Page 357 of 1865
3B COOLANT
86U03X-004
69G03A-006
COOLANT
INSPECTION
Coolant Level (Engine cold)
1. Check that the coolant level is near the radiator inlet
port.
2. Check that the coolant level in the coolant reser-
voir is between the FULL and Low marks.
Add coolant if necessary.
Warning
a) Never remove the radiator cap while the en-
gine is hot.
b)Wrap a thick cloth around the cap when
removing it.
Coolant Quality
1. Check that there is no build-up of rust or scales
around the radiator cap or radiator filler neck.
2. Check that coolant is free from oil.
3. Replace the coolant, if necessary.
Coolant Leakage
1. Connect a tester and SST to the radiator inlet port.
2. Apply 103 kPa (1.05 kg/cm2, 15 psi) pressure
to the system.
3. Check that the pressure is held.
If not, check for coolant leakage.
Warning
When removing either the radiator cap or the
tester, loosen it slowly until the pressure in
the radiator is released, and then remove it.
86U03X-005
REPLACEMENT
1. Remove the radiator cap and loosen the drain plug.
2. Drain the coolant into a suitable container.
Warning
a) Never open the radiator cap while the en-
gine is hot.
b)Wrap a thick cloth around the cap when
loosening.
c) Use caution when draining hot coolant.
86U03X-006
3B—4
Page 358 of 1865
RADIATOR CAP 3B
86U03X-028
86U03X-007
86U03X-008
3. Set the heater control switch to the maximum heat
position.
4. Flush the cooling system with water until all traces
of color are gone, then let the system drain com-
pletely.
5. Fill with the proper mixture and amount of ethy-
lene glycol-based coolant.
Caution
a) Do not use alcohol- or methanol-based
coolant.
b) Use only soft (demineralized) water in the
coolant mixture.
Anti-freeze solution mixture percentage
Protection Volume percentage Gravity
at
20°C (68°F) Protection Solution Water
Gravity
at
20°C (68°F)
Above —16°C (3°F) 35 65 1.054
Above -26°C (-15°F) 45 55 1.066
Above -40°C (-40°F) 55 45 1.078
6. Run the engine at idle with the radiator cap re-
moved. Let any air bleed from the system, and add
more coolant.
7. Install the radiator cap, and inspect all connections
for leakage.
RADIATOR CAP
INSPECTION
Radiator Cap Valve
1. Remove foreign material (such as water residue)
from between the radiator cap valve and the valve
seat.
2. Attach the radiator cap to a tester with the SST.
Apply pressure gradually to 74—103 kPa
(0.75—1.05 kg/cm2, 11—15 psi).
3. Wait about 10 seconds; then check that the pres-
sure has not decreased.
Negative Pressure Valve
1. Pull the negative-pressure valve to open it. Check
that it closes completely when released.
2. Check for damage on the contact surfaces, and
for cracked or deformed seal packing.
3. Replace the radiator cap if necessary.
86U03X-009
3B-5
Page 359 of 1865
3B RADIATOR
Note
a) Position the hose clamp in the original location on the hose.
b) Squeeze the clamp lightly with large pliers to ensure a good fit. 86U03X-010
RADIATOR
REMOVAL AND INSTALLATION
1. Drain the engine coolant.
2. Remove in the sequence shown in the figure.
3. Install in the reverse order of removal.
1. Coolant reservoir hose
2. Fast idle solenoid
3. Coolant level sensor connector
4. Cooling fan connector
76G03B-005
5. Upper and lower radiator hose
6. Cooling fan and radiator assembly
7. Cooling fan
INSPECTION
Check the following points. Repair or replace if
necessary.
1. Cracks, damage, or water leakage
2. Bent fins (Repair with a screwdriver)
3. Distorted or bent radiator inlet
86U03X-012
3B-6
Page 360 of 1865
WATER PUMP 3B
WATER PUMP
REMOVAL
1. Disconnect the negative battery cable.
2. Turn the crankshaft so that the No. 1 cylinder is at TDC of compression.
3. Drain the engine coolant.
4. Remove in the sequence shown in the figure. 69G03A-025
31—46 N m (3.2—4.7 m-kg, 23—34 ft-lb)
19—26 N-m (1.9—2.6 m-kg, 14—19 ft-lb)
(?) 8—11 N-m (80—110 cm-kg, 69—95 In-lb)
37—52 N-m (3.8—5.3 m-kg, 27—38 ft
55—65 N-m (5.6—6.6 m-kg, 41-48 ft-lb)
(80—110 cm-kg, 69—95 In-lb)
59—69 N-m (6.0—7.0 m-kg, 43—51 ft-lb)
76G03B-006
1. Timing belt (Refer to page 1C—11)
2. Camshaft pulley (Refer to page 1C—36)
3. Injection pump pulley (Refer to page
1C—36)
4. Seal plate
Note
Do not disassemble the water pump body, if a problem is found replace it as a unit.
5. Alternator
6. Water pipe
7. Water hose
8. Water pump body
9. Water pump inlet
3B-7
Page 362 of 1865
THERMOSTAT 3B
THERMOSTAT
REMOVAL
1. Drain the engine coolant.
2. Disconnect the upper radiator hose, and water
thermo switch connector.
3. Remove the thermostat cover.
4. Remove the thermostat.
76G03B-010
76G03B-011
Sub valve Main valve
I
INSPECTION
Check the thermostat. Replace if necessary.
1. Visually check that the valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Gradually heat the water and check the following:
Valve opening temperature
Sub valve : 78.5—81.5°C (173—179°F)
Main valve : 86.5—89.5°C (188—193°F)
Full open lift
Sub valve : 1.5 mm (0.06 in) min. at
100°C (212°F)
Main valve : 8 mm (0.31 in) min. at
100°C (212°F)
Valve closing temperature
Sub valve : 75°C (167°F)
Main valve : 83°C
(181
°F)
69G03B-012
76G03B-012
INSTALLATION
1. Install the thermostat into the thermostat case with
jiggle pin at the top.
2. Install a new gasket with the seal print side facing
the thermostat case.
3. Install the thermostat cover.
Tightening torque:
7—10 N-m (70—100 cm-kg, 61—87 in-lb)
4. Install the upper radiator hose and water thermo
switch connector.
5. Replenish the coolant.
6. Start the engine and check for leaks.
3B-9
Page 366 of 1865
4A
FUEL AND EMISSION
CONTROL SYSTEMS
(CARBURETOR)
OUTLINE 4A— 2
SYSTEM DIAGRAM 4A— 2
VACUUM HOSE ROUTING
DIAGRAM 4A— 5
EMISSION COMPONENTS
LOCATION 4A— 8
COMPONENT DESCRIPTIONS 4A—12
SPECIFICATIONS 4A—15
TROUBLESHOOTING GUIDE 4A—17
PARTS INSPECTION 4A—23
AIR CLEANER ELEMENT 4A—23
ACCELERATOR LINKAGE 4A—23
INTAKE MANIFOLD 4A—23
CHOKE CABLE 4A—23
FUEL SYSTEM 4A—24
TROUBLESHOOTING 4A—25
CARBURETOR 4A—26
FUEL PUMP 4A—35
FUEL TANK 4A—36
SEPARATOR 4A—37
TWO-WAY CHECK VALVE 4A—37
THREE-WAY CHECK VALVE 4A—37
FUEL FILTER 4A—37
IDLE SPEED AND IDLE MIXTURE.. 4A—38
ADJUSTMENT 4A—38
AUTO-RETURN CHOKE SYSTEM... 4A—40
TROUBLESHOOTING 4A—40
PTC HEATER SYSTEM 4A—42
TROUBLESHOOTING 4A—42
DECELERATION CONTROL SYSTEM 4A—45
TROUBLESHOOTING 4A—45
BYPASS AIR CONTROL SYSTEM.. 4A—48
DASH POT 4A—50
ANTI-AFTERBURN VALVE 4A—50
MAIN AIR BLEED CONTROL
SYSTEM 4A—51
SLOW FUEL CUT SYSTEM 4A—53
COAST ENRICHMENT SYSTEM .... 4A—54
COASTING LEANER SYSTEM 4A—56
AIR INJECTION SYSTEM 4A—58
INTAKE AIR TEMPERATURE CONTROL
SYSTEM 4A—60
TROUBLESHOOTING 4A—60
PURGE CONTROL SYSTEM 4A—63
VACUUM SWITCH VALVE 4A—63
EXHAUST GAS RECIRCULATION
(EGR) SYSTEM 4A—64
TROUBLESHOOTING 4A—65
POSITIVE CRANKCASE VENTILATION
SYSTEM 4A—67
PCV VALVE 4A—67
IDLE-UP CONTROL SYSTEM 4A—68
TROUBLESHOOTING 4A—70
IDLE-UP SOLENOID VALVE 4A—76
EVAPORATIVE EMISSION CONTROL
SYSTEM 4A—78
TROUBLESHOOTING 4A—79
IGNITION TIMING CONTROL
SYSTEM 4A-80
TROUBLESHOOTING 4A—81
CONTROL SYSTEM 4A-83
RELATIONSHIP CHART 4A—84
ENGINE CONTROL UNIT 4A—86
INHIBITOR SWITCH 4A—93
IDLE SWITCH 4A—93
VACUUM SWITCH 4A—94
WATER THERMO SWITCH 4A—95
EXHAUST SYSTEM 4A—96
76G04A-001
Page 369 of 1865
Engine
control
unit
Engine
control
unit
Ignition coil
Slow fuel cut solenoid
valve ^Reed valve
ATX1
1
MTY
Page 373 of 1865
4A OUTLINE
EMISSION COMPONENTS LOCATION
ECE, Hong Kong, and Singapore
Dashpot*
Reed valve
Solenoid valve*2 (Ignition timing control system)
Vacuum switch*5
Anti-afterburn valve
Choke opener
Idle-up solenoid valve^*5
or coasting leaner*6
Water thermo switch
Thermo valve*6
Water thermo switch
PTC heater*5
Air bypass solenoid valve*3
Solenoid valve*5
(Choke opener)
jr'-f
Choke breaker diaphragm
Solenoid valve*5 (Main air bleed control system)
Solenoid valve (P/S)*1
Solenoid valve (A/C)*1
Engine control unit
Fuel pump
*1 If equipped
*2 FE and F8 ATX
*3 F8 MTX and FE
*4 MTX
*5 FE and F8
*6 F6
76G04A-008
4A—8
