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FUEL SYSTEM Return To Main Table of Contents GENERAL SERVICE ADJUSTMENT PROCEDURES FUEL TANK 29 FUEL LINE 45 FUEL PUMP 47 CARBURETOR 50 42 ENGINE CONTROL 70 GENERAL GENERAL SPECIFICATIONS Fuel tank Capacity [Original] Capacity [Optional] Fuel filter Type [In-line filter] Type [In-tank filter] Fuel pump Type Driven by Feed pressure Carburetor Type Identification mark For Federal - M/T A/T For California - M/T A/T Throttle bore Primary Secondary Feedback solenoid valve (FBSV) 40 lit (10.6 U.S gal., 8.8 Imp.gal.) 50 lit (13.2 U.S gal., 11.0 Imp.gal) Cartridge type Open type Mechanical diaphragm type Camshaft 19-25 kPa (2.76-3.63 psi) at 2,500 rpm Down-draft, 2-barrel, feed back type 410 411 412 413 30 mm (1.181 in.) 32 mm (1.260 in.) Type Coil resistance Slow cut solenoid valve (SCSV) Duty cycle solenoid 54-66 R [At 20°C (68F)] Type Coil resistance Throttle position sensor (TPS) Duty cycle solenoid 48-60 R [At 20°C (68°F)] Type Regulating voltage (When throttle valve fully closed) Coil resistance Bow vent valve (BVV) Variable resistor type (Rotary type) 0.25V Type Vacuum orifice Mixture control valve (MCV) Vacuum type 0.3 mm (0.012 in.) Type Air flowing quantity Operating time Dash pot Vacuum type 5.1 ± 0.1 gr/sec 0.8 ± 0.2 sec Type Operating rpm (When SAS touches free lever) Outer venturi dia Primary Secondary Conventional type Approx 1,800 rpm 31-2 3.5 - 6.5 KR 20 mm (0.787 in.) 25 mm (0.984 in.) GENERAL Inner venturi dia Primary Secondary Main jet Primary Secondary Main air jet Primary - First Second Secondary Pilot jet Primary Secondary Pilot air jet Primary - First Second Secondary Main nozzle Primary Secondary Throttle valve plate Thickness Primary Secondary Fuel closing angle Primary Secondary Full opening angle Enrichment jet Slow air jet Accelerating pump Diaphragm dia Pump jet dia Choke Type Choke valve operating angle Bimetal Temperature constant Spring constant Choke breaker opening First stage Second stage 9-14 mm (0.354-0.551 in.) 9-12 mm (0.354-0.472 in.) # 83.8 # 145 # 80 # 60 # 70 # 46.3 # 70 # 120 # 200 # 100 2.6 mm (0.102 in.) 2.8 mm (0.110 in.) 1.0 mm (0.040 in.) 1.5 mm (0.060 in.) 8° 15° 90° # 50 # 110 24 mm (0.945 in.) 0.35 mm (0.014 in.) Automatic (Electric type) 25° (When fully closed) 90° (When fully opened) 1.0 deg/°C 60 gr.mm/deg 1.4-1.6 mm (0.056-0.064 in.) 2.9-3.1 mm (0.116-0.124 in.) 31-3 GENERAL Electric control unit for FBC Identification mark For Federal - M/T A/T For California - M/T A/T FOM FOA COM COA Input sensor Engine coolant temperature sensor Type Resistance Thermistor type 2.5 KR [at 20°C (68°F)] 0.3 K!J [at 80°C (176°F)] Oxygen sensor Type Vacuum switch Type Operating condition - ON OFF Vehicle speed sensor Top gear sensing switch Output actuator Cold mixture heater Zirconia sensor Contact type switch More than 40 kPa (5.8 psi) Less than 26 kPa (3.9 psi) Reed switch type Contact type switch Type Secondary air control solenoid valve Positive Temperature Coefficient (PTC) heater Type Resistance Advance control solenoid valve ON-OFF solenoid valve 38-44 Cl [at 20°C (68°F)] Type Resistance Cold advance control solenoid valve ON-OFF solenoid valve 38-44 R [at 20°C (68°F)] Type Resistance Throttle opener control solenoid valve ON-OFF solenoid valve 38-44 Q [at 20°C (68°F)] Type Resistance 31-4 ON-OFF solenoid valve 38-44 R [at 20°C (68°F)] GENERAL SERVICE STANDARD Basic ignition timing Curb idle speed For the first 500 km (300 miles) After 500 km (300 miles) Throttle opener adjusting rpm for power steering and electrical load For the first 500 km (300 miles) After 500 km (300 miles) Throttle opener adjusting rpm for air conditioner load TIGHTENING TORQUE Accelerator arm bracket to body Accelerator cable guide to body Carburetor attaching bolt Engine coolant temperature sensor Oxygen sensor Fuel tank drain plug BTDC 5° ± 2° 700 rpm 750 ± 100 rpm 800 rpm 850 ± 100 rpm 875 ± 25 rpm Nm kg.cm Ib.ft 7.8-12 2.9-4.9 15-20 20-40 39-49 78-98 80-120 30-50 150-200 200-400 400-500 800-1,000 5.8-8.7 2.2-3.6 11-14 14-29 29-36 58-72 LUBRICANT Grease for accelerator arm pin and return spring Multipurpose grease SAE J310a, NLGI grade # or equivalent 31-5 GENERAL SPECIAL TOOLS 31-6 GENERAL TROUBLESHOOTING When checking and correcting engine troubles, it is important to start with inspection of the basic systems If you experience one of the followings, (A) engine start failure, (B) unstable idling or (C) poor acceleration, you should first check the following basic systems Power supply (a) Battery (b) Fusible link (c) Fuse Body ground Fuel supply (a) Fuel line (b) Fuel filter (c) Fuel pump Ignition system (a) Spark plug (b) High-tension cable (c) Distributor (d) Ignition coil Emission control system (a) PCV system (b) EGR system (c) Vacuum leak Others (a) Ignition timing (b) Idle speed Troubles with the FBC system are often caused by poor contact of harness connector It is, therefore, important to check harness connector contact 31-7 GENERAL Fuel Tank and Fuel Line Symptom Engine malfunctions due to insufficient fuel supply Evaporative emission control malfunctions (Pressure released when fuel tank cap is removed) 31-8 Remedy Probable cause Bent or kinked fuel pipe or hose Repair or replace Clogged fuel pipe or hose Clean or replace Clogged fuel filter or in-tank fuel filter Replace Water in fuel filter Replace the fuel filter or clean the fuel tank and fuel line Dirty or rusted fuel tank interior Clean or replace Malfunctioning fuel pump (Clogged filter in the pump) Replace Misrouted vapour lines Correct Disconnected vapor line piping joint Correct Folded, belt, cracked or clogged vapor line Replace Faulty fuel tank cap Replace Malfunctioning overfill limiter (two-way valve) Replace GENERAL Carburetor and FBC System Symptom Engine will not start or start to hard Carburetor FBC system Rough idle or engine stalls Remedy Probable cause Carburetor FBC system Choke valve remains open-cold engine Clean choke bore and linkage Improper choke breaker operation Check and adjust choke breaker Electric choke malfunction Check electric choke body and choke valve operation Needle valve sticking or clogged Repair or replace Engine coolant temperature sensor malfunction Check by using checker (Check component and replace if faulty) Vacuum hose disconnected or damaged Repair or replace Slow-cut solenoid valve malfunction Check component Feedback solenoid valve malfunction Check component Vacuum switch malfunction-cold engine Check component Faulty ECU Replace Harness broken/short-circuited or loose connection Repair or replace Choke valve malfunction Clean choke bore and link Improper fast idle-cold engine Adjust fast idle speed Improper idle adjustment Adjust idle speed Electric choke malfunction Check choke body and choke valve operation Primary pilot jet clogged Clean up or replace Dash pot malfunction Adjust Slow-cut solenoid valve malfunction Check drive signal by using checker Check component Engine coolant temperature sensor malfunction Check by using checker (Check component and replace if faulty) Vacuum hose disconnected or damaged Repair or replace Throttle position sensor malfunction Check component and adjust Engine speed sensor malfunction Check by using checker Check harnesses for continuity Timing control system malfunction Check system If faulty, check components Throttle opener control system malfunction Check system If faulty, check components Harness broken/short-circuited or connector not connected securely Repair or replace 31-9 GENERAL Engine hesitates or poor acceleration Remedy Probable cause Symptom Carburetor FBC system Acceleration pump malfunction Clean pump discharge rate Choke valve remains open-cold engine Clean choke bore and link Check choke valve operation Choke valve remains closed-hot engine Clean choke bore and link Check choke valve operation Main jet clogged Clean up Enrichment jet clogged Clean up Secondary valve operation abnormal Check valve operation Feedback solenoid valve malfunction Check drive signal by using checker Check component Vacuum switch malfunction Check with checker (Replace if faulty) Timing control system malfunction Check system If faulty, check components Timing control system malfunction Check system If faulty, check components Engine coolant temperature sensor malfunction Check by using checker (Check component and replace if faulty) Throttle position sensor malfunction Check component and adjust Engine speed sensor malfunction Check by using checker Check harnesses for continuity Cold mixture heater relay control system malfunction-cold engine Check system If faulty, check components Harness broken/short-circuited or connector not connected properly Repair or replace Air conditioner power relay control system malfunction Check system Engine dieseling (runs after ignition switch is turned off) Carburetor Engine idle speed too high Adjust idle speed FBC system Slow-cut solenoid valve malfunction Check component Poor fuel mileage Carburetor Choke valve operation abnormal Check valve operation Engine idle speed too high Adjust idle speed Electric choke malfunction Check choke body and valve operation Enrichment valve kept open Repair or replace 31-10 ... 100 rpm 875 ± 25 rpm Nm kg.cm Ib.ft 7. 8-1 2 2. 9-4 .9 1 5-2 0 2 0-4 0 3 9-4 9 7 8-9 8 8 0-1 20 3 0-5 0 15 0-2 00 20 0-4 00 40 0-5 00 80 0-1 ,000 5. 8-8 .7 2. 2-3 .6 1 1-1 4 1 4-2 9 2 9-3 6 5 8-7 2 LUBRICANT Grease for accelerator... deg/°C 60 gr.mm/deg 1. 4-1 .6 mm (0.05 6-0 .064 in.) 2. 9-3 .1 mm (0.11 6-0 .124 in.) 3 1-3 GENERAL Electric control unit for FBC Identification mark For Federal - M/T A/T For California - M/T A/T FOM FOA... Resistance Throttle opener control solenoid valve ON-OFF solenoid valve 3 8-4 4 Q [at 20°C (68°F)] Type Resistance 3 1-4 ON-OFF solenoid valve 3 8-4 4 R [at 20°C (68°F)] GENERAL SERVICE STANDARD Basic