Tài liệu sửa chữa ford laser repair manual (2001MY)

AP Accelerator Pedal — Accelerator Pedal ACL Air Cleaner — Air Cleaner A/C Air Conditioning — Air Conditioning BARO Barometric Pressure — Atmospheric Pressure B+ Battery Positive Voltage

repair manuals and this covers only main

service points of major parts modified from

them As to the service points, important

safety notice and general service

instructions in service which are not

covered by this supplement, please refer to

the previous Manuals shown on the

following page.

All information in this manual was the

best available at the time of printing.

Vehicle specification and other information

will be updated in Service Information.

Ford Japan Limited

APPLICATION:

This manual is applicable to vehicles

beginning with the Vehicle ldentification

Numbers (VIN), and related materials

shown on the following page.

Explanations are given only for blackened sections (ąą).

2001 Ford Japan Limited All rights reserved Reproduction by any means, electronic or mechamical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Japan

ST

Special Tools

G15M-R F25M-R

J2

VEHICLE IDENTIFICATION NUMBERS (VIN)

Australian specs.

JC0 AAAS#NL✽✽ 400001 Ċ JC0 AAAS#NM✽✽ 400001 Ċ JC0 AAAS#PL✽✽ 400001 Ċ JC0 AAAS#PM✽✽ 400001 Ċ JC0 AAAS#PN✽✽ 400001 Ċ General specs (R.H.D L.H.D.) JC6 AAAS#NJ✽✽ 400001 Ċ JC6 AAAS#NK✽✽ 400001 Ċ JC6 AAAS#NL✽✽ 400001 Ċ JC6 AAAS#PK✽✽ 400001 Ċ JC6 AAAS#PL✽✽ 400001 Ċ

RELATED MATERIALS

LASER TRAINING MANUAL

(Australia, General (R.H.D L.H.D.)) F328-10-98K LASER REPAIR MANUAL

(Australia, General (R.H.D L.H.D.)) F162-10-98K LASER REPAIR MANUAL SUPPLEMENT

(Australia, General (L.H.D.)) F164-10-99H LASER OVERHAUL MANUAL

(Australia, General (R.H.D L.H.D.)) F162-20-98K LASER OVERHAUL MANUAL

(Australia, General (R.H.D L.H.D.)) F173-20-01B EOBD TRAINING MANUAL

(Australia, Genral (R.H.D L.H.D.)) F335-10-01B LASER WIRING DIAGRAMS

(Australia, General (R.H.D.)) F173-30-01B LASER WIRING DIAGRAMS

(General (L.H.D.)) F173-40-01D LASER BODYSHOP MANUAL

(Australia, R.H.D.) F329-10-98K

GENERAL INFORMATION

VIN CODE GI-2

VIN CODE GI-2

HOW TO USE THIS MANUAL GI-2

RANGE OF TOPICS GI-2

NEW STANDARDS GI-3

NEW STANDARDS TABLE GI-3

ABBREVIATIONS GI-5

ABBREVIATIONS TABLE GI-5

SCHEDULED MAINTENANCE GI-5

SCHEDULED MAINTENANCE TABLE GI-5

VIN CODE , HOW TO USE THIS MANUAL

AP Accelerator Pedal — Accelerator Pedal

ACL Air Cleaner — Air Cleaner

A/C Air Conditioning — Air Conditioning

BARO Barometric Pressure — Atmospheric Pressure

B+ Battery Positive Voltage VB Battery Voltage

— Brake Switch — Stoplight Switch

— Calibration Resistor — Corrected Resistance #6

CMP sensor Camshaft Position Sensor — Crank Angle Sensor

CAC Charge Air Cooler — Intercooler

CLS Closed Loop System — Feedback System

CTP Closed Throttle Position — Fully Closed

— Closed Throttle Position Switch — Idle Switch

CPP Clutch Pedal Position — Clutch position

CIS Continuous Fuel Injection System EGI Electronic Gasoline Injection System

CS sensor Control Sleeve Sensor CSP sensor Control Sleeve Position Sensor #6

CKP sensor Crankshaft Position Sensor — Crank Angle Sensor 2

DLC Data Link Connector — Diagnosis Connector

DTM Diagnostic Test Mode — Test Mode #1

DTC Diagnostic Trouble Code(s) — Service Code(s)

DI Distributor Ignition — Spark Ignition

DLI Distributorless Ignition — Direct Ignition

EI Electronic Ignition — Electronic Spark Ignition #2

ECT Engine Coolant Temperature — Water Thermo

EM Engine Modification — Engine Modification

— Engine Speed Input Signal — Engine RPM Signal

EVAP Evaporative Emission — Evaporative Emission

EGR Exhaust Gas Recirculation — Exhaust Gas Recirculation

FC Fan Control — Fan Control

FF Flexible Fuel — Flexible Fuel

4GR Fourth Gear — Overdrive

— Fuel Pump Relay — Circuit Opening Relay #3

FSO

solenoid Fuel Shut Off Solenoid FCV Fuel Cut Valve #6

GEN Generator — Alternator

GND Ground — Ground/Earth

HO2S Heated Oxygen Sensor — Oxygen Sensor With heater

IAC Idle Air Control — Idle Speed Control

— IDM Relay — Spill Valve Relay #6

— Injection Pump FIP Fuel Injection Pump #6

— Input/Turbine Speed Sensor — Pulse Generator

IAT Intake Air Temperature — Intake Air Thermo

KS Knock Sensor — Knock Sensor

MIL Malfunction Indicator Lamp — Malfunction Indicator Light

MAP Manifold Absolute Pressure — Intake Air Pressure

MAF sensor Mass Air Flow Sensor — Airflow Sensor

MFL Multiport Fuel Injection — Multiport Fuel Injection

OBD On-Board Diagnostic — Diagnosis/Self Diagnosis

#4 : Device that controls engine and powertrain

#5 : Directly connected to exhaust manifold

#6 : Part name of diesel engine

End Of Sie

OL Open Loop — Open Loop

— Output Speed Sensor — Vehicle Speed Sensor 1

OC Oxidation Catalytic Converter — Catalytic Converter

O2S Oxygen Sensor — Oxygen Sensor

PNP Park/Neutral Position — Park/Neutral Range

— PCM Control Relay — Main Relay #6

PSP Power Steering Pressure — Power Steering Pressure

PCM Powertrain Control Module ECU Engine Control Unit #4

— Pressure Control Solenoid — Line Pressure Solenoid Valve

PAIR Pulsed Secondary Air Injection — Secondary Air Injection System Pulsed

injection

— Pump Speed Sensor — NE Sensor #6

AIR Secondary Air Injection — Secondary Air Injection System

Injection with air pumpSAPV Secondary Air Pulse Valve — Reed Valve

SFI Sequential Multipoint Fuel Injection — Sequential Fuel Injection

— Shift Solenoid A — 1-2 Shift Solenoid Valve

— Shift A Solenoid Valve

— Shift Solenoid B — 2-3 Shift Solenoid Valve

— Shift B Solenoid Valve

— Shift Solenoid C — 3-4 Shift Solenoid Valve

3GR Third Gear — 3rd Gear

TWC Three Way Catalytic Converter — Catalytic Converter

TB Throttle Body — Throttle Body

TP sensor Throttle Position Sensor — Throttle Sensor

TCV Timer Control Valve TCV Timing Control Valve #6

TCC Torque Converter Clutch — Lockup Position

TCM Transmission (Transaxle) Control

Module — EC-AT Control Unit

— Transmission (Transaxle) Fluid

Temperature Sensor — ATF Thermosensor

TR Transmission (Transaxle) Range — Inhibitor Position

TC Turbocharger — Turbocharger

VSS Vehicle Speed Sensor — Vehicle Speed Sensor

VR Voltage Regulator — IC Regulator

VAF sensor Volume Air Flow Sensor — Air Flow Meter

WU-TWC Warm Up Three Way Catalytic

Converter — Catalytic Converter #5

WOT Wide Open Throttle — Fully Open

Remark Abbrevi-

ABBREVIATIONS , SCHEDULED MAINTENANCE

I : Inspect and clean, repair, or replace if necessary (Inspect, and if necessary replace air cleaner element only.)

A : Adjust: Examination resulting in adjustment or replacement

R : Replace

T : Tighten

Remarks:

ABBREVIATIONS

AAS Air adjusting screw

ABDC After bottom dead center

ABS Antilock brake system

ACC Accessories

ATDC After top dead center

ATF Automatic transaxle fluid

ATX Automatic transaxle

BBDC Before bottom dead center

BTDC Before top dead center

CM Control module

E/L Electric load

EBD Electronic brakeforce distribution

ELR Emergency locking retractor

HI High

HU Hydraulic unit

IG Ignition

LCD Liquid crystal display

LED Light emitting diode

ON Switch onP/S Power steeringP/W CM Power window control modulePCV Positive crankcase ventilationPRC Pressure regulator control

RH Right handR.H.D Right hand driveSAS Sophisticated air bag sensorSST Special service tool

SW SwitchTAS Throttle adjusting screwTCS Traction control systemTFT Transaxle fluid temperatureTNS Tail number side lightsVICS Variable inertia charging systemWDS World wide diagnostic system4SD 4 Door Sedan

5HB 5 Door Hatchback

SCHEDULED MAINTENANCE

• To ensure efficient operation of the engine and all systems related to emission control, the ignition and fuel systems must

be serviced regularly It is strongly recommended that all servicing related to these systems be done by an authorized Ford Dealer

• After 150,000 km {90,000 miles} or 90 months, continue to follow the described maintenance at the recommended

intervals

• Refer below for a description of items marked* in the maintenance chart

*1: If the vehicle is operated under any of the following conditions, change the engine oil and oil filter more often than

recommended intervals

a Driving in dusty conditions

b Extended periods of idling or low speed operation

c Driving for long periods in cold temperatures or driving regularly at short distances only

d Towing a heavy trailer, caravan or carrying high roof rack loads continuously.(only for Australia)

e Driving less than 10,000 km in 12 months.(only for Australia)

*2: Replacement of the timing belt is required at every 100,000 km {60,000 miles} Failure to replace the timing belt may

result in damage to the engine

*3: If the vehicle is operated in very dusty or sandy areas, inspect and, if necessary, replace the air cleaner element more often than the recommended intervals

*4: Also adjust and inspect the power steering and air conditioner drive belts, if equipped

*5: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle is

operated in extremely humid climates, change the brake fluid annually

Engine valve

clearance

for B3 I I I I I I I I I I I I I I Ifor ZL, ZM, FP

Drive belts

(except forAustralia)*4 A I I I I I I I I I I I I I I I(for Australia)*4 I I I I I I I I I I I I I I IEngine oil *1 R R R R R R R R R R R R R R ROil filter *1 R R R R R R R R R R R R R R RCOOLING SYSTEM

Engine coolant (except for Australia) Replace every 2 years

(for Australia) Replace every 25 months regardless of distance travelledFUEL SYSTEM

Spark plugs (except for Australia) I I I I I I I I I I I I I I I

EVAPOLATIVE EMISSION CONTROL SYSTEM

Evaporative emission control system I I I I I I IELECTRICAL SYSTEM

CHASSIS & BODY

Brake & clutch pedals I I I I I I I I I I I I I I IBrake lines, hoses & connections I I I I I I IBrake fluid level (for Australia) I I I I I I I I I I I I I I I

Brake fluid

(except forAustralia)*5 I I I R I I I R I I I R I I I(for Australia)*5 Replace every 24 months regardless of distance travelled

Clutch fluid level (for Australia) I I I I I I I I I I I I I I I

Clutch fluid

(except for Australia,

Malaysia) I I I I I I I I I I I I I I I(for Australia,

Malaysia) I I I R I I I R I I I R I I I

fluid & lines

(except for Australia) I I I I I I I I I I I I I I I I(for Australia) I I I I I I I I I I I I I I ISteering operation & gear housing I I I I I I I

Steering linkages, tie rod ends &

Exhaust system

heat shields

(except for Australia) I I I

Bolts & nuts on

chassis & body

(except for Australia) T T T T T T T T

OUTLINE OF CONSTRUCTION

Z4F240202000W01

• The FS engine model has been adopted

• The construction and operation of the FP and FS engines is the same as that of the previous LASER (BJ) FP engine models, except for the following features (See LASER Training Manual F328-10-98K.)

End Of Sie

FEATURES

Z4F240202000W02

Reduced Vibration

• A roll damper has been added to the No.2 engine mount (FS engine models for ATX)

Modification to Match Vehicle Characteristics

• The shape of the No.4 engine mounting brackets has been modified (FS engine models for MTX)

Cylinder arrangement and number In-line, 4-cylinder

Valve system DOHC, timing belt driven, 16 valves

Displacement (ml {cc, cu in}) 1,840 {1,840, 112.2} 1,991 {1,991, 121.5}Bore× stroke (mm {in}) 83.0 × 85.0 {3.27 × 3.35} 83.0 × 92.0 {3.27 × 3.62}

• A roll damper has been added to the No.2 engine mount so that engine and transaxle vibration caused by

vehicle bound is absorbed quickly to reduce vibration on the vehicle body

• Engine and transaxle vibration is transmitted from the No.2 engine mount bracket to the roll damper through

the rod, rotating the roll damper The rotating part A on the roll damper, however, is resistant to rotation, so

engine and transaxle vibration is absorbed quickly Therefore, vibration from the engine and the transaxle to

the vehicle body has been reduced

• Due to the modification of the manual transaxle, the No.4 engine mounting bracket has been modified (FS

engine models for MTX)

.

ENGINE MOUNT

Y3E2402W01

1 Roll damper

2 No.2 Engine mount

3 Engine mount member

ENGINE MOUNT

End Of Sie

Y3E2402W02

Y3A2424W999

OUTLINE , COMPRESSION PRESSURE

SUPPLEMENTAL SERVICE INFORMATION

•••• When the engine and the oil are hot, they can cause severe burns Be careful not to burn yourself

during removal/installation of each component.

1 Verify that the battery is fully charged Recharge it if necessary

2 Warm up the engine to the normal operating temperature

3 Stop the engine and allow it to cool off for about 10 minutes.

4 Perform "Fuel Line Safety Procedures" Leave the fuel pump relay removed

5 Ignition coil removed

6 Remove the spark plugs

7 Disconnect the ignition coil connector

8 Connect a compression gauge into the No.1 spark plug hole

9 Fully depress the accelerator pedal and crank the engine

10 Note the maximum gauge reading

11 Check each cylinder as above

(2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required

(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required

13 Disconnect the compression gauge

14 Connect the ignition coil connector

15 Install the fuel pump relay

16 Install the spark plugs

Minimum 1,079

{11.0, 156} [300]

1,030{10.5, 149} [300]

Maximum

difference

between cylinders

196 kPa {2.0 kgf/cm2, 28psi}

•••• Fuel vapor is hazardous It can very easily ignite, causing serious injury and damage Always keep

sparks and flames away from fuel.

•••• Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and

damage Fuel can also irritate skin and eyes To prevent this, always complete the “Fuel Line

Safety Procedures”.

1 Disconnect the negative battery cable

2 Drain the engine coolant (See ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)

3 Remove the radiator (See RADIATOR, RADIATOR REMOVAL/INSTALLATION.)

4 Remove the air cleaner

5 Remove the accelerator cable (See INTAKE-AIR SYSTEM, ACCELERATOR CABLE INSPECTION/

ADJUSTMENT.)

6 Disconnect the fuel hose (See FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (See FUEL SYSTEM,

AFTER REPAIR PROCEDURE.)

7 Remove the front pipe (See EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)

8 Remove the rods, cables and pipes related to the transaxle

9 Remove the battery

10 Remove the fuse box

11 Remove the P/S oil pump with the oil hose still connected Position the P/S oil pump so that it is out of the way

12 Remove the A/C compressor with the pipe still connected Position the A/C compressor so that it is out of the way

13 Remove the drive shaft (See DRIVESHAFT, DRIVESHAFT REMOVAL/INSTALLATION.)

14 Remove in the order indicated in the table

15 Install in the reverse order of removal

16 Start the engine and

(1) Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage

(2) Inspect the ignition timing, idle speed and idle mixture (See ENGINE TUNE-UP, IGNITION TIMING

INSPECTION.) (See ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) (See ENGINE TUNE-UP, IDLE

MIXTURE INSPECTION.)

17 Perform a road test

ENGINE

No.3 Engine mount

(See B3–9 No.3, No.4 Engine Mount Installation

Note)

4 No.1 Engine mount

5 No.2 Engine mount

6

No.4 Engine mount(See B3–9 No.3, No.4 Engine Mount Installation Note)

7 Engine, transaxle

B3

Roll damper Installation Note

1 Assemble the rod and roll damper as shown in

the figure

No.3, No.4 Engine Mount Installation Note

1 Hand tighten the No.3 and No.4 engine mount

rubber bolts and nuts (A—M)

2 Tighten the No.4 engine mount rubber bolts and

Adoption of the FS engine models

• The FS engine models have been added

Improved Installation precision

• When installing integrated stiffener, bolt tightening order has been specified (ZL, ZM)

Relief pressure kPa {kgf/cm2, psi}

[rpm]

295—392{3.0—4.0, 43—56} [3,000]

393—490 {4.0—5.0, 57—71} [3,000]

By-pass pressure kPa {kgf/cm2, psi} 78—118 {0.80—1.20, 11.4—17.1}

OIL PAN

D

OIL PAN REMOVAL/INSTALLATION

Z4F332019900W02

1 Disconnect the negative battery cable

2 Drain the engine oil

3 Remove the front pipe

4 Remove in the order indicated in the table

5 Install in the reverse order of removal

6 Start the engine and inspect for engine oil leakage

(See D–4 Oil Pan Removal Note)

(See D–6 Oil Pan Installation Note)

3 Oil strainer

4 MBSP (Main bearing support plate)(See D–5 MBSP (Main bearing support plate) Removal Note)

(See D–5 MBSP (Main bearing support plate) Installation Note)

OIL PAN

.

Oil Pan Removal Note

1 Remove the oil pan mounting bolts

2 Screw in a oil pan bolt in a weld nut hole to make

a small gap between the oil pan upper block and

the oil pan (FP, FS)

Caution

•••• Pry tools can easily scratch the cylinder

block and MBSP contact surfaces Prying

off the MBSP can also easily bend the

MBSP flange (B3, ZL, ZM)

Y3A1111W003

1 Oil pan

(See D–4 Oil Pan Removal Note)

(See D–6 Oil Pan Installation Note)

2 Oil strainer(See D–6 Oil Strainer Installation Note)

X3U111WA8

OIL PAN

D

3 Remove the oil pan using a separator tool

MBSP (Main bearing support plate) Removal Note

B3, ZL, ZM

1 Using a separator tool, separate the MBSP

MBSP (Main bearing support plate) Installation Note

B3, ZL, ZM

1 Apply silicon sealant to the shaded areas as

shown

2 Apply silicone sealant to the MBSP along the

inside of the bolt holes

OIL PAN Oil Strainer Installation Note

FP, FS

1 Install the oil strainer gasket as shown

2 Tighten the bolts in the order shown

Oil Pan Installation Note

Caution

•••• If the bolts are reused, remove the old sealant from the bolt threads Tightening a bolt that has old

sealant on it can cause bolt hole damage.

1 Apply silicone sealant to the contact surfaces of

new oil pan gaskets as shown (B3, ZL, ZM

OIL PAN

D

2 Install the new gaskets onto the oil pump body

and the rear cover with the projections in the

notches as shown (B3, ZL, ZM)

3 Apply silicone sealant onto the area of oil pan

gasket indicated by A and B (B3, ZL, ZM)

Thickness

2.0 mm {0.079 in}

4 Apply silicone sealant to the oil pan along the

inside of the bolt holes and overlap the ends

OIL PAN

2 Hand-tighten the lock bolt B

3 Tighten the lock bolt C

4 Tighten the lock bolt D

5 Tighten the lock bolt A

FEATURES

Adoption of the FS engine models

• The specifications for the FS engine models have been added

Cooling system Water-cooled, force circulation

Coolant capacity (Approximate quantity)

6.0 {6.3, 5.3} 7.5 {7.9, 6.6}

(L {US qt, lmp qt})Water pump Type Centrifugal,V-ribbed belt driven

Thermostat

two-stage Wax, flow-control Wax, bottom bypass

Opening temperature (°C {°F})

Sub:

83.5—86.5{183—187}

Main:

86.5—89.5{188—193}

31}min

8.5 {0.33}

Radiator

Cap valve opening pressure

Number 4, Intensely hot areas: 5 4

FUEL SYSTEM F1-3

STRUCTURAL VIEW F1-3OUTLINE F1-4QUICK RELEASE CONNECTOR

(ENGINE ROOM SIDE) F1-4QUICK RELEASE CONNECTOR

(FUEL DISTRIBUTOR SIDE) F1-5

ON-BOARD DIAGNOSTIC F1-6

OUTLINE F1-6PID/DATA MONITOR AND RECORD F1-6

REMOVAL/INSTALLATION F1-16PRESSURE REGULATOR INSPECTION F1-16FUEL PRESSURE INSPECTION F1-17

CONTROL SYSTEM F1-20

PCM INSPECTION F1-20

FEATURES

SERVICE

Face-lifted LASER Current LASER

Air cleaner element Type Paper element (wet type)

Idle air control (IAC) valve Type Duty control

Fuel injector

Fuel delivery type Top-feed

Pressure regulator Regulating pressure 280 {2.9, 41}

(kPa {kgf/cm2, psi})Fuel pump Type Impeller (in-tank)

(L {US gal, lmp gal})Fuel Specification Refer to owner’s manual

Evaporative emission control system Type Canister

4 Quick release connector

5 Fuel pump relay

6 To fuel tank

7 From fuel tank

• Plastic fuel hoses and quick release connectors have been adopted on the engine room side to ease

connecting and disconnecting the fuel lines for improved serviceability

Structure

• A new-type quick release connector is adopted for engine room side

• The quick release connector and plastic fuel hose are integrated and cannot be disconnected

Operation

• The quick release connector will be disconnected from the fuel pipe when the tab is squeezed

• A click is heard when the retainer is correctly pushed into the locked position

• The new quick release connectors are equipped with a checker, which fixes the retainer When the connector

is correctly seated in the fuel pipe, the checker is released from the quick release connector, but stays on the fuel pipe This enables verification that the quick release connector has been completely coupled

End Of Sie

YMU114SA9

Z4A3912W001

• A new-type quick release connector is adopted for fuel distributor side.

• The quick release connector and plastic fuel hose are integrated and cannot be disconnected

Operation

• The quick release connector will be disconnected from the fuel pipe when the tab is squeezed

• A click is heard when the flare of the quick release connector are correctly pushed into the locked position

• Fixing the quick release connector with the lock clip ensures that the highly pressurized fuel will not leak, even

if the quick release connector should happen not to be completely coupled

End Of Sie

YMU114SA9

Z4A4002W001

— Some PIDs have been adopted.

— The OBD tester has been changed from the NGS tester to WDS Therefore, the PID names have been changed

A/C relay ACCS ON/OFF A/C RLY ON/OFF 1SA/C switch ACSW ON/OFF A/C SW ON/OFF 1PGenerator field current control duty valve ALTF % ALTF % 1OGenerator output voltage ALTT V V ALTT V V 1TTarget engine speed ARPMDES rpm RPM DES rpm —

Brake switch BOO ON/OFF BRK SW ON/OFF 1FGenerator warning light CHRGLP ON/OFF CHRGLMP ON/OFF 1QEngine coolant temperature

ECT °C, °F ECT °C, °F 3EEngine coolant temperature signal voltage V ECT V V 3EPurge solenoid valve EVAPCP % PRGV % 4LCooling fan relay FAN3 ON/OFF FAN3 ON/OFF 1RFuel pump relay FP ON/OFF FP RLY ON/OFF 4NPressure regulator control solenoid valve FPRC ON/OFF PRCV ON/OFF 4TFuel injection duration FUELPW1 ms INJ ms 4W, 4X,

4Y, 4ZOxygen sensor heater (front) HTR11 ON/OFF FHO2SH ON/OFF 1UIdle air control valve IAC ms IACV ms 4M,4OIntake air temperature

IAT °C, °F IAT °C, °F 3BIntake air temperature signal voltage V IAT V V 3B

Long term fuel trim LONGFT1 % LONGFT1 % —Mass airflow signal voltage MAF V MAF V V 3LOxygen sensor (front) O2S11 V FHO2S V 3CNeutral / clutch switch PNP ON/OFF NL SW ON/OFF 1VPower steering pressure switch PSP ON/OFF PSP SW ON/OFF 1G

Short term fuel trim SHRTFT1 % SHRTFT1 % —Ignition timing SPARKADV BTC IGT BTC 4HTEN terminal in DLC TEST ON/OFF TEN ON/OFF 1LThrottle position sensor signal voltage TP V TP V V 4EBattery positive voltage VPWR V B+ V 1B

Vehicle speed VSS km/h, mph VS km/h, mph 3D

OUTLINE , ENGINE TUNE-UP

F1

SUPPLEMENTAL SERVICE INFORMATION

Z4F390218881W04

• The following changes and/or additions have been made since publication of the LASER REPAIR MANUAL

VOLUME1 (F162-10-98K) and the LASER REPAIR MANUAL SUPPLEMENT (F164-10-99H)

• Removal/installation procedure has been modified

• Inspection procedure has been modified

Fuel pump unit

• Inspection procedure has been modified

Using the SSTs (WDS or equivalent)

1 Perform “ENGINE TUNE-UP PREPARATION”

2 Verify that the RPM PID is within the specification

• If not as specified, adjust the idle speed

Specification

700—800 (750 ±±±± 50) rpm

3 Set TEST PID to ON using WDS or equivalent

4 Connect the timing light to the high-tension lead of No.1 cylinder

5 Verify that the timing mark (yellow) on the

crankshaft pulley is within the specification

Ignition timing

BTDC 9 °°°°—11°°°° (10°°°° ±±±± 1°°°°)

6 Set the TEST PID to OFF using WDS or

equivalent

7 Verify that the timing mark (yellow) on the

crankshaft pulley is within the specification

• If not as specified, inspect the following:

ENGINE TUNE-UP Not Using the SSTs (WDS or equivalent)

1 Perform “ENGINE TUNE-UP PREPARATION”

2 If using the SST (system selector) to turn on the test mode, perform as follows:

(1) Connect the SST (system selector) to the DLC.

(2) Set the system select switch to position 1

(3) Set the test switch to SELF TEST

3 If using a jumper wire to turn on the test mode,

perform the following:

(1) Connect the DLC terminals TEN and GND

using a jumper wire

Caution

•••• Connecting the wrong DLC terminal may

possibly cause a malfunction Carefully

connect the specified terminal only.

4 Verify that the idle speed is within the

specification

• If not as specified, adjust the idle speed

Specification

700—800 (750 ±±±± 50) rpm

5 Connect the timing light to the high-tension lead of the No.1 cylinder

6 Verify that the timing mark (yellow) on the

crankshaft pulley is within the specification

Ignition timing

BTDC 9 °°°°—11°°°° (10°°°° ±±±± 1°°°°)

7 Disconnect the SST (system selector) or a jumper

wire

8 Verify that the timing mark (yellow) on the

crankshaft pulley is within the specification

• If not as specified, inspect the following:

•••• Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death

Fuel can also irritate skin and eyes To prevent this, always complete “BEFORE REPAIR

PROCEDURE”.

Caution

•••• Disconnecting/connecting the quick release connector without cleaning it may possibly cause

damage to the fuel pipe and quick release connector Always clean the quick release connector

joint area before disconnecting/connecting using a cloth or soft brush, and make sure that it is

free of foreign material.

1 Complete “BEFORE REPAIR PROCEDURE”

2 Disconnect the negative battery cable

3 Remove the accelerator cable bracket

4 Disconnect the fuel injector connectors and remove the harness from the fuel distributor

5 Remove in the order indicated in the table

6 Install in the reverse order of removal

7 Complete “AFTER REPAIR PROCEDURE”

Plastic Fuel Hose Removal Note

1 For engine side, push apart the lock clip on the

quick release connector and unlock it

2 Disconnect the quick release connector as

follows:

FUEL SYSTEM

1 Plastic fuel hose

(See F1–9 Plastic Fuel Hose Removal Note)

(See F1–11 Plastic Fuel Hose Installation Note)

2 Vacuum hose

3 Fuel distributor

4 Fuel distributor insulator

5 Fuel injector insulator

• The blue stopper may be removed from the

quick connector Take care not to loose it

Reinstall it to the quick release connector

before reconnecting the fuel line

• The blue locking coupler has two internal

locking tabs which retrain the pulsation

damper pipe Be sure that the tab on the

locking coupler is rotated until it stops to

release two internal locking tabs

3 Cover the disconnected quick release connector

with vinyl sheet or the like to prevent it from being

scratched or contaminated with foreign material

Fuel Injector Installation Note

1 Use new fuel injector O-rings

2 Apply a small amount of clean engine oil to the O-rings and install them into the fuel distributor

3 Verify that the O-rings and the fuel injector sealing surfaces are free of foreign material

• Clean with gasoline if necessary

4 Install the fuel injectors in the fuel distributor with

light twisting motion so that the O-rings will not be

FUEL SYSTEM

F1

Plastic Fuel Hose Installation Note

1 Inspect the plastic fuel hose and fuel pipe sealing surface for damage and deformation

• If the quick release connector O-ring is damaged or has slipped, replace the plastic fuel hose

2 Slightly apply clean engine oil to the sealing surface of the fuel pipe

3 Connect the plastic fuel hose to the fuel pipe until a click is heard

4 Lightly pull and push the quick release connector a few times by hand and verify that it can move 2.0—3.0 mm

{0.08—0.11 in} and it is connected securely.

• If quick release connector does not move at all, verify that the O-ring is not damaged and slipped, and

reconnect the quick release connector

5 Attach the lock clip to the quick release connector

in the direction of the fuel distributor and lock it,

as shown in the figure

6 Verify that the lock portion is installed correctly

• Perform the following test only when directed

1 Disconnect the negative battery cable

2 Remove the rear seat cushion

3 Remove the service hole cover

4 Disconnect the fuel pump unit connector

5 Inspect for continuity between fuel pump unit connector terminals B and D

• If there is no continuity, replace the fuel pump body

• If there is continuity, carry out the “Circuit Open/Short Inspection”

Circuit Open/Short Inspection

1 Disconnect the fuel pump relay connector and the fuel pump relay connector

2 Inspect for an open or short circuit in the following wiring harnesses by probing the fuel pump unit and fuel

pump relay terminals with ohmmeter leads

Open circuit

• GND circuit (Fuel pump unit connector terminal D and body GND)

• Power circuit (Fuel pump relay connector terminal E and fuel pump unit connector terminal B through

common connector)

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FUEL SYSTEM Short circuit

• Fuel pump relay connector terminal E and

fuel pump unit connector terminal B through

common connector to GND

3 Repair or replace faulty areas

4 Reconnect the fuel pump unit connector

5 Install the service hole cover

6 Install the rear seat cushion

7 Reconnect the negative battery cable

Fuel Pump Maximum Pressure Inspection

Warning

•••• Fuel line spills and leakage are dangerous Fuel can ignite and cause serious injuries or death and

damage Always carry out the following procedure with the engine stopped.

Caution

•••• Disconnecting/connecting the quick release connector without cleaning it may possibly cause

damage to the fuel pipe and quick release connector Always clean the quick release connector joint area before disconnecting/connecting, and make sure that it is free of foreign material Note

• Perform the following test only when directed

1 Complete the “BEFORE REPAIR PROCEDURE”

2 Disconnect the negative battery cable

3 Disconnect the quick release connector from the fuel main pipe as follows:

(1) Lift the tab on the blue locking coupler until

the fuel line can be released

(2) Pull the fuel hose straight back

Note

• The blue stopper may be removed from the

quick connector Take care not to loose it

Reinstall it to the quick release connector

before reconnecting the fuel line

• The blue locking coupler has two internal

locking tabs which retrain the fuel main pipe

Be sure that the tab on the locking coupler is

rotated until it stops to release two internal

locking tabs

4 Turn the lever as shown to plug the SST outlet.

5 Push the SST quick release connector into the

fuel main pipe until a click is heard

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