ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or ignition system, ensure engine mechanical condition is okay.
VALVE CLEARANCE
Note. Swift DOHC uses hydraulic lifters. No adjustments are required.
SAMURAI & SIDEKICK
- Remove valve cover. Rotate engine until zero degree (TDC) timing mark of timing belt cover is in line with timing mark on crankshaft pulley. (Scheme 6)
- Ensure cylinder No. 1 is at TDC on compression stroke. Remove distributor cap. On Samurai and Sidekick (TBI), ensure rotor is pointed upward at distributor hold-down bolt and to No. 1 terminal of distributor cap. On Sidekick (MPI), ensure rotor is at about 1 o'clock position and pointed to No. 1 terminal of distributor cap. If rotor is not as described, rotate crankshaft 360 degrees.
- Measure valve clearance between adjustment screw and valve stem using shim thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1and 3. See the «VALVE CLEARANCE SPECIFICATIONS»(ref-25800-S00460605822001010500000) table.
- Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4.
- Adjust valves by loosening lock nut and turning adjusting screw until clearance is as specified. After adjusting clearance, tighten adjusting screw lock nut to 11.0-13.5 ft. lbs. (15-18 N.m) for Samurai or 90-108 INCH lbs. (10-13 N.m) on Sidekick. On all models, recheck clearance.
| Application | In. (mm) |
|---|
| Samurai, Sidekick (TBI) & Swift SOHC |
| Engine Cold |
| Intake | .005-.007 (.13-.18) |
| Exhaust | .006-.008 (.15-.20) |
| Engine Hot |
| Intake | .009-.011 (.23-.28) |
| Exhaust | .010-.012 (.25-.30) |
| Sidekick (MPI) |
| Engine Cold: Intake & Exhaust | .003-.005 (.08-.12) |
| Engine Hot: Intake & Exhaust | .005-.006 (.12-.16) |
| Swift DOHC | (1) * |
| (1) Hydraulic valve lash adjusters are used and no adjustment is required. |
| (1) | Hydraulic valve lash adjusters are used and no adjustment is required. |
VALVE CLEARANCE SPECIFICATIONS
SWIFT SOHC
- Remove valve cover. Remove right inner fender apron extension to enable timing marks to be seen. Align crankshaft pulley timing mark with TDC mark on timing belt cover. (Scheme 6)
- Remove distributor cap. Ensure rotor is pointing upward toward distributor hold-down bolt and to No. 1 terminal of distributor cap. If rotor is not as described, rotate crankshaft 360 degrees.
- Measure valve clearance between adjustment screw and valve stem using shim thickness gauge. Check intake valve clearance of cylinders No. 1 and 2 and exhaust valve clearance of cylinders No. 1and 3. See the «VALVE CLEARANCE SPECIFICATIONS»(ref-25800-S00460605822001010500000) table. Turn crankshaft one complete revolution (360 degrees). Check intake valve clearance of cylinders No. 3 and 4 and exhaust valve clearance of cylinders No. 2 and 4.
- Adjust valves by loosening lock nut and turning adjusting screw until clearance is as specified. Hold adjusting screw while tightening lock nut to 11.0-13.5 ft. lbs. (15-18 N.m). Recheck clearance.
IGNITION TIMING
Note. Verify that increasing engine speed advances ignition timing.
- Ensure transmission is in Neutral or Park and parking brake is set. Inspect crankshaft pulley timing mark and timing mark indicator on timing belt cover. (Scheme 6) Clean marks as required. Start engine, and warm it to normal operating temperature. Turn engine off with ignition on for 5 seconds. Restart engine. Run engine at 2000 RPM for 5 minutes, and then return it to idle. Turn all accessories off. Attach timing light to No. 1 spark plug wire. Ensure idle speed is correct. See «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table under IDLE SPEED & MIXTURE. CAUTION: Driving with jumper wire installed in monitor coupler will damage catalytic converter.
- Remove protective cap from monitor coupler located next to battery. Connect jumper wire between terminals "C" (ground) and "D" (test switch). (Scheme 7) Aim timing light at crankshaft pulley and timing cover timing marks. If ignition timing is not within specification, loosen distributor hold-down flange bolts, and rotate distributor to obtain correct ignition timing. See IGNITION TIMING table. Tighten distributor hold-down flange bolts, and recheck ignition timing. NOTE: With jumper wire installed, timing should be fixed. If timing varies, terminal "D" is not properly grounded.
- Remove jumper wire from monitor coupler. Ensure ignition timing advances as engine speed increases. If ignition timing does not advance, check TPS, monitor coupler wiring circuit, engine start signal circuit and ECM.
Scheme 6
Scheme 7
| Application | Man. Trans. | Auto. Trans. |
|---|
| Samurai | (2) 7-9 @ 800 | Not Used |
| Sidekick |
| MPI | (2) 4-6 @ 800 | (2) 4-6 @ 800 |
| TBI | (2) 7-9 @ 800 | (2) 7-9 @ 800 |
| Swift |
| DOHC | (3) 5-7 @ 800-900 | (3) 5-7 @ 800-900 |
| SOHC | (3) 4-6 @ 750 | (3) 4-6 @ 850 |
| (1) (Scheme 6)for timing mark location. (2) With jumper wire installed between "C" and "D" terminals of monitor coupler connector, located near battery. (Scheme 7) (3) With jumper wire installed between "D" and "E" terminals of monitor coupler connector, located near ignition coil. (Scheme 8) |
| (2) | With jumper wire installed between "C" and "D" terminals of monitor coupler connector, located near battery. (Scheme 7) |
| (3) | With jumper wire installed between "D" and "E" terminals of monitor coupler connector, located near ignition coil. (Scheme 8) |
IGNITION TIMING (Degrees BTDC @ RPM) (1)
SWIFT
- Ensure transmission is in Neutral or Park. Set parking brake. Inspect crankshaft pulley timing mark and timing mark indicator on timing belt cover. (Scheme 6) Clean marks as required. Start engine, and warm it to normal operating temperature. Turn all accessories off. Attach timing light to No. 1 spark plug wire. Ensure idle speed is correct. See «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table under IDLE SPEED & MIXTURE. CAUTION: Driving with jumper wire installed in monitor coupler will damage catalytic converter.
- Connect terminals "D" (ground) and "E" (test switch) of monitor coupler. (Scheme 8) Aim timing light at crankshaft pulley and timing cover timing marks. If ignition timing is not within specification, loosen distributor hold-down bolt and rotate distributor to obtain correct ignition timing. See «IGNITION TIMING»(ref-25800-S04496394442001010500000) table. Tighten distributor hold-down bolt, and recheck ignition timing.
Scheme 8
PICK-UP COIL AIR GAP
- Remove distributor cap and rotor. Using non-magnetic shim thickness gauge, measure air gap between reluctor tooth and pick-up coil. See «PICK-UP COIL AIR GAP»(ref-25800-S17167493652001010500000) table. If adjustment is required, loosen pick-up coil plate hold-down screws.
- Using blade screwdriver, move pick-up coil plate to adjust air gap to specification. See «PICK-UP COIL AIR GAP»(ref-25800-S17167493652001010500000) table. Tighten screws, and recheck air gap. Ensure no metal particles are on pick-up coil tooth.
| Application | In. (mm) |
|---|
| Samurai | (1) * |
| Sidekick | (1) * |
| Swift |
| DOHC (2) | .008-.012 (.20-.30) |
| SOHC | .008 (.20) |
| (1) Not adjustable. (2) Also referred to as crank angle sensor air gap. |
| (2) | Also referred to as crank angle sensor air gap. |
IDLE SPEED & MIXTURE
Note. Mixture is not adjustable. Mixture is controlled by ECM from various sensor inputs.
COLD (FAST) IDLE
Note. Cold start or fast idle speed is not adjustable. Air valve operation supplies by-pass air for cold starting.
IDLE SPEED
Note. DO NOT adjust idle speed in areas above 8200 ft. elevation.
Samurai
- Start engine, and warm it to normal operating temperature. Install spare fuse into diagnosis terminal of fuse box, and ensure Malfunction Indicator Light (MIL) indicates Code 12. (Scheme 9)
- Turn engine off. Connect Duty Meter (99963-00006) to monitor coupler duty check terminal "A" and ground terminal "C". (Scheme 7) Test connector is located near battery. Turn ignition on, and wait 5 seconds.
- Start engine, run it at 2000 RPM for 5 minutes and then return it to idle. Using duty meter, ensure idle speed and IAC duty percentage are within specification. See «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) and «IAC DUTY AT SPECIFIED IDLE SPEED»(ref-25800-S18446941722001010500000) tables. If idle speed and/or IAC duty percentage require adjustment, remove idle speed adjusting screw protective cap on throttle body. To adjust idle speed, turn adjusting screw. (Scheme 10)
- When idle speed and IAC duty percentage are within specification and vehicle is equipped with A/C, go to step 5). If vehicle is not equipped with A/C, reinstall idle speed adjusting screw protective cap to throttle body. Remove duty meter from monitor coupler, and rein-stall cap. Remove spare fuse from diagnosis terminal of fuse box.
- Turn A/C on, and set fan switch to LOW position. Check idle speed and IAC duty percentage. If idle speed and/or IAC duty percentage is not within specification, turn A/C VSV adjusting screw to adjust idle. (Scheme 11)
Scheme 9
Scheme 10
Scheme 11
| Application | Idle RPM |
|---|
| Samurai |
| With A/C Off | 750-850 |
| With A/C On | (2) 950-1050 |
| Sidekick |
| With A/C Off | 750-850 |
| With A/C On | (3) 950-1050 |
| Swift |
| DOHC |
| With A/C Off | 800-900 |
| With A/C On | (2) 850-950 |
| SOHC |
| With A/C Off |
| Auto. Transaxle | 800-900 |
| Man. Transaxle | 700-800 |
| With A/C On |
| Auto. Transaxle (4) | (2) 800-900 |
| Man. Transaxle (4) | (2) 700-800 |
| Auto. & Man. Transaxles (5) | 850-950 |
| (1) Transaxle or transmission in Neutral or Park. (2) A/C idle speed is adjusted by rotating adjusting screw on A/C Vacuum Switching Valve (VSV). (3) With auto. transmission in gear, idle RPM is 750-850. (4) When ECM part number ends with "0". (5) When ECM part number ends with number other than "0". |
| (1) | Transaxle or transmission in Neutral or Park. |
| (2) | A/C idle speed is adjusted by rotating adjusting screw on A/C Vacuum Switching Valve (VSV). |
| (3) | With auto. transmission in gear, idle RPM is 750-850. |
| (4) | When ECM part number ends with "0". |
| (5) | When ECM part number ends with number other than "0". |
IDLE SPEED SPECIFICATIONS (1)
| Application | Percent |
|---|
| Samurai & Sidekick | 50 |
| Swift |
| DOHC | 30-40 |
| SOHC (2) | 25-35 |
| (1) See the IDLE SPEED SPECIFICATIONS table. (2) With A/C turned off (if equipped). |
| (1) | See the IDLE SPEED SPECIFICATIONS table. |
| (2) | With A/C turned off (if equipped). |
IAC DUTY AT SPECIFIED IDLE SPEED (1)
Sidekick
- Start engine, and warm it to operating temperature. Turn all accessories off. Ensure all fuel and emission control system wire connectors and hoses are properly connected. Ensure accelerator cable has free play at throttle body. Ensure ignition timing is correct. See «IGNITION TIMING»(ref-25800-S04496394442001010500000) table under IGNITION TIMING. Ensure air cleaner and ducts are properly installed and air filter element is in good condition.
- Connect service wire between terminals "B" (diagnosis switch) and "C" (ground) of monitor coupler. (Scheme 7) Ensure MIL (CHECK ENGINE light) indicates Code 12. Turn engine off, and connect Duty Meter (99963-00006) to monitor coupler duty terminals "A" (output) and "C" (ground). Test connector is located near battery. Connect tachometer.
- Start engine, and warm it to operating temperature. Ensure idle speed and IAC duty percentage are within specification. Refer to the appropriate «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table in this article and/or the «IAC DUTY AT SPECIFIED IDLE SPEED»(ref-25800-S18446941722001010500000) table. If idle speed and/or IAC duty percentage require adjustment, remove idle speed adjusting screw protective cap on throttle body. Turn idle speed adjusting screw to adjust idle to specification. (Scheme 10)
- When idle speed and IAC duty percentage are as specified and vehicle is equipped with A/C, go to next step. If vehicle is not equipped with A/C, reinstall idle speed adjusting screw protective cap to throttle body and remove service jumper wire. Remove duty meter from monitor coupler, and reinstall cap.
- Turn A/C on, and set fan switch to LOW position. Check idle speed and IAC duty percentage with A/C on. If idle speed and IAC duty percentage are not as specified, turn A/C VSV adjusting screw to adjust idle to specification. (Scheme 11)
Note. On Swift, specified values used for this inspection and adjustment vary depending on type of ECM. Type of ECM can be identified by last digit of ECM part number. Last digit will be "0" or a number other than "0".
- Idle speed is controlled by ECM using IAC valve and requires no adjustments under normal conditions. If conditions require idle speed to be adjusted, start engine and warm it to operating temperature. Turn all accessories off. Ensure all fuel and emission control system wire connectors and hoses are properly connected. Ensure accelerator cable has free-play, air cleaner and ducts are properly installed and air filter element is in good condition.
- Ensure ignition timing is correct. See «IGNITION TIMING»(ref-25800-S04496394442001010500000) table under IGNITION TIMING. Connect terminal "B" (diagnosis switch) to terminal "D" (ground) using a service wire. (Scheme 8) MIL (CHECK ENGINE light) should indicate Code 12. Attach duty meter to duty output terminal "F" and ground terminal "D". Remove idle speed adjusting screw cap from side of throttle body, just above throttle lever. Turn idle speed adjusting screw to obtain correct idle speed. Refer to the appropriate «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table and/or the «IAC DUTY AT SPECIFIED IDLE SPEED»(ref-25800-S18446941722001010500000) table. On vehicles without A/C, remove service wire, reinstall protective cap to throttle body and recheck idle speed.
- On vehicles equipped with A/C, turn A/C switch to ON position and set fan switch to HIGH position. (Scheme 12) With A/C operating correctly, verify idle speed is 850-950 RPM. If adjustment is required, turn A/C Vacuum Switching Valve (VSV) adjusting screw as necessary. See «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table. Remove service wire, reinstall protective cap to throttle body and recheck idle speed.
Scheme 12
Swift DOHC
- Idle speed is controlled by IAC valve and should not require adjustment. If idle speed needs to be changed, start engine and warm it to operating temperature. Turn all accessories off. Ensure all fuel and emission control system wire connectors and hoses are properly connected. Ensure accelerator cable has free play. Ensure air cleaner and ducts are properly installed and air filter element is in good condition.
- Ensure ignition timing is correct. See «IGNITION TIMING»(ref-25800-S04496394442001010500000) table under IGNITION TIMING. Connect terminal "B" (diagnosis switch) to terminal "D" (ground) using a service wire. (Scheme 8) MIL (CHECK ENGINE light) should indicate Code 12. Attach duty meter to duty output terminal "F" and ground terminal "D". Remove idle speed adjusting screw protective cap from top of throttle body. (Scheme 12) Turn idle speed adjusting screw to obtain correct idle RPM. Refer to the appropriate «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table in this article and/or the «IAC DUTY AT SPECIFIED IDLE SPEED»(ref-25800-S18446941722001010500000) table.
- On vehicles equipped with A/C, turn A/C switch to ON position and set fan switch to HIGH position. With A/C operating correctly, verify idle is 850-950 RPM and IAC duty is 30-40 percent. If adjustment is required, turn A/C Vacuum Switching Valve (VSV) adjusting screw to obtain correct idle. See «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table. Remove service wire, reinstall protective cap to throttle body and recheck idle speed.
- Ensure throttle cable has 0.4-0.6" (10-15 mm) free play. Hold exposed portion of cable at center and move cable up and down to measure play. Use lock nut and adjusting nut on cable bracket to adjust free play. (Scheme 13)
- If throttle opener rod is pushed back by hand (i.e., throttle valve is at idle position), cable free play should be 0.12-0.20" (3.0-5.0 mm). Use lock nut and adjusting nut on cable bracket to adjust free play.
Scheme 13
Sidekick (MPI)
- With throttle valve closed, accelerator pedal play should be 0.08-0.27" (2.0-7.0 mm). Use lock nut and adjusting nut on cable bracket to adjust free play. (Scheme 14)
- With accelerator pedal depressed fully, check clearance between throttle lever and lever stopper at throttle body. If clearance is not 0.02-0.07" (0.5-2.0 mm), correct by changing height of pedal stopper bolt located under accelerator pedal. After throttle cable adjustment is complete, adjust transmission kickdown cable.
- Check A/T cable free play. (Scheme 14) If clearance is not 0.03-0.06" (0.8-1.5 mm), use lock nut and adjusting nut on cable bracket to adjust free play.
Scheme 14
Sidekick (TBI)
- Ensure cable has 0.4-0.6" (10-15 mm) free play. Hold exposed portion of cable at center and move cable up and down to adjust free play. (Scheme 13)
- After throttle cable adjustment is complete, adjust transmission kickdown cable. Loosen and back off kickdown lock nut and adjusting nut considerably. With accelerator pedal fully depressed, pull on kickdown cable housing to remove cable free play. With free play removed, ensure clearance between kickdown cable bracket and upper lock nut is 0.039" (1.00 mm). Adjust upper lock nut as necessary.
- Holding upper lock nut position on kickdown cable, release accelerator pedal. While holding upper lock nut position, securely tighten lower adjusting nut to bracket.
Ensure cable has.12-.20" (3.0-5.0 mm) free play. Hold exposed portion of cable at center and move cable up and down to measure free play. Use lock nut and adjusting nut on cable bracket to adjust free play. (Scheme 13)
- Ensure transmission is in Park or Neutral and parking brake is set. Start engine, and warm it to operating temperature. Turn all accessories off. Ensure idle speed is within specification. See «IDLE SPEED SPECIFICATIONS»(ref-25800-S41946901632001010500000) table under IDLE SPEED.
- Operate throttle lever to increase and decrease engine RPM while noting RPM at which dashpot rod contacts throttle lever. Adjust the dashpot adjusting screw to specified RPM at which dashpot rod should contact throttle lever. (Scheme 13)and see scheme 13. Also, refer to the «DASHPOT ADJUSTMENT»(ref-25800-S42507781362001010500000) table.
| Application | (1) RPM |
|---|
| Swift DOHC | 3000-3400 |
| (1) Engine speed when throttle lever contacts dashpot rod after deceleration. |
| (1) | Engine speed when throttle lever contacts dashpot rod after deceleration. |
- Ensure transmission is in Neutral or Park. Set parking brake. Turn ignition on for 5 seconds, and then start engine. Run engine at 2000 RPM for 5 minutes to warm it to operating temperature. Return engine to idle speed. Turn all accessories off. Disconnect and plug vacuum hose from throttle opener on throttle body.
- Engine speed should increase to 2150-2250 RPM when vacuum hose is removed from throttle opener. If engine speed is not within specification, adjust by turning throttle opener adjusting screw. (Scheme 15) Reconnect vacuum hose when adjustment is within specification. See «THROTTLE OPENER SPECIFICATIONS»(ref-25800-S29371313612001010500000) table.
- Ensure transmission is in Neutral or Park, and set parking brake. Warm engine to operating temperature. Turn all accessories off. Disconnect and plug vacuum hose from throttle opener on throttle body.
- Engine speed should increase to 2100-2300 RPM when vacuum hose is removed from throttle opener. If engine speed is not within specification, adjust by turning throttle opener adjusting screw. (Scheme 15) Reconnect vacuum hose when adjustment is within specification. See «THROTTLE OPENER SPECIFICATIONS»(ref-25800-S29371313612001010500000) table.
| Application | (1) RPM |
|---|
| Samurai | 2150-2250 |
| Sidekick TBI | 2100-2300 |
| (1) Transaxle or transmission in Neutral or Park with vacuum hose disconnected and plugged at throttle opener. |
| (1) | Transaxle or transmission in Neutral or Park with vacuum hose disconnected and plugged at throttle opener. |
THROTTLE OPENER SPECIFICATIONS
Scheme 15
THROTTLE POSITION SENSOR (TPS)
| Application | Ohms |
|---|
| Samurai |
| Between Terminals "C" & "D" |
| With .008" (.20 mm) Clearance At Stop Screw | 0-550 |
| With .016" (.41 mm) Clearance At Stop Screw | Infinity |
| Between Terminals "A" & "D" | 3500-6500 |
| Between Terminals "B" & "D" |
| At Idle (1) | 0-2000 |
| At Wide Open Throttle | (2) 2000-6500 |
| Sidekick (MPI) |
| Between Terminals "A" & "B" |
| With .020" (.50 mm) Clearance At Stop Screw | 0-500 |
| With .031" (.80 mm) Clearance At Stop Screw | Infinity |
| Between Terminals "A" & "D" | 3500-6500 |
| Between Terminals "A" & "C" |
| At Idle | 300-2000 |
| At Wide Open Throttle | 2000-6500 |
| Sidekick (TBI) |
| Between Terminals "C" & "D" |
| With .012" (.3 mm) Clearance At Stop Screw | 0-500 |
| With .020" (.5 mm) Clearance At Stop Screw | Infinity |
| Between Terminals "A" & "D" | 3500-6500 |
| Between Terminals "B" & "D" |
| At Idle | (1) 300-2000 |
| At Wide Open Throttle | (2) 2000-6500 |
| Swift (DOHC) |
| Between Terminals "C" & "D" |
| With .012" (.30 mm) Clearance At Stop Screw | 0-500 |
| With .035" (.89 mm) Clearance At Stop Screw | Infinity |
| Between Terminals "C" & "A" | 3500-6500 |
| Between Terminals "C" & "B" |
| At Idle | 0-2000 |
| At Wide Open Throttle | 3500-6500 |
| Swift (SOHC) |
| Between Terminals "A" & "B" |
| With .012" (.30 mm) Clearance At Stop Screw | Less Than 5000 |
| With .035" (.89 mm) Clearance At Stop Screw | Infinity |
| Between Terminals "A" & "D" | 4370-8130 |
| Between Terminals "A" & "C" |
| At Idle | 240-1140 |
| At Wide Open Throttle | 3170-6600 |
| (1) To obtain idle position, apply 19 in. Hg vacuum to throttle opener. (2) There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
| (1) | To obtain idle position, apply 19 in. Hg vacuum to throttle opener. |
| (2) | There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
THROTTLE POSITION SENSOR (TPS) RESISTANCE
| CAUTION | DO NOT rotate Samurai throttle stop screw to adjust idle. Throttle stop screw is factory-set, and is used as zero reference point for all other adjustments. |
POWER STEERING VSV
Disconnect VSV connector, and check resistance between terminals. If resistance is not 33-39 ohms, replace VSV. If resistance is 33-39 ohms, disconnect vacuum hoses from 3-way joints. Blow into top hose. Air should not come out of other hose. With 12 volts and ground applied to terminals, blow into top hose. Air should pass through hoses. If results are not as described, replace VSV.
