VALVE CLEARANCE
| Application | Engine Cold: In. (mm) | Engine Hot: In. (mm) |
|---|
| Samurai & Sidekick (TBI) |
| Intake | .005-.007 (.13-.18) | .009-.011 (.23-.28) |
| Exhaust | .006-.008 (.15-.20) | .010-.012 (.25-.30) |
| Sidekick (MPI) |
| Intake & Exhaust | .003-.005 (.08-.12) | .005-.006 (.12-.16) |
| Swift SOHC |
| Intake | .005-.007 (.13-.18) | .009-.011 (.23-.28) |
| Exhaust | .006-.008 (.15-.20) | .010-.012 (.25-.30) |
| 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
VALVE ARRANGEMENT
Note. Right and left sides refer to engine, as viewed from flywheel.
Right Side
Left Side
IGNITION COIL
| Application | Primary | Secondary |
|---|
| Samurai | .90-1.10 | 10,200-13,800 |
| Sidekick | .72-.88 | 10,200-14,000 |
| Swift |
| DOHC | .72-.88 | 10,200-14,000 |
| SOHC | 1.13-1.38 | 11,500-15,500 |
IGNITION COIL RESISTANCE - Ohms @ 68°F (20°C)
DISTRIBUTOR SENSORS
| 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. |
| Application | Ohms |
|---|
| Samurai | (1) |
| Sidekick | (1) |
| Swift |
| DOHC (2) | 588-882 |
| SOHC | 140-180 |
| (1) Information is not available from manufacturer. (2) Also referred to as crank angle sensor. |
| (1) | Information is not available from manufacturer. |
| (2) | Also referred to as crank angle sensor. |
PICK-UP COIL RESISTANCE - Ohms @ 68°F (20°C)
HIGH TENSION WIRE RESISTANCE
| Application | Ohms |
|---|
| Samurai, Swift & Sidekick | 3000-6700 Per Foot |
HIGH TENSION WIRE RESISTANCE
SPARK PLUGS
| Application | Nippondenso | NGK |
|---|
| Samurai | W20EPR-U | BPR5ES |
| Sidekick |
| TBI | W16EXR-U | BPR5ES |
| MPI | K20PR-U | BKR6E |
| Swift |
| DOHC | W20EPR-U | BPR6ES |
| SOHC | W20EPR-U11 | BPR6ES-11 |
| Application | Gap: In. (mm) | Torque: Ft. Lbs. (N.m) |
|---|
| Samurai | .027-.031 (.69-.79) | 18-22 (24-30) |
| Sidekick | .027-.031 (.69-.79) | 15-22 (20-30) |
| Swift |
| DOHC | .027-.031 (.69-.79) | 18-22 (24-30) |
| SOHC | .039-.043 (.99-1.09) | 18-22 (24-30) |
SPARK PLUG SPECIFICATIONS
Firing Order & Distributor Rotation (Samurai & Sidekick). Scheme 1
Scheme 1: Firing Order & Distributor Rotation (Samurai & Sidekick)
Firing Order & Distributor Rotation (Swift). Scheme 2
Scheme 2: Firing Order & Distributor Rotation (Swift)
IGNITION TIMING
| 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 3)for timing mark location. (2) With jumper wire installed between "C" and "D" terminals of test connector, located near battery. (3) With jumper wire installed between "D" and "E" terminals of test connector, located near ignition coil. |
| (2) | With jumper wire installed between "C" and "D" terminals of test connector, located near battery. |
| (3) | With jumper wire installed between "D" and "E" terminals of test connector, located near ignition coil. |
IGNITION TIMING (Degrees BTDC @ RPM) (1)
Note. Ensure ignition timing advances as engine speed increases.
Scheme 3
FUEL PUMP
Note. Fuel pump performance is a measurement of fuel pressure availability, not regulated pressure.
| Application | (1) psi (kg/cm 2 ) |
|---|
| Samurai & Sidekick (TBI) | (2) 34.1-39.8 (2.4-2.8) |
| Sidekick (MPI) | (3) 35.6-42.7 (2.5-3.0) |
| Swift |
| DOHC | (3) 35.5-38.4 (2.5-2.7) |
| SOHC | (4) 22.7-29.9 (1.6-2.1) |
| (1) Key on and engine off. (2) Pressure should maintain at least 21.3 psi (1.5 kg/cm 2 ) for one minute after fuel pump is turned off. (3) Pressure should maintain at least 25.6 psi (1.8 kg/cm 2 ) for one minute after fuel pump is turned off. (4) Pressure should maintain at least 12.8 psi (.9 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (1) | Key on and engine off. |
| (2) | Pressure should maintain at least 21.3 psi (1.5 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (3) | Pressure should maintain at least 25.6 psi (1.8 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (4) | Pressure should maintain at least 12.8 psi (.9 kg/cm 2 ) for one minute after fuel pump is turned off. |
| Application | Psi (kg/cm 2 ) |
|---|
| Samurai | (1) (2) 24.2-29.9 (1.7-2.1) |
| Sidekick |
| MPI | (1) (3) 29.8-37.0 (2.1-2.6) |
| TBI | (2) (4) 34.1-39.8 (2.4-2.8) |
| Swift |
| DOHC | (1) (3) 25.6-29.9 (1.8-2.1) |
| SOHC | (1) (5) 12.8-20.0 (.9-1.4) |
| (1) Engine idling. (2) Pressure should maintain at least 21.3 psi (1.5 kg/cm 2 ) for one minute after fuel pump is turned off. (3) Pressure should maintain at least 25.6 psi (1.8 kg/cm 2 ) for one minute after fuel pump is turned off. (4) Key on and engine off. (5) Pressure should maintain at least 12.8 psi (.9 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (2) | Pressure should maintain at least 21.3 psi (1.5 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (3) | Pressure should maintain at least 25.6 psi (1.8 kg/cm 2 ) for one minute after fuel pump is turned off. |
| (4) | Key on and engine off. |
| (5) | Pressure should maintain at least 12.8 psi (.9 kg/cm 2 ) for one minute after fuel pump is turned off. |
INJECTOR RESISTANCE
| Application | Ohms |
|---|
| Samurai | .8-1.8 |
| Sidekick |
| MPI | 12.0-17.0 |
| TBI | .8-1.8 |
| Swift |
| DOHC | 1.5-2.2 |
| SOHC | .5-1.5 |
INJECTOR RESISTANCE SPECIFICATIONS
IAC DUTY AT SPECIFIED IDLE SPEED
| Application | Percent |
|---|
| Samurai & Sidekick | 50 |
| Swift |
| DOHC | 30-40 |
| SOHC (2) | 25-35 |
| (1) See appropriate IDLE SPEED SPECIFICATIONS table. (2) With A/C turned off (if equipped). |
| (1) | See appropriate IDLE SPEED SPECIFICATIONS table. |
| (2) | With A/C turned off (if equipped). |
IAC DUTY AT SPECIFIED IDLE SPEED (1)
THROTTLE OPENER
| 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
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SAMURAI
| Application | Ohms |
|---|
| 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 (2) | 0-2000 |
| At Wide Open Throttle | (3) 2000-6500 |
| (1) (Scheme 4)for terminal identification. (2) To obtain idle position, apply 19 in. Hg vacuum to throttle opener. (3) There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
| (2) | To obtain idle position, apply 19 in. Hg vacuum to throttle opener. |
| (3) | There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SAMURAI (1)
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SIDEKICK MPI
| Application | Ohms |
|---|
| 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 | (2) 2000-6500 |
| (1) (Scheme 5)for terminal identification. (2) There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
| (2) | There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SIDEKICK MPI (1)
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SIDEKICK TBI
| Application | Ohms |
|---|
| 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 | (2) 300-2000 |
| At Wide Open Throttle | (3) 2000-6500 |
| (1) (Scheme 4)for terminal identification. (2) To obtain idle position, apply 19 in. Hg vacuum to throttle opener. (3) There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
| (2) | To obtain idle position, apply 19 in. Hg vacuum to throttle opener. |
| (3) | There should be more than 2000 ohms difference between idle and wide open throttle resistance. |
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SIDEKICK TBI (1)
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SWIFT SOHC
| Application | Ohms |
|---|
| 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) (Scheme 5)for terminal identification. |
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SWIFT SOHC (1)
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SWIFT DOHC
| Application | Ohms |
|---|
| 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 |
| (1) (Scheme 6)for terminal identification. |
THROTTLE POSITION SENSOR (TPS) RESISTANCE - SWIFT DOHC (1)
Scheme 4
Scheme 4: Throttle Position Sensor Terminal ID (Samurai & Sidekick TBI)
Scheme 5
Scheme 5: Throttle Position Sensor Terminal ID (Sidekick MPI & Swift SOHC)
Scheme 6
Scheme 6: Throttle Position Sensor Terminal ID (Swift DOHC)
