ro m the positive (+) ter
minal of the ammeter to terminal B of the alterna
tor.
• Connect the positive (+) lead of the voltmeter to
terminal B of the alternator.
• Ground the negative (-) lead of the voltmeter.
(b) Check the c harging circuit as follows :

1 3.5 - 1 5. 1 V 1 0 A or less With the engine running from idling to 2,000 rpm,
check the read ing on the ammeter and voltmeter.
Standard amperage: 1 0 A or less
Standard voltage: 1 3. 9 - 1 5. 1 V at 25°C (77 °F)
°
1 3.5 - 1 4.3 v at 1 1 5 °c (239 F)
V If the voltage reading i s g reater than standard voltage,
Voltmeter Ammeter replace the IC reg ulator.
CH04 l 2 CH0010
CH-6 CHA_R GING SYSTEM - On-Vehicle Inspection
If the·voltage reading is l ess than standard voltage, check

the IC regulator and alternator as follows :
• With terminal F grounded, start the engine and check
the voltage reading of terminal B.
• If the voltage reading is more than standard voltage,
replace the IC regulator.
• If the voltage reading is less. than standard voltage,
check the alternator.
8. CHECK CHARGING C IRCUIT WITH LOAD

30 A or More (a) With the engine running at 2,000 rpm, turn on the
high beam headlights and place the heater fan con
trol switch on "HI".
(b) Check the reading on the ammeter.
Standard amperage: 30 A or more
If the ammeter reading is less t_h an 30 A, repair the alter
nator. (See pages CH- 7)
NOTE : If the battery is fully charged, the indication will
CH0067 CH0068
sometimes be less than 30 A.
CHARGING SYSTEM - 'Alternator C H-7
ALTERNAT.O R
COM PONENTS
Rotor
Front Bearing
Drive End Frame
Bearing Cover
Rear Bearing
Brush Holder and Cover
IC Regulator
, &,
'
Terminal lnsulator--�t.:;;:..Jf
I
Pulley
Rectifier End Frame
Rear End Cover
Rectifier Holder
CH0329
DISASS EM BLY OF A LTERNATOR

1. REMOVE REAR END COVER
(a} Remove the nut and terminal insulator.
(b} Remove the three nuts and end cover.
CH0330
2. REMOVE BRUSH HOLDER

Remove the two screws, brush holder and cover.
CH033 1
CH-8 CHARGING SYSTEM - Alternator
3. REMOVE IC REGU LATOR

Remove the three screws and IC regulator.
CH0333
4. REMOVE RECTIF I ER HOLDER

(a) Remove the four screws and rectifier holder.
(b) Remove the four rubber insulators.
5. REMOVE PULLEY
(a)· Hold SST A with a torque wrench, and tighten SST B
clockwise to the specified torque.
SST 09820-630 1 0
(b) Check that SST A is secured to the rotor shaft.
(c) As shown i n the figure, mount SST C i n a vise, and

install the alternator to SST C.
(d) To loosen the pulley n ut turn SST A i n the direction
shown in the figure.
CAUTION: To prevent damage to the rotor shaft, do
not loosen the pulley nut more that one-half of a turn.
(el Remove the alternator from SST C.
(fl Turn SST B and remove SSTs A and B.
(g) Remove the pulley n ut and pulley.
6. REMOVE RECTIFIER END FRAM E

(al Remove the four nuts.
{b) Using SST, remove the rectifier end frame.
SST 09286-460 1 1
7. REMOVE ROTOR FROM DRIVE END FRAM E

:·�i��Jf�iz.::·,·.,;
CHARGING SYSTEM - Alternator
' i\'.k\C.H-9
INSPECTION AND REPAIR OF ALTER NAT� R

Rotor
1. INSPECT ROTOR FOR O P E N CI RCUIT
Using an ohmmeter, c heck that t here is continuity b�-
tween the slip rings.
Standard resistance (cold) : 2.8 - 3.0 n
If there is no conti nuity, replace the rotor.
Continuity
CH0190
2. INSPECT ROTOR FOR G RO U N D

Using an ohmmeter, check that there is n o continuity be
tween the slip ring and the rotor.
If there is continuity, replace the rotor.
No continuity
CH01 9 1
3. I NSPECT SLIP RINGS

(a) Check that the slip rings are not rough or scored.
If rough or scored, replace the rotor.
(b) Using cali pers, measure the slip ring diameters.
Standard dia meter: 1 4.2 - 1 4.4 mm
(0.559 - 0.567 in.}
Minimum diameter: 1 2.8 mm (0.504 i n.)
If the diameter i s less than minimum, replace the rotor.
Stator
1. I NSPECT STATOR FOR OPEN C I RC U IT
Using an oh mmeter, c heck that there i s continuity be
tween the coi l leads.
If there is no conti nuity, replace the d rive end frame
assembly.
Continuity
CH0245
2. INS PECT STATOR FOR GRO U N D

Using an ohmmeter, check that there i s no continuity be
tween the coil leads and d rive end frame.
If th ere is continuity, replace the drive end frame assemb
ly.
No continuity
CH0246
CH- 1 0 CHARG I NG SYSTEM ;.;.. Alternator
Brushes
1. INSPECT EXPOS ED BRUSH LENGTH
Using a scale, measure the exposed brush length.
Standard exposed length: 1 0.5 tnm (0.41 3 in.)
Minimum exposed length: 1 .5 mm (0.069 in.)
If the exposed length is less th an minimum, replace the
brushes.
CH0247
2. IF NECESSARY, REPLACE BRUSH ES

(a) Unsolder and remove the brush and spring.
(bl Run the wire of the brush through the hole i n the
brush holder, and insert the spring and brush into the
brush holder.
CH024S
(cl Solder the brush wire to the brush holder at the

exposed length.
Exposed length: 1 0.5 mm (0.41 3 in.)
(d) Check that th e brush moves smoothly i n the brush
tv,tder.
(e) Cut off the excess wire.
(f) Apply insulation paint to the soldered point.
Ohmmeter Rectifiers (Rectifier Holder)

DL]
@1-:---
1. INSPECT POSITIVE S IDE RECTIFIER
(a) Using an ohmmeter, connect one tester prove to the
positive (+) stud and the other to each rectifier ter
minal.
CH0465
Ohmmeter
(b) Reverse the polarity of the tester probes.
DL] (c) Check that one shows continuity and the other
IQ l,� EB_____
o "'" shows no continuity.
1
o e If not, replace the rectifier holder.
CH0466
CHARGING SYSTEM .-.. Alternator CH-1 1
Ohmmeter 2. INSPECT NEGATIVE SIDE RECTIFIER. �- ·· -- ·-·- '"·-· · ·

[][] (a) Connect one tester probe to each ' rec.tifler terminal .
EB Negative (-) Terminal and the other to each rectifier negative (-) terminal.
Q e
1.:::::==:::=.1
CH0487
Ohm meter (b) Reverse the polarity of the tester probes.

[JD (c) Check that one shows continuity and the other
shows no continuity. .
0 If not replace the rectifier holder.
CH04118
Bearings
1. INSPECT FRONT BEARING
Check that the bearing is not rough or worn.
2. IF NECESSARY, REPLACE FRONT BEA RING

(a) Remove the four screws and bearing retainer.
CH0228
(b) Using a press and socket wrench, press out the front
bearing.
CH-1 2 CHARGING SYSTEM ...:.. Alternator
(c) Using SST and a press, press a new front bearing

into the drive end frame.
S ST 09608-200 1 2 (09608-00030)
(d) Install the bearing retainer with the four screws.
3. INSPECT REAR B EARING

Check that the bearing is not rough or worn.
CH0199
4. IF NECESSARY, REPLACE REAR B EARING

(a) Using SST, remove the bearing cover and bearing.
SST 09820-0002 1
CH0200
(b) Using SST and a press, press in a new bearing and

SST the bearing cover.
SST 09285-7601 0
CH0201
CHARGING SYSTEM . - .Alternator
ASSEMBLY OF ALTERNATOR
(See page CH-7)
1. I NSTALL ROTOR TO D RIVE END F RA M E
2. I NSTALL RECTIFIER E N D FRA M E

(a) Using a plastic-faced ha mmer: lightly tap in the �nd
frame.
(b) Install the four n uts.
CH0218
3. INSTALL PULLEY
(a) · Install the pulley to the rotor shaft by tightening th e
pulley nut by hand.
(b) Hold SST A with a torque wrench, and tighten SST B
clockwise to the s pecified torque.
SST 09820-630 1 0
Torque: 400 kg-cm (29 ft-lb, 39 N ·m)
(c) Check that SST A is secured to the pulley sh aft.
(d) As shown in the figure, mount SST C in a vise, and

install the alternator to S ST C.
(e) To torque the pulley nut turn SST A in the direction
shown in the figure.
Torque: 1 , 1 25 kg-cm (81 ft-lb, 1 1 0 N ·m)
(f) Remove the alternator from SST C .
(g) Turn SST B and remove SSTs A and B.
4. IN STALL RECTIFI E R HOLDER

(a) Install the four rubber insulators on the lead wires.
CH0357
(b) Install the rectifier holder with the four screws.

CH- 1 4 CHARGING SYSTEM .;_ Alternator
6. ' INSTALL BRUSH HOLDER AND IC REGULATOR

(a) Place the brush holder.
(b) Install the IC regulator and brush holder to the rear
end frame horizontally as shown in the figure.
NOTE: Make sure the brush holder's cover doesn't slip
to one side during installation.
(c) Tighten the five screws until there is a clearance of at

least 1 .m m (0.04 in.) between the brush holder cover
and connector.
CH03 1 6 CH0358
6. INSTALL REAR END COVER

(a) Install the end cover with the three nuts.
(b) Install the terminal i nsulator with the nut.
CH0330
7. MAKE SURE ROTOR ROTATES S MOOTHLY

ENGINE M ECHANICAL • • • • � . • • . • . • • • • . //'; . • •. u-•-•·-•·-& : •
TURBOCHARGER SYSTEM • . . • • • • . , • • . ', • . • ·� '':iffPAP9
EFI -SYSTEM • . . . . . . . . . . . . . . . . . . . . . . . .•,.. . .�, . . . . .. . . ' A:.?

• . ... ' .•/". i:: /: n_tl;i:;
COC)LINC3 SYSTEM • . . • . . • • . . . . . . . . . . . • • . . • • • • • • A�1 1
LUBRICATION, ·SY$T�M • • • . • • • • . • . • . • • • . • . • • • •. i• .,, ·., A711 1 .
IGNITION SYSTEM • • • • • . • • • • . • . • • • • • . • . • • • • • • . • A-1 2
S'[ARTiNG SYSTEM • . ; • • • • • • • • • • • . . . • • • . • • • . • • • A-1 3 1
CHARGING SYSTEM • • • • • • • . • • . . . • • • • • . • • • • • • . • • A-1 3'.�
-
rV.
SERVICE SPECIFICATIONS - Engine· Mechanical
,,.,"
'. 1<,;,'J,v ., .•,p•
E E·,MECMANJCAL
11!' •.; i;' ' "
'
.�i�atlons
Drive belt deflection or tension .,1 ·, w/� 1 ·,0' kg (22. 1 lb, 9 8 N) w/ SST (Reference)
�ater Pump - Alternator Newbelt 19 - 1•2 : m m 0.39 - 0.47 in. 70 - 80 kg
Used belt 16, - 1 7 mm 0.59 - 0.87 in. 30 - 45 kg
c�: nkshaft - PS pump New belt ?- 8 mm 0.28 - 0.3 1 in. 5 6 - 65 kg
Used belt 9 - 1 1 rrim 0.35 - 0.43 in. •. 25 - 40 kg
·t:rankshaft - A/C compressor New bait MA 7 :... 9.5 ' mm 0.28 - 0.374 in. 53 - 77 kg
· MS. ,· 7,.5 - 9;5 m m 0.29 5 - 0.374 in. 53 - 77 kg
Used belt MA : . 1 0.s - 1 2 m m 0.4 1 3 - 0.47 In. 30 - 40 kg
MS 1 0 - ,.1 3' mm 0.39 - 0.5 1 in. 30 - 40 kg
Engine coolant capacity
MA
w/ Heater or air con. M/T 8. 1 l iters 8.5 US qts 7.1 Imp. qts
A/T 8.0 liters 8.5 US qts 7.0 Imp. qts .
w/o Heater or air con. MIT 7.5 liters 7.9 US qts 6.6 Imp. qts
A/T 7.4 llte·rs 7.8 US qts 6.5 Imp. qts
MS. (GCC Countires")
w/ Heater or air con. 8.5 liters 9.0 US qts 7.5 Imp. qts
w/o Heater or air con. 7.8 liters 8.2 US qts 6.9 Imp. qts
..,.� '. o j
._i-J _;j MS (Others)
w/ Heater or air con. 7.8 liters 8.2 us qts 6.9 Imp. qts
w/o Heater or air con. 7 . 1 liters 7.5 US qts 6.2 Imp. qts
Engine oil capacity
Dry fill
7M-GE MA (GCC Countires•) 5.0 liters 5.3 US qts 4.4 Imp. qts
7 M-GE MA (Others) 4.9 liters 5.2 US qts 4.3 lrnp. qts
7M-GE MS 5.3 liters 5.6 us qts 4.7 Imp. qts
7M-GTE (M/T) 5. 1 liters 5.4 US qts 4.5 Imp. qts
7 M-GTE (A/T) 5.0 liters 5.3 US qts 4.4 Imp. qts
Drain and refill
w/o Oil filter change
MA 3.9 liters 4.1 U$ qts 3.4 Imp. qts
MS 4.1 liters 4.3 US qts 3.6 Imp. qts
w/ Oil filter change
MA 4.2 liters 4.4 US qts 3.7 Imp. qts
MS 4.4 liters 4. 7 U S qts 3.9 Imp. qts
Battery specific gravity 1 .25 - 1 .2 7 when fully charged at 2 0 c (68 ° F)
°
High-tension cord resistance Limit 25 kn per cord

Spark. plug
Conventional tipped type
Type ND 020R-U
NGK BCPR 6EY
Air gap 0.8 mm 0.03 1 in.
Platinum tipped type
T ype 7M-GE NO P Q 1 6R
NGK BCPR5EP 1 1
7M-GTE ND PQ20R-P8
NGK BCPR6EP-N8
Air gap 7 M-GE 1 . 1 mm 0.043 in.
7M-GTE 0.8 mm 0.0 3 1 in.
Saudi Arabia, Sultanate of Oman, Bahrain, United Arab Emirates, Qatar, Kuwait.
SERVICE SPECIFICATIONS ....; Engine �edhanlc_al_'
. Specifications (Cont'd)
·· l ·.
Ignition timing T/M in N range 1 0 °BTDC @ idle .. , .
Il Firing order
' [w/ Termin�ls T (TE 1 ) and E 1 short-circuited]
1 - 5 - 3 -, 6 - 2 - 4
I ,. .
Valve clearance '(cold) .lnta.ke 0 . 1 5 - 0.25 mm 0.0059 - 0.0098 in.
Exhaust .. 0.20 - 0.30 mm 0,0.0 7� ,- 0.01 88 in.
Idle speed 7 M-GE wlo TWC 800 rpm
w/ TWC 700 rpm
7M-GTE 800 rpm
.w/o TWC 1 .0 ± 0.5 %
' w/, :TWC 0 ;;.. 0.5 %
\ Dash pot setting speed .2 ,000 rpm
j .rfr1take manifold vacuum at idfe speed ' 440 mmHg (1.7�32 in.Hg, 1 30 kPa) or more \
l Compression press�re· , at 250 rpm
7M-GE STD · 1 1 .0 kg/cm2 1 56 psi 1 ,0 7 9 kPa
Limit 9.0 kg/cmll 1:zE psi
F
883 kPa
7M-GTE : �TD · 1 0.0 kg/cm2 1 42 psi 9 8 1 kPa
'Lfrnit · 9.C> kg/c:m2 .· . 1 28 psi 8 8 3 kPa
Differential qf . pressure between 1:1ach cylinder 1 .0 kg/cm2 (14 psi, 98 kPa) or less
Cylinder head · · Warpage Cylinder: !;>tock side Lirriit O.JO mm 0.0039 in.
Intake manifold side Limit 0. 1 0 mm · 0.0039 in.
Exhaust manifold side • Limit OXO mm 0.0039 in.
Valve guide bore · · STD 1 1 .000 - 1 1 .027 mm 0.43 3 1 - 0.4341 in.
0/S 0.05 1'1 ;050 - 1 1 .0 7 7 mm 0.43 50 - 0.436 1 in.
Valve seat Reracing angle 30°, 45'\ 60 °
Contacting �ngle 45 °
Con!actil"lg width 1.0 - 1 .4 mm ·· 0;039 ·;.. 0.05.5 in . .
· . V.alve guide Inside diai;neter 6.0 1 0 - ·a .0.30
...., .... . , mm 0.2366 - 0.2374 ln.
bushing
,.
. Outside diameter . STD 1 1 .033 - 1 1 .044 mm 0.4344 - 0.4348 In .
" { ' .
0/S 0.05 . , ··• 1J .()83 - 1 1 .094 mm 0.4363 - 0.4368 in. '

Replacing temp. (Cylinder h1:1ad side) . . 9 0?C 1 94 °F
.:• valve Valve overall length STD . 98.'1 5 mm 3.8642 in.
97.75 mm 3.8484 in.
·vaive' iac; arih1e ·· 44.5' .
°
Steih dlarrietir . Intake 5.970 - 5.985 mm 0.23 5() . - .0.2356 ln. '
·"b.234'8. _;,6;2354 in.
c:
Exhaust · 5 .965 - 5:980 ninf . ; ·: __ 9q�:z. tEJJtX.f'. ; ·
STD · intake . . 0,025 - 0.060 mm 0,90,1 0 ..:. 0.0024 in.
Exhaust 0.030 - <1.065 mm 0.001 2 - 0.0026 In.
Limit Intake 0'. 08 mrn . J).603 in. f
. Exhaust 0. 1 0 mm O,.QQ39 in.
Valve margin .thickness STD 1.3 mm C>.61,5 1 in.
Limit 0.5 mm 6.qio in.
Valve spring Free length 4 1 .64 mrtr,1.';, .6394 in.
Installed height 35 mm ; 1 .37 8 in.
Installed load at 35 mm (1 .378 in.)
' STD 1 6 kg 3 5 lb 1 57 N
Squareness · umit · ,:g'\nm 0.05 9 in.
Valve lifter Lifter diameter SJD 27.975 - 27.985 mm 1 . 1 0 1 4 - 1 . 1 0 1 8 in.
Oil clearance STD 0.0 1 5 - 0.046 mm 0.0006 - 0.00 1 8 in.
0:1 0 mm · 0.0039 in;
· SERVICE SPECIFICATIONS - Engine Mechanical
Specifications (Cont'd)
Intake. exhaust Warpage
manifold and Intake Limit 0. 1 0 mm 0.0039 in.
intake chamber
Exhaust 7M-GE Limit 0.75 mm · 0.0295 in.
7M-GTE Limit 0.50 mm 0.0 1 97 in.
Intake chamber Limit 0. 1 0 mm 0.0039 in.
Camshaft Thrust clearance STD 0.08 - 0.1 9 mm 0.003 1 - 0.0075 in.
Limit 0.30 mm 0.01 1 0 in.
Journal oil clearance
No. 1 STD 0.035 - 0.072 mm 0.00 1 4 - 0.0020 in.
Limit 0.1 3 mm 0.005 1 in.
No. 2 - No. 7 STD 0.025 - 0.093 mm 0.00 1 0 - 0.0037 in.
Limit 0.1 3 mm 0.005 1 in.
Journal diameter No. 1 STD 26.949 - 26.965 mm 1 .06 1 0 - 1 .06 1 6 in.
No. 2 - No. 7 STD 26.888 - 26.975 mm 1 .0586 - 1 .0620 in.
Circle runout Limit 0.03 mm 0.001 2 in.
,,.,. , Cam lobe height
Intake 7M-GE (MA) STD 38.3 6 mm 1 .5 1 02 in.
Limit 3 8.00 mm 1 .496 1 in.
7M-GE (MS) STD 38.1 6 mm 1 .5024 in.
Limit 37.85 mm 1 .4901 in.
7M-GTE STD 38.35 mm 1 .5098 in.
Limit 38.00 mm 1 .496 1 in.
Exhaust 7M-GE (MA) STD 38.36 mm 1 .5 1 02 in.
Limit 38.00 mm 1 .496 1 in.
Others STD 38.35 mm 1 .5098 in.
Limit 38.00 mm 1 .496 1 in.
Idler pulley Free length 69 mm 2.72 in.
tension spring
Cylinder block Cylinder head surface warpage Limit 0.05 mm 0.0020 in.
Cylinder bore STD STD 82.99 - 83.04 mm 3.2673 - 3.2693 in.
Limit 83.24 mm 3.2772 in.
0/S 0.50 Limit 83.74 mm 3.2968 in.
Cylinder block main journal bore
,
STD Mark 1 64.024 - 64.030 mm 2.5206 - 2.5209 in.
.. Mark 2 64.03 1 - 64.036 mm 2.5209 - 2.52 1 1 in.
Mark 3 64.037 - 64.042 mm 2.52 1 1 - 2.52 1 3 in.
U/S 0.25 64.022 - 64.046 mm 2.5205 - 2.5 2 1 5 in.
Piston and Piston diameter 7M-GE STD 82.90 - 8 2.9 5 mm 3.2638 - 3.26 58 in.
piston ring 0/S 0.50 83.40 - 83.45 mm 3.2835 - 3.2854 in.
7 M-GTE STD 8 2.9 1 - 82.96 mm 3.2642 - 3.266 1 in.
0/S 0.50 83.4 1 - 83.46 mm 3.2839 - 3.2858 in.
Piston oil clearance 7M-GE STD 0.08 - 0.1 0 mm 0.003 1 - 0.0039 in.
Limit 0.1 3 mm 0.00 5 1 in.
7 M-GTE STD 0.07 - 0.09 mm 0.0028 - 0.0035 in.
Limit 0.1 3 mm 0.00 5 1 in.
Piston ring end gap
No. 1 STD 0.29 - 0.44 mm 0.01 1 4 - 0.0 1 73 in.
Limit 0.74 mm 0.029 1 in.
No. 2 STD 0.25 - 0.53 mm 0.0098 - 0.0209 in.
Limit 1 .1 3 mm 0.0445 in.
Oil STD 0. 1 0 - 0.44 mm 0.0039 - 0.0 1 13 in.
Limit 1 .04 mm 0.0409 in.
SERVICE SPECIFICATIONS - Engine. Mechanical A-5
· l:'iston and 7M-GE (w/ TWC)
: piston ring No. 1 STD 0.23 - 0.38 mm 0.009 1 - 0.0 1 50. in.
(Cont'd)
Limit 0.68 mm 0.0268 in.
No. 2 STD 0.25 - 0.53 mm 0.0098 - 0.0209 in.
Limit 1 . 1 3 mm , 0.005 1 in.
Oil STD 0. 1 0 - 0.40 mm p.0039 - 0.01 5 7 in.
Limit 1 .00 mm · 0.0394 in.
Piston ring groove clearance
No. 1 Limit 0.03 - 0.07 mm 0.00 1 2 - 0.0028 in.
No. 2 Limit 0.02 - 0.06 mm 0.0008 - Q.0924 in.
Connecting rod Thrust clearance STD 0.1 60 - 0.296 mm 0.0063 - cf6L1 1 in.
and bearing ·· Limit 0.3 mm 0.0 1 2 in.
Big end inner diameter
STD Mark 1 5 5.0 1 5 - 5 5.025 mm 2. 1 65 9 - 2.1 663 in,
Mark 2 5 5.026 - 55.035 rilrri ' 2. 1 664 - 2.1 667 in.
.
( •,.
\
Mark 3 55 .036 - 55.045 mm 2. 1 66 8 ".'.". 2. 1 67J in.,
U/S 0.25 55.0 1 5 - 55.045 mm 2.1 6 5 9 - 2. 1 67 1 in.
Connecting rod bearing center wall thickness
STD .. Mark 1 . . .... .. . l.490. - 1.495 mm. .0.0.5 87 """.. 0,0589 in.
Mark 2 1 ,496 """. -1.500
. "
mm 0,()58 9 - 0.059 1 in .
Mark 3 1 .501 - ·1 .p,0 S1 ,mm, ,.;9,9?9r .,. 0.0593 in.
Mark 4 1.5,Q� .7 1-5. H::>; _r;nrn. 1,<>,,0_593. - o.o.!5 94 in.
Mark 5 1 .5 1 1 - 1 .5 1 5 mm 0.Q,5�5 - 0,0!5�.6 in.
U/S 0.25 1 .622 - 1 .632 mm .o.o�.39. - ()i0643 in.
Bearing oil clearance STD 0.02 1 ·;.,. 0.053 mm o.ooqa - .o.opi 1 jn.
Limit 0.07 mm , 0.QQ28 in"
Busing inside diameter 22.Q0!5 - 22.Q,1 7 mm 01_8 663 - ():866� in.
Piston pin oil clearance STD 0.005 -. 0.0 1 1 mm 0.0002.. - 0.0004 in.
Limit 0.-02 mm 0.0008 in,
Piston pin diameter 21.99e ..,. 22.009 mm 0.8660 .,.. 0.866 5 in.
Rod be.nd Limit per 1 00 mm (3.94 in.l 0.05 mm 0.0020 in.
Rod twist Limit p�r 1 00 m m · (3.94 in.l 0. 1 5 mm 0.005 9 in.
Crankshaft and Thrust clearance STD 0.05 - 0.25 mm 0..0020 - 0.0098 in.
bearing Limit 0.30 mm 0.011 8 in.
Thrust.washer thickness STD 2.925 - 2.975 mm 0•.1 1 52 - 0. 1 1 7 1 in.
0/5 0. 1 25 2.988 � 3,038 mm 0.1 1 76 - 0.1 1 96 in.
Main journal oil clearance STD 0.030 - 0.048 mm 0.001 2 - 0.00 1 9 in.
Limit 0.07 mm 0,0028 in.
Mainjournal diameter
STD Mark 0 60.007 - 60.0 1 2 mm 2.3625 """. 2.3627 in.
Mark 1 60.001 - 60.006 mm .2:3622 - 2.3624)n.
Mark 2 59.994 - 60.000 mm 2.3620 - 2.3 efi in.
U/S 0.25 5 9.730 - 59.740 mm 2.35 1 6 - 2.? 5.2 0 in.
Main bearing center wall thickness
STp Mark 1 1 .988 - 1 .9 9 1 mm 0.0783 - 0.0784 in. .
Mark 2 1 .992 - 1 .994 mm 0.0784 - o.q7,8Jt in..
Mark 3 1 .995 - 1 .997 mm 0.0785 ··;_; · 0:0786 'iii.
Mark 4 1 .998 - 2.000 mm 0.0787 - 0.0787 in.
Mark 5 2.00 1 - 2.003 mm 0.0788 - Ct9?�.� J°': .
U/S 0.25 2. 1 23 - 2. 1 33 mm 0.0836 - 0,0840 in.
A-6 SERVICE SPECIFICATIONS - Engine Mechanical
Specifications {Cont'd)
Crankshaft and Crank pin diameter STD Mark 0 5 1 .993 - 52.000 mm 2.04 70 - 2.0472 in.
bearing Mark 1 5 1 .985 - 5 1 .992 mm 2.0466 � 2.0469 in.
(Cont'd)
Mark 2 5 1 .9 7 6 - 5 1 .984 mm 2.0463 - 2.0466 in.
UIS 0.25 5 1 .7 2 5 - 5 1 .735 mm 2.0364 - 2.0368 in.
.
Circle runout Limit 0.06 mm 0.0024 in.
Main journal taper and out-of-round
Limit 0.02 mm 0.0008 in.
Check pin journal taper and out-of-round
Limit 0.02 mm 0.0008 in.
Pump drive Thrust clearance . . STD 0.06 - 0.1 3 mm 0.0024 - 0.005 1 in.
shaft Limit · 0.30 mm 0.01 1 8 in.
Oil clearance STD 0.025 - 0.066 mm 0.001 0 - 0.0026 in.
Limit 0.08 mm 0.0031 in. ,'
Journal diameter Front 40.95 9 - 40.9 7 5 mm 1 .6 1 26 - 1 .6 1 32 in.

I Rear 32.959 - 32.975 mm 1 .2976 - 1 .2982 in.
Torque Specifications
Part tightened kg-cm ft-lb N·m
Camshaft timing pulley x Camshaft 500 36 49
Oil pump drive pulley x Oil pump drive shaft 220 16 22
Crankshaft x Crank pulley 2,700 1 95 265
Crankshaft x Flywheel 750 54 74
Crankshaft x Drive plate 750 54 74
Air intake chamber x Intake manifold 1 80 13 18
Air intake chamber x Air intake connector (7M-GE) 1 80 13 18
Throttle body x Air intake connector 1 30 9 13
Cylinder head x No. 1 and No. 2 cylinder head cover 25 22 in.-lb 2.5
Cylinder head x No. 3 cylinder head cover 1 80 13 18
Cylinder head x Cylinder block 800 58 78
Cylinder head x Spark plug 1 80 13 18
Cylinder head x No. 2 engine hanger 400 29 39
Cylinder head x Heat union 600 43 59
Cylinder head x EGR cooler 1 40 10 . 14
Cylinder head x Camshaft bearing cap 200 14 20
Cylinder head x Intake manifold 1 80 13 18
Cylinder head x Delivery pipe 1 80 13 18
Cylinder head x Exhaust manifold 400 29 39
Cylinder head x Distributor (7M-GE) 1 40 10 14
Cylinder head x Cam position sensor 17M-GTE) 1 40 10 14
Connecting rod cap x Connecting rod 650 47 64
Cylinder block x Main bearing cap 1 ,040 75 1 02
Cylinder block x Oil nozzle 250 18 25
Cylinder block x Timing belt case x Idler pulley 500 36 49
Cylinder block x Oil pump drive shaft thrust plate 1 45 11 14
�-
ti
if
A-7
Specifications
'. . ' . '-•\ ',
.
. . • ·.
J;;: Turbocharger Turbocharging pre�sure . M/T STD 0.39 - 0.53 kg/cm2
i;
!· '· . ..
'A/T STD
(5.5 - 7.5 psi, 3 8 - 5 2 kPa)
0.34 - (142 kg/crn2
it Bearing shaft �xial play · .. .�TO
(4.8 - 6.0 psi, 33 - 4 1 kPa)
0.1 3 mm (0.005 1 in.) or: less
Torque specifications
' :i" :
Part tightened '

kg-cm. ft-lb . : ;ciNr·m· •
Turbocharger X Turbin outlet elbow 440 32 43
Oil pipe x Turbocharger 1 30 9 13
Water pipe x Turbocharger , ., . 75 6 5 in.-lb 7.4
Oil pipe x Cylinder block (Bolt) 350 25 34
Oil pipe x Cylinder block (Nut) 1 30 9 13 ,�.
Turbocharger stay x Tu!bocharger 810 59 79
i Turbocharger stay x Enginfmounting bracket 590 43 58
Turb�charg�r. x E�haust manifold ·' 450 33 44
Front . exhallst_ pipe x Turbocharger 630 46 62
EFI SYSTEM
· Specifications
Fuel pressure Fuel pressure at No vacuum
.. . ' .'
2.3 - 2.8 kg/cm2
regulator )\/ ..... . -, (3� - 40 psi, 275 kPa)
Cold start Resistance \
.2 - 4 n
injector . . . Fuel leakage One drop or less per minute
Injector Resistance 7 M-GE .·1 .if- 3.4 n
7M-GTE 2.0··- 3.8 n
Injection volume 7 M-GE 55··... 80 cc (4.0 - 4.9 cu in.) per 1 5 sec.
j- 7M-GTE
..
or ;_ ·,
1 1 4 cc
;:
(6.2
'�
- 7.0 cu in.)
.
per 1 5 sec.
1 ,; Difference between eac:h injector 9 cc . (0.5 cu in.) or less
Fuel leakage One drop or less per minute
Throttle Clearance between stop
position sensor screw and lever Between terminals Resistance
7M-GE 7 M-GTE
0 mm (0 in.l VT'PI. - E2 0.3 - 6.3 k O
.0.40 mm,(O,Pl57 in.I 0.5, mm (0,01 97 inJ IQ,!,.: ":"' E2 Less than 2.3 kO
0.75 ·mm {(l0295 int) .1 0;9 ·- mm.(0.0354 in.) · AOL . -,. E2 00
vc
Throttle valve fully VTA ,.. E2 3.5 - 1 0.3 kO
opened position
.,, · .•
- E2 4.25 - 8.25 kO
__
ISC valve Resistance B 1 - S 1 or S3 1 0 - 30 n

B2 - S2 or S4 1 0 - 30 n
Solenoid Resistance No. 1 0
resistor +B - I 3 n each
No. 30
SERVICE SPECIFICATIONS -· EFI System
�ee.cifications (Cont'd)
. Cold . jtart Resistance w/ TWC STA - STJ 25 - 50 n below 1 5 ° C (59 ° F)

-�i nJector n
· ··time switch . ;'
STA - Ground
60
25
-
-
85
85 n -
above 30° C (86 ° F).
\��-
Resistance w/o TWC STA - STJ 20 - 40 n below 30° C (86 °F)

n
-
40 - 60 above 40° C ( 1 04 °F)
STA - Ground 20 - so n '
n
. ' " "·"•" .
Fuel pump Resistance Approx. 0.7

Resistor
. V$V (FPU) Resistance 30 - 50 n
. Air flow meter Resistance 7M-GE E2 - VS 20 - 600 n
(Measuring plate fully closed)
20 - 1 ,200 n
(Measuring plate fully open)
E2 - VC 200 - 400 n
E 1 - FC Infinity
(Measuring plate fully closed)
Zero
(Other than closed position)
E2 - THA 1 0 - 20 k!l at ...:.20 ° c (-4°F)
4 - 7 k!l at 0 °C (32 ° Ff
2 - 3 k!l at 20 °c (68 °F)
0.9 - 1 .3 k!l at 40 ° C (1 04° Fl
0.4 - 0.7 k!l at 60°C ( 1 40 °F)
7M-GTE KS - E1 00
E 1 - KS 5 - 1 0 k!l
VC - E1 1 0 - 1 5 k!l
E 1 - VC 5 - 1 0 k!l
E2 - THA 1 0 - 20 k!l at -20° C (-4° F)
4 - 7 k!l at 0° C (32 °F)
2 - 3 k!l at 20 °c (68 ° F)
0.9 - 1 .3 k !l at 40°c (1 04°F)
0.4 - 0.7 k !l a t 60 °C ( 1 40 ° F}
· Water temp. Resistance 1 0 - 20 kfi • at -20° C (-4° F)
sensor 4 - 7 k!l ' at 0 ° C (32 ° F)
2 - 3 k!l at 20°c (68 °F)
,
0.9 - 1 .3 k!l at 40 °C (1 04 °F)
0.4 - 0.7 k !l at 60°C (1 40°F)
0.2 - 0.4 k!l at 80°C ( 1 76 °F)
ECU NOTE:
'·
• Perform all voltage and resistance measurements with the computer connected.
• Verity that the battery voltage is 1 i V or above with the ignition switch is ON.
Voltage
Terminals Condition STD voltage . (V)
BATT - E 1
I G S/W - E 1
. M-REL - E 1 Ignition S/W ON 10 - 14

+ B (+B 1 ) _ E 1
B (B1 ) ··· ·
�--·--·---"--'-�-��-,
.... . ·- · · ·--•- - . ... . ;,
Sl:FIVICE SPECIFICATIONS_ � . !:Fl'.Syst�m
-
ECU (Cont'd) Terminals . . Cond,tion STD voltage W)
IDL E2 - 14
-
Throttle valve open 10
vc (VCC) - E2 -; .
,i
4-6
0.1 - 1 .0
Ignition S/W ON ' '' '
:n�rC?!t,W valve full\, closed
. · .;.· , , .
' VTA - E2
4-6
;·i
Throute valve; fuUy·open

4-
' . •.-. . . i . �--· .
-
.. . . Meas�rlng ·ptate·�fully closed
Ignition S/W ON ,. . .-.. '" ,'''- ·' ....,, _ _ __ C., .,. ·. ;,_,,, .
•1 vs - E2 Measuring plattqµny QP81'1 _ 0.02

-4
0.08
.. - ··Idling·
-, .. 2
0.3 - 1 .0
·- -·-
3,000 rpm ,.... -� J
4-6
.. .,,, ,., !\ }�
toN ""' ""•' . · · .
2
.*. KS - E2 lg nltiOtfS/W
' '_ ; \, ,, ·---� -::�-!'�t"'t- _:,, ·'.; -�-- "'' . ..
< <-
2 -4
.9r�tttilrt,; .. -
,,_,.., ....,
- -
Cranking � 'c:'·
f, '""'. ,, ':,
vc E2 Ignition S/WJON :.C'S.. : 4 6

;.;, , : ·
THA - E2 -
. / , .•, -,�,�> ·
Ignition S/W ON Intake air 1ertiperature� 20�C (68 F) °
1
THW - E2 0. 1 - 1 .0
• ",• • """ 1, . ,·•. ···�• ''•'$.';--';. ';.(I":
Ignition S/W ON Coolant tempe�tUre BO�C (1 76 °F)

',
-
··· .;� \!�
, ¾c ., , I ;
:;, ' - � .
,. S t">--.,: l'.\ i . 't -..,•"
No. 20 -
No. 1 0 E0 1 ._.
Ig. nitlor
---
. . . S/Wo�i
··· · t-· . . 9
t
14
E02 -
-
No. 30 --, ..
¥ s-;:., : .J
-. .... - ... •-• .... .. •-- ...
STA - E 1 Cranking =, -fi, --�-"·-i-!A", 6
, .., ��"' ""
14
-
•..,
. ,., , -
- E1
ISC 1
l Ignition S/W
..
oN 9 - 14
ISC4 .--_ ,:-:;s,; :� : ,
IGF, IGT - E 1
'••- ""'~ • •
C' "i.
0, 7 ' - 1 .0
-
· tctlinQ~-�: ., _ _
j
,. .., .
I
" '"
Idling 1
·-·; ' ,,··�· �· -.... ,,,q
1 GdA, IGdB - E 1 3
1 .s,
2
• rnCJ1 rnut::),i ,,,,, .::;
- --- 54C:i'mrn g
• HAC
2 - E2 Ignition S/W ON
H t2T2sii,.Flt"1·Jz.�f k
' '" ,. ' •P.ar-·
7 6 0 mmHg ( 1 29.5�\19.!JlgiJ1�Q.©·kPa
' . , ...... ➔�
Approx. 2.8
Approx. 3.6
w - E1 No trouble ("CHECK ENGI
• '
engine running
_Nr��wajnlff(flig'flfoffrand . ,,
••· -.-. . '·'"'''' ,,, • L
. r:t til',t ,-,,;
9 4
'" - Nc ''::ir �',.� ��:r;'t�."
-
·. - -
A/C - E 1 -
"•/4 ••,c>
•.
8 ,.. .. .
Air ·cori�iti6h1nf��':f, '::� ,: );
-- · 1 0 1 4 '.: .>L · -� , --
Check �onnect�;'-'
.., "' ,::
•' ::fre:,') ::_: ,E1-- not
T - E1 sho rt - ' f
_: ,.. 4. - 6
Ignition S/W ON
-:.-:nr.Y :.,.-1'
Check connectot'f 'fre11

'. .' ,: ::·· .. '"" ' ' ··- �. -,.,t,_..•"i!ifi,'":·, ,.,,,. ,._,_. .., ; , i ,1 :, ,··;
\:::"e{ sfi'orf .. _; . ._·, .
0
•aNSW (A/T) - E1 Ignition S/W ON

S hift po�itic:m, Pi1;.Qr,:tfi�ng�; <
Ex. P or -N range· "'
,; · 0
1 0 ...,. 1 4
-
. ,,....��·�----,·--"-
•sN/ C (M/T) - E1 Ignition S/W ON

Clutch peclalnot .depressed
Clutch pedal depressed 10
0
- 14
10 - 14
*8 DFG - E1 Ignition S/W ON
Defogger S/W OFF
Defogger S/W ON 0
- E1 Headlight S/W OFF 10 - 14

•
8
LP
Headlight S/W ON 0
•1 7M-GE only
-- -- ,. --- t
SERVICE SPECIFICATIONS· .:.:. EFI· System
•:,n :�t�;�f I �.:? ( . '
- <_EGIJ·(Cont'd) Resistance .
' . .
. - -� , ,, . ' ' .,., Terminals Condition Resistance (n)
Throttle valve open 00

IDLE - E2 ·; ' '
I · . Throttle valve fully closed Less than 2,300

,.
' -,� """ '

Throttle valve fully open · 3,500 -- 1 0,300
VTA - E2
. ,.
.
. Throttle valve fully closed 300 - 6,300
i
VC (VCC) - E2
,. .
- 200 - 400
., .. .. Measuring plate fully closed 20 - 600
'.
•
1
vs - E2
· Measuring plate fully open 20 - 1 ,200
2
KS - E 1 - '
-
• 00
e1 - KS
2
5,000 - 1 0,000
-
•
'
( '":>.
•2vc - E t . 1 0,000 - 1 5,000
•2e 1 - ve t
- '
5 ,000 - 1 0,000
.,. .
THA - E2 Intake air temperature 20 °C (68° F) 2,000 - 3,000
THW - E 2 , ,, Coolant temperature 80 C ( 1 7 6 F) ° °
200 - 400
G 1 , G2 - G - -
NE - G - - 1 40 ,- 1 80
ISC 1 , ISC2
ISC3, ISC4
- +B - 1 0 - 30
· *2 HAC - E2 - 2,900 - 4,200

,., Fuel cut rpm Fuel cut rpm 1 ,800 rpm
Fuel re!urn rpm 1 ,200 rpm
' c' ,
*1 7M-GE only
�2 7M-GTE only
r<>,tque Specific_a tions

. ..
. .
.- .· �
.
Ftiel ptmp X Fuel tank 35 30 in.-lb 3 .4

,,., .
· · Coh;I start injector x Intake chamber 55 48 in.-lb 5.4
.,
Pressure regulator x Delivery pipe 250 18 25
. N<:1, 2 Ju.�I pipe x Pressure regulator 250 18 25
\' , pulsation damper x Delivery pipe 400 29 39
!
I
SERVICE SPECIFICATIONS - EFI System, Cooling System, Lubrication System A-1 1
Torque Specifications (Cont'd) __

Part tightened kg-cm .. ft-,lb N·m
, ,- Cold start injector tube x Delivery pipe
..
300 22 29
r ·.
! Cold start injector tube x Cold start injector 1 80 13 1. €3
No. 1 fuel pipe x Fuel pipe support 300 22 29 .
j ISC valve x Intake chamber 1 30 9 ,q
Air intake connector x Intake chamber 1 80 13 ,1 8
Throttle body x Air intake connector 1 30 9 ,., ;> 1,:t,
COOLING SYSTEM
Specifications
Engine coolant capacity See page A-2

Thermostat Valve opening temperature 86 ... 90"C 1 87 - 1 94 °F
·/
•.. -·
Valve lift at 1 00 ° C (21 2 °F) 8 mm (0.3 1 in.) or more. ·•
Radiator Relief valve opening pressure STD 0.75 - 1 .05 kg/cm2

(1 0.7 - 1 4.9 psi, 74 - 1 03 kPa)
limit 0.6 kg/cm2 8.5 psi 59 kPa
Torque Specifications
Drain plug 300 22 29
Water outlet x Water outlet housing 65 56 in.-lb 6.4
Water pump x ·Cylinder block 1 80 13 18
LUBRICATION SYSTEM
Specifications
Engine oil capacity

',/ ,. See page A-2
.. ···.
Oil pressure a�1 ldje, speed

at 3,000 rpm 1-1 � 15, r- 5.0 kg/cm 36
2 -
0.3 kg/cm2 (4.3 psi: 29 kPa) or more
7 1 psi 245 - 490 kPa
Oil pump Body clearance -, STD -
0.1 05 0.1 75 mm
..
0.0041 - 0.0069 in..
0.2 i-pij\, :/ ;,;, ·
-
.�.. "''
Limit
, ·:;.
0.008 in .
Side clearance �TD •9;9� t- 0.09 mm 0.00 1 2 0.0035 in.
,Limit
.-. >�-·'
0.1 5 mm 0.0059 in.
Gear backlash STD -. Q,5,
'--�
.· -:'· 0.6 mm 0.020 - 0.024 in.
limit o,.� ,lllffl ·.·•
0.035 in.
-
Wor:que Specifications
' __.,_-�-,,.••••F-•�-� <' < -• ••, • •••••• . .. " .
L�" c- ,.�:�_,,; .. .
1.
Engine 0H drain plug 350 25 34
, Oil purrl� cover x Oil pump body 75 65 in.-lb 7.4
Relief �alve x Oil pump cover 375 27 37
Oil pump strainer x Oil pump body (MA only) 1 30 9 13
Oil pump x Cylin(ler block 220 16 22
i: OiLpump strainer x Cylinder block (MA only) 6,0 52 in.-lb 5'.9
011 pump outlet pipe x Oil pump 350 25 34
Oil pump outlet pipe x Union 350 25 34
Oil pan x Cylinder block 1 30 9 13
Oil pressure regulator x Cylinder block (7M-GE only) 1 45 10 14
· Oir pressure regulator plug . 375 27 37
Oil filter bracket x Cylinder block 500 36 49
• IGNITION SYSTEM
Ignition timing 1 0° BTDC @ idle
[w/ Terminals T (TE 1) and E1 _s hort-circuit]
Firing order 1 - 5 - 3 - 6 - 2 -4
High-tension Resistance Limit 25 kfi per cord
cord
Spark plug Conventional tipped type
Type ND Q20R-U
NGK BCPR6EY
Air gap 0.8 mm 0.03 1 in.
Platinum tipped type
Type 7M-GE ND PQ1 6R
NGK BCPR5EP1 1
7M-GTE ND PQ20R-P8
NGK BCPR6EP-N8
Air gap 7M-GE STD 1 . 1 mm 0.043 in.
Limit 1 .3 nim 0.05 1 in.
,.
7M.;GTE STD o ..e mm 0;03 1 in.

Limit 1 .0 mm 0.039 in.
lgoitior;i coil Primary coil resistance at cold
7M-GE MA 0.24 - o.3o n
MS 0.41 - 0;50 n
7M-GTE o.3 - o.5 n
Secondary coil resistance
7M-GE MA 9.2 - 1 2 .4 kfi
MS 1 0.2 - 1 3.8 kO
Distributor Air gap NE, G1 and G2 Pickups 0.2 - 0.4 mm 0.008 - 0.0 1 6 in.
(7M-GE) or Pickup coil resistance
can position
sensor NE, G1 and G2 Pickups · 1 40 - 1 00 n
(7M-GTE)
SERVICE SPECIFICATIUN:S - �tarting .:,y::m:111 1, '"'1 101
y
11 1
y
� , ... .... . . . ·
STARTING SYSTEM
Starter Rated voltage and ciutput power
No-load characteristic Ampere
1 2 V 1 .0 kW
90 A or less a.t .1 1 .5 V
3,000 r·pm or more
-
1 2 V 1 .4 kW
rpm 3,500 rpm or more

Brush Lengtf:! STD 1 3.5 mm 0.5 3 1 in. 1 5.5 mm 0.6 1 0 in.
--
Limit 8.5 mm 0.335 in. 1 0.0 mm 0.394 in.
Spring installed load STD 1 ,785 - 2,41 5 g
(3.9 - 5.3 lb, 1 7 - 24 N)
Limit 1 .2 kg 2.6 lb 12N
Commutator
Outer diameter STD 30 mm 1 .1 8 in.
.,
--
Undercut depth
Limit
STD
29 mm
0.6 mm
1 .1 4 in.
0.024 in. --
Circuit runout
Limit
Limit
0.2 mm
0.05 mm
0.008 in.
0.0020 in. -
CHARG ING SYSTEM
Drive belt tension See page A-2
Battery specific gravity when fully charged at 20 C (68 F)
° °
1 .25 - 1 .27
Alternator Rated output 1 2 V 70 A
Rotor coil resistance 2.8 - '3.0 0
Slip ring diameter STD 1 4.2 - 1 4.4 mm 0.559 - 0.567 in.
Limit 1 2.8 mm 0.504 in.
Brush exposed length STD 1 0.5 mm 0.4 1 3 in.
Limit 1 .5 mm 0.05 9 ln.
Alternator Regulating voltage at 25 ° C (77 ° F) 1 3.9 - 1 5. 1 V
regulator (IC) at 1 1 s 0 c (239° Fl 1'3.5 - 1 4.3 V
____�-:)
- MEMO -
__________________________,::C:..:
y1
SST AND SSM

Page
SST (SPECIAL SERVICE TOOLS! • • • • • • . • • • • • • • • • • • C-2
SSM (SPECIAL SERVICE MATERIALS) • • • , • • • • • • • • C-6
I
C-2 SST AND SSM - SST (Special Service Tools) .SST AND SSM - SST (Special Servlce' Tools)
SST (SPECIAL SERVICE TOOLS) SST (S PECIAL SERVICE TOOLS) (Cont'd)

NOTE: Classification - ,, �
\•
A = SST required for vehicle inspections end minor repairs end Section ,1 ,;;H;;l!cB
multipurpose SST.
Cla111flcatlon , ; C\;/ u :,ilii,l,;1$1:)
B = SST required for major repairs Involving disassembly of com
Part Name EM TC Fl co LU 10 ST CH Notl t ,!i"I
\
ponents.
C = SST required for rather special, less frequent work not of Part No. .nti<'I
classifiable es either A or B. lllustratlon \ , :¥t:u1H
Crlnklhaft Pulley)
•
(
& Gear Raplecoer
09214-80010 · B }
�
•
\
Section
�•II•• amthalt Bearing
Classlficatlon 09216-001111 Remover & Replacer )
c C Drive 1halt bea"'1g
CH 1-------------
.'ft;�
------ -----
Set
---
•
Part Name EM TC Fl co LU IG ST Note
Part No.
Illustration \ �
(09215-00120) !Gata "A"l
09032-00100 (
OIi Pan Seai )
Cutter
A • � (08215-00130) (Botti •
•
·:.,,.,.;
(H•xegon 10 mm)
� 09043-38100 Wrench
A •
i} IOIZ1&-00140l (Null
-
�
;
09166-18100 ($park Plug Wrench> A . • �
(0921&-1111110) !Pini •
�
08201-41020
( Valve Siem OU)
Seal Replacer
B • •• • siartar front bearing
for 1.4 kW only
� (08215-00210) tRemover & Replacer! •
� 09201-70010
{Valve Guida Bushing)
Remover & Replacer
B •
e (08215-11112201 (Remover & Replecerl •
�
011202-70010 ( Valve Spring )
Compressor
A .
�
09218-80020 fllalt Tenolon Ga�l A • •
�
011213-31021
{ Crankshaft Pulley)
Puller
A .
�
0821&-IJDll30 (Ben Tanalon Cable) A • •
'@ � (
Crankshaft Pulley )
1Connecting Rod
lltJ8hing Remover ) •
�--�-
Puller
Ofl213-640l4 A • MS 09222-30010 B
� ;;;a,,- � , & Replacer
--.. -=,., -.:=.

-=:,.. -::::,.. -;::. -;:.
1111213-110017
( Crankshaft Pulley )
& Gaar Pulley Set
A .
®-' 08221-41 020 (
Cranklheft Rear )
OU Saal Replacer
B •
�
09213-70010
( Crankshall Pulley )
Holding Tool
A • MA
�
09223-&0010 (
Crank1halt Front )
OII Saal R�
B • Camthalt ol 1"81
�
09214-41010
( Crankshaft Damper)
& Geer Replacer
B • OllpumpoN nal
�
08228-07600 (Oil FIiter Wrench) A •
C-4 SST AND SSM - SST (Special Service Tools) ·
SST A, . J ssM - SST (Special Service Tools), SSM (Special Service Materials)
SST (SPECIAL SERVICE TOO LS) (Cont'd) SST (SPECIAL SERVICE TOOLS) (Cont'd)
\ \
Section Section
Classification Classification
Part Name EM TC Fl co LU IG ST CH Note Part Name E M TC Fl co LU IG ST CH Note
Part No.
\ Part No.
\
�,
\ \
•
Illustration lllustratlon
�
�j��
.Re_
09230-00010
( Radiator Service)
Tool Set
B
�lm� 09814-20010
( Outer Rear View )
Mirror Wrench
C • Cold 11art Injector
time 1wltch
09243-00020
( Idle Adjusting )
Screw Wrench
A • �
Alternator Rear
08820-00021 (Bearing Puller ) B •
�
09248-6601 0
(Valve Clearance )
Adjusting Tool Set
A • () � 09820-83010
( Alternator Pulley Set)
Nut Wrench Set
B •
:it:;:� ::_�.
� -llv> ,�
=
�J.� �-'�� ..
')
09288-41045 (
Injection Measuring )
Tool Set
B • tt (1111142-30050
( Wiring "A" EFI)
Inspection
B • :
�,,��
��
09268-45012 (
EFI Fuel Pressure
Gauge
) A • �
09842-30080
( Wiring "E" EFI)
lnapectlon
B •
•
·�
� ;, 08278-54012
(Drive Shaft Holding)
Tool
A
Camshaft timing
pulley
� 09923-0001 0 (Hexagon Wrench) B •
(CkJJ.<//�)·;i;;·· --.r.1'',� 09286-76010
Infection Pump
( Camshaft Bearing ) C ••
•1 •2 d Starter front bearing
for 1.D kW only
.. I\Jnlveroal Puller) •
v
.a Rotor rear bearing
099&i.-20017 B
Cone Repklcer
��-o-.
��
�
09286-4801 1
( Injection Pump
Spline Shaft Puller
)
C ••
•1 • 2 •1 Starter bearing
•1 R�ctifier end frame
900 09992-00241 (
Turbocharger )
Pressure Gauge
C • 7M-GTE
�
09308-65010 IOU Saal Puller) A •
�
09330-00021
( Companion Flange)
Holding Tool
A • SSM (SPECIAL SERVICE MATERIALS)
�
09608-35010
Diflorontiel Drive
( Pinion Rear Bearing )
Replacer
B • Crankshaft front oil
seal Part Name Part No. Sec. Use etc.
"'@@ Q
09808-20012
�-------------- ------- -- . --------
nt Hub &
Drive Pinion Bearing )
C°
Tool Sat
B • Over the space between the timing
belt case and cylinder block
•
�-@@@
EM Cylinder head x No. 1 and No. 2
Seal packing or equivalent 08B26-000BO cylinder head cover
(Raplacer) Rotor front bearing
@ (09808-00030) Cylinder head x No. 1 camshaft
bearing cap
�
09831-22020 c
ower Steering
Hose Nut 1 4 x 1 7 )
Wrench.Set
A • Fuel line flare nut
Adhesive 1 324,
Three bond 1 324 or equivalent
0B833-00070
LU
EM
Engine oil pan
Timing belt case mounting
bolt ( 1 0 mm)

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What systems are covered in the manual?

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TOYOTA

© 1996 TOYOTA MOTOR CORPORATION

HOW TO USE THIS MANUAL

TROUBLESHOOTING tables are included for each system to

175 (66 ln.-lb, 7.4) !1----:13

The procedures are presented in a step-by-ste format:

Detail text: how to do it

This format provides the experienced techni ian with a FAST

WARNINGS, CAUTIONS, NOTE

GENERAL REPAIR INSTRUCTIONS

2. During disassembly, keep parts in order to facilitate

3. Observe the following:

4. Check hose and wiring connectors to make sure that they

etc. with new ones.

illustrations by the "*" symbol.

7. When necessary, use a sealer or gaskets to prevent leaks.

9. Use of special service tools (SST) and special service

(c} When disconnecting vacuum hoses, pull on the end

Engine will not start/ Vacuum leaks Repair as necessary

(cranks OK) • (w/ EGR)

TRO UBLESHOOTING (Cont'd)

Unpleasant odor Incorrect idle speed Check ISC system Fl- 1 08

I NSPECTION OF ENG INE OIL

INSPECTION OF. AIR FILTER

INSPECTION OF HIGH-TENSION CORDS

I NSPECTION OF SPARK PLUGS

INSPECTION OF DRIVE BELT

INSPECTION AND ADJUSTMENT OF VALVE

, {b) (ex. MS RHO)

(g) Remove the air intake connector bracket mounting

2. REMOVE CYLINDER HEAD COVERS

3. MEAS URE VALVE CLEARANCI:

(c) Turn the crankshaft pulley 2/3 revolution (240° ) and

;� ·.. · . . . . • Check that the valve lifters on the No. 3 cylinder

{d) Turn the crankshaft pulley 2/3 revolution (240 °) and

4. ADJUST VA LVE CLEARANCE ·

(b) Determine the replacement shim size by using the

(c) Install a new adjusting shim.

5. RECHECK VALVE CLEARANCE

6. INSTALL CYLI N DER HEAD COVERS

7. INSTALL AIR INTAKE CONNECTOR

(b) Install the air intake connector bracket mounting

. , (c) .: Install the throttle body bracket(s).

2. REMOVE PCV PIP! WITH HOSES

3. REMOVE INTAKE AIR CONN ECTOR

4. REMOVE IGN ITION COVER

5. REMOVE IGNITION COIL WITH BRACKET

6. REMOVE CYLIND ER HEAD COVERS

·· 7. M EASURE VALVE CLEARANCE

8. · ADJ UST VALVE CLEARANCE

9, flECH"ECK. VALVE CLEARANCE

1 0. INSTALL CYLIN DER H EAD COVERS

. '.1 ; 1'·1 . . INSTALL IGNITION COIL WITH BRACKET

(c) Install the; No. 1 and No.2 high-tensiQn·tords to igni­

(d) Install and torque the nut

1 2. INSTALL IGN ITION COIL COVER

(c) Install the; No. 1 and No.2 high-tensiQn·tords to igni

(b) Connect the positive (+) probe of a voltmeter to ter