SQ416 420 625 2 [PDF]

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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



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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



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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)



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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



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