
CHECK COOLING SYSTEM FOR LEAK.
Apply pressure to the cooling system with
a tester, and check if the pressure drops.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
Pressure should not drop.
CAUTION:
Higher than the speci®ed pressure may
cause radiator damage.
OK
cNG
Check the following for
leak.
+Hose
+Radiator
+Water pump
Refer to LC section (``Water
Pump'').
CHECK RADIATOR CAP.
Apply pressure to cap with a tester.
Radiator cap relief pressure:
78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0
kg/cm
2, 11 - 14 psi)
OK
cNG
Replace radiator cap.
CHECK THERMOSTAT.
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
2. Check valve opening temperature and
valve lift.
Valve opening temperature:
82ÉC (180ÉF) [standard]
Maximum valve lift:
More than 10 mm/95ÉC
(0.39 in/203ÉF)
3. Check if valve is closed at 5ÉC (9ÉF)
below valve opening temperature.
For details, refer to LC section (``Thermo-
stat'').
OK
cNG
Replace thermostat.
Check engine coolant temperature sensor.
Refer to ``COMPONENT INSPECTION'',
EC-82.
OK
cNG
Replace engine coolant
temperature sensor.
If the cause cannot be isolated, go to
``MAIN 12 CAUSES OF OVERHEATING''
on next page.
INSPECTION END
Perform FINAL CHECK by the following procedure after repair
is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instrument
panel. If the reading shows an abnormally high temperature,
another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and exhaust
systems for leaks by listening for noise or visually inspecting the
components.
3. Allow engine to cool and visually check for oil and coolant leaks.
Then, perform ``OVERALL FUNCTION CHECK''.
SLC754AA
SLC755AB
SLC343
.
.
.
.
.
TROUBLE DIAGNOSIS FOR ``OVER HEAT'' (DTC 28)
Cooling Fan (Overheat) (Cont'd)
EC-119

3. After-glow system
a. Connect ``S'' terminal to starter motor.
b. Start engine and read voltage.
Voltage:
Battery voltage for 5* minutes
* Engine coolant temperature is lower than 50ÉC
(122ÉF).
COMPONENT INSPECTION
Glow relay
1. Check relay for coil continuity.
Continuity should exist.
2. Check relay for proper operation.
Coil voltage Continuity Contact point
0V No OFF
12V Yes ON
Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.8W[at 25ÉC (77ÉF)]
+If NG, replace glow plug.
3. Install glow plug connecting plate securely.
+Do not bump glow plug heating element. If it is bumped,
replace glow plug with new one. (If glow plug is dropped
from a height of 10 cm (3.94 in), replace with new one.)
+If glow plug installation hole is contaminated with carbon,
remove using a reamer or suitable tool.
+Hand-tighten glow plug by turning it two to three times,
then tighten using a tool to speci®ed torque.
:15-20Nzm (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SEF781V
SEC564B
SEF701V
SEC565B
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Cont'd)
EC-155

Trouble Diagnoses
Before conducting an alternator test, make sure that the battery is fully charged. A 30-volt voltmeter and suit-
able test probes are necessary for the test. The alternator can be checked easily by referring to the Inspec-
tion Table.
+Before starting, inspect the fusible link.
+Use fully charged battery.
WITH IC REGULATOR
Check the fol-
lowing:
+Warning
lamp bulb
+Fuse for
warning lamp
Ignition switch
``ON''Warning lamp
``OFF''Disconnect connector (S, L) and
ground L harness side.Warning lamp
``OFF''
Warning lamp
``ON''Damaged IC
regulator.
Replace.
Warning lamp
``ON''
Engine start.
Engine speed:
1,500 rpmWarning lamp
``ON''Check the following:
+Drive belt
+Fuse for S terminal
+Connector (S, L terminal) con-
nectionEngine idlingWarning lamp
``OFF''OK
Warning lamp
``ON''
Warning lamp
``OFF''OKEngine speed:
1,500 rpm
(Measure B
terminal volt-
age)More than
15.5VDamaged IC
regulator.
Replace.
No generationField circuit is
open.
Warning lamp: ``CHARGE'' warning lamp in combination meter
Note:
+If the inspection result is OK even though the charging system is malfunctioning, check the B ter-
minal connection. (Check the tightening torque.)
+When ®eld circuit is open, check condition of rotor coil, rotor slip ring and brush. If necessary,
replace faulty parts with new ones.
MALFUNCTION INDICATOR
The IC regulator warning function activates to illuminate ``CHARGE'' warning lamp, if any of the following
symptoms occur while alternator is operating:
+Excessive voltage is produced.
+No voltage is produced.
CHARGING SYSTEM
EL-53

Electrical Components Inspection
FUEL WARNING LAMP SENSOR CHECK
+It will take a short time for the bulb to light.
NOTE: Inspection for sub fuel warning lamp sensor is the
same as for fuel warning lamp sensor.
OIL PRESSURE SWITCH CHECK
Oil pressure
kPa (bar, kg/cm2, psi)Continuity
Engine startMore than 10 - 20
(0.10 - 0.20, 0.1 - 0.2,1-3)NO
Engine stopLess than 10 - 20
(0.10 - 0.20, 0.1 - 0.2,1-3)YES
Check the continuity between the terminals of oil pressure switch
and body ground.
DIODE CHECK
+Check continuity using an ohmmeter.
+Diode is functioning properly if test results are as shown in the
®gure at left.
NOTE: Speci®cation may vary depending on the type of tester.
Before performing this inspection, be sure to refer to
the instruction manual for the tester to be used.
+Diodes for warning lamps are built into the combination meter
printed circuit.
MEL828F
MEL425F
CEL520
CEL740
WARNING LAMPS
EL-134

Trouble Diagnoses
RADIO
Symptom Possible causes Repair order
Radio inoperative (no digital
display and no sound from
speakers).
See NOTE.1. 10A fuse
2. Poor radio case ground
3. Radio1. Check 10A fuse [No.
10, located in fuse block (J/B)].
Turn ignition switch ON and verify battery positive volt-
age is present at terminalj
10of radio.
2. Check radio case ground.
3. Remove radio for repair.
Radio controls are operational,
but no sound is heard from
any speaker.1. Radio output
2. Radio1. Check radio output voltages.
2. Remove radio for repair.
Radio presets are lost when
ignition switch is turned OFF.1. 10A fuse
2. Radio1. Check 10A fuse (No.
56, located in fuse and fusible link
box) and verify battery positive voltage is present at terminal
j
6of radio.
2. Remove radio for repair.
Individual speaker is noisy or
inoperative.1. Speaker
2. Radio output
3. Speaker circuit
4. Radio1. Check speaker.
2. Check radio output voltages.
3. Check wires for open or short between radio and speaker.
4. Remove radio for repair.
Radio stations are weak or
noisy.1. Antenna
2. Poor radio ground
3. Radio1. Check antenna.
2. Check radio ground.
3. Remove radio for repair.
FM stations are weak or noisy
but AM stations are OK. (with
window antenna)1. Window antenna
2. Radio1. Check window antenna.
2. Remove radio for repair.
Radio generates noise in AM
and FM modes with engine
running.1. Poor radio ground
2. Loose or missing ground bonding straps
3. Ignition condenser or rear window defogger
noise suppressor condenser
4. Alternator
5. Ignition coil or secondary wiring
6. Radio1. Check radio ground.
2. Check ground bonding straps.
3. Replace ignition condenser or rear window defogger noise
suppressor condenser.
4. Check alternator.
5. Check ignition coil and secondary wiring.
6. Remove radio for repair.
Radio generates noise in AM
and FM modes with accesso-
ries on (switch pops and motor
noise).1. Poor radio ground
2. Antenna
3. Accessory ground
4. Faulty accessory1. Check radio ground.
2. Check antenna.
3. Check accessory ground.
4. Replace accessory.
NOTE:
If the radio has anti-theft function, check the anti-theft function of the radio before circuit inspection.
(Radios which have anti-theft function are equipped with a code indicator. For details, refer to EL-173.)
Speaker inspection
1. Disconnect speaker harness connector.
2. Measure the resistance between speaker terminalsj
1andj2.
+The resistance should be2-4W.
3. Using jumper wires, momentarily connect a 9V battery between speaker terminalsj
1andj2.
+A momentary hum or pop should be heard.
Antenna inspection
Using a jumper wire, clip an auxiliary ground between antenna and body.
+If reception improves, check antenna ground (at body surface).
+If reception does not improve, check main feeder cable for short circuit or open circuit.
Radio inspection
All voltage inspections are made with:
+Ignition switch ON or ACC
+Radio ON
+Radio connected (If removed for inspection, supply a ground to the case using a jumper wire.)
AUDIO
EL-172

ENGINE MECHANICAL
SECTION
EM
CONTENTS
PRECAUTIONS...............................................................1
Parts Requiring Angular Tightening .............................1
Liquid Gasket Application Procedure ..........................1
PREPARATION................................................................2
NOISE, VIBRATION AND HARSHNESS (NVH)
TROUBLESHOOTING.....................................................6
NVH Troubleshooting Chart Ð Engine Noise .............7
OUTER COMPONENT PARTS.......................................8
COMPRESSION PRESSURE........................................10
Measurement of Compression Pressure ...................10
OIL PAN.........................................................................13
Removal .....................................................................13
Installation ..................................................................14
TIMING BELT.................................................................15
Removal .....................................................................15
Inspection...................................................................17
Installation ..................................................................18
OIL SEAL REPLACEMENT..........................................20
TURBOCHARGER.........................................................23
Removal and Installation ...........................................23
Inspection...................................................................24CHARGE AIR COOLERS..............................................27
CYLINDER HEAD..........................................................28
Removal .....................................................................29
Disassembly...............................................................30
Inspection...................................................................31
Assembly ...................................................................37
Installation ..................................................................37
VALVE CLEARANCE....................................................40
Checking ....................................................................40
Adjusting ....................................................................41
ENGINE REMOVAL.......................................................43
Removal .....................................................................44
Installation ..................................................................44
CYLINDER BLOCK.......................................................45
Disassembly...............................................................46
Inspection...................................................................46
Assembly ...................................................................53
SERVICE DATA AND SPECIFICATIONS (SDS)..........56
General Speci®cations ...............................................56
Inspection and Adjustment ........................................56
EM

NVH Troubleshooting Chart Ð Engine Noise
Use the chart below to help you ®nd the cause of the problem.
1. Locate the area where noise occurs.
2. Con®rm the type of noise.
3. Specify the operating condition of engine.
4. Check speci®ed noise source.
If necessary, repair or replace these parts.
Location of
noiseType of
noiseOperating condition of engine
Source of
noiseCheck itemReference
page Before
warm-upAfter
warm-upWhen
startingWhen
idlingWhen
racingWhile
driving
To p o f
engine
Rocker
cover
Cylinder
headTicking or
clickingCAÐABÐTappet
noiseValve clearance EM-41
Rattle C A Ð A B CCamshaft
bearing
noiseCamshaft journal clearance
Camshaft runoutEM-37
Crankshaft
pulley
Cylinder
block (Side
of engine)
Oil panSlap or
knockÐAÐB BÐPiston pin
noisePiston and piston pin clear-
ance
Connecting rod bushing
clearanceEM-47, 53
Slap or rap A Ð Ð B B APiston slap
noisePiston-to-bore clearance
Piston ring side clearance
Piston ring end gap
Connecting rod bend and
torsionEM-48, 49
Knock A B C B B BConnecting
rod bearing
noiseConnecting rod bushing
clearance (Small end)
Connecting rod bearing
clearance (Big end)EM-52, 53
Knock A B Ð A B CMain bear-
ing noiseMain bearing oil clearance
Crankshaft runoutEM-51
Timing belt
coverWhine or
hissingCAÐAAÐTiming belt
noise (too
tight)
Loose timing belt
Belt contacting caseEM-18
Clatter A B Ð C A ÐTiming belt
noise (too
loose)
Front of
engineSqueaking
or ®zzingABÐBÐCOther drive
belts
(Sticking or
slipping)Drive belts de¯ection
*1
CreakingABABABOther drive
belts (Slip-
ping)Idler pulley bearing operation
Squall
CreakABÐBABWater pump
noiseWater pump operation *2
A: Closely related B: Related C: Sometimes related Ð: Not related
*1: MA section (``Checking Drive Belts'', ``ENGINE MAINTENANCE'')
*2: LC section (``Water Pump Inspection'', ``ENGINE COOLING SYSTEM'')
NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING
EM-8

Inspection
Visually check the condition of timing belt.
Replace if any abnormality is found.
Item to check Problem Cause
Tooth is broken/tooth root
is cracked.
SEM394A
+Camshaft jamming
+Distributor jamming
+Damaged camshaft/crankshaft oil seal
Back surface is cracked/
worn.
SEM395A
+Tensioner jamming
+Overheated engine
+Interference with belt cover
Side surface is worn.
+Belt corners are worn and round.
+Wicks are frayed and coming out.
SEM396A
+Improper installation of belt
+Malfunctioning crankshaft pulley plate/timing belt
plate
Teeth are worn.
+Canvas on tooth face is worn down.
+Canvas on tooth is ¯uffy, rubber layer is worn
down and faded white, or weft is worn down and
invisible.
SEM397A
+Poor belt cover sealing
+Coolant leakage at water pump
+Camshaft not functioning properly
+Distributor not functioning properly
+Excessive belt tension
Oil/Coolant or water is
stuck to belt. Ð+Poor oil sealing of each oil seal
+Coolant leakage at water pump
+Poor belt cover sealing
TIMING BELT
EM-18