Page 749 of 1839
16-1
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM 2................
GENERAL INFORMATION 2................
SERVICE SPECIFICATIONS 3..............
SPECIAL TOOL 4.........................
ON-VEHICLE SERVICE 5..................
Alternator Output Line Voltage Drop Test 5....
Output Current Test 6.......................
Regulated Voltage Test 8....................
Waveform Check Using An Analyzer 11.......
ALTERNATOR 13.........................
STARTING SYSTEM 23................
GENERAL INFORMATION 23..............
SERVICE SPECIFICATIONS 24............
STARTER MOTOR 24.....................
IGNITION SYSTEM 37.................
GENERAL INFORMATION 37..............
SERVICE SPECIFICATIONS 38............
SPECIAL TOOL 38.......................
ON-VEHICLE SERVICE 38................
Ignition Coil (With Built-in Power Transistor)
Check 38...................................
Spark Plug Check and Cleaning 39...........
Ignition Failure Sensor Check 40.............
Camshaft Position Sensor Check, Crank angle
Sensor Check, Detonation Sensor Check 40...
IGNITION COIL <6G7> 41.................
CRANKSHAFT ANGLE SENSOR
<6G7> 42................................
CAMSHAFT POSITION SENSOR
<6G7> 42................................
DETONATION SENSOR <6G7> 43.........
GLOW SYSTEM 44....................
GENERAL INFORMATION 44..............
SERVICE SPECIFICATIONS 45............
ON-VEHICLE SERVICE 45................
Self-regulating Glow System Check 45........
Glow & EGR Control Unit Check 48..........
Engine ECU Check 49.......................
Glow Plug Relay Check 50..................
Glow Plug Check 51........................
Engine Coolant Temperature Sensor
Check 51...................................
GLOW PLUG 52..........................
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Page 803 of 1839
17-1
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL SYSTEM 3........
GENERAL INFORMATION 3................
SERVICE SPECIFICATIONS 3..............
ON-VEHICLE SERVICE 3..................
Accelerator Cable Check and Adjustment
<4D5> 3...................................
ACCELERAOR CABLE AND PADAL 4......
AUTO-CRUISE CONTROL SYSTEM 7..
GENERAL INFORMATION 7................
SPECIAL TOOL 8.........................
TROUBLESHOOTING 9....................
ON-VEHICLE SERVICE 27................
Auto-cruise Control Main Switch Check 27....
Auto-cruise Control Switch Check 28..........
Auto-cruise Control Component Check 29.....
AUTO-CRUISE CONTROL SWITCH 30.....
EMISSION CONTROL SYSTEM
<6G7> 31.............................
GENERAL INFORMATION 31..............
Emission Control Device Reference
Table 31....................................
SERVICE SPECIFICATIONS 32............
SPECIAL TOOL 32.......................
VACUUM HOSE 32.......................
Vacuum Hose Piping Diagram 32.............
Vacuum Circuit Diagram 33..................
Vacuum Hose Check 33.....................
Vacuum Hose Installation 33.................
CRANKCASE EMISSION CONTROL
SYSTEM 34..............................
General Information 34......................
System Diagram 34.........................
Component Location 34......................
Positive Crankcase Ventilation System
Check 35...................................
PCV Valve Check 35........................
CONTINUED ON NEXT PAGE
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Page 804 of 1839
17-2
EVAPORATIVE EMISSION CONTROL
SYSTEM 36..............................
General Information 36......................
System Diagram 36.........................
Component Location 36......................
Purge Control System Check 37..............
Purge Port Vacuum Check 37................
Purge Control Solenoid Valve Check 38.......
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 39..............................
General Information 39......................
Operation 39................................
System Diagram 39.........................
Component Location 39......................
Exhaust Gas Recirculation (EGR) Control
System Check 40...........................
EGR Valve (Stepper Motor) Check 40........
EGR VALVE 42...........................
CANISTER 43............................
CATALYTIC CONVERTER 44..............
General Information 44......................
EMISSION CONTROL SYSTEM
<4D5> 45.............................
GENERAL INFORMATION 45..............
SERVICE SPECIFICATIONS 45............
SEALANT 45.............................
SPECIAL TOOL 45.......................
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 46..............................
General Information 46......................
System Diagram 46.........................
Component Location 46......................
Function Check 47..........................
EGR Solenoid Valve Operation Check 47.....
EGR Solenoid Valve Resistance Check 48....
Lever Position Sensor (LPS) Adjustment 48...
Engine Speed Sensor Check 49..............
Engine Coolant Temperature Sensor
Check 49...................................
CHECK AT THE GLOW & EGR CONTROL
UNIT 51..................................
EMISSION CONTROL SYSTEM
<4M4-VEHICLES WITH EGR> 52........
GENERAL INFORMATION 52..............
SERVICE SPECIFICATIONS 52............
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 53..............................
General Information 53......................
System Diagram 53.........................
Component Location 53......................
Function Check 54..........................
EGR Solenoid Valve Operation Check 54.....
EGR Solenoid Valve Resistance Check 55....
Accelerator Pedal Position Sensor (APS),
Engine Coolant Temperature Sensor, Intake
Air Temperature Sensor, Fuel Temperature
Sensor Check 55............................
Check at Engine-ECU 55....................
CATALYTIC CONVERTER 55..............
General Information 55......................
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Page 812 of 1839
Page 854 of 1839
ENGINE AND EMISSION CONTROL -Emission Control System
<4M4-Vehicles with EGR>17-52
EMISSION CONTROL SYSTEM <4M4-VEHICLES WITH
EGR>
GENERAL INFORMATION
The electronically-controlled EGR system and the
fuel injection timing control system (load timer)
reduce the level of exhaust gases (NO
x).
ItemsNameSpecification
Exhaust emission
control systemExhaust gas recirculation system
DEGR valve
DEGR solenoid valve No.1
DEGR solenoid valve No.2Electronically-controlled EGR system
Single type
Duty cycle solenoid valve
ON-OFFsolenoid valve
SERVICE SPECIFICATIONS
ItemsStandard value
EGR solenoid valve No.1/No. 2 resistance (at 20_C)W36 - 44
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Page 859 of 1839
17-1
ENGINE AND
EMISSION
CONTROL
CONTENTS
ENGINE CONTROL SYSTEM 2........
GENERAL 2...............................
Outline of Change 2.........................
EMISSION CONTROL SYSTEM
<4D5-STEPIII>
2 .....................................
GENERAL 2...............................
Outline of Changes 2........................
GENERAL INFORMATION 2................
SERVICE SPECIFICATIONS 2..............
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 3................................EGR VALVE AND EGR COOLER 6.........
CATALYTIC CONVERTER 8................
EMISSION CONTROL SYSTEM <4M4>
9 .....................................
GENERAL 9...............................
Outline of Change 9.........................
SERVICE SPECIFICATIONS 9..............
EXHAUST GAS RECIRCULATION (EGR)
SYSTEM 9................................
EGR VALVE AND EGR COOLER 11........
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Page 860 of 1839
ENGINE AND EMISSION CONTROL -EngineControlSystem/EmissionControl
System <4D5-Step III>17-2
ENGINE CONTROL SYSTEM
GENERAL
OUTLINE OF CHANGE
Electronic-controlled throttle valve system has been used instead of a conventional cable-type accelerator
mechanism <4D5>.
Its service procedure is the same as for previous models with 6G7 or 4M4 engine.
EMISSION CONTROL SYSTEM <4D5-STEP
III>
GENERAL
OUTLINE OF CHANGES
Some service procedures have been established as the following changes have been made due to the
compliance with the Emission Regulation Step III.
DAn electronic-controlled EGR valve and EGR cooler have been used.
DA catalytic converter has been added.
GENERAL INFORMATION
The electronically-controlled EGR system reduces
the level of exhaust gases (NO
x).
ItemsNameSpecification
Exhaust emission
control systemExhaust gas recirculation system
DEGR valve
DEGR solenoid valve No.1
DEGR solenoid valve No.2
DEGR valve position sensorElectronically-controlled EGR system
Single type
ON-OFF solenoid valve
ON-OFF solenoid valve
Variable resistor type
SERVICE SPECIFICATIONS
ItemsStandard value
EGR solenoid valve Nos. 1 and 2 resistance (at 20_C)Ω36 - 44
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Page 872 of 1839
21-1
CLUTCH
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
LUBRICANTS 2..............................
ON-VEHICLE SERVICE 2.....................
Clutch Pedal Inspection and Adjustment 2.......Clutch Pedal Position Switch
Continuty Check 3.............................
Bleeding 3.....................................
CLUTCH PEDAL 4...........................
CLUTCH CONTROL 5........................
Clutch Master Cylinder 8.......................
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