Engine Electrical
Speciaf Tools ............. 4-2
Starting System
Component Location Index ............ 4-3
Circuit Diagram ................................ 4-4
Starter Test ........... 4-5
Starter Solenoid Test ...................... 4'5
Starter Replacement ....................... 4-7
Field Winding Test ........................... 4-7
Starter Overhaul ............................,. 4-8
Brush Inspection ...........................,., 4-9
Overrunning Glutch Inspection ...... 4-9
Armature lnspection and Test ........4-10
Brush Holder Test ............................ 4-12
Starter Reassemb|y ......................... 4-1 2
Perf ormance Test ............................. 4- 1 3
lgnition System
Component Location Index ............ 4-14
Circuit Diagram ................................ 4-15
lgnition Timing Inspection and
Setting .......................................... 4-16
Distributor Replacement ........,........ 4-17
Distributor Overhaul .............,,......... 4-18
lgnition Control Module (lCM) Input
Test ..............................,................ 4-19
fgnition Coil Test .............................. 4-2O
lgnition Wire Inspection and
Test ............................................... 4-20
Spark Plug Inspection ..................... 4-21
-+
ENGINE
Charging System
Component Location Index ............ 4-22
Circuit Diagram ....................,........... 4-23
Troubleshooting .............................. 4-24
Alternator Replacement ..........,....... 4-30
Alternator Overhaul .......,,................ 4-31
Rectifier Test .........4-32
Alternator Brush Inspection ........... 4-32
Rotor Slip Ring Test ........................ 4-33
Stator Test ............. 4-33
Alternator Belt Inspection and
Adiustment ........4-34
Gruise Control
Component Location Index .,,,........ 4-36
Circuit Diagram ................................ 4-37
Control Unit Input Test ................... 4-38
Main Switch Test/Replacement ..... 4-40
Set/Resume Switch Test/
Replacement .......................,........ 4'40
Actuator Test ....,,., 4-41
Actuator Replacement ...............,.... 4-42
Actuator Cable Adiustment ............ 4-43
Clutch Switch Test .......................... 4-43
Brake Switch Test .................. .......... 4-44
Actuator Solenoid Test .............. ...,. 4-44
Actuator Disassembly ..................... 4-45
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Disconnest the lilP connector from the control unit.
Csvity WireTest condition
R€conn€ct tho 14P connGctor to the control unit.
Test: Desired resultPossible cause it result is not obtained
BRNAr'VHTUnder all conditionsCheck for resistance to groundl
There should be 80 - 120 o.
Faulty actuator solenoid
Poor ground (G202)
An open in the wire1BRNUnder all conditionsCheck for resistance to groundl
There should be 40 - 60 0.
11BRN/BLKUnder all conditionsCheck for resistance to ground:
There should be 70 - 110 O.
2GRY
lgnition switch ON (ll),
main switch ON and
brake pedal depressed,
then released
Check for voltage to ground:
There should be 0 V with the pedal
depressed and battery voltage with
the pedal released.
. Faulty brake switch. An open in the wire
BLKUnder all conditionsCheck for continuity to ground:
There should be continuity.
. Poor ground (G401). An open in the wire
5GRNMHT
Brake pedal depressed,
then released
Check for voltage to ground:
There should be battery voltage with
the pedal depressed, and 0 V with
the pedal released.
Blown No.52 1'15 Alfuse in the
under-hood fuse/relay box
Faulty brake switch
An open in the wire
LT GRN/
RED
Set button pushedCheck for voltage to ground:
There should be battery voltage.Blown No. 52 {'15 A} fuse in the
under-hood fuse/relay box
Faulty horn relay
Faulty sevresume switch
Faulty cable reel
An open in the wire7LT GRN/
BLK
Resume button pushed
10RED/BLU
lgnition switch ON lll)Attach to ground:
Cruise indicator light in the gauge
assembly should come on.
Elown bulbBlown No. 25 (7.5 A) tuse in theunder-dash fuse/relay box
Faulty dimming circuit in the gauge
assembly
An open in the wire
ELU^r'r'HT
lgnitjon switch ON {ll}and main switch ON;
raise the front of the
vehicle, block one wheel
and rotate the other
wheel slowly.
Check for voltage between the
ELUA/VHT @ and BLK O terminalsl
There should be 0 - 5 V or more-0 - 5 V or more repeatedly.
Faulty vehicle speed sensor (VSS)
An open in the wire
r3LT GRN
lgnition switch ON {ll}and main switch ONCheck for voltage to ground:
There should be battery voltage.
Blown No. 14 (7.5 A) fuse in theunder-dash fuse/relay box
Faulty main switch
An open in the wire
l4PNK
A'/T: Shift lever in E, EotE
lvl/T: Clutch pedal
releaseo
Check for continuity to ground:
There should be continuity.NOTE: There should be no continu-
ity when the shift lever is in otherpositions or when the clutch pedal is
oepresseo.
Faulty A/f gear position switch 1A,/TlFaulty or misadjusted clutch switch
fi{/r)Poor ground (G101)
An open in the wire
BLU
Start tho engine. turnthe main switch ON, anddrive the vehicle over 25
mph (40 km/h)with the
crurse control set
Check for voltage to ground:
There should be approx.5 V
. Faulty cruise control unit. Shod to ground
*: '98 - 00 models with Automatic Transmission.
4-39
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Actuator Cable Adiustment
'1.Check that the actuator cable operates smoothly
with no binding or sticking.
Start the engine. Hold the engine at 3,000 rpm with
no load (A,/T in E or E position, M/T in neutral)
until the radiator fan comes on, then let it idle.
Measure the amount of movement of the actuator
rod until ths cable pulls on the accelerator lever
(engine speed starts to increase). Free play should
be 11 t 1.0 mm (0.43 i 0.04 in).
LOCKNUT FREE PLAY: 11 t 1.0 mm
10.43 r 0.04 in)
lf free play is not within specs, loosen the locknut,
and turn the adjusting nut as requirsd,
NOTE: lf necessary, check the throttl€ cable frso
play (s€e section 11), then recheck the actuator rod
free play.
Retighten the locknut, and recheck the free play.
st
te
ACTUATOR ROD
Clutch Switch Test
1. Disconngct ths 2P connector from the clutch switch.
CLUTCH SWITCH 2P CONNECTORTerminalside ofmale terminals
2.
5.
Remove the clutch switch,
Check for continuity between the terminals accord-
ing to the table.
4. lf necessary, replace the switch or adjust the pedal
height (see section t2).
Terminal
Clutch Switch \
OEPRESSED
RELEASEDoo
4-43
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Engine Removal/lnstallation
Removal (cont'dl
Remove the cruise control actuator (see section 4).
Remove the mounting bolt and lock bolt, then
remove the P/S pump belt and pump.
10.
1t.
MOUNNNG BOLT8 x 1.25 mm2a N.m 12.4 kg{.m, 17 lbtftlP/S PUMPBELT
LOCK BOLTI x 1.25 mm24 N.m {2.4 kgtm, '17 lbf.ftl
12.Loosen the idler pulley bracket bolt and adjusting
bolt, then remove the air conditioning (A,/C) com-
pressor belt.
ID1TR PULI.f,Y ARACKET BOLT10 r 1.25 mma{ N.m 14.5lgtm,33 lbf.ft)
ADJUSTING BOLTLOCKNUT8 x 1.25 mm24 N.m {2.4 kgf.m, 17 lbf.ftl
5-4
13. Relieve fuel pressure {see section 11).
@ Do not 3mok6 whil€ working on th6
tugl systsm. Koep open flam€ or spark away from
the work area. Drain fuel only inlo an approved
container.
14. Remove the evaporative emission (EVAP) control
canister hose and tuel feed hose.
33 N.m (3.4 kgt.m,2s tbf.ft)
,%l
*ryft'fltr
\'t,f
EVAP CCCANISTER HOSE
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Timing Belt
Removal
Replace the timing belt at 105,000 miles (168,000 km)
according to the maintenance schedule {normal condi-
tions/severe conditions). lf the vehicle is regularly driven
in either of the following conditions, replace the timing
belt at 60,000 miles (U.S.A.l 100.000 km (Canada).
- ln very high temperatures (over 110'F, 43"C).- In very low temperatures (under -20"F. -29"C).
Turn the crankshaft pu\ley so the No. 1 piston is at
top dead center (TDC).
Remove the guard bar and splash shield (see page
5-7 ).
Loosen the mounting bolt and lock bolt. then remove
the power steering (P/S) pump belt.
MOUNNNG BOLT8 x 1.25 rnm
1.
2.
,l
4. Loosen the idler pulley bracket bolt and adjusting
bolt, then remove the air conditioning (lVC) compres
sor belt (see page 5-4).
6-10
24 N.m {2.4 kgt.m, 17 lbf.ftl
24 N.m 12.4 kgf.m, lt lbf.ftl
5. Loosen the mounting nut and locknut, then remove
the altefnator belt.
LOCKNUTI x 1.25 mm2a N.m 12.4 kgt m, 17 lblftl
6.
10 x 1,25 mm4,1 N.m (,1.5 kgt m, 33 lbtftl
Remove the cruise control actuator (see section 4).
Support the engine with a jack, then remove the
upper bracket. Make sure to place a cushion
between the oil Dan and the iack.
12 x 1.25 mm74 N.m (7.5 kgf m, 54 lbtftl
7.
BRACKET
AELT
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13. Remove the upper radiator hose, heater hose and
water bypass hose.
WATER BYPASS
UPPEBRADIATORHOSE
17
HEATERHOSE
Remove the engine wire harness connectors and
wire harness clamps from the cylinder head and the
intake manifold.
o Four fuel injector connectors
. Engine coolant temperature (ECT) sensor con-
neclor
. Radiator fan switch connector
. Coolant temperature gauge sendlng unlt connec-
tor
. Throttle position sensor connector
. Manifold absolute pressure {MAP) sensor con-
nector
Primary heated oxygen sensor (primary HO2S)
connector
ldle air control (lAC) valve connector
Distributor connector
Remove the spark plug caps and distributor from the
cylinder head.
Remove the cruise control actuator (see section 4).
Support the engine with a jack, then remove the
upper bracket. Make sure to place a cushion
between the oil pan and the iack (see page 6-10).
a
18. Remove the cylinder head cover.
19. Inspect the timing belt (see page 6-9).
CYLINDER
(cont'd)
6-19
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Gonnector ldentification and Wire Harness Routing
Engine Compartment Wire Harness
Connector ol
Terminal
Number of
CavitiesLocationConnects toNotes
c20'l
c202
c203
c204
c205
c206
c207
c208
c209
c210
c212
c213
c2't4
c215
c216
c217
c21A
c218
14
2
2
1'l
2
10
Left side of engine compartment
Left side of engine compartment
Behind front bumper
Behind right headlight
Behind front bumper
Behind right headlight
Left side of engine compartment
Left side of engine compartment
Left side of engine compartment
Behind left headlight
Left side of engine compartment
Behind front bumper
Behind front bumper
Right side of engine compartment
Behind right headlight
Behind right headlight
Behind right headlight
Right side of engine compartment
Right side of engine compadment
Main wire harness (C307)
Cruise actuator
Rear window washer motor
Left front turn signal/side marker lights
Windshield washer motor
Left front parking light
Condenser fan motor
Front fog lights
IVC compressor clutch
Left headlight
IVC pressure switch
Left horn
Right horn
Radiator fan motor
Right headlight
Right front turn signal/side marker
lights
Right front parking light
Main wire harness 1C357)
Main wire harness (C357)
Optional
'97 - 98
models'99 - 00
mooets
G201
G202
Right side of engine companment
Left side of engine compartment
Body ground, via engine compartment
wire harness
Body ground, via engine compartment
wire harness
23-16
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