11 0 18 MB
TABLE OF CONTENTS
SECTION
TABLE OF CONTENTS
SECTION
ENGINE
GENERAL INFORMATION General Information
0A
Maintenance and Lubrication
0B
HEATING AND AIR CONDITIONING
0A
6
0B
6A1
General Information and Diagnosis
6
1A
6A2
Engine Mechanical (G16)
6A1
1B
6A4
Engine Mechanical (H25)
6A2
3
6B
3A
6C
3B1
6E1
3C
6E2
Heater and Ventilation
1A
Engine Mechanical (J20)
6A4
Air Conditioning
1B
Engine Cooling
6B
Engine Fuel
6C
Engine and Emission Control System (SF1 for G16/J20)
6E1 6E2
3C1
6F1
3D
6F2
3E
6G
3F
6G1
4A2
6H
4B
6K
5
7A
5A
7A1
5B
7B1
STEERING, SUSPENSION, WHEELS AND TIRES Front End Alignment
3 3A
Power Steering (P/S) System
3B1
Steering Wheel and Column (Not Equipped with Air Bag)
Engine and Emission Control System (SF1 for H25)
3C
Ignition System (G16)
6F1
Ignition System (J20/H25)
6F2
Cranking System (Reduction Type)
6G
Cranking System (No-Reduction Type)
6G1
Air Bag Steering Wheel and Column
3C1
Front Suspension
3D
Rear Suspension
3E
Wheel and Tires
3F
DRIVE SHAFT/PROP. SHAFT Front Drive Shaft/Shaft Bearing, Oil Seal
4A2
Propeller Shaft
4B
BRAKES
5
Charging System
6H
Exhaust System
6K
TRANSMISSION, CLUTCH AND DIFFERENTIAL Manual Transmission (Type 1)
7A
Manual Transmission (Type 2)
7A1
Brake Pipe/Hose /Master Cylinder
5A
Automatic Transmission
7B1
5C
7C1
Front Brakes
5B
Clutch (Hydraulic Type)
7C1
5E1
7D
Transfer
7D
Differential (Front)
7E
Differential (Rear)
7F
Parking and Rear Brakes
5C
Antilock Brake System
5E1
BODY ELECTRICAL SYSTEM
8
7E 7F 8
Wiring Diagram
8A
Lighting System
8B
8A
Instrumentation/Driver Information
8C
8B
Windows, Mirrors, Security and Lock
8D
Immobilizer Control System
8G
8C 8D
BODY SERVICE
9
8G
RESTRAINT SYSTEM
10
9
Seat Belt
10A
Air Bag System
10B
SERVICE BULLETIN Power Steering (P/S) System 3B1 NOTE: The screen toned Sections 0A – 5E1 and 7A – 10B are included in Volume 1 and section 8A is in Wiring Diagram Manual mentioned in Foreword of this manual.
10 10A 10B 3B1
J2 ESCUDO 2 of 2
ENGINE MECHANICAL (H25 ENGINE) 6A2-15
10) Remove exhaust No.1 pipe.
1. Stiffener 2. Exhaust No.1 pipe
11) For Type 2 exhaust system only: Detach exhaust manifold stiffener from transmission case. 12) Remove exhaust manifolds and their gaskets from cylinder heads.
1. Exhaust manifold stiffener 2. Exhaust No.1 pipe 3. Transmission
INSTALLATION 1) Install new manifold gaskets to cylinder heads and No.1 pipe gasket to exhaust pipe No.1. 2) Install exhaust manifolds. Always install new bolts with pre-coated adhesive to the locations with mark. Tighten manifold nuts and bolts to specified torque. Tightening Torque (a): 30 N.m (3.0 kg-m, 21.5 lb-ft)
1. Left (No.1) exhaust manifold 2. Right (No.2) exhaust manifold
3) For Type 2 exhaust system only: Attach exhaust manifold stiffener to transmission. 4) Install exhaust No.1 pipe and stiffener. Tighten exhaust No.1 pipe bolts and nuts to specified torque. Tightening Torque (b): 50 N.m (5.0 kg-m, 36.5 lb-ft)
1. Exhaust No.1 pipe 2. Catalytic converter 3. Stiffener
J2 ESCUDO
6A2-22 ENGINE MECHANICAL (H25 ENGINE)
CLEAN Clean sealing surface on timing chain cover, crankcase, cylinder block and cylinder heads. Remove oil, old sealant, and dust from sealing surface.
INSPECTION Check oil seal lip for damages or deterioration. Replace as necessary. NOTE: When installing new oil seal, top it in until its surface is flash with edge of timing chain cover. To install oil seal, use special tool (bearing installer). Special Tool (D): 09913-75510
1. Timing chain cover 2. Oil seal
INSTALLATION Reverse removal sequence to install timing chain cover noting following points. 1) Apply sealant “A” and “B” to timing chain cover sealing surface area as shown in figure. “A”: Sealant 99000-31150 “B”: Sealant 99000-31140 2) Apply engine oil to oil seal lip and water pump O-ring, then install timing chain cover. 1. Timing chain cover 2. Sealant “A” 3. Cylinder head 4. Cylinder block 5. Cylinder head gasket 6. Rub into 7. Jig “a”: 7 mm (0.28 in.) “b”: 67 mm (2.64 in.) “c”: 17 mm (0.67 in.) “d”: 18 mm (0.71 in.) “e”: 10 mm (0.39 in.)
(a)
1. Crankshaft pulley 2. Bolt 3. Wrench
Tightening torque Timing chain cover bolt: 11 N.m (1.1 kg-m, 7.5 lb-ft)
3) Install crankshaft pulley. To lock crankshaft pulley, use special tool (camshaft pulley holder) with it at shown in figure. Special Tool (A): 09917-68221 CAUTION: Be sure to use the following bolt for fixing special tool to crank pulley. Bolt size: M8, P1.25 ȏ = 45 mm Strength: 7T Tightening Torque (a): 150 N.m (15 kg-m, 108.5 lb-ft)
ENGINE MECHANICAL (H25 ENGINE) 6A2-43
4) Apply oil to sliding surface of each camshafts and camshaft journals.
5) Install RH bank 2nd timing chain on camshaft sprockets by aligning match marks with the plates in silver or yellow color.
1. Yellow or silver colored plate 2. Match mark of RH bank 2nd timing chain exhaust camshaft sprocket 3. Match mark of RH bank 2nd timing chain intake camshaft sprocket
6) Install camshaft housing pins as shown in figure.
1. RH bank intake camshaft 2. RH bank exhaust camshaft 3. Pin
I: Intake side E: Exhaust side
7) Check position of camshaft housings. Embossed marks are provided on each camshaft housing, indicating position and direction for installation. Install housings as indicated by these marks.
Position from timing chain side Timing chain side
8) After applying oil to housing bolts, tighten them temporarily first. Then tighten them by following sequence as indicated in figure. Tighten a little at a time and evenly among bolts and repeat tightening sequence two or three times before they are tightened to specified torque below. Tightening Torque 12 N.m (1.2 kg-m, 8.5 lb-ft)
J2 ESCUDO
IGNITION SYSTEM (FOR G16 ENGINE) 6F1-3
COMPONENTS TYPE-II RESISTER SHAPE AND LOCATION (Located in the engine room)
NOTE: Above figure shows left hand steering vehicle. For right hand steering vehicle, parts with (*) are installed at the other side.
1. Ignition coil assembly for No.1 and No.4 cylinders 2. Ignition coil assembly for No.2 and No.3 cylinders 3. Monitor coupler (*) 4. CMP sensor 5. ECM (or PCM) (*) 6. High-tension cord 7. Spark plug 8. Noise suppressor 9. Ignition resistor (*) ... Type-I 9-1. Ignition resister (*) ... Type-II 10. Ignition Label
DIAGNOSIS Condition Engine cranks, but will not start or hard to start
Poor fuel economy or engine performance
Possible Cause
Correction
No spark
Blown fuse for ignition coil Loose connection or disconnection of lead wire or high-tension cord(s) Faulty high-tension cord(s) Faulty spark plug(s) Faulty ignition coil assembly (s) Faulty CMP sensor Faulty ECM (or PCM)
Replace. Connect securely.
Incorrect ignition timing Faulty high-tension cord(s) Faulty spark plug(s) Faulty ignition coil assembly (s) Faulty CMP sensor Faulty ECM (or PCM)
Adjust. Replace. Adjust, clean or replace. Replace. Clean, tighten or replace. Replace.
Replace. Adjust, clean or replace. Replace. Clean, tighten or replace. Replace.
J2 ESCUDO
Prepared by
Overseas Service Department
1st Ed. Jan., 1998 3rd Ed. Oct., 2001 Printed in Japan Printing:
610
J2 ESCUDO 2 of 2