General instructions.

FOREWORD

This manual (Volume 1) contains maintenance and repair procedures for the engine of the 1991 MR2. Applicable models: SW20, 21 series. For repair procedures for the chassis and body, and for electrical service procedures, refer to VOLUME 2 (Pub. No. RM179U2). The manual is divided into 12 sections and 2 appendixes with a thumb index for each section at the edge of the pages. Please note that the publications below have also been prepared as relevant service manuals to the components and systems in this vehicle. All information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without notice.

HOW TO USE THIS MANUAL

See page IN-2

IDENTIFICATION INFORMATION

See page IN-4

GENERAL REPAIR INSTRUCTIONS

See page IN-4

PRECAUTIONS FOR VEHICLES EQUIPPED WITH SRS AIRBAG

See page IN-7

PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER

See page IN-11

PRECAUTIONS FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT-IN ANTI-THEFT SYSTEM

See page IN-11

VEHICLE LIFT AND SUPPORT LOCATIONS

See page IN-12

ABBREVIATIONS USED IN THIS MANUAL

See page IN-13

HOW TO USE THIS MANUAL

To assist you in finding your way through the manual, the Section Title and major heading are given at the top of every page. An INDEX is provided on the first 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 problem and find the cause. The repair for each possible cause is referenced in the remedy column 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. The overview illustration uses torque callouts in kg-cm (ft-lb, N·m) format to indicate specified torque values, and marks non-reusable parts with a diamond symbol.

STEP-BY-STEP FORMAT

The procedures are presented in a step-by-step format: The illustration shows what to do and where 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 and warnings.

REFERENCES

References have been kept to a minimum. However, when they are required you are given the page to refer to.

SPECIFICATIONS

Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Appendix A, for quick reference.

CAUTIONS

CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people.

NOTICES

NOTICES are also presented in bold type, and indicate the possibility of damaged to the components being repaired.

HINTS

HINTS are separated from the text but do not appear in bold. They provide additional information to help you efficiently perform the repair.

USE PROTECTIVE COVERS

Use fender seat and floor covers to keep the vehicle clean and prevent damage.

KEEP PARTS IN ORDER DURING DISASSEMBLY

During disassembly, keep parts in the appropriate order to facilitate reassembly.

OBSERVE BATTERY AND ELECTRICAL SAFETY PRECAUTIONS

Observe the following battery and electrical safety precautions.

• Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (–) terminal cable is disconnected from the battery (See page AB-2).

CHECK HOSE AND WIRING CONNECTORS

Check hose and wiring connectors to make sure that they are secure and correct.

NON-REUSABLE PARTS

Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. Non-reusable parts are indicated in the component illustrations by the "♦" symbol.

PRECOATED PARTS

Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. Precoated parts are indicated in the component illustrations by the "★" symbol.

USE SEALER ON GASKETS

When necessary, use a sealer on gaskets to prevent leaks.

OBSERVE BOLT TIGHTENING TORQUES

Carefully observe all specifications for bolt tightening torques. Always use a torque wrench.

USE SPECIAL SERVICE TOOLS (SST) AND SPECIAL SERVICE MATERIALS (SSM)

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.

REPLACING FUSES

When replacing fuses, be sure the new fuse has the correct amperage rating. DO NOT exceed the rating or use one with a lower rating.

JACKING UP AND SUPPORTING THE VEHICLE

Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (See page IN-12).

DO NOT OPEN ECU COVER OR CASE UNLESS ABSOLUTELY NECESSARY

Do not open the cover or case of the ECU unless absolutely necessary. If the IC terminals are touched, the IC may be destroyed by static electricity.

PULL APART ELECTRICAL CONNECTORS BY THE CONNECTOR ITSELF

To pull apart electrical connectors, pull on the connector itself, not the wires.

DO NOT DROP ELECTRICAL COMPONENTS

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.

INSERT TESTER PROBE CAREFULLY WHEN CHECKING CONTINUITY

When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending.

DISCONNECT VACUUM HOSES FROM THE END

To disconnect vacuum hoses, pull on the end, not the middle of the hose.

PROTECT DISTRIBUTOR, COIL, AIR FILTER AND VCV WHEN STEAM CLEANING

When steam cleaning an engine, protect the distributor, coil, air filter and VCV from water.

NEVER USE IMPACT WRENCH ON TEMPERATURE SWITCHES OR SENSORS

Never use an impact wrench to remove or install temperature switches or temperature sensors.

USE STEP-DOWN ADAPTER WHEN VACUUM GAUGE HOSE IS TOO SMALL

When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter instead. Once the hose has been stretched, it may leak.

TAG HOSES BEFORE DISCONNECTING THEM

When disconnecting vacuum hoses, use tags to identify how they should be reconnected. After completing a job, double check that the vacuum hoses are properly connected. A label under the hood shows the proper layout.

PRECAUTIONS FOR VEHICLES EQUIPPED WITH SRS AIRBAG

The 1991 MR2 for USA specifications is equipped with an SRS (Supplemental Restraint System) airbag. Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the airbag system, it is possible the airbag may fail to operate when required. Before performing servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual.

• Failure to carry out service operations in the correct sequence could cause the airbag system to unexpectedly deploy during servicing, possibly leading to a serious accident.
• If a mistake is made in servicing the airbag system, it is possible the airbag may fail to operate when required.

INSPECT DIAGNOSTIC CODES BEFORE DISCONNECTING BATTERY

Malfunction symptoms of the airbag system are difficult to confirm, so the diagnostic codes become the most important source of information when troubleshooting. When troubleshooting the airbag system, always inspect the diagnostic codes before disconnecting the battery (See page AB-24).

WAIT 20 SECONDS AFTER IGNITION LOCK AND BATTERY DISCONNECT

Work must be started after approx. 20 seconds or loner from the time the ignition switch is turned to the LOCK position and the negative (-) terminal cable is disconnected from the battery. The airbag system is equipped with a back-up power source so that if work is started within 20 seconds of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.

• If work is started within 20 seconds of disconnecting the negative (-) terminal cable of the battery, the airbag may be deployed.

FRONT AIRBAG SENSOR — Never reuse after collision

Never reuse the front airbag sensors involved in a collision when the airbag has deployed. Replace both the left and right airbag sensors.

FRONT AIRBAG SENSOR — Install with arrow facing front

Install the front airbag sensor with the arrow on the sensor facing toward the front of the vehicle.

FRONT AIRBAG SENSOR — Replace set bolts and nuts

The front airbag sensor set bolts and nuts have been anti-rust treated. When the sensor is removed, always replace the set bolts and nuts with new ones.

FRONT AIRBAG SENSOR — Lock electrical connector securely

The front airbag sensor is equipped with an electrical connection check mechanism. Be sure to lock this mechanism securely when connecting the connector. If the connector is not securely locked, a malfunction code will be detected by the diagnosis system (See page AB-9).

SPIRAL CABLE (IN COMBINATION SWITCH)

The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position; otherwise cable disconnection and other troubles may result. Refer to page AB-16 of this manual concerning correct steering wheel installation.

STEERING WHEEL PAD (WITH AIRBAG) — Place pad top surface facing up

When removing the steering wheel pad or handling a new steering wheel pad, it should be placed with the pad top surface facing up. In this case, the twin-lock type connector lock lever should be in the locked state and care should be taken to place it so the connector will not be damaged. And do not store a steering wheel pad on top of another one. (Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason.)

• Storing the pad with its metallic surface up may lead to a serious accident if the airbag inflates for some reason.

STEERING WHEEL PAD (WITH AIRBAG) — Never measure resistance of airbag squib

Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which is very dangerous.

• Never measure the resistance of the airbag squib. This may cause the airbag to deploy, which is very dangerous.

DO NOT APPLY GREASE TO STEERING WHEEL PAD

Grease should not be applied to the steering wheel pad and the pad should not be cleaned with detergents of any kind.

STORE STEERING WHEEL PAD PROPERLY

Store the steering wheel pad where the ambient temperature remains below 90°C (200°F), without high humidity and away from electrical noise.

DISCONNECT AIRBAG CONNECTOR BEFORE ELECTRIC WELDING

When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work.

DEPLOY AIRBAG BEFORE DISPOSAL

When disposing of a vehicle or the steering wheel pad alone, the airbag should be deployed using an SST before disposal (See page AB-82). Perform the operation in a place away from electrical noise.

CENTER AIRBAG SENSOR ASSEMBLY — CONNECT/DISCONNECT WITH SENSOR MOUNTED

The connectors to the center airbag sensor assembly should be connected or disconnected with the sensor mounted on the floor. If the connectors are connected or disconnected while the center airbag sensor assembly is not mounted to the floor, it could cause undesired ignition of the airbag system.

WIRE HARNESS AND CONNECTOR

The airbag system's wire harness is integrated with the cowl wire harness assembly. The wires for the airbag wire harness are encased in a yellow corrugated tube. All the connectors for the system are also a standard yellow color. If the airbag system wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it as shown on page AB-21.

PRECAUTIONS FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER

If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard. To prevent this, observe the following precautions and explain them to your customer.

• If large amounts of unburned gasoline flow into the converter, it may overheat and create a fire hazard.

USE ONLY UNLEADED GASOLINE

Use only unleaded gasoline.

AVOID PROLONGED IDLING

Avoid running the engine at idle speed for more than 20 minutes.

AVOID SPARK JUMP TEST

Spark jump test only when absolutely necessary. Perform this test as rapidly as possible. While testing, never race the engine.

AVOID PROLONGED ENGINE COMPRESSION MEASUREMENT

Engine compression tests must be made as rapidly as possible.

DO NOT RUN ENGINE WHEN FUEL TANK IS NEARLY EMPTY

This may cause the engine to misfire and create an extra load on the converter.

AVOID COASTING WITH IGNITION TURNED OFF AND PROLONGED BRAKING

Avoid coasting with ignition turned off and prolonged braking.

DO NOT DISPOSE OF USED CATALYST ALONG WITH PARTS CONTAMINATED WITH GASOLINE OR OIL

Do not dispose of used catalyst along with parts contaminated with gasoline or oil.

PRECAUTIONS FOR VEHICLES WITH AN AUDIO SYSTEM WITH BUILT-IN ANTI-THEFT SYSTEM

Audio Systems displaying the sign 'ANTI-THEFT SYSTEM' shown on the left has a built-in anti-theft system which makes the audio system soundless if stolen. If the power source for the audio system is cut even once, the anti-theft system operates so that even if the power source is reconnected, the audio system will not produce any sound unless the ID number selected by the customer is input again. Accordingly, when performing repairs on vehicles equipped with this system, before disconnecting the battery terminals or removing the audio system the customer should be asked for the ID number so that the technician can input the ID number afterwards, or else a request made to the customer to input the ID number. For the method to input the ID number or cancel the anti-theft system, refer to the Owner's Manual.

JACK POSITION — FRONT

Jack up support of front under cover center.

JACK POSITION — REAR

Rear suspension crossmember.

PANTOGRAPH JACK POSITION

Use the pantograph jack at the designated pantograph jack position points shown on the underbody diagram.

SUPPORT POSITION — SAFETY STAND

Place safety stands at the support position points indicated by the hatched symbols on the underbody diagram.

ABBREVIATIONS USED IN THIS MANUAL

ABS: Anti-Lock Brake System; A/C: Air Conditioner; Approx.: Approximately; A/T: Automatic Transaxle; ATF: Automatic Transmission Fluid; B1: Second Coast Brake; B2: Second Brake; B3: First and Reverse Brake; B4: Underdrive Brake; BTDC: Before Top Dead Center; BVSV: Bimetal Vacuum Switching Valve; C1: Forward Clutch; C2: Direct Clutch; C3: Underdrive Clutch; CALIF.: Vehicles Sold in California; CB: Circuit Breaker; CD: Compact Disc; DP: Dash Pot; ECT: Electronic Controlled Transaxle; ECU: Electronic Control Unit; EFI: Electronic Fuel Injection; EGR: Exhaust Gas Recirculation; ELR: Emergency Locking Retractor; ESA: Electronic Spark Advance; EVAP: Evaporative (Emission Control); EX: Exhaust (manifold, valve); Ex.: Except; F1: No.1 One-Way Clutch; F2: No.2 One-Way Clutch; F3: Underdrive One-Way Clutch; FIPG: Formed in Place Gasket; FL: Fusible Link; FR, Fr: Front; IN: Intake (manifold, valve); IG: Ignition; ISC: Idle Speed Control; J/B: Junction Block; LED: Light Emitting Diode; LH: Left-Hand; Max.: Maximum; MP: Multipurpose; M/T: Manual Transaxle; OD, O/D: Overdrive; O/S: Oversize; P & BV: Proportioning and Bypass Valve; PCV: Positive Crankcase Ventilation; PS: Power Steering; RH: Right-Hand; Rr: Rear; SRS: Supplemental Restraint System; SSM: Special Service Materials; SST: Special Service Tools; STD: Standard; SW: Switch; TDC: Top Dead Center; T-VIS: Toyota-Variable Induction System; TWC: Three-Way Catalyst; U/D: Underdrive; U/S: Undersize; VSV: Vacuum Switching Valve; w/: With; w/o: Without

MAINTENANCE SCHEDULE SELECTION

The maintenance schedule for the vehicle consists of separate A and B schedules which are applicable depending on the conditions the vehicle is used in. Confirm the vehicle's usage conditions, select the appropriate schedule and service the vehicle accordingly.

PERFORM EVERY SERVICE ITEM

Every service item in the periodic maintenance list must be performed.

REFERENCE PAGES IN SCHEDULE

Next to the columns of periods in the schedule, reference pages have been added for easy access to service data and procedures necessary for each position.

SERVICE INTERVAL BASIS

Periodic maintenance service must be performed according to whichever interval in the periodic maintenance list occurs first, the odometer reading (miles) or the times interval (months).

MAINTENANCE AFTER LAST PERIOD

Maintenance services after the last period should be performed at the same interval as before unless otherwise noted.

IMPORTANCE OF COMPLETE MAINTENANCE

Failure to do even one item can cause the engine to run poorly and increase exhaust emissions.

CHECK AUTOMATIC TRANSAXLE FLUID

Visually check the transaxle for fluid leakage. If leakage is found, check for the cause and repair. Check the fluid level; if the level is low, add fluid. Transmission fluid: See item 21 (B).

DO NOT OVERFILL A/T FLUID

Do not overfill. The transmission and differential are separate units.

• Do not overfill. The transmission and differential are separate units.

RECHECK A/T FLUID LEVEL AT NORMAL OPERATING TEMPERATURE

Recheck the fluid level with the normal temperature (70–80°C (158–176°F)) and add as necessary.

TIRES

Check the pressure with a gauge. Adjust if necessary. Check for cuts, damage or excessive wear.

WHEEL NUTS

When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them.

WINDSHIELD WIPER BLADES

Check for wear or cracks whenever they do not wipe clean. Replace if necessary.

FLUID LEAKS

Check underneath for leaking fuel, oil, water or other fluid. If you smell gasoline fumes or notice any leak, have the cause found and corrected.

DOORS AND ENGINE HOOD

Check that all doors including the trunk lid and back door operate smoothly, and that all latches lock securely. Check that the engine hood secondary latch secures the hood from opening when the primary latch is released.

LIGHTS

Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. Check the headlight aim.

WARNING LIGHTS AND BUZZERS

Check that all warning lights and buzzers function properly.

HORN

Check that it is working.

WINDSHIELD GLASS

Check for scratches, pits or abrasions.

WINDSHIELD WIPER AND WASHER

Check operation of the wipers and washer. Check that the wipers do not streak.

WINDSHIELD DEFROSTER

Check that air comes out from the defroster outlet when operating the heater or air conditioner at defroster mode.

REAR VIEW MIRROR

Check that it is mounted securely.

SUN VISORS

Check that they move freely and are mounted securely.

STEERING WHEEL

Check that it has specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noise.

SEATS

Check that all front seat controls such as seat adjuster, seatback recliner, etc. operate smoothly. Check that all latches lock securely in any position. Check that the locks hold securely in any latched position. Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position. For fold-down rear backs, check that the latches lock securely.

SEAT BELTS

Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. Check that the belt webbing is not cut, frayed, worn or damaged.

ACCELERATOR PEDAL

Check the pedal for smooth operation and uneven pedal effort or catching.

CLUTCH PEDAL (See page CL-3)

Check the pedal for smooth operation. Check that the pedal has the proper freeplay.

BRAKE PEDAL (See page BR-6)

Check brake pedal condition.

BRAKES

At a safe place, check that the brakes do not pull to one side when applied.

PARKING BRAKE (See page BR-8)

Check parking brake condition.

AUTOMATIC TRANSMISSION "PARK" MECHANISM

Check automatic transmission park mechanism.

WINDSHIELD WASHER FLUID

Check that there is sufficient fluid in the tank.

ENGINE COOLANT LEVEL

Check that coolant level is between the "FULL" and "LOW" lines on the see-through reservoir.

RADIATOR AND HOSES

Check radiator and hoses condition.

BATTERY ELECTROLYTE LEVEL

Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If level is low, add distilled.

BRAKE AND CLUTCH FLUID LEVELS

Check brake and clutch fluid levels.

ENGINE DRIVE BELTS

Check all drive belts for fraying, cracks, wear or oiliness.

ENGINE OIL LEVEL

Check the level on the dipstick with the engine turned off.

POWER STEERING FLUID LEVEL

Check the level on the dipstick. The level should be in the "HOT" or "COLD" range depending on the fluid temperature.

AUTOMATIC TRANSMISSION FLUID LEVEL

Check automatic transmission fluid level.

EXHAUST SYSTEM

Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected.

CHECK REMAINING VALVES AFTER CRANKSHAFT ROTATION

Turn the crankshaft one revolution (360°) and align the mark as above (See procedure step 8). Check only the valves indicated as shown. Measure the valve clearance (See procedure step (a)).

TIMING BELT TENSIONER SETUP — FEELER GAUGE AND IDLER PULLEY BOLT

Insert a 1.90 mm (0.075 in.) feeler gauge between the tensioner body and No.1 idler pulley stopper. Turn the No.1 idler pulley bolt counterclockwise to obtain the specified torque. To apply the correct torque, apply the torque wrench along the axis through the bolts of the No.1 idler pulley and exhaust camshaft timing pulley.

TIGHTEN TENSIONER BOLTS ALTERNATELY

While pushing the tensioner, alternately tighten the two bolts to the specified torque.

REMOVE HEXAGON WRENCH FROM TENSIONER

Remove the 1.27 mm hexagon wrench from the tensioner.

ALIGN CRANKSHAFT PULLEY TO ATDC 60°

Slowly turn the crankshaft pulley one revolution, and align its groove with the ATDC 60° mark of the No.1 timing belt cover.

• Always turn the crankshaft clockwise.

FINAL IDLER PULLEY BOLT TORQUE

Turn the No.1 idler pulley bolt counterclockwise to obtain the specified torque. To apply the correct torque, apply the torque wrench along the axis through the bolts of the No.1 idler pulley and exhaust camshaft timing pulley.

CHECK TENSIONER CLEARANCE WITH FEELER GAUGE

Using a feeler gauge, check the specified clearance between the tensioner body and No.1 idler pulley stopper.

REMOVE SHOCK ABSORBER

Step 5 of the preceding removal procedure.

• Cover the drive shaft boot with cloth to avoid damaging it.

RELEASE GAS BEFORE DISCARDING SHOCK ABSORBER

Before discarding the shock absorber, first loosen the ring nut 2 or 3 turns to release the gas completely. SST 09720-00012 (09721-00071)

REMOVAL OF LOWER ARM

See page SA-69. Procedure to remove the rear suspension lower arm.

INSTALLATION OF STRUT ROD

See page SA-69. Install rear suspension arm No.1, then temporarily install the strut rod holding bolt and nut and cushion to the body.

INSTALL REAR SUSPENSION ARM No.1

Install the retainers, cushions, collar and suspension arm No.1 to the strut rod with the nut as shown. Install the nut to the bolt end. Do not misinstall the front and rear cushions. Temporarily install the strut rod holding bolt and nut and cushion to the body.

• Install the nut to the bolt end.
• Do not misinstall the front and rear cushions.

DISCONNECT EXHAUST PIPE MOUNTING FROM REAR SUSPENSION CROSSMEMBER

Remove the two exhaust pipe mounting installation bolts.

DISCONNECT REAR ENGINE MOUNT FROM REAR SUSPENSION CROSSMEMBER

Remove the three installation bolts of the rear engine mounting.

REMOVE SUSPENSION CROSSMEMBER MOUNTING BOLTS

Hold the rear suspension crossmember with a jack. Remove the four bolts, then remove the rear suspension crossmember.

REMOVE STABILIZER BAR

Lift down the crossmember until the front side bolt of the stabilizer bar bracket can be removed. Be careful not to damage the exhaust pipe by shoving with the stabilizer bar. Remove the two bolts and two nuts. Remove the stabilizer bar with brackets. Remove the brackets and cushions from the stabilizer bar.

CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT, AS SHOWN

Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. Pedal reserve distance from asphalt sheet at 50 kg (110.2 lb, 490 N): More than 117 mm (4.61 in.). If the reserve distance is incorrect, troubleshoot the brake system.

OPERATIONAL TEST OF BRAKE BOOSTER — OPERATING CHECK

(a) Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. (b) Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal.

OPERATIONAL TEST OF BRAKE BOOSTER — AIR TIGHTNESS

(a) Start the engine and stop it after one or two minutes. Depress the brake pedal several times slowly. If the pedal goes down the farthest the first time, but gradually rises after the second or third time, the booster is air tight. (b) Depress the brake pedal while the engine is running, and stop the engine with the pedal depressed. If there is no change in the pedal reserve travel after holding the pedal for thirty seconds, the booster is air tight.

BLEEDING OF BRAKE SYSTEM — NOTICE

Do not let brake fluid remain on a painted surface. Wash it off immediately.

CHECK AND ADJUSTMENT OF PARKING BRAKE

Check and adjust the parking brake lever travel.

CHECK THAT PARKING BRAKE LEVER TRAVEL IS CORRECT

Pull the parking brake lever all the way up and down for two or three times. Then return the parking brake lever. Depress the brake pedal for several times. Pull the parking brake lever all the way up, and count the notches of lever travel. Parking brake lever travel at 20 kg (44.1 lb, 196 N): 5 – 8 clicks. If incorrect, adjust the parking brake.

INSPECT CYLINDER BORE FOR RUST OR SCORING

Inspect cylinder bore for rust or scoring.

INSPECT CYLINDER FOR WEAR OR DAMAGE

Inspect cylinder for wear or damage. If necessary, clean or replace the cylinder.

CLEAN DISASSEMBLED PARTS

Clean the disassembled parts with compressed air.

ECU CONNECTOR CHECK

Is connector of ECU properly connected? And are all terminals in the connector? If NO: Faulty connector.

POWER CIRCUIT CHECK

Is there 10–16 V between terminal IG on ECU wire harness side connector and body ground? (Ignition switch on) If NO: Faulty power circuit.

WARNING LIGHT CHECK WITH CONNECTORS DISCONNECTED

Does warning light go off when both the ECU connector and service connector are disconnected? (Ignition switch on) If NO (Come on): Short circuit in wire harness between ECU terminal WA and actuator terminal WA. If YES (Goes off): Faulty ECU.

DIAGNOSTIC CODE BLINK PATTERN HINT

The first number of blinks will equal the first digit of a two digit diagnostic code. After a 1.5 second pause, the 2nd number of blinks will equal the 2nd number of a two digit code. If there are two or more codes, there will be a 2.5 second pause between each code, and then indication will begin again after a 4.0 second pause, continuing in order from the smaller value up to the larger one. Each blink is 0.12s ON and 0.12s OFF. Initial normal pattern blinks rapidly before the trouble code sequence begins (0.5s pause, then digits). Example shown is Code 72: 7 blinks, 1.5s pause, 2 blinks, followed by 2.5 or 4.0s pause.

REPLACE PARTS PROPERLY

Care must be taken to replace parts properly because they could affect the performance of the steering system and result in a driving hazard.

AIRBAG PRECAUTION (USA)

The steering wheel pad has an airbag built in, so take all due precautions when handling it. For more details, see the SRS AIRBAG section.

INSTALL WHEEL PAD — TORX SCREW ENGAGEMENT

Install the wheel pad after confirming that the circumference groove of the torx screws is caught on the screw case.

TIGHTEN TORX SCREWS TO SPECIFIED TORQUE

Using a torx wrench, tighten the four screws to the specified torque.

• Make sure the wheel pad is installed to the specified torque.
• If the wheel pad has been dropped, or there are cracks, dents or other defects in the case or connector, replace the wheel pad with a new one.
• When installing the wheel pad, take care that the wirings do not interfere with other parts and are not pinched between other parts.

CHECK STEERING WHEEL CENTER POINT AFTER INSTALLING STEERING COLUMN

Check steering wheel center point after installing steering column.

INSPECTION AND REPLACEMENT OF STEERING COLUMN

Inspection and replacement procedures for the steering column components.

INSPECT KEY CYLINDER

Check that the steering lock mechanism operates properly.

IF NECESSARY, REPLACE KEY CYLINDER

(a) Place the ignition key at the ACC position. (b) Push down the stop pin with a thin rod, and pull out the key cylinder. (c) Make sure the ignition key is at the ACC position. (d) Install a new key cylinder.

IF NECESSARY, REPLACE MAIN SHAFT BUSHING

(a) Remove the snap ring. (b) Using a screwdriver, remove the bushing.

INSPECT UPPER BEARING

Check the upper bearing rotation condition and check for abnormal noise.

INSPECT KEY INTERLOCK SOLENOID (A/T)

See page AT-165

INSTALL BUSHING IN COLUMN TUBE

Align the holes of the tube and projections of a new bushing, and insert the bushing in the column tube. Install the snap ring.

CHECK THAT FLUID IN RESERVOIR IS NOT FOAMY OR CLOUDY AND DOES NOT RISE OVER MAXIMUM WHEN ENGINE IS STOPPED

Measure the fluid level with the engine running. Stop the engine and measure the fluid level. Maximum rise: 5 mm (0.20 in.)

USE TOYOTA POWER STEERING FLUID EH

When supplementing the power steering fluid, use TOYOTA POWER STEERING FLUID EH or equivalent which is exclusively for EHPS use.

DO NOT DISASSEMBLE POWER STEERING PUMP

The power steering pump is not to be disassembled, so if a malfunction occurs, replace it as an assembly.

FRONT AIRBAG SENSOR

The front airbag sensors are mounted inside of the radiator upper support. The sensor unit is a mechanical type. When the sensor detects deceleration force above a predetermined limit in a collision, the contacts in the sensor make contact, sending a signal to the center airbag sensor assembly. The sensor cannot be disassembled.

SPIRAL CABLE (in COMBINATION SWITCH)

A spiral cable is used as an electrical joint from the vehicle body side to the steering wheel.

STEERING WHEEL PAD (with AIRBAG)

The inflater and bag of the airbag system are stored in the steering wheel pad and cannot be disassembled. The inflater contains a squib, igniter charge, gas generant, etc., and inflates the bag in case of a frontal collision.

AIRBAG WARNING LIGHT

The airbag warning light is located on the combination meter. It goes on to alert the driver of trouble in the system when a malfunction is detected in the center airbag sensor assembly self-diagnosis. In normal operating condition when the ignition switch is turned to the ACC or ON position, the light goes on for about 6 seconds and then goes off.

CENTER AIRBAG SENSOR ASSEMBLY

The center airbag sensor assembly is mounted on the floor inside the center cluster. The center airbag sensor assembly consists of a center airbag sensor, safing sensors, ignition control and drive circuit, diagnosis circuit, etc. It receives signals from the airbag sensors, judges whether the airbag must be activated or not and diagnoses system malfunctions.

HINT: STEERING WHEEL HORN BUTTON CONTACT PLATE

If the horn button contact plate of the steering wheel is deformed, never repair it. Always replace the steering wheel with a new one.

HINT: STEERING WHEEL PAD CLEARANCE

There should be no interference between the steering wheel pad and the steering wheel, and the clearance should be uniform all the way around when the new steering wheel pad is installed on the steering wheel.

REPLACEMENT REQUIREMENTS

In the following cases, replace the steering wheel pad, steering wheel or spiral cable. CAUTION: For replacement of the steering wheel pad, see page AB-15, 'REMOVAL AND INSTALLATION' and be sure to follow the correct procedure. Replace if: the airbag has been deployed; the steering wheel pad or spiral cable has been found to be faulty in troubleshooting; the steering wheel pad, steering wheel or spiral cable has been found to be faulty during the check in item 1.-(b) or 2.-(b); the steering wheel pad has been dropped.

REPLACEMENT REQUIREMENTS — FRONT AIRBAG SENSOR

In the following cases, replace the front airbag sensor: If the airbag has been deployed in a collision (replace both the left and right airbag sensors); If the front airbag sensor has been found to be faulty in troubleshooting; If the front airbag sensor has been found to be faulty during the check in item 2.-(b); If the front airbag sensor has been dropped. For replacement of the front airbag sensor, see page AB-17, 'REMOVAL AND INSTALLATION'.

REPLACEMENT REQUIREMENTS — CENTER AIRBAG SENSOR ASSEMBLY

In the following cases, replace the center airbag sensor assembly: If the center airbag sensor assembly has been found to be faulty in troubleshooting; If the center airbag sensor assembly has been found to be faulty during the check in item 2.-(b); If the center airbag sensor assembly has been dropped. For replacement of the center airbag sensor assembly, see page AB-19, 'REMOVAL AND INSTALLATION'. If the center airbag sensor assembly interferes with any other parts, perform a check after repairs.

WIRE HARNESS AND CONNECTOR HINT

The airbag system wire harness is integrated with the cowl wire harness assembly and luggage compartment wire harness assembly. The wires for the airbag wire harness are encased in a yellow corrugated tube and all the connectors in the system are a standard yellow color.

INSPECTION ITEMS — VEHICLES NOT INVOLVED IN A COLLISION

Perform a diagnostic system check (See page AB-29).

INSPECTION ITEMS — VEHICLES INVOLVED IN A COLLISION

Perform a diagnostic system check (See page AB-29). Check if there is a break in any of the wires in the airbag system wire harness, or if conductors are exposed. Check if the airbag system wire harness connectors are cracked or chipped.

REPLACEMENT REQUIREMENTS

In the following cases, replace the wire harness or connector: If any part of the airbag system wire harness or any connector has been found to be faulty in troubleshooting. If any part of the airbag system wire harness or any connector has been found to be faulty during the check in item 2. – (b) or (c). NOTICE: If the wire harness used in the airbag system is damaged, replace the whole wire harness assembly. When the connector to the front airbag sensors can be repaired alone (when there is no damage to the wire harness), use the repair wire specially designed for the purpose (See page AB-21).

DO NOT DISCONNECT WIRING CONNECTOR WITH IGNITION ON OR ACC

If the wiring connector of the airbag system is disconnected with the ignition switch at ON or ACC, diagnostic codes will be recorded.

NEVER USE AIRBAG PARTS FROM ANOTHER VEHICLE

Never use airbag parts from another vehicle. When replacing parts, replace with new parts.

NEVER REUSE SENSOR AFTER COLLISION WITH DEPLOYMENT

Never reuse the sensor involved in a collision when the airbag has deployed.

NEVER REPAIR A SENSOR FOR REUSE

Never repair a sensor in order to reuse it.

INSTALL SENSOR ASSEMBLY TO SPECIFIED TORQUE

Make sure the sensor assembly is installed to the specified torque.

REPLACE DROPPED OR DAMAGED SENSOR ASSEMBLY

If the sensor assembly has been dropped, or there are cracks, dents or other defects in the case, bracket or connector, replace the sensor assembly with a new one.

PREVENT AIRBAG WIRING INTERFERENCE

When installing the sensor assembly, take care that the airbag wirings do not interfere with other parts and are not pinched between other parts.

CHECK FOR LOOSENESS AFTER INSTALLATION

After installation, shake the sensor assembly to check that there is no looseness.

SRS AIRBAG SYSTEM CHECK SHEET

A Customer Problem Analysis Check Sheet for SRS Airbag system troubleshooting. Fields include: Customer's Name, Registration No., Registration Year, Frame No., Date Vehicle Brought In, Odometer Reading (Miles). Date of Problem Occurrence. Conditions at Time of Problem Occurrence covering Weather (Fine, Cloudy, Rainy, Snowy, Various/Other), Outdoor Temperature (Hot, Warm, Cool, Cold with approx °C/°F), Vehicle Operation (Starting, Idling, Driving with sub-options: Constant speed, Acceleration, Deceleration, Other), and Condition of road. Free-text fields for Details of Problem and Vehicle Inspection/Repair History Prior to Occurrence of Malfunction (Including Airbag System). Diagnosis System Inspection section covering Airbag Warning Light Inspection (1st Time and 2nd Time, each with options: Remains On, Sometimes Lights Up, Does Not Light Up) and Diagnostic Code Inspection (1st Time and 2nd Time, each with options: Normal Code, Malfunction Code with code entry field).

SOURCE VOLTAGE DROP HINT

When the airbag warning light remains lit up and the diagnostic code is the normal code, this means a source voltage drop. This malfunction is not stored in memory by the center airbag sensor assembly and if the power source voltage returns to normal, after approx. 10 seconds the airbag warning light will automatically go out.

CODE 22 RECORDING

Code 22 is recorded when a malfunction occurs in the airbag warning light system. If an open malfunction occurs in the airbag warning light system, the airbag warning light does not light up, so that until the malfunction is repaired, the diagnostic codes (including code 22) cannot be confirmed.

CODES 11–31 MEMORY CLEARING

When a malfunction occurs in the airbag system, malfunction codes 11 to 31 are output. After repairing the malfunction indicated by malfunction codes 11 to 31, codes 11 to 31 are cleared from the memory, but code 41 is output instead. Once the malfunction has been detected, the airbag warning light will remain lit up until code 41 is cleared, even though the malfunction has been repaired.

MULTIPLE CODES

When two or more codes are indicated, the lowest numbered code will appear first.

UNLISTED CODE

If a code not listed on the chart is displayed, then the center airbag sensor assembly is faulty.

HINT: Normal code with warning light lit

When the airbag warning light remains lit up and the diagnostic code is the normal code, this means a source voltage drop.

HINT: Code 22 recording condition

Code 22 is recorded when a malfunction occurs in the airbag warning light system. If an open malfunction occurs in the airbag warning light system, the airbag warning light does not light up, so that until the malfunction is repaired, the diagnostic codes (including code 22) cannot be confirmed.

HINT: Code 41 behavior

When a malfunction occurs in the airbag system, malfunction codes 11 to 31 are output. After repairing the malfunction indicated by malfunction codes 11 to 31, codes 11 to 31 are cleared from the memory, but code 41 is output instead. Once the malfunction has been detected, the airbag warning light will remain lit up until code 41 is cleared, even though the malfunction has been repaired.

PROBLEM SYMPTOM: Airbag warning light always lit up

With the ignition switch at ACC or ON, the airbag warning light sometimes light up after approx. 6 seconds have elapsed. Airbag warning light lights up even when ignition switch is in the LOCK position. Inspection Item: Airbag warning light system (Always lit up). See page AB-75.

PROBLEM SYMPTOM: Diagnostic code display issues

Diagnostic code not displayed. Diagnostic code continuously displayed. Inspection Item: Tc terminal circuit. See page AB-77.

DIAGNOSTIC CHART — WIRING DIAGRAM

Wiring diagram showing the Tc terminal circuit connections. The Check Connector (terminals E1 and Tc) connects via the Tc line to the Center Airbag Sensor Assembly (Tc terminal, with diode). The same Tc line branches to three ECUs, each with a diode on their Tc terminal: Power Steering ECU, Cruise Control ECU, and ABS ECU. The E1 terminal of the Check Connector is grounded.

CONFIRM FUNCTIONING OF SST

When deploying the airbag, always use the specified SST: SRS AIRBAG DEPLOYMENT TOOL. SST 09082-00700.

CONNECT SST TO BATTERY

Connect the red clip of the SST to the battery positive (+) terminal and the black clip to the battery negative (-) terminal. HINT: Do not connect the yellow connector which connects with the airbag system.

CONFIRM FUNCTIONING OF SST

Press the SST activation switch, and confirm the LED of the SST activation switch lights up.

• If the LED lights up when the activation switch is not being pressed, SST malfunction is probable, so definitely do not use the SST.

Daytime Running Light System Description

The daytime running light system has front fog lights and taillights that go on automatically when the engine is started. This system is standard equipment on all grade models for Canada. The daytime running lights are controlled by the light retractor relay.

Standby Operation

The daytime running light system is activated when the ignition switch is turned on and the engine is started. The lights are turned on and off, as shown below, depending on the condition on applicable switches. Lights do not go on when the ignition switch is merely turned on. Lights remain on when the running engine stalls.

Terminal Bracket Note

The terminals indicated in brackets ( ) are for models w/ Light Auto Turn Off System.

Power Source Circuit Note

The POWER SOURCE CIRCUIT has been simplified. For full details, see page BE-9.

CONNECTOR DIAGRAMS

Connector diagrams for Ignition Switch (10-pin), Wiper Motor (4-pin), Wiper and Washer Switch Connector A (15-pin) and Connector B (20-pin), Washer Motor for Canada/USA with Cold Area Spec (3-pin), and Washer Motor for USA without Cold Area Spec (2-pin).

PARTS REPLACEMENT

See Parts Replacement of Combination Switch on page BE-30.

PARTS LOCATION — POWER DOOR LOCK CONTROL SYSTEM

Diagram identifying the location of all power door lock control system components on the vehicle: Ignition Switch (driver side dash/steering column area), Door Lock Control Relay (driver side lower dash/kick panel area), Door Lock Manual Switch (driver door panel — left side), Door Lock Manual Switch (center console/dash — top center), Key Unlock Warning Switch (driver side lower area), Door Key Lock and Unlock Switch (passenger door), Door Lock Assembly and Door Lock Motor (passenger door), Door Courtesy Switch (passenger door lower area).

POWER MIRROR CONTROL SYSTEM — Parts Location

Outer Rear View Mirror (Mirror Motor) located on both left and right sides of the vehicle. Mirror Switch located on the driver's door/interior panel area.

POWER MIRROR CONTROL SYSTEM — Wiring and Connector Diagrams

The power source circuit is powered through Fuse RAD CIG via the Ignition Switch (ACC position) from the Battery. The Mirror Switch (Control Switch) contains Up/Left, Down/Right, Up, Down, Left, Right positions and a Left/Right Adjustment Switch. Connector terminals: Mirror Switch pins 2, 3, 4, 5, 7, 8, 10. Circuit nodes connect to Left Side Mirror Motor (terminals 1, 2, 3) and Right Side Mirror Motor (terminals 1, 2, 3). Wire nodes 2, 3, 4, 5, 7, 8 connect switch to motors. Mirror Motor connector is a 3-pin connector (pins 1, 2, 3). The POWER SOURCE CIRCUIT has been simplified — for full details, see page BE-9.

STARTER CUT SYSTEM CIRCUIT

Turn ignition switch to ST. Disconnect TD ECU connector and inspect connector on wire harness side as follows. Inspect Starter Cut System Circuit: Turn ignition switch to ST position (*1 with shift lever at N or P position or *2 with clutch pedal depressed). Is there battery voltage between terminal 18 and ground? If Yes: Replace TD ECU. Then recheck system. If No: Short or open circuit in starter relay circuit. HINT: If starter does not operate, even when system is cancelled, before checking the circuit, use the key to turn the door lock to the unlock position and recheck starter operation. *1 A/T, *2 M/T.

AUDIO SYSTEM PARTS LOCATION

Diagram identifying the location of all audio system components within the vehicle, including: Front Window Printed Antenna, Radio-Tape Player Unit, CD Player, Tweeter (left and right), Front Speaker (left and right), Rear Speaker (left and right), Woofer Amplifier, Woofer, Power Amplifier, Motor Antenna Assembly (Antenna Motor, Antenna Motor Control Relay).

Radio-Tape Player Unit (Separate Power Amplifier, w/Woofer): Symbol P

Wiring diagram for Radio-Tape Player Unit with separate power amplifier and woofer, denoted by symbol P.

Radio-Tape Player Unit + CD Player: Symbol C

Wiring diagram for Radio-Tape Player Unit combined with CD Player, denoted by symbol C.

THE POWER SOURCE CIRCUIT has been simplified.

For full details, see page BE-8.

SOUND QUALITY POOR (VOLUME PAINT) — Tape Player Diagnostic 12

Diagnostic flowchart for poor sound quality on tape player. U = Radio–Tape Player Unit (Built-in Power Amplifier); P = Radio–Tape Player Unit (Separate Power Amplifier). Steps: (1) Function OK if different cassette tape inserted? Yes → Cassette tape faulty. No → (2) Operates normally after cleaning the heads? (See page BE-137) Yes → Head dirty. No → (3) Is radio operating normally? Yes → Radio assembly faulty. No → (4) Is speaker properly installed? No → Install properly. Yes → (5) Temporarily install another speaker. Functions OK? Yes → Speaker faulty. No → U: Radio assembly faulty. P: Radio assembly or power amplifier faulty.

TAPE JAMMED, MALFUNCTION WITH TAPE SPEED OR AUTO-REVERSE — Tape Player Diagnostic 13

Diagnostic flowchart for tape jammed or tape speed/auto-reverse malfunction. Steps: (1) Functions OK if different tape (less than 120 mins.) is inserted? Yes → Cassette tape faulty. No → (2) Is there a foreign object inside tape player? Yes → Remove foreign object. No → (3) Operates normally after cleaning the heads? (See page BE-137) Yes → Head dirty. No → Radio assembly faulty.

APS, SKIP, RPT BUTTONS NOT OPERATING — Tape Player Diagnostic 14

Diagnostic flowchart for APS, SKIP, RPT buttons not operating. Steps: (1) Functions OK if different cassette tape inserted? No → Radio assembly faulty. Yes → Cassette tape faulty. (Less than 3 secs. of silence between songs (APS, RPT). Less than 15 secs. of silence (SKIP).)

CLOCK CIRCUIT TROUBLESHOOTING

As shown in the illustration, those are clock circuit and connector diagrams. Inspect each terminal for applicable trouble.

HEAT BODY AND MOULDING

Be sure that the body and moulding are heated to the proper temperature.

DO NOT DEPRESS ADHESIVE-COATED PARTS EXCESSIVELY

Do not depress the adhesive-coated parts excessively just hold them down with your thumb.

SCRAPE OFF OVERFLOWING ADHESIVE

Scrape off any overflowing adhesive with a plastic spatula and clean the surface with a dry rang.

DO NOT WASH VEHICLE FOR 24 HOURS

After installation, do not wash the vehicle for 24 hours.

REMOVE BACK WINDOW LOWER MOULDING

Using the knife, cut off the moulding as shown.

• Do not damage the body with the knife.

REMOVE BACK WINDOW GLASS

Remove two screws. Remove the glass in the same manner as windshield. See step 11 on page BO-38.

DISASSEMBLY OF SUNSHADE TRIM

See page BO-48. REMOVE SUNSHADE TRIM HOLDER: Remove two screws and the holder.

ASSEMBLY OF SUNSHADE TRIM

See page BO-48. INSTALL SUNSHADE TRIM HOLDER: Install the holder with two screws.

MOON ROOF COMPONENTS

Exploded diagram identifying all moon roof components: Removable Roof, Sunshade Trim, Wind Defector Panel, Sun Visor, Holder, Inner Rear View Mirror, Map Light, Map Light Cover, Hinge Case, Opening Trim, Auxiliary Catch, Front Pillar Garnish, Sunshade Lock Stopper, Sunshade Trim Knob, Inner Weatherstrip, Roof Headlining, Removable Roof Garnish, Lock Handle, Spacer, Lock Base, Lock Garnish, Door Scuff Plate.

SCREW SIZE CODE REFERENCE

Screw sizes in the illustration on the previous page are indicated using the code below for removal and installation of instrument panel. Code A: φ=6 (0.24) mm, L=20 (0.79) mm. Code B: φ=4.5 (0.177) mm, L=12 (0.47) mm. Code C: φ=5.22 (0.2055) mm, L=16 (0.63) mm. Code D: φ=6 (0.24) mm, L=14 (0.55) mm. Code E: no size listed.

REMOVE FOLLOWING PARTS FROM SAFETY PAD

Step 27: Remove the following parts from safety pad: Defroster nozzle, Defroster nozzle No. 1 garnish, Defroster nozzle No. 2 garnish, Meter hood No. 1 retainer, Meter hood No. 2 retainer, Glove compartment door lock mounting bracket, Duct heater to register No. 1, Duct heater to register No. 4, No. 3 register, Under cover No. 1 bracket, Pin.

REMOVE FOLLOWING PARTS

Step 28: Remove the following parts: Defroster lower nozzle, Duct heater to register No. 3, No. 1 brace, No. 2 brace, Console box mounting No. 1 bracket.

BASIC DIMENSIONS — Three-dimensional distance

Straight-line distance between the centers of two measuring points.

BASIC DIMENSIONS — Two-dimensional distance

Horizontal distance in forward/rearward between the centers of two measuring points, and the height from an imaginary standard line.

BASIC DIMENSIONS — Symmetry

In cases in which only one dimension is given, left and right are symmetrical.

BASIC DIMENSIONS — Actual distance

The dimensions in the following drawing indicate actual distance. Therefore, please use the dimensions as a reference.

MEASURING — Use tracking gauge

Basically, all measurements are to be done with a tracking gauge. For portions where it is not possible to use a tracking gauge, a tape measure should be used.

MEASURING — Tracking gauge condition

Use only a tracking gauge that has no looseness in the body, measuring plate, or pointers.

MEASURING HINT 1 — Equal pointer heights

The height of the left and right pointers must be equal.

MEASURING HINT 2 — Calibrate before measuring

Always calibrate the tracking gauge before measuring or after adjusting the pointer height.

MEASURING HINT 3 — Handle with care

Take care not to drop the tracking gauge or otherwise shock it.

MEASURING HINT 4 — Secure pointers

Confirm that the pointers are securely in the holes.

MEASURING — Tape measure: avoid twists and bends

When using a tape measure, avoid twists and bends in the tape.

MEASURING — Diagonal measurement along panel surface

When tracking a diagonal measurement from the front spring support inner hole to the suspension member upper rear installation hole, measure along the front spring support panel surface.

AIRBAG SENSOR MOUNTING ANGLE NOTICE

True up the mounting section of the front airbag sensor very carefully and accurately so that the sensor can be mounted at the correct angle.

ELECTRICAL PARTS

Before removing and inspecting the electrical parts, set the ignition switch to the LOCK position and disconnect the negative (-) terminal cable from the battery.

• Work must not be started until after at least 20 seconds or longer from the time the negative (-) terminal cable is disconnected.

SRS AIRBAG SYSTEM

Failure to carry out service operation in the correct sequence could cause the airbag system to deploy, possibly leading to a serious accident. When removal or installation of the parts and the yellow wire harness and connector for the airbag is necessary, refer to the precautionary notices in the AB section before performing the operation.

• Failure to carry out service operation in the correct sequence could cause the airbag system to deploy, possibly leading to a serious accident.

WHEN HANDLING REFRIGERANT (R-12), FOLLOWING PRECAUTIONS MUST BE OBSERVED

Do not handle refrigerant in an enclosed area or near an open flame. Always wear eye protection. Be careful that liquid refrigerant does not get in your eyes or on your skin. If liquid refrigerant gets in your eyes or on your skin: Do not rub. Wash the area with lots of cool water. Apply clean petroleum jelly to the skin. Go immediately to a physician or hospital for professional treatment. Do not attempt to treat yourself.

• Do not handle refrigerant in an enclosed area or near an open flame.
• Always wear eye protection.
• Be careful that liquid refrigerant does not get in your eyes or on your skin.
• If liquid refrigerant gets in your eyes or on your skin: Do not rub, wash the area with lots of cool water, apply clean petroleum jelly to the skin, go immediately to a physician or hospital for professional treatment, do not attempt to treat yourself.

WHEN REPLACING PARTS IN REFRIGERANT LINE

Discharge the refrigerant in the line slowly before replacement. Insert a plug immediately in disconnected parts to prevent the entry of moisture and dust. Do not leave a new condenser or receiver, etc., lying around with the plug removed.

DAMPARS POSITION

Diagram and table describing the position of air inlet damper, mode damper, and air mix damper based on A/C control switch and lever positions. Air Inlet Control Lever: Fresh = position 1 (outside air); Recirc = position 2 (inside air recirculation). Temperature Control Lever: Warm = positions 3, 4 (air mix damper range); Cool = positions 4, 5 (air mix damper range). Mode Control Lever positions and corresponding damper numbers and air flow vents: Def. = dampers 8, 11, 15 — Side (large), DEF (large); Foot/Def. = dampers 9, 12, 15 — Side (large), Foot (large), DEF (large); Foot = dampers 10, 13, 15 — Side (large), Foot (large), DEF (small); Bi-Level = dampers 9, 14, 16 — Center (large), Side (large), Foot (large); Face = dampers 8, 14, 17 — Center (large), Side (large). The size of circle indicates the proportion of the air flow volume.

DISCHARGING OF REFRIGERANT IN REFRIGERATION SYSTEM

See Air Conditioning Fundamentals and Repairs Pub. No. 36950E.

EVACUATING OF AIR IN REFRIGERATION SYSTEM AND CHARGING WITH REFRIGERANT

See Air Conditioning Fundamentals and Repairs Pub. No. 36950E.

INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS

Inspect hose and tube connections for looseness.

INSPECT HOSES AND TUBES FOR LEAKAGE

Using a gas leak tester, check for leakage of refrigerant.

INSPECT CLEARANCE OF MAGNETIC CLUTCH

Set the dial-gauge to the pressure plate of the magnetic clutch. Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. Check the clearance between the pressure plate and rotor, when connect the negative (–) terminal of the battery. Standard Clearance: 0.8 ± 0.2 mm (0.32 ± 0.08 in.). If the clearance is not within standard clearance, adjust the clearance using shims to obtain the standard clearance.

INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE

If the fins are clogged, wash them with water and dry with compressed air. Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers.

• Be careful not to damage the fins.

INSPECT CONDENSER FITTINGS FOR LEAKAGE

Repair as necessary.

REMOVAL OF COOLING UNIT

1. DISCONNECT NEGATIVE CABLE FROM BATTERY 2. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 3. DISCONNECT SUCTION TUBE FROM COOLING UNIT OUTLET FITTING 4. DISCONNECT LIQUID TUBE FROM COOLING UNIT INLET FITTING — Cap the open fittings immediately to keep moisture out of the system. 5. REMOVE GLOVE BOX 6. DISCONNECT CONNECTORS 7. REMOVE COOLING UNIT — Remove the three nuts and four bolts and the cooling unit.

REMOVAL OF THERMISTOR

See Disassembly of Cooling Unit on page AC-30.

INSTALLATION OF THERMISTOR

See Assembly of Cooling Unit on page AC-32.

INSPECT THERMISTOR OPERATION

Place the thermistor in cold water. While varying the temperature of the water, measure the resistance at the connector and at the same time, measure the temperature of the water with a thermometer. Compare the two readings on the chart. If the intersection is not between the two lines, replace the thermistor. Thermistor must be more than 10 cm (3.94 in.) from ice.

INSPECT SWITCH CONTINUITY (Fresh/Recirc)

Check continuity at Connector A terminals for switch positions: FRESH (Free): continuity between A-1 and A-9 (diode), and A-1 to A-15; RECIRC (Pushed in): continuity between A-9 and A-15 (diode). If continuity is not as specified, replace the A/C control assembly.

INSPECT SWITCH CONTINUITY

Using Connector C, verify continuity between terminals C-5 and C-6 when switch is in A/C position. No continuity expected in OFF position. If continuity is not as specified, replace the A/C switch.

ADJUST AIR MIX DAMPER CONTROL CABLE

Set the air mix damper and the control lever to COOL, then install the control cable and lock the clamp.

ADJUST WATER VALVE CONTROL CABLES

Set the water valve and the control lever to COOL, then install the control cable and lock the clamp.

ENGINE STALL REVOLUTION

Engine stall revolution: 2,550 ± 150 rpm

TIME LAG

Time lag N range → D range: Less than 1.2 seconds. N range → R range: Less than 1.5 seconds.

ENGINE IDLE SPEED (A/C OFF, N RANGE)

700 ± 50 rpm

SHIFT SCHEDULE — D RANGE (THROTTLE VALVE FULLY OPEN [FULLY CLOSED])

1→2: 53-59 km/h (33-37 mph); 2→3: 102-112 km/h (63-70 mph); 3→O/D: 137-149 km/h (85-93 mph); [3→O/D]: 46-52 km/h (29-32 mph); [O/D→3]: 19-24 km/h (12-15 mph); O/D→3: 131-143 km/h (81-89 mph); 3→2: 98-108 km/h (61-67 mph); 2→1: 44-50 km/h (27-31 mph)

SHIFT SCHEDULE — 2 RANGE (THROTTLE VALVE FULLY OPEN [FULLY CLOSED])

1→2: 53-59 km/h (33-37 mph); 2→1: 44-50 km/h (27-31 mph)

SHIFT SCHEDULE — L RANGE

2→1: 34-40 km/h (21-25 mph)

LOCK-UP POINT — D RANGE (THROTTLE VALVE OPENING 5%)

Lock-up ON O/D: 80-87 km/h (50-54 mph). Lock-up OFF O/D: 74-80 km/h (46-50 mph).

Measure cylinder bore diameter in thrust directions

(b) Measure the cylinder bore diameter in the thrust directions. (See step 4 on page EM-152) (c) Subtract the piston diameter measurement from the cylinder bore diameter measurement. If the oil clearance is greater than maximum, replace all the four pistons. If necessary, replace the cylinder block.

HINT (Use new cylinder block)

Use a piston with the same number mark as the cylinder bore diameter marked on the cylinder block.

RETIGHTEN CAP NUTS 90°

Retighten the cap nuts 90° in the numerical order shown.

CHECK PAINTED MARK ANGLE

Check that the painted mark is now at a 90° angle to the front.

CHECK CRANKSHAFT ROTATION

Check that the crankshaft turns smoothly.

CHECK CONNECTING ROD THRUST CLEARANCE

Check the connecting rod thrust clearance. See step 2 on page EM-193.

INSTALL REAR OIL SEAL RETAINER

Install a new gasket and the retainer with the six bolts. Torque: 95 kg-cm (82 in.-lb, 9.3 N·m).

IDLE ENGINE AFTER HARD DRIVING

Do not stop the engine immediately after pulling a trailer or high speed or uphill driving. Idle the engine for 20 – 120 seconds, depending on the severity of the driving condition.

AVOID SUDDEN RACING ON COLD START

Avoid sudden racing or acceleration immediately after starting a cold engine.

DO NOT RUN ENGINE WITHOUT AIR CLEANER

If the engine is run with the air cleaner removed, foreign material entering will damage the wheels which run at extremely high speed.

CHECK CAUSE OF DEFECT BEFORE REPLACING TURBOCHARGER

If the turbocharger is defective and must be replaced, first check for the cause of the defect in reference to the following items and replace parts if necessary: Engine oil level and quality; Conditions under which the turbocharger was used; Oil lines leading to the turbocharger.

HANDLE TURBOCHARGER ASSEMBLY WITH CARE

Use caution when removing and reinstalling the turbocharger assembly. Do not drop it or bang it against anything or grasp it by easily-deformed parts, such as the actuator or rod, when moving it.

PLUG PORTS BEFORE REMOVING TURBOCHARGER

Before removing the turbocharger, plug the intake and exhaust ports and oil inlet to prevent entry of dirt or other foreign material.

CHECK OIL PIPES FOR SLUDGE WHEN REPLACING TURBOCHARGER

If replacing the turbocharger, check for accumulation of sludge particles in the oil pipes, and if necessary, replace the oil pipes.

REMOVE GASKET FROM OIL PIPE AND TURBOCHARGER FLANGES

Completely remove the gasket adhered to the lubrication oil pipe flange and turbocharger oil flange.

USE SPECIFIED NEW BOLTS OR NUTS

If replacing bolts or nuts, do so only with the specified new ones to guard against breakage or deformation.

PRIME NEW TURBOCHARGER WITH OIL

If replacing the turbocharger, put 20 cc (1.2 cu in.) of oil into the turbocharger oil inlet and turn the impeller wheel by hand to spread oil to the bearing.

DISTRIBUTE OIL AFTER ENGINE OVERHAUL OR REPLACEMENT

If overhauling or replacing the engine, cut the fuel supply after reassembly and crank the engine for 30 seconds to distribute oil throughout the engine. Then allow the engine to idle for 60 seconds.

TROUBLESHOOTING HINT

Before troubleshooting the turbocharger, first check the engine itself. (Valve clearance, engine compression, ignition timing etc.)

INSPECT IMPELLER WHEEL ROTATION

See step 1 on page TC-13

INSPECT TURBOCHARGING PRESSURE VSV

See page FI-165

INSPECT TURBOCHARGING PRESSURE SENSOR

See page FI-171

EMISSION CONTROL SYSTEMS TABLE OF CONTENTS

Index listing all emission control system sections for both 3S-GTE and 5S-FE engines, with page references. Sections covered: SYSTEM PURPOSE, COMPONENT LAYOUT AND SCHEMATIC DRAWING, POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM, FUEL EVAPORATIVE EMISSION CONTROL (EVAP) SYSTEM, EXHAUST GAS RECIRCULATION (EGR) SYSTEM, THREE-WAY CATALYST (TWC) SYSTEM. NOTE: TROUBLESHOOTING (See pages EM-6 to 9).

COMPONENT LAYOUT AND SCHEMATIC DRAWING

Illustrates the physical component layout and vacuum/emissions schematic for the 3S-GTE engine emission control system. Components identified include: EGR Vacuum Modulator, BVSV (For EVAP), Charcoal Canister, VSV (For EGR), EGR Valve, Jet, ISC Valve, BVSV (For EVAP), Sub-TWC, Main TWC, Oxygen Sensor.

PCV SYSTEM DESCRIPTION

To reduce HC emissions, crankcase blow-by gas (HC) is routed to the intake manifold for combustion in the cylinders.

EGR SYSTEM OPERATION — COOLANT BELOW 54°C (129°F)

VSV is CLOSED. EGR Valve is CLOSED. Exhaust gas is not recirculated regardless of throttle valve position.

EGR SYSTEM OPERATION — COOLANT ABOVE 60°C (140°F), THROTTLE ABOVE E PORT

VSV is OPEN. Throttle valve positioned above E port. Pressure in EGR valve pressure chamber condition (1). EGR Vacuum Modulator not activated. EGR Valve is CLOSED. Exhaust gas is not recirculated.

EGR SYSTEM OPERATION — COOLANT ABOVE 60°C (140°F), THROTTLE BELOW E PORT

VSV is OPEN. Throttle valve positioned below E port. Pressure in EGR valve pressure chamber condition (2). EGR Vacuum Modulator closes passage to atmosphere. EGR Valve is OPEN. Exhaust gas is recirculated (increase).

EGR VACUUM MODULATOR REMARK

When the throttle valve is positioned above the E port, the EGR vacuum modulator will close the atmosphere passage and open the EGR valve to increase the EGR gas, even if the exhaust pressure is insufficiently low.

EGR SYSTEM PURPOSE

To reduce NOx emissions, part of the exhaust gases are recirculated through the EGR valve to the intake manifold to lower the maximum combustion temperature.

EGR SYSTEM AIR FLOW TEST AT 2,500 RPM

Start the engine, and maintain speed at 2,500 rpm. Repeat the above test. Check that there is a strong resistance to air flow. Reconnect the vacuum hoses to the proper locations.

INSPECTION OF HEAT INSULATOR (Sub-Catalytic Converter)

1. Check heat insulator for damage. 2. Check for adequate clearance between catalytic converter and heat insulator.

REINSTALL IDLER PULLEY BRACKET AND A/C COMPRESSOR WITHOUT DISCONNECTING HOSES

See step 16 on pages EM-173 and 174.

REINSTALL FRONT EXHAUST PIPE

See step 3 on page EC-17.

REINSTALL TAILPIPE

See step 4 on page EC-18.

REINSTALL NO.1 AND NO.2 AIR INTAKE CONNECTORS

See steps 38 and 39 on page EM-179.

REINSTALL ENGINE UNDER COVERS

CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY

SYSTEM PURPOSE

Table listing emission control systems, their abbreviations, and purposes: PCV (Positive Crankcase Ventilation) reduces blow-by gas (HC); EVAP (Fuel evaporative emission control) reduces evaporative HC; EGR (Exhaust gas recirculation) reduces NOx; TWC (Three-way catalyst) reduces HC, CO and NOx; EFI (Electronic fuel injection) regulates all engine conditions for reduction of exhaust emissions. For inspection and repair of the EFI system, refer to EFI section of this manual.

EGR SYSTEM OPERATION — COOLANT BELOW 55°C (131°F)

When coolant temperature is below 55°C (131°F), VSV is CLOSED regardless of engine RPM or throttle position. EGR valve is CLOSED and exhaust gas is not recirculated.

EGR SYSTEM OPERATION — COOLANT ABOVE 60°C (140°F), ENGINE BELOW 4,000 RPM, VSV OFF

When VSV is OFF and throttle valve is positioned below E port (regardless of PIM), EGR valve pressure chamber has no pressure, EGR valve is CLOSED and exhaust gas is not recirculated.

EGR SYSTEM OPERATION — COOLANT ABOVE 60°C (140°F), ENGINE BELOW 4,000 RPM, VSV OFF, THROTTLE BELOW E PORT WITH CONDITION (1)

When VSV is OFF, throttle positioned below E port, and condition (1) applies, pressure in EGR valve pressure chamber is present but EGR vacuum modulator state is not activated. EGR valve remains CLOSED and exhaust gas is not recirculated.

EGR SYSTEM OPERATION — COOLANT ABOVE 60°C (140°F), ENGINE BELOW 4,000 RPM, VSV ON, THROTTLE BETWEEN E AND R PORTS — CONDITION (2)

When VSV is ON, throttle positioned between E port and R port, pressure in EGR valve pressure chamber is HIGH (condition 2). EGR vacuum modulator CLOSES passage to atmosphere. EGR valve OPENS and exhaust gas is recirculated. Pressure increase → Modulator closes → EGR valve opens → Pressure drops → EGR valve close → Modulator opens.

EGR SYSTEM OPERATION — COOLANT ABOVE 60°C (140°F), ENGINE BELOW 4,000 RPM, VSV ON, THROTTLE ABOVE R PORT — CONDITION (3)

When VSV is ON and throttle valve is positioned above R port, pressure in EGR valve pressure chamber is HIGH (condition 3). EGR vacuum modulator CLOSES passage to atmosphere and opens EGR valve to increase exhaust gas recirculation even if exhaust pressure is insufficiently low.

EGR SYSTEM OPERATION — ENGINE ABOVE 4,000 RPM

When engine RPM is above 4,000 rpm, VSV is OFF and throttle is CLOSED. EGR valve is CLOSED and exhaust gas is not recirculated.

VSV DIAGNOSTIC SWITCH NOTE

If terminals TE1 and E1 of check connector are connected, the VSV switches ON.

INSPECTION OF EGR VALVE — REMOVE EGR VALVE

Check for sticking and heavy carbon deposits. If a problem is found, replace the valve.

INSPECTION OF EGR VALVE — REINSTALL EGR VALVE

Install a new gasket.

INSPECTION OF HEAT INSULATOR (Sub-Catalytic Converter (CALIF. only))

1. CHECK HEAT INSULATOR FOR DAMAGE. 2. CHECK FOR ADEQUATE CLEARANCE BETWEEN CATALYTIC CONVERTER AND HEAT INSULATOR.

DISCONNECT POWER BEFORE REMOVING EFI WIRING

Before removing EFI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the battery terminals. Always check the diagnosis code before disconnecting the battery terminals.

CONNECT BATTERY CABLES CORRECTLY

When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (−) cables.

HANDLE EFI PARTS WITH CARE

Do not permit parts to receive a severe impact during removal or installation. Handle all EFI parts carefully, especially the ECU.

AVOID CARELESS TROUBLESHOOTING

Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can cause further troubles.

DO NOT OPEN THE ECU COVER

Do not open the ECU cover.

PREVENT WATER ENTRY DURING INSPECTION

When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the EFI parts and wiring connectors.

REPLACE PARTS AS AN ASSEMBLY

Parts should be replaced as an assembly.

CARE WHEN PULLING OUT AND INSERTING WIRING CONNECTORS

Care is required when pulling out and inserting wiring connectors.

INSPECTING A CONNECTOR WITH A VOLT/OHMMETER

When inspecting a connector with a volt/ohmmeter.

INSERT TEST PROBE FROM WIRING SIDE

Insert the test probe into the connector from wiring side when checking the continuity, amperage or voltage.

DO NOT APPLY UNNECESSARY FORCE TO TERMINAL

Do not apply unnecessary force to the terminal.

REINSTALL WATER-PROOFING RUBBER

After checking, install the water-proofing rubber on the connector securely.

USE SST FOR INJECTOR INSPECTION

Use SST for inspection or test of the injector, cold start injector or its wiring connector. SST 09842-30050 (A) and 09842-30060 (B) for 3S-GTE; 09842-30050 (A) and 09842-30070 (C) for 5S-FE.

DISCONNECTING HIGH FUEL PRESSURE LINE

When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures.

CONNECTING FLARE NUT OR UNION BOLT ON HIGH PRESSURE PIPE UNION

When connecting the flare nut or union bolt on the high pressure pipe union, observe the following procedures.

CHECK FOR FUEL LEAKS WITH RETURN HOSE PINCHED

When the fuel return hose is pinched, the pressure within high pressure line will rise to approx. 4 kg/cm² (57 psi, 392 kPa). In this state, check to see that there are no leaks from any part of the fuel system.

• Always pinch the hose. Avoid bending as it may cause the hose to crack.

TURN OFF IGNITION AND REMOVE SST AFTER INSPECTION

Turn the ignition switch OFF. Remove the SST. SST 09843-18020.

CHECK IDLE SPEED

Standard idle speed: 3S-GTE 800±50 rpm; 5S-FE 750±50 rpm USA M/T, 700±50 rpm USA A/T, 850±50 rpm CANADA M/T, 750±50 rpm CANADA A/T. If BAD: 1. ISC system — (1) Wiring connection, (2) ISC valve (See page FI-148 or 151), (3) ECU (test by substitution). 2. (5S-FE) Idle speed — Adjust (See page EM-20).

CHECK IGNITION TIMING

1. Connect terminals TE1 and E1 of the check connector. 2. Check ignition timing. Standard: 10° BTDC @ idle. If NO: Ignition timing — Adjust (See page IG-17 or 22).

CHECK SPARK PLUGS

Standard gap: 3S-GTE 0.8 mm (0.031 in.); 5S-FE 1.1 mm (0.043 in.). HINT: Check compression pressure and valve clearance if necessary. If NO: 1. Spark plugs (See page IG-6 or 11). 2. Compression pressure (See page EM-25) Minimum (at 250 rpm): 3S-GTE 9.0 kg/cm² (128 psi, 883 kPa); 5S-FE 10.0 kg/cm² (142 psi, 981 kPa). 3. Valve clearance (Cold) (See page EM-11 or 16).

CHECK COLD START INJECTOR

See page FI-99 or 102. If BAD: 1. Cold start injector (See page FI-99 or 102). 2. Cold start injector time switch (See page FI-158).

CHECK FUEL PRESSURE

See page FI-87. If BAD: 1. Fuel pump (See page FI-85). 2. Fuel filter. 3. Fuel pressure regulator (See page FI-105 or 107).

CHECK INJECTORS

See page FI-110 or 120. If BAD: Injection condition. Continue OK on page FI-16.

CHECK SPARK PLUGS

Check spark plugs against standard gap. 3S-GTE: 0.8 mm (0.031 in.), 5S-FE: 1.1 mm (0.043 in.). HINT: Check compression pressure and valve clearance if necessary. If NO: 1. Spark plugs (See page IG-6 or 11); 2. Compression pressure (See page EM-25) Minimum at 250 rpm: 3S-GTE 9.0 kg/cm2 (128 psi, 883 kPa), 5S-FE 10.0 kg/cm2 (142 psi, 981 kPa); 3. Valve clearance (Cold) (See page EM-11 or 15).

CHECK T-VIS VALVE (3S-GTE)

See page EM-22. Check if air control valve is open with engine running at 4,200 rpm above. If BAD: 1. T-VIS VSV (See page FI-163); 2. Vacuum leaks.

CHECK EFI ELECTRONIC CIRCUIT USING VOLT/OHMMETER

See page FI-33. If BAD: 1. Wiring connections; 2. Power to ECU: (1) Fusible links, (2) Fuses, (3) EFI main relay (See page FI-156); 3. (3S-GTE) Air flow meter (See page FI-131); 4. (5S-FE) Vacuum sensor (See page FI-170); 5. Water temp. sensor (See page FI-168); 6. Intake air temp. sensor (See page FI-131 or 169); 7. Throttle position sensor (See page FI-134 or 141); 8. Injection signal circuit: (1) Injector wiring, (2) (3S-GTE) Solenoid resistor (See page FI-159), (3) ECU (See page FI-176).

DIAGNOSIS SYSTEM DESCRIPTION

The ECU contains a built-in, self-diagnosis system that detects which troubles within the engine signal network and then flashes a warning on the 'CHECK' engine warning light on the instrument panel. By analyzing various signals shown in the tables (See page 28 or 30) the ECU detects system malfunctions which are related to the various operating parameter sensors or actuator. The ECU stores the failure code associated with the detected failure until the diagnosis system is cleared by removing the EFI fuse with the ignition switch OFF.

CHECK ENGINE WARNING LIGHT CHECK

1. The 'CHECK' engine warning light will come on when the ignition switch is placed at ON and the engine is not running. 2. When the engine is started, the 'CHECK' engine warning light should go off. If the light remains on, the diagnosis system has detected a malfunction or abnormality in the system.

FUEL PUMP WIRING DIAGRAM — 5S-FE

Wiring diagram showing the EFI fuel pump circuit for the 5S-FE engine. The circuit originates from the Battery through FL MAIN 2.0L fusible link, FL 1.0Y fusible link, and FL AM2 40A fusible link. The Ignition Switch (AM2) provides IG2 and ST2 outputs. The EFI Main Relay is powered via Fuse AM2 7.5A and Fuse EFI 15A. The Starter Relay is activated through the Clutch Start Switch (M/T) or Neutral Start Switch (A/T) via ST2. The Circuit Opening Relay receives +B supply and is controlled by the ECU via FC, E1, and STA terminals. The Fuel Pump is powered through the Check Connector (FP and +B terminals) and the Circuit Opening Relay (FP terminal). The FC terminal of the Circuit Opening Relay connects to the ECU (FC).

ASSEMBLY OF FUEL PUMP

See page FI-95

INSTALL FUEL PUMP FILTER TO FUEL PUMP

Install the pump filter with a new clip.

INSTALL FUEL PUMP TO FUEL PUMP BRACKET

(a) Connect the fuel hose to the outlet port of the fuel pump. (b) Connect the lead wire to the fuel pump with the spring washer and nut. Connect the three lead wires. (c) Install the rubber cushion to the fuel pump. (d) Install the fuel pump by pushing the lower side of the fuel pump.

REMOVE COLD START INJECTOR

Remove the two bolts, cold start injector and gasket.

REMOVAL OF DELIVERY PIPE AND INJECTORS

Preceding steps on this page cover removal of delivery pipe and injectors for the 5S-FE engine.

• Be careful not to drop the injectors when removing the delivery pipe.

COOLING SYSTEM TABLE OF CONTENTS

Index listing all subsections of the Cooling System chapter with corresponding page numbers: DESCRIPTION (CO-2), TROUBLESHOOTING (CO-4), ENGINE COOLANT CHECK (CO-4), REPLACEMENT OF ENGINE OF COOLANT (CO-5), WATER PUMP (CO-10), THERMOSTAT (CO-14), RADIATOR (CO-16), ELECTRIC COOLING FANS (CO-21), Radiator Cooling Fans (w/ A/C) (CO-21), Radiator Cooling Fan (w/o A/C) (CO-28), Engine Compartment Cooling Fan (3S-GTE) (CO-31).

COOLING SYSTEM DESCRIPTION

This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by-pass valve mounted on the inlet side.

CHECK ENGINE COOLANT LEVEL AT RESERVE TANK

The coolant level should be between the "LOW" and "FULL" lines. If low, check for leaks and add coolant up to the "FULL" line.

CHECK ENGINE COOLANT QUALITY

There should not be any excessive deposits of rust or scales around the radiator (water filler) cap or water filler hole, and the coolant should be free from oil. If excessively dirty, replace the coolant.

THERMOSTAT REMOVAL HINT

Removal of the thermostat would have an adverse effect, causing a lowering of cooling efficiency. Do not remove the thermostat, even if the engine tends to overheat.

AVOID BURNS — COOL ENGINE BEFORE WORK

To avoid the danger of burns, do not begin work until the engine and coolant are properly cooled down.

• Do not begin work until the engine and coolant are properly cooled down.

PERFORM WORK ON LEVEL AREA

To ensure that coolant is poured in properly, perform the operation at a level area. Performing work with the vehicle inclined may cause improper removal of coolant or improper air removal when pouring coolant.

• Performing work with the vehicle inclined may cause improper removal of coolant or improper air removal when pouring coolant.

CHECK WATER LEVEL AFTER REPLACEMENT

When replacement has been performed, check the water level in the water filler and reservoir tank once or twice within 500 km (311 miles) of driving or within one week.

INSPECT WATER PUMP

Turn the pulley and check that the water pump bearing moves smoothly and quietly.

INSPECTION OF THERMOSTAT — INSPECT THERMOSTAT

HINT: The thermostat is numbered with the valve opening temperature. (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80–84°C (176–183°F). If the valve opening temperature is not as specified, replace the thermostat. (c) Check the valve lift. Valve lift: 8 mm (0.31 in.) or more at 95°C (203°F). If the valve lift is less than specification, replace the thermostat. (d) Check that the valve spring is tight when the thermostat is fully closed. If necessary, replace the thermostat.

SYSTEM CIRCUIT — Radiator Cooling Fan (w/o A/C)

The radiator cooling fan circuit (without A/C) consists of: Battery → FL MAIN 2.0L → FL ALT 120A → Fan Main Relay → (power path) Fuse AM2 7.5A → Ignition Switch (AM2/IG2) → Fan Main Relay coil. High-current path: Fuse RAD FAN 30A → Cooling Fan Relay → No. 1 Radiator Cooling Fan Motor (M). The Water Temp. Switch controls the Cooling Fan Relay coil to switch the fan on/off based on coolant temperature.

LOCATION OF RADIATOR COOLING FAN COMPONENTS

Components are located as follows: Fan Main Relay ('FAN MAIN') — underhood fuse/relay block. Cooling Fan Relay ('FAN No. 1') — underhood fuse/relay block. Fuse AM2 7.5A — underhood fuse/relay block. Fuse RAD FAN 30A — underhood fuse/relay block. FL ALT 120A — underhood fuse/relay block. No. 1 Radiator Cooling Fan — front of engine bay at radiator. Water Temp. Switch — engine coolant outlet.

LUBRICATION SYSTEM DESCRIPTION

A fully pressurized, fully filtered lubrication system has been adopted for this engine. Oil flow path: OIL PAN → OIL STRAINER → OIL PUMP (with RELIEF VALVE) → OIL FILTER (with RELIEF VALVE) → OIL COOLER (with RELIEF VALVE) → MAIN OIL HOLE → distributed to: CRANKSHAFT (→ CONNECTING RODS → PISTONS), OIL NOZZLES, CYLINDER HEAD (→ CAMSHAFT JOURNALS → CAMS → VALVE LIFTERS & VALVE STEMS), and TURBOCHARGER. All return paths lead back to OIL PAN.

LUBRICATION SYSTEM OPERATION — 5S-FE

Oil flows from the OIL PAN through the OIL STRAINER to the OIL PUMP. From the OIL PUMP it passes through the OIL FILTER (with a RELIEF VALVE bypass) and through the OIL COOLER (with a RELIEF VALVE bypass) into the MAIN OIL HOLE. A third RELIEF VALVE is also present in the circuit. From the MAIN OIL HOLE oil is distributed to: (1) CRANKSHAFT → CONNECTING RODS → PISTONS; (2) CYLINDER HEAD → CAMSHAFT JOURNALS → CAMS → VALVE LIFTERS & VALVE STEMS → CAMSHAFT GEARS. Excess/bypassed oil returns to the OIL PAN.

LUBRICATION SYSTEM OVERVIEW

A pressure feeding lubrication system has been adopted to supply oil to the moving parts of this engine. The lubrication system consists of an oil pan, oil pump, oil filter and other external parts which supply oil to the moving parts in the engine block. The oil circuit is shown in the illustration at the top of the previous page. Oil from the oil pan is pumped up by the oil pump. After it passes through the oil filter, it is fed through the various oil holes in the crankshaft and cylinder block. After passing through the cylinder block and performing its lubricating function, the oil is returned by gravity to the oil pan. A dipstick on the center left side of the cylinder block is provided to check the oil level.

OIL PUMP

The oil pump pumps up oil from the oil pan and sends it under pressure to the various parts of the engine. An oil strainer is mounted in front of the inlet to the oil pump. The oil pump itself is a trochoid type pump, inside of which there is a drive rotor and a driven rotor. When the drive rotor rotates, the driven rotor rotates in the same direction, and since the axis of the driven rotor shaft is different from the center of the driven rotor, the space between the two rotors is changed as they rotate. Oil is drawn in when the space is wide and is discharged when the space is narrow.

OIL PRESSURE REGULATOR

At high engine speeds, the engine oil supplied by the oil pump exceeds the capacity of the engine to utilize it. For that reason, the oil pressure regulator works to prevent an oversupply of oil. During normal oil supply, a coil spring and valve keep the bypass closed, but when too much oil is being fed, the pressure become extremely high, overpowering the force of the spring and opening the valves. This allows the excess oil to flow through the valve and return to the oil pan.

OIL FILTER

The oil filter is a full flow type filter with a built-in paper filter element. Particles of metal from wear, airborn dirt, carbon and other impurities can get into the oil during use and could cause accelerated wear or sizing if allowed to circulate through the engine. The oil filter, integrated into the oil line, removes these impurities as the oil passes through it. The filter is mounted outside the engine to simplify replacement of the filter element. A relief valve is also included ahead of the filter element to relieve the high oil pressure in case the filter element becomes clogged with impurities. The relief valve opens when the oil pressure overpowers the force of the spring. Oil passing through the relief valve by-passes the oil filter and flows directly into the main oil hole in the engine.

SKIN CONTACT WARNING

Prolonged and repeated contact with mineral oil will result in the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition, used engine oil contains potentially harmful contaminants which may cause skin cancer.

• Prolonged and repeated contact with mineral oil may cause skin cancer.

PROTECTIVE MEASURES WHEN HANDLING ENGINE OIL

Care should be taken, therefore, when changing engine oil, to minimize the frequency and length of time your skin is exposed to used engine oil. Protective clothing and gloves, that cannot be penetrated by oil, should be worn. The skin should be thoroughly washed with soap and water, or use waterless hand cleaner, to remove any used engine oil. Do not use gasoline, thinners, or solvents.

• Do not use gasoline, thinners, or solvents to clean skin.

ENVIRONMENTAL DISPOSAL

In order to preserve the environment, used oil and used oil filter must be disposed of only at designated disposal sites.

INSPECT RELIEF VALVE

Coat the valve with engine oil and check that it falls smoothly into the valve hole by its own weight. If it doesnt, replace the relief valve. If necessary, replace the oil pump assembly.

INSPECT DRIVE AND DRIVEN ROTORS — Rotor body clearance

Using a feeler gauge, measure the clearance between the driven rotor and body. If the body clearance is greater than maximum, replace the rotors as a set. If necessary, replace the oil pump assembly.

INSPECT DRIVE AND DRIVEN ROTORS — Rotor tip clearance

Using a feeler gauge, measure the clearance between the drive and driven rotors. If the tip clearance is greater than maximum, replace the rotors as a set.

REPLACEMENT OF CRANKSHAFT FRONT OIL SEAL

See page EM-160.

ASSEMBLY OF OIL PUMP

See page LU-12. Steps: 1. INSTALL DRIVE AND DRIVEN ROTORS: (a) Place the drive and driven rotors into pump body with the marks facing the pump body cover side. (b) Install a new O-ring to the pump body. (c) Install the pump body cover with the two bolts. Torque: 90 kg-cm (78 in.-lb, 8.8 N·m). 2. INSTALL RELIEF VALVE: (a) Insert the relief valve, spring and retainer into the pump body hole. (b) Using snap ring pliers, install the snap ring.

REMOVE WATER BY-PASS HOSE HEAT PROTECTOR

Remove the bolt, two nuts and heat protector.

DISCONNECT WATER BY-PASS HOSES FROM OIL COOLER

Disconnect the two water by-pass hoses.

REMOVE OIL COOLER

Remove the relief valve and plate washer, then the nut and oil cooler, then the O-ring and gasket from the oil cooler.

IGNITION SYSTEM TABLE OF CONTENTS

Index listing sections: PRECAUTIONS (IG-2), TROUBLESHOOTING (IG-3), IGNITION SYSTEM CIRCUIT (IG-4), ON-VEHICLE INSPECTION (3S-GTE) (IG-5), ON-VEHICLE INSPECTION (5S-FE) (IG-10), DISTRIBUTOR (3S-GTE) (IG-14), DISTRIBUTOR (5S-FE) (IG-19).

INSPECTION OF IGNITER

See procedure Spark Test on page IG-5.

INSPECT FIELD COIL FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity between the lead wire and field coil brush lead. If there is no continuity, replace the field frame.

INSPECT FIELD COIL FOR GROUND

Using an ohmmeter, check that there is no continuity between the field coil end and field frame. If there is continuity, replace the field frame.

INSTALL END COVER

Install the end cover with two new O-rings (1.4 kW and 1.6 kW types) and the two screws.

COMPONENTS — 70 A Type

Exploded view of 70 A Type alternator components: Pulley, Drive End Frame (Stator), Front Bearing, Retainer, Bearing Cover, Rear Bearing, Rotor, Rear End Cover, Brush Holder Cover, Brush Holder, Spring, Brush, IC Regulator, Rectifier Holder, Rubber Insulator, Rectifier End Frame, Terminal Insulator.

COMPONENTS — 80 A and 100 A Types

Exploded view of 80 A and 100 A Type alternator components: Pulley, Drive End Frame (Stator), Front Bearing, Retainer, Alternator Washer, Bearing Cover, Rear Bearing, Rotor, Rear End Cover, Brush Holder Cover, Brush Holder, IC Regulator, Rectifier Holder, Rubber Insulator, Rectifier End Frame, Seal Plate, Terminal Insulator.

REMOVE RECTIFIER END FRAME

Using SST, remove the rectifier end frame. SST 09286-46011

REMOVE ALTERNATOR WASHER (80 A and 100 A Types)

For 80 A and 100 A Types, remove the alternator washer.

INSPECT ROTOR FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance (Cold): 2.8 – 3.0 Ω. If there is no continuity, replace the rotor.

INSPECT ROTOR FOR GROUND

Using an ohmmeter, check that there is no continuity between the slip ring and rotor. If there is continuity, replace the rotor.

INSPECT STATOR FOR OPEN CIRCUIT

Using an ohmmeter, check that there is continuity between the coil leads. If there is no continuity, replace the drive end frame assembly.

INSPECT STATOR FOR GROUND

Using an ohmmeter, check that there is no continuity between the coil lead and drive end frame. If there is continuity, replace the drive end frame assembly.

INSPECT EXPOSED BRUSH LENGTH

Using scale or vernier calipers, measure the exposed brush length. If the exposed length is less than minimum, replace the brushes (70 A type) or brushes and brush holder assembly (80 A and 100 A types).

ECU MEASUREMENT HINTS

Perform all voltage and resistance measurements with the ECU connected. Verify that the battery voltage is 11 V or above with the ignition switch is ON.

HOW TO DETERMINE BOLT STRENGTH

Bolt class is determined by the mark on the bolt head or the type of bolt. Hexagon head bolt with bolt head number 4 = 4T, 5 = 5T, 6 = 6T, 7 = 7T, 8 = 8T, 9 = 9T, 10 = 10T, 11 = 11T. Hexagon head bolt with no mark = 4T. Hexagon flange bolt / w/ washer hexagon bolt with no mark = 4T. Hexagon head bolt with two protruding lines = 5T. Hexagon flange bolt / w/ washer hexagon bolt with two protruding lines = 6T. Hexagon head bolt with three protruding lines = 7T. Hexagon head bolt with four protruding lines = 8T. Stud bolt with no mark = 4T. Stud bolt with grooved shank = 6T. Welded bolt = 4T.

INSPECTION OF MASTER CYLINDER

Clean the disassembled parts with compressed air.

INSPECT MASTER CYLINDER BORE FOR SCORING OR CORROSION

If a problem is found, clean or replace the cylinder.

INSPECT PISTON AND CUPS FOR WEAR, SCORING, CRACKS OR SWELLING

If either one requires replacement, use the parts from the cylinder kit.

INSPECT PUSH ROD FOR WEAR OR DAMAGE

If necessary, replace the push rod.

ASSEMBLY OF RELEASE CYLINDER

See page CL-8. Steps: (1) Coat piston with Lithium Soap Base Glycol Grease, as shown. (2) Install piston. (3) Install boot and insert push rod.

INSTALLATION OF RELEASE CYLINDER

See page CL-8. Steps: (1) Install release cylinder — Torque: 120 kg-cm (9 ft-lb, 12 N·m). (2) Install engine front mounting bracket set bolts — Torque: 790 kg-cm (57 ft-lb, 77 N·m). (3) Remove supports for engine and transaxle.

TRANSAXLE TYPES S54 AND E153

Transaxle types S54 and E153 are constant mesh synchronizers for forward gears, and a sliding mesh reverse gear.

INPUT AND OUTPUT SHAFT COMPOSITION

The input shaft is composed of the 1st and 2nd speed gears and the reverse drive gear, and the output shaft is composed of the drive gear (for use with the ring gear).

OIL USED IN TRANSAXLES

The oil used in the transaxles are as follows: S51 — ATF type DEXRON II; E153 — Transaxle oil E50 (08885-80206) or equivalent.

S54 AND E153 TRANSAXLES — GEAR ENGAGEMENT ILLUSTRATIONS

The illustrations below show the engagements of transaxle gears for 1st, 2nd, 3rd, 4th, 5th, and Reverse. Each gear position engages a specific Drive Gear and Driven Gear pair on the input/output shafts, which then drives the Differential Drive Gear and Differential Assembly. Reverse uses an additional Reverse Idler Gear between the Reverse Drive Gear and Reverse Driven Gear to achieve reverse rotation.

FIPG MATERIAL PRECAUTIONS

When working with FIPG material, you must observe the following.

REMOVE OLD PACKING

Using a razor blade and gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces.

CLEAN ALL COMPONENTS

Thoroughly clean all components to remove all the loose material.

CLEAN SEALING SURFACES

Clean both sealing surfaces with a non-residue solvent.

APPLY SEAL PACKING

Apply the seal packing in approx. 1 mm (0.04 in.) bead along the sealing surface.

ASSEMBLE WITHIN 10 MINUTES

Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.

COMPONENTS (Cont'd)

Exploded diagram showing the component parts of the S54 Manual Transaxle including: Oil Seal (non-reusable), Transaxle Case, No.2 Shift Fork Shaft, Transaxle Case Oil Receiver, Reverse Shift Fork, Interlock Pin, No.1 Shift Fork, No.2 Shift Fork, No.1 Shift Fork Shaft, No.1 Shift Head, Differential Assembly, Reverse Shift Arm, Input Shaft, Output Shaft Front Bearing, Output Shaft Cover, Input Shaft Front Bearing, Output Shaft, Reverse Idler Gear and Shaft, Synchronizer Ring, Spacer, Needle Roller Bearing, 4th Gear, Radial Ball Bearing, Snap Ring, Slotted Spring Pin, 3rd Gear, Needle Roller Bearing, Synchronizer Ring, No.2 Hub Sleeve, Snap Ring.

INSTALL TRANSMISSION CASE AND MEASURE SIDE BEARING PRELOAD

Steps (c) through (f): Install the transmission case to the transaxle case. Install and torque the seventeen bolts. Using SST 09564-32011, rotate the differential in both directions to snug the bearing down. Using SST 09564-32011 and a torque meter, measure the preload of the side bearing. If the preload is not within specification, remove the bearing retainer from the case. Re-select the transmission case side adjusting shim.

INSPECTION OF COMPONENT PARTS

Inspection procedures for manual transaxle E153 component parts.

INSPECT SYNCHRONIZER RING FOR FIFTH GEAR

(a) Check for wear or damage. (b) Turn the ring and push it in to check the braking action. (c) Measure the clearance between the synchronizer ring back and the gear spline end. If the clearance is less than the minimum limit, replace the synchronizer ring.

FUNCTION OF COMPONENTS

Describes the function of each component in the automatic transaxle: C1 Forward Clutch connects input shaft and front planetary ring gear; C2 Direct Clutch connects input shaft and front & rear planetary sun gear; C3 U/D Clutch connects underdrive sun gear and underdrive planetary carrier; B1 2nd Coast Brake prevents front & rear planetary sun gear from turning either clockwise or counterclockwise; B2 2nd Brake prevents outer race of F1 from turning either clockwise or counterclockwise, thus preventing the front & rear planetary sun gear from turning counterclockwise; B3 1st & Reverse Brake prevents rear planetary carrier from turning either clockwise or counterclockwise; B4 U/D Brake prevents underdrive sun gear from turning either clockwise or counterclockwise; F1 No. 1 One-Way Clutch — when B2 is operating, this clutch prevents the front & rear planetary gear from turning counterclockwise; F2 No. 2 One-Way Clutch prevents rear planetary carrier from turning counterclockwise; F3 U/D One-Way Clutch prevents underdrive planetary sun gear from turning clockwise; Planetary Gears change the route through which driving force is transmitted, in accordance with the operation of each clutch and brake, in order to increase or reduce the input and output speed.

A241E Electronic Control System — General

The electronic control system for the A241E automatic transaxle provides extremely precise control of the gear shift timing and lock-up timing in response to driving conditions as sensed by various sensors located throughout the vehicle and in response to the engine's running condition. At the same time, the ECU control reduces vehicle squat when the vehicle starts out the gear shift shock. The electronic control system is also equipped with a self diagnosis system which diagnoses malfunctions of electronically controlled components and warns the driver, and a fail-safe which makes it possible for the vehicle to continue functioning when a malfunction occurs.

A241E Electronic Control System — Construction

The electronic control system can be broadly divided into three groups; the sensors, ECU and actuators. Sensors include: Throttle Position Sensor (IDL — Idling Signal, VTA — Throttle Position Signal), Water Temperature Sensor (THW), Distributor (Ne — Engine RPM Sensor, G1/G- — Crankshaft Angle Signal), No. 1 Speed Sensor (SPD), No. 2 Speed Sensor (SP2), Neutral Start Switch (NSW — Neutral Start Signal, 2/L — Shift Lever Position Signal), Stop Light Switch (STP), O/D Main Switch (OD2), Cruise Control Computer (OD1), Battery (+B). The Engine & Transaxle ECU contains: Engine — Ignition Timing Control (outputs IGt, IGf); Transaxle — Control of Shift Timing (outputs S1, S2), Control of Lock-Up Timing (output SL), Self-Diagnostic System (output OD2), Back-Up System. Actuators include: ESA — Igniter → Ignition Coil → Distributor → Spark Plugs; No. 1 Solenoid Valve (S1); No. 2 Solenoid Valve (S2); Lock-Up Solenoid Valve (SL); O/D OFF Indicator Light / Diagnostic Code Display (OD2).

TROUBLESHOOTING OVERVIEW

Trouble occurring in the ECT can stem from one of three sources: the engine, the ECT electronic control unit or the transaxle itself. Before troubleshooting, determine in which these three sources the problem lies, and begin troubleshooting with the simplist operation, gradually working up in order of difficulty.

Basic Troubleshooting

Before troubleshooting and ECT, first determine whether the problem is electrical or mechanical. To do this, just refer to the basic troubleshooting flow-chart provided below. If the cause is already known, using the basic troubleshooting chart below along with the general troubleshooting chart on the following page should speed the procedure. Flow: (1) Preliminary Check (See page AT-12) — Bad → Repair or Replace; OK → (2) Read Diagnostic Code (See page AT-15) — Bad → Repair or Replace; OK → (3) Manual Shifting Test (See page AT-19) — Bad → Mechanical System Tests (See page AT-31) — Bad → Repair Transaxle; OK → Electrical Control System Check (See page AT-20) — Bad → Repair or Replace; OK → Mechanical System Tests (See page AT-31).

Overdrive OFF indicator blink warning

If diagnostic code Nos. 42, 61, 62 or 63 are output, the overdrive OFF indicator light will begin to blink immediately to warn the driver. However, an impact or shock may cause the blinking to stop; but the code will still be retained in the Engine and ECT ECU memory until canceled out.

No warning for code 64

There is no warning for diagnostic code No. 64.

Simultaneous malfunction of both speed sensors

In the event of a simultaneous malfunction of both No. 1 and No. 2 speed sensors, no diagnostic code will appear and the fail-safe system will not function. However, when driving in the D range, the transaxle will not up-shift from first gear, regardless of the vehicle speed.

PERFORM TEST AT NORMAL FLUID TEMPERATURE

Perform the test at normal operation fluid temperature (50 – 80°C or 122 – 176°F).

DO NOT RUN TEST LONGER THAN 5 SECONDS

Do not continuously run this test longer than 5 seconds.

CONDUCT TEST IN SAFE AREA

To ensure safety, conduct this test in a wide, clear, level area which provides good traction.

CARRY OUT STALL TEST IN PAIRS

The stall test should always be carried out in pairs. One should observe the condition of wheels or wheel stoppers outside the vehicle while the other is performing the test.

EVALUATION — STALL SPEED SAME FOR BOTH RANGES, LOWER THAN SPECIFIED

If the stall speed is the same for both ranges without the rear wheels rotating but lower than specified value: Engine output may be insufficient; Stator one-way clutch is not operating properly.

EVALUATION — STALL SPEED IN D RANGE HIGHER THAN SPECIFIED

If the stall speed in D range is higher than specified: Line pressure too low; Forward clutch slipping; No. 2 one-way clutch not operating properly; Underdrive one-way clutch not operating properly.

EVALUATION — STALL SPEED IN R RANGE HIGHER THAN SPECIFIED

If the stall speed in R range is higher than specified: Line pressure too low; Direct clutch slipping; First and reverse brake slipping; Underdrive brake slipping.

EVALUATION — STALL SPEED IN BOTH R AND D RANGES HIGHER THAN SPECIFIED

If the stall speed in both R and D ranges are higher than specified: Line pressure too low; Improper fluid level; Underdrive brake slipping.

WORK START DELAY AFTER IGNITION LOCK

Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the 'LOCK' position and the negative (–) terminal cable is disconnected from the battery.

ON-VEHICLE COMPONENT REPLACEMENT

The components mentioned below can be replaced on the vehicle without any necessity for removal of the transmission. For the respective operating procedures refer to the following pages: Valve body — Removal AT-49 to AT-51, Installation AT-157 to AT-160; Throttle cable — Removal AT-39, Installation AT-39 and AT-40.

INSPECT BRAKE BAND

If the lining of the brake band is exfoliated or discolored, or even part of the printed numbers are defaced, replace the brake band.

REMOVE SPRING, WASHER AND PISTON ROD

Remove the spring, washer and piston rod.

KEY, STOPPER AND PIN

Diagram showing location of keys (a, b, c), pins, and vibrating stopper on the automatic transaxle valve body. Three keys are identified: (a) Accumulator Control Valve key, (b) Cut-back Valve key, and (c) Low Coast Modulator Valve key. A vibrating stopper and multiple pins are also located on the valve body as shown in diagram AT5689.

CHECK BALL

Diagram (AT5678) showing the location of check balls on the automatic transaxle valve body.

LOCATION OF KEYS AND STRAINER

Diagram showing the location of keys (a through f) and the strainer on both the Upper Side and Lower Side of the automatic transaxle valve body.

PLANETARY RING GEAR INSTALLATION CHECK

If the planetary ring gear and the other parts are installed correctly into the case, the end of the bushing with the ring gear flange will be flush with a shoulder of the intermediate shaft or under.

INSTALL RACES AND BEARING ONTO RING GEAR FLANGE

Coat the races and bearing with petroleum jelly and install them onto the tip of ring gear flange as shown. Front Race: outer diameter 37.9 mm (1.492 in.), inner diameter 22.0 mm (0.866 in.). Bearing: outer diameter 36.1 mm (1.421 in.), inner diameter 22.2 mm (0.874 in.). Rear Race: outer diameter 35.7 mm (1.406 in.), inner diameter 23.0 mm (0.906 in.).

TROUBLESHOOTING

Diagnostic table mapping suspension and axle problems to possible causes and remedies with front and rear page references. Problems covered: Wanders/pulls, Bottoming, Sways/pitches, Front wheel shimmy, Abnormal tire wear. Possible causes and remedies are listed with corresponding front and rear section page references.

INSTALL ROTOR DISC TO AXLE HUB

Before removing the rotor disc, place the matchmarks on the axle hub and rotor disc.

INSTALL DISC BRAKE CALIPER TO STEERING KNUCKLE

Install and torque the two bolts. Torque: 600 kg-cm (43 ft-lb, 59 N·m)

INSPECT BALL JOINT FOR ROTATION

Remove the ball joint. Flip the ball joint stud back and forth 5 times as shown in the figure, before installing the nut. Using a torque gauge, turn the nut continuously one turn each 2-4 seconds and take the torque reading on the fifth turn. Torque (turning): 8-25 kg-cm (7-22 in.-lb, 0.8-2.5 N·m). If not within specification, replace the ball joint. Install the ball joint.

REMOVAL OF STRUT BAR — MEASURE LENGTH "L" BEFORE REMOVE

Measure length "L" before removing the strut bar.

INSTALLATION OF STRUT BAR

See page SA-24

INSTALL STRUT BAR

(a) Install the nut, retainer, cushion and collar to the strut bar. (b) Install the strut bar to the body, and connect to the lower arm. (c) Install the cushion, retainer spring washer and nut.

• Do not misinstall the front and rear cushions.

INSTALL ROTOR DISC

Align the matchmarks and install the rotor disc to the axle hub.

INSTALL BRAKE CALIPER

Torque: 600 kg-cm (43 ft-lb, 59 N·m)

INSTALL PLATE WASHER, BEARING LOCK NUT, BEARING LOCK NUT CAP AND NEW COTTER PIN

Install the plate washer and lock nut. With the parking brake engaged, tighten the nut. Install the lock nut cap and a new cotter pin.

INSPECT REAR WHEEL ALIGNMENT

See page SA-31

COMPRESSION TEST — REPEAT FOR EACH CYLINDER

Repeat steps (a) through (c) for each cylinder. This measurement must be done in as short a time as possible.

• This measurement must be done in as short a time as possible.

LOW COMPRESSION DIAGNOSIS

If the 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 (c) for cylinders with low compression. If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket.

SUSPEND A/C COMPRESSOR

Suspend the A/C compressor to strut rod with a string.

MEASURE PLASTIGAGE OIL CLEARANCE

Measure the Plastigage at its widest point. If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft. HINT: If using a standard bearing, replace it with one having the same number marked on the connecting rod cap. There are three sizes of standard bearings, marked '1', '2' and '3' accordingly.

KEEP BEARINGS AND CONNECTING ROD TOGETHER

Keep the bearings, connecting rod and cap together.

ARRANGE PISTON AND CONNECTING ROD ASSEMBLIES IN ORDER

Arrange the piston and connecting rod assemblies in correct order.

MEASURE PLASTIGAGE AT WIDEST POINT

Measure the Plastigage at its widest point to determine main bearing oil clearance. Standard clearance for No.3 STD: 0.025–0.044 mm (0.0010–0.0017 in.), U/S 0.25: 0.021–0.061 mm (0.0008–0.0024 in.). Others STD: 0.015–0.034 mm (0.0006–0.0013 in.), U/S 0.25: 0.029–0.069 mm (0.0011–0.0027 in.). Maximum clearance: 0.08 mm (0.0031 in.).

REPLACE BEARINGS IF CLEARANCE EXCEEDS MAXIMUM

If the oil clearance is greater than maximum, replace the bearings. If necessary, grind or replace the crankshaft.

SELECT CORRECT STANDARD BEARING BY NUMBER

If using a standard bearing, replace it with one having the same number. If the number of the bearing cannot be determined, select the correct bearing by adding together the numbers imprinted on the cylinder block and crankshaft, then selecting the bearing with the same number as the total. There are five sizes of standard bearings, marked '1', '2', '3', '4' and '5' accordingly. EXAMPLE: Cylinder block '2' + Crankshaft '1' = Total number 3 (Use bearing '3'). Bearing selection table: Cylinder block mark 1 / Crankshaft 0→Use 1, 1→Use 2, 2→Use 3; Cylinder block mark 2 / Crankshaft 0→Use 2, 1→Use 3, 2→Use 4; Cylinder block mark 3 / Crankshaft 0→Use 3, 1→Use 4, 2→Use 5.

REPLACEMENT CYLINDER BLOCK BEARING CLEARANCE HINT

If replacing the cylinder block subassembly, the bearing standard clearance will be: No.3: 0.027–0.054 mm (0.0011–0.0021 in.), Others: 0.017–0.044 mm (0.0007–0.0017 in.).

Completely remove the Plastigage

Completely remove the Plastigage.

ARRANGE MAIN BEARING CAPS IN ORDER

Arrange the main bearing caps, bearings and thrust washers in correct order.

CYLINDER BLOCK INSPECTION

Inspection procedure for the cylinder block after disassembly.

CLEAN CYLINDER BLOCK — Remove gasket material

Using a gasket scraper, remove all the gasket material from the top surface of the cylinder block.

CLEAN CYLINDER BLOCK — Clean cylinder block

Using a soft brush and solvent, thoroughly clean the cylinder block.

INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS

Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder head gasket for warpage. If warpage is greater than maximum, replace the cylinder block.

PISTON AND PIN ARE A MATCHED SET

The piston and pin are a matched set.

ARRANGE PARTS IN CORRECT ORDER

Arrange the pistons, pins, rings, connecting rods and bearings in correct order.

REMOVE PISTON PIN AND CONNECTING ROD

Using plastic-faced hammer and brass bar, lightly tap out the piston pin and remove the connecting rod.

INSTALL PISTON RINGS — COMPRESSION RINGS

Using a piston ring expander, install the two compression rings with the code mark facing upward. Code mark: R

INSTALL PISTON RINGS — RING END POSITIONING

Position the piston rings so that the ring ends are as shown.

• Do not align the piston ring ends.

INSTALL BEARINGS

Align the bearing claw with the groove of the connecting rod or connecting cap. Install the bearings in the connecting rod and connecting rod cap.

CYLINDER BLOCK ASSEMBLY — GENERAL HINTS

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.

DISCONNECT HOSES FROM NO.1 AIR TUBE AREA

Disconnect the following hoses: (2) Water by-pass hoses from No.1 air tube; (3) Air hose from turbocharging pressure VSV; (4) Heater water hose.

REMOVE WATER BY-PASS PIPE

Remove the three bolts, two nuts, water by-pass pipe, gasket and O-ring.

HEAT CYLINDER HEAD FOR GUIDE BUSHING INSTALLATION

Gradually heat the cylinder head to 80–100°C (176–212°F).

TAP IN NEW GUIDE BUSHING

Using SST 09201-70010 and a hammer, tap in a new guide bushing until the snap ring makes contact with the cylinder head.

REAM GUIDE BUSHING

Using a sharp 6 mm reamer, ream the guide bushing to obtain the specified clearance (see step 5 above) between the guide bushing and valve stem.

CHECK VALVE OVERALL LENGTH

Check the valve overall length. If the overall length is less than minimum, replace the valve.

CHECK VALVE STEM TIP

Check the surface of the valve stem tip for wear. If the valve stem tip is worn, resurface the tip with a grinder or replace the valve.

• Do not grind off more than minimum.

CORRECT VALVE SEAT POSITION — TOO LOW

If the seating is too low on the valve face, use 75° and 45° cutters to correct the seat. Target seating width: 1.0 – 1.4 mm.

HAND-LAP VALVE AND VALVE SEAT

Hand-lap the valve and valve seat with an abrasive compound. After hand-lapping, clean the valve and valve seat.

THOROUGHLY CLEAN ALL PARTS

Thoroughly clean all parts to be assembled.

APPLY NEW ENGINE OIL

Before installing the parts, apply new engine oil to all sliding and rotating surfaces.

REPLACE GASKETS AND OIL SEALS

Replace all gaskets and oil seals with new ones.

DESCRIPTION

The 3S-GTE engine is an in-line, 4-cylinder, 2.0 liter DOHC 16-valve engine.

Troubleshooting — CO/HC Concentration

If the CO/HC concentration does not comply with regulations, perform troubleshooting in the order given below: (a) Check oxygen sensor operation (See Main Oxygen Sensor Inspection under SMPI System). (b) See the table below for possible causes, and then inspect and correct the applicable causes if necessary.

ENGINE MECHANICAL DESCRIPTION

The 3S-GTE engine is an in-line, 4-cylinder, 2.0 liter DOHC 16-valve engine.

ENGINE CONFIGURATION

The 3S-GTE engine is an in-line, 4-cylinder engine with the cylinders numbered 1-2-3-4 from the front. The crankshaft is supported by 5 bearings inside the crankcase. These bearings are made of aluminum alloy.

CRANKSHAFT

The crankshaft is integrated with 8 weights for balance. Oil holes are placed in the center of the crankshaft to supply oil to the connecting rods, bearing, pistons and other components. The ignition order is 1-3-4-2.

CYLINDER HEAD

The cylinder head is made of aluminum alloy, with a cross flow type intake and exhaust layout and with pent-roof type combustion chambers. The spark plugs are located in the center of the combustion chambers.

INTAKE MANIFOLD AND CAMSHAFTS

The intake manifold has 8 independent long ports and utilizes the inertial supercharging effect to improve engine torque at low and medium speeds. Both the intake camshaft and the exhaust camshaft are driven by a single timing belt. The cam journal is supported at 5 places between the valve lifters of each cylinder and on the front end of the cylinder head. Lubrication of the cam journals and cams is accomplished by oil being supplied through the oiler port in the center of the camshaft.

VALVE CLEARANCE ADJUSTMENT

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.

PISTONS

Pistons are made of high temperature-resistant aluminum alloy, and a depression is built into the piston head to prevent interference with the valves.

PISTON PINS

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.

PISTON RINGS

The No.1 compression ring is made of steel and the No.2 compression ring is made of cast iron. The oil ring is made of a combination of steel and 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 gas leakage from the cylinder and the oil ring works to scrape oil off the cylinder walls to prevent it from entering the combustion chambers.

CYLINDER BLOCK

The cylinder block is made of cast iron. It has 4 cylinders which are approximately twice the length of the piston stroke. The top of each cylinder is closed off by the cylinder head and the lower end of the cylinders becomes the crankcase, in which the crankshaft is installed. In addition, the cylinder block contains a water jacket, through which coolant is pumped to cool the cylinders.

OIL PAN

The oil pan is bolted onto the bottom of the cylinder block. The oil pan is an oil reservoir made of pressed steel sheet. A dividing plate is included inside the oil pan to keep sufficient oil in the bottom of the pan even when the vehicle is tilted. This dividing plate also prevents the oil from making waves when the vehicle is stopped suddenly and the oil shifts away from the oil pump suction pipe.

SST (SPECIAL SERVICE TOOLS)

List of special service tools required for 3S-GTE engine mechanical work. Tools listed: 09043-38100 Hexagon 10 mm Wrench (Cylinder head bolt); 09201-41020 Valve Stem Oil Seal Replacer; 09201-70010 Valve Guide Bushing Remover & Replacer; 09202-70010 Valve Spring Compressor; 09213-54015 Crankshaft Pulley Holding Tool with (90119-08216) Bolt; 09213-31021 Crankshaft Pulley Puller; 09222-30010 Connecting Rod Bushing Remover & Replacer; 09223-50010 Crankshaft Front Oil Seal Replacer (Camshaft oil seal); 09223-63010 Crankshaft Rear Oil Seal Replacer; 09228-06500 Oil Filter Wrench; 09248-55020 Valve Clearance Adjust Tool Set with (09248-05011) Valve Lifter Press.

EQUIPMENT

List of equipment required for 3S-GTE engine mechanical service: Battery specific gravity gauge, Belt tension gauge, Caliper gauge, CO/HC meter, Compression gauge, Connecting rod aligner, Cylinder gauge, Dial indicator, Dye penetrant, Engine Tune-up tester, Heater, Magnetic finger, Micrometer, Piston ring compressor, Piston ring expander, Plastigage, Precision straight edge, Soft brush, Spring tester (Valve spring), Steel square (Valve spring), Thermometer, Torque wrench, Valve seat cutter, Vernier calipers.

COMPONENT DIAGRAM — ENGINE MECHANICAL (3S-GTE)

Exploded view diagram of the 3S-GTE engine upper assembly showing the following components and their relationships: High-Tension Cord, Spark Plug, Seal Washer, Cylinder Head Cover, Gasket (non-reusable), Vacuum Hose, EGR Vacuum Modulator and VSV, Vacuum Hose (left side), Engine Wire Protector, Air By-Pass Hose, VTV, Throttle Position Sensor Connector, Water By-Pass Hose, Gasket (non-reusable, marked with diamond), IACV Connector, Vacuum Hose, Air Hose, PCV Hose, Accelerator Cable, Intake Air Connector Stay, Intake Air Connector, Spacer, No.1 Intake Air Connector.

NON-REUSABLE PARTS

Parts marked with a diamond (◆) symbol are non-reusable and must be replaced during reassembly. On this page the Gasket between the intake manifold and throttle body is identified as a non-reusable part.

TIMING BELT WEAR CHECK

If there is noticeable wear on the belt teeth, check the timing cover for damage, correct gasket installation, and the foreign material on the pulley teeth. If necessary, replace the timing belt.

TROUBLESHOOTING TABLE USAGE

You will find the source of the trouble more easily by correctly using the table shown below. In this table, each number shows the order of priority of the causes of the trouble. Check each part in the order shown. If necessary, replace the part.

WIRING HARNESS INSPECTION HINT

When inspecting a wire harness or circuit, the electrical wiring diagrams at the end of volume 2 of repair manual should be referred to and the circuits of related systems also should be checked.

SYMPTOM-TO-COMPONENT DIAGNOSTIC CROSS-REFERENCE TABLE

This table cross-references engine symptoms (rows) with suspect components/systems (columns). Numbers in cells indicate the inspection/diagnostic step sequence for that symptom-component combination. Components listed include: Circuit Opening Relay (EG1-376), Fuel Cut System (EG1-411), Theft Deterrent Control Module (BE-1), PCME (EG1-406), Fuel Quality, Fuel Leakage, Coolant Leakage, Oil Leakage, Vacuum Leakage, Starter Relay (ST-25), Clutch Start SW (CL-1), Starter (ST-5), Spark Plug (IG-8), Distributor (IG-11), Ignition Coil (IG-11), EGR System (EG1-243), Turbocharger (EG1-196), Accelerator Pedal Link, Brakes Drag Even When Released, Cooling Fan System (EG1-441), Clutch (CL-1), Compression (EG1-32), Valve Clearance (EG1-16).

ENGINE OIL INSPECTION — CHECK OIL QUALITY

Check the oil for deterioration, entry of water, discoloring or thinning. If oil quality is poor, replace it.

ENGINE OIL INSPECTION — 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.

AIR FILTER INSPECTION AND CLEANING

Step 1: REMOVE AIR FILTER — Remove the air cleaner cap and air filter. Step 2: INSPECT AND CLEAN AIR FILTER — (a) Visually check that the air filter is not excessively damaged or only. If necessary, replace the air filter. (b) Clean the air filter with compressed air. First blow from the inside thoroughly, then blow off the outside of the air filter. Step 3: REINSTALL AIR FILTER.

NEW BELT DEFINITION

"New belt" refers to a belt which has been used less than 5 minutes on a running engine.

USED BELT DEFINITION

"Used belt" refers to a belt which has been used on a running engine for 5 minutes or more.

CHECK BELT SEATING AFTER INSTALLATION

After installing the belt, check that it fits properly in the ribbed grooves.

CONFIRM BELT GROOVE ENGAGEMENT

Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

RECHECK TENSION AFTER NEW BELT RUN-IN

After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.

ADJUSTING SHIM SELECTION CHART (INTAKE)

Use the chart to select the correct replacement shim. Find the row corresponding to the measured clearance and the column corresponding to the installed shim thickness; the intersection gives the new shim number. New shims have the thickness in millimeters imprinted on the face. Shim thicknesses: No.1=2.500mm(0.0984in), No.2=2.550mm(0.1004in), No.3=2.600mm(0.1024in), No.4=2.650mm(0.1043in), No.5=2.700mm(0.1063in), No.6=2.750mm(0.1083in), No.7=2.800mm(0.1102in), No.8=2.850mm(0.1122in), No.9=2.900mm(0.1142in), No.10=2.950mm(0.1161in), No.11=3.000mm(0.1181in), No.12=3.050mm(0.1201in), No.13=3.100mm(0.1220in), No.14=3.150mm(0.1240in), No.15=3.200mm(0.1260in), No.16=3.250mm(0.1280in), No.17=3.300mm(0.1299in). EXAMPLE: The 2.800mm(0.1102in) shim is installed, and the measured clearance is 0.450mm(0.0177in). Replace the 2.800mm(0.1102in) shim with a new No.12 shim.

SHIM SELECTION — EXHAUST

New shims have the thickness in millimeters imprinted on the face. Use the Adjusting Shim Selection Chart (Exhaust) to select the correct replacement shim: locate the installed shim thickness column and the measured clearance row; the intersection gives the new shim number. Example: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.450 mm (0.0177 in.). Replace the 2.800 mm (0.1102 in.) shim with a new No. 9 shim.

AVOID BURNS — COOL ENGINE BEFORE WORK

To avoid the danger of burns, do not begin work until the engine and coolant have properly cooled down.

• Do not begin work until the engine and coolant have properly cooled down.

PERFORM WORK ON LEVEL AREA

To ensure that coolant is poured in properly, perform the operation at a level area. Performing work with the vehicle inclined may cause improper removal of coolant or improper air removal when pouring coolant.

• Performing work with the vehicle inclined may cause improper removal of coolant or improper air removal when pouring coolant.

CHECK WATER LEVEL AFTER REPLACEMENT

After replacing the coolant, check the water level in the water filler and reservoir tank once or twice within 500 km (311 miles) of driving or within one week.

COOLING SYSTEM DESCRIPTION

This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by-pass valve mounted on the inlet side.

COOLING SYSTEM OPERATION

The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, electric fan, hoses and other components. Coolant which is heated in the water jacket is pumped to the radiator, through which an electric fan blows air to cool the coolant as it passes through. Coolant which has been cooled is then sent back to the engine by the water pump, where it cools the engine. The water jacket is a network of channels in the shell of the cylinder block and cylinder head through which coolant passes. It is designed to provide adequate cooling of the cylinders and combustion chambers which become heated during engine operation.

PARTS LOCATION — ENGINE COMPARTMENT ELECTRIC COOLING FAN

Identifies the physical location of all components in the engine compartment electric cooling fan system, including: AM2 Fuse, AM1 H-Fuse, AM2 H-Fuse, ALT H-Fuse, GAUGE Fuse, ECU-IG Fuse, VENT Fuse, Cooling Fan Relay ('VENT'), Ignition Main Relay ('IGN'), Engine Compartment Temp. Sensor, Engine Compartment Cooling Fan, and Cooling Fan Control Module.

SYSTEM CIRCUIT — ENGINE COMPARTMENT ELECTRIC COOLING FAN

Wiring diagram showing the complete electrical circuit. Battery feeds MAIN FL 2.0L, then AM1 50A and ALT 120A fuses. AM2 40A fuse feeds the Ignition Main Relay. AM1 feeds AM2 7.5A fuse via IG1; AM2 feeds AM2 7.5A fuse via IG2. VENT 20A fuse supplies the Cooling Fan Relay coil. GAUGE 7.5A fuse supplies the Cooling Fan Warning Light and the Cooling Fan Control Module. ECU-IG 7.5A fuse also feeds the control module. The Cooling Fan Relay drives the Engine Compartment Cooling Fan motor (M). The Engine Compartment Temp. Sensor connects to the Cooling Fan Control Module on pins 6, 3, 1. The Cooling Fan Control Module has additional connections on pins 2, 9, 7, 5.

COOLING FAN INSTALLATION — INSTALL COOLING FAN

(a) Install the cooling fan with the three bolts. (b) Connect the cooling fan connector.

DISASSEMBLY — REMOVE FAN MOTOR

Remove the three screws, rubber bushings, steel plate bushings and motor.

IGNITION MAIN RELAY INSPECTION

1. REMOVE IGNITION MAIN RELAY. 2. INSPECT IGNITION MAIN RELAY: A. Inspect relay continuity: (a) Using an ohmmeter, check that there is continuity between terminals 1 and 3. (b) Check that there is continuity between terminals 2 and 4. (c) Check that there is no continuity between terminals 4 and 5. If continuity is not as specified, replace the relay.

INSPECT RELAY OPERATION (Ignition Main Relay — Section B)

(a) Apply battery voltage across terminals 1 and 3. (b) Using an ohmmeter, check that there is no continuity between terminals 1 and 2. (c) Check that there is continuity between terminals 4 and 5. If operation is not as specified, replace the relay.

REINSTALL IGNITION MAIN RELAY

Reinstall the ignition main relay after inspection.

COOLING SYSTEM DESCRIPTION

This engine utilizes a pressurized forced circulation cooling system which includes a thermostat equipped with a by-pass valve mounted on the inlet side.

COOLING SYSTEM OPERATION

The cooling system is composed of the water jacket (inside the cylinder block and cylinder head), radiator, water pump, thermostat, electric fan, hoses and other components. Coolant which is heated in the water jacket is pumped to the radiator, through which and electric fan blows air to cool the coolant as it passes through. Coolant which has been cooled is then sent back to the engine by the water pump, where it cools the engine. The water jacket is a network of channels in the shell of the cylinder block and cylinder head through which coolant passes. It is designed to provide adequate cooling of the cylinders and combustion chambers which become heated during engine operation.

RADIATOR

The radiator cools the coolant which has passed through the water jacket and become hot, and it is mounted in the front of the vehicle. The MR2 radiator is different from that in other models, in that it is a cross flow type in which the coolant flows horizontally. It includes side tanks and a core which connects them. The inlet for coolant from the water jacket and the drain cock for draining out coolant are located in the left tank. The outlet coolant and an air drain, which facilitates the supply of coolant to the engine are located in the right tank. The core contains many tubes through which coolant flows from left tank to the right tank as well as cooling fins which radiate heat away from the coolant in the tubes. Air sucked in by the electric cooling fan, as well as the wind generated by the vehicle's travel, passes through the radiator, cooling the coolant heated by the water jacket as it passes through the tubes in the core. Models with automatic transmission include an automatic transmission fluid cooler incorporated into the cooling pipes. A fan with an electric motor is mounted behind the radiator to assist the flow of air through the radiator. The fan operates when the coolant temperature becomes high in order to prevent it from becoming too high.

RADIATOR CAP

The radiator cap is a pressure type cap which seals the radiator, resulting in pressurization of the radiator as the coolant expands. The pressurization prevents the coolant from boiling even when the coolant temperature exceeds 100°C (212°F). A relief valve (pressurization valve) and a vacuum valve (negative pressure valve) are built into the radiator cap. The relief valve opens and lets steam escape through the overflow pipe when the pressure generated inside the cooling system exceeds the limit (coolant temperature: 110–120°C (230–248°F), pressure: 59–103 kPa (0.60–1.05 kgf/cm², 8.5–14.9 psi)). The vacuum valve opens to alleviate the vacuum which develops in the coolant system after the engine is stopped and the coolant temperature drops. The valve's opening allows the coolant in the reservoir tank to return to the cooling system.

RESERVOIR TANK

The reservoir tank is used to catch coolant which overflows the cooling system as a result of volumetric expansion when the coolant is heated. The coolant in the reservoir tank returns to the radiator when the coolant temperature drops, thus keeping the radiator full at all times and avoiding needless coolant loss. Check the reservoir tank level to learn if the coolant needs to be replenished.

WATER PUMP

The water pump is used for forced circulation of coolant through the cooling system. It is mounted on the front of the cylinder block and driven by a timing belt.

THERMOSTAT

The thermostat has a wax type by-pass valve and is mounted in the water inlet housing. The thermostat includes a type of automatic valve operated by fluctuations in the coolant temperature. This valve closes when the coolant temperature drops, preventing the circulation of coolant through the engine and thus permitting the engine to warm up rapidly. The valve opens when the coolant temperature has risen, allowing the circulation of coolant. Wax inside the thermostat expands when heated and contracts when cooled. Heating the wax thus generates pressure which overpowers the force of the spring which keeps the valve closed, thus opening the valve. When the wax cools, its contraction causes the force of the spring to take effect once more, closing the valve. The thermostat in this engine operates at a temperature of 82°C (180°F).

RADIATOR ELECTRIC COOLING FAN (WITHOUT AC) — PART LOCATION

Identifies the location of cooling fan system components: Fan Main Relay ('FAN MAIN'), Cooling Fan Relay ('FAN No.1'), AM2 Fuse, RAD FAN H-Fuse, ALT H-Fuse, No.1 Radiator Cooling Fan, and Engine Coolant Temperature Switch on the 3S-GTE engine vehicle.

SYSTEM CIRCUIT

Wiring diagram showing the radiator electric cooling fan circuit (without AC). Circuit includes: Battery → MAIN FL 2.0L → ALT 120A → Fan Main Relay; AM2 7.5A fuse powered from AM2 terminal through Ignition Switch (IG2); RAD FAN 30A fuse → Cooling Fan Relay → No.1 Radiator Cooling Fan (motor); Engine Coolant Temperature Switch controls the Cooling Fan Relay ground circuit.

INSTALL RADIATOR LOWER AIR DEFLECTOR

Install the radiator lower air deflector.

CONNECT CABLE TO NEGATIVE TERMINAL OF BATTERY

Connect the cable to the negative terminal of the battery.

INSTALL HOOD WEATHERSTRIP

Install the hood weatherstrip.

FAN MAIN RELAY INSPECTION

See Radiator Cooling Fans w/ A/C

NO-1 COOLING FAN RELAY INSPECTION

See Radiator Cooling Fans w/ A/C

RADIATOR ELECTRIC COOLING FAN (WITH AC) — Parts Location

Identifies locations of cooling fan system components including: No.3 Cooling Fan Relay ('FAN MAIN'), Fan Main Relay ('FAN MAIN'), AM2 Fuse, No.2 Cooling Fan Relay ('FAN No.2'), RAD FAN Fuse, CDS FAN Fuse, No.1 Cooling Fan Relay ('FAN No.1'), ALT H-Fuse, AM1 H-Fuse, GAUGE Fuse, ECTS, A/C Amplifier, No.2 Radiator Cooling Fan (A/C), No.1 Radiator Cooling Fan (Engine).

RADIATOR ELECTRIC COOLING FAN (WITH AC) — System Circuit

Wiring diagram showing: Battery, MAIN FL 2.0L, ALT 120A, AM1 50A, AM2 7.5A fuses; Ignition Switch (AM1/IG1, AM2/IG2); Fan Main Relay; RAD FAN 30A fuse; CDS FAN 30A fuse; GAUGE 7.5A fuse; No.1 Cooling Fan Relay; No.2 Cooling Fan Relay with Diode; No.3 Cooling Fan Relay; A/C Pressure Switch; No.1 Radiator Cooling Fan (Engine) with motor M; No.2 Radiator Cooling Fan (A/C) with motor M; ECTS; A/C Amplifier (pins 1,2,4,6,8,9,10,11,13,14,15,17,18) connecting to: A/C Idle-Up Valve, A/C Pressure Switch, A/C Control Assembly, PCME, A/C Magnet Clutch Relay, A/C Thermistor (x2), Igniter.

COOLING FANS INSTALLATION

See Components for Disassembly and Assembly. Install the cooling fan with the three bolts. Install the two cooling fans.

FAN MAIN RELAY INSPECTION

Remove Fan Main Relay. Inspect relay continuity using an ohmmeter: (a) Check that there is continuity between terminals 1 and 3. (b) Check that there is continuity between terminals 2 and 4. (c) Check that there is no continuity between terminals 4 and 5. If continuity is not as specified, replace the relay.

FAN MAIN RELAY — Inspect Relay Operation

B. Inspect relay operation: (a) Apply battery voltage across terminals 1 and 3. (b) Using an ohmmeter, check that there is no continuity between terminals 2 and 4. (c) Check that there is continuity between terminals 4 and 5. If operation is not as specified, replace the relay.

REINSTALL FAN MAIN RELAY

Step 3: Reinstall Fan Main Relay after inspection.

NO.2 COOLING FAN RELAY INSPECTION — Remove

Step 1: REMOVE NO.2 COOLING FAN RELAY from the relay block.

INSPECT NO.2 COOLING FAN RELAY — Relay Continuity

A. Inspect relay continuity: (a) Using an ohmmeter, check that there is continuity between terminals 1 and 2. (b) Check that there is continuity between terminals 3 and 4. (c) Check that there is no continuity between terminals 3 and 5. If continuity is not as specified, replace the relay.

INSPECT NO.2 COOLING FAN RELAY — Relay Operation

B. Inspect relay operation: (a) Apply battery voltage across terminals 1 and 2. (b) Using an ohmmeter, check that there is no continuity between terminals 3 and 4. (c) Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay.

REINSTALL NO.2 COOLING FAN RELAY

Reinstall the No.2 Cooling Fan Relay after inspection.

RADIATOR CLEANING

Using water or a steam cleaner, remove any mud and dirt from the radiator core.

• If using a high pressure type cleaner, be careful not to deform the fins of the radiator core. If the cleaner nozzle pressure is 2,942 – 3,432 kPa (30 – 35 kgf/cm², 427 – 498 psi), keep a distance of at least 40 – 50 cm (15.75 – 19.69 in.) between the radiator core and cleaner nozzle.

COMPONENTS FOR REMOVAL AND INSTALLATION

Exploded diagram showing all components involved in the removal and installation of the 3S-GTE engine cooling system, including: Dash Panel Front Trim Cover, Upper Radiator Support Seal, Upper Radiator Support, Hood Lock, Cooling Fan Connector, Radiator Hose, ECTS Connector, O-Ring (non-reusable), ECTS, O-Ring (non-reusable), Drain Plug, Radiator Lower Air Deflector, Lower Radiator Support, Radiator, No.1 Cooling Fan, No.2 Cooling Fan, Cooling Fan Connector, Radiator Hose.

RADIATOR REMOVAL — Remove radiator and lower supports

Steps (b) and (c) of radiator removal: (b) Remove the radiator. (c) Remove the two lower radiator supports.

(w/ A/C) REMOVE ECTS FROM RADIATOR

(a) Remove the ECTS. (b) Remove the O-ring from the ECTS.

(w/o A/C) REMOVE ENGINE COOLANT TEMPERATURE SWITCH FROM RADIATOR

(a) Remove the temperature switch. (b) Remove the O-ring from the temperature switch.

INSPECT THERMOSTAT

HINT: The thermostat is numbered with the valve opening temperature. (a) Immerse the thermostat in water and gradually heat the water. (b) Check the valve opening temperature. Valve opening temperature: 80–84°C (176–183°F). If the valve opening temperature is not as specified, replace the thermostat. (c) Check the valve lift. Valve lift: 8 mm (0.31 in.) or more at 95°C (203°F). If the valve lift is not as specified, replace the thermostat. (d) Check that the valve spring is tight when the thermostat is fully closed. If not closed, replace the thermostat.

REMOVE WATER PUMP FROM WATER PUMP COVER

Remove the screw, two bolts, water pump and gasket.

INSPECT WATER PUMP

Turn the pulley and check that the water pump bearing moves smoothly and quietly.

AC IDLE-UP VALVE

The A/C Idle-Up Valve is located between the IACV (Idle Air Control Valve) and the intake manifold. Air flows from IACV through the A/C Idle-Up Valve to the intake manifold. The valve is controlled electrically via the PCME (& T): power is supplied from the MPI Main Relay through the +B (+B1) terminal, the valve coil (solenoid), and ground through terminal E1. The ISCV terminal on the PCME connects to the valve circuit.

MPI SYSTEM OVERVIEW

The MPI system is composed of three basic sub-systems: Fuel, Air Induction and Electronic Control Systems.

FUEL SYSTEM

Fuel is supplied under constant pressure to the MPI injectors by an electric fuel pump. The injectors inject a metered quantity of fuel into the intake port in accordance with signals from the PCME (& T) (Powertrain Control Module (Engine & Transmission)).

AIR INDUCTION SYSTEM

The air induction system provides sufficient air for engine operation.

ELECTRONIC CONTROL SYSTEM

The MR2 5S-FE engine is equipped with a TOYOTA Computer Controlled System (TCCS) which centrally controls the MPI, EI, IAC diagnosis systems etc. by means of a Powertrain Control Module (Engine & Transmission) (PCME (& T)–formerly MPI computer) employing a microcomputer. The PCME (& T) controls the following functions: 1. Electronic Fuel Injection — The PCME (& T) receives signals from various sensors indicating changing engine operation conditions such as: Intake manifold pressure, Intake air temperature, Coolant temperature, Engine rpm, Throttle valve opening angle, Exhaust oxygen content etc. The signals are utilized by the PCME (& T) to determine the injection duration necessary for an optimum air-fuel ratio. 2. Electronic Ignition (EI) — The PCME (& T) is programmed with data for optimum ignition timing under any and all operating conditions. Using data provided by sensors which monitor various engine functions (rpm, coolant temperature, etc.), the microcomputer (PCME (& T)) triggers the spark at precisely the right instant. 3. Idle Speed Control (IAC) — The PCME (& T) is programmed with target idling speed values to respond to different engine conditions (coolant temperature, air conditioner ON/OFF, etc.) Sensors transmit signals to the PCME (& T) which controls the flow of air through the by-pass of the throttle value and adjust idle speed to the target value. 4. Diagnosis — The PCME (& T) detects any malfunctions and abnormalities in the sensor network and lights a 'CHECK' engine warning light on the combination meter. At the same time, trouble is identified and a diagnostic trouble code is recorded by the PCME (& T). The diagnostic trouble code can be read by the number of blinks of the 'CHECK' engine warning light when terminals TE1 and E1 are connected. The diagnostic trouble codes are referred to the later page (See page EG2-209). 5. Fail-Safe Function — In the event of the sensor malfunction, a back-up circuit will take over to provide minimal drivability, and the 'CHECK' engine warning light will illuminate.

DIAGNOSIS SYSTEM DESCRIPTION

The PCME (& T) 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 combination meter lights up. By analyzing various signals as shown in the later table (See page EG2-209) the PCME (& T) detects system malfunctions relating to the sensors or actuators. The self-diagnosis system has two modes, a normal mode and a test mode. If a malfunction is detected when in the normal mode, the PCME (& T) lights up the 'CHECK' engine warning light to inform the driver of the occurrence of a malfunction. (For some codes the light does not come on.) The light goes off automatically when the malfunction has been repaired. But the diagnostic trouble code(s) remains stored in the PCME (& T) memory (except for code No. 16). The PCME (& T) stores the code(s) until it is cleared by removing the EFI fuse with the ignition switch off. The diagnostic trouble code can be read by the number of blinks of the 'CHECK' engine warning light when TE1 and E1 terminals on the data link connector 1 are connected. When 2 or more codes are indicated, the lowest number (code) will appear first. If a malfunction is detected when in the test mode, the PCME (& T) lights up the 'CHECK' engine warning light to inform the technician of the occurrence of a malfunction (except for code Nos. 42, 43 and 51). In this case, TE2 and E1 terminals on the data link connector 1 should be connected as shown later (See page EG2-206). In the test mode, even if the malfunction is corrected, the malfunction code is stored in the PCME (& T) memory even when the ignition switch is off (except code Nos. 42, 43 and 51). This also applies in the normal mode. The diagnostic mode (normal or test) and the output of the 'CHECK' engine warning light can be selected by connecting the TE1, TE2 and E1 terminals on the data link connector 1, as shown later. A test mode function has been added to the functions of the self-diagnosis system of the 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 implemented by the technician following the appropriate procedures of check terminal connection and operation described later (See page EG2-206).

CHECK ENGINE WARNING LIGHT CHECK

1. The 'CHECK' engine warning light will come on when the ignition switch is placed at ON and the engine is not running. 2. When the engine is started, the 'CHECK' engine warning light should go off. If the light remains on, the diagnosis system has detected a malfunction or abnormality in the system.

MALFUNCTION CODE INDICATION

In the event of a malfunction, the light will blink every 0.52-seconds. The first number of blinks will equal the first digit of a 2-digit diagnostic trouble code and, after a 1.5-second pause, the 2nd number of blinks will equal the 2nd. If there are two or more codes, there will be a 2.5-second pause between each code. After all the codes have been output, there will be a 4.5 second pause and they will all be repeated as long as the terminals TE1 and E1 of the data link connector 1 are connected. HINT: In the event of a number of trouble codes, indication will begin from the smaller value and continue to the larger.

2 TRIP DETECTION LOGIC

Diagnostic trouble codes 25, 26, 27 and 71 use '2 trip detection logic'. With this logic, when a malfunction is first detected, the malfunction is temporarily stored in the PCME (& T) memory. If the same case is detected again during the second drive test, this second detection causes the 'CHECK' engine warning light to light up. The 2 trip repeats the same mode a 2nd time. (However, the ignition switch must be turned OFF between the 1st time and 2nd time.) In the Test Mode, the 'CHECK' engine warning light lights up the 1st time a malfunction is detected.

REMOVE SST AFTER DIAGNOSIS CHECK

After the diagnosis check, remove SST. SST 09843-18020.

REMOVE SST AFTER DIAGNOSIS CHECK

After the diagnosis check, remove SST 09843-18020.

TEST MODE START CONDITION

The test mode will not start if terminals TE2 and E1 are connected after the ignition switch is turned on.

STARTER SIGNAL AND VEHICLE SPEED SIGNAL DIAGNOSIS

The starter signal and vehicle speed signal will be diagnosed by the PCME (& T) as malfunctions, and code Nos. 42 and 43 will be output, if the operation in step 4 is not performed.

CODE 51 NORMAL CONDITION

When the automatic transmission shift lever is in the "D", "2", "L" or "R" shift position, or when the air conditioner is on or when the accelerator pedal is depressed, code "51" (Switch condition signal) is output, but this is not abnormal.

ALTERNATIVE CANCELLATION METHOD — BATTERY NEGATIVE TERMINAL

Cancellation can also be done by removing the battery negative (–) terminal, but in this case, other memory systems (clock, etc.) will also be cancelled out.

RETAINED CODE IF NOT CANCELLED

If the diagnostic trouble code is not cancelled out, it will be retained by the PCME (& T) and appear along with a new code in the event of future trouble.

CHECK FOR STORED CODE BEFORE BATTERY REMOVAL

If it is necessary to work on engine components requiring removal of the battery terminal, a check must first be made to see if a diagnostic trouble code has been recorded.

MULTIPLE CODES DISPLAY ORDER

When 2 or more codes are indicated, the lowest number (code) will appear first.

DIAGNOSTIC TROUBLE CODE RETENTION

All detected diagnostic trouble codes, except code Nos. 43 and 53 will be retained in memory by the PCME (& T) from the time of detection until cancelled out.

CHECK ENGINE WARNING LIGHT BEHAVIOUR AFTER MALFUNCTION CLEARED

Once malfunction is cleared, the "CHECK" engine warning light on the combination meter will go off but the diagnostic trouble code(s) remains stored in PCME (& T) memory (except for code Nos. 43 and 51).

ELECTRONIC PARTS LOCATION

Diagram showing the location of electronic components in the MPI system for the 5S-FE engine on the Toyota MR2 SW20. Components identified include: Oxygen Sensor (Main), Sub-Oxygen Sensor (CALIF. only), ECTS, MAP, EGR Function Sensor (CALIF. only), VSV (for Fuel Pressure), VSV (for EGR), PCME (& T), A/C Idle-Up Valve, Ignition Main Relay ("IGN"), MPI Main Relay ("EFI"), Circuit Opening Relay ("C/OPN").

DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR

Disconnect the vacuum sensing hose from the fuel pressure regulator.

DISCONNECT FUEL RETURN PIPE FROM FUEL PRESSURE REGULATOR

Remove the union bolt and two gaskets, and disconnect the return pipe from the pressure regulator. HINT: Put a suitable container or shop towel under the pressure regulator. Slowly loosen the union bolt.

REMOVE FUEL PRESSURE REGULATOR

Remove the two bolts, and pull out the pressure regulator. Remove the O-ring from the pressure regulator.

NO FUEL PRESSURE — CHECK THE FOLLOWING PARTS

If there is no pressure, check the following parts: Fusible links (2.01, 1.0Y), H-fuse (AM2 40A), Fuses (EFI 15A, AM2 7.5A), MPI main relay, Fuel pump, Wiring connections.

COMPONENTS FOR REMOVAL AND INSTALLATION

Diagram identifying interior components relevant to MPI system removal and installation, including: Lower No.1 Instrument Panel Finish Panel, Center Instrument Cluster Finish Panel, Ash Receptacle Box, Ash Receptacle Retainer, Upper Console Panel, Console Box, Grommet, Service Hole Cover, Fuel Sender Gauge Connector, Shifting Hole Cover, Fuel Pump Connector.

FUEL PUMP ASSEMBLY

See Components for Disassembly and Assembly.

INSTALL FUEL PUMP FILTER TO FUEL PUMP

Install the pump filter with a new clip.

INSTALL FUEL PUMP TO FUEL PUMP BRACKET

(a) Connect the fuel hose to the outlet port of the fuel pump. (b) Connect the lead wire to the fuel pump with the spring washer and nut. Connect the three lead wires. (c) Install the rubber cushion to the fuel pump. (d) Install the fuel pump by pushing the lower side of the fuel pump.

ALWAYS USE NEW GASKETS

Always use new gaskets when replacing the fuel tank or component parts.

APPLY PROPER TORQUE

Apply the proper torque to all parts tightened.

IACV INSTALLATION

See Components for Removal and Installation.

INSTALL IACV

Place a new gasket on the throttle body, then install the IACV with the four screws.

INSTALL THROTTLE BODY

See Throttle Body Installation.

INJECTOR SYSTEM OVERVIEW

Diagram showing the fuel injector layout on the 5S-FE engine including: Delivery Pipe, Fuel Pulsation Damper, Fuel Inlet Pipe, Fuel Return Hose, and Fuel Injectors (Connector Color: Green). Four injectors (No.1, No.2, No.3, No.4) are controlled by the PCME (& T) via terminals #20, #10, E01, E02. Power supply is via AM2 7.5A fuse from battery, through Ignition Main Relay (AM2 40A) activated by Ignition Switch IG2. Main FL 2.0L fuse also present in circuit.

REMOVE DELIVERY PIPE AND INJECTORS ASSEMBLY

Remove the two bolts, the delivery pipe and four injectors assembly from the RH side of the engine.

• Be careful not to drop the injectors when removing the delivery pipe.

REMOVE INSULATORS, SPACERS AND INJECTORS

Remove the four insulators and two spacers from the cylinder head. Pull out the four injectors from the delivery pipe. Remove the O-ring and grommet from each injector.

FUEL SYSTEM OPERATION

Fuel pumped up by the fuel pump, flows through the fuel filter and is distributed to each injector at a set pressure maintained by the pressure regulator. The fuel pressure regulator adjusts the pressure of the fuel from the fuel line (high pressure side) to a pressure 284 kPa (2.9 kgf/cm2, 41 psi) higher than the pressure inside the intake manifold, and excess fuel is returned to the fuel tank through the return pipe. The pulsation damper absorbs the slight fluctuations in fuel pressure caused by fuel injector from the injector. The injectors operate on input of injection slights from the PCME (& T) and inject fuel into the intake manifold.

AIR INDUCTION SYSTEM OVERVIEW

Air is filtered through the air cleaner and the amount flowing to the air intake chamber is determined according to the throttle valve opening in the throttle body and the engine rpm. Intake air controlled by the throttle valve opening is distributed from the air intake chamber to the manifold of each cylinder and is drawn into the combination chamber. At low temperatures the IACV opens and the air flows through the IACV and the throttle body, into the air intake chamber. During engine warming up, even if the throttle valve is completely closed, air flows to the air intake chamber, thereby increasing the idle speed (first idle operation). The air intake chamber prevents pulsation of the intake air. It also prevents intake air interference in each cylinder.

ELECTRONIC CONTROL SYSTEM OVERVIEW

The control system consists of sensors which detect various engine conditions, and a PCME (& T) which determines the injection volume (timing) based on the signals from the sensors. The various sensors detect the intake air pressure, engine rpm, oxygen density in the exhaust gas, coolant temperature, intake air temperature and atmospheric etc. and convert the information into an electrical signal which is sent to the PCME (& T). Based on these signals, the PCME (& T) calculates the optimum ignition timing for the current conditions and operates the injectors. The PCME (& T) not only controls the fuel injection timing, but also the self diagnostic function which records the occurrence of a malfunction, ignition timing control, idle rpm control and EGR control.

DISCONNECT NEGATIVE BATTERY CABLE BEFORE WORKING ON FUEL SYSTEM

Before working on the fuel system, disconnect the cable from negative (–) terminal of the battery. Any diagnostic trouble code retained by the computer will be erased when the battery terminal is removed. Therefore, if necessary, read the diagnosis before removing the terminal.

DO NOT SMOKE OR WORK NEAR OPEN FLAME WHEN WORKING ON FUEL SYSTEM

Do not smoke or work near an open flame when working on the fuel system.

KEEP GASOLINE AWAY FROM RUBBER OR LEATHER PARTS

Keep gasoline away from rubber or leather parts.

CHECK CORRECT ENGINE TUNE-UP

See Tune-Up under Engine Mechanical.

PRECAUTION WHEN CONNECTING GAUGE

Use battery as the power source for the timing light, tachometer, etc. Connect the tester probe of a tachometer to the terminal IG(–) of the data link connector 1.

IN EVENT OF ENGINE MISFIRE, FOLLOWING PRECAUTIONS SHOULD BE TAKEN

Check proper connection of battery terminals, etc. Handle high-tension cords carefully. After repair work, check that the ignition coil terminals and all other ignition system lines are reconnected securely. When cleaning the engine compartment, be especially careful to protect the electrical system from water.

PRECAUTIONS WHEN HANDLING OXYGEN SENSOR

Do not allow oxygen sensor to drop or hit against an object. Do not allow the sensor to come into contact with water.

IF VEHICLE IS EQUIPPED WITH MOBILE RADIO SYSTEM (HAM, CB, ETC.)

The PCME (& T) has 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 10 W output), it may, at times, have an affect upon PCME (& T) operation, especially if the antenna and feeder are installed nearby. Therefore, observe the following precautions:

INSTALL ANTENNA FAR FROM PCME

Install the antenna as far away as possible from the PCME (& T). The PCME (& T) is located on the partition panel into rear luggage compartment so the antenna should be installed at the rear side of the vehicle.

KEEP ANTENNA FEEDER AWAY FROM PCME WIRES

Keep the antenna feeder as far away as possible from the PCME (& T) wires—at least 20 cm (7.87 in.)—and, especially, do not wind them together.

CHECK FEEDER AND ANTENNA ADJUSTMENT

Check that the feeder and antenna are properly adjusted.

DO NOT EQUIP POWERFUL MOBILE RADIO SYSTEM

Do not equip your vehicle with a powerful mobile radio system.

DO NOT OPEN PCME COVER UNLESS NECESSARY

Do not open the cover or the case of the PCME (& T) unless absolutely necessary. If the IC terminals are touched, the IC may be destroyed by static electricity.

AIR INDUCTION SYSTEM — SEPARATION OF ENGINE COMPONENTS

Separation of the engine oil dipstick, oil filler cap, PCV hose, etc. may cause the engine to run out of turn.

AIR INDUCTION SYSTEM — DISCONNECTION OR CRACKS

Disconnection, looseness or cracks in the parts of the air induction system between the throttle body and cylinder head will allow air suction and cause the engine to run out of tune.

ELECTRONIC CONTROL SYSTEM — DISCONNECT POWER BEFORE REMOVING MPI CONNECTORS

Before removing MPI wiring connectors, terminals, etc., first disconnect the power by either turning the ignition switch OFF or disconnecting the battery terminals. HINT: Always check the diagnostic trouble code before disconnecting the battery terminal.

BATTERY CONNECTION

When installing the battery, be especially careful not to incorrectly connect the positive (+) and negative (-) cables.

HANDLE MPI PARTS CAREFULLY

Do not permit parts to receive a severe impact during removal or installation. Handle all MPI parts carefully, especially the PCME (& T).

TROUBLESHOOTING CAUTION

Do not be careless during troubleshooting as there are numerous transistor circuits and even slight terminal contact can further troubles.

DO NOT OPEN PCME COVER

Do not open the PCME (& T) cover.

PREVENT WATER ENTRY

When inspecting during rainy weather, take care to prevent entry of water. Also, when washing the engine compartment, prevent water from getting on the MPI parts and wiring connectors.

REPLACE PARTS AS ASSEMBLY

Parts should be replaced as an assembly.

PULLING OUT AND INSERTING WIRING CONNECTORS

Care is required when pulling out and inserting wiring connectors.

INSPECTING A CONNECTOR WITH A VOLT/OHMMETER

When inspecting a connector with a volt/ohmmeter.

CONNECTOR INSPECTION PRECAUTIONS

Insert the test probe into the connector from wiring side when checking the continuity, amperage or voltage. Do not apply unnecessary force to the terminal. After checking, install the water-proofing rubber on the connector securely.

USE SST FOR INJECTOR INSPECTION

Use SST for inspection or test of the injector or its wiring connector. SST 09842-30070.

DISCONNECTING HIGH FUEL PRESSURE LINE

When disconnecting the high fuel pressure line, a large amount of gasoline will spill out, so observe the following procedures: (a) Put a container under the connection. (b) Slowly loosen the connection. (c) Disconnect the connection. (d) Plug the connection with a rubber plug.

CONNECTING FLARE NUT OR UNION BOLT — UNION BOLT TYPE

When connecting the flare nut or union bolt on the high pressure pipe union (Union Bolt Type): (a) Always use a new gasket. (b) Tighten the union bolt by hand. (c) Tighten the union bolt to the specified torque.

CONNECTING FLARE NUT OR UNION BOLT — FLARE NUT TYPE

When connecting the flare nut or union bolt on the high pressure pipe union (Flare Nut Type): (a) Apply a light coat of engine oil to the flare and tighten the flare nut by hand. (b) Using SST, tighten the flare nut to the specified torque. SST 09631-22020. HINT: Use a torque wrench with a fulcrum length of 30 cm (111.81 in.).

PRECAUTIONS WHEN REMOVING AND INSTALLING INJECTORS

Observe the following precautions when removing and installing the injectors.

• Never reuse the O-ring.
• When placing a new O-ring on the injector, take care not to damage it in any way.
• Coat a new O-ring with spindle oil or gasoline before installing — never use engine, gear or brake oil.

INSTALL INJECTOR TO DELIVERY PIPE AND CYLINDER HEAD

Install the injector to delivery pipe and cylinder head as shown in the illustration.

CHECK FOR FUEL LEAKS AFTER MAINTENANCE

Check that there are no fuel leaks after performing any maintenance on the fuel system.

• Do not start the engine.
• Always pinch the hose, avoid bending as it may cause the hose to crack.

SST (SPECIAL SERVICE TOOLS)

List of special service tools required for MPI system service on the 5S-FE engine.

RECOMMENDED TOOLS

List of recommended tools for MPI system service on the 5S-FE engine.

EQUIPMENT

List of equipment used for MPI System service procedures on the 5S-FE engine: Graduated cylinder (Injector), Carburetor cleaner (Throttle body), Sound scope (Injector), Tachometer, Torque wrench, Vacuum gauge, Soft brush (Throttle body).

SERVICE DATA — 5S-FE ENGINE MPI SYSTEM

Fuel pressure regulator: Fuel pressure at no vacuum 265-304 kPa (2.7-3.1 kgf/cm², 38-44 psi). Fuel pump resistance: 0.2-3.0 Ω. Injector resistance: Approx. 13.8 Ω; injection volume 49-59 cm³ (3.0-3.6 cu in.) per 15 sec; difference between each cylinder 5 cm³ (0.3 cu in.) or less; fuel leakage one drop or less per minute. Throttle body fully closed angle: 6°; throttle opener setting speed 1,300-1,500 rpm (w/ Cooling fan OFF). Throttle position sensor clearance/resistance values as tabulated. IACV resistance (+B - ISCC or ISCO): 19.3-22.3 Ω. ECTS resistance: 10-20 kΩ at -20°C (-4°F), 4-7 kΩ at 0°C (32°F), 2-3 kΩ at 20°C (68°F), 0.9-1.3 kΩ at 40°C (104°F), 0.4-0.7 kΩ at 60°C (140°F), 0.2-0.4 kΩ at 80°C (176°F). TATS resistance: same values as ECTS. VSV (for Fuel pressure) resistance (Cold): 37-44 Ω. VSV (for EGR) resistance (Cold): 33-39 Ω. A/C idle-up valve resistance (Cold): 30-34 Ω. EGR function sensor (Calif. only) resistance: 69-89 kΩ at 50°C (122°F), 11-15 kΩ at 100°C (212°F), 2-4 kΩ at 150°C (302°F). Oxygen sensor heater coil resistance: 5.1-6.3 Ω at 20°C (68°F).

Disconnect tachometer

E. Disconnect tachometer

TROUBLESHOOTING PROCEDURES OVERVIEW

The following troubleshooting procedures are designed for inspection of each separate system, and therefore the actual procedure may vary somewhat. However, troubleshooting should be performed while referring to the inspection methods described in this manual.

CHECK FUSES AND CONNECTORS FIRST

Before beginning inspection, it is best to first make a simple check of the fuses, H-fuses, fusible link and the condition of the connectors.

TROUBLESHOOTING ASSUMPTION

The following troubleshooting procedures are based on the supposition that the trouble lies in either a short or open circuit within the computer.

PCME REPLACEMENT CONDITION

If engine trouble occurs even though proper operating voltage is detected in the computer connector, then it can be assumed that the PCME(& T) is faulty and should be replaced.

FUSES, H-FUSES AND FUSIBLE LINK LOCATION

Fuse and fusible link locations include: AM2 Fuse, AM1 H-Fuse, AM2 H-Fuse, ALT H-Fuse (located in the main fuse box), EFI 15A (located in the engine compartment fuse box), and GAUGE 7.5A (located in the instrument panel fuse box).

PERFORM VOLTAGE MEASUREMENTS WITH CONNECTORS CONNECTED

Perform all voltage measurements with the connectors connected.

VERIFY BATTERY VOLTAGE

Verify that the battery voltage is 11 V or more when the ignition switch is in the 'ON' position.

USE HIGH IMPEDANCE VOLTMETER

Using a voltmeter with high impedance (10 kΩ/V minimum), measure the voltage at each terminal of the wiring connectors.

VTA-E2

Diagnostic flowchart for no specified voltage at PCME terminals VTA and E2. Step 1: There is no specified voltage at PCME terminals VTA and E2 (IG SW ON). Step 2: Check that there is voltage between PCME terminals VC and E2 (IG SW ON). If NO: Refer to VC-E2 trouble section. If OK: Check throttle position sensor (See page EG2-288). If BAD: Repair or replace. If OK: Check wiring between PCME and throttle position sensor. If BAD: Repair or replace. If OK: Try another PCME.

NO VOLTAGE BETWEEN IGT AND E1 AT IDLING — DIAGNOSTIC FLOW

(1) There is no voltage between PCME terminals IGT and E1. (Idling). (2) Check that there is voltage between PCME terminal IGT and body ground. (Idling). If NO: (3) Check wiring between PCME terminal E1 and body ground. If BAD: Repair or Replace. If OK: Try another PCME. If OK at step 2: Check fuse, H-fuse, fusible link, ignition switch and ignition main relay. If BAD: Repair or replace. If OK: Check distributor (See IG section). If BAD: Repair or replace. If OK: Check wiring between PCME and battery. If BAD: Repair or replace. If OK: Check igniter (See IG section). If BAD: Repair or replace.

NO VOLTAGE BETWEEN PCME TERMINALS THG AND E2 (IG SW ON)

Step 1: There is no voltage between PCME terminals THG and E2 with IG SW ON. Step 2: Check that there is voltage between PCME terminal +B or +B1 and body ground with IG SW ON. If OK, proceed to check wiring between PCME terminal E1 and body ground. If NO, refer to No.1 (See page EG2-220). If E1 wiring is BAD, repair or replace. If E1 wiring is OK, check EGR system (See page EG2-173). If EGR system is BAD, repair or replace. If EGR system is OK, check EGR function sensor (See page EG2-321). If EGR function sensor is BAD, replace EGR function sensor. If EGR function sensor is OK, check wiring between PCME and EGR function sensor. If wiring is OK, try another PCME. If wiring is BAD, repair or replace.

PERFORM VOLTAGE MEASUREMENTS WITH CONNECTORS CONNECTED

Perform all voltage measurements with the connectors connected.

VERIFY BATTERY VOLTAGE

Verify that the battery voltage is 11 V or more when the ignition switch is in the 'ON' position.

USE HIGH IMPEDANCE VOLTMETER

Using a voltmeter with high impedance (10 kΩ/V minimum), measure the voltage at each terminal of the wiring connectors.

VC-E2 DIAGNOSTIC FLOWCHART

Flowchart for diagnosing no voltage between PCME & T terminals VC and E2 (IG SW ON). Step 1: Check for voltage between PCME & T terminal +B (+B1) and body ground (IG SW ON). If OK, proceed to check throttle position sensor (See page EG2-288). If BAD, repair or replace. If OK after TPS check, check wiring between PCME & T and throttle position sensor. If wiring OK, try another PCME & T. If wiring BAD, repair or replace wiring. If no voltage at +B/+B1, refer to No-1 (See page EG2-236).

VTA-E2 DIAGNOSTIC FLOWCHART

Flowchart for diagnosing no specified voltage at PCME & T terminals VTA and E2 (IG SW ON). Step 1: Check that there is voltage between PCME & T terminals VC and E2 (IG SW ON). If NO, refer to VC-E2 trouble section. If OK, proceed to step 3: Check throttle position sensor (See page EG2-288). If BAD, repair or replace. If OK, check wiring between PCME & T and throttle position sensor. If BAD, repair or replace. If OK, try another PCME & T.

VSV (For Fuel Pressure)

Diagram showing the location and circuit of the VSV (Vacuum Switching Valve) for fuel pressure on the 5S-FE engine MPI system. The VSV is connected via vacuum sensing hoses to the fuel pressure regulator. The circuit diagram shows connections from the PCME (&T) to: STA (to Ignition Switch ST2), +B/+B1 (to MPI Main Relay), FPU (through VSV for Fuel Pressure), THW (through ECTS), E2, THA (through IATS), and E1 (ground).

TIRES

Check the pressure with a gauge. Adjust if necessary. Check for cuts, damage or excessive wear.

WHEEL NUTS

When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them.

WINDSHIELD WIPER BLADES

Check for wear or cracks whenever they do not wipe clean. Replace if necessary.

FLUID LEAKS

Check underneath for leaking fuel, oil, water or other fluid. If you smell gasoline fumes or notice any leak, have the cause found and corrected.

DOORS AND ENGINE HOOD

Check that all doors including the trunk lid operate smoothly, and that all latches lock securely. Check that the engine hood secondary latch secures the hood from opening when the primary latch is released.

LIGHTS

Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. Check the headlight aim.

WARNING LIGHTS AND BUZZERS

Check that all warning lights and buzzers function properly.

HORN

Check that it is working.

WINDSHIELD GLASS

Check for scratches, pits or abrasions.

WINDSHIELD WIPER AND WASHER

Check operation of the wipers and washer. Check that the wipers do not streak.

WINDSHIELD DEFROSTER

Check that the air comes out from the defroster outlet when operating the heater or air conditioner at defroster mode.

REAR VIEW MIRROR

Check that it is mounted securely.

SUN VISORS

Check that they more freely and mounted securely.

STEERING WHEEL

Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noise.

SEATS

Check that all seat controls such as seat adjusters, seat back recliner, etc. operate smoothly. Check that all latches lock securely in any position. Check that the locks hold securely in any latches position. Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position.

SEAT BELTS

Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. Check that the belt webbing is not cut, frayed, worn or damaged.

ACCELERATOR PEDAL

Check the pedal for smooth operation and uneven pedal effort or catching.

CLUTCH PEDAL (See CL section)

Check the pedal for smooth operation. Check that the pedal has the proper freeplay.

BRAKE PEDAL (See BR section)

Check the pedal for smooth operation. Check that the pedal has the proper reserve distance and freeplay. Check the brake booster function.

BRAKES

At a safe place, check that the brakes do not pull to one side when applied.

PARKING BRAKE (See BR section)

Check that the lever has the proper travel. On a safe incline, check that the vehicle is held securely with only the parking brake applied.

WINDSHIELD WASHER FLUID

Check that there is sufficient fluid in the tank.

ENGINE COOLANT LEVEL

Check that the coolant level is between the "FULL" and "LOW" lines on the see-through reservoir.

RADIATOR AND HOSES

Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. Check hoses for cracks, kinks, rot or loose connections.

BATTERY ELECTROLYTE LEVEL

Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If level low, add distilled water only.

BRAKE AND CLUTCH FLUID LEVELS

Check that the brake fluid level is near the upper level line on the see-through reservoir. Check that the clutch fluid level is within ±5 mm (0.20 in.) of the reservoir hem.

ENGINE DRIVE BELTS

Check all drive belts for fraying, cracks, wear or oiliness.

ENGINE OIL LEVEL

Check the level on the dipstick with the engine turned off.

POWER STEERING FLUID LEVEL

Check the level. The level should be in the "HOT" or "COLD" range depending on the fluid temperature.

EXHAUST SYSTEM

Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected.

SPARK PLUG ELECTRODE GAP CHECK AND INSTALLATION

Check the electrode gap of new spark plugs. If adjusting the gap of a new plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug. Using a 16 mm plug wrench, reinstall the spark plugs. Reconnect the high-tension cords. Reconnect the No.1 intake air connector to the throttle body.

• If adjusting the gap of a new plug, bend only the base of the ground electrode. Do not touch the tip. Never attempt to adjust the gap on a used plug.

ENGINE COOLANT MIX

Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's instructions. Using coolant which includes more than 50% ethylene-glycol (but not more than 70%) is recommended.

CONDITIONS FOR SCHEDULE A

Schedule A applies under the following conditions: Towing a trailer, using a camper or car top carrier. Repeated short trips less than 8 km (5 miles) and outside temperature remains below freezing. Extensive idling and/or low speed driving for long distances such as police, taxi or door-to-door delivery use. Operating on dusty, rough muddy or salt spread roads.

FOOTNOTE 1 — TIMING BELT

Applicable to vehicles operated under conditions of extensive idling and/or low speed driving for a long distance such as police, taxi or door-to-door delivery use.

FOOTNOTE 2 — AIR FILTER

Applicable when operating mainly on dusty road. If not, apply SCHEDULE B.

FOOTNOTE 3 — FUEL LINES AND CONNECTIONS

Includes inspection of fuel tank band and vapor vent system.

FOOTNOTE 4 — STEERING GEAR HOUSING

Check for oil leaks from steering gear housing.

FOOTNOTE 5 — BOLTS AND NUTS ON CHASSIS AND BODY

Applicable only when operating mainly on rough, muddy roads. The applicable parts are listed below. For other usage conditions, refer to SCHEDULE B. Parts: Front and rear suspension member to cross body; Strut bar bracket to body bolts; Bolts for sheet installation.

SCHEDULE B CONDITIONS

Conditions other than those listed for SCHEDULE A.

MAINTENANCE BEYOND 96,000 KM (60,000 MILES)

Maintenance service beyond 96,000 km (60,000 miles) should continue to be performed at the same intervals shown for each maintenance schedule.

EMISSION CONTROL WARRANTY ITEMS

Items marked with * indicate maintenance which is part of the warranty conditions for the Emission Control System. The warranty period is in accordance with the owner's guide or the warranty booklet. (*: California specification vehicles).

FUEL LINES AND CONNECTIONS — INSPECTION SCOPE

Includes inspection of fuel tank band and vapor vent system.

TRANSAXLE AND DIFFERENTIAL — INSPECTION METHOD

Check for leakage.

STEERING GEAR HOUSING OIL — INSPECTION METHOD

Check for oil leaks from steering gear housing.

BOLTS AND NUTS ON CHASSIS AND BODY — APPLICABLE PARTS

The applicable parts are listed below: Front and rear suspension member to cross body; Strut bar bracket to body bolt; Bolts for sheet installation.

TIRES

Check the pressure with a gauge. Adjust if necessary. Check for cuts, damage or excessive wear.

WHEEL NUTS

When checking the tires, check the nuts for looseness or for missing nuts. If necessary, tighten them.

WINDSHIELD WIPER BLADES

Check for wear or cracks whenever they do not wipe clean. Replace if necessary.

FLUID LEAKS

Check underneath for leaking fuel, oil, water or other fluid. If you smell gasoline fumes or notice any leak, have the cause found and corrected.

DOORS AND ENGINE HOOD

Check that all doors including the trunk lid operate smoothly, and that all latches lock securely. Check that the engine hood secondary latch secures the hood from opening when the primary latch is released.

LIGHTS

Check that the headlights, stop lights, taillights, turn signal lights, and other lights are all working. Check the headlight aim.

WARNING LIGHTS AND BUZZERS

Check that all warning lights and buzzers function properly.

HORN

Check that it is working.

WINDSHIELD GLASS

Check for scratches, pits or abrasions.

WINDSHIELD WIPER AND WASHER

Check operation of the wipers and washer. Check that the wipers do not streak.

WINDSHIELD DEFROSTER

Check that the air comes out from the defroster outlet when operating the heater or air conditioner at defroster mode.

REAR VIEW MIRROR

Check that it is mounted securely.

SUN VISORS

Check that they more freely and mounted securely.

STEERING WHEEL

Check that it has the specified freeplay. Be alert for changes in steering condition, such as hard steering, excessive freeplay or strange noise.

SEATS

Check that all seat controls such as seat adjusters, seatback recliner, etc. operate smoothly. Check that all latches lock securely in any position. Check that the locks hold securely in any latches position. Check that the head restraints move up and down smoothly and that the locks hold securely in any latched position.

SEAT BELTS

Check that the seat belt system such as buckles, retractors and anchors operate properly and smoothly. Check that the belt webbing is not cut, frayed, worn or damaged.

ACCELERATOR PEDAL

Check the pedal for smooth operation and uneven pedal effort or catching.

CLUTCH PEDAL

Check the pedal for smooth operation. Check that the pedal has the proper freeplay. See CL section.

BRAKE PEDAL (See BR section)

Check the pedal for smooth operation. Check that the pedal has the proper reserve distance and freeplay. Check the brake booster function.

BRAKES

A safe place, check that the brakes do not pull to one side when applied.

PARKING BRAKE (See BR section)

Check that the lever has the proper travel. On a safe incline, check that the vehicle is held securely with only the parking brake applied.

AUTOMATIC TRANSMISSION PARK MECHANISM

Check that lock release button of the selector lever for proper and smooth operation. On a safe incline, check that the vehicle is held securely with the selector lever in the 'P' position and all brakes released.

WINDSHIELD WASHER FLUID

Check that there is sufficient fluid in the tank.

ENGINE COOLANT LEVEL

Check that the coolant level is between the 'FULL' and 'LOW' lines on the see-through reservoir.

RADIATOR AND HOSES

Check that the front of the radiator is clean and not blocked with leaves, dirt or bugs. Check that hoses for cracks, kinks, rot or loose connections.

BATTERY ELECTROLYTE LEVEL

Check that the electrolyte level of all battery cells is between the upper and lower level lines on the case. If level low, add distilled water only.

BRAKE AND CLUTCH FLUID LEVELS

Check that the brake fluid level is near the upper level line on the see-through reservoir. Check that the clutch fluid level is within ±5 mm (0.20 in.) of the reservoir hem.

ENGINE DRIVE BELTS

Check all drive belts for fraying, cracks, wear or oiliness.

ENGINE OIL LEVEL

Check the level on the dipstick with the engine turned off.

POWER STEERING FLUID LEVEL

Check the level. The level should be in the 'HOT' or 'COLD' range depending on the fluid temperature.

AUTOMATIC TRANSMISSION FLUID LEVEL

Park the vehicle on a level surface. With the engine idling and the parking brake applied, shift the selector into all positions from 'P' to 'L' and then shift into 'P'. Pull out the dipstick and wipe off the fluid with a clean rag. Re-insert the dipstick and check that the fluid level is in the HOT range. Perform this check with the fluid at normal driving temperature (70-80°C (158-176°F)). HINT: Wait about 30 minutes before checking the fluid level after extended driving at high speeds in hot weather, driving in heavy traffic or with a trailer.

EXHAUST SYSTEM

Visually inspect for cracks, holes or loose supports. If any change in the sound of the exhaust or smell of the exhaust fumes is noticed, have the cause located and corrected.

BELT CONDITION HINTS

Cranks on the rib side of a belt are considered acceptable. If the belt has chunks missing from the ribs, it should be replaced.

NEW BELT DEFINITION

'New belt' refers to a belt which has been used less than 5 minutes on a running engine.

USED BELT DEFINITION

'Used belt' refers to a belt which has been used on a running engine for 5 minutes or more.

BELT INSTALLATION CHECK

After installing the belt, check that it fits properly in the ribbed grooves.

PULLEY GROOVE CHECK

Check by hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

NEW BELT RECHECK

After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.

REINSTALL SPARK PLUGS

Using a 16 mm plug wrench, reinstall the spark plugs. Reconnect the high-tension cords.

ENGINE COOLANT HINTS

Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's instructions. Using coolant which includes more than 50% ethylene-glycol (but not more than 74%) is recommended.

CHECK BRAKE LINES AND HOSES

Check all brake lines and hoses for: Damage, Wear, Deformation, Cracks, Corrosion, Leaks, Bends, Twists.

CHECK CLAMPS AND CONNECTIONS

Check all clamps for tightness and connections for leakage.

CHECK HOSE AND LINE CLEARANCE

Check that the hoses and lines are clear of sharp edges, moving parts and the exhaust system.

CHECK GROMMET ALIGNMENT

Check that the lines installed in grommets pass through the center of the grommets.

INSPECT STEERING GEAR HOUSING OIL

Check the steering gear housing for oil leakage.

INSPECT DRIVE SHAFT BOOTS

Check the drive shaft boots for clamp looseness, leakage or damage.

CHECK TRANSAXLE OIL (FLUID)

Visually check the transaxle for oil (fluid) leakage. If leakage is found, check for the cause and repair.

REPLACE TRANSAXLE OIL (FLUID) (INCL. DIFFERENTIAL OIL) — Replace transaxle oil (M/T)

Remove the filler and drain plugs, and drain the oil. Reinstall the drain plug securely.

Add transaxle oil (M/T)

Add new oil until it begins to run out of the filler hole. In case the recommended oil grade is unavailable, use Type A (API GL-4, SAE 75W-90) or Type B (AN GL-5, SAE 75W-90). Reinstall the filler plug securely.

FIRING ORDER

Firing order: 1 – 3 – 4 – 2

INSPECTION BATTERY VOLTAGE

Battery voltage: 10-14.5 V

DISCONNECT CONNECTORS

Disconnect the three connectors from the actuator as shown.

DESCRIPTION

The ABS is a brake system which controls the brake cylinder hydraulic pressure of all four wheels during sudden braking and braking on slippery road surfaces, preventing the wheels from locking. This ABS provides the following benefits: (1) Enables steering round an obstacle with a greater degree of certainty even when panic braking. (2) Enables stopping in a panic brake while keeping the effect upon stability and steerability to a minimum, even on curves. The function of the ABS is to help maintain directional stability and vehicle steerability on most road conditions. However, the system cannot prevent the vehicle from skidding if the cornering speed limit is exceeded. In case a malfunction occurs, a diagnosis function and fail-safe system have been adopted for the ABS to increase serviceability.

COMPONENTS FUNCTION

Front Speed Sensor: Detect the wheel speed of each of the left and right front wheels. Rear Speed Sensor: Detect the wheel speed of each of the left and right rear wheels. A6S Warning Lamp: Lights up to alert the driver when trouble has occurred in the Anti-Lock Brake System. Actuator: Controls the brake fluid pressure to each disc brake cylinder through signals from the computer. ABS ECU: From the wheel speed signals from each sensor, it calculates acceleration, deceleration and slip values and sends signals to the actuator to control brake fluid pressure.

SYSTEM PARTS LOCATION

Diagram showing the location of ABS system components on the Toyota MR2 SW20: ABS ECU (engine bay, upper left area), ABS Actuator (engine bay, central area), Front Speed Sensor (front wheel hubs, left and right), and Rear Speed Sensor (rear wheel hubs, left and right).

ABS ACTUATOR CONNECTORS

Connector A (6-pin): pins labeled MR, SR, R-, WA, GND (pins 1,2,4,5,6). Connector B (6-pin): pins labeled MT, AST, SRR, SFL, SFR (pins 2,3,4,5,6). Connector C (2-pin): pins labeled +BM (pin 1), +BS (pin 2).

FRONT SPEED SENSOR (LH) CONNECTOR

2-pin connector: pin 1 = FL+, pin 2 = FL-.

FRONT SPEED SENSOR (RH) CONNECTOR

2-pin connector: pin 1 = FR+, pin 2 = FR-.

REAR SPEED SENSOR (LH) CONNECTOR

2-pin connector: pin 1 = (unlabeled positive), pin 2 = (unlabeled negative).

REAR SPEED SENSOR (RH) CONNECTOR

2-pin connector: pin 1 = (unlabeled positive), pin 2 = (unlabeled negative).

ABS ECU CONNECTOR PIN ASSIGNMENTS

34-pin connector layout. Upper row pins 23-28: pin 23=WA, pin 24=FSS, pin 25=FSS, pin 26=FL+, pin 27=R-, pin 28=SR/SFL. Lower row pins 29-34: pin 29=AST, pin 30=MT/AST, pin 31=MT, pin 32=FL-, pin 33=SRR, pin 34=MR/SRR. Upper row pins 1-11: pin 1=SFR, pin 2=GND, pin 3=RL-, pin 4=TS/STP, pin 5=RSS, pin 6=W, pin 7=IG1, pin 8=FR+, pin 9=FSS, pin 10=W, pin 11=SFL. Lower row pins 12-22: pin 12=GND, pin 13=RL+, pin 14=EX, pin 15=TC, pin 16=PKB, pin 17=RR-, pin 18=RR+, pin 19=BAT, pin 20=FR-, pin 21=FL-, pin 22=RR+.

DIAGNOSIS SYSTEM DESCRIPTION

If a malfunction occurs, the system will identify the problem and the ECU will store the codes for the trouble items. At the same time, the system informs the driver of a malfunction via the "ABS" warning light in the combination meter. To identify the trouble by the number of blinks (diagnostic code) of the warning light turn on the ignition switch, disconnect the service connector, and use SST to connect Tc and E1 of the data link connector. In the event of two codes, that having the smallest number (code) will be identified first. HINT: The warning light does not show the diagnostic codes while the vehicle is running.

ABS TROUBLESHOOTING TABLE

Problem index: 'A6S' warning light — Always comes on after ignition switch is turned on (No.1); Does not come on for 3 seconds after ignition switch on (No.2); Comes on and off (No.3); Comes on while running (No.1). Brake condition — Brakes pull (No.4); Braking inefficient (No.4); ABS operates at ordinary braking (No.4); ABS operates just before stopping at ordinary braking (No.4); Brake pedal pulsates abnormally while ABS is operating (No.4); Skidding noise occurs while ABS operating — ABS operates inefficiently (No.5).

ECU CONNECTOR CHECK

Check if connector of ECU is properly connected and all terminals are in the connector. If NO: Faulty ECU connector.

POWER CIRCUIT VOLTAGE CHECK

Check if there is 10-16 V between terminal IG on ECU wire harness side connector and body ground with ignition switch on. If NO: Faulty power circuit.

WARNING LIGHT CHECK WITH CONNECTORS DISCONNECTED

Check if warning light goes off when both the ECU connector and service connector are disconnected with ignition switch on. If NO (comes on): Short circuit in wire harness between ECU terminal W and control relay Terminal W. If YES (goes off): Faulty ECU.

ABS WARNING LIGHT DOES NOT COME ON FOR 3 SECONDS AFTER IGNITION SWITCH ON

Diagnostic flowchart for condition 2: ABS warning light does not come on for 3 seconds after ignition switch on. Step 1: Pull out the short pin and ground terminal W of the female side connector with ignition switch on. If warning light does NOT come on: bulb burned out or open circuit in wire harness between warning light and control relay terminal W. If YES: Disconnect connectors from ECU and control relay and ground terminal W of ECU wire harness side connector with ignition switch on. If warning light does NOT come on: open circuit in wire harness between ECU terminal W and warning light. If YES: With ignition switch off, disconnect control relay connectors and check continuity between terminal W and BS on actuator side. Reverse tester leads and check again. If there is NOT one-way continuity between terminals: short circuit in control relay inside diode. If YES (one-way continuity confirmed): Faulty ECU. HINT: If the diode is short-circuited, a malfunction at ECU terminal W will occur. When inspecting the terminal, connect the ECU connector, and disconnect actuator connectors and data link connector. Then turn the ignition switch on, and check that the warning light goes on. If it does, the ECU terminal is OK.

ABS WARNING LIGHT COMES ON AND OFF (Symptom 3)

Check for short circuit in wire harness between terminal Te and E, of check connector.

BRAKES PULL / BRAKING INEFFICIENT / ABS OPERATES AT ORDINARY BRAKING (Symptom 4)

Symptoms include: Brakes pull; Braking inefficient; ABS operates at ordinary braking; ABS operates just before stopping at ordinary braking; Brake pedal pulsates abnormally while ABS is operating. Diagnostic flowchart: Pull out the short pin and connect terminals Tc and E of check connector (See page BR-53). If warning light does NOT show the diagnostic normal code (ignition switch on), see diagnostic code (See page BR-55). If YES, check that each speed sensor is installed in place and each installation bolt is tightened securely. If NO, speed sensor installation is faulty. If YES, try speed sensor diagnosis system — check if sensor signal level is OK (See page BR-62). If NO, inspect speed sensor and replace if necessary. If YES, try speed sensor diagnosis system — check if sensor signal change is OK (See page BR-62). If NO, inspect sensor rotor and replace if necessary. If YES, disconnect connector from ECU, inspect continuity between each speed sensor terminals on wire harness side (See page BR-66). If abnormal change occurs in continuity when connectors or wire harness of the speed sensor and intermediate connectors are twisted or bent, the wire harness is faulty. If no change, continued on page BR-61.

FOREIGN MATERIAL / FERRIC CHIPS CHECK

If there is foreign material or ferric chips on the sensor tip, clean chips from the speed sensor. If not, inspect the actuator operation (See page BR-66). If actuator operation is not OK, replace faulty actuator. If actuator operation is OK, replace ECU.

SYMPTOM 5 — ANTI-LOCK BRAKE SYSTEM OPERATES INEFFICIENTLY

Pull out the short pin and connect terminals Tc and E1 of data link connector (See page BR-53). Check if warning light shows the diagnostic normal code with ignition switch on. If NO, see diagnostic code (See page BR-55). If YES, check for battery voltage between ECU terminal STP and body ground when depressing brake pedal. If NO, there is an open circuit in stop light switch and/or wire harness. If YES, inspect actuator (See page BR-66).

CHECK THAT PEDAL RESERVE DISTANCE IS CORRECT, AS SHOWN

Release the parking brake. With the engine running, depress the pedal and measure the pedal reserve distance, as shown. If the reserve distance is incorrect, troubleshoot the brake system.

REPLACE PARTS PROPERLY

Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent.

KEEP PARTS AND AREA CLEAN

It is very important to keep parts and the area clean when repairing the brake system.

INSTALL INSIDE PAD

Install inside pad with the pad wear indicator plate facing downward.

INSTALL OUTSIDE PAD

Install outside pad.

• There should be no oil grease adhering to the friction surfaces of the pads or the rotor disc.

INSTALL ANTI-SQUEAL SPRINGS

Install the two anti-squeal springs.

INSTALL CYLINDER

Draw out a small amount of brake fluid from the reservoir tank. Place a wooden plate on the piston, and press in the piston with a hammer handle or similar implement. HINT: If the piston is difficult to punch in, loosen the bleeder plug and push in the piston while letting some brake fluid escape. Temporarily install the cylinder on the torque plate with two installation bolts. Hold the sliding pin and torque the installation bolts.

INSTALL FRONT WHEEL

Install front wheel.

CHECK FLUID LEVEL

Check that fluid level is at MAX line.

REMOVE FOLLOWING PARTS

Remove the following parts: (a) Two anti-squeal springs, (b) Two brake pads, (c) Four anti-squeal shims, (d) Pad wear indicator, (e) Two pad support plates.

CYLINDER DISASSEMBLY — REMOVE FOLLOWING PARTS

Remove the following parts during cylinder disassembly: (a) Two sliding bushings, (b) Four dust boots.

REMOVE CYLINDER BOOT SET RING AND CYLINDER BOOT

Using a screwdriver, remove the cylinder boot set ring and cylinder boot.

REPLACE THE DISC IF NECESSARY

If rotor disc runout is not within specification, replace the disc following the procedure below.

REPLACE PARTS PROPERLY

Care must be taken to replace each part properly as it could affect the performance of the brake system and result in a driving hazard. Replace the parts with parts of the same part number or equivalent.

KEEP PARTS AND AREA CLEAN

It is very important to keep parts and the area clean when repairing the brake system.

MASTER CYLINDER COMPONENTS INSPECTION

HINT: Clean the disassembled parts with compressed air.

INSPECT CYLINDER BORE FOR RUST OR SCORING

INSPECT CYLINDER FOR WEAR OR DAMAGE

If necessary, clean or replace the cylinder.

FOOT BRAKE OPERATION

When the brake pedal is depressed, a vacuum builds up in the booster which amplifies the pedal force, pressing on the piston in the master cylinder. The piston raises the hydraulic pressure in the cylinder. This hydraulic pressure is then applied to each front brake cylinder and rear wheel cylinder (or rear brake cylinder), and acts to press the front brake pads and rear brake pads (or rear brake shoes) against the rotating rotor discs (or brake drums). The resulting friction converts the rotational energy to thermal energy, stopping the vehicle.

SST (SPECIAL SERVICE TOOLS)

List of special service tools required for brake system service.

TROUBLESHOOTING PRIORITY TABLE

You will find the troubles easier using the table well shown below. In this table, each number shows the priority of causes in troubles. Check each part in order. If necessary, replace these parts.

FRONT AXLE DESCRIPTION

The wheel bearings are double-row angular ball bearings combined with the oil seals having small rolling resistance and are free from maintenance. There is no need for bearing grease maintenance or preload adjustment.

FRONT AXLE HUB ASSEMBLY — INSTALL HUB BEARING

1. INSTALL HUB BEARING (a) Using SST, install a new axle hub bearing. SST 09608-30012 (09608-04070) (b) Using snap ring pliers, install the hole snap ring.

INSTALL HUB GREASE CAP

Using SST, install the hub grease cap. SST 09608–30012 (09608–04020), 09649–17010

TORQUE STEERING KNUCKLE TO SHOCK ABSORBER

Torque the steering knuckle to shock absorber.

INSTALL ROTOR DISC TO AXLE HUB

HINT: Before removing the rotor disc, place the matchmarks on the axle hub and rotor disc.

INSTALL DISC BRAKE CALIPER TO STEERING KNUCKLE

Install and torque the two bolts.

INSTALL FRONT WHEEL AND LOWER VEHICLE

Install front wheel and lower vehicle.

CHECK FRONT WHEEL ALIGNMENT

See page SA-3.

BALL JOINT INSPECTION — INSPECT BALL JOINT FOR ROTATION

(a) Remove the ball joint. (b) Flip the ball joint stud back and forth 5 times as shown in the figure, before installing the nut. (c) Using a torque gauge, turn the nut continuously one turn each 2–4 seconds and take the torque reading on the fifth turn. If not within specification, replace the ball joint.

FRONT SUSPENSION DESCRIPTION

The front suspension of the new model use MacPherson struts as in the previous model. The strut bar changed the cushion type into the bushing type. The basic construction and operation remain the same, but the suspension geometry and the bushings have been modified to improve stability and riding comfort.

DISASSEMBLY — REMOVE DUST COVER AND NUT

(b) Remove the dust cover. (c) Using SST, hold the spring seat so that it will not turn, and remove the nut. SST 09729-22031. (d) Remove the suspension support, dust seal, spring seat, spring, insulators and bumper.

FRONT SHOCK ABSORBER ASSEMBLY INSTALLATION — INSTALL BUMPER COIL SPRING, SPRING SEAT AND DUST SEAL

(a) Using SST, compress the coil spring. SST 09727-00045, 09727-30020. (b) Install the bumper to the piston rod. (c) Align the coil spring end with the lower seat hollow and install. (d) Face the 'OUT' mark of the spring seat toward the outside of the vehicle, and install it. (e) Install the dust seal on the spring seat. (f) Install the suspension support.

DISCONNECT STRUT BAR FROM LOWER ARM

Remove the two nuts and disconnect the strut bar from the lower arm.

REMOVE LOWER ARM

Remove the bolt and washer, then remove the lower arm from the body.

SST (SPECIAL SERVICE TOOL)

Special service tools required for front suspension service: 09610-20012 Pitman Arm Puller; 09720-00012 Shock Absorber Overhaul Tool Set (includes 09721-00071 Front Shock Absorber Ring Nut Wrench); 09727-00045 Arm Set; 09727-30020 Coil Spring Compressor; 09729-22031 Front Spring Upper Seat Holder.

RECOMMENDED TOOLS

09025-00010 Small Torque Wrench.

EQUIPMENT

Torque wrench.

REMOVE STABILIZER BAR FROM BODY

(a) Remove the nuts and bolts. (b) Remove the stabilizer bar with the brackets and cushion.

REMOVE STABILIZER BAR BRACKETS AND STABILIZER BAR CUSHIONS FROM STABILIZER BAR

Remove the stabilizer bar brackets and stabilizer bar cushions from the stabilizer bar.

INSPECT STABILIZER LINK

Rotate ball joint arm in all directions. If movement is not smooth and free, replace stabilizer link.

REAR AXLE DESCRIPTION

The rear axle also uses oil-sealed double-row angular ball bearings for wheel bearings as the front axle. The preload of the bearings can be determined only by tightening the axle hub nut at a specified torque, improving serviceability.

SST (SPECIAL SERVICE TOOLS)

List of special service tools required for rear axle service procedures.

RECOMMENDED TOOLS

09025-00010 Small Torque Wrench; 09905-00013 Snap Ring Pliers

EQUIPMENT

Dial indicator; Torque wrench

INSTALL DUST DEFLECTOR

Using SST and a hammer, drive in a new dust deflector to the rear axle carrier. SST 09316-60010 (09316-00010, 09316-00040)

STABILIZE SUSPENSION

Install the rear wheel and lower vehicle. Bounce the vehicle up and down several times to allow the suspension to settle.

TIGHTEN BOLT AND NUT

Tighten the bolt and nut with the vehicle load applied onto the suspension.

CHECK REAR WHEEL ALIGNMENT

Check rear wheel alignment. See page SA-3.

REAR DRIVE SHAFT (3S-GTE) DESCRIPTION

The drive shaft has a cross-groove type CVJ (Constant Velocity Joint) on the differential side and Rzeppa type CVJ on the wheel side. The LH shaft consists of a Cross-Groove Type CVJ on the differential side and a Rzeppa Type CVJ on the wheel side. The RH shaft consists of a Center Bearing and Cross-Groove Type CVJ on the differential side and a Rzeppa Type CVJ on the wheel side.

SST (SPECIAL SERVICE TOOLS)

List of special service tools required for rear drive shaft service on 3S-GTE engine vehicles.

OIL SEAL REPLACEMENT — REMOVE OIL SEALS

Using SST, drive out the oil seals. SST 09308-00010

OIL SEAL REPLACEMENT — INSTALL NEW OIL SEAL (LH)

Using SST and hammer, tap in a new LH oil seal. SST 09223-15010

OIL SEAL REPLACEMENT — INSTALL NEW OIL SEAL (RH)

Using SST and hammer, tap in a new RH oil seal. SST 09316-60010 (09316-00010)

INBOARD JOINT REASSEMBLY HINT

Should the joint become disassembled, reassemble it in the way shown.

SERVICE HINT — INBOARD JOINT REASSEMBLY

Steps for reassembling the inboard joint after disassembly.

ALIGN MATCHMARKS

Align the matchmarks placed before disassembly.

INSERT SPARK PLUG WRENCH

Insert the spark plug wrench into the inner race.

INSERT SIX BALLS

Lift the outer race and cage, and insert the six balls.

SEAT BALLS IN GROOVES

Jiggle the outer race and cage as shown to place the balls in their respective grooves.

LOWER OUTER RACE AND CAGE

Lower the outer race and cage so that they fit tightly with the inner race.

INSTALL DUST COVER TO CENTER DRIVE SHAFT

Using a press, press in a new dust cover to the inboard joint.

INSTALL NEW SNAP RING

Using a snap ring expander, install a new snap ring.

ALIGN MATCHMARKS AND INSTALL INBOARD JOINT

Align the matchmarks placed before remove, and install the side gear shaft or center drive shaft and a new gasket to the inboard joint sub-assembly.

TEMPORARILY TIGHTEN HEXAGON BOLTS

Using SST, temporarily tighten the six hexagon bolts with three washers. SST 09923-00020

CHECK DRIVE SHAFT

Check to see that there is no play in the inboard joint and outboard joint. Check to see that the inboard slide smoothly in the thrust direction.

REAR DRIVE SHAFT (5S-FE) DESCRIPTION

The drive has a tripod type CVJ (Constant Velocity Joint) on the differential side and Rzeppa type CVJ on the wheel side. Both LH and RH rear drive shafts share this configuration.

SST (SPECIAL SERVICE TOOLS)

Special service tools required for rear drive shaft service on 5S-FE: 09316-60010 Transmission & Transfer Bearing Replacer (includes 09316-00010 Replacer Pipe); 09350-32014 TOYOTA Automatic Transmission Tool Set (includes 09351-32111 Side Bearing Race Replacer, 09351-32130 Handle, 09351-32150 Oil Seal Replacer); 09608-16041 Front Hub Bearing Adjusting Tool (includes 096008-02020 Bolt & Nut, 096008-02040 Retainer); 09950-00020 Bearing Remover — used for Center drive shaft dust cover.

RECOMMENDED TOOLS

09905-00012 Snap Ring No. 1 Expander — For removing and installing snap ring.

EQUIPMENT

Torque wrench.

AXLE BEARING PROTECTION NOTICE

The axle bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft removed. Therefore, if it is absolutely necessary to place the vehicle weight on the axle bearing, first support it with SST.

ABS SENSOR ROTOR PROTECTION (w/ ABS)

After disconnecting the drive shaft from the axle hub, work carefully so as not to damage the sensor rotor serrations on the drive shaft.

ABS SENSOR ROTOR CAUTION

With ABS: Be careful not to damage the sensor rotor of the drive shaft.

REMOVE LH DRIVE SHAFT

Using a hammer and hub nut wrench or an equivalent, remove the LH drive shaft.

• Be careful not to damage the dust cover.
• Cover the hub nut wrench or an equivalent with cloth so as not to damage the transaxle body.

REMOVE RH DRIVE SHAFT

Using a hammer and brass bar, drive out the RH drive shaft.

INSTALL LH OIL SEAL (A/T)

Using SST and hammer, tap in a new LH oil seal. SST 09350-32014 (09351-32111, 09351-32150). HINT: Coat the oil seal lip with MP grease.

INSTALL RH OIL SEAL (A/T)

Using SST and hammer, tap in a new RH oil seal. SST 09350-32014 (09351-32130, 09351-32150). HINT: Coat the oil seal lip with MP grease.

REMOVE DAMPER

Step 7 of rear drive shaft removal.

REMOVE OUTBOARD JOINT BOOT CLAMPS AND BOOT

Step 8 of rear drive shaft removal.

• Do not disassemble the outboard joint.

REMOVE DUST COVER

Step 9 of rear drive shaft removal. (a) LH Drive Shaft: Using SST and press, press out the dust cover from the inboard joint tulip. SST 09950-00020. (b) RH Drive Shaft: Using a press, press out the dust cover.

BALL JOINT INSPECTION — INSPECT BALL JOINT FOR ROTATION CONDITION

Flip the ball joint stud back and forth 5 times as shown in the figure, before installing the nut. Using a torque gauge, turn the nut continuously one turn each 2–4 seconds and take the torque reading on the fifth turn. Torque (turning): 1.47–2.94 N–m (15–30 kgf–cm, 13–26 in.–lbf). If not within specification, replace the ball joint.

BALL JOINT INSTALLATION — INSTALL BALL JOINT TO REAR AXLE CARRIER

Install the ball joint in place with the two bolts. Torque: 113 N–m (1,150 kgf–cm, 83 ft–lbf)

REAR SUSPENSION DESCRIPTION

The rear suspensions of the new model use MacPherson struts as in the previous model. The basic construction and operation remain the same, but the suspension geometry and bushing have been modified to improve stability and riding comfort.

REMOVE ENGINE LATERAL CONTROL ROD

(a) Remove the engine lateral control rod with the No.1 and No.2 brackets. (b) Remove the engine lateral control rod from the engine No.1 lateral control rod brackets.

DISASSEMBLY ENGINE LATERAL CONTROL ROD

Remove the following parts: Nut, Three retainers, Two cushions, No.2 bracket.

REMOVE LOWER ARM

Step 4 of the preceding removal procedure: (a) Remove the bolt holding the lower arm to the body and remove the lower arm. (b) Remove the strut bar cushions, collar and retainer from the lower arm.

REMOVE SHOCK ABSORBER

Remove the three suspension holding nuts. Remove the two upper bolts and remove the axle carrier assembly. Remove the shock absorber.

• Cover the drive shaft boot with cloth to avoid damaging it.

INSPECT STABILIZER LINK

Rotate the ball joint arm in all directions, if the movement is not smooth and free, replace the stabilizer link.

INSTALL STABILIZER BAR

Install the cushions and brackets touching the line painted on the stabilizer bar. Install the stabilizer bar to the rear suspension crossmember and tighten the bracket bolts.

INSTALL SUSPENSION CROSSMEMBER

Install the suspension crossmember in place, then install and tighten the four bolts.

SUSPENSION ARM DISASSEMBLY

Disassemble suspension arm by: (a) Loosen the tie rod adjusting tube two nuts. (b) Turn the tie rod adjusting tube, and remove the tie rod adjusting tube, and remove the tie rod end and the suspension arm No.2.

SUSPENSION ARM ASSEMBLY — INSTALL TIE ROD END AND SUSPENSION ARM NO. 2 TO TIE ROD TUBE

(a) Install the tie rod adjusting tube, tie rod adjusting tube nuts, tie rod end and rear suspension arm No. 2. (b) Adjust the rear suspension arm. (c) Temporarily tighten the tie rod adjusting tube nut. HINT: Fully tighten after adjusting the rear wheel alignment.

TROUBLESHOOTING PRIORITY TABLE

Use the table to find troubles easier. Each number shows the priority of causes in troubles. Check each part in order. If necessary, replace these parts. Troubles covered: Wander/pulls, Bottoming, Sways/pitches, Front wheel shimmy, Abnormal tire wear. Parts checked: Tires, Cold tire inflation pressure, Wheel alignment, Springs, Stabilizer bar, Shock absorber, Ball joint, Hub bearings, Steering linkage, Steering gear, Suspension parts, Overloaded, Wheel balance.

TIE ROD LENGTH EQUALITY CHECK

If wheel angles differ from the standard specifications, check to see if the lengths of the left and right tie rods are the same. If the rod lengths are not equal, the wheel angle cannot be adjusted properly. If the tie rod lengths were changed to adjust the wheel angle, inspect the toe-in.

TIE ROD LENGTH EQUALITY CHECK

If wheel angles differ from the standard specifications, check to see if the lengths of the left and right tie rods are the same. If the rod lengths are not equal, the wheel angle cannot be adjusted properly. If the tie rod lengths were changed to adjust the wheel angle, inspect the toe-in.

MASTER CYLINDER INSPECTION

HINT: Clean the disassembled parts with compressed air.

INSPECT MASTER CYLINDER BORE FOR SCORING OR CORROSION

If a problem is found, clean or replace the cylinder.

INSPECT PISTON AND CUPS FOR WEAR, SCORING CRACKS OR SWELLING

If either one requires replacement, use the parts from the cylinder kit.

INSPECT PUSH ROD FOR WEAR OR DAMAGE

If necessary, replace the push rod.

MASTER CYLINDER INSTALLATION

Sequential installation steps for the clutch master cylinder.

INSPECT CONTINUITY OF CLUTCH START SWITCH

Check that there is continuity between terminals when the switch is ON (pushed). Check that there is no continuity between terminals when the switch is OFF (free). If continuity is not as specified, replace the switch.

DISCONNECT CLUTCH LINE UNION

Using SST 09751-36011, disconnect the union. Use a container to catch the brake fluid. Remove the retainer.

SUPPORT ENGINE AND TRANSAXLE

Support the engine and transaxle using a wooden block.

REMOVE ENGINE FRONT MOUNTING BRACKET SET BOLTS

Remove the two bolts from engine side.

REMOVE BOLT AND PULL OUT RELEASE CYLINDER ASSEMBLY

Remove the bolt and pull out the release cylinder assembly.

RELEASE CYLINDER ASSEMBLY

1. COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE, AS SHOWN 2. INSTALL PISTON 3. INSTALL BOOT AND INSERT PUSH ROD

RELEASE CYLINDER INSTALLATION

1. INSTALL RELEASE CYLINDER — Torque: 12 N-m (120 kgf-cm, 9 ft-lbf) 2. INSTALL ENGINE FRONT MOUNTING BRACKET SET BOLTS — Torque: 77 N-m (790 kgf-cm, 57 ft-lbf) 3. REMOVE SUPPORTS FOR ENGINE AND TRANSAXLE

DESCRIPTION

The diaphragm spring turnover type clutch providing lighter release performance.

TROUBLESHOOTING TABLE USAGE

You will find the cause of trouble more easily properly using the table shown below. In this table, the numbers indicate the priority of the probable cause of trouble. Check each part in the order shown. If necessary, repair or replace the part.

EGR SYSTEM OVERVIEW

To reduce NOx emissions, part of the exhaust gases is recirculated through the EGR valve to the intake manifold to lower the maximum combustion temperature.

EGR OPERATION — BELOW 54°C (129°F)

When coolant temperature is below 54°C (129°F), VSV is CLOSED. EGR Valve is CLOSED. Exhaust gas is not recirculated regardless of throttle valve position.

EGR OPERATION — ABOVE 60°C (140°F), THROTTLE ABOVE PORT E

When coolant temperature is above 60°C (140°F) and throttle valve is positioned above port E (condition 1): VSV is OPEN, pressure in EGR valve pressure chamber is condition (1), EGR vacuum modulator state is dash (not active), EGR valve is CLOSED, exhaust gas is not recirculated.

EGR OPERATION — ABOVE 60°C (140°F), THROTTLE BELOW PORT E

When coolant temperature is above 60°C (140°F) and throttle valve is positioned below port E (condition 2): VSV is OPEN, pressure in EGR valve pressure chamber is condition (2) (bullet present), EGR vacuum modulator CLOSED passage to atmosphere, EGR valve is OPEN, exhaust gas is recirculated (increase).

REMARK — THROTTLE ABOVE PORT E

When the throttle valve is positioned above the port E, the EGR vacuum modulator will close the atmosphere passage and open the EGR valve to increase the EGR gas, even if the exhaust pressure is insufficiently low.

EGR VALVE INSPECTION — REMOVE EGR VALVE

Steps to remove the EGR valve prior to inspection.

EGR VALVE INSPECTION — INSPECT EGR VALVE

Check for sticking and heavy carbon deposits. If a problem is found, replace the valve.

JET INSPECTION

1. REMOVE JET. 2. INSPECT JET: Blow air from each side of the jet, and check for stoppage. If operation is not as specified, replace the jet. 3. REINSTALL JET.

LAYOUT AND SCHEMATIC DRAWING

Physical layout drawing showing the emission control components on the 3S-GTE engine including: VSV (for EGR), EGR Vacuum Modulator, EGR Valve, TVS (for EVAP), and Charcoal Canister. Schematic drawing showing the interconnection of: EGR Vacuum Modulator, EGR Valve, VSV (For EGR), IACV, Jet, BVSV (For EVAP), Charcoal Canister, Sub-TWC, Main TWC, and Oxygen Sensor.

SYSTEM PURPOSE

Lists emission control systems for the 3S-GTE engine: Positive crankcase ventilation (PCV) reduces blow-by gas (HC); Fuel evaporative emission control (EVAP) reduces evaporative HC; Exhaust gas recirculation (EGR) reduces NOx; Three-way catalyst (TWC) reduces HC, CO and NOx; Electronic fuel injection (SMPI) regulates all engine conditions for reduction of exhaust emissions. For inspection and repair of the SMPI system, refer to SMPI Section.

SYSTEM PURPOSE

Lists emission control systems for the 3S-GTE engine: Positive crankcase ventilation (PCV) reduces blow-by gas (HC); Fuel evaporative emission control (EVAP) reduces evaporative HC; Exhaust gas recirculation (EGR) reduces NOx; Three-way catalyst (TWC) reduces HC, CO and NOx; Electronic fuel injection (SMPI) regulates all engine conditions for reduction of exhaust emissions. For inspection and repair of the SMPI system, refer to SMPI Section.

THREE-WAY CATALYST (TWC) SYSTEM OPERATION

To reduce CO, HC and NOx emissions, they are oxidized, reduced and converted to carbon dioxide (CO2), water (H2O) and nitrogen (N2) by the catalyst. Exhaust port emissions (CO, HC, NOx) pass through the Main TWC (oxidation and reduction), then the Sub-TWC (oxidation and reduction), resulting in exhaust gas of CO2, H2O, N2.

SUB-TWC INSPECTION — INSPECT FOR DENTS OR DAMAGE

If any part of protector is damaged or dented to the extent that it contacts the sub-TWC, repair or replace it.

EXHAUST PIPE REMOVAL ROUTING

The stabilizer bar and drive shaft will be in the way while removing the exhaust pipe. Follow directions according to illustration. Sequence: 1st — pull pipe clear of drive shaft; 2nd — clear stabilizer bar (pull); 3rd — clear stabilizer bar (pull).

COMPONENTS FOR DISASSEMBLY AND ASSEMBLY — 70 A TYPE

Exploded diagram identifying all components of the 70 A Type alternator: Pulley, Drive End Frame (Stator), Front Bearing, Retainer, Rotor, Rear Bearing, Bearing Cover, Terminal Insulator, Brush Holder Cover, Brush Holder, Spring, Brush, Rear End Cover, IC Regulator, Rubber Insulator, Rectifier Holder, Rectifier End Frame.

COMPONENTS FOR DISASSEMBLY AND ASSEMBLY — 80 A OR 90 A TYPE

Exploded diagram identifying all components of the 80 A or 90 A Type alternator: Pulley, Drive End Frame (Stator), Front Bearing, Retainer, Rotor, Rear Bearing, Bearing Cover, Alternator Washer, Terminal Insulator, Brush Holder Cover, Brush Holder, Seal Plate, IC Regulator, Rubber Insulator, Rectifier Holder, Rectifier End Frame, Plate Terminal, Rear End Cover.

CHECK BATTERY CABLE CONNECTIONS

Check that the battery cables are connected to the correct terminals.

DISCONNECT BATTERY CABLES DURING QUICK CHARGE

Disconnect the battery cables when the battery is given a quick charge.

DO NOT USE HIGH VOLTAGE INSULATION RESISTANCE TESTER

Do not perform tests with a high voltage insulation resistance tester.

NEVER DISCONNECT BATTERY WHILE ENGINE IS RUNNING

Never disconnect the battery while the engine is running.

NEW BELT DEFINITION

New belt refers to a belt which has been used less than 5 minutes on a running engine.

USED BELT DEFINITION

Used belt refers to a belt which has been used on a running engine for 5 minutes or more.

BELT INSTALLATION CHECK — RIBBED GROOVES

After installing a belt, check that it fits properly in the ribbed grooves.

BELT INSTALLATION CHECK — PULLEY GROOVE

Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley.

POST-INSTALLATION TENSION RECHECK

After installing a new belt, run the engine for about 5 minutes and recheck the belt tension.

OPERATION

When the ignition switch is turned ON, current from the battery flows from terminal L of the alternator through the IC regulator to terminal E, causing the discharge warning light to light up. Then when the engine is started, the voltage output increases as the alternator rpm increases. When the voltage output becomes greater than the battery voltage, current for recharging flows from terminal B. Simultaneously, voltage at terminal L increases and the potential difference between battery and terminal L disappears, causing the discharge warning light to go off. When the voltage output exceeds the regulator adjustment voltage, the transistor inside the IC regulator regulates the voltage so that the voltage from the alternator remains constant.