Installation
INTAKE MANIFOLD:
INSTALLATION
Install intake manifold bolts in the reverse order of removal.
Tighten Intake Manifold Lower Bolts in numerical order as shown in the figure.
NOTE: No. 7 and 8 have longer bolt length than others.
Tighten Intake Manifold Upper Bolts in numerical order as shown in the figure.
NOTE: No. 1 to 4 have longer bolt length than others.
Installation of Electric Throttle Control Actuator
Install intake manifold adapter gasket and electric throttle control actuator gasket so that three protrusions for installation identification do not face downward.
Tighten fixing bolts of electric throttle control actuator equally and diagonally in several steps.
After installation perform procedure in "INSPECTION AFTER INSTALLATION".
Connecting Water Hose
Install water hose so that its overlap width for connection is between 27 mm (1.06 inch) and 32 mm (1.26 inch) (target: 27 mm, 1.06 inch).
Connecting Quick Connector of Fuel Tube
Install quick connector as follows. (The steps are the same for quick connectors on engine side and vehicle side excepting quick connector cap.)
1. Make sure no foreign substances are deposited in and around tube and quick connector and no damage on them.
2. Thinly apply new engine oil around the fuel tube from tip end to the spool end.
3. Align center to insert quick connector straightly into fuel tube.
On vehicle piping side:
Insert until the paint mark for engagement identification (white) goes completely inside quick connector so that you cannot see it from the straight side of the connected part. Use a mirror to check this where it is not possible to view directly from the straight side, such as quick connector on vehicle side.
On engine side:
Insert fuel tube into quick connector until upper spool is completely inside quick connector, and lower spool exposes right below quick connector.
CAUTION: Hold A position in illustration when inserting fuel tube into quick connector.
Carefully align center to avoid inclined insertion to prevent damage to O-ring inside quick connector.
Insert until you hear a "click" sound and actually feel the engagement.
To avoid misidentification of engagement with a similar sound, be sure to perform the next step.
4. Before clamping fuel tube with hose clamps, pull quick connector hard by hand holding A position. Make sure it is completely engaged (connected) so that it does not come out from fuel tube.
NOTE: Recommended pulling force is 50 N (5.1 kg, 11.2 lbs.).
5. Install quick connector cap on quick connector joint (on engine side only).
6. Install fuel tube to hose clamp.
INSPECTION AFTER INSTALLATION
Perform procedures for "Throttle Valve Closed Position Learning" after finishing repairs.
Throttle Valve Closed Position Learning
DESCRIPTION
Throttle Valve Closed Position Learning� is an operation to learn the fully closed position of the throttle valve
by monitorizing the throttle position sensor output signal. It must be performed each time harness connector of electric throttle control actuator or ECM is disconnected.
OPERATION PROCEDURE
1. Turn ignition switch ON.
2. Turn ignition switch OFF wait at least 10 seconds.
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.
If electric throttle control actuator is replaced, perform procedures for "Idle Air Volume Learning" after finishing repairs.
Idle Air Volume Learning
DESCRIPTION
Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions:
- Each time electric throttle control actuator or ECM is replaced.
- Idle speed or ignition timing is out of specification.
PREPARATION
Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied.
Learning will be cancelled if any of the following conditions are missed for even a moment.
- Battery voltage:..........More than 12.9V (At idle)
- Engine coolant temperature:......70 - 99�C (158 - 210�F)
- PNP switch:.......ON
- Electric load switch:......OFF
(Air conditioner, headlamp, rear window defogger)
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light only small lamps.
- Steering wheel:......Neutral (Straight-ahead position)
- Vehicle speed:.......Stopped
- Transmission:.......Warmed-up
For models with CONSULT-II, drive vehicle until "FLUID TEMP SE" in "DATA MONITOR" mode of A/T system indicates less than 0.9V.
For models without CONSULT-II, drive vehicle for 10 minutes.
OPERATION PROCEDURE
With CONSULT-II
1. Perform "Throttle Valve Closed Position Learning" .
2. Start engine and warm it up to normal operating temperature.
3. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order.
4. Select "IDLE AIR VOL LEARN" in WORK SUPPORT mode.
5. Touch START and wait 20 seconds.
6. Make sure that "CMPLT" is displayed on CONSULT-II screen. If "INCMP" is displayed, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the problem by referring to the Diagnostic Procedure.
7. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications.
ITEM SPECIFICATION
Idle speed.............650 ± 50 rpm (in P or N position)
Ignition timing.......17 ± 5° BTDC (in P or N position)
Without CONSULT-II
NOTE: It is better to count the time accurately with a clock. It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction.
1. Perform "Throttle Valve Closed Position Learning" .
2. Start engine and warm it up to normal operating temperature.
3. Check that all items listed under the topic PREPARATION(previously mentioned) are in good order.
4. Turn ignition switch OFF and wait at least 10 seconds.
5. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
6. Repeat the following procedure quickly five times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
7. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MIL goes off.
8. Fully release the accelerator pedal within 3 seconds after the MIL goes off.
9. Start engine and let it idle.
10. Wait 20 seconds.
11. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications.
12. If idle speed and ignition timing are not within the specification, the result will be incomplete. In this case, find the cause of the problem by referring to the Diagnostic Procedure.
ITEM SPECIFICATION
Idle speed........650 ± 50 rpm (in P or N position)
Ignition timing..........17 ± 5° BTDC (in P or N position)
DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle valve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttle valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the problem.
It is useful to perform "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . (Refer to Computers and Control Systems / Non-Trouble Code Diagnostic Procedures).
5. If any of the following conditions occur after the engine has started, eliminate the cause of the problem and perform Idle air volume learning all over again:
- Engine stalls.
- Erroneous idle.