Page 401 of 557
6E1-10 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
6) Start engine and warm it up to normal operating temperature.
If engine doesn’t start, turn ignition switch ON to operate fuel
pump and after 2 seconds turn it OFF. Repeat this 3 or 4 times
and then check fuel pressure.
NOTE:
Check that battery voltage is 11 V or more before operating
fuel pump.
7) Measure fuel pressure under each of the following conditions.
CONDITION
FUEL PRESSURE
At specified idle speed
0.9 – 1.4 kg / cm2
90 – 140 kPa
12.8 – 20.0 psi
With fuel pump operating
and engine at stop1.6 – 2.1 kg / cm2
160 – 210 kPa
22.7 – 29.9 psi
Within 1 min. after engine
(fuel pump) stop (Pressure
reduces as time passes)Over 0.9 kg / cm2
90 kPa
12.8 psi
If measured pressure doesn’t satisfy specification, refer to
“DIAGNOSTIC FLOW TABLE B-3” and check each possibly
defective part. Replace if found defective.
8) Relieve fuel pressure, referring to Section 6.
9) Remove fuel pressure gauge, hose & 3-way joint after remov-
ing air cleaner assembly.
10) Connect fuel feed hose to throttle body and clamp it securely.
11) Install air cleaner assembly.
12) With engine “OFF” and ignition switch “ON”, check for fuel
leaks.
Page 402 of 557
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-11
1. Fuel filler
2. Ignition switch3. Fuel return hose
4. Fuel feed hose
1. Fuel pump 2. Filter 3. Fuel tank
FUEL PUMP
ON-VEHICLE INSPECTION
WARNING:
When fuel filler cap is removed in any procedure, work must be
done with no smoking, in a well-ventilated area and away from
any open flames.
1) Remove filler cap and turn ON ignition switch.
Then fuel pump operating sound should be heard from fuel filler
for about 2 seconds and stop. Be sure to reinstall fuel filler cap
after checking.
If above check result is not satisfactory, advance to “DIAGNOS-
TIC FLOW TABLE B-2”.
2) Fuel pressure should be felt at fuel return hose for 2 seconds af-
ter ignition switch ON.
If fuel pressure is not felt, advance to “DIAGNOSTIC FLOW
TABLE B-3”.
REMOVAL
1) Remove fuel tank from body according to procedure described
in Section 6C and remove fuel pump from fuel tank.
2) Remove fuel pump from its bracket.
INSPECTION
Check fuel pump filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel tank.
INSTALLATION
1) Install fuel pump to its bracket.
2) Install fuel pump to fuel tank and then install fuel tank to body ac-
cording to procedure described in Section 6C.
Page 403 of 557
6E1-12 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Fuel injector wire
2. Fuel injector
3. Upper O-ring
4. Lower O-ring
5. Throttle upper body
6. Gasket
7. Throttle lower body
8. ISC actuator
9. TP sensor
10. Injector sub wire coupler
11. O-ring
12. Injector wire cover
CAUTION:
As throttle stop screw and throttle lever screw are fac-
tory adjusted precisely, don’t remove or adjust them.
Throttle
stop
screw
Throttle lever
screwPositive
terminal Negative
terminal
Viewed from “A”
1. Throttle body
2. Vacuum nozzle
1. Injector coupler
2. TP sensor
3. Water hose
4. Vacuum hose
5. ISC actuator
6. Fuel return hose
7. Fuel feed hose
THROTTLE BODY
ON-VEHICLE INSPECTION
Check that throttle valve lever moves smoothly.
Vacuum passage inspection.
With fingers placed against vacuum nozzle, increase engine
speed a little and check that vacuum is applied.
REMOVAL
1) Relieve fuel pressure, referring to Section 6.
2) Disconnect battery negative cable at battery.
3) Remove air cleaner assembly referring to Section 6A.
4) Drain cooling system.
5) Disconnect following wire harness couplers:
TP sensor
Fuel injector
ISC actuator
6) Disconnect following hoses from throttle body.
Fuel feed and return hoses
Engine cooling water hoses
Vacuum hoses
7) Disconnect accelerator cable from throttle valve lever and cable
bracket.
8) Remove throttle body from intake manifold.
Page 406 of 557
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-15
1. Injector coupler
2. TP sensor
3. Water hose
4. Vacuum hose
5. ISC actuator
6. Fuel return hose
7. Fuel feed hose
1. Injector coupler
Good No good
2) Install throttle body to EFE heater and tighten bolts to specified
torque.
Tightening Torque
(a): 23 N
.m (2.3 kg-m, 17.0 lb-ft)
3) Install accelerator cable to throttle valve lever and cable brack-
et.
4) Connect fuel, cooling water and vacuum hoses to throttle body,
and clamp securely.
5) Connect TP sensor and injector couplers securely.
6) Refill cooling system referring to Section 6B.
7) Connect negative cable at battery.
8) With engine “OFF” and ignition switch “ON”, check for fuel
leaks around fuel line connection.
9) Install air cleaner assembly referring to Section 6A.
10) Upon completion of installation, start engine and check for fuel
leaks and engine coolant leaks.
Adjust cable play to specification according to procedure de-
scribed in ACCELERATOR CABLE ADJUSTMENT.
FUEL INJECTOR
ON-VEHICLE INSPECTION
1) With battery negative cable disconnected, disconnect injector
coupler.
2) Connect ohmmeter to each injector terminal and measure resis-
tance.
Resistance of injector: 0.5 – 1.5 Ω at 20C (68F)
If resistance is out of specification, replace fuel injector.
3) Connect injector coupler.
4) Remove air cleaner assembly without disconnecting IAT sensor
coupler.
5) Check that fuel is injected out in conical shape from fuel injector
when cranking or running engine.
If no fuel is injected, check wiring harness for continuity and cou-
plers for proper connection referring to “DIAGNOSTIC FLOW
TABLE B-1”.
If fuel is not injected out in conical shape, replace injector.
6) Check injector for fuel leakage after injection is stopped (i.e., af-
ter cranking or engine stop).
Replace if leakage exists.
Fuel leakage: Less than 1 drop/min.
7) Install air cleaner assembly.
Page 407 of 557
6E1-16 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1. Injector
1
3
2
1. Injector cavity
2. Lower O-ring
3. Upper O-ring
1. Positive terminal
REMOVAL
NOTE:
Use care when handling fuel injector especially not to damage
filter and its needle.
Also, because injector is an electrical component, it should
not be immersed in any type of liquid solvent or cleaner, or it
may get damaged.
1) Relieve fuel pressure, referring to Section 6.
2) Disconnect battery negative cable at battery.
3) Remove air cleaner assembly referring to Section 6A.
4) Remove air cleaner mounting stay from throttle body.
5) Remove injector wire and then remove fuel injector from throttle
body.
INSPECTION
Check fuel injector filter for evidence of dirt and contamination. If
present, clean and check for presence of dirt in fuel lines and fuel
tank.
INSTALLATION
1) Apply thin coat of spindle oil or gasoline to new upper and lower
O-rings, install lower O-ring and upper O-ring to injector.
2) Install injector by pushing it straight into fuel injector cavity.
Never turn injector while pushing it.
Page 408 of 557
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-17
1. ECM
2. Instrument panel
3. Steering wheel
1. Injector wire
2. Screws
1. Stay
3) Make sure that injector wire O-ring is free from any damage and
deterioration, and apply thin coat of spindle oil or gasoline to O-
ring.
Install injector wire and tighten new wire screw to specified
torque.
Tightening Torque
(a): 3.5 N
.m (0.35 kg-m, 2.5 lb-ft)
4) Connect battery negative cable at battery.
5) With engine “OFF” and ignition switch “ON”, check for fuel leaks.
6) Install air cleaner mounting stay as shown left.
7) Install air cleaner assembly referring to Section 6A.
ELECTRONIC CONTROL SYSTEM
ENGINE CONTROL MODULE (ECM)
CAUTION:
As ECM consists of precision parts, be careful not to ex-
pose it to excessive shock.
REMOVAL
1) Disconnect battery negative cable at battery.
2) Lower fuse box after removing bolt.
3) Disconnect couplers from ECM while releasing coupler lock.
4) Remove ECM from body.
INSTALLATION
1) Install ECM to body.
2) Connect couplers to ECM securely.
3) Install fuse box and tighten its bolt.
4) Connect battery negative cable at battery.
Page 409 of 557
6E1-18 ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10)
1
2
43
1. MAP sensor
2. 1.5 V battery (4.5 V in total)
3. Vacuum pump
4. Digital type voltmeter
MANIFOLD ABSOLUTE PRESSURE SENSOR
(MAP SENSOR)
MAP SENSOR INDIVIDUAL CHECK
1) Disconnect MAP sensor vacuum hose from filter.
2) Disconnect coupler from MAP sensor.
3) Remove MAP sensor.
4) Arrange 3 new 1.5 V batteries in series (check that total voltage
is 4.5 – 5.0 V) and connect its positive terminal to “Vin” terminal
of sensor and negative terminal to “Ground” terminal. Then
check voltage between “Vout” and “Ground”.
Also, check if voltage reduces when vacuum is applied up to
40 cmHg by using vacuum pump.
Output voltage (Vin voltage 4.5 – 5.0 V, ambient temp.
20 – 30C, 68 – 86F)
ALTITUDE
(Reference)
BAROMETRIC
PRESSUREOUTPUT
VOLTAGE
(ft)(m)(mmHg)KPa(V)
0
|
2 0000
|
610760
|
707100
|
94
3.1 – 3.6
2 001
|
5 000611
|
1 524Under 707
over 63494
|
85
2.8 – 3.4
5 001
|
8 0001 525
|
2 438Under 634
over 56785
|
76
2.6 – 3.1
8 001
|
10 0002 439
|
3 048Under 567
over 52676
|
70
2.4 – 2.9
If check result is not satisfactory, replace MAP sensor.
5) Install MAP sensor and connect vacuum hose securely.
6) Connect MAP sensor coupler securely.
Page 410 of 557
ENGINE AND EMISSION CONTROL SYSTEM (TBI FOR G10) 6E1-19
1. TP sensor
2. TP sensor
adjusting holes
3. TP sensor
screw holes4. Turn TP sensor after
fitting and align holes.
1. Throttle stop screw
2. Throttle lever
3. Thickness gauge
THROTTLE POSITION SENSOR (TP SENSOR)
INSPECTION
Check TP sensor referring to step 2 of DTC P0121 Flow Table. If
malfunction is found, replace.
REMOVAL
1) Disconnect battery negative cable at battery.
2) Remove air cleaner assembly referring to Section 6A.
3) Disconnect coupler from TP sensor.
4) Remove TP sensor from throttle body.
INSTALLATION
1) Install TP sensor to throttle body.
Fit TP sensor to throttle body in such way that its adjusting holes
are a little away from TP sensor screw holes as shown in left fig-
ure and turn TP sensor clockwise so that those holes align.
Then hand-tighten TP sensor screws.
2) Connect coupler to TP sensor securely.
3) Install air cleaner assembly referring to Section 6A.
4) Connect battery negative cable battery.
5) Adjust installation angle of TP sensor according to procedure
described in item “ADJUSTMENT”.
ADJUSTMENT
1) Insert 3.5 mm (0.14 in.) thickness gauge between throttle stop
screw and throttle lever.
CAUTION:
As throttle stop screw is factory adjusted precisely, don’t
remove or adjust it.