17 ADJUSTMENT THROTTLE POSITION SWITCH CLOSED POSITION-II
Without CONSULT-II
1. Temporarily tighten sensor body fixing bolts as follows.
+Gradually move the sensor body clockwise and stop it when the continuity comes to exist, then temporarily
tighten sensor body fixing bolts.
SEF964W
2. Make sure two or three times that the continuity exists when the throttle valve is closed and continuity does not exist
when it is opened.
3. Remove 0.05 mm (0.0020 in) feeler gauge then insert 0.15 mm (0.0059 in) feeler gauge.
4. Make sure two or three times that the continuity does not exist when the throttle valve is closed.
5. Tighten throttle position sensor.
6. Check the continuity again.
Continuity does not exist while closing the throttle valve.
OK or NG
OK©GO TO 18.
NG©GO TO 16.
18 RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY
Without CONSULT-II
NOTE:
Always warm up engine to normal operating temperature. If engine is cool, the throttle position sensor idle posi-
tion memory will not be reset correctly.
1. Confirm that proper vacuum is applied. Refer to Test No. 10.
2. Attach blind cap to vacuum port from which vacuum hose to throttle opener was disconnected.
3. Start engine.
4. Warm up engine to normal operating temperature.
5. Stop engine. (Turn ignition switch ªOFFº.)
6. Turn ignition switch ªONº and wait at least 5 seconds.
SEF864V
7. Turn ignition switch ªOFFº and wait at least 9 seconds.
8. Repeat steps 6 and 7, 20 times.
©GO TO 19.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONQG
Basic Inspection/Sedan (Cont'd)
EC-110
17 ADJUSTMENT THROTTLE POSITION SWITCH CLOSED POSITION-II
Without CONSULT-II
1. Temporarily tighten sensor body fixing bolts as follows.
+Gradually move the sensor body clockwise and stop it when the continuity comes to exist, then temporarily
tighten sensor body fixing bolts.
SEF964W
2. Make sure two or three times that the continuity exists when the throttle valve is closed and continuity does not exist
when it is opened.
3. Remove 0.05 mm (0.0020 in) feeler gauge then insert 0.15 mm (0.0059 in) feeler gauge.
4. Make sure two or three times that the continuity does not exist when the throttle valve is closed.
5. Tighten throttle position sensor.
6. Check the continuity again.
Continuity does not exist while closing the throttle valve.
OK or NG
OK©GO TO 18.
NG©GO TO 16.
18 RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY
Without CONSULT-II
NOTE:
Always warm up engine to normal operating temperature. If engine is cool, the throttle position sensor idle posi-
tion memory will not be reset correctly.
1. Confirm that proper vacuum is applied. Refer to Test No. 10.
2. Attach blind cap to vacuum port from which vacuum hose to throttle opener was disconnected.
3. Start engine.
4. Warm up engine to normal operating temperature.
5. Stop engine. (Turn ignition switch ªOFFº.)
6. Turn ignition switch ªONº and wait at least 5 seconds.
SEF864V
7. Turn ignition switch ªOFFº and wait at least 9 seconds.
8. Repeat steps 6 and 7, 20 times.
©GO TO 19.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONQG
Basic Inspection/Hatchback (Cont'd)
EC-139
6 ADJUST THROTTLE POSITION SENSOR IDLE POSITION
With CONSULT-II
1. Loosen throttle position sensor fixing bolts.
2. Turn throttle position sensor body clockwise or counterclockwise until ªTHRTL POS SENº indication becomes 0.35 to
0.65V.
SEF964W
3. Tighten the throttle position sensor fixing bolts.
©GO TO 7.
7 RESET THROTTLE POSITION SENSOR IDLE POSITION MEMORY
With CONSULT-II
NOTE:
Always warm up engine to normal operating temperature. If engine is cool, the throttle position sensor idle posi-
tion memory will not be reset correctly.
1. Start engine and warm it up to normal operating temperature.
2. Select ªCLSD THL POSº in ªDATA MONITORº mode with CONSULT-II.
3. Stop engine. (Turn ignition switch ªOFFº.)
4. Turn ignition switch ªONº and wait at least 5 seconds.
SEF864V
5. Turn ignition switch ªOFFº and wait at least 9 seconds.
6. Repeat steps 4 and 6 until ªCLSD THL POSº indication changes to ªONº.
SEF061Y
©GO TO 11.
TROUBLE DIAGNOSIS Ð BASIC INSPECTIONQG
Basic Inspection/Hatchback (Cont'd)
EC-146
ªHISTORY OF ERRORSº TABLE=NJEL0520S02
Detected items Description Diagnosis/service procedureRefer-
ence
page
Gyro sensor disconnectedCommunications malfunction between
NAVI control unit and internal gyroPerform self-diagnosis to confirm
whether the NAVI control unit is mal-
functioning or not. If no failure is
detected, a momentary and/or tempo-
rary malfunction may have been caused
by strong electromagnetic wave interfer-
ence.EL-476
Connection problem of speed
sensorInput malfunction of NAVI control unit
and speed sensorCheck vehicle speed sensor signal in
ªDiagnosis for signals from the carº
mode. If the input signal is not detected
correctly, check harness for open or
short between combination meter and
NAVI control unit.EL-483
GPS disconnected
Communications malfunction between
NAVI control unit and GPS boardPerform self-diagnosis to confirm
whether the NAVI control unit is mal-
functioning or not. If no failure is
detected, a momentary and/or tempo-
rary malfunction may have been caused
by strong electromagnetic wave interfer-
ence.EL-476 GPS transmission cable malfunc-
tion
GPS input line connection error
GPS TCXO overThe transmission circuit of the GPS
board frequency synchronization oscilla-
tor (inside the NAVI control unit) is send-
ing an oscillation frequency that is
greater or less than the set value.A location error occurs. Strong electro-
magnetic wave interference may have
occurred. The GPS antenna may be in a
very hot or very cold environment. This
is usually a temporary malfunction.Ð
GPS TCXO under
GPS ROM malfunction
Internal malfunction of GPS board RAM
or ROM inside the NAVI control unit.Perform self-diagnosis to confirm
whether the NAVI control unit is mal-
functioning or not. If no failure is
detected, a momentary and/or tempo-
rary malfunction may have been caused
by strong electromagnetic wave interfer-
ence.EL-476 GPS RAM malfunction
GPS RTC malfunctionMalfunction of GPS board clock IC
inside the NAVI control unit.
GPS antenna disconnected ÐPerform self-diagnosis to confirm GPS
antenna connection. If no failure is
detected, a momentary and/or tempo-
rary malfunction may have been caused
by a strong impact.EL-476
Low voltage of GPSPower supply voltage for GPS board
inside the NAVI control unit is low.1. Check power supply circuits for NAVI
control unit.EL-504
2. Perform self-diagnosis to confirm
GPS antenna connection.EL-476
3. If above diagnosis results are OK, a
momentary and/or temporary malfunc-
tion may have been caused by a strong
impact.Ð
CD-ROM communication errorCD-ROM driver malfunction (inside the
NAVI control unit)Perform self-diagnosis to confirm
whether the NAVI control unit is mal-
functioning or not. If no failure is
detected, a momentary and/or tempo-
rary malfunction may have been caused
by strong electromagnetic wave interfer-
ence.EL-476
NAVIGATION SYSTEM
Confirmation/Adjustment Mode (Cont'd)
EL-481
SEM886F
InstallationNJEM01071. Install crankshaft sprocket on crankshaft.
+Make sure mating marks on crankshaft sprocket face front
of engine.
SEM890F
2. Position crankshaft so that No. 1 piston is at TDC and key way
is at 12 o'clock.
SEM891F
3. Install slack side timing chain guide and timing chain tension
guide.
SEM892F
4. Install timing chain on crankshaft sprocket.
+Support chain with a suitable tool to keep the mating mark
aligned.
+Set timing chain by aligning its mating mark with that on
the crankshaft sprocket.
+Make sure sprocket's mating mark faces engine front.
SEM905F
5. Install camshaft sprocket.
+Set timing chain by aligning mating marks with those of
camshaft sprockets.
TIMING CHAINQG
Installation
EM-28
JEM121G
3. Remove front chain case.
+Move power steering fluid reservoir tank from the bracket.
+Loosen fixing bolts in the reverse order of that shown in the
figure and remove them.
+Remove No. 6, 10, and 11 bolts with the rubber washer as
space is limited for pulling them out.
SEM514G
CAUTION:
+While front chain case is removed, cover openings to pre-
vent entry of foreign material into engine.
+Do not remove two mass dampers on the back of cover.
SEM515G
4. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the alignment mark
(punched mark) on each camshaft sprocket is positioned as
shown in the figure.
+No position indicator is provided on the crankshaft pulley.
+When installing, color coded links on the secondary tim-
ing chain can be used as alignment marks. Marking may
not be necessary for removal; however, make alignment
marks as required because the alignment mark on fuel
injection pump sprocket may not be easy to see.
JEM124G
5. Remove chain tensioner.
a. Push the plunger of chain tensioner and keep it pressed with
a push pin.
JEM125G
b. Using a hexagon-head wrench (face to face: 5 mm, SST),
remove bolts to remove chain tensioner.
TIMING CHAINYD
Secondary Timing Chain (Cont'd)
EM-95
JEM175G
3. Install camshaft brackets.
+Install correctly, identifying brackets by the journal No. and
front mark on top surface.
JEM160G
4. Tighten bolts in the order shown in the figure according to the
following procedure:
a. Tighten to 2.0 N´m (0.2 kg-m, 17 in-lb).
+Make sure camshaft thrusting parts (on rear side) securely fit
in their mating parts on the cylinder head.
b. Tighten to 6 N´m (0.6 kg-m, 52 in-lb).
c. Tighten to 12 to 13 N´m (1.2 to 1.4 kg-m, 9 to 10 ft-lb).
5. Install camshaft sprockets.
+Camshaft sprockets are commonly used for RH and LH.
+Align camshaft sprocket and dowel pin on camshaft, and
install.
+Holding the hexagonal part of camshaft with a wrench, tighten
bolt securing camshaft sprocket.
6. Before installing spill tube after installing secondary timing
chain, check and adjust valve clearance. Refer to EM-133,
ªValve Clearanceº.
7. Hereafter, install in the reverse order of removal.
JEM176G
Valve ClearanceNJEM0068CHECKINGNJEM0068S01Check valve clearance while engine is cold and not running.
1. Set the No. 1 piston to TDC on its compression stroke.
+Turn crankshaft pulley clockwise so that the knock pin on cam-
shaft LH faces straight above. (No position indicator, etc. is
provided on the crankshaft pulley.)
JEM177G
2. Put an alignment mark with paint, etc. on the crankshaft pul-
ley and on the oil pump as an angle indicator.
CYLINDER HEADYD
Installation (Cont'd)
EM-133
JEM178G
3. Check only those valves shown in the figure.
Crank positionValve
No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
No. 1 TDC
(Compression
stroke)jjj j
JEM179G
+Using a feeler gauge, measure clearance between valve lifter
and camshaft.
+Record any valve clearance measurements which are out of
specification. They will be used later to determine the required
replacement adjusting shim.
Valve clearance for checking (Cold):
Intake
0.24 - 0.32 mm (0.0094 - 0.0126 in)
Exhaust
0.26 - 0.34 mm (0.0102 - 0.0134 in)
JEM180G
4. Rotate crankshaft clockwise by one turn to set the No. 4 pis-
ton to TDC on the compression stroke.
5. Check only those valves shown in the figure.
Crank positionValve
No. 1 No. 2 No. 3 No. 4
INT EXH INT EXH INT EXH INT EXH
No. 4 TDC
(Compression
stroke)jj jj
JEM181G
ADJUSTINGNJEM0068S02Adjust valve clearance while engine is cold.
1. Turn crankshaft, to position cam lobe on camshaft of valve that
must be adjusted upward.
2. Place Tool (A) around camshaft as shown in figure.
Before placing Tool (A) (SST), rotate notch toward center
of cylinder head (See figure.), to simplify shim removal
later.
CAUTION:
Be careful not to damage cam surface with Tool (A).
SEM497G
3. Rotate Tool (A) (See figure.) so that valve lifter is pushed down.
CYLINDER HEADYD
Valve Clearance (Cont'd)
EM-134