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Datsun 1980 200SX, Service Manual

The Datsun 1980 200SX Service Manual is an essential resource for owners and enthusiasts of this classic car. This comprehensive manual provides step-by-step instructions, diagrams, and specifications for maintaining, repairing, and servicing the vehicle. Download your free copy today from manualshive.com and keep your 200SX running smoothly.

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Summary of Contents for 1980 200SX

Page 1: ...v IDATSUNI 0 o 1980 DATSUN 200SX rl1 SERVICE MANUAL A J i I I h t fi t i t i CI o IIV INI55ANI HlUM lOco ...

Page 2: ...mation illustrations and specifica tions contained in this manual are based on the latest product information available at the time of publication If your DATSUN model differs from the specifications con tained in this manual consult your NISSANI DATSUN dealer for information CLUTCH C MANUAL TRANSMISSION M AUTOMATIC TRANSMISSION A PROPELLER SHAFT DIFFERENTIAL CARRIER P FRONT AXlE FRONT SUSPENSION ...

Page 3: ...uga Ontario Canada L5A 3P2 The measurements given in this manual are primarily expressed with the Sl unit International System of Unit and alternately expressed in the metric system and in the yard pound system The back cover of the manual provides maintenance data for quick reference In the text the following abbreviations are used s o s Service Data nd Specifications L H R H left Hand Right Hand...

Page 4: ...TION CONTENTS GENERAL VIE WS MODEL VARIATION IDENTIFICATION NUMBER LIFTING POINTS AND TOWING PANTOGRAPH JACK GARAGE JACK AND SAFETY STAND GI 2 GI 3 GI 4 GI 5 GI 5 GI 5 TIE DOWN TOWING SPECIAL SERVICE TOOLS TIGHTENING TORQUE OF STANDARD BOLT GI 5 GI 5 GI 6 GI 6 ...

Page 5: ... LI 345 53 O J 1 680 66 1 Unit mm in Hatchback t c iq L1 345 53 0 1 680 66 1 Unit mm in GI 2 GENERAL VIEWS J c f 1 11 I I r L 1 m 41 f 1 1 g t I ll t X 990 39 0 2 400 94 5 1 090 42 9 480 176 4 SGIOO2 fT d r Ii r bt I I J I t iL L J J I I J J r 1 t uJJ Il IY 1 T 2 400 94 5 t 090 42 9 4 480 t 76 4 990 39 0 5GI003 ...

Page 6: ...70 SR14 Hatchback Non I KPLSIIOAEU I 3N71B California I PLSllOFEN I FS5W71B Hardtop I I 2 PLSllOAEN 3N71B 4 T x 16 35 T135 Canada I KPLSllOFEN I FS5W7IB 1 38 70D16 2 Hatchback I KPLSllOAEN I 3N71B Prefix and suffix designations K o P L Hatchback I Hardtop J Z20 engine Left hand drive K P L SIlO J I 0 PST LT 0 means no indication I Aluminum wheel Option 2 Spare tire Sun roof Glass Sport Luxury mode...

Page 7: ...cylinder block I Q SGIOO6 GI 4 IDENTIFICATION NUMBER EMISSION CONTROL INFORMATION LABEL K P SlID r x X X X X X I MANUAL TRANSMISSION NUMBER The transmission seria number is stamped on the front upper face of the transmission case TM235 SGI004 Car serial number AUTOMATIC TRANSMISSION NUMBER The transmission serial number plate is attached on the right hand side of the transmission case AT344 ...

Page 8: ...the position indicated below in a safe manner TIE DOWN FRONT SIDE Use front towing hooks for tie down REAR SIDE Use rear towing hooks for tie down TOWING CAUTION a It is necessary to use proper towing equipment to avoid possible dam age to the car during a towing operation Towing is in accordance with Tow ing Procedure Manual at dealer side Towing hook 7 r J II 1I 6 Towing hook SG 1007 b All appli...

Page 9: ...MI4 1 Special pam are excluded 2 This standard is applicable to bolu having the following marks embossed on the bolt head Grade Mark 4T 7T 9T GI 6 Bolt or nut diam eter mm Pitch mm 6 0 10 1 25 10 15 1 25 175 1 25 1 5 10 1 25 10 1 5 1 25 175 125 1 5 10 1 25 10 15 125 1 75 1 25 15 8 0 10 0 12 0 14 0 6 0 8 0 10 0 12 0 14 0 6 0 8 0 10 0 12 0 14 0 Nominal diameter 4 7 9 M6 TT Tightening torque N m kg m...

Page 10: ... AND APPROXIMATE REFILL REAR SUSPENSION MA 27 CAPACITIES MA 5 BRAKE SYSTEM MA 28 ENGINE MAINTENANCE MA 6 WHEEL AND TIRE fVlA 29 BASIC MECHANICAL SYSTEM MA 6 STEERING SYSTEM MA 33 IGNITION AND FUEL SYSTEM MA 9 BODY MA 35 EMISSION CONTROL SYSTEM MA 14 HEATER AND AIR CONDITIONER MA 36 MINOR TROUBLE DIAGNOSES SERVICE DATA AND AND CORRECTIONS MA 15 SPECIFICATIONS MA 39 CHASSIS AND BODY ENGINE MAINTENAN...

Page 11: ...erated under extreme adverse weather conditions or in ar s where ambient temperaturas are either extremely low or extremely high the filter might become clogged In such an event replace the filt immmiatefy D an are the maintenance intervals required by California Regulations limits the warranty COYIIto these re placement InterYals and R the uired mainUNInce intervals Other maintenance items and in...

Page 12: ...and clean every 12 months OUTSIDE AND INSIDE MAINTENANCE Rotate wheel position nspect wheel balance wheel alignment MA 26 30 32 y J Disc brake pads other brake components for wear deterioration leaks See NOTE 111 MA 28 Front wheel bearing MA 25 Locks hinges hood latch Seat betts buckles retractors anchors adjuster Foot brake parking brake clutch forstroke free play operation See NOTE 11 L L L MA 3...

Page 13: ... 30 000 miles or 24 onth whichever cornel fll lt If the vehicle i operated under extreme adverse wheather conditon or in erel l where ambient temperature lIre either extremely low or extreme IV high the filter might become cloggltd In such an event replICe the filter Immediatelv BATTERY ELECTROLYTE WINDSHIELD AND REAR WINDOW WASHER FLUID FUEL FILTER POWER STEERING GEAR OIL OILFILTER ENGINEOIL MANU...

Page 14: ...C11lllllll101 11 F T Jl Nut O Ch Differential API GL 5 Automatic T M and power steering fluid Type DEXRON Multi purpose grease NLGI No 2 lithium soap base Brake and clutch fluid DOT 3 US FMVSS No 116 APPROXIMATE REFILL CAPACITIES liter us measure Imp measure Fuel tank Hardtop 53 14gal II 5 8 gal Hatchback 60 15 7 8 gal 13 1 4 gal Coolant With heater 9 5 IOqt 8 3 8 qt Without heater 8 8 9 1 4qt 7 3...

Page 15: ...sure clear ance between valve stem end and rocker arm screw Feeler gauge should move with a very slight drag 8M AQSO 2 If the clearance is not within spec ified value loosen rocker arm nut and turn rocker ann screw to provide pro per clearance 3 Hold rocker arm screw and tighten rocker arm nut SMA051 dl Rocker arm nut 16 22 N m 1 6 2 2 kg m 12 16 ft b 4 Recheck clearance 4 Turn crankshaft and set ...

Page 16: ...ENANCE Engine Maintenance Alternator t ilJ J Idler puUey LoCk nut Adjust Loosen Compressor pulley Crank pulley Idler pulley Adjusting bolt Adjust 8MA053 CHANGING ENGINE OIL AND OIL FILTER 1 Start engine and warm up engine until water temperature indicator points to the middle of gauge then stop engine 2 Remove oil pan drain plug and oil fiUer cap and allow oil to drain A milky oil indicates the pr...

Page 17: ...3 CHANGING ENGINE COOLANT WARNING To BVoid the danger of being scalded never attempt to change the coolant when the engine is hot When changing engine coolant on heater equipped model set heater TEMP control lever at fully HOT position I Open drain cock at bottom of radiator and remove radiator cap r l ild 1xrC rl 1 rli I v t III 1 4 il I I ll LOOSEN CS015 2 Remove cylinder block drain plug locate...

Page 18: ...d surface Oil and water in combustion cham bers can result from this problem IGNITION AND FUEL SYSTEM REPLACING SPARK PLUGS I Disconnect spark plug wire at boot Do not pull o the wires O K N G SMAO 1 7 2 Remove spark plugs with spark plug wrench 3 Using feeler gauge check new spark plug gap If it is not within specified range set gap by bending side ele trode Side electrode if Gap 08 0 9 mm 10 03t...

Page 19: ...gine at about 2 000 rpm for abou 2 undet no load WARNING a WIlen selector lever is shifted to 0 position apply parking brake and block both front and reanvheels with chocks b When racing engine on auto matic transmission equipped modelsimake sure that shift lever is in N or P position and depress brake pedal to pre vent forward SUI 8of car c After tha adjustment has been made shift thelever to the...

Page 20: ...rigine two or three times under 00 I load then run engine at idlespeed Check CO with CO meter 1 3 t 1 O K I Turn off engine and connect air induction rhose to air induction pipe i Start engine Race engine two or three times under no load then run engine at idle speed I Check idle speed M nu 1 Transmission 700 t 100 rpm Automatic Tr nsmission 7 1 100 rpm in 0 position O K I N G END MAINTENANCE Engi...

Page 21: ...ne on auto matic transmission equipped models make sure that shift lever is in N or P position and depress brake pedal to pre vent forward surge of car c After the adjlUtrDent has been made shift the lever to the N or P position and remove wheel chockS START 1 Start engine and warm up engine until water temperature indicatQf points to the middle of gauge j Open engine hood Run engine about 2 000 r...

Page 22: ... should be replaced as an assembly I Follow the procedure below to re duce fuel pressure to zero CAUTION Before disconnecting fuel hose release fuel pressure from fuel line to elimi nate danger I Start the engine MAINTENANCE Engine Maintenance Fuel return pipe l To fuel tan rbm f el tank rFue pipe Fuel damper t Fuel pump r Fuel pipe l tr btor J J Jf 1j Injector W W W J Fuel hose clamps 1 0 1 5N m ...

Page 23: ...ir induction valve case from air cleaner and take out air in duction valve fIlter Then instaIl new air induction valve filter When replacing pay strict attention to which direction the valve i facing so that exhaust gas will not flow back ward J 1 CHECKING VAPOR LINES Check all hoses and fuel tank filler cap for leaks I Dsiconnect the vapor vent line connecting carbon canister to fuel tank 2 Conne...

Page 24: ...ND CORRECTIONS Condition Probable cause CANNOT CRANK ENGINE OR SLOW CRANKING Improper grade oil Partially discharged battery Malfunctioning battery Loose fan belt Trouble in charging system Wiring connection trouble in starting circuit Malfunctioning ignition switch Malfunctioning starting motor Corrective action Replace with proper grade oil Charge battery Replace Adjust Inspect Correct Repair or...

Page 25: ... Inspect primary circuit for short Check distributorpick up coil operation Check IC ignition system No spark occurs Low or no cunenL Malfunctioning distributorpick up coil Improper air gap Leak at rotor cap and rotor Malfunctiflning spark plug Improper ignition timing Malfunctioning ignition coil Disconnection of high tension cable Loose connection or disconnection 41 primary circuit Irregnlar rev...

Page 26: ...compression Compression increases Compression does not change Malfunctioning ignition system spark plug high tension cable distributor IC ignition unit ignition coil etc Incorrect basic ignition timing Loose manifold and cylinder head bolts Incorrect valve clearance Clogged air cleaner f1lter Incorrect idle adjustment Damaged manifold gaskets Intake air leakage at following points Dipstick Oil fil...

Page 27: ...ctioning distributor pick up coil Throttle valve does not open fully Damaged electronic fuel injection harness Seized injector Usten to operating sound Malfunctioning air flow meter Malfunctioning throttle valve switch Irregular fuel pressure Clogged fuel pipe Dirty or clogged fuel ftIter Fuel pwnp will not work properly Corrective action Replace Replace Replace For inspection procedures for elect...

Page 28: ... Malfunctioning E G R control system Overloaded engine Carbon knocking Timing knocking Fuel knocking Preignition misusing of spark plug This strong dull noise increases when engine is accelerated To locate the place cause a misfire on each cylinder If the noise stops by the misfire this cylinder generates the noise Corrective action Replace filter Replace gasket Repair or replace Replenish Adjust ...

Page 29: ...liding parts An improper adjustment of valve clearance Noiseoftinringchmn An excessive end play on crankshaft Wear on clutch pilot bushing This noise will be heard when clutch is disengaged Improper ignition tinring Improper heat range ofspark plugs Intake air leakage at following points Dipstick Oil f1l1er cap Blow by hoses Intake air duct air flow meter to throttle chamber etc Damaged electronic...

Page 30: ...idling revolution Fuel leakage from fuel line Damaged electronic fuel injection harness Damaged control unit Malfunctioning air flow meter Damaged air temperature sensor Malfunctioning throttle valve switch Irregular fuel pressure Corrective action Adjust Remove head and get rid of carbon Replace it with a new one Correct or replace Tighten it Renew gasket or tighten it Renew gaskei or tighten it ...

Page 31: ...ation of oil Air leakage from air intake duct Damaged air cleaner Overheat or overcoat Improper fuel mixture Decrease ofoil pressure Insufficient clearances Overheat Improper fuel mixture Corrective action Use the designated oil Previously mentioned Disassemble oil pump and repair or renew it Repair or replace it with a new ne Renew it Disassemble and replace the worn parts with new ones Clean it ...

Page 32: ...fl7 8 11 8 10 8 1 2 5 8 8 71 A fl N m kg m ft lb SMA102 Pedal height H 168 174 mm 6 61 6 85 in Padal free play A J 5 mm 0 04 020 in I Adjust pedal height with pedal stopper Then tighten lock nut 2 Adjust pedal free play with master cylinder push rod Then tighten lock nut 8 Pedal free play means the following total measured at position of pedal pad Play due to clevis pin and clevis pin hole in peda...

Page 33: ... transmission If fluid is very dark or smells burned the frictional material clutches band etc may need reo placemen t Oleck fluid for contamination I Check fluid for smell SMA107 PROPELI ER SHAFT AND DIFFERENTIAL CAR IER CHECKING PROPELLER SHAFT Check propeller shaft replace if necessary Oteek tube surfaces fOJ denu or cracks SMA231 Oleck tightening torque CHECKING DIFFEREN11AL CARRIER OIL LEVEL ...

Page 34: ... BR 8 Check wheel bearing If there is any axial end play or if wheel bearing does not smoothly turn adjust bearing to specifications Replace worn or damaged bearings Refer to Front Axle Section FA SMAllS ADjUSTING WHEEL BEARING PRELOAD After wheel bearing has been reo placed or front axle has been reo assembled be sure to adjust wheel bearing preload as described below I Before adjustment thorough...

Page 35: ...each front axle and suspen sion pam Measure car height when not loaded Repair or replace the damaged por tion or parts Camber caster and kingopln inclination Camber caster and king pin inclina tion are preset at the factory and can not be adjusted If camber caster or king pin in clination alignment is not within speci fications check pertinent parts Repair or replace as necessary Camber 40 50 Cast...

Page 36: ...n ng radius gauge properly MAINTENANCE Chassis and Body Maintenance 2 Remove stopper pin of turning radius gauge and then fully rotate steering wheel to the right and left measure turning angle on inner wheel and make necessary adjustments FA632 Front wheel turning angle Toe ut turns When inner wheel 200 Outer wheel 18 70 Full turns On power steering mo dels wheel turning force at cir cumference o...

Page 37: ...RAKE BOOSTER VACUUM HOSES coNNECTIONS AND CHECK VALVE 1 Check condition of vacuum hoses and connections 2 Check vacuum hoses and check valve for air tightness SMA125 CHECKING BRAKE SYSTEM I Check brake system fr proper attachment leaks chafmg abrasion deterioration etc SMA133 CHECKING DISC BRAKE I Check condition of disc brake components beck pads for wear SMA134 Oteck caliper operation and X insp...

Page 38: ...7 8 SMA142 2 Use adjuster to adjust lever stroke I Lock fiU t SMA143 3 Bend parking brake warning lamp switch plate down so that brake warn ing light comes on when ratchet at parking brake lever is moved back one notch and goes out when returned to its original positi on WHEEL AND TIRE CHECKING TIRE CONDITION Tire condition 1 Tires are provided with tread wear indicator at six places around tire c...

Page 39: ...ccordingly to equaliZe tire wear it is necessary to rot8te tires periodh cally Radial tires Right front Right rear c c l c l c l Left front Left rear 4 WHEELS SMA126 TIRE REPLACEMENT CAUTION Different types of tires Rich es bias bias belted and radial tirl S murt not be mixed under any cinumstances Mind use of different types of tiies can adversely affect car handling and may cause driver to lose ...

Page 40: ...ons Precautions whenuslng T type spa tire Pe iodicallycheck tire inflation pres sure and always keep it at 60 psi 412 kPa Do not drive car at speed faster than 80 km h 50 MPH The T type spare tire is designed only fpr tempora ry use as a spare Dismount it and keep it as a spare as soon as the standard tire repair has been completed Do not enter into an automatic car wash with the T type spare tire...

Page 41: ...einflate it If the tira is overinflated the bead might break possibly resulting in serious plr sunal injury WHEEL INSPEcnON Inspect wheel taking care of the following points in order to ensure satisfactory steering condition as well as maximum tire life If any defect is present repair or replace as necess uy I Check wheel rim especially rim flange and bead seat for rust distor tion cracks or other...

Page 42: ...himmy SMA075 a Be sur to place correct balance weights on inner edge of rim b Do not put more than two weights on each side c Two type 6f balance weight are used one is designed for use with steel wheel and tha other for u e with aluminum wheel Do not mix different types of balance weights d Properly rebalance the wheel and ti e whenever puncture is repaired STEERING SYSTEM CHECKING STEERING GEAR ...

Page 43: ...r looseness wear or damage Retighten if neccessary Refer to Section ST for tightening torque Steerlna Ilnkeae Check parts for looseness wear or damag Retighten if necessary Refer to Section ST for tightening torque Check ball joints and idler arm for grease leakage Check for any missing parts cotter pins washer etc SMA190 Q Ch ck grease leakage Check tightening torque MA 34 SMA145 ...

Page 44: ...assis and Body Maintenance BODY LUBRICATING LOCKS HINGES AND HOOD LATCH Lubrication points TlI i c SMA191 CHECKING SEAT BELTS BUCKLES RETRACTORS ANCHORS AND ADJUSTER O1eck retractors for smooth operation SMA232 MA 35 ...

Page 45: ... to the ight glass Be u to chock MA 36 Insufficient High pressure side is warm and low pressure side is fairly cold The bubbles are seen at intervals of 1 2 seconds n r I AC257 Both press re on high and tow pressure sides are slightly low Check fot gas leakage repaiI a lequited re plenish and charge system the amount when it exceeds 2DoC 68DF In higher temperatura the bubble ara easy to show up b ...

Page 46: ...rvice operations which are accompanied by disassembly or loosening of connection fittings MoIJor check point I Compressor Compressor shaft seal rotate the compressor by hand Flexible hose connections Front and rear head gaskets Service valve 2 Condenser Condenser pipe fitting Condenser inlet and outlet pipe connections 3 Refrigerant lines Flared section of high pressure and low pressure flexible h...

Page 47: ...ow the check point If eny trace of oil i noted at and around connection fittings it is a sure indication that refrigerant is le king Ifa gas leak is detecteil proceed as follows I Check torque on the connection fitting and if too loose tighten to the proper torque Oieck for gas leakage with a leak detector 2 If leakage continues even after the fitting has been retightened dis charge refrigerant fr...

Page 48: ...els I ManuOl tran mission 8 t 20 B T D C 60 B T D C I 700 l 100 700 l 100 I Automatic tran mission 8 l 20 B T D C 60 B T O C I lin 0 position I 700 tOO 700 tOO 1 3i t Idle mixture screw CO at idling speed is preset and No air sealed at factory Emission control system Unit kPa mmH20 inH201 Vapor line leakage es Supplied pressure 3 923 400 15 751 Pressure variation Less than 0 245 25 0 981 TIGHTENIN...

Page 49: ...e prlSlure should be checked when tires are COLD Wheel rim lateral and radial mm in runout LeCs than 1 0 0 039 05 10 020 02 Difference between right end left lateral runout Less than 0 5 0 020 1 0 2 10 008 2 mm in Wheel balance Maximum allowable unbelance at im flange gr ozl to 10 35 Tire balancing weight 10 60 10 35 2 121 Spac ng to 10 351 gr loz 1 Steet wheel 2 Aluminum wheel TIGHTENING TORQUE U...

Page 50: ... CYLINDER BLOCK PISTON PISTON PIN AND PISTON RING EM 2 EM 3 EM 4 EM 4 EM 4 EM 6 EM 6 EM 6 EM 7 EM 7 EM 8 EM 8 EM 8 EM 8 EM 9 EM lO CONNECTING ROD CRANKSHAFT MAIN BEARING AND CONNECTING ROD BEARING MISCELLANEOUS COMPONENTS ENGINE ASSEMBLY PRECAUTIONS ASSEMBLING CYLINDER HEAD ASSEMBLING PISTON AND CONNECTING ROD ASSEMBLING INTAKE MANIFOLD ASSEMBLING ENGINE OVERALL SERVICE DATA AND SPECIFICATIONS INS...

Page 51: ... coble 1 l Intake manifold st y I l34 44 3 5 4 5 25 33 E A tube E G R ValVe Exhaust manifold 1 l16 21 iti6 2 t Starter motor 1 l16 21 16 2 1 t2 t5 Intake manifold 157 12 16 87 116 Alternator adjusting bar Fan belt J 29 39 3 0 4 0 22 P C V valve Oil pump J N m tg m ft lb 1 5 8 11 SEM136 EM 2 ...

Page 52: ...embly Exhaust tntake 9 Vatve cotter eam shaft Spring retainer Rubber e 1 Oil seal plug Spring seat j snap ring Valve gUide Cylinder head bolt If 69 18 Valve at 1 0 8 0 51 58 Cylinder head Camshalt sprocket Cylinder liner Only for service Cylinder block t51 t6 116 Drive plate 151 16 116 Oil drain plug If 20 29 2 0 3 0 14 22 If N m kg m ft lb EM137 EM 3 ...

Page 53: ...cuum tube assembly for distribu tot and canister EM4 ENGINE DISASSEMBLY Crankshaft pulley Use suitable tool on air conditioner equipped model SEMl39 5 Remove engine left side parts Distributor cap and high tension cables Distributor Exhaust manifold with air in duction tubes after removing E G R tube SEM140 Compressor brac ret ifequipped Oil level gauge Engine mounting bracket Spark plugs 6 Remove...

Page 54: ...n guide 4 0 il thrower 5 Oil PUJlP drive gear 6 Crankshaft sprocket If it is hard to extract crankshaft sprocket use a suitable puller EM286 12 Remove piston and connecting rod assembly I Remove connecting rod bearing cap with bearing 2 Push out piston with connecting rod toward cylinder head side J1c l J C j I r G 0 II OEJ S7 8 Piston can be easily removed by scraJiing carbon off top face of cyli...

Page 55: ...ng parts using Too ST12070000 Keep the disassembled parts in order DISASSEMBLING INTAKE MANIFOLD 1 Remove following fuel system parts referring to Section EF I Throttle chamber 2 Air regulator 3 Fuel and vacuum tube assembly 4 Fuel pressure regulator 5 Injectors 6 Throttle control cable bracket 2 Remove cooling system parts 1 Water outlet 2 Thermostat 3 Water gallery 4 Water outlet 5 Semol housing...

Page 56: ...eter from valve guide bore to obtain the stem to guide clear ance Stem to guide clearance limit 0 1 mm 10 004 in 2 Expedient method Pry valve in lateral direction and measure deflection at stem end with dial gauge Stem end deflection limit 0 2 mm 0 008 in Valve should be moved in parallel with rocker arm Generally a large amount of wear occurs in this direC tion SEM151 Replacement of valve guide 1...

Page 57: ... valve seat EM 8 VALVE I Check each of the intake and exhaust valve for worn damaged or defonned valve head or stem Correct or replace the valve that is faulty Refer to S os 2 Valve face or valve stem end sur face should betefaced by using a valve grinder Valve head margin Limit 0 5 mm 10 020 inl Grinding of valve stem end Limit 0 5 mm 10 020 in EM111 vALVE SPRING 1 Check valve spring for squarene...

Page 58: ...mit A B 0 2 mm 0 008 in 3 Using a bore gauge measure cylin der bore for wear out of round or taper If those are excessive rebore the cylinder walls by means of a boring machine Measurement should be taken along bores for taper and around bores for out of round Refer to S O S Out of round X y Taper A B FA J 1 zU 0 791 I IiIL 60 12 361 III I flit 17 X I Unit mm in EM422 L I EM124 4 When wear taper o...

Page 59: ...n and cylinder be heated to 200C 680F EM 10 I l t J l l EM641 PISTON PISTON PIN AND PISTON RING PISTON I Scrape carbon off piston and ring grooves with a carbon scraper and a curved steel wire The wire will be useful in cleaning bottom land of ring groove Oean out oil slots in bottom land of oil ring groove 2 Check for damage scratches and wear Replace if such a fault is de tected PISTON RING I Me...

Page 60: ... of round Measurement should be taken along journals for taper and around journals for out of round Ifout of round or taper exceeds the specified limit replace or repair Out of round X Y limit 0 03 mm 0 0012 in Taper A BI Limit 0 03 mm 0 0012 in I A B EPEM767 3 After regrinding crankshaft finish it to the necessary size indicated in the chart under S D S by using an adequate undersize bearing acco...

Page 61: ...nce Limit 0 12 0 0047 in 3 If clearance exceeds the specified value replace bearing with an under size bearing and grind crankshaft journal adequately Refer to S D S CONNECTING ROD BEARING I Measure connecting rod bearing clearance in the same manner as above rJJ Connecting rod bearing cap nut 44 54 N m 14 5 5 5 kg m 33 40 ft lb Connecting rod bearing dearance Limit 0 12 mm 0 0047 in 2 If clearanc...

Page 62: ...y ReplaC8 ring gear at about 180 to 2200C 356 to 4280F FRONT AND REAR OIL SEAL Check front and rear oil seals for worn or folded over sealing lip or oil leakage If necessary replace with a new seal When installing a new seal pay attention to its mounting direc tion It is good practice to renew oil seal whenever engine is overhauled Front l F 1 Front L EM150 Rear EM 13 ...

Page 63: ... d Apply sealant at these points EM152 4 Front and rear side of cylinder head Mating surfaces with rubber plug Apply sealant SEMl58 ASSEMBUNG CYLINDER HEAD I Install valve and valve spring I Set valve spring inner and outer seat and valve oil seal 2 Install valve valve spring inner and outerJ valve spring retainer Com press springs and fit valve spring collets by using Tool Oil seal Inner spring t...

Page 64: ... tight en to the specified torque lil Rocker shaft bracket bolt 15 25 N m 1 5 2 5 kg m 11 18 ft lb a Tighten bolts gradually in two to three stages outwardly from center bracket b When tightening bolts make space under cylinder head since some valves will open and interfered t Z 5 After assembling Ll1IU r head turn camshaft until No 1 piston is at T D C on its compression stroke ASSEMBLING PISTON ...

Page 65: ... Install lower main bearings and caps and tighten bolts to specified torque C l Main bearing cap bolt 4454 N m 4 5 5 5 kg m 33 40 ft lb a Apply sealant to each side of rear main bearing caP and each corner of cylinder block Refer to Pre cautions b Arrange the parts so that tha arrow mark on bearing cap faces toward the front of engine c Prior to tightening bearing cap bolts placo bearing cap in pr...

Page 66: ... cylinder block and head 2 Turn crankshaft until No 1 piston is at T D C on its compression stroke 3 When installing cylinder head make SUre that all valves are apart from head of pistons If necessary loosen adjusting screws of rocker ann to draw valves in 4 Temporarily tighten two center bolt CfJ Cylinder head bolt ITemporary 20 N m 2 kg m 14 ft lbl a Final tightening should be carried out after ...

Page 67: ...9 78 N m 7 0 8 0 kg m 51 58 ft lb a Be sure to tighten bolts securing cylinder head to front cover b After engine has been operated for several minutes retighten if neces sary I I Adjust valve clearance to cold specifications referring to Section MA Valve clearance Cold Intake 0 21 mm 0 008 in Exhaust 0 23 mm 0 009 inl At ambient temperature 200C 680F After engine has been assembled finally adjust...

Page 68: ...gine right side and rear side parts remained with the specified torque if designated Refer to Mounting Engine on Work Stand and S D s for tightening tor que When installing clutch assembly use Tool KV30100100 16 Fill engine oil and coolant to the specified level after engine has been installed on car Refer to Section MA ENGINE TUNE UP 17 Referring to Section MA finally adjust following items 1 Dri...

Page 69: ...12 048171 8 000 8 01810 3150 031571 11 985 11 996 1 2 85 12 196 10 4718 0 4723 10 4797 0 4802 0 027 0 049 0 0011 0 0019 Standard Limit 0 020 0053 10 0008 0OO21 0 1 0 004 0 040 0 073 0 0016 0 0029 0 2 10 OOSI Valve seat Seal insert dimensions Intake xLQ I I I o Contacting face angle r t Contacting width W Stendard Standard Outer diameter 0 Service Exhaust C mtactlng face angle cr Contacting width W...

Page 70: ...ata ere common to both intake and exhaust Unit mm in I Standard Free I Outer 49 7711 9594 height I Inner 44 1011 7362 mm N 40 0 226 23 01 Assem Outer kg 1575 50 7 bled lin lb height mm N tension Inner Ikg 35 0 108111 0 linllbl 1 3783 24 31 Cut 0 Outer square Inner limit 40 0 189119 31 1 575 42 61 35 0 87 18 91 11 3783 19 61 2 2 0 0871 1 9 10 075 ROCKER ARM AND ROCKER SHA Unit mm in 1 I I I Rocker ...

Page 71: ... AND PISTON PIN Piston Unit rnm in f I A cr a About 20 10 791 EM714 Standard 84 985 85 035 13 3459 3 34781 Piston diameter A 0 50 10 01971 85 465 85 515 Oversize 13 3648 3 36671 1 00 10 03941 85 965 86 015 O ersize 3 3844 3 38641 Side clearance of piston ring Unit mm Unl Standard Limit I Top ring I Second ring I Oil ring 0 040 0 073 10 0016 0 00291 0 1 0 0041 0 030 0 063 0 0012 0 00251 Ring gap 1 ...

Page 72: ...an 001 0 00041 Less than 0 05 0 00201 0 05 O lB 10 0020 000711 8 EM715 Limit 003 0 00121 J I 0 03 10 00121 I 0 10 0 00391 I 0 3 10 0121 4 0 0 1571 Main bearing undersize Unit mm in T EM738 Bearing top Crank jou rnal thickness T diameter I STD 1822 1835 54 942 54 955 10 0717 0 0722 12 1631 2 1636 I 0 25 10 00981 Undersize 1 947 1 960 54 692 54 705 0 0767 0 07721 2 1532 2 15371 I 0 50 0 01971 Unders...

Page 73: ...9 7 2 7 12 87 116 7 12 7 12 12 15 29 43 14 22 22 29 Engine left side Unit I Distributor support bolt I Exhaust manifold bolt and nut I E G R tube nut I E A I tube nut I Air conditioner cern pressor bracket bolt N m 3 9 7 8 16 21 34 44 34 44 44 54 Engine top side I Cylinder head bolt 69 78 I Cylinder head to front COYer bolt 3 9 7 8 I Rocker shaft bracket bott 15 25 I Camshaftsprocket bolt 118 157 ...

Page 74: ...orn rocker bearing Worn rocker face Loose valve stem in guide Weakened valve spring Seized valve Excessive camshaft bearing clearance Excessive axial play Wom earn gear Improper shaft end play Broken impeller Stuck valve II Other mechanical troubles Improper valve clearance Insufficient clearance between valve stem and guide Weakened or broken valve spring Seized or damaged valve stem Poor quality...

Page 75: ...kshaft Clogged oil passage Bearing worn or eccentric Bearing improperly assembled loose bearing Incorrect connecting rod alignment Shortage of engine oil low oil pressure Poor quality engine oil Crankshaftjournal worn or out of round Clogged oil pasSage incrankshaft Bearing worn or eccentric Bearing improperly assembled Eccentri crankshaft or bearing Corrective action Adjust Replace Replace valve ...

Page 76: ...100 100 KVlO105001 ST050lS000 126023 CD ST050l1000 126023 2 CVST05012000 126023 1 ENGINE MECHANICAL Special Service Tools SPECIAL SERVICE TOOLS Tool name Clutch aligning bar Engine attachment Engine stand assembly Engine stand Base ...

Page 77: ... 3 STlI032000 125618 2 STl1320000 125618 1 STl165000I STl6610001 123907 KVlOI05500 125640 01 EM03470000 EM 28 Tool name Valve guide reamer set Reamer 12 2 mm 0 480 in dia Reamer 8 0 mm 0 315 in dia Drift Valve seat cutter set Pilot bushing puller Crankshaft rear oil seal drift Piston ring compressor D M ...

Page 78: ...IL PRESSURE RELIEF VALVE COOLING SYSTEM COOLING CIRCUIT RADIATOR THERMOSTAT WATER PUMP LC 2 LC 2 LC 3 LC 4 LC 4 LC 4 LC 5 LC 5 LC 6 LC 6 LC 7 TEM COUPLlNG SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS LUBRICATION SYSTEM COOLING SYSTEM SPECIAL SERVICE TOOL LC 7 LC 8 LC 8 LC 8 LC 8 LC 9 LC 9 LC 9 LC 10 ...

Page 79: ...p Intermittently j Pump drive gear r oiling portion Oil passage Oil filter I Relief valve I l Main aring f I Con ecting rod II Oil J et II Chain tensioner I bearing I Connecting rod IITiming chain I I I l Piston Pin pis I ton and cylinder I A Rocker arm t j I Camshaft bearing I Cam surface LC 2 I Cylinder head I oil gallery I Center earn bracket I Rocker shaft Cam bracket t I Timing chain I and fr...

Page 80: ...e sure that the tip of the drive spindle fits distributor fitting hole securely 5 Tighten bolts securing oil pump to front cover lfJ Oil pump mounting bolts 11 15 N m 111 1 5 kg m 8 11 ft lb 6 Install distributor cap DISASSEMBLY AND ASSEMBLY 1 1 EL032 I 1 Oil pump body 2 Outer rotor 3 Inner rotor and shaft 4 Gasket 5 Oil pump cover 6 Regulator valve 7 Regulator spring 8 Regulator cap lfJ Oil pump ...

Page 81: ... rotor set or entire oil pump as sembly LC4 OIL PRESSURE REGULATOR VALVE INSPECTION Check valve sliding surface and valve spring and replace entire valve assembly ifnecessary E L076 N OIL FILTER REMOVAL AND INSTALLATION When removing oil f1lter use Tool When installing it lightly coat oil on oil seal and fasten it by hand Do not overtighten filter or oil leakage may occur S lC028 OIL PRESSURE RELI...

Page 82: ...To avoid serious peRonal injury never remove I Idiator cap quickly when engine is hot Sudden release of cooling system pressure is very dal1llerous If it is necessary to remove Iadiator cap when Iadiator is hot turn cap slowly counterclockwise to the fillt stop After all pressure in the coo ing system is released turn cap passing the stop and remove it Radiator cap F Reservoir tank t Radiator Ther...

Page 83: ... tears cracks or deterioration after cleaning it Then install radiator cap on a tester Ifcap does not hold or will not release at the specified pres sure replace cap Cap relief pressure 88 kPa 0 9 kg cm2 13 psi ET012 2 Inspection of water leakage With radiator cap removed apply test pressure to radiator on a car If leakage is detected repair or replace radiator Leakage test pressure 157 kPa 1 6 kg...

Page 84: ... suitable water pump seal lubricant to prevent squeak TEM COUPLlNG DISASSEMBLY The coupling is so designed that it cannot be disassembled INSPECTION Inspect the coupling for oil leakage or bend of bimetal If necessary reo place as a pump assemhly ENGINE LUBRICATION COOLING SYSTEMS Cooling System cf N m kg ln ft Ib Belt dcllcction mmin fN kg Ib M6 3 9 9 810 4 1 0 2 9 7 21 M8 10 16 10 16 7 121 a 121...

Page 85: ...0 0059 0 llO831 5 197 004 0 08 I 0 1 00016 0 00311 20 00079 OIL PRESSURE REGULATOR VALVE Free length mm jn Reulator valve spring Installed lengthl loed mm in N Ikg lbl Regulator valve opening pressure kPa kg cm2 psi rpm LC 8 52 5 2 0671 34 8 1 3701 77 5 85 3 7 9 8 7 174 19 21 343 412 13 5 4 2 50 601 3 000 RADIATOR CaP relief pressure kPa kg cm2 psi 88 0 9 13 157 116 231 Leakage test pressure kPa I...

Page 86: ...LING SYSTEM Condition Probable cause Water leakage Damaged radiator seams Leaks from heater connections or plugs Leak from water pump shaft seal Leak from water temperature gauge Leaks from gaskets or small cracks Loose joints Damaged cylinder head gasket Water leakage Cracked cylinder block Cracked cylinder head Loose cylinder head bolts Corrective action Replace Replace Tighten or replace Replac...

Page 87: ...rity in water Malfunctioning thennostat Inaccurate temperature gauge Squeak at water pump mechanical seal Damaged or worn water pump bearing Carrective action Check hoses for crimps and clear the system of rust and sludge by flushing radiator Replenish Replace Adjust Replace Use soft clean water rain water is satis factory Cooling system should be drained and flush ed thoroughly at least twice a y...

Page 88: ... EF 18 EF 19 EF 19 EF 20 EF 20 EF 20 EF 20 EF 20 EF 21 EF 21 EF 21 EF 21 EF 21 EF 22 EF 22 EF 22 EF 22 EF 22 EF 23 F 23 EF 24 DESCRIPTION PREPARATIONS FOR INSPECTION INSPECTION INSPECTION PROCEDURE TABLE EFI CIRCUIT DIAGRAM COMPONENT PARTS INSPECTION FUEL PRESSURE CHECK FUE L PUMP FUEL DAMPER FUEL FILTER INJECTOR PRESSURE REGULATOR AIR FLOW METER AIR TEMPERATURE SENSOR AIR REGULATOR THROTTLE CHAMB...

Page 89: ...mp L cu witch California modelA Switching module Idle speed adjus ing screw i Ji t 0 r Air pipe EA tube Oil pressure switch 1 lliru California models I a I C J I 8j 8 I ON 1ST U 0 Ih Fuel pump relay Ignition coil Ignition switch q EF 2 Air inducti ln valve Air cleaner Ai r nwmei dlJ fj 1r Lb I Air temperature y pall semOl ew II c I J s lt1 Control unit SEF081 ...

Page 90: ...Watet tem Perature sensot Vacuum wltch I A ltCl iforni l models f A 11 i 0i 0 II i yuel pump fue d aIn pex Altitude 5en oor California model Ci TC I contro unit Dropping tes1 tot MI ternpetaW re n or ...

Page 91: ...pressure As it flows through the mechanical fuel damper pulsation in the fuel flow is damped Then the fuel is filtered in the fuel filter goes through the fuel line and is injected into the intake manifold cyl inder branch from the injector Surplus fuel is led through the pres sure regulator and is returned to the fuel tank The pressure regulator con trois the injection pressure in such a manner t...

Page 92: ...ries with the movement of the air flow meter and the quantity of fuel to be injected should be controlled correctly in cor Injector 11 R A respondence with the present air flow In the EFI system the injection pressure is held constant at 250 kPa 2 55 kg cm2 36 3 psi and the area of the injector noule hole is also con stant Therefore the fuel injection quantity can be determined by the l 11 I ENGIN...

Page 93: ...l pump continues to operate using current supplied from fuel pump relay 2 monitoring the en gine revolution and fuel pump reo lay 1 If the engine stalls for some reason fuel pump relay 2 receives the en gine stall signal and stops feeding current thereby stopping the opera tion of the fuel pump the duration of the pulse computed in the control unit AIR TEMPERATURE HTempctalUIel SENSOR of mtake air...

Page 94: ...gine rpm infonnation and load state information are created by two signals which pro vide for the rolation of the engine One of these two signals is sent out from the ignition coil that detects the engine rpms The other one is the signal sent from the air flow meter which monitors the suction air quan tity The injection quantity deter mined by these signals is caIled the basic injection quantity E...

Page 95: ...Io0e 17601 ConSlant On California models the Full enrichment ctinted when the vacuum switch ON when the Full throttle contactis ON oGC 32oF Const nt restart Intake air temperature at Isoe S90F constant and water temperature rises from 600e I400F AFTER START ehment 1F niliOn ch W t r emperalure Ilensm Hot Ijlnilion ilch W telh mpcl lIUll sensor TluoltlevlIlYeswilCh Air 1 lemar Air no meter I nilion...

Page 96: ...t de creases gradually as time passes finally becoming zero and is detennined by cooling water temperature ENGINE FUEL Fuellnjection Control Full enrichment The smooth ance full enrichment provides full throttle driving perfonn California models The full enrichment is activated when the intake manifold vacuum is below 21 3 kPa 160 mmHg 6 30 inHg or when the throttle valve open ing is more than 450...

Page 97: ...ut off ALTITUDE COMPENSATION California models The density of ail becomes thin in proportion to the altitude so that the air fuel ratio becomes riche t high altitude The altitude compensator is a device to correct air fuel mixture to an optimum ratio automatically EF l0 The graph below shows the fuel shut offtange Manual nmodels 3 OC 2 600 s e 2 200 0 0 Il 0 1 800 1 400 1 000 Deceleration from zon...

Page 98: ...ses over 294 to 44I kPa 3 0 to 4 5 kgcm2 43 to 64 psi due to malfunction in the pressure system The check valve prevents abrupt drop of pressure in the fuel pipe when stopping the engine Operation When the ignition switch is turned Nhene ine When nline opped opEration Allenulor L rmilUll OLlprclSurt witch ON 011 START No No ON generate pressure ON Gentrate Normal ON ON Failure NOllTUI1 ON ON Gencr...

Page 99: ... the needle valve for fuel injection The quantity of injected fuel is in propor tion to the duration of the pulse pplied from the control unit SEF099 1 Injector lower rubber insulator 2 Injector lower holder 3 Injector upper rubber insula or 4 Injector upper holder 5 Injector o le FJectric terminal li 11 I f Filter PRESSURE REGULATOR To intake manifold t Air chamber Diaphragm Fuel inlet SEF100 The...

Page 100: ...is converted into the voltage ratio signal V VB which in turn is sent to the Potentiometer To EFI harness control unit for computation The flap is able to rotate to an angle where an equilibrium between the air flow pressure and the return torque of lhe coil spring can be main tained The damper chamber and damper plate are provided as a damper for the flap so that the flap will not be disturbed by...

Page 101: ...ugh by pass line between air pipe and throttle chamber Idle adjustment is made by the idle speed adjusting screw at the 1A S unit AIR PIPE The air pipe located on the line be tween the air flow meter and the throttle chamber prevents the pulsat ing of the intake air THROTTLE CHAMBER The throttle chamber located be tween the air flow meter and the in take manifold is equipped with a valves This val...

Page 102: ...in response to the air temperature rise THROTTLE VALVE SWITCH The throttle valve switch is attach ed to the throttle chamber and ac tuates in response to accelerator pedal movement This switch has two sets of contact points One set monitors the idle position and the other set monitors full throttle position EN GIN E FUEL EFI System Component Parts Construction and Function WATER TEMPERATURE SENSOR...

Page 103: ...sensor is transmitted to the elec ronic control unit and ihe injection duration of the injectors is detennined to ob tain the optimum air fue ratio by the electronic control unit CONTROL UNIT The control unit is connected to the EFI harness by means of a multi connector and the EFI harness is connected to other sensoIS The essential role of the control unit is to generate a pulse Upon receiving an...

Page 104: ...pwnp refer to Fuel Pump EFI HARNESS One wiring harness is used to con nect lines between the control unit and the related major units The 35 pin connector of the EFI harness is connected to the control unit and runs to the engine compart ment The harness runs to various units the air flow meter throttle valve switch vacuum switch air regu lator altitude sensor water tempera ture sensor dropping re...

Page 105: ...rge voltll e to develop in coil and condenser thus rerulting in damage tolCcircuitKeep EFt h rne t e t 10 em 1 91n away from adjacent hlU llesses to prevent an EFl syltetn malfunction due to reception of external noise degraded operation of Ie circuit etc Keep EFt parts end h rne dIY BefotO removing pl1Ita turn off ignition switch and then duccnnect batter ground cable 00 not operate fuel pump whe...

Page 106: ...Disconnect fuel feed hose and fuel return hose from fuel pipe Place a rag under fuel pipe to pre vent splashing of fuel 4 Remove vacuum hose connecting 8 Unfasten hose clamp on fuel in jector and remove fuel injector from fuel pipe Place a rag under injector when dis J connecting fuel pipe to prevent splash ing of fuel pressure regulator to intake mani fold 5 Remove boits securing fuel pipe and pr...

Page 107: ...e and disconnect hose 3 Remove setscrews and remove air regulator 4 Disconnect electric connector from air regulator S To install air regulator reverse the order of removal WATER TEMPERATURE SENSOR I Disconnect battery ground cable 2 Remove radiator cap Drain coolant by opening drain plug CAUTION The coolant should not be drained until it has cooled off completely Otherwise burns may be incuned 3 ...

Page 108: ...isconnect vacuum hose and har ness connector from vacuum switch 3 Remove vacuum switch from bracket 4 To install vacuum switch reverse the order of removal ALTITUDE SENSOR Left side dISh panel SEF323 1 Disconnect ground cable from battery 2 Remove control unit Refer to Control Unit for removal 3 Remove altitude sensor attaching bolts 4 Disconnect harness connector from altitude sensor 5 To install...

Page 109: ...e bolts securing air cleaner to air cleaner bracket and detach air cleaner with air flow meter as an as sembly 5 Disconnect air flow meter harness connector 6 Remove air flow meter from air cleaner Refer to Air Flow Meter for removal 7 To install air cleaner reverse the order of removal AIR FLOW METER I I l I DiSConnect battery ground cable 2 Disconnect air ducts and hoses connecting air cleaner a...

Page 110: ...rve the follow ing CAUTION a Do not reuse fuel hose clamps after loosening b Clean dull and dirt from parts with compreS 8d airwhen assembling c Tighten high pressure rubber hose clamp so thilt clamp end is 3 mm 0 12 in from hose end or screw position wider than other portions of clamp is flush with hose end Tightening torque specifications are the same for all rubber hose clamps SEF138 If Clamps ...

Page 111: ...e electrical system use a circuit tester Continuity test can be perfonnedeasily by measuring resist ance and voltage between terminals of 35 pin EFI harness connector installed on car CAUTION Do not touch the circuit tester probe to any unnecessary pin on the 35pin connector Doing so could cause dam age to the circuit tester For items to be checked refer to Inspection Procedure Table RESISTANCE ME...

Page 112: ...ition switch OFF 3 Disconnect oil pressure switch harness connector 4 Turn ignition switch ON and measure voltage in step 23 S Turn ignition switch OFF 6 Connect oil pressure switch har ness connector 7 Disconnect alternator 2 pin con nector L and S terminals 8 Turn ignition switch ON and measure voltage in step 24 7 Turn ignition switch OFF 8 Connect EFI harness connector to control unit 9 Connec...

Page 113: ...0n 30 24 Canfornla model 1 Connect vacuum switch harness connector and dbconnect hose vacuum switch t6 itttake manifold at intake manifold side 2 Disconnect tnrottle valve switch and altitude sensor harnels connector Circuit betweon ignition switch Bnd control unit power source Circuit between ignition switch fuel pump relay and air regulator Note a Before disconnecting and connectiria electrical ...

Page 114: ...j I Be Auxiliary operation or condition 1 Connect dtemator 2 pin connector uL and S terminals START CAUTION Exerci care in performing step 1 lIS it involve turning engine r ON ON ON 18 2 6 5 7 27 v E Standard value Pointer deflects Battery voltage Above O SY ov Battery voltage Battery voltage Note a Before disconnecting and connecting electrical connectors and terminab ensure that ignition switch ...

Page 115: ...t nopped BATTERY t AiternetorLterminal ON Oil prullureswitch DROPPINGRESISTOR 43 37 3840 4 cp FUEL PUMP Whln anaina Is in operation INJECTOA CYLINOER NO WATER TEMP 111 121 131 14 oo j 11 l N 0 l J IGNITION eQ L 2 l 7 r 1415 1819l21 24 2526278 9 103233 34 t c f it GROUND Jjln R Jre 11l 1O I I DLE FULL U THROTTLE L T ALTITUDE VALVE SW SENSOR AlA FLOW Cellfornle METER models A R TEMP SENSOR I I I I V...

Page 116: ...ing alternator L terminal or oil pressure switch connec tor set ignition switch at ON posi tion Then make sure that fuel pump operating sound is heard If not check all fuel pump circuits If all circuits are checked out OK eplace fuel pump FUEL DAMPER If noise from fuel pump is abnor mally loud replace fuel damper and recheck for noise FUEL FILTER Ifthe car is operated under extreme adverse weather...

Page 117: ...30 2 Measure the resista nce between tenninals and The standard resistance is 200 to 500 ohms EF483A 3 While sliding flap measure resist ance between tenninals and If resistance is at any value other t 1aJl 0 and 0Cl ohm air flow meter is nonnaJ UlI EF319A CHECKING INSULATION RESISTANCE Check insulation resistance between the air flow meter body and anyone of the tennin s and If continuity exists ...

Page 118: ...passage is narrowed by pinching hose during warm up After warm up shutter closes Therefore engine speed remains unchanged when passage is narrowed by pinching hose after warm up 2 Disconnect electric connector of air regulator and check continuity Continuity should exist If not air regulator is faulty 3 Disconnect hoses from both ends of air regulator and visually check to see if air regulator shu...

Page 119: ... COF EF334A THROTTLE VALVE SWITCH ADJUSTING SWITCH POSITION Disconnect throttle valve switch connector 2 Connect ohmmeter between ter minals and and make sure continuity eXists 3 Adjust throttle valve switch posi tion with retaining screw so that idle switch may be changed from ON to OFF when engine speed is specified idle rpm 70 rpm M T Neutral A T N position under no load To adjust position of t...

Page 120: ...y orally ucking port back 4 If the test results are not the specifications the vacuum switch is malfunctioning ENG INE FU EL Component Parts Inspection Vacuum gauge 1 1 Resistance lkn Voltmeter I I EB ova o 0 Regstan 30kn Battery 12V o SEF324 ALTITUDE SENSOR I Connect the test lead wires as follows iBattery Jf 12V III Voltmeter 0 4 SEF166 2 Measure the output voltage More thOriO 5V O K 3 If the te...

Page 121: ...set lamp in it EF 34 a c kll lllllilod l CD 00 j j 3 Use flat plate tenninals 3 mm 0 12 in wide 0 8 mm 0 031 in thick as male terminals Place flat plate terminals parallel with each other and keep distance between inside faces 2 mm 0 08 in Then secUre terminals by wrapping insulation tape or with suitable terminal body 2 Disconnect injector harness con nector 3 Connect inspection lamp to injec tor...

Page 122: ...NG AIR LEAKAGE IN AIR INTAKE SYSTEM Make sure even a slight air leak does not occur When inspecting the electronic fuel injection system pay particular atten tion to hose connections dipstick oil filler cap etc for any indication of air leaks Since the air flow meter used in the electronic fuel injection system directly measures the quantity of in take air to permit the supply of the optimum fuel ...

Page 123: ... em Appro 206 12 1 301 PII Fuel Coil resistance injector n 2 35 Airflow n 100 400 metar Potentia fl 200 SOO meter resistance fl Except 0 and Air tem peratu re At tOOC t4OFI kfl 1 0 114 sensor water tempera At 200C 168OF kfl 2 1 2 9 lUre sensor therml tor re At5OC t22F kfl 0 68 1 0 sistance Air Heater coil 25 90 reQulstor resistance n Engine speed Specified idle rpm Throttle wh dl ch 70 in Neutn I ...

Page 124: ...meter to throttle chamber air duct etc 3 Make sure the ignition and start ing systems are satisfactory and the battery is in good condition Probable cause Engine will not start or hard to start Improper ignition system Intake air leakage at following points P C V valve V C valve dipstick seal oil ftller cap blow by hoses Air flow meter hoses and clamps Manifold gaskets etc Fuel pump does not work ...

Page 125: ...or b Injectors do not click check the follow ing circuits Control unit power input circuit Ignition coil trigger input circuit Control unit groundcircuit e Injector circuit Check each circuit Then proceed to Com ponent checks Check charge circuit Recharge battery ifnecessary Check ignition signal input Connect a lead wire to ignition coil negative terminal With ignition switch ON attach other end ...

Page 126: ...f necessary To check air regulator proceed to the following steps Start engine Pinch offhose to air regulator Results al Ifidle speed drops perfonn circuit test Ifno fault is found replace air regulator b If idle speed remains high or unstable perfonn the following checks Check for manifold vacuum leaks includ ing at P CV valve V C valve dipstick nd oil f1ller cap seals If no problem is found perf...

Page 127: ...iller cap seals Manifold gaskets Air flow meter hoses etc Improper fuel pressure Improper idle CO ll adjustment Improper EFI circuit Check and corrective action Tap control unit while driving to see if this aggravates or aIleviates the problem If so try another control unit Perfonn fuel pressure test Perfonn all circuit tests Then perfonn Component checks Check IC ignition unit pick up coil and ig...

Page 128: ... Air flow meter potentiometer Control unit ground circuit Air temperature sensor Water temperature sensor Altitude sensor Air regulator and fuel pump circuit Ignition coil trigger input circuit Control unit power input circuit Injector circuit Intake air leakage at the following points P C V valve V C valve Dipstick and oil ftller cap seals Manifold gaskets Air flow meter hoses etc Improper fuel p...

Page 129: ...nsor Water temperature sensor Injection circuit e START signal input Check and corrective action Check each circuit Then proceed to the Component checks Check each circuit Then proceed to Component checks COMPONENT CHECKS To be performed only after circuit tests are completed Control Air flow meter Fuel system Problem Injector Air unit Flap Relay Resist sound regulator replace Fuel pres Injector o...

Page 130: ...ir conditioner equipped models checks should be carried out while the air conditioner i OFF START Start engine and warm up engine until waL temperature indicator points to he middle of gauge Open engine hood Run engine at about 2 000 rpm for about 2 minutes under noload SMA021 1 Run engine at idling speed For Canada I u S A For Disconnect hose from aii indUction pipe and install proper cap on air ...

Page 131: ...k the following Following hoses for proper connections VaCWlm hoses Blow by hoses Air regulatOJ hOle Air duct hoses Canister purge hoses Air leaks at throttle chamber mounting and intake manifold Remove blind plug from air by PUl SCItW on air flow meter Californi models Steel plug Non califomia models Rubber plug Noii canrornia models Race engine two or tluee times under noload then run engine at ...

Page 132: ... connect air induction hose to air induction pipe I Start engine t Race engine two or three times under no J load then run engine at idle L Oleck idle speed MfT 7OO 100rpm AfT 700 1100 rpm in 0 position O K I N G END I O K SMA061 Install blind plug on air flowmeter I California Non Calitom e HIM steel plug Original rubber plug California models Turn off engine and remove air flow meter from Cat I ...

Page 133: ...CRIPTION AIR INDUCTION SYSTEM A I S l EXHAUST GAS RECIRCULATION E G R l CONTROL SYSTEM EC 2 EC 3 EC 5 EC 5 EC 5 EC 6 EC 6 EC 6 EC 9 SPARK TIMING CONTROL SYSTEM DECELERATION CONTROL SYSTEM I lntake manifold vacuum control type CATALYTIC CONVERTER EVAPORATIVE EMISSION CONTROL SYSTEM DESCRIPTION OPERATION INSPECTION SERVICE DATA AND SPECIFICATIONS TIGHTENING TORQUE EC 15 EC1 EC 17 EC19 EC19 EC 20 EC ...

Page 134: ...switch X X I0 Air regulator X X X X X X 0 r Water temperature sensor X X X X X X C l Altitude sensor X X C l IC ignitor for I plug X X X X I Ignition m system IC ignitor for 2 plugs X X 3 Water temperature control X X I X X Exhaust air induction system Type A X X A I S Exhaust air induction system Type B X X E G R system with V V T valve Type 1 X X E G R E G R system with V V T valve Type 2 X X sy...

Page 135: ...p hannful emissions to a minimum CALIFORNIA MODELS Vacuum control valve Throttle chamber lntake manifold Airregulator 01IL IT 11 1 en I I Airpipe i I T n f i rr J u c j tP Catalytic convert r j i f o C r I Ii If 1 Idle adjust aew umt lj r Distributor i f A I tube Canister l L Air induction valve J Ail cleaner Thermal vacuum valve Ported vacuum Distributor Ported vacuum E G R Air Venturi vacuum Man...

Page 136: ...e 1 J Air cleaner Fuel tank vapor vent line CANADA MODELS Intake manif ld acuum con tvacuum vaIve Throttle chamber E G R val n i ii M pipe 1 kL Ji 1 J B P T val J II I II I E G R tube 7 1 gr 21 r r ta yticcon rter Y JA J Muffier Idle adjust saew t II t 1t 1 JF Distributor Canister Fuel tank vapor vent line EC 4 1 Ported vacuum Distributor Porled vacuum E G R Venturi vacuum Air Canister purge Q Q S...

Page 137: ...nt to draw the blow by flow through the valve and its flow goes through the tube connection in the reverse diIee lion On cars with an excessiveiy high blow by some of the flow will go through the tube connection to air pipe under all conditions Flame arrester iC Intake manifold J v l T r J Air L pipe R Throttle chamber P C V valve Steel net Fresh air Blow by gas SECOO4 INSPECTION p C V VALVE AND F...

Page 138: ...A I A3 Catalytic converter exhaust manifold The exhaust pressure in the exhaust manifold usually pulsates in response to the opening and closing of the exhaust valve and it decreases below atmospheric pressure periodically If a secondary air intak pipe is opened to the atmosphere under DESCRIPTION The air induction system A I S is designed to send seco dary air to the exhaust manifold utilizing a ...

Page 139: ...r is attached to the air cleaner There are two types of air induc tion valve cases The type A is equip ped with two hose connectors and is installed on California models and the type B is equipped with one connector and is installed on all non Californla models except Canada EC921 TypeA To exhaust manifold 1 Air Induction pipe The secondary air fed from the air induction valve goes through the EA ...

Page 140: ...clamp EC 8 The air induction pipe can then be taken out Installation is in the reverse sequence of removal TypeB INSPECTION Preliminary Inspection Check hose for looseness flatting damage or faulty connections and each part for proper installation If nere ry replare AIr induction valve and fDter I Disconnect air induction hose at air induction pipe side Suck or blow hose to make sure that air flow...

Page 141: ... gas is led from the exhaust manifold to the E G R chamber The exhaust gas is then controlled in quantity by the E G R valve and is introduced into the intake manifold JJ From air pipe JT II 1 All n o Throttle I chamber venturi II 1 Throttle valve E G R vacuum port r Engine coolant Advance oontrollinel v L J tExhaust gas from exhaust manifold Thermal vacuum valve Type A2 LThermal vacuum valve Type...

Page 142: ... R Oc oF Type A2 Type A3 Venturi vacuum Exhaust gas pressure Operation control system High Low I High High Closed Below 15 59 Open Closed Not actuated I Low High Low Low Open High Low 15 60 J High High Closed Slightly Leak Closed 59 140 I Low High actua ted Low Low Open Not actuated High Low High High Closed 60 95 Closed Closed Actuated 140 203 Low High Low Low Open Not actuated High Low High High...

Page 143: ... control valve The E G R control valve controls the quantity of exhaust gas to be led to the intake manifold through vertical movement of the taper valve connect ed to the diaphragm to which vacuum is applied in response to the opening of the throttle valve E G R control valve construction and type vary with transmission type and car destinatiol For identification purposes the part number is stamp...

Page 144: ... other words the amount of recircu tated exhaust gas varies with the posi tion of the E G R valve regulated by the operating condition of the engine To E G R ubber ClIp control1ine Air f Exhaust pressure SEC20a SEC023 REMOVAL AND INSTALLATION Venturi vacuum transducer V V T valve The v V T valve monitors the pressure of the exhaust gas which actuates the diaphragm and the venturi vacuum which in t...

Page 145: ...back pressure tube from V V T valve The V V T valve can then be taken out SEC029 4 Installation is in the reverse sequence of removal When replacing the V V T valve with a new one verify that the type number on the noYi part is the same as that on the former one i J V V T valve mounting crew i 3 7 5 0 N m 0 38 0 51 kg m 2 7 3 7 ft lb 8P T valve 1 Remove vacuum tube on the B P T valve 2 Remove scre...

Page 146: ... end E GR control valve side of vacuum hose Type Al TypeA2 Canada Airregulatort f T V V J C035 Ifvacuum pressure is either weak or nonexistent replace thermal vacuum valve Ifvacuum Psess lJe is detected replace E G R valve If any difficulty is encountered in judging the condition of any com ponent during above inspection check the questionable component inde pendently as follows E G R corit ol val...

Page 147: ...alve and check it for leakage as shown below Ifa leak is noted replace vaive SEC037 Apply vacuum above t 1 961 kP 200 mmH20 7 87 inH OJ 2 Apply vacuum pressure above 0 785 kPa 80 mmH20 3 15 inH20 to V V T valve and check for leakage as shown below If a leak is discover ed replace valve B P T valve 1 Disconnect two cuum hoses on B P T valve 2 Plug one of two ports of B P T valve Apply a pressure ab...

Page 148: ...2 To E G R control line e C From I air cleaner TYpeA3 Spring t1 ii Valve i i1i I e To distributor advance control line Wax Wax SEC020 EC 16 I Ensure that vacuum hoses are properly connected to their con I Q 19 controllme 2 Make sure that distributor vacuum controller functions properly 3 Set timing light 4 Check thennal vacuum valve beginning with a cold engine 1 Using a timing light check the spa...

Page 149: ... w en the preset vacuum level has been at tained thus preventing excessive in creases in the intake manifold vacuum during deceleration Air is directed from the 3 way connector through the air hose and vacuum control valve To keep oil consumption low as the air enters the intake manifold vacum will be maintained at less than the specified level Vacuum control valve V C V To check for operating pro...

Page 150: ... speed increases readjust it to specified speed with throttle adjusting screw SWann up engine for about four minutes at 2 000 rpm under no load 6 Measure CO percentage at idle speed After step S has been com pleted wait for one minute before making CO percentage measurement 7 If CO percentage measured in step 6 is less than 03 the catalytic con verter is nonnal 8 IfCO percentage measured in step 6...

Page 151: ... 0 3 in step 7 catalytic converter is mal functioning Replace catalytic con verter EVAPORATIVE EMISSION CONTROL SYSTEM DESCRIPTION This system is made up of the following 1 Fuel tank with positive sealing filler cap 2 Fuel check valve 3 Vapor vent line 4 Carbon canister S Vacuum signal line 6 Canister purge line 7 Vapor liquid separator Hatchback models Removal and installation of above components...

Page 152: ...e Sea lli1g gas cap with aCllum relief valve Vacu1 J111 lline7 jFUel vapor I vent line r n Fuel che L Freshair Fuet vapor t j LFuel tank Intake ffillIlifOldJ ij f fJ SEC041 HATCHBACK m odeb Yaporjliquid separator L J Vacuum signal line 7 Purge control ialve G tr I I LJ r Fuel vapor vent line Fuel check Fixed orifice I Con tant purge i lice Si S iji i ji J sitive sealing gas cap with vacuum relief ...

Page 153: ...r INSPECTION FUEL TANK AND VAPOR VEfoT LINE Check all hoses and fuel tank IDler cap 2 Disconnect the vapor vent line C Onnecting carbon canister to fuel iank 3 Connect a 3 way connector a manometer and a cock or an equiva lent 3 way charge cock to the end of the vent line 4 Supply fresh air into the vapor vent line through t e cock little by little until pressure becomes 3 923 kPa 400 mmH20 15 75 ...

Page 154: ...rge flow in the intake manifold vacuum line at the constant purge orifice of carbon canister To check the purge flow proceed as follows EC 22 SEC053 CARBON CANISTER FLTER Check for a contaminated element Element can be removed at the bottom of canister installed on car body FUn TANK VACUUM RnlEF VALVE Remove fuel filler cap and see it functions properly I Wipe clean valve housing and have it in yo...

Page 155: ...Unit N m kg m ft Ib E G R tube securing nut 34 44 3 5 4 5 25 33 I V V T valve mounting 3 7 5 0 038 0 51 2 7 3 7 E A I tube securing nut 44 4 5 25 33 screw 34 3 5 Less than Less than Less than 18 P T valvo mounting 3 7 5 0 038 0 51 2 7 3 7 Thermal vacuum valve 22 2 2 1 6 screw I Catalytic converter bolt 31 42 3 2 43 23 31 EC 23 ...

Page 156: ... Mod 1 S II 0 Series SECTIONER ENGINE REMOVAL INSTAllATION CONTENTS ENGINE REMOVAL AND INSTALLATION CONSTRUCTION REMOVAL ER 2 ER 2 ER 2 INSTALLATION SERVICE DATA AND SPECIFICATIONS TIGHTENING TORQUE ER 5g ER 5 ER 5 ...

Page 157: ...ressure to zero ER 2 CAUTION Before disconnecting fuel hose release fuel pressure from fuel line to elimi nate danger I Start the engine 2 Disconnect the harness connector of fuel pump relay 2 while the en gine is running Relay bracket SEF131 3 After the engine staUs crank the engine two or three times 87 8 7 19 Iii 30 40 3 1 4 1 22 30 31 42 3 2 4 3 23 31 SERD01 4 Turn the ignition switch OFF 5 Re...

Page 158: ...djusting bolt P fi qa 9 5 ey nut a 1 n djUS ing I 11 l I AOO Yr p t 1 J 0 2 Remove compressor Place removed compressor as shown below Ne er d ilCherge gas from compres sor while service repair work is being performed III r I o o SER003 Power steering equipped models Remove power steering oil pump foUowing the procedures below I Remove oil pump drive belt To remove this belt loosen both idler puUey...

Page 159: ...r cable 9 Disconnect down shift solenoid wire and inhibitor switch wire AfT only 10 Disconnect vacuum hose AfT only II Remove clutch operating cylinder front exhaust tube and propeUer shaft Place marks on propeller haft be fora remo al to facilitate reinstall tion Mk 1 ar mgp SER024 Plug open holes in rear extension housing as hown 12 Attach suitable wires to engine sIingers and raise engine using...

Page 160: ... to Pump Belt Adjustment Section ST for adjustment 3 When installing exhaust front tube on exhaust manifold be sure to instaU a new gasket 4 When reinstalling the hood foUw ing engine instaUation be sure that it is properly centered and that hood lock operates securely Refer to Hood Section BF for adjuslment 5 Add the correct amount of engine coolant 6 For automatic transmission mod els add the sa...

Page 161: ...L FUEL EXHAUST SYSTEMS CONTENTS ENGINE CONTROL SYSTEM ADJUSTMENT REMOVAL INSPECTION INSTALLATION FUEL SYSTEM REMOVAL FE 2 FE 2 FE 3 FE 3 FE 3 FE 4 FE 5 INSPECTION INSTALLATION EXHAUST SYSTEM REMOVAL INSPECTION INSTALLATION FE 6 FE 7 FE S GII FE 9 FE 9 FE 9 ...

Page 162: ...st accelerator pedal free play to specifICation using adjusting nuts a Depress accelerator pedal to make Iura its linkage moves lIDootItly without jamming or dragging re lease pedal to make lure it returns to its original position smoothly b Check to see if throttle valve fully open when accelerator pedal i completely depressed and if it returns to idle when releasad c Pedal height adjustment i no...

Page 163: ...e pedal arm assembly by removing pedal arm bracket retain r ing 01t EF156 INSPECTION I Check pedal return spring for rust fatigue or damage Replace if neces sary 2 Check accelerator wire cases socket and fastening locations for rust damage or looseness Repair or replace ifnecessaiy INSTALLATION To instaU reverse the order of removal a Check accelerator controrparts for improper contact with any ad...

Page 164: ...filler cap Fuel filler tube Ventilation ho Fuel filler hole Fuel outlet hoae Fuel fetum hOle o Fuel outlet tube Fuel return tube Enporation tulx II m Q Q om Fuel tank Iii 14 18N m 1 4 1 8 Itg m 10 13 fHb Iii N m kg m fHb mr en enImi rl I m ZG Zm n o zl 0 o r T1 Cm r ll mX J Ic C l lC l C l l m sC l ...

Page 165: ...el outlet hose Fuel return hose ENGINE CONTROL FUEL EXHAUST SYSTEMS Fuel System Evaporation hose Fuel filler hose Hardtop 5 Remove bolts which secure fuel tank in place and dismount fuel tank SFE012 1 4 18N m 3ft lb RESERVOIR TANK Hatchback I Remove battery ground cable 2 Remove protector from luggage compartment Also remove R H speaker and side lower flnisher l SFE013 3 Remove evaporation hoses a...

Page 166: ... as an assem bly How er do not disconnect any fuel line unless absolltely necessary I Disconnect batlery ground cable 2 Drain fuel from fuel tank 3 Loosen fuel hose clamps and disconnect fuel tube at each end Plug hose and tube opening to prevent entry of dust or dirt while removing 4 Remove fuel tube clamps and fuel pump bracket from underbody Re move fuel tubes and fuel pump as an assembly Leave...

Page 167: ...is caution could result in damage to the urf e of fuel tube c Do not kink or twist ole and tube when they are routed d Run the engine and check for leak at connection e Fuel tank Install fuel filler hose etter fuel tank has been mounted in place Failure to follow this rule could result in lea ge from around hose connections Do not twist or smash ventilation and evaporation hoses when they are rout...

Page 168: ... 6 Iii 2 9 4 9 0 3 0 5 2 2 3 6 Front ePaust tube lower heat iniulatOJ m 0 IIUmer bond opper Iii 7 8 H 8 0 8 1 2 5 8 j ounlill8 RiIl8 rUbJer fj 7 8 H 8l 0 8 1 2 5 8 8 7 I Exhaust murtler Catalytic converter 4 23 31l 8 7 Rear mutner mounting l Iii 7 8 1l 8 0 8 1 2 5 8 8 7 1fJ7 8 H 8 0 8 1 2 5 8 8 7 Iii N m kg m ft b m JIic f f f m3 l I 11 mZc Zm o Zl Do r C mr Ii mXI C J Jl m J ...

Page 169: ...arts that are cracked fatigued or sweated INSTALLATION InstaU the exhaust system parts in the reverse order of removal ifl Exhaust manifold to front tube nuts 26 31 N m 2 7 3 2 kg m 20 23 ft lb Front tube mounting bracket nuts 7 8 11 8 N m 0 8 1 2 kgm 5 8 8 7 ft lb Catalytic converter attching bolts 31 42 N m 3 2 4 3 kg m 23 31 ft lb Rear muffler mounting insulator nut 7 8 11 8 N m 0 8 1 2 kg m 5 ...

Page 170: ...NG N CON ROL fU L E1 AUS S S e f j q o E 1 1 j j II II a P A Q 9 1 a Q oJ a j 6 j O e SFI ...

Page 171: ...CH DISC AND COVER RELEASE BEARING CLUTCH CONTENTS CL 2 l Ci 2 CL 2 CL 4 t 5 CL 5 C 7 CL 7 CL 9 PILOT BUSHING SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENiNG TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS CL 9 CL 11 clli CL 11 CL11 CL12 CL14 Refer to Section MA Clutch for CHECKING CLUTCH PEDAL HEIGHT AND FREE PLAY ...

Page 172: ...ue or damage Cl 2 r D G SC l002 l INSTAllATION I Install clutch pedal in reverse or der of removal Observe foUowing a Apply grea to boss ofclutch ped al return spring and fiih rum pin SCL003 b Firmly attach E ring to fulcrum pin SCL0Q4 Q Co I nstall clevis pin on tha left of clutch pedal and attach snap pin sa curaly d I nstall return spring as shown in Figure on this page 2 After assembly adjust ...

Page 173: ... Never use mineral oils such as gasoline and kerosene It will ruin the rubber parts of the hydraulic system 1 Check cylinder bore and piston for score or rust and iffo nd replace 2 Check cylinder bore and piston Lock nut lii7 8 118 0 8 12 5 8 8 7 Iii N m kg m fHb SCL005 for wear If the clearance between cylinder bore and piston exceeds specified value replace piston as sembly or master cylinder as...

Page 174: ...iston cup and dun cover 3 Remove bleeder screw CL222 1 Push rod 2 Dwt cover 3 Piston spring 4 Piston 5 Piston cup 6 Operating cylinder 7 Bleeder screw INSPECTION Visually inspect all disassembled parts and replace parts which are worn or damage CAUTION To clean or wash all parts of operating cylinder clean brake fluid must be used Never USe mineral oils such is gasoline and kerosene It will ruin t...

Page 175: ...nect clutch tube to master cylinder with flare nut 2 Fix clutch tube to dash panel with clamp 3 Then tighten flare nut l i Clutch hose to master cylinder 15 18 N m 1 5 1 8 kg m t1 13 ft lb 2 Install clutch hose on operating cylinder with a gasket in place Use new gasket l i Clutch hose to operating cylinder 17 21 N m 1 7 2 1 kg m 12 15 ft lb 3 Engage opposite end of hose with bracket Install lock ...

Page 176: ...rew 6 9 8 8 N m 0 7 0 9 kg m 5 1 6 5 fHbl 7 Depress and release dutch pedal several tim s then check for external hydraulic leaks at connections a Brake fluid containing air i white and has visible air bubbles b Brake fluid containing no air runs out of bleeder screw in a solid stream without air bubbles c Pay close attention to clutch fluid leve in reservoir during bleeding operation d Add brake ...

Page 177: ...table cleaning SCLOll solvent to remove dirt and grease before making inspection and adjust ment Flywheel end pressure plate Check friction surface of Ilywheel and pressure plate for scoring or roughness Slight roughness may be smoothed by using fine emery cloth If surface is deeply scored or grooved the part should be replaced Clutch disc assembly Inspect clutch disc for worn or oily facings loos...

Page 178: ...fied value at outer edge of clutch disc CL 8 CL 151 2 Measure height A at several points with a vernier caliper depth gauge Oiaphragnt spring height A 31 6 33 6 mm 11 244 1 323inl l SCL014 If height A of spring end beyond specified value dju t spri lll height with Tool ST20050240 1 necessary replace clutch cover as sembly SCL018 Also unevenness of diaphragm spring toe height should be wilhin the s...

Page 179: ...aring on sleeve using a press l j l I u SCL015 Do not depress outer race 2 Before or during assembly lubri cate the following points with a light coat of multi purpose grease 1 Inner groove of release bearing sleeve L SCL016 2 Contact surfaces of withdrawal lever lever ball pin and bearing sleeve 3 Bearing sleeve sliding surface of transmission case front cover SMT016 CLUTCH Clutch Unit 4 Transmis...

Page 180: ...e time INSTALLATION 1 Before installing a new bushing thoroughly clean bushing hole 2 Inser1 pilo1 bushing until distance A between flange end and pilot bushing is specified distance CL10 Distance A 4 0 mm 0 157 inl Do not oil bushing When inserting pilot bushing be careful not to d amage edge of pilot bushing A Pilot bushing EM719 3 InstaU clutch disc and clutch cover assembly Refer to Clutch Dis...

Page 181: ...ton mrn in I Lessthan 0 15 10 00591 J a UTCH DISC Unit mm In I Model 200CBL I Wear limit offacing surface to rivet 0 3 10 0121 I hood Runout limit 0 5 10 0201 I Distance of nout checking point 9513 741 from the hub center I Maximum backlash of spline 0 4 10 016 at outer edge of disci aUTCH COVER Unit mm lin I Model C200S I Dioph agm spring ho ght 31 6 33 6 11 244 13231 I Unevenness of diophragm sp...

Page 182: ...while simultaneously engaging clutch If engine stops while clutch is being engaged clutch is functioning properly If car does not move and the engine does not slop clutch is slipping Probable cause Corrective action Clutch facing hardened or wet with oil Clutch facing excessively worn Diaphragm springweak or damaged Flywheel or pressure plate warped Particles in return port of master cylinder Pist...

Page 183: ...ragm spring fatigued Clutch facing hardened Clutch facing warped Pressure plate worn or warped Engine mounting loose or rubber deteriorated Clutch facing rivets loose Replace Replace Replace Repair or replace Replace Tighten or replace Replace NOISY CLUTCH Probable cause Corrective action Release bearing sleeve damaged or improperly lubricated Pilot bushing worn jammed or damaged Clutch facing riv...

Page 184: ...me Kent Moore No KV30100100 Clutch aligning bar CLJI 2 1 ST20050100 Distance piece ST200500 10 Base plate 39 ST20050051 Set bolt ST200S0240 Diaphragm spring adjusting wrench STI661 000I 123907 Pilot bushing puUer n o GG94310000 Flare nut torque wrench IIIIlII lII1A CL14 ...

Page 185: ... TRANSMISSION CASE FORKS AND FORK RODS GEARS AND SHAFTS REPLACEMENT OF OIL SEALS CONTENTS MT 2 MT 2 MT 2 MT 3 MT 6 MT 7 MT 8 MT 9 MT14 REPLACEMENT OF BEARINGS SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS MT14 MT16 MT16 MT16 MT17 MT18 MT2 2 ...

Page 186: ...emove bolts securing 1ransmis sian to engine Then support the engine and trans mission with jacks and slide transmis sion rearward away ffom engine and remove from the car CAUTION Take care in dismounting transmission not to strike any adjacent parts and main drive gear INSTALLATION Install the transmission in reverse order of removal paying attention to the foUowing points I Before installing cle...

Page 187: ...9 2 0 Revet lampowS29 2 0 3 0 14 22 23 1 6 2 3 12 17 f Bearing 3 0 14 2 Adapter plate Front cover Filler plll8 Iii 25 34 2 5 3 5 18 25 Apply sealant to thread of bolts Drain plug Iii 25 34 2 5 3 5 18 25 E 21 1 6 2 1 12 15 Iii N m kg m ft lb C1I en m m C f0 Zen3 enen5z 3 Z C r I ZCJl 3 enCJl o Z I i a 3 oQ1 JJ C1I e OJ I iii g ClIt l l ...

Page 188: ...ad spring Pay attention to its direction Shifting imert r G 1st a 2nd synchronizer hub 2nd maingear 123 CounterJbaCt lock nut ifJ 98 127 10 0 13 0 12 94 counter geu Apply gear oil to needle bearing Counter front bearing Snap ring Woodruff key Reverse idlet sear bearing Reverse idler thro t washer Reverse idler shaft Shim Refer to transmission case for assembly Iii N m kg m ft b SMT040 MT 4 ...

Page 189: ...read of bolt t Retrun pri Iii 7 8 9 8 O g 10 Check prins 1 plunger 5 8 7 2 Return checking Check ball pl1lll SPriDl Apply locking sealer to thread of bolt qeontrollever bushing 0 J Lock pin Apply gear oil to O ControlleYer 5Controlleverb ahUw Retainins Pin Interlock baD 3m 4th Cork rod Reverse OD shift Cork 3m 4th shift Cork Iii 19 25 19 2 5 14 18 Ioterlock baD Iii lm k8 m Ct lb SMT150 MT 5 ...

Page 190: ...ing and rear extension housing sion SMT003 6 Remove rearextension SMTOOS 7 Remove lock pin and then remove striking rod MT 6 ASSEMBLY I Stand transmission case assembly on wooden plates of more than 20 rom 0 79 in thick 2 Clean mating surfaces of adapter plate and rear extension 3 Apply sealant to mating surface of adapter plate 4 InstaU rear extension as foUows I Se gears at Neutral 2 Turn striki...

Page 191: ...mm O 79 in thick 3 Apply sealant to mating surface of transmission case 4 Slide gear assembly onto adapter plate by lightly tapping with a soft hammer 5 Make certain that mainshaft roo tates freely SMT014 6 Fit main drive bearing snap ring 7 Select countershaft front bearing shim as foUows 1 Measure height A I TM371 1 Tranlmission case 2 Counter gear front bearing 3 Counter gear 2 Select a shim of...

Page 192: ...ct baD ED Interlock ball TM198A 6 Drive out retaining pins 7 Drive out fork rods and remove interlock baUs and check baUs Be careful not to lose three 3 check balls and four 4 interlock balls INSPECTION Clean with solvent and check for wear scratches projection damage or other faulty conditions Replace any part which is worn or darnaged one 6 SMT137 ASSEMBLY I InstaU 1st 2nd 3rd 4th and Q D Rev sh...

Page 193: ...NSMISSION 5 speed Transmission Model FS5W71B TM398 6 Remove counter drive gear snap ring 7 Draw out counter drive gear with main drive gear When drawing out main drive gear mbly b car ful not to drop pilot n edle bearing and baulk ring 3rd meln geer I Remove snap ring and thrust washer 2 Draw out 3rd 4th synchronizer and 3rd gear o D geer end reverse geer 1 Remove main drive and counter drive gear...

Page 194: ...372 2 When race and baU surfaces are worn or rough or when balls are out of round or rough replace bearing with a new one 3 Replace needle bearing if worn or damaged Gears snd ahafts I Check all gears for excessive wear chips or cracks replace as required 2 Check shaft for bending crack wear d worn spline if necessary replace 3 Measure gear end play It is necessary to measure end play before disas...

Page 195: ...SSEMBLY Adapter plate I Place new dowel pin mainshaft bearing on adapter plate and tap them Adapter plate Dowel pin 2 places Mainshaft bearing7 1fU11 Unit mm in SMT027 2 Insert reverse idler shaft 3 InstaU bearing retainer 4 Tighten each screw then stake it at two points I I r A 5 InstaU counter rear bearing with a soft hammer Synchronizer 1st 2nd and 3rd 4th I Assemble couplingsleeve and hub 2 Po...

Page 196: ...until they are seated securely MT12 Vl SMT031 4 Install thrust washer on mainshaft and secure it with snap ring of proper 1hickness that will minimize clearance of groove in mainshafl Mainshaft front snspring Refer to S O S TM441 cHOJ L Main drive and counter drive 8ear 1 Install baulk ring on synchronizer Be RU to align of baulk ring with inserts 2 Apply gear oil to mainshaft pilot bearing and in...

Page 197: ... replacing main 0 0 gear and counter 0 0 gear be sure to re place as a set of main 0 0 and counter 0 0 gears 3 Assemble reverse counter gear overdrive counter gear 4 Assemble new mainshaft nut and tighten it temporarily 5 InstaU bearing 6 Mesh 2nd and reverse gear and tighten mainshaft lock nut and count er gear lock nut w ST22520000 Iii 137 167 N m 114 0 17 0 kgm 101 123ft lbl SMT044 iJ Counter g...

Page 198: ...ase bear ing and withdrawal lever MT14 MAIN DRIVE AND 7 COUNTER FRONT 1 Remove main drive and counter drive gear Refer tb Gears and Shafts for disassembly 2 Remove main drive gear snap ring and spacer 3 Remove main drive bearing 5 Remove front CO Ier 6 Remove oil seal 7 Apply coat of gear oil 0 oil seal surface then drive new seal into place ST23800000 PreS Z Y o J oV 80 SMT036 8 Lubricate seal li...

Page 199: ...Draw out mainshaft assembly together with counter gear by tapping rear end of main shaft and counter gear Hold front of meinshaft essembly by hand being careful not to drop counter gesr TP 347 8 Remove bearing retainer SMT039 9 Replace mainshaft bearing by new one 10 Press out countershaft rear bear ing CAUTION When pressing out bearing gear hold shaft by hand so as not to drop it III Countenhaft ...

Page 200: ...4 3 121 INSPECTION AND ADJUSTMENT GEAR END PLAY 1 st main gear 2nd main gear 3rd main gear 5th main gear Rev idler gasr Unit mm in FS5W718 0 27 0 34 00106 00134 0 12 0 19 00047 00075 0 13 03710 0051 0 01461 0 10 0 17 0 0039 0 00671 005 0 50 0 0020 0 0197 a EARANCE BETWEEN BAULK RING AND GEAR I Standard I Wear limit Unit rnm in All models 120 1 60 10 0472 0 06301 0 810 0311 Main drlv s er b erlns A...

Page 201: ...allation I Clutch operating cylinder 30 40 3 1 4 1 22 30 I Transmission to engine 43 58 44 5 9 32 43 I Gusset to transmission 25 35 2 6 3 6 19 26 transmission I Crossmember to body 31 42 3 2 4 3 23 31 I Rear mounting insulator 31 42 3 2 4 3 23 31 to crossmember I Rear mounting insulator 31 42 3 2 4 3 23 31 to reaf extension I Transmission case to 16 21 16 2 1 12 15 rear extension I Starter motor t...

Page 202: ... Disassemble and check gear in which l noise occurs for meshing surface nd bearings 1 Replace gear and or bearing MIlS Noise in position other than Neutral Noise stops Noise in transmission Noise may be caused by variations in engine torque Adjust engine idle speed High roaring noise occurs in all positions and peaks 8t specific engine rpm I Noise occurs in all positions except Neutral and peaks a...

Page 203: ...assemble and check transmission Adjust or replace Replace Check end play of jump out gear I End play O K Check for engaging damage or wear on coupling sleeve synchronizer hub and clutch gear of main gear I End play excessive Damage or wear OK Check for wear or damage on check ball and fatigue or breaks on check spring I Replace Damage or wear Replace O K Check for wear or deformation of fork rod b...

Page 204: ... clutch Refer to Clutch Drags Section CL for trouble diagnoses and corrections I O K Problem may be inside transmision Disassemble and check transmission 1 Measure baulk ring to gear clearance Refer to Baulk Ring for inspection Clearance O K l Check for w ar on chamfered area of baulk ring I Chamfered area not worn 1 Check contact pattern of baulk ring and tapered cone ofclutch gear Proper contact...

Page 205: ...ir or replace O K Check gear end faces and gear bores for any sign of stickingjamming If detected replace faulty parts O K N G Check engine idle speed I Adjust O K I Check for improper dis engaging of clutch Check for improper oper ation of clutch operating cylinder master cylinder I Operation N G Operation O K I Check lubrication oil level and color I Repair clutch N G Add replace oil I O K Check...

Page 206: ...4 n ST23860000 ST22360002 125679 ST22520000 ST23800000 125691 KV32 101330 ST22350000 125678 MT 22 SPECIAL SERVICE TOOLS Tool name Adapter setting plate Fork rod pin punch Bearing puUer Transmission press stand Counter gear drift Bearing drift Wrench Transmission drift Bearing puUer Mainshaft bearing drift 9 Lo rQ OJ rUoLh ifi ...

Page 207: ...Tool number Kent Moore No ST33400001 126082 MANUAL TRANSMISSION Special Service Tools Tool name OU seal drift MT23 ...

Page 208: ...SMISSION ASSEMBLY MAJOR OVERHAUL OPERATIONS SERVICE NOTES FOR DISASSEMBLY DISASSEMBLY COMPONENT PARTS AT 2 AT 3 AT 5 AT 25 AT 28 AT 28 AT30 AT31 AT31 AT 34 FINAL ASSEMBLY TROUBLE SHOOTING AND DIAGNOSES PRELIMINARY CHECKS Prior to road testing DIAGNOSTIC ROAD TEST PRESSURE TESTING STALL TESTING SERVICE DATA AND SPECIFICATIONS SPECIAL SERVICE TOOLS AT 44 AT51 AT 51 AT 52 AT 54 AT 55 AT 52 AT 53 ...

Page 209: ... if 1 Transmission case 2 Oilpump 3 Frorit clutch 4 Band brake 5 Rear clutch 6 Front planetary gear 7 Rear planetary gear DEScRIPTION FLUID RECOMMENDATION Use DEXRON type automatic transmission fluid only IDENTIFICATION NUMBER Stamped position The plate is attached to the right hand side oftransmission case AT344 8 Oneway clutch 9 Low Reverse brake 10 Oil distributor 11 JQvemor 12 Outputshaft 13 R...

Page 210: ...r and throttle pressure or accelerator position sole noid downshift valve See Hydraulic Control Circuits Drive 3 Range 2 3 Timing valve For 23 shifts a restrictive orifice slows the application fluid to the front clutch while the slower reacting band is allowed to release This prevents a hard 2 3 or 3 2 shift Under heavy load however the engine will tend to run away during the 2 3 or 3 2 shift pau...

Page 211: ...ontrol valVe rTil SV J AT094 1 Pressure regulating valve 2 Manual valve 3 lst 2nd shift valve 4 lnd 3rd shift valve 5 Pressure modifier valve 6 Vacuum throttle valve 7 Throttle back up valve 8 Solenoid down shift valve 9 Second lock v8Ive 10 2 3 timing valve AT 4 ...

Page 212: ...overnor feed pressure 1 pressure 1 Servo tightening o 0 pressure 9 1 1 lnl Front clutch rr I I Low reverse brake pressure 12f pressure 11 U 0 0 Jj J o P sucti e Oil pump discharge hole 7 Torque converter pressure 14 q Rear clutch pressure 1 Front clutch pressure 11 LOiiJ u nm P suction hole a AT10S AT107 MECHANICAL OPERATION In the 3N71 B automatic transmission each part operates as shown in the f...

Page 213: ...lined to the output shaft preventing movement of the car When the engine is running the low and reverse brake is applied by pressure from the manual v Uve passing through the 1 2 shift valye F Locr 11 A T086 Fluid flow Manual Valve 4 Downshift Valve 13 2nd 3rd Shift valve 1st 2nd Shift Valve Throttle Back up Valve 5 Ist 2nd Shift Valve 12 I 1 hottle Back up Vave y Low Reverse Brake I AT 6 ...

Page 214: ...ler TIC Oil r Slllt ro O j 01 Rnt lubrication o Drain 14 01 Front lubricati 0 0 1 1 J 1 x J l I 6 II CD P ur otor JJI 1 p 1 1 Throttl drain 1 I C 1 SII JL J 2Z II x 1J IE 2no 3 d Ii mino vol 1 I II I I ck II r3 I I 15 Jji t 2 Sh I j I ru I II Monuol YOI I I xn llrr Itr Not Mork d X ort droin Secondory Qovunar lOlv Lin prulUr lGoy rnor fud pt r Primo OO lIOr olv Go rnor prUI1 l11l I Torqu con t t r...

Page 215: ...terclockwise in a reduction ratio of approximately 2 18 to I Fluid flow Manual Valve 4 Mechaitical Operation during R Range Front gear set Front clutch ON Rear gear set Output Input through front clutch Held by low reverse brake A T329 Low reverse brake ON N Front clutch Rear clutch Low and reverse brake Brak band servo One way clutch Downshift Valve I3 5 Throttle Back up Valve 6 Ist 2nd Shift Val...

Page 216: ...al I II xjJl uff I n ui i M O k II r 1 L J U lr 1 vci I u r l l 1 x No Markld X dfoin lrto Lin preuur Gornor ud pr ur Oil Pressure Circuit Diagram R range Reverse Torque ton l rt r broil Brok band J12 Oil cool x jJ G9 2nd 3rd liming olv x CD p Jr ator L r G av rnor prn ure fm Torqu COMut r prl ll Th ronl pr un ID 24 Ool l r rl 6 I Secondory gornOI lGlv Primor go itlr 01 1 AT456 AT 9 ...

Page 217: ...Hydraulic Control Cirwiu AUTOMATIC TRANSM ISSION N RANGE NEUTRAL Power flow In ange no friction elements are in use thus no power is trans mitted to the output shaft AT10 ...

Page 218: ... Front lubricaf t Drain 01 1 t x Xl II CD P otor Bond YO I 1 Throttle drain 101 11 10 c o Z2 II t1J x 21 6 IV ilL d lock frO 6 II r OI Not Worked on drain lint prUSUft Go rnor ud pr nur G o no prlssure nI tI Torqu conyut pnn r ft Th rottl p ur I 12 x Vacuum Ihrottl oh Throtllt bacll up wolv I JI F e X own i1t OIY rI5 I jULj I I II II fLx 5 l r J t 2 dl ShiflIllGIY I I I I Slcondar OOv nor 01 Primo...

Page 219: ...he sun gear causes the rear planet gears to rotate clockwise With the one way clutch holding the rear planet carrier the rear planetary gears turn the rear internal gear and outpu1 shaft clock wise in a reduction ratio of approxi mately 2 46 to I Fluid flow Manual Valve Mechanical Operation during 61 Range Front gear set Reargear set Output shaft Held by one way clutch Input from front gear set Ou...

Page 220: ...ar 1 Torqu ean rl r Oi I pump t 1 Pres ur rlQulo1or valv L Front cluleh t I 6 2 J 1 t Rlar cl utch Brake bond Low Q nd r v 1 brake 3 Shill OI o t Bond I b 7 ervo I 1 Torque conyerter pressure Throttle prlssure It l l 1 Throttle pr sur t I Governor pressure lint pr s ur Governor pre sure AT446 AT13 ...

Page 221: ...ion ratio of about 146 to I Front gear set Rear gear set AT331 Front clutch OFF Rearclutch ON LOw and revelSe biake OFF llr Ike band servo ON One way clutch OFF AT079 Fluid flow As car speed and governor pressure increase the governor pressure acting on the end of the 1 2 shift valve overcomes the force of the 1 2 shift valve spring and line pressure This aUows the 1 2 shift valve to move to the u...

Page 222: ...Oil pump t f J Tor q ua conYerter Pressure r oulator valve Line pressure Gover or pressure Front clutch Brake ba nd Low and revers broke Reor clutch I tl t 2 hjf llvOIV t rt u l 1Itrrr 1ltrrr 1Itrrr Throttl e It pressure j P RND21 Govern or pressure Torque converter pressure Throlll prellur AT448 AT15 ...

Page 223: ...ual Valve Mechanical Ojleiation during D3 Range Front gear set Rear gear set Input through front and rear clutches Output shaft AT332 Front clutch ON Rear clutch ON Il N Front clutch Rear clutch Low and reverse brake Brake band servo One way clutch valve When the 2nd 3rd shift valve opens pressure passes through the valve lands to the 2 3 timing valve and on to apply the front clutch and Governor ...

Page 224: ...pump To rq ue c anYlrter r l Pressure re QU lator valve L in pressure Governor pressure Fronf clutch Low and rever brake Rear clutch Brake bond 0 t Bond JJ JI 1 y W r t I t sY if t tr Il PRN021 t t Throttle pressure Ya Iv Governor pressure i tlo IIDJWq Torque eonv rter pr ur Iijp I Throlll preuur AT449 AT 17 ...

Page 225: ...ergizes the downshift sole noid which opens the solenoid down shift valve Oil pressure is then exerted against the shift valves Between 50 and 100 km h 30 and 60 MPH this pressure wiD close the 2nd 3rd shift valve against governor pressure and the car downshifts When the car speed is below 50 km h 30 MPH the Ist 2nd shift valve will be closed and the 1rans mission will be in 1 st gear As car speed...

Page 226: ... Oraln 14 vohl IFront lubriCQtif W 11 X J j D 1 I t 1 Qto j oz n l II m I lID Vacuum throttl 01 i d Yol 23 Ol yol l PRND2 I f SD o t y d I 3r J lu i I own i1 01 lI S U I I 8 18 16 Z l 3n IShift Yol Hmu u Jr 5 r r 1 pul B 2 d I ii lJlu r I N Tr Throttle drain 10 1 I C JI J Z2 g2nd 3rd limine a vI X J L 1 I Hot Worbd l ore Oroln IIo U Lin pr r Govlrnor fud p uunl L GOY flU pr u Tor4 lt c on I r prsu...

Page 227: ...ressure As this valve opens pressure then passes to apply the band servo Line pressure also flows to the throttle back up valve The range 2 position is used to lock he car in 2nd gear preventing upshifts or downshifts under any con ditions Manual Valve Governor Valve 15 Pressure Modifier Valve 2nd 3rd Timing Valve L 2nd 3rd Shift Valve Is1 2nd Shift Valve lst 2nd Shift Valve Rear Clutch I 2 Band S...

Page 228: ...tit WI x x 1 J Q Pr or Iau otor 01 1 Rlor r r r l v it I 9 10 ll 14 12 boc k up downall ft volv yolv t 6 f f I I I l r 13 Vacuum Ihrottlt 01 Throttl drain 01 11 l 11 i 22 2nr3rd Shift 01 In II 21 6 6 II Manual I P R f No worktd X or droln lint pr ur l o rnor t d pr urel Primory QO nor volvl 1 i l S Ga tnor p U Ur l JA Torque con pt r Th rottl pt fI AT459 AT 21 ...

Page 229: ...e 1 2 shift valve is used to close the 1 2 shift valve preventing a 1 2 up shift Manual pressure passing through the downshift valve locks the 2 3 shift valve closed along with applying addi tional c1 sing pressure to the 1 2 shift valve 2nd lnl Tuning Valve to lst 2nd Shift Valve lst 2nd Shift Valve 2nd lrd Shift Valve jRear Clutch I 4 Solenoid Downshift Valve 13 t2nd lrd Shift Valve Ist 2nd Shif...

Page 230: ...ft lol 1 I 01 1 vol ll 1 I II r 1 I i i f c 1 J I Ij l wr X Ie 16 1 2nct 3rd Shift val D ft m I II 1 lr 11 I f n j J ij jl N dX d ooo X Secondory Qov rnor 01 Torqul con r I 11 cooler Rlor lubricalion I Drain yo Oroln Yol Front lubriCG ltc tu I x rl u CD P UI otor C m con o Et oPhrogm ThroW drain vol II Lin prusur Goy rnor tud pr un Primory 90 Ie r nor 101 1 G ov rnor pr ul t A 0 3 Torqul converler...

Page 231: ... Olloro J I oB 0 l I oro l JI Rlor lubrication n 4 Iii II 11 Orain 0 01 FrOnt lub icotic Throttl drain 101 1 Or ain 1 01 1 f I D Pr uro nou otor vol uum oot ol hro m 2 I II 17 1 t 6 b JJ III 11i Th t1 IItIOl1 g bocll up downahi tyol 101 I 3 ldI I zo 1 r Sh l u L 6 I w Manual 2 PRND2 I f1 n Not Mork d X on drain Lute pru Gov rnor d pt urt Goy rnOt prlS U U T T rquI COn pr lur Th otll p nut AT 24 S ...

Page 232: ...TERY FUSIBLE LINK ST ON t CC OFF J D rIl J 6 r I BW 8 r WR IGNITION SWITCH MAIN HARNESS WB Q O O O O O O D lIl 0 0 0 0 U l 0 Ul O J 0 0 UI 0 o q o 0 0 0000 l D O Q O D FUSE BLOCK G I I J rOl E S G1 No 2 0 DOWNSHIFT 8 SOLENOID J iO I I the transmission to downshift on part throttle DIAGNOSIS Switch can be heard clicking and the transmission still does not kickdown Check the continuity of the switch...

Page 233: ...ch has two major functions It allows the back up lights to illuminate when the shift lever is placed in the reverse range It also acts as a neutraJ safety switch allowing Wiring DIagram 00 00 BACK UP LAMP R H gg ii ii RB RB 00 B 8 o BODY HARNESS BO BACK UP LAMP L H R O W B TTE a E WR 5T ON ACC Off 1 g g J J I11LBw J 6 0 rrw IGNITION SWITCH W W we c 2 BW IGNITION AND lJ ACCESSORY R ii W O U ii ii i...

Page 234: ...6 05 10098 10256 26 15 26 55 10295 10453 26 65 2705 10492 10650 Over 27 15 10689 BRAKE BAND ADJUSTMENT Proper brake band adjustment results in smooth shifting between 1st 2nd and 2nd 3rd Although the adjustment is very simple it is im portant to use an accurate torque wrench I Loosen locknut 2 Torque band servo piston stem to 12 to I5 N m 1 2to 15 kg m 9 to II ft lb VACUUM DIAPHRAGM ROD ADJUSTMENT...

Page 235: ... pan and jack Support transmission by means of a transmis sion jack AT 28 CAUTION Do not place the jack under the oil pan drain plug 12 Detach converter housing dust cover Remove bolts securing torque converter to drive plate QOOOO Before removing torque converter inscribe chalk maria on two parts so that they may be replaced in their original positions at assembly 13 Remove rear engine mount se c...

Page 236: ...Check inhibitor switch for oper ation Starter should be brought into operation only when selector lever is in P and N positions it should not be started when lever is in D 2 I and R positions Back up lamp should also light when selector lever is placed in R position IO Check fluid level in transmission For detailed procedure see page AT 51 11 Move selector lever through aU positions to be sure tha...

Page 237: ...ANSMISSIO N MAJOR OVERHAUL OPERATIONS Torque converter Input shaft Needleb reftTsebraJce Bearing race Needle bearins L Needle bearing Output abaft Oil chaIJing pipe c iI Speedometer pinion Valve body otIl Let L Parking mechanism SAn01 AT 30 ...

Page 238: ...T006 5 Remove speedometer lock plate retaining bolt Remove speedometer pinion SAT102 6 Remove oil pan and inspect its contents An analysis of any foreign matter can indicate the types of prob lems to look for If the fluid is very dark smells burned or contains for eign particles the frictional material clutches band may need replace men A tacky film that will not wipe clean indicates varnish build...

Page 239: ...ake band elwaYI secure it with a clip as shown in the figure be low Leave the clip i ition fter ra moving the brake band Flexible type bend I nk Unit mm in SAT106 oW 157 ApprOXimately 2 0 08 dia wire clip 13 Remove pump thrust bearing and rear clutch thrust washer SAT013 14 Remove rear clutch hub front planetary carrier and connecting sheU rear clutch thrust bearing front plane tary carrier thrust...

Page 240: ... retainer washer 01 23 Remove outpu1 shaft with gover nor 24 Remove governor thrust washer and needle bearing Remove one way clutch inner race attaching hex head slotted bolts using Tool SAT020 25 Remove one way clutch inner race return thrust washer low and reverse return spring and spring thrust ring o L I C EiL J 0 J l O 0 CJ r 11 AT021 26 Using an air gun with a tapered rubber tip carefuUy app...

Page 241: ...T024 3 Inspect gears and aU internal sur faces for faults and visible wear 4 Measure clearance between outer gear and crescent Standard dearanc e 0 14 0 21 mm 0 0055 0 0083 in Replace if the clearance exceeds 0 25 mm 0 0098 in SAT025 5 Measure clearance between outer gear and pump housing Standard dearance 0 05 0 20 mm 0 0020 0 0079 in Replace if the clearance exceeds 0 25 mm 0 0098 in SAT026 6 Us...

Page 242: ...ed total indicator reading 0 ST25580001 10 Tighten pump securing bolts to specified torque b Oil pump housing to oil pump cover 5 9 7 8 N m 0 6 0 8 kg m 4 3 5 8 ft lb 1 t t AT166 Recheck run out Replace Q ring and gasket AT264 FRONT CLUTCH O ring Spring retainer Dish plate Driven plate steel plate Drive plate riction plate Snap ring SAT086 AT 35 ...

Page 243: ... from drum SA T030 6 Check clutch drive plate facing for wear or darnage Drive plate thickness must no1 be less than 1 4 mm 0 055 in Standard driplate thickness 1 50 1 65 mm 0 0591 0 0650 in J 7 Check for wear on snapring weak or broken coil springs and warped spring retainer S Lubricate clutch drum hub and seals and instaU inner seal and piston seal as illustrated Be careful not to stretch seals ...

Page 244: ... different thicknesses un til correct clearance is obtained Available retaining plate Thickness mm in Part number 10 6 0 417 10 8 0 425 110 0 433 112 0 441 II 4 0 449 116 0 457 31537 XOIOO 31537 XOIOI 31537 X0102 31537 XOI03 31537 XOI04 31537 X0105 SA T034 14 Testing front clutch With front clutch assembled on oil pump cover direct a jet of air into hole in clutch drum for definite clutch operatio...

Page 245: ...in Test piston return spring for weak ness Discard if it is too weak BRAKE BAND AND BAND SERVO AT 38 Inspect band friction material for wear If cracked chipped or burnt spots are apparent replace the band SAT036 Check band servo components for wear and scoring Rep ace piston a rings and aU other components as necessary GOVERNOR To control valve 11 3 I Go rnot prc 15 z 1 Anchor end pin 2 Band strut...

Page 246: ...length Length Load mm in mm in coil mm in mm in N kg lb Primary governor 0 45 8 75 5 0 218 7 5 2 109 0 0177 0 3445 0 858 0 295 0 215 0 474 Secondary governor 0 70 9 20 5 5 25 1 10 5 10 788 0 0276 0 3622 0 988 0 413 1 100 2 426 PLANETARY CARRIER The planetary carrier cannot be divided into its individual components If any part of the component is faulty replace the carrier as a unit Check clearance...

Page 247: ...body HT61000800 AT168 9 9 J Q J IOIi c I 9 I 19uDdI io J uii LI 1 I ll AT1 9 3 During valve body separation do not scatter or lose orifice check valve servo orifice check valve and thro11le AT 40 relief check valve baU and related springs 4 Remove side plate A pressure regulator valve spring spring seat sleeve aod plug and second lock valve aod spring Place each loose part on a rack to retain corr...

Page 248: ... too coarse and can scratch the valves or valve bores Scratches can lead to future deposits of varnish or foreign matter SAT044 During cleaning do not remove the sharp edges of the valve When edges are rounded or scratched entry is pro vided for dirt or foreign matter to work into the sides of the valves and hinder valve movement The valves may be cleaned using alcohol or lacquer thinner The valve...

Page 249: ... 129 0 024 0 260 1 260 0 630 0 625 1378 2nd 3rd shift valve 0 7 6 9 18 410 17 0 13 73 0028 0 272 1614 0 669 I 40 3 09 2nd 3rd timing valve 0 7 6 2 15 32 5 27 0 5 39 0 028 0 244 1 280 1063 0 55 1 21 Throttle back up valve 0 8 7 3 14 36 0 18 8 18 83 0 031 0 287 1417 0740 192 4 23 Solenoid downshift valve 0 55 5 55 12 22 0 12 5 5 88 0 0217 0 2185 0 866 0 492 0 60 1 32 Second lock valve 0 55 5 55 16 3...

Page 250: ...N m 0 25 0 35 kg m 1 8 2 5 ft lb 14 Install orifice check valve valve spring 1hrottle relief valve spring and steel ball in valve body AT173 Orifice check valve AT430 side plate C group in same manner as A group SAT095 15 Install upper and lower valves cD Uppersnd lower VBlves 2 5 3 4 N m 0 25 0 35 kg m 1 8 2 5 ft lb Reamer bolt 4 9 6 9 N m 0 5 0 7 kgm 3 6 5 1 fNb ST25160000 16 Install oil straine...

Page 251: ... and iUustration as a guide to instaUation Oring seal ring use the foUowing procedures and locations Co Q gE do 0 a 0 c 2 Q Q 0 c u 5 Co e Q O C Q QC S oU e ll 3 0 C e oS F 8 i d 8 Co cii a8 Q a 5 H Q u e r 1 ll Ji Q Q U U e e C S d a j Q 1 5 zj Q U e I 8 f l il d e C C Co cii Q U e S a 5 Q a z s 8 S Co f t e IS SA T099 AT 44 ...

Page 252: ...ear of case WARNING Check that return spring is centered on race before tightening Tighten the bolts G J One way clutch inner race to transmission case 13 18 N m 1 3 1 8 kg m 9 13 ft lb I I i i 7 l i ST25570001 lfiu ST25490000 GG91060000 5 Install steel dished pla1e first then steel and friction plates and fmaUy retaining plate and snap ring 6 After low and reverse brake has been completely assemb...

Page 253: ...rust washer with petroleumjeUy and instaU rear planetary carrier SATOSS 15 Install rear planetary carrier snap ring This snap ring is thinner than 8 clutch drum snap ring so ba sure you are using correct size If you have in sufficient spaco to install snap ring int drum groove pull connecting drum forward a far as possible This will give you sufficient groove clear anco to install drum nap ring 16...

Page 254: ... drum 3 Rear clu tch drum 4 Thrust bearing 5 Measure from top of oil pump shaft to gasket installed dimension C 1c I G k I ty oilPump SAT063 fU 0 III SAT064 6 Install thrust washer Measure from top of oil pump shaft to thrust washer dimension D I L fffi llV Oil pumpU SAT096 7 Difference between dimension A 0 1 mm 0 004 in B and C D is front end play and must be within specified value Specified fro...

Page 255: ... 16 0 063 31556 XOI02 18 0071 31556 XOI03 2 0 0079 31556 XOI04 2 2 0 087 31556 XOl05 AT 48 18 Install brake band band strut and band servo Lubricate servo Orings before installing Care should be taken to avoid damaging O rings when re mbling 19 Install and torque the retainer bolts Loosen piston stem rfl Servo piston retainer bolt 4 9 6 9N m 0 5 0 7 kg m 3 6 5 1 ft b 20 Finger tighten brake band s...

Page 256: ...manual valve is in alignment with selector pin u o tK oo1 o 28 Tighten control valve body attach ingbolts dl 5 4 74N m 0 55 0 75 kg m 4 0 5 4 ft Ibl Control valve body attaching bolts vary in length Care must be taken to ensure that each bolt is returned to correct hole 29 Check pump to transmission align I11ent and install converter housing dl 44 54 N m 4 5 5 5 kg m 33 40 ft Ibl 30 Before install...

Page 257: ...tion in each range using a circuit tester Refer to Minor Adjust ment SAT082 35 Before installing oil pan check alignment and operation of control lever and parking pawl engagement Blow mechanism with air to clean Make fmal check to be sure all bolts are installed in valve body 36 Install oil pan with new gasket tfl Oil pan to transmission ease 4 9 6 9 N m 0 5 0 7 kgm 3 6 5 1 ft Ibl Part number 319...

Page 258: ...7 8 US pt 3 4 Imp pt low Add only clean Dexron transmis sion l1uid or equivalent Fluid leakage To detect a l1uid leak I Raise car 2 Clean area suspected of leaking 3 Start engine apply foot brake place gear selector in drive and wait a few minutes 4 Stop engine 5 Check for fresh leakage If the transmission breather is 8US pected I Raise car 2 Clean the area around the breather 3 Run the car at hig...

Page 259: ... throttle After completing the road test compare the test results to lIIe Trouble shooting Chart on page AT 56 ROAD TESTING L Park Range Place the gear selector in P range and start the engine Stop the engine and repeat the procedure in all other ranges and neutral In park the car should be locked in position unable to roll or move Mark all results on the Symptom Chart 2 Reverse Manually shift the...

Page 260: ... 4 5 6 1 64 87 O2 0 II 18 7 II 350 600 o Full throttle I I 54 46 33 29 1750 1 500 549 706 5 6 7 2 80 102 40 0 300 1181 I I 54 46 33 29 1 750 1 500 549 706 5 6 7 2 80 102 Car speed can be calculated by the following formula v where V Np RF r v where V Np RF r 0 0307 x Np 1 2 x x r x Npx 60 RF x 1 000 Car speed km h Propeller shaft revolution rpml Final gear ratio 13 700 Tire effective radius m 185n...

Page 261: ...e install pressure gauge to port CD and when in R range install pressure gauge to port shown above Locate the gauge so it can be seen by driver Measure line pressure at idling and at stall test 2 Road test car and note pressure under different throttle conditions AT 54 20 90 100 130 140 30 40 50 30 60 70 120 70 80 10 20 80 40 50 60 SAT105 At idling Range Line pressure kPa kgcm2 psi 412 549 4 2 5 6...

Page 262: ...oper warm up c During test never hold throttle wide open for more than 5 seconds d Do Not test more than two gear ranges without driving car to cool off engine and transmission STALL TEST PROCEDURE 1 Install a tachometer where it can be seen by driver during test 2 Set hand brake and block wheels 3 Start engine and place shift lever in D range 4 Apply foot brake and accelerate to wide open throttl...

Page 263: ... will not run in 0 range but runs in 2 and R ranges Car will not run in D I 2 ranges but rims in R range Clutch slips Very poor acceleration Clutches or brakes slip somewhat in tarting Excessive creep No creep at all Failure to change gear from I st to 2nd Failure to change gear from 2nd to 3rd Too high a gear change point from 1st to 2nd from lnd to 3rdu Gear change directly from 1st to 3rd occur...

Page 264: ...ock felt during deceleration by releasing accelerator pedal Too high a change point from 3rd I to 2nd from 2nd to 1st Kickdown does not operate when depressing pedal in 3rd within kick down car speed Kickdown operates or engine over runs when depressing pedal in 3rd beyond kickdown car speed limit Races extremely or slips in changing from 3rd to 2nd when depress ing pedal AUTOMATIC TRANSM 15510 N ...

Page 265: ... Engine brake does not operate in 1 range Gear change from 1st to 2nd or from 2nd to 3rd in I range Does not change from 2nd to 1st in 1 range large shock changing from 2nd to st in range Transmission overheats n n 0 f a 0 g 0 ii S o o f l 601 2 3 123 I 2 Oil shoots out during operation White smoke emitted from 3 exhaust pipe during operation Offensive smell at oil charging pipe AT 58 ON CAR E e J...

Page 266: ...t R N I I I I I I I I II N I ENG START II I I I I I I I I RANGE IN II I I I I I I I I I Man shift N D II I I I I I I I I lIst I I I I I I I I I Auto shift 2 I I I I I I I 2nd I I I I I I I D I Auto shift 2 3 I I I I I I I II RANGE I 3rd I I I I I I I Decel 3 2 I I I I II I Kickdown 3 2 j I I I I I I Decel 2 1 I I I I I I Kickdown 2 1 I I I I I I 2 I Man shift 0 2 I I I I RANGE I 2nd II I I I I II ...

Page 267: ...0 mmHg 17 72 inHg in idling and whether it decreases with increasing rpm Check whether transmission engages positively by shifting N D 2 N and N R range while idling with brake applied Check whether there is any creep in D I and R ranges Measure line pressures in D 2 I and OR range while idling Measure engine rpm and line pressure in D 2 and R ranges during full throttle operation Temperature of t...

Page 268: ... I range with the accelerator pedal released and the engine vacuum pressure of 0 kPa 0 mmHg o inHg while driving at about 50 km h 30 MPH in D3 range Check for quick shifting down 0 2 and engine braking after shifting the lever into 2 range while driving at about 50 km h 30 MPH in 0 range Also check for locking of the transmission in 2nd gear ratio regardless of car speed Check for failure of the t...

Page 269: ...tomatic transmission assembly Model code number Torque converter assembly Stamped mark on the TIC Number of drive plates I Number of driven plates Clearance mm in Front clutch Thickness of retaining plate AT 62 Brake band X2305 Piston size Big dia mmlin Small dia G Control valve assembly Stamped mark on strainer 3 Governorassembly Stamped mark on governor body 3 1 6 2 0 0063 00791 Thicknesi mmOnl ...

Page 270: ... 3 6 5 1 Inhibitor switch to 4 9 6 9 0 5 0 7 3 6 5 t ca transmission case Servo piston retainer 4 9 6 9 0 5 0 7 3 6 5 1 Manual shaft lock nut 29 39 3 0 4 0 22 29 to transmission case Oil cooler pipe to 29 49 3 0 5 0 22 36 Piston stem when 12 15 12 1 5 9 11 transmission case adjusting band brake Test plug oil pressure 14 21 14 2 1 10 15 Piston stem lock nut 15 39 1 5 4 0 11 29 nspecticn hole One wa...

Page 271: ...ing compressor ST25320001 125710 Snap ring remover o ST2557000 I Hex head extension ST2557000Q J25718 ST25490000 Socket extension ST255 1200 I 125713 HT62350000 Spinner handle ST25160000 Torque driver ST25580001 Oil pump assembling gauge Q 125719 HT6 I000800 Hexagon wrench j ST2505S001 Oil pressure gauge set 125695 c AT 64 ...

Page 272: ... DIFFERENTIAL CASE INSPECTION PD 2 PD 2 PD 2 PD 3 PD 3 PD 3 PD 3 PD 3 PD 3 PD 3 PD 5 PD 6 PD 6 PD 6 PD 6 PD 7 PD 7 PD B PD 9 ASSEMBL Y DIFFERENTIAL CASE DIFFERENTIAL CARRIER ADJUSTMENT SIDE BEARING ADJUSTMENT PINION HEIGHT ADJUSTMENT FINAL VERIFICATION SERVICE DATA AND SPECIFICATIONS PROPELLER SHAFT GENERAL SPECIFICATIONS SERVICE DATA TIGHTENING TORQUE DIFFERENTIAL CARRIER GENERAL SPECIFICATIONS S...

Page 273: ...dents or cracks If damaged replace propeller shaft assembly If center bearing is noisy or damaged replace center bearing If journal is damaged or worn re place propeller shaft assembly PD 2 PROPELLER SHAFT VIBRATION To check and correct an unbalanced propeller shaft proceed as follows I Remove undercoating and other foreign material which could upset shaft balance and check shaft vibra tion by roa...

Page 274: ... the contact surface of the cushion facing upward Connecting portion Cushion c c r SPD124 INSPECTION PROPELLER SHAn RUNOUT Inspect propeller shaft runout If ronout exceeds specifications replace propeller shaft assembly Runout limit 0 6 mm 0 024 in itM SPD106 FLANGE YOKE AND SLEEVE YOKE If l1ange yoke and sleeve yoke are damaged or worn replace propeller shaft assembly SP0107 JOURNAL AXIAL PLAY In...

Page 275: ...aring with OF mark toward front of car Apply a coat of multi purpose lith iuin grease containing molybdenum di sulfide to the end faoe of the cente bearing and both sides of the washer 7 Insert the washer into the end of the center bearing Align the mark on the companion flange and install the companion flange 9 center bearing Washer Companion flange Locking nut I SPD115 8 Tighten locking nut usin...

Page 276: ... a te p ace J 111911 8 10 511 11 49 59 5 6 36 43 L ftna1 dl Ie assern ty DJ taCe Outct Side a i1 l adiustiflsbin l oetetrninitW side oeatIDS tnict t es Gas et tt l HaYt replace Ditfelentcattiet front oil a A aY replace Corovaniotll1 l y nWP mate hatt 34 15 15 3 5 18 1 5 u to 1 11 in on P 10 O 10 vep 1 43 iI ON HI u un I 13 19 1 00 l of 0 btained 1 plte P ue valuen 11 0 ad to 1 8 1 10 6 g Ct l1 t M...

Page 277: ...ould be replaced When backlash varies excessively in different places the variance may have resulted from foreign matter caught between ring gear and differential case I Runout limit 0 04 mm 10 0016 in SPD003 3 Check tooth contact referring to TOOTH CONTACT 4 Check backlash of side gear Using a thickness gauge measure clearance between side gear and differential case If it is not within specificat...

Page 278: ...make drive pinion go away from ring gear c DISASSEMBLY DIFFERENTIAL CARRIER 1 Put match mark on one side of side bearing cap with paint or punch to ensure that it is replaced in proper position during reassembly Bearing caps are line bored during manufacture and should be put back in their original place 1 08 Correct tooth conae1 2 Remove side bearing caps SP 0009 1W 3 Using a pry bar remove diffe...

Page 279: ... outer race using a brass drift SPD017 9 Remove collapsible spacer from drive pinion 10 Pull out rear bearing inner race with a press and Tool Care should be taken when setting Tool in press to maka sura that parting line of Tool is a right angle to support fixture of press This is to prevent bonding Tool SP0018 O K N G lie Support fIXture DIFFERENnAL CASE I Remove side bearing inner race with Too...

Page 280: ...ld be replaced by new ones each time they are removed CD Gasket Frontoilseal ID Collapsible spacer Lock strap SP0028 ASSEMBLY Assembly should be done in the reverse order of disassembly while making any necessary inspections and adjust 1ents PRECAUTION a Arrange shims and washers to in stall them correctly b Thoroughly clean the surfaces on which shims washers bearings and bearing caps are install...

Page 281: ...aring outer races using Tools SP 0035 1 2 Select pmlOn height adjusting washer referring to PINION HEIGHT ADJUSTMENT 3 Install pinion height adjusting washer in drive pinion bevel side toward gear and press fit rear bearing inner race in it using press and Tool 4 Lubricate front bearing with gear oil and place it in gear carrier SPD045 5 Using Tool carefully fit a new oil seal into carrier Make lu...

Page 282: ...y and side bearing miter races into dif ferential carrier and install side bear ing cap Tap on the cap with 8 soft ham mer to settle it in the carrier The bearing cap should be installed with the marks put 8t disassembly aligned IiJ 49 59 N m 5 0 6 0 kg m 36 431t IOI If SPD044 ADJUSTMENT SIDE BEARING ADJUSTMENT Side bearing SPD046 Side bearing adjulting shim When the differential case side bearing...

Page 283: ...en width of left E or right F side bearing and standard width A B C D and H are dimensional variations in a unit ofl 100 mm against each standard value race and inner race to be measured on the opposi e side outer race and place the weight block on that bearing assembly If the bearing embly i placed on the base plate the bearing width cannot be accurately determined due to its cage being in contac...

Page 284: ... 0 05 x I 0 05 Total thickness 0 35 mm Right side T2 B D H xO 01 0 09 F 2 3 2 xO OI 0 09 0 20 I B 2 D 3 I H 2 3 2 3 x 0 01 0 03 3 0 03 0 09 0 06 4 0 06 0 20 0 26 F T 0 26mm Right side Calculated value T 2 0 26 mm Used shims Thickness 0 07 x 0 05 x Quantity 3 0 21 I 0 05 Total thickness 0 26 mm PINION HEIGHT ADJUSTMENT I I l Hiit SP0056 When replacing the hypoid gear set drive pinion bearing or gea...

Page 285: ... and the dummy shaft face PO 14 CAUTION To avoid any confusion while calculat ing it is necessary to stay with the metric system If you measure any thing in inches the result should be converted to the metric system D s n 3 H D and S aredimensional variations in a unit of 1 100 mm against each standard value ST31141000 SPD061 SP 0127 4 Substitute these values into the equation to calculate the thi...

Page 286: ...ring the rotating resistance in a backlash Preload At ring gear bold 14 7 26 5 N 11 5 2 7 kg 3 3 6 01bl SPD067 If prelOad i too great remove the same amount of shims to each side If preload i too mall add the same amount of shims to each side Never add or remove different amount of shims to each side or ring gear beckla h will be changed 5P0031 3 Check runout of ring gear with a dial indicator SP0...

Page 287: ... 8 0 9 1 2 I Center bearing bracket I to body 25 39 2 6 4 0 PD 16 Unit mm in 3S63A 3 Sleeve type 63 2481 Shell type Non Disassemblv type 3201 2 601 730 28 741 75 0 2 9531 50B 2 0001 Unit mm in 0 6 0 0241 kg m fHb 2 4 3 3 17 24 25 30 8 217 45 74 6 5 8 7 9 29 DIFFERENTIAL CARRIER GENERAL SPECIFICATIONS I Model I TVpe I Ring gear pitch dianleter mm Unl I Gear ratio I Number of teeth Ring gear drive p...

Page 288: ...ntial co io to 3 66 10 14411 38154 U1519 rear axle case 25 34 2 5 3 5 18 25 TROUBLE DIAGNOSES AND CORRECTIONS PROPELLER SHAFT Condition Vibration during at medium or high speed Knocking sound during starting or noise during coasting on propeller shaft Scraping noise Whine or whistle Probable cause Worn or damaged journal beari n Unbalance due to bent or dented propeller shaft Loose propeller shaft...

Page 289: ...earing under preload Loose drive pinion miL Loose boltS and nuts such as ring gear bolts Shortage ofoil or use ofunsuitable oil Excessively small backlash Incorrect adjustment ofbearings or geats Severe ser vice due to an excessive loading improper use of clutch Loose bolts and nuts such as ring gear bolts Worn out damaged or improperly driven front oil seal or bruised dented or abnor mally worn s...

Page 290: ...0 See 125269 01 CD ST31141000 ST31942000 PROPELLER SHAFT DIFFERENTIAL CARRIER Special Service Tools SPECIAL SERVICE TOOLS Tool name Engine stand Engine stand Base Diff attachment Drive pinion feaf bearing inner race puller set Puller Base Drive pinion bearing outer race drift bar Drive pinion rear bearing outer race drift Drive pinion front bearing Quter race drift 6 Drive pinion setting gauge set...

Page 291: ... Torque wrench Socket adapter 1 2 1 Socket adapter 3 8 t o e ST31530000 Drive pinion l1ange wrench 125774 ST32501000 Weight block 125407 3 ST33051001 Diff side bearing puller ST33052000 Adapter 125797 1 5J ST33400001 Oil seal fitting tool 126082 ST33741000 Master gauge See 125407 1 18 5 mm 0 728 in 8 KY311 00300 Solid punch KY38102100 125803 Diff side bearing drift PD 20 ...

Page 292: ...TRANSVERSE LINK AND LOWER BALL JOINT SUSPENSION CROSSMEMBER FA 2 FA 3 FA 5 FA 5 FA 9 SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS FA 12 FA 12 FA12 FA13 FA10 FA ll FA 14 FA 17 Refer to Section MA Front Axle and Front Su pen ionl for ADJUSTING WHEEL BEARING PRELOAD CHECKING WHEEL ALlGNMENT ...

Page 293: ...bilizer bar l Te llion rod Tranl Vcue link J 50 60 5 1 6 1 37 44 J 78 98 8 10 58 72 Wheel bearing Do not overtighten wheel bearing nuts as this can cawe wheel bearing seizure Axial play 0 mm 0 in Preload As measured at wheel bolt with used parts 2 0 7 8 N 0 2 0 81rg 0 4 1 8 lb When measuring bearing preload do not include dragging resistance with brake pads Refer to Section MA for Adju linB Wheell...

Page 294: ...nd then sup port it with safety stands Refer to Section GI for Lifting Points and Towing 2 Remove wheel and tire assembly 3 Remove caliper assembly Refer to Section BR for removal Screwdriver 7 Separate outside wheel bearing inner race and washer 8 Separate brake rotor and hub O riJ11 5 Pry off cotter pin take out adjusting cap and wheel bearing nut Cotter pin must not be reused 6 Remove wheel hub...

Page 295: ...ter race with Tool until it seats in hub FA 4 I I 1 11 1 Y III SFA 124 2 Pack hub and hub cap with re commended multi purpose grease Coat oring with recommended multi purpose grease O l q MuIt purpo grease point SFA125 3 Coat each bearing with reCom mended multi purpo gr 4 Place inner bea J in in hub and install a new grease seal coating seal ing lips with recommended multi pur PO gr Multi purpo g...

Page 296: ...bilizer bar 1 J4454 4 5 5 5 33 Z Tension rod bracket I J 31 42 3 2 4 3 23 31 I J N m kg m ft Ib SFA128 SPRING AND STRUT ASSEMBLY Strut kit I J 59 74 6 0 7 5 Gland packing 43 54 I J 25 34 rstruI packing kit C 2 5 3 5 O nng 3 18 25 I ton rud I uldebusllIng Mountingin u1alor ShoCk Lock nut Mounting bearing b O ber kit withdust seal I Washer sPring upper seal Inner cylinder GBound bumper rubber DUSI c...

Page 297: ...dledge 25 34 N m 2 5 3 5 kg m 18 25 ft Ibl Strut to knuckle arm 72 97 N m 7 3 9 9 kg m 53 72 ft Ibl DISASSEMBLY When disassembling strut assambly extra caution should be exercised to prevent dirt and dust from entering strut Set up Tools on strut assembly Compress spring just for enough to permit turning of strut mounting in sulator by hand HT7t730000 ST35652001 SFA133 2 Remove lock nut from top o...

Page 298: ...rmation or other damage As for inner cylin der replace shock absorber kit As for outer casing replace strut assembly FRONT AXLE FRONT SUSPENSION FrontSuspension Inner diameter Inner cylinder 30 02 30 10 mm 1 1819 1 1850 in SFA136 Maximum runout Inner cylinder Less than 0 2 mm 0 008 in t r O cYlinder SFA137 Piston rod Inspect piston rod for cracks defoffilation or other damage Re place shock absorb...

Page 299: ...8 58 o 0 3 o u Converted torquel p 59 6 43 N m q ft lb 0 3 0 4 0 5 0 6 m SFA144 10 1 5 2 0 L Effective length of torque wrench ft 8 Remove trut from Tool KV48100301 9 After the above steps have been completed air should be removed from shock absorber syst m Repeat above procedure everal timal 10 that air will ba bled out from strutthoroughly al hown FA 279 1 FA280 10 Reinstall strut on Toot KV48 1...

Page 300: ...ON Front Suspension Coil spring miI I I Sprmg seat dPlace pnng In po ilton SFA149 Spnng InstallatIon TENSION ROD AND STABIUZER BAR e Stabilizer braCketlj rl1 IV 31 42 3 2 4 3 23 411 IV 50 60 To tension rod bracket 5 1 6 1 IV 44 54 In cJO J I 37 44 4 5 5 5 l 33 40 Tension rod J To tension rod t 1 bracket Transverse link A IV 16 21 16 2 1 1215 IV N m kg m ftIb SFA150 Remove under cover Set load of c...

Page 301: ...t I Stabilizer Tension rod SFA1511 6 Remove transverse link from crossmember SFAl58 7 Separate following parts I Ball joint to knuckle arm using press FA712 I Unk bushing to transverse link using Set Tool ST36720000 f rG SFA159 8 Install transverse link and lower ball joint in the reverse order of re moval noting the following I Wh n instelling tremver link spindle insert it from rear lide of susp...

Page 302: ...s place Pump grease slowly until old grease is completely forced out After greas ing reinstall plug When a high pressure grease gun is used operate the grease gun carefully so that grease is injected slowly and new grease does not come out from the clamp ponion SUSPENSION CROSSMEMBER REMOVAL AND INSTALLATION I Bl6ck rear wheels with chocks and raise front of car and then sup port it with safety st...

Page 303: ... BAR I Bar diameter mm in t9 10 75 FA 12 INSPECTION AND ADJUSTMENT WHEEL ALIGNMENT Unladen 1 1 Camber degree 40 50 I Caster degree 045 3015 Kingpin inclination degree 1025 S055 mm in 0 2 0 0 081 Toe in degree 2 0 12 Front wheel Inside 330 350 3 turning ngle 290 3 Full turn degree Outside 270 Front wheel Inside 200 Toe out turns degree Outside 18 70 1 Tankful of fuel radiator coolant and engine oil...

Page 304: ...nit I N m I kg m ft Ib I Hub I Wheel hub nut I 78 98 8 10 I 58 72 I Disc brake I Rotor to hub I 38 52 I 3 9 5 3 I 28 38 I Strut I Strut to hoodledge 25 34 2 5 3 5 18 25 I Piston rod sei Iocklng 59 74 60 7 5 43 54 nut Gland packing 9B 118 10 0 12 0 U2 87 Strut to knuckle arm 72 97 7 3 9 9 53 72 Caliper to strut 72 97 7 3 9 9 53 72 Knuckle arm I Knuckle arm to side rod 54 98 5 5 10 0 I 40 72 ball jo...

Page 305: ...s Improperly adjusted or wom front wheel bearing Faulty wheel alignment Wom transverse link bushings Insufficiently tightened steering gear hous ing Wear ofsteering linkage Wom suspension ball joint Excessive backlash due to improper adjust ment of the steering gear box Damaged idler arm Worn column bearing weakened column bearing spring or loose clamp Malfunction of shock absorber inside the stru...

Page 306: ...ed steering gear Deformed steering linkage Incorrect wheel alignment Damaged strut mounting bearing Damaged or stiff piston or shock absorber piston rod in the strut Interference of steering column with turn signal swi tch Incorrectly adjusted steering gear housing Worn steering linkage Improperly fitted gear housing Incorrectly adjusted wheel bearing Worn transverse link and tension rod bush ings...

Page 307: ...Jumping of disc wheel Improper tire pressure Imbalanced road wheels Faulty shock absorber Faulty tire Deformed wheel rim Excessively or partially worn tire Improper tire pressure Incorrect wheel alignment Faulty wheel bearing Incorrect brake adjustment Tires not rotated Rough and improper driving manner FA 16 Corrective action Retighten Retighten Adjust Adjust Replace Adjust Adjust Replace Replace...

Page 308: ...0 ST36720000 125847 ST35652001 FRONT AXLE FRONT SUSPENSION Special Service Tool SPECIAL SERVICE TOOLS Tool name Bearing outer race drift set Drift bar Drift A Drift B Screw A Screw B Screw C Strut and steering gear housing attachment Coil spring compressor G land packing wrench Gland packing guide Ball joint remover Transverse link bushing replacer Clamp V V I J tL t 3 o FA 17 ...

Page 309: ... SUSPENSION REAR SUSPENSION STABILIZER BAR SHOCK ABSORBER COIL SPRING UPPER LINK AND LOWER LINK CONTENTS RA 2 RA 2 RA 2 RA 3 RA 5 RA 5 RA 6 RA 6 RA 7 RA 7 SERVICE DATA AND SPECIFICATIONS GENERAL SPECIF ICA TIONS INSPECTION AND ADJUSTMENT TIGHTENING TORGUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS RA 8 RA 8 RA 8 RA 8 RA 9 RA lO GII ...

Page 310: ... 72 BeuiDg Ax1 I II ease Axle shafl Bearingcol1ar Bearing spacer fiJ Aal shaft Beerin8 fIanse side ide 1r f Gap C 0iI w W Gap C 0 0 1 0 0 004 J C J N m kg m ft Ib Unit rom in SAA014 RA 2 REAR AXLE ASSEMBLY Removal and Inatallatlon Block front wheels Place stands Support under differential carrier with garage jack I I A 2 Remove stabilizer bar Refer to Stabilizer Bar for installation 4 1 I It SAA01...

Page 311: ...ide REAR AXLE REAR SUSPENSION Rear Axle 7 Release jack and pull it out Installation is in reverse order of removal Refer to Upper Link and Lower Link for installation of upper link and lower link In p ction Check axle case for yield deforma tion or cracks and replace ifnecessary REAR AXLE SHAFT AND WHEEL BEARING R mov 1 nd dl mbl I Block front wheels Place stands Remove rear wheel A 2 Disconnect p...

Page 312: ...s with recommended multi purpose grease KV40100300 SAA031 4 Insert axle shaft into axle case applying multi purpose grease to the outer periphery of bearing collar Re move guide when distance A be tween axle l1ange and bearing is 70 to 90mm 2 76 to 3 54 in CD 1 J 9AJ r A 70 90mm 12 76 3 54 in RA560 1 Rear axle shaft 2 Rear axle shaft gune ST37840000 3 Rear axle case 4 Oil seal 5 Adjust gap C betwe...

Page 313: ...w Shock absorber Upper link bolt 8 0 51 58 dl 3 7 5 0 0 38 0 51 2 7 3 7 Lower link bushing Replaceable Removed or installed by a pressing force of 39 69 KN 4 11 4 4 7 7 US ton 3 9 6 9 Imp ton Differ in length from upper link bolt 78 7 0 8 0 51 58 Differ in length from upper link bolt dl16 21 16 2 1 12 2 1 12 15 dl N m kg ft lb SAA033 AA 5 ...

Page 314: ...l stabilizer bar being careful not to confuse right and left sides b InstJU rubber bushing with metal fining on axle case lide c Install bolt attaching bushing so that bolt is inside the car 21 11 6 2 1 SRA035 s C flilr SAA038 L7 0 8 0 kg m 51 58 ft lbl c i r I I t t r RA486 Inspection Test shock absorber and compare with specifications given in S O S Replace if necessary Check for oil leakage and...

Page 315: ...as necessary CAUTION 00 not tap end face of bushing direct ly with a hammer as deformation may result in loose bolt Removed or installed by a pressing force of 39 69 KN 4 71 4 4 7 7 USton 3 9 6 9 Imp ton KV40101420 BUshing t KV401O 47 a w w SRA039 Installation a Securing bolts for use with lower link differ in length from those for upper link If used wrong securing bolts cannot be tightened secure...

Page 316: ...XLE End play mm On 0 05 OAO 10 0020 001571 Thickness mm n Part umber Thickness of rear xle case end shim 0 075 10 00301 43036 H5000 0 1SO 10 00591 43036 H5oo1 0 225 10 00891 43036 HS002 0 300 10 01181 43036 H5003 TIGHTENING TORQUE Unit N m kg m ft Ib Broke tube flare nut 15 18 15 1 8 11 13 Brake caliper fixing bolt 38 52 3 9 5 3 28 38 Baffle plate fixing ut 22 26 2 2 2 7 16 20 Propeller shaft to c...

Page 317: ...nuts One or more securing bolts loose Lack oflubricating oil or grease Faulty shock absorber Incorrect adjustment of rear axle shaft end play Damaged or worn wheel bearing Worn spline portion of rear axle shaft Loose journal connections etc Unbalance of wheel and tire Damage of the rubber parts such as link bushing shock absorber mounting bush ing Faulty propeller shaft journal Breakage of coil sp...

Page 318: ...25604 1 Rear axle stand ST36230000 J 25840 Sliding hammer lIT72480000 Rear axle shaft bearing puller ST38210000 J 25869 1 Wheelbearing collar press stand KV40100300 J 25405 Rear axle oil seal drift ST37840000 Rear axle shaft guide KV40l0l4S0 Link rubber bushing drift CD KV4010141O Drift h V KV40101420 Drift KV40101430 Base KV40101440 Ring useless RA I0 ...

Page 319: ...DISC BRAKE AN12H REAR DISC ROTOR BR 2 BR 3 BR 3 BR 4 BR 5 BR 5 BR 6 BR 6 BR 9 BR lO BR 13 BRAKE BOOSTER PARKING BRAKE PARKING BRAKE SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOL BR 14 BR 16 BR 16 BR 1B BR 18 BR 18 BR 19 BR 20 BR 22 Refe to Section MA Brake System for CHECKING FOOT BRAKE CHEC...

Page 320: ... which operates independently on front and rear wheels The brake booster is a power assist device which utilizes engine intake manifold vacuum The NP valve is a pressure control device for the rear brakes The rear disc brake is equipped with a mechanically operated parking brake mechanism The pad clearances of the front and rear brakes are automatically adjusted BR 2 ...

Page 321: ...1 5 8 8 0 10 8 0 8 1 1 5 8 8 0 Pedal bracket ki l13 Return spring 18 1 3 1 8 9 13 l t Brakelamp witCh Lock nut i l12 15 12 15 9 11 Pedal stopper Lubricating point Brake pedal o 00 lf O o I II INSPECTION Check brake pedal for the following items servicing as necessary SBR120 I Check brake pedal for bend 2 Check return springs for fatigue 3 Check clevis for deformation and crack at welded part SBR12...

Page 322: ...emove stopper screw Primary and secondary piston assemblies can then be taken out BR 4 H piston return spring Secondary pilton Prim pilton Primary piston return spring 88 8 0 9 0 58 65 tfJ 6 9 8 8 0 7 0 9 5 1 6 5 SBR011 3 Disassemble piston assembly Secondary piston Primary piston assembly a uembly SBR012 4 Remove piston cups and discard them l J N m ii m ft Ib SBA009 Secondary piston Primary pist...

Page 323: ...brake ho e Brake tube Lock spring I SBA006 a After installation is completed bleed brake system Refer to Bleeding Hydraulic System BLEEDING HYDRAULIC SYSTEM 1 Top up reservoir with recom mended brake l1uid a Do not mix two different brand braka fluid b C refully monitor brake fluid le el at master cylinder during bleeding operation c Do not reuse drained brake fluid r BRAKE SYSTEM SelYice Brake 2 ...

Page 324: ...N m 0 4 0 5 Irgm 2 9 3 6 ft lbl SBROO1 FRONT DISC BRAKE N22 Piston eal Replace at each disassembly i J12 91 1 3 9 9 53 72 Dustse a1 Apply cfuc bJake grease r Cy1inder body aet ainingring You holder D Installed by pressing force 196 294N 20 30 leg 44 66 Ib I1 rupj Yoke II Minimum thickness 10 5 0 413 Spring 21 1 6 2 1 12 15 Pad WeaJ limit 1 J i J N m Ieg m Jt lb Unit rom in 2 0 08 SBA014 BR 6 ...

Page 325: ...ssur ed or moved piston seal will be damaged If piston has been pushed in too far remove caliper assembly and disassemble it Then push piston out in direction shown by arrow Assemble it again referring to the following Piston seal 2 Piston B Y Normal POSitiOn Do not push too far BR780 4 Install inner pad Pull yoke to outer side SBA230 5 Install outer pad Coat the following points with recommended ...

Page 326: ...Yoke Check for wear cracks or other damage Replace if any fault i detect ed PIston Check piston for score rust wear damage or presence of foreign sub stances Replace if any fault is detect ed CAUTION Piston sliding surface is plated 00 not polish with emery paper eveil if rust or foreign matter is sticked on sliding surface Gripper and oke holder Check for wear cracks or other damage Replace if an...

Page 327: ...ke holder If yoke holder is damaged or pl8uing force is out of specification replace with a new one Preaing force 196 294 N 20 30 kg 44 66 Ibl BR959 6 Install pads Refer to Pad Replace ment for installation FRONT DISC ROTOR REMOVAL AND INSTALLATION Refer to section FA INSPECTION I Sliding surface If there are cracks or considerable chips repair or replace 2 Runout Adjust wheel bearing correctly Me...

Page 328: ... 339 ke Retaining rins Spring cover Shim Be sure to apply brake grease to both sides when installing Anti lueal spring Yoke Ipring I Retainer r CyUnder body A Return Pring Toggle lever Unit mm in SBA037 aIII IIa a Itn m aII III I IIz N ZI 2 I C1l m en en l m 3 ...

Page 329: ...ad Align Ie I I J Ie 1 J Jrr rfBR191A D 4 7 r 6 1 Coat the following points with re commended pad grease Cylinder body to pad clearance Y oke to pad clearance Pad pin to pad clearance Pad pin to bracket clearance 8 Do not grease friction face of pad b Be sure to apply pad grease to both sides of shims SBR234 2 Check that the following points are coated with silicone based grease BRAKE SYSTEM Servi...

Page 330: ... return spring and nut Remove dust seal and cam tt Nut Return spong 8 Toggle lever Caml LDust seal SBR047 ASSEMBLY I Before assembling apply thin coat of rubber grease to the following e Groove in push rod and new O ring Strut ends Oil seal Piston seal Inside of dust seal Securely install oil seal in specified direction BAlBOA 2 Engage square hole in key plate with push rod Also engage convex in k...

Page 331: ...installation INSTAUATION fl Coliper fixing bolt 38 52 N m 3 9 5 3 kg m 28 38 ft Ib After installation depress brake pedal few times to properly adjust brake pad to rotor clearance and check for oil leakage When brake pedal stroke is constant brake pad to rotor clearance is properly adjusted It will be automatically adjusted by depressing brake pedal BRAKE SYSTEM Service Brake REAR DISC ROTOR REMOV...

Page 332: ...e cause in accordance with the following chart Air tight test No load 1 Connect a vacuum gauge between check valve and brake booster Maximum vacuum leekege 15 seconds after engine is stopped 3 3 kPa 25 mmHg 0 98 inHg J 60 coo HI 76 J saRD D SBR216 Probable cause Corrective action Air leakage at check valve Air leakage at output rod seal Air leakage between valve body and seal Air leakage at valve ...

Page 333: ...ng test 1 Connect an oil pressure gauge to brake line at connection on master cylinder 2 Install a pedal force gauge on brake pedal 3 Start engine and increase engine speed until a vacuum pressure of 66 7 kPa 500 mmHg 19 69 inHg is reo gistered on vacuum pressure gauge With a steady vacuum pressure of 66 7 kPa 500 mmHg 19 69 inHg measure oil pressure with respect to each pedal operating force Rela...

Page 334: ...pecifica tions replace brake booster assembly Input rod length Adjust length by turning clevis Length 8 130 mm 5 12 in PARKING BRAKE Front cable BR 16 SBA066 r j B BR110A INSTAllATION IiJ M cylinder to brake booster 7 8 10 8N m 10 8 1 1 kgm 5 8 8 0 ft Ibl Brake booster to body 7 8 10 8 N m 10 8 1 1 kgm 5 8 80 fHbl Input rod lock nut 16 22 N m 11 6 2 2 kgm 12 16 fHb PARKING BRAKE REMOVAL Control le...

Page 335: ...lock plate and disconnect rear cable from lever by removing cotter pin BRAKE SYSTEM Parking Brake L l SBRQ73 INSPECTION I Check control lever for wear or other damage Replace if necessary 2 Replace worn or fatigued spring 3 Check wires for discontinuity or deterioration Replace if necessary 4 Replace malfunctioning warning light or switch 5 Check parts at each connection and if found deformed or d...

Page 336: ... d I Pedal height h PARKING BRAKE 1 Pulling force N kg Ibl I Number of notches IStroke mm in MASTER CYLINDER I Allo N8ble clearance between cylinder and piston BR 18 Unit mm in 5 0 04 0201 More than 60 2 36 155 t6t 6 10 6 34 196 20 441 7 8 90 100 3 54 3 941 mmOnl Less than I 0 15 0 0059 BRAKE BOOSTER Maximum vacuum leakage 15s8cond after engine iutopped kPa mmHg inHg Output rod length A mmlin Inpu...

Page 337: ... OB 11 5 8 8 0 I nput rod lock nut 16 22 16 2 2 12 16 Flange to shell ver 7 8 10 8 0 8 11 5 8 8 0 I Mascylinder to broke 7 8 10 8 0 8 11 5 8 8 0 booster I Front disc per IIXI I 72 97 7 3 9 9 53 72 bolt I Front disc rotor fixing 36 52 3 9 5 3 28 38 bolt Rear disc caliper fixing 38 52 3 9 5 3 28 38 bolt Baffle plate fixing bolt 22 26 2 2 2 7 18 20 I Brake lamp switch lock 12 15 1 2 1 5 9 11 nut I 3 ...

Page 338: ...pads Local fit of pads Pads excessively worn Master cylinder Or caliper assembly in poor conditions Frozen or seized caliper pistons on disC brakes Binding mechanical linkage at brake pedal BR 20 Corrective action Fill and bleed as necessary Test for source ofleakage by examining aIllmes and connec tions Overhaul master cYlinder Replace check valve and bleed system Bleed system Adjust pad to rotor...

Page 339: ...tion of caliper because of faulty piston seals Excessive ronout of rotor Hand brake will not return Clogged master cylinder return port Clogged brake lines Incorrect adjustment of wheel bearings Improper pad to rotor clearance No free travel in brake pad return Corrective action Inflate to correct pressure Readjust Clean brake mechanism and check for cause of problem Replace pads Clean Replace Rep...

Page 340: ...ar oftires Poor front braking effect Grease oil mud or water on pads Excessive wear pads Local fit pads Master cylinder or caliper cylinder in poor condition Corrective action Grind or replace as required Tighten support plate bolts to specified torque or replace plate Replace as necessary Replace pads Blowout assembly with compressed air or refmish rotor Replace faulty unit Grind pad to eliminate...

Page 341: ...psible type STEERING GEAR Model VRB47l POWER STEERING GEAR Model I P S 56l AIiID Oil PUMP STEERING LINKAGE CONTENTS ST 2 ST 3 ST 3 ST 3 ST 4 ST 6 SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS ST 23 ST 25 ST 21 ST 21 ST 21 ST 22 ST 10 ST 19 a ...

Page 342: ...n5 fotc e to tcet n8 column Q 31 jael et tube bt1 c 101 3 4 4 4 0 35 0 35 0 45 2 5 3 3 141 81m 3 42 3 2 4 3 23 0 bOdy tame tlU lbCl coupUns 39 49 4 0 5 0 29 36 10 wor1 haft teerl nllpt a ternbW Vv l I1L 52 62 5 3 6 3 8 46 0 bOdY frame c e r 52 62 5 3 603 38 46 1l g l pte uto 10 Il d pipins 1J VI ute hot d pipins Side tad bly 11 J 54 9s 5 5 10 0 40 12 ol nuc d atm nd 055 tad 18 98 8 0 0 0 58 12 1 0...

Page 343: ... Tighten steering wheel nut l J n 51 N m 13B 5 2 kg m 27 38 ft lb SST071 4 After installing steering wheel bJm it clockwise and counterclock wise checking for catch or drag Also check horn operation STEERING LOCK REMOVAL Before removing steering lock dis connect battery ground cable I Remove steering wheel using Tool 8T27180001 2 Remove steering column shell cover y 1 Upward Igi Ii SST072 3 Break ...

Page 344: ...anel Cnuplinj Plat jfJ 39 49 4 0 5 0 29 36 To wormshaft N m kj rn ft Jb SST125 REMOVAL I Disconnect battery ground cable 2 Remove bolt securing stub shaft or worm shaft and universal joint or rubber coupling al SST076 3 Remove steering wheel Refer to Steering Wheel ST 4 S eerillj oolumn bly tiJ 13 18 1 3 18 9 13 To instrument panel 16 4 Remove steering column shell covers 5 Remove combination swit...

Page 345: ...unting bracket 13 18 N m 1 3 1 8 kg m 9 13 ft Ibl CAUTION I Mike Rife that Iny undue strea is not Ipplied to rubber coupling b To Ivoid dlmlging bolt or serrl tions align groove in stub shaft or worm shaft with bolt hole in rubber coupling 9 Remove centering band and then install column band l P S 56L equipped model only 10 Install steering wheel Refer to Steering Wheel 8 After installation make s...

Page 346: ... 2 5 11 18 SeetorsIWlCOV v to 0 rt J Goskel Adjustmshim Refer to S O S Sector shar adjusting saew 0 When adjustirj backla h use it Sector maft Steering gear housing 147 15 94 108 REMOVAL AND INSTALLATION Worm shaft to rubber couplin I J 39 49 4 0 5 0 29 36 Align the groove in worm shaft with the bolt hole in rubber coupling flange yoke and prcssooupling bolt through the undercut section of wonn sh...

Page 347: ...aft cover from sector shaft 6 Remove sector shaft oil seal if necessary SST084 7 Loosen adjusting plug lock nut using Tool SST085 8 Draw out worm gear with worm bearing CAUTION a Be careful not to allow ball nut to run down to either end of worm Ends of ball guides will be damaged if nut is until it stops It end of worm b Do not detach ball nut from worm shaft assembly If necessary replace entire ...

Page 348: ... specification Sector shaft end play Select suitable adjusting shim and adjust end play between sector shaft and adjusting screw Sector shaft adjusting screw shims Refer to S O S Adjusting him Upper I sector cover side Sector shaft end play O Ol 0 03 mm 10 0004 0 0012 n Steering gear preload I Press oil seal to steering gear housing using Tool Before pressing oil seal coat seal contacting face of ...

Page 349: ...Also check gear housing for deformation Steering worm assembl I Inspect ball nut gear tooth sur face and teplace if pitting burrs wear or any other damage is found 2 Ball nut must rotate smoothly on worm gear If found too tight assem bly should be replaced Check rotation of ball nut as follows I Move ball nut to either end of worm gear and gradually stand worm shaft and ball nut assembly until bal...

Page 350: ...oil pressure mechanism In disassembling it be careful to keep dust iron powder and other foreign particles out ofthe gear housing Only the sealing parts of the gear assembly can be replaced The remain ing parts must be replaced as an gear assembly ST10 CAUTION a The parts which can be disassem bled are strongly J and never disassemble other parts than the specified ones If parts not indicated in t...

Page 351: ...er Once removed must not be used again i l N m Icg m ft lb 011 pump and r volr tank Malfunctioning Replace as an oil pump assembly I O ring lock nut cf i l 28 34 2 9 3 5 21 25 Copper washer i l26 32 J V 2 7 3 3 20 fill 24 O rins Between sector cover to gear housing o o Special washer Small OUseal 0 Special washer La IJle DUst sea1 apring ospring washer Nut I tY i l127 147 13 15 94 108 To gear arm ...

Page 352: ...duct at air cleaner 2 Loosen oil pump pulley lock nut Turn belt adjusting bolt counter clockwise 3 Remove oil pump belt 4 Loosen not remove hoses at pump ST 12 5 Remove oil pump and reservoir tank 51 j1 Plug openings of gear housing and securely locate hose connectors at a position higher than oil pump and cover with rag Be extremely cucful to prevent entry of foreign matter into hoses through con...

Page 353: ...ld steering wheel at lock position for more thin fifteen seconds It I time Hydreulic system check To determine whether problem is in steering gear or oil pump measure operating pressure Before conducting hydraulic system test carefully check belt tension and condition of driving pulley Tires must be inflated to normal pressu reo I Check fluid level and fluid leak age adding oil if necessary 2 Run ...

Page 354: ... engine runing at 1 000 to 1 500 rpm repeat step 9 2 Turn steering wheel to right and left from lock to lock five to ten times Carefully check fluid leakage with steering wheel held at each lock position for five seconds CAUTION 00 not hold steering wheel at lock position for more than fifteen seconds at a time Steering wheel turning torque check I Park car on a level dry surface and set parking b...

Page 355: ... they are not within specifications replace gear assembly DISASSEMBLY Before disassembly measure turn ing torque If they are not within specifica tions replace steering gear assembly CAUTION Each oil sealing parts dust seal special washers and snap ring once removed must not be used again AdJusting screw lock nut se 1 Remove adjusting screw lock nut and replace a ring O mg Lock nut Copper washer S...

Page 356: ...ermediate cpver through piston Q g I I J t I SST050 4 Turn stub shaft counterclockwise and place piston worm gear in its straight ahead position S Remove sector shaft Refer to Seetor Shalt Seal for disas sembly 6 Remove rear cover bolts 7 Pull out rear cover intermediate cover with worm gear assembly ST700 CAUTION a When worm assembly is removed piston may turn and come off under iU own weight Hol...

Page 357: ...ew C rings prior to their installa tion Be careful not to install wrong O rings as some of them resemble in size t J SST054 3 Fit rear cover onto intermediate cover with worm gear assembly CAUTION a Do not tilt ball bearing b Make sure that O rings are not pro truding or extruding ST705 4 Insert worm gear assembly with rear cover and intermediate cover into gear housing CAUTION a Be careful that t...

Page 358: ...acing oil seal R face Imide snap ring Outside I talling snap ring SST058 3 Fit new O ring into sector shaft cover Before installing apply a thin coat of vaseline to O ring Make certain that O ring is installed properly and not damaged by sec tor shaft ST695 4 Set piston worm gear at straight al1ead position Turn piston rllck about 100 to 150 toward youself with your finger This is for smooth inser...

Page 359: ... arm and cross rod SST010 5 Remove side rod from knuckle ann using Tool STa8l BaD joints Be careful not to damage dust cover Tighten nut to the specified torque and align the cotter pin hole inthe tightening direction Be sure to insert new cotter pin and bend it ecurely Side rod adjusting bar When adjusting toe in use it Make sure that side rod bar is crewed in socket 25 mm 0 98 in OJ more SST099 ...

Page 360: ...ock nut r l 78 98 N m 18 0 10 0 kg m 58 72 ft b a Lock side rod adjusting bar lock nut so that ball joint on outer socket is 770 with respeet to that on inner socket b Make sure that adjusting bar is saewed in each socket at least 25 mm 0 98 inl INSPECTION AND REPAIR Ball joint I When ball stud is worn or axial play exists replace side rod ball joint with a new one 2 When dust cover is broken or d...

Page 361: ...nd adjusting screw mm tinl 0 4 06 14 6 3 5 5 21 Less than 1 23112 5 10 9 o 0 1 0 0004 0 01 0 03 0 0004 0 00121 Adjusting shim thickness Thickness mm in 1575 1600 10 0620 0 0630 1550 1575 0 0610 0 06201 1 525 1550 10 0600 0 0610 1500 1 525 10 0591 0 06001 1475 1500 0 0581 00591 1450 1 475 0 0571 0 0581 I 0 1 pad y I IUS p Imp p Model I P 5 56L Oil pump belt deflection mm inl Steering wheel turning ...

Page 362: ... 16 screw lock nut mod 1 only I 0 pump to bracket 27 3 7 I 20 27 26 36 I Hose to oil pump 29 49 3 0 5 0 I 22 36 I Oii seoi tank to en 29 4 9 0 3 0 5 I 2 2 36 glne compartment Hose to suspension c oss l 29 4 9 0 3 0 5 I 22 36 member STEERING GEAR Model VRB47L Hose to gear housing 49 69 5 0 7 0 I 36 51 Unit N m kg m ft lb I Worm shaft to coupling STEERING LINKAGE 39 49 4 5 29 35 Steering gear housin...

Page 363: ...tment of steering gear Insufficiently tightened or improperly in stalled steering gear housing Wear of steering linkage Damaged idler arm Worn column bearing weakened column bearing spring or loose clamp Deformed steering linkage and or suspension link Insufficient lubricants or mixing impurities in steering linkage or excessively worn steer ing linkage Worn or damaged steering gear and bearing In...

Page 364: ...operly adjusted Internal gears dragged or gouged Oil leakage in steering gear Stuffy oil passage in steering gear Wheel bearing not properly adjusted Stuck or damaged control valve in steering gear Front wheel alignment not properly Excessive steering gear play Play at suspension and linkage ball joint Lack of oil in oil pump Hoses or oil filter clogged Loose pulley Belt noisy or slapping Broken p...

Page 365: ...KV48 100301 125729 Strut steering gear box attachment x x ST3127S000 Preload gauge See 125765 Torque wrench CD i CD GG91030000 Socket adapter See 125765 Socket adapter X X HT62940000 HT62900000 ST29020001 Steering gear arm puller J25725 X X HT72520000 Ball joint remover KV48 101 500 Lock nut wrench X KV48101 400 Adjusting plug wrench X ST27091000 Pressure gauge X Shut ff valve ST 25 ...

Page 366: ...number Tool name Kent Moore No KV48I 009S0 Oil seal drift set 126367 CD KV48lO091O Drift KV48100920 Adapter KV48100930 Adapter CDsT35322000 Front wheel bearing drift ST35325000 Drift bar ST 26 I Unit application I Model VRB47L Model IP S 56L x x ...

Page 367: ...ack OPERA WINDOW Hardtop OPERA WINDOW Hatchback BF 2 BF 2 BF 3 BF 3 BF 3 BF 3 BF 4 BF 6 BF 7 BF 11 BF 11 BF 12 BF13 BF 16 BF 16 BF 19 BF 21 BF 22 BF 22 REAR WINDOW Hardtop BACK WINDOW Hatchback TRIM AND MOLDING ROOM TRIM BODY SIDE TRIM AND MOLDING REAR PARCEL SHELF Hardtop INSTRUMENT AND SEAT INSTRUMENT CONSOLE BOX SEAT SEAT BELT SUN RDOF REMOVAL AND INSTAllATION BODY ALIGNMENT DESCRIPTION ENGINE ...

Page 368: ...r is filled with a high pressure gas and should not be disassembled drilled or exposed to an open flame 5 Installation is in reverse order of removal ADJUSTMENT Bumper height I Adjust bumper height so that BF 2 Shock absorber 31 42 3 2 4 3 23 31 59 78 6 0 8 0 43 58 B wq bucket OYerrider N m Icg rn ftlb SBF126 distance from top edges to ground meets the specifications p p t Unit 111m in Section A A...

Page 369: ...embly Refer to Front Bumper for removal 2 Remove front apron 1 SBF129 3 Installation is in reverse order of removal When installing front apron be sure to sea mating surface of front fender and front apron Seal completely to mating surface of fender and hoodJedse BO DY Body Front End FRONT SIGHT SHIELD REMOVAL AND INSTALLATION 1 Remove headJamp fmisher and headlamp 2 Remove radiator grille 3 Remov...

Page 370: ... remove washer tube 2 Support hood and remove bolts attaching hood hinge and then remove hood BF 4 CAUTION Fender panel and hoodledge are secured with sealant Before removing front fender be sure to remove seal ent I 7 lIB 21 N m 11 6 2 1 kg m 12 15fHb S8F133 5 Installation is in reverse order of removal When installing front fender apply sealant to mating surface of front lender and hoodledge Hoo...

Page 371: ...cable out through pas senger compartment 5 Installation is in reverse order of removal Adjust hood Refer to Hood Adjustment fj Hood lock attaching bolU 16 21 N m 1 6 2 1 kgm 12 15 ft lb Check hood lock control operation ADJUSTMENT Hood and lock I Loosen bolts attaching hood hinge and move hood forward or backward and side to side until it is set in optimum position SBF137 BODY Body F ontEnd 2 Loos...

Page 372: ...Door BODY DOOR Outside haodle Door gtus Door outside moulding Doot stabilizer i1 II Front guide rail liar npper It i t lnad hand1e J screen Ann Door f misher SBf140 BF 6 ...

Page 373: ...arts 6 Installation is in reverse order of removal 8 To prevent water from entering passenger compartment affix seal ing SCreen firmly with adhesive tape or bonding agent b With door window closed use set pins to install regulator handle as shown in Figure below Front 300 r BF879B Door glass and regulator I Remove door trim 2 Remove door outer molding 3 Remove both front and rear upper stoppers IY...

Page 374: ... 5 Remove door outside handle 6 Installation is in reverse order of rcptoval Apply grease to sliding surfaces of leven and springs BF B ADJUSTMENT Door assembly Inside lock knob s Imide handle escutcheoD j 4 i d Il I Loosen bolts attaching door hinge to body side Move door up or down and forward or backward until it is correctly positioned Using an offset wrendl remove Imide handle SBF147 SBF148 b...

Page 375: ...t adjustment upper side of glass 4 Glass upper stop adjustment 5 Glass fore and aft adjustment SBF149 11 2 mm 0 441 in SBF151 In out adjustment Upper side ofglass 1 Loosen nuts securing lower end of guide rail and turn adjusting bolts until glass is set in position as showni n Figure below Side roof rail crt 14 17 mmLn g 10 55 0 67 inlrOoorgla SBF152 BODY Ooor Tilt adjustment Upper side of glass I...

Page 376: ...nt and rear until free play of lock knob is mini mum Check lock knob and inside handle to insure that they are flush with each other when lock is engaged Tighten lock knob attaching screws 11i U I II J P SBF157 2 Turn adjusting nut until clearance between outside handle rod and door lock lever is 0 to I mm 0 to 0 04 in Adjust nut U 0 1mm 0 0 04 inl SBF158 Mter adjustment check to deter mine if doo...

Page 377: ...y and detach bumper assembly 4 Remove shock absorber from car body M 600 23 621 M 600 23 62 CAUTION The shock absorber is filled with a high pressure gas and should not be disassembled drilled or exposed to an open flame 512 544 20 16 21 42 t t 5 Installation is in reverse order of removal ADJUSTMENT Unit mm in Section A A SBF160 Bumper height I Adjust bumper height so that distance from top edges...

Page 378: ...unk lid lock end striker I Remove trunk rear fmisher 2 Remove trunk lid attaching bolts and then remove striker 3 Remove lock attaching bolts and then remove lock Trunk lid opener 1 Remove rear seat cushion and rear seat back 2 Remove kicking plate 3 Remove trunk lid lock attaching bolts and then remove trunk lid lock 4 Trun up floor carpet near trunk lid opener handle S Remoye trunk lid opener ha...

Page 379: ... and rear win dow wiper harness connector and hose 4 Support back door by hand and remove back door to back door hinge attaching bolts Then remove back door This operation requires two men CAUTION Place rags between roof and upper end ofback door to avoid damaging paint ed surfaces 5 Installation is in reverse order of removal t l Back door stay retaining bolt 16 21 N m 1 6 2 1 kg m 12 15 ft lb BO...

Page 380: ... lock I Loosen bolts attaching back door to back door hinge BF 14 Back door lock cable 2 To make side to ide adjustment move back door to left or right as required to obtain an equal clearance between back door and rear fender on both sides 3 To make fore and aft adjustment move back door in fore and aft direc tion required to obtain an equal clearance between backdoor and roof P U BF6848 4 After ...

Page 381: ...until they are correctly positioned when door lock is engaged as shown in Figure below II J C c 0 mm 0 004 inl Key rOd Adjust nut SBF173 BODY Body Rear End Balik door opener Adjust clearance between rear door opener cable end and locking plate when door is locked until it is within range indicated in Figure below r v o 0 0 o Locking lever SBF174 BF 15 ...

Page 382: ...e ndshield pers front pillar gamishes and windshield garnish Refer to Roof Trimming for re moval 3 Remove front pillar moldings 4 With a sharp cutting knife cut off caulking ma1erial gttached to upper and lower moldings Then reo move moldings Cut here BF330B 5 Reaching from inside car strip dam rubber from around windshield glass Ye I I Bf288B 6 With a sharp cutting knife cut off caulking material...

Page 383: ...sing a heat giltl 2 Attach molding fastener to body and press it more than 490 kPa 5 kg em 71 psi using a suitable roller Make certain that molding fastener does t not come off from body as shown Molding fastener 3 Apply glass sealant beside mold ing fastener Sealant 8 F 3338 3 Clean glass surface where the sealant will be applied and dam with non lead gasoline About 20 mm 079 in Cleaning area BF5...

Page 384: ...caution label to glass surface CAUTION LEAVE ONE WINDOW OPEN SLlGtlTlT FOR THREE OATS This is to protett f04 ew wfndshield nstallation from pre ure lnduC8d Iuks before the ubb 1 has com pletely ulconizecl BF6988 Be lure that it does not obstruct visibility The label noting the faet that sealing will be impaired if door is opened or osed with window dosed before sealant has dried will be furnished ...

Page 385: ...e or polyureth ne sulant Work into joints 4 l Silicone 81lant BF498B REAR QUARTER WINDOW Hardtop REMOVAL AND INSTALLATION I I J I tJf J Rear upper stopper Front upper stopper 0 V D Guide plate Rear quarter window glaM Ann rest Regulator handle SBF175 BF 19 ...

Page 386: ...wa t erea Close rear quarter window com pletely Adjust position of adjusting bolt securing upper end of guide plate until distance between glass and rear quarter waist molding rubber seal is I 1 2 mm 0 441 in as shown 11 2mm 0 441 in SBF161 Narrow I L Glass adjusted too far to forward ID em Glass inclined liD In ciut adJu t nt Upper lde of g Adjust rear quarter window glass position as shown in Fi...

Page 387: ...move rear seat cushion and seal back 2 Remove regulator handle rear side fmisher and top luggage side finisher and remove sealing screen 3 Remove bolts attaching glass to regulator b SBF181 I f SBFl 2 BODY Windshield and Windows 4 Remove regulator attaching bolts and detach regulator f 00 0 0 0 06 III 5l SBF18 5 Remove air outlet grille and rear fender molding SBF184 6 Remove rear body side retain...

Page 388: ...seat back rear side finisher and luggage side upper fInisher 2 Remove air outlet grille 3 Remove opera window attaching nuts then remove window REAR WINDOW Hardtop Sedan CD Rubber Glass y 1 SBF189 4 Installation is in reverse order of removal 1 Weatherstrip 2 Window glass 3 Molding set 4 Roof panel 5 Outer panel REMOVAL L Place protective covers on back door and rear fenders 2 Rem ve parsel shelf ...

Page 389: ...dy check relationship between glass and opening around entire perimeter of glass 1 Entire inside surface of glass should be in contact with opening 2 Curvature of glass should con form to that of opening 3 Mark any section of opening to be reformed Remove glass and reform opening as required 4 Install rear window glass as follows 1 Install rear window weatherstrip to glass t BF647 2 Insert a stron...

Page 390: ...yl tape off glass and door panel using non leaded gasoline 2 Affix butyl tape to entire surface of glass as shown in Figure below 1 C B Jr tyltape 6 mm 0 24 in Cross section B B Be sure to affix butyl tape starting at point A figure bon and ending at point A and overlap some length of tape at point A Use care to a oidtouching adhesive side of butyl tape with fingen as finger prints or stains may r...

Page 391: ...Temporarily tighten four reo tainers and lightly tap around glass with a rubber faced haJ11ffier until glass fits panel at all points as shown Be careful notto scratch molding 4 5mm 0 16 o 20in G S c Butyltape ml J Backdoor panel SBF195 BODY Windshield and WindOM 9 Tighten all four retainers securely and attach corner molding 10 Do not apply vibration or shocks to glass for at least one hour after...

Page 392: ...ins Room lamp mbly Wirul hieJd upper prnish I if ii 1 tl SBF198 5 Remove rear seat cushion and back 6 Remove assist grip Hardtop or coat hanger Hatchback 7 Remove rear side finisher 8 Remove rear corner finisher Hardtop or luggage upper side finisher Hatchback Hardtop AssistgriP Rear L upper garnish SBF196 9 Remove rear window upper gar nish r SBF199 10 Remove head lining II Installation is in rev...

Page 393: ...BO DY Trim and Molding BODY SIDE TRIM AND MOLDING HARDTOP Rear sid finisher Kicking plate SBF200 HATCHBACK Rear body side retainer Rear side finisher SBF201 BF 27 ...

Page 394: ...Trim and Molding BO DY REAR PARCEL SHELF Hardtop SBF202 BF 28 ...

Page 395: ...dSeat ent an 600 IrislflJ EA1 AND S NS1RUtAEN1 ftEtlT STRU i a II 1 u ll g II i 5 g J u II 8 e g c u a 0 lit l s ...

Page 396: ... cover and side ventilator duct S Remove cluster lid D Remove console box 6 Disconnect wlOng connectors from junction block 7 Disconnect speedometer cable harness connectors and antenna cable BF 30 SBF204 8 Remove heater control attaching screws and floor attaching bolts 9 Remove defroster grille 10 Remove instrument securing bolts and then remove instrument assembly by pulling it out 11 Installat...

Page 397: ... AND INSTALLATION I Remove screws attaching console box and slide console box rearward 2 Remove parking brake and lift out console box SEAT FRONT SEAT I 1 1 S6 F207 ifi16 22N m 11 6 22 kg m 12 3 Installation is in reverse order of removal SBF208 BF 31 ...

Page 398: ...InstrumenundSeat BO DY REAR SEAT Hardtop SBF209 Hatchback l iiiJ rJ SBF210 BF 32 SEAT BELT FRONT SEAT BELT SBF211 itJ Seat belt anchorage bolt 24 31 N m 2 4 3 2k 17 23 ft Ib ...

Page 399: ...REAR SEAr BEL r HARDTOP I 1 J2434N m 12 4 32 k 17 g m 23ft lbl HATCHBACK BODY Instrument and Seat I J 24 34N m 2 4 32kg m 17 23 ft lbl SBF212 BF 33 ...

Page 400: ... Installation is in reverse order of removal BF 34 SUN ROOF Bndet EICutcheon Sun roof handle Safety catch Sun roof rmi5her SBF213 DRAIN HOSES o SBF215 SBF214 I Remove roof trim front pillar trim rear pillar trim and da side trim and then remove drain hoses 2 Installation is in reverse order of removal After installing drain h s emure 1hat watar is property drained outside car with no seepage into ...

Page 401: ...me value ENGINE COMPARTMENT BODY ALIGNMENT MEASUREMENT OPERATIONS When car body measurements are taken in accordance with the thick line careful consideration should be given to the following points 1 Measurement method I When a tram tracking gauge is used adjust pointe A and B to equal lengths as shown in the figure be low Check the pointe and gauge itself to make sure there is no free play I A f...

Page 402: ...lumlin en r2 4 t sOtO 2 t h 1 91tO 008l 0 02 if rl J 1 97tO 008 tt I 0 93tO 2 28 1 l1 l c I 11 s 5 S5 3 6610 008 o I I 0 ALLOWANCE FOa STG PIXING I L A I L SIDE VIEW LG i J D mHo j 91 8 3 61 14 1 0 95l n IolJ 0 I I I U 11 II L IJ 1 11 l 2 0 I l L o J L 1 11 3 0 5 L 8 70 917 D tum line 695 17 36 R H lide 109 68 7 i 70S 8 0 31 19 I IJ5 31 87 37 3 1 69 161 1 I L H lde 6 39 611 14 45 1 400 9 9 40 19 1...

Page 403: ...Tool number Kent Moore No ST08800000 ST08810000 SPECIAL SERVICE TOOLS Tool name Sucker 8W Caulking hand gun BODY Special Service Tools BF 37 ...

Page 404: ... AND INSTALLATION REFRIGERANT LINES COMPRESSOR IDLER PULLEY COMPRESSOR CONDENSER RECEIVER DRIER ILlOUID TANK FAST IDLE ACTUATOR COOLER RELAY COOLING UNIT AMBIENT SWITCH EXPANSION VALVE AND SUCTION THROTTLE VALVE AIR CONDITIONER CONTROL ASSEMBLY BLOWER UNIT RESISTOR MAGNET VALVE COMPRESSOR SWP167 PRECAUTIONS COMPRESSOR CLUTCH SHAFT SEAL SIDE COVER REAR END COVER AND REAR CYLINDER HEAD REPLACEMENT O...

Page 405: ...UlT nn J au J j i 1I11 hJ L 1b To ear L Air mix r S er I door Blower motor To floor To floor To rear heater duct Heater core Side view SHA113 HEATIER COMPONENTS Side defroster QDterddroster oo Side defrolter Heater core fIIJrffi5 noule Heater control assembly I I oClfj Blower motor Water coet Heater duct 0 fr itchAir uide AirSUide C eonaol tiniaher Side ventilatnr duct J SHA114 HA 2 ...

Page 406: ...tion FRESH POsit 7 HEAT POsitioo J tb1 o II 4 Move the lever daired POI V REC position REC7 ition TpoIition r o o J 0 Move the Ie the desired Ji io Y I li C Side view HEATER Description Fresh air 1 j 1 l H 111111111111 rlrl 1I Il Jc TOVentil torduc roster 17 1 l jfd o l i i j L To floor To rear To floor heater duct l r To defroster nozzle L To floor To rear To floor heater duct Recirculation Tfrl ...

Page 407: ...assembly 6 Installation is in the reverse order of removal Alter installing adjust control cable by ref ring to Adjusting Heater Con trol INSPECTION Fan switch Test continuity through switch with a test lamp or ohnuneter HA 4 SERVICE PROCEDURE Always conduct I Tenn I DIQ I r Wuntinatioo lamp SHA118 ADJUSnNG HEATER CONTROL REC position I Inbke door control cable I Set air intake lever at REC posi t...

Page 408: ... position I I SHA121 Water cock control linkage I Set air mix door lever at max COW position 2 Securely clamp control rod while pushing water cock lever to its full closed position 1 c c I4f a Max COLD position Adjusting saew r SHA122 HEATER UNIT REMOVAL AND INSTALLATION I Set TEMP lever to max HOT position and drain engine coolant 2 Disconnect heater hoses from heater unit 3 Remove foUowing Wis I...

Page 409: ...se order of disassembly a After installing heater core and water cock lKljust water cock co trol linkage by referring to Adjust ing Heater Control b When assembling air control link age set it as illustrated SHA131 INSPECTION Ce e If it is cracked or deformed re place r Il core Clean fms and check for water leak age BLOWER UNIT REMOVAL AND INSTAlLATION I Remove instrument lower oover and cluster l...

Page 410: ... the item on Heater Unit DEFROSTER NOZZLE REMOVAL AND IN TALLATION Front window defroster nozzle Proceed after reJlKving instrument assembly SHA137 Side window defroster nozzle Proceed after removing instrument lower covers and cluster lids Left side Right side HEATER Service Procedures VENTILATOR DUCT REMOVAL AND INSTALLATION Center ventilator duct Refer to the item on Heater Unit Side ventilator...

Page 411: ...NITION RELAY I c J 15 1 r ILLUMINATION CONTROL SWITCH BATTERY IGNITION SWITCH B Q I FUSIBLE LINK SHA141 WIRING DIAGRAM BLOWER j MOTOR RESISTOR 4J LHJ TO WI P fR G ow LIGHTING SWITCH 3 J JI TO AIR CONDITIONER SWITCH 00 4 e FUSE 2 It f j FAN SWt reH ILlUMlNATIONC J CONTROL SWI reH tl GN T ON RELAY 1 I G IITION SWITCH IUUIIIINATION L P FUSIBLE LINK i f BATTERY SHA14 HA S ...

Page 412: ...efroster nozzle plugged Leak at defroster duct to nozzle connection Water cock not operating properly Mode door not operating properly or seal damaged Refer to Trouble Diagnoses and Corrections Air conditioner Innerwire rubbing against outer case end Control cable bent excessively Malfunctioning doorn door levers etc Air intake door not operating properly Control cable out of adjustment Loose bolt...

Page 413: ... Discluuges refrigerant to atmosphere at pres lfes above 3 727 IcPa 38 kgfem2 540 psi Low pmmue switch Tums OFF at pressures below 196 IcPa 2 81 em 2 28 psi cutting compressOI power supply HA l0 w w q v i t e w fL w tmfJ High pressure gas t l High presswe liquid Evaporator The refrigerant evaporates and the air liquid cools o Expansion valve DeliVers sprayed refrig erant to the eVaporator to facil...

Page 414: ...AIR CON DITION ER Description AIR CONDITIONING COMPONENTS a o I 1I 5 l s a o 5 2 e l L e 8 j j u 8 SH 143 HA ll ...

Page 415: ... is the same as that of HEATER except that passes through cooling unit aU air discharged with blower unit To To O ide air defroster ventilator n Ventilator door nozzlll duct To delio tor now 1 1 r 1t t i 7u 1Mi T lJ 7 iIllJlL 1 i ll Qjr lr mower motor To floor To f1oor To To floor Side view rear heater Heater core duct SMA146 J HA 12 ...

Page 416: ...e torch 5 Do not steam clean on the sys tem especially condenser since excessively high pressure will build up in the system resulting in explosion of the system Connection to service v lve I Funy close both valves of mani fold gauge Connect high and low pressure charging hoses to manifold gauge 2 Remove caps from service valves Connect high and low pressure charg ing hoses to service valves in sy...

Page 417: ...ystem I Close high and low pressure valves of manifold gauge fuUy 2 Connect two charging hoses of manifold gauge to their respective service vavles WARNING Securely connect high pressure dis charge service valve to that of manifold gauge with a hose also cOnnect low pressure suction service valve to that of manifol gauge 3 Open both manifold gauge valves and discharge refrigerant from system LO rJ...

Page 418: ...acuate refrigerant system 2 Close manifold gauge valves securely and disconnect charging hose from vacuum pump 3 Purge air from center charging hose I Connect center charging hose to refrigerant can through can top 2 Break seal of refrigerant can and purge air I 1 Purging air k R 12 SHA048 4 Charge refrigerant into system I I n case of charging re igerant gas Open high and low pressure valves of m...

Page 419: ...stem Be sure to install valve cap on service valve 9 ConIum that there are no leaks in system by checking with a leak detec tor Refer to Checking for Leaks MA section Conducting a performance test prior to removing manifold gauge is 8 good service operation Refer to Per formance Test COMPRESSOR OIL LEVEL CHECK The oil used to lubricate the com pressor circulate into the system from the ail sump wh...

Page 420: ...ity and temperature Measurement of ambient air relative humidity and temperature AIR CONDITIONER Performance Te t PERFORMANCE TEST Indoors or in the shade outside wind velocity Less than 2 m 7 ft sec Closed Open Open Max COLD position Max COLD position 4 positions 1 500 rpm constant Connect manifold gauge to high discharge and low suction service valves Center outlet grille Blower assembly inlet A...

Page 421: ... 41 42 20 68 7 5 8 5 46 47 25 77 9 8 110 50 52 50 60 30 86 12 2 13 5 54 56 35 95 14 5 16 2 58 61 40 104 17 0 18 9 63 66 15 59 5 8 6 5 42 44 20 68 8 5 94 47 49 25 77 11 0 12 3 52 54 60 70 15 2 56 30 86 J3 5 59 35 95 162 18 2 61 65 40 104 18 9 21 1 66 70 15 59 6 5 7 1 44 45 20 68 94 10 3 49 51 25 77 12 3 13 7 54 57 70 80 30 86 15 2 17 0 59 63 35 95 18 2 20 2 65 68 40 104 21 1 23 5 70 74 15 59 7 1 7 ...

Page 422: ...8 132 4 8 5 94 121 134 1 15 1 35 16 4 19 2 25 77 1 010 1 118 137 3 152 0 65 90 10 3 II 4 146 162 140 1 55 19 9 22 0 30 86 1 196 1 314 156 9 171 6 12 2 13 4 173 191 160 1 75 22 8 24 9 35 95 1 372 1 510 176 5 196 1 14 0 154 199 219 1 80 2 00 25 6 28 4 40 104 1 550 1 716 196 1 220 7 15 8 17 5 225 249 2 00 2 25 28 4 32 0 a The pressure will change in the following manner with manges in cond itions Whe...

Page 423: ...g action In sight glass appear a lot of bubbles or something like mist Sight cooling Sweating or frosted expan sion valve inlet Probable cause Refrigerant is small or leaking a little Serious refrigerant leak Expansion valve restricts refrigerant flow Expansion valve is clog ged Expansion valve is in operative Valve stuck closed Thermal bulb has lost charge Corrective action I Leak test 2 Repair l...

Page 424: ...se Expansion valve allows too much refrigerant through evaporator Faulty expansion valve Suction throttle valve is inoperative Suction throttle valve restricts refrigerant flow CorreCtive action Check valve for operation If suction side does not show a pressure decrease replace valve L Discharge system 2 Replace valve 3 Evacuate and replace system I Discharge system 2 Replace valve 3 Evacuate and ...

Page 425: ...ry hot Probable cause Air mixed with refrigerant in system Drier is saturated with moisture Moisture has fro zen at expansion valve Refrigerant flow is restrict ed Usually a malfunctioning condenser Corrective action I Discharge system 2 Replace receiver drier 3 Evacuate and charge system I Discharge system 2 Replace receiver drier twice if necessary 3 Evacuate system com pletely Repeat 30 minute ...

Page 426: ...in high pressure line Internal problem in com pressor or damaged gasket and valve Too much oil circulates with refrigerant causing the cooling capacity of the system to be reduced Corrective action I Discharge system 2 Remove receiver drier or strainer and replace it 3 Evacuate and charge system I Discharge system 2 Remove and check compressor 3 Repair or replace com pressor 4 Check oil level 5 Re...

Page 427: ...mmediately to prevent entrance of dirt and moisture Plug SH A058 5 Compressed air must never be usad to dean dirty line Clean with refrigerant gas 6 When connecting tubes install new a ring never reuse used one into connection and be sure to apply com pressor oil to seating surface and 0 ring I uamnr s SHA059 7 Check tightening torque of con nedions to lpecification 8 Make sure refrigerant line is...

Page 428: ...0 1 5 2 0 11 14 i J125 29 2 5 3 0 18 22 SHA148 COMPRESSOR IDLER PULLEY Loosen REMOVAL AND INSTAlLATION 1 Rem e under cover 2 Loosen idler pulley lock nut and fully loosen adjusting bolt 3 Remove drive belt 4 Remove idle pulley assembly 5 Installation is in the reverse order ofremoval Refer to Section MA for adjusting drive belt Adjusting bolt SHA149 HA 25 ...

Page 429: ...llll damage would result To expel oil from chambers hand crank compressor several times in its installed condition 6 Installation is in the reverse order of removal When conneeting high and low flexible hoses to compressor install new O ring into connectiQn CONDENSER REMOVAL AND INSTALLATION I Remove radiator grille 2 Remove stay for hood locI upport 3 Disconnect refrigerant lines from condenser 4...

Page 430: ...ion is in the reverse order of removal DISASSEMBLY AND ASSEMBLY Expansion valve Thermo bulb SHA378 I Remove clips fIxing upper case to lower case 2 Withdraw evaporator assembly 3 Assembly is in the reverse order of disassembly INSPECTION c Check for cracked or deformed case Ev por tor mbly I Clean fms and check for corro sion If fins are corroded replace CAUTION Do not clean evaporator with steam ...

Page 431: ...o not disassemble val neces sary replace as Iy HA 28 AIR CONDITIONER CONTROL ASSEMBLY REMOVAL AND INSTALLATION Refer to Heater Control Assembly INSPECTION Fan switch Refer to Fan Switch in Heater Air conditioner switch Electrical conductivity Ch CD 2 3 CID c ON 0 0 0 OFF IUwnination lamp is located between CD anCl 00 SHAle1 BLOWER UNIT Refer to Blower Unit in Heater RESISTOR Refer to Resistor in H...

Page 432: ...or s hell 4 suction valVe plate 14 Rear end cover assembly 32 D a in plug lnd gas ket 5 Gaslo et 15 Rear end cover iling bolt 23 Coil assemblY 33 Silencer piece ling 6 Key a nd w9 8her 24 Gasket 34 Silencer piece 7 Compressor cylinder assemblY 16 Shan nut 2S Front end cover 3S Silencer spring l 8 Gasket 11 Hub nut 26 Coil mounting screw 36 Gasket t 9 Rear end covet O ring 18 Spaoet 21 Felt 37 Side...

Page 433: ... l low pressure side and purge air at the high pressure side COMPRESSOR CWTCH The most common problem is clutch slippage Service procedures are listed below Exercise care I Clearance between clutch hub and pulley should be 0 5 to 0 8 mm 0D20 to ODJI in at all peripheral points 2 Make sure that there is no oil or dirt on friction surfaces of clutch disc clutch hub and pulley Remove any oil or dirt ...

Page 434: ... INSTALLATION I Using a Phillips screwdriver tighten coil assembly mounting screws in an alternating pattern After screws have been frrmly tightened puncWock each at one location to prevent loosen ing ifJ Coil mounting screw 2 7 3A N m 0 28 0 35 kg m 2 0 2 5 ft lb AC029 2 Using a plastic mallet drive pulley and bearing assembly onto the neck of the installed coil assembly Turn the pulley making su...

Page 435: ... hole in middle of blind cover at low pressure side 5 Wrap shaft end with ra8 Apply refrigerant pressure of 196 to 490 kPa 2 to 5 kg em 28 to 71 psi thrnugh low pressure line of compressor until shaft seal seat is received at rag CAUTION a Do not use air to prevent entry of moisture dust ete b If shaft slllll seat is not plucked out ins llll it again and apply refrigerant pressure KV994C1552 KV994...

Page 436: ... refrigerant from low pressure side and purge air from high pressure side by loosening blind cap 4 Conduct a leak test If there is a leak remove and then install again KV994C4531 KV994C1552 KV994C4534 KV994C4559 t lbiJ SHA166 SIDE COVER REMOVAL I Drain oil 2 Loosen and remove eight side cover mounting bolts in an alternate pattern Note that two silencer springs inside the cover will force up side ...

Page 437: ...use Tool Insert this tool into hole in cyl inder head With the nut in frrm con tact with the back side of cylinder head tighten the bolt slowly to break loose the head AC210 INSPECTION I Make sure that the gasket contact surfaceis free of damage 2 If replacement of rear end cover connector and check valve is neces sary replace rear end cover with anew one 3 Check suction valve plate and cylinder h...

Page 438: ...pe hIS been removed do not attempt the following steps AC212 7 With the front facing downward support compressor shell Using a plastic mallet tap at the rear end of the shell flange driving shell straight downward Discard front end cover gasket AC213 8 Detach front end cover from cylinder assembly Using a plastic mallet drive end cover upward Re frain from excessive force to avoid cover damage AC0...

Page 439: ...ut ofplace HA 36 AC690 5 Turnover the asSembled shell and cylinder assembly so that the front may face downward 6 Coat oil pipe and O ring with an ample amount of oil Insert oil pipe at the rear of the cylinder After making sure that the hole lines are matched as specified in step 4 continue with stepp 6 work AC226 7 Continue with work up to instal lation of rear end cover according to Installatio...

Page 440: ...RELAY COMPR ESSQR MAGNET CLUTCH RESISTOR OFF FAN SWITCH COMPRESSOR MAGNET CLUTCH RESISTOR COMPRESSOR MAGNET CLUTCH AMBIENT SWITCH LOW PRESSURE SWITCH I COOLER Ie 01 RELAY 1 1 1 L BATTERY R FUSIBLE LINK IGNITION SWITCH o F I C O MAGNET VALVE BLOWER MOTOR M FUSE 20A F IC O MAGNET VALVE AMBI ENT SWITCH LOW PRESSURE SWITCH IGNITION SWITCH D BATTERY R FUSIBLE LINK BLOWE R MOTOR M BATTERY G IGNITION SWI...

Page 441: ...COlolPRESSORIoI GIle l C UCI I lll Il o O c t J IoI GIle l 11 1 all a N Ul J lEII 1 15 IRO 1I01l C UI I t MP S II11CI I f ll UI IIl 1I01l lOIlER tkMP COllOl1 l f ON IR lCI I 0 S IlI IGI IIIIlG S II11CI I aJJ It S Il11CI I IGllll101l S Il11CI I fUSIll E I t Iu UI I 1l 1I01l COlllRO S Ill1CI I JI ...

Page 442: ...t to correct level Air is mixed in Discharge sys tern and replace drier Evacuate and recharge system Condenser s fin is dented or clogged with dust Clean exterior surface with water Suction pressure is low Suction pressure is high while discharge pres sure is low Valve or gasket of compressor is damaged Repair or replace compressor Pipe at receiver drier outlet has low temperature Receiver drier i...

Page 443: ...tor does not rotate Refer to Blower Motor Diagnosesu F IC D does not operate Refer to Fast Idle Control Device Diagnoses Noisy Belt is loose Adjust belt Compressor ON r Compressor itself makes noise Repair or replace compressor Compressor does not run When engine rpm Is changed there are resonant sounds Retighten compres sor bracket bolts Refer to Compressor Clutch Diagnoses and Compressor Diagnos...

Page 444: ...washer operate Ifthey do not operate check fuse l5A in fuse block at first Position ofignition switch ACC Position of fan sWitch ON II Blower motor does not run II Remove instrument lower cover and cluster lid Connect test light to blue white wire leading to blower motor I I Ught ON Ugh OFF Ground SHA168 Ground blue black wire leading to blower motor SHA169 I Motor does not fun I Motor runs I Faul...

Page 445: ...eck fan switch for con ductivity Refer to Fan Switch I Motor runs I I Motor does not run Check resistor for conductivity Refer to Resistor I N G I ot Check other lead wire and connection I Speed ofblower motor does not change J1 Remove instrument lower cover and cluster lid Check resistor on heater unit Refer to Resistor Faulty resistor without problem in lead wire connection l Replace HA 42 N G I...

Page 446: ...nd washer operate II AC371 A I Compressor clutch is not engaged Connect two wires leading to low pressure switch I Clutchis engaged 1 Check refrigerant level I I O K N G L Faulty low pressure switch without problem lead yire connection Replace Insufficient re frigerant t Add Ground earth terminals leadingto magnet clutch Clutch is not engaged Clutch is engaged I Clutch is not engaged o Connect tes...

Page 447: ...t temperature switch without problem in lead wire connection Replace Faulty air conditioner switch without problem inlead wire connection Replace HA44 Remove instrument lower cover and clust r lid leading to ambient temperature switch I Clutch is engaged I I Clutch is not engaged Connect wire between green and blue wire leading to air conditioner switch I Clutchis engaged J ClutCh1is no engaged U ...

Page 448: ...s worn out or damaged replace it Internal problem in compressor cyl inder Checksystem Repair or replace if necessary High torque Overcharge ofrefrigerant 1 1 Air in refrigeration system Discharge refrigerant gas to an extent that sight glass of receiver drier has only a few bubbles Engine speed 1 500 rpm Discharge system from service valve on discharge side Evacuate and recharge the system Check f...

Page 449: ...replace compressor Wipe clean oil with rag HA 46 Compressor is noisy Noisy only when clutch is engaged Check for loose compres sor mounting bolts Retighten bolts Compressor drive belt is loose Adjust belt tension Ifcompressor is still noisy repair or replace compressor Noisy when clutch is not engaged Remove compressor belt Turn pulley of compres sor clutch by hand and check for noise Ifnoise is h...

Page 450: ...ssor clutch I Clutch is not engaged Check electric circuit of clutch reo ferring to compressor clutch dia gnoses Faulty F lC D magnet valve Replace Faulty F lC D device Replace II q Condition I I Check I I Probable cause I Outch is engaged j D Run engine at idle speed Disconnect vacuum F LC D magnet valve to F LC D device hose at F LC D magnet valve and check vacuum I Vacuum N G I I Vacuum O K Dis...

Page 451: ... to lOB corilpreuor 7 8 10 8 1 1 5 8 0 LUBRICATING OIL Compressor I 0 28 035 1 I Coil mounting screw 2 7 3 4 2 0 2 5 Type SUNISO 5GS 12 5 I I Lock nut 25 27 2 8 18 20 Capacity ml US fl OZ Imp fI 02 270 19 1 9 51 Hub nut 18 21 11 8 2 1 I 13 15 REFRIGERANT Shaft nut 16 17 11 6 1 7 1116 12 3 Type R 12 Side cover bolt 18 20 118 2 0 I 13 14 Capacity kg UbI 0 9 1 1 12 0 2 411 Reaf end coyer bolt 29 34 1...

Page 452: ...ket 124878 2 KV99412306 Clutch hub puller 124878 3 KV99412310 Lock nut socket QD 1248784 KV99412313 Puller adapter 126066 KV99412312 125472 KV994C1552 KV994C4548 CD KV994C453I KV994C4532 KV994C4533 KV994C4534 KV994C4559 Puller pilot Charge nozzle Blind cover set Blind cover Gasket Useless 3 1 c 11 1 0 39 0 39 0 61 0 51 Gasket Gasket Bolt Unit rom in HA49 ...

Page 453: ...o KV9941232I 126067 KV99412322 125473 KV99412329 126072 KV99412327 KV99412328 KV99412330 KV99412315 HA 50 Tool name Shaft seal remover and installer Shaft seal pilot Shaft handle socket Silencer piece installer O ring insta11er Allen socket Cylinder head remover o ...

Page 454: ... EL 65 STARTING SYSTEM EL 8 WARNING CHIME EL 70 SCHEMATIC EL B WIPER AND WASHER EL 73 WIRING DIAGRAM EL 8 WINDSHIELD WIPER AND WASHER EL 73 STARTING SYSTEM REAR WINDOW WIPER AND WASHER EL 79 TROUBLESHOOTING EL 9 ELECTRICAL ACCESSORIES EL 81 STARTER MOTOR ELla REAR WINDOW DEFOGGER EL 81 SERVICE DATA AND SPECIFICATIONS EL 16 REMOTE CONTROL DOOR MIRROR EL 83 CHARGING SYSTEM EL 17 CLOCK EL 85 DESCRIPT...

Page 455: ...AND ACCESSORY RELAY l l in ir 1 f I I FUSE BLOCK o L HEADLAMP STOP LAMP i HAZARD FLASHER HORN CIGARETTE LIGHTER CLOCK LAMP MONITOR VOLT GAUGE z 0 w t z i INTERIOR LAMP STEP LAMP LUGGAGE COM PERTMENT LAMPS KE WARNING TAIL CLEARANCE SIDE MARKER AND LICENSE PLATE LAMPS METER ILLUMINATION 7HEATER OR AIR CONDITIONER BLOWER MOTOR 7AIR CONDITIONER WIPER AND WASHER WINDSHIELD AND REARl RAOIO POWER ANTENNA...

Page 456: ...of problem b Never wrap periphery of fusible link with vinyl tape Extreme care should be taken with this link to ensure thet it does not come into contact with any other wiring har ness or vinyl or rubber parts A melted fusible link can be detect ed either by visual inspection or by feeling with fmger tip Ifits condition is questionable use circuit tester or test lamp B A sr t T 01 g Q B From batt...

Page 457: ...the level is low fUI with distilled water EL 4 BATTERY CHECK G SPECIFIC GRAVITY J Read hydrometer and thermal gauge indications at eye level Reed top level with leale r Thermal gauge SE L045 2 Correct specific gravity et 200C 1680 Fl O St 0 0007 t 20 Where St S20 Specific gravity of electrolyte at tOC Specific gravity of electrolyte corrected at 20C 680F Electrolyte temperature t Examples 1 When e...

Page 458: ...nts lfil fil W Check Corrosion r 8 A M rating Cracks I Y I Warped case SEL046 1 Check battery rating against that of original factory equipment 2 Check for cracks and warpage of the case 3 Make sure cables are clean and tight 4 Check acid level 5 Make sure vents are not clogged 6 Make sure top of battery is clean 2 BATTERY LEAKAGE TEST Check to make sure battery is not discharging across top betwe...

Page 459: ...ery cell nearest the batteiy positive post WRITE DOWN voltmeter reading SEL050 EL 6 5 Now put positive probe in ceU nearest the positive post Put negative probe in next cell down Record reading SEL051 6 Continue on down the battery recording reading each time SE L052 7 When you get to point where positive probe is in last cell of battery touch negative probe to negative post Record this reading ee...

Page 460: ...c ficI26f 1 i 28 g iliYJa 6 F 1 t t a4 f c li Y t C r1 iICALL STEM Battriry 9 j 1 N i i J t r Il 7 i r 4 t i tt I f 1 l 1 L j yj t I i fT t lI f r o O t tYt f Ii 1Iit o 4 Jt rl t e t j 1i el f V 6 f t i t j V M 7r 1 rt l f 7 t j C I t w l r Jf j GI ItX9 I i i c p J l I fi Jii t 135 L ht c f c S ti a i Co jt 1 j ltiiH J tt it AAi j i y H 3 b ttjj t 1 EIi 7 1 L 7 ...

Page 461: ...SW o 0 STARTER MOTOR 1 BATTERY INHIBITOR RELAY SEL098 WIRING DIAGRAM re Cf R o BATTERY FUSIBLE LINK sr ON Ace Off g DD IEI BW J 6 Ie r ey 5 s r WR ll w ID1 WB BW oJ It IGNITION AND ACCESSORY RELAY IGNITION SW r 0 O Q tJl 0 0 0 0 0 0 0 o 0 O ij ij ij ij o o 0 COO 000000 0 00 0 0 FUSEBL CK Ji E ri g INHIBITORRELAY t1 e a m al 3 lD g o g WB ao LW ao I We SEL099 STARTER MOTOR INHIBITOR SW EL 8 ...

Page 462: ...ic switch uM terminal Terminal connected to starter 4 Pull coil wire out of distributor cap and ground it 5 Crank engine Less than IV Less than 0 5 Less than I 5V Connect jumper wire between battery positive terminal and the s terminal on magnetic switch Less than 150A Speed normal Plug coil wire back in Start engine but hold key over to start so that starter docs not stop Starter turns r t fast l...

Page 463: ...nion stopper 0 3 2 5 0 012 0 098 Dust 00 Adjllllin8 er Adjust clearance 2 Washer thickness 0 5 0 020 0 8 0 031 Dust cover E ring Brush spring Tension 13 7 17 7N 14 18 kg 3 1 4 0 Ib l J3 7 5 0 0 38 0 51 2 7 Commutator min dia 39 154 Center bracket 5114 180F only Pinion assembly Pinion stopper Depth of insulating mica 0 5 0 8 0 020 0 031 Armature shaft bend Les s than 0 08 0 0031 l J N m lcg m ft4b ...

Page 464: ...f co Commutator min dia 29 1 14 Depth of insulating mica 0 5 0 8 0 020 0 031 Drush Brush min length 11 0 43 Center bearing Brush holder Brush spring Tension 15 1 19 6 N 16 2 0 k8 3 5 4 41b Field coil 3 1 C i 6 3 8 3 0 64 0 85 4 6 O ring C i N m kg m fHb Unit mm in Pinion gear Difference in height of pinion Packing 0 3 1 5 0 012 0 059 Gear ca SE LOOS ELll ...

Page 465: ...utch Remove pinion stopper clip push ing pinion stopper toward clutch side EE277 Pinion stopper clip RedueUon rtJpe I Remove magnetic switch assemb ly 2 Remove torsion spring 3 Remove through bolts and rear cover CAUTION Ba careful not to damage O ring 4 Remove yoke armature and brush holder as an assembly from center housing CAUTiON Be careful not to knock brush com mutator or coil against Iny ed...

Page 466: ... Check brush spring tension Spring tension Non reduction gear type 13 7 17 7 N 14 1 8 kg 3 1 4 0Ib Reduction gear type 15 7 19 6 N 1 6 2 0 kg 3 5 4 4 Ib Not in the specified value Repair or replace Sprin scale WI SEL 109 Arm ture mbl I Check commutator surface Rough Sand lightly with No 500 sandpaper 2 Check depth of insulating mica from commutator surface Less than 0 2 mm 0 008 in Undercut to 0 5...

Page 467: ... switch body No continuity Replace 2 Continuity test between tenni naIs S and M No continuity Replace ASSEMBLY Apply gre e to gear case and rear cover bearing metal ond Ipply oil to pinion slightly Non duction Il 8 type With the switch on push pinion back to remove all slack ond me ure the clearance en between pinion front edge and pinion stopper Clearince 2 0 3 25 mm 0 012 0 098 in r I J L e SEL0...

Page 468: ...on magnetic switch is pro perly functioning 1 CI ELECTRICAL SYSTEM Sta ing Sysrem jrJ SEL012 S rle coil I Connect terminal M of magne tic switch and negative e terminal of battery with a jumper lead wire 2 Connect terminal S of magnetic switch and positive tJ terminal ofbat tery with a jumper wire 3 With these connections having been made if plunger is pulled in by force series coil i properly fun...

Page 469: ...IMoreth 6 ooolMore than 7 000 I More than 39 1 54 1 12 047 13 7 17 7 14 18 3 1 4 0 Less than 100 Revolution rpm More than 3 900 Outer diamet r of commutator mm in mm in More than 29 1 14 Minimum length of brush 11 043 Brush spring tension N kg lb 15 7 19 6 16 2 0 3 5 4 4 Clearance between bearing metal and armature shaft mm in Less than 0 2 0 008 Clearance between pinion front edge and pinion stop...

Page 470: ...ing lamp which causes the charge warning lamp to turn off In other words current does not flow from the battery to terminal L Accordingly current flow through the rotor is taken over by current produced at the stator The circuit between terminal F and Tr 1 is then closed The IC voltage regulator monitors generating voltage to be applied to the battery at terminal S When current I 0 D3 J 7 t 0 0 a ...

Page 471: ...m R BATTE RY fUSIBLE L1NK iAgCOFF lffLBW J 1 6 IG r if WR 6 s l IGNITION SW c a s 0 0 0 0 0 O JCJ 0 0 0 0 0 0 0 0 0 0 0 u FUSE BmCK c WB G B fii l CJ L CONDENSER v E W fil WR L J fil WR W S W d B S i I ALTERNATOR ELlS I I If i l rt I WhIte a I II r FUSE CHARGE WARNING LAMP SEl100 Bj 1 BW IGNITION AND t ACCESSORY RELAY R f t I COMBINATION METER C RGE J 1 G For radio noise prewntion SEL10 ...

Page 472: ...terminal and negative lead to L terminal Bumed out bulb Replace and Proceed to A Ignition switch ON Check light for operation Engine idling Check light for operation Dim light OFF J Mure than IS SV I Faulty 1C RG 1 Engine speed Replace 1 500 rpm Measure 8 teoninal volt 13 to 15V age Engine idling Measure the voltage across 8 and L terminals More thanO 5 I Faulty A C G I Light OFF 1 Engine speed 1 ...

Page 473: ...m rear UD 1 SELOSl 3 Remove pulley and fan I Place rear cover side of rotor in a vice 2 Remove pulley nut EL 20 Resistance per phuc la 200C 680 I 0 051 n Rear cover Ie ro1use rtBulator Brushassembly Min brush length 7 5 0 295 Spring pressure 2 501 3 383 N Diode SOl plate a mbly 255 345 I 8 99 12 17 oz SEL060 SE L062 4 Separate rotor front cover Remove setscrews from bearing re tainer SEL083 5 Pull...

Page 474: ...place stator Diode Perform a continuity test on diodes in both directions using an ohmmeter Circuit tester terminal Conduction Positive Negative plate I Diode Yes Holder plate terminal Diode I plate Nn terminal Holder plate plate I Diode No Rear cover terminal Diode I plate Yes terminal Rear cover Po ltlve dlod EE536 1 Diode holder plate 2 Positive diode Conduction test is N G diode assembly Repla...

Page 475: ... per lmm O 04 in r 2 mm 10 08 in nT I eeOEf Not in the specified value Re place ASSEMBLY Assemble alternator in the reverse order of disassembly noting the follo ng 1 When soldering each stator coil lead wire to diode assembly terminal carry out the operation as fast as possible 2 When installing diode A ter minal install insulating bushing cor rectly 3 Tighten pulley nut and make sure that deflec...

Page 476: ...rforming test continuously resistor may generate heat If it becomes high temperature stop test ing for a while to avoid burning I The following test equipment and accessories are required ELECTRICAL SYSTEM Charging System 1 Resistor R 1 10 ohms 20 watts x I 2 Variable resistor Rv O to 300 ohms 20 watts x I 3 Batteries I and 2 12 volts x2 4 DC voltmeter o to 30 volts x 1 2 Measure voltage V I at ba...

Page 477: ... ofl4to 15 volts o o o o 0 z o u 1 IU I m M 10 cHI I IIIIM ll21l IwICIJlICIUICIMllllllUlGl Rc ul tor case temperature Oc OF SE L092 EL 24 7 Reconnect wlftng as shown in Fugure and repeat steps 5 and 6 If voltage V 4 is 0 5 to 2 0 wolb higher than that in step 6 regulator is functioning properly If it i not replace 1 j Ie regulator J rSEl093 ...

Page 478: ...plied rpm Hot output current A rpm Pulley ratio Regulated output voltage v Minimum length of brush mm in Brush spring pressure N g oz Slip ring outer diameter mm in ELECTRICAL SYSTEM Charging System lR16047 All 12 60 Negative Less than 1 050 More than 45 2 500 More than 60 5 000 2 09 144 15 0 7 5 0 295 2 501 3 383 255 345 8 99 12 17 316 1 244 EL 25 ...

Page 479: ...E BLOCK f l f ia models Q CIl I L I J ff IGNITION COIL EL 26 8 Q TERMINAL BLOCK VB O G a L a e JiljlJ1J1J SPAR K PLUGS IGNITION COIL w iP t WB BW 0 0 lJlJ Jf IGNITION AND 1 1 ACCESSORY RELA 9 California models Non California models INon Califomia models DISTRIBUTOR we L 0 B cJ I n I if 0 u L J j SPARK PLUGS J ff IGNITION COIL SEL 102 ...

Page 480: ...istor Ignition Analyzer However if an analyzer is not available a volt ohm milliammeter V OM may be used to diagnose transistor ignition malfunctions While this method requires more time it can nevertheless provide accurate results Follow the steps in the sequence indicated If a fault is found correct the problem before continuing If all tests indicate O K replace the Ie Ignition Unit DO NOT REPLA...

Page 481: ...nect ohmmeter as illustrated L Connect voltmeter 35 illustrated and set to appropriate scale 2 Turn ignition key to ON position RESULT 11 5 12 5volts Below 11 5 yolts Voltage reading greater than 9 6 volts Voltage reading less than 9 6 volts Resistance readings less than 30 000 ohms Resistance readings greater than 30 000 ohms California models 7 400 11 000 ohms Non Gllifornia models 8 200 12 400 ...

Page 482: ...il California models replace or 0 84 1 02 ohms Non california EE567 models 9 JC Unit I Connect voltmeter as Ground illustrated and set to 0 5 volts or less Proceed to Step 10 Circuit appropriate scale 2 Pull out coil wire from Check distributor distributor cap and ground wiring from ground it More than 0 5 chassis ground to 3 Tum key to START volts battery including position and observe battery ca...

Page 483: ... California models only EL30 TEST METHOD Ie ignition uni SEL084 CONDITIONS 1 Connect voltmeter as illustrated and set to appropriate scale 2 Turn ignition key to ON position RESULT II S 12 Svolts Below 11 5 volts ACTION Check wiring from ignition switch Co ICunit ...

Page 484: ...tion System ELECTRICAL S Cap aSJembly Carbon point g YRo orhead I RoUpin RelUclor S tor r Magnet ICignitionunit j G J Setter unit Ell ll J m controller Vacuu ow connecting Q Breaker plate I Il assembly Packing r li Rotor shaft 1 sembIY Thru t w er GovernorWeight Governor ng c SE lOOl EL31 ...

Page 485: ...n 2 Check vacuum diaphragm for air leak If leak is found replace vacuum controller assembly 3 Inspect breaker plate for smooth moving If plate doe not move smoothly this condition could be due to sticky Cap and rotor head Check cap and rotor head for dust carbon deposits and crack Advance mechanlsma Specifications Refer to D EL32 cap mbly st el balls or pivot Apply grease to steel balls or if nece...

Page 486: ...ing and fixing plate ELECTRICAL SYSTEM Ignition System SE L004 7 Remove fixing plate Mark housing and fixing plate SE LOOS 8 Remove collar EE104 9 Remove rotor shaft and drive shaft EE705 10 Mark rotor shaft and drive shaft Remove packing from the top of rotor shaft and remove rotor shaft EE706 II Mark one of the govemor springs and its bracket Also mark one of the governor weights and its pivot p...

Page 487: ...g instruction CAUTION Before inslallinglC ignition unit make sure mati R1rfaces of IC ignition unit and distributor are clean and free from dust sand and moisture Align match marks so that part are assembled to their original posi tions 2 Ensure that reluctor is properly oriented when installing on shaft Al ways drive in new roll pin as shown in Figure 3 When installing pinion on shaft be sure to ...

Page 488: ...il and amplifies the signal 2 Lock preventing circuit This circuit cuts off the ignition coil primary current when the ignition switch is ON and the engine is sta tionary If the ignition coil primary current is allowed to flow under such condi tions excessive current will be drawn because of low internal resistance of the ignition coil This can result in an abnormal temperature rise in the ignitio...

Page 489: ...e of the conventional point type dis tributor In order to provide high perfonnancespark firing over a wide range of driving speeds this duty can be controlled by the source voltage and the ambient temperature as well as by the engine rpm 4 Power switching c rcuit This circuit is used to make or break directly the primary circuit current of the ignition coil Ige51Ch eh B I I J 101 101 L J Ignition ...

Page 490: ... x reach mm in Plug gap mm in D4N9 o5 D4N9 04 D4K9 1O D4K9 09 California Non Califomia Canada A T I AT M T M T 134 2 Coun terc10ckwise 0 3 0 5 0 012 0 020 More than 50 More than 50 10 0 39 12 0 47 00 9 3 00 9 3 00 9 3 00 9 3 70 2 76 70 2 76 70 2 76 70 2 76 3 50 12 0 3 50 12 0 2 50 12 0 2 50 12 0 90 3 54 90 3 54 90 3 54 90 3 54 3 50 13 3 3 50 13 3 2 50 147 2 50 14 7 100 3 94 100 3 94 11 0 4 33 110 ...

Page 491: ...nitor lamp Turn signal and beam indicator lamp Cigarette lighter illumination lamp Heater Air on control panel illumination lamp Glove box lamp Cruise control switch lamp Selector lever illumination lamp AT model EL38 Wattage 50 40 60 27 8 27 8 27 34 34 27 80r 10 10 8 5 5 34 3 4 2 34 14 3 4 3 4 14 34 SAE trade number 4651 4652 1157 1157 1156 158 158 1156 67 158 158 158 158 158 158 COMBINATION SWIT...

Page 492: ...ECTRICAL SYSTEM LighringSystems o JI I 1r111fUUJUUU I TURN SIGNAL SWITCH 1 LEVER I I i NIL If LIGHTING SWITCH 1 1 OFF 1ST 2ND I ABC A Be A 8 C zuni I 0 I tf MUMJ o iF 90 ON OFF WIPER AND WASHER SWITCH 1 1 WIPER IOFF INT L O HI 111 l 12 WITH 1i X TINE CONTRod f rq tJtu AAQ SWITCH nON 22 SEL310 EL39 ...

Page 493: ... Faulty lighting switch High low beam comes on when CD and D and terminals of hamess con nector to lighting switch are connected with test lead including lOA fuse Partly discharged or run down battery Inoperative charging system Poor ground or loose connection Loose headlamp connection Faulty headlamp udi LIGHTING SWITCH HEAD LAMP MONITOR l j HEADLAMP SENSOR 1 SEL371 Corrective action Correct caus...

Page 494: ...HEADLAMP R H fi ir RY RR Tr 1 RW R HEADLAMP L H 0 RY RL RW II White QrJ g g giJ I I r V RY1th jR I YRW LIGHTING SWITCH I OFF 1ST 2ND 4 R r 4 R r 4 I a lL 661t D L l3 0 H gXZ 6 6 g II r Green J I l lQ g gglrgg CI I I COMBINATION METER O U HEADL MP MONITOR HEAD LAMP SENSOR l D DO DO SE L372 EL 41 ...

Page 495: ... cool nt engine oil filled up to correct level and full fuel tank other than the driver or equivalent weight pl ced in driver s position When performing headlamp aiming adjustment use an aiming machine aiming wall screen or headlamp tester For operating instructions of any aimer it should be in good repair calibrated and used according to respective operation manuals supplied with the unit If any ...

Page 496: ...ITCH TAIL LAMP MONITOR STOP LAMP MONITOR r TAl L ANO STOP LAMP SENSOR SCHEMATIC TURN SIGNAL AND HAZARD WARNING LAMPS OACC r o 4c FUSleLE LINK Sf o c FUSIBLE LINK T I BATTERY L I TURN fl FRONT COMBINATION l LAMP TURN E1 o c FUSE IGNITION SWITCH 1 L IGNITION AND ACCESSORY RELAY C 0 0 FUSE Fl HAZARD FLASHER UNIT Fl TURN SIGNAL FLASHER UNIT PILOT LAMP R H PILOT LAMP LH REAR SIDE MARKER LAMP RH STOP j ...

Page 497: ...ONT COMBINA TION LAMP LH GB I FRONT SIDE Y MARKER LAMP LH ELM W I J I GW I I OF 1ST 2ND ABCABCABC Lg jI 00 1 I 00 3 4 5 LIGHTING SWITCH GW 00 00 00 1B 00 V 00 ft White I G LICENSE PLATE LAMP l e r GW i lI ltJ ill Ij f ill o WL e gg 00 g g Black i5 O g r TAIL WGH HATC CK M B I ry I wARD TOP TAIL LA P WG LH I I a fB 14 Gll L j J J j Gf REAR SIDE MARKER I LAMP LH II JtU W l TAIL AND STOP LAMP SENSOR ...

Page 498: ...ON METER L Au2 y U CID I I J ggggllggt Bluel White II J IIF J J GY L cLIi White OOIIOOOO Iqj oo 0000 11 I f I tf11 TAIL AND STOP LAMP SENSOR SEli71 B YG STOP LAMP MONITOR HATCHBACK STOP AND TAIL LAMP R H f HARDTOP f YG I fB 41 tJ I L STOP LAMP I R H HATCHeACK STOP AND TAIL LAMP LH J rII J Black o ooooo OJ rO I B1 Cill u B l YG rHARDTOP I I I STOP LAMP L LH EL 45 ...

Page 499: ... I BI l co fP 1 GY t J FRONT COMBI NATION LAMP R H TURN SIGNAL FLASHER UN IT L G C B TURN SIGNAL SWITCH LN R f 1t i I GB Y j I i II CD aJ I IWhi e 6 Ilt 00 White Y oc I 00 I ll fi a IG een I 1 i FRONT COMBI NATION LAMP L H OOllOO OilfJ I 00 0000 co ill COMBINATION METER L H RH jJif GR PILOT LAMP R a I I EL 46 IGNITION SWITCH I CJT iI t ICJN ST U9Q A 0 0 J IG b Q s IGNITION AND ACCESSORY RELAY r I ...

Page 500: ... IGNITION AND ACCESSORY RELAY BACK UP LAMP SWITCH INHIBITOR SWITCH 1 3 SEL380 WIRING DIAGRAM BACK UP LAMP FUSE BLOCK 1 IGNITION AND 9 ACCESSORY RELAY Jl RB 00 RB 00 i White BACK UP LAMP R H F T IGNITION SWITCH BW WR BB t o tf R FUSIBLE LINK G B RB B I 1 o BATTERY INHIBITOR SWITCH I ll ll C a a C 9 Q 0 O 11 11 t I BACK UP LAMP SWITCH RBB t BACK UP LAMP L H SEL381 EL 47 ...

Page 501: ...ulb Loose connection or open circuit Probable cause Burnt fuse Faulty stop switch Faulty tail and stop lamp sensor Stop lamps light when and terminals of main harness connector to tail and stop lamp sensor are connected with test lead including lOA fuse Loose connection or open circuit Bumt bulb Loose bulb Loose connection or open circuit Corrective action Correct cause and replace Check wiring an...

Page 502: ...side lamps operate when and terminals of harness connector to hazard switch are connected with test lead including lOA fuse Faulty hazard switch Loose connection Burnt bulb Faulty flasher unit Loose connection Bulb other than specified wattage being used Burnt bulbs Loose connection Faulty flasher unit Burnt bulb Loose connection Bulbs other than specified wattage being used Faulty flasher unit EL...

Page 503: ...enIOr en ure that aU bulb meet specifications Inspection Stop lamp Stop lamp switch on EL 50 VJ Bulb in good ord Ap 2 volts Approx 12wofts SEL385 Bulb removed Tail lamp light switch on Bulb in good ord r Approx 2 volts Approx 12voltl SEL386 Bulb nmoved HAZARD SWITCH Inspection lt 145 OM OF SEL296 TURN SIGNAL FLASHER UNIT AND HAZARD FLASHER UNIT Location Steering column Turn signal flasher Hazard f...

Page 504: ...mpered with gasoline SCHEMATIC INTERIOR LUGGAGE COMPARTMENT AND STEP LAMPS Hatchback model with Interior lamp timer INTERIOR LAMPS WITH SPOT LAMPI 6 6 6 ij 011 STEP LAMP RH INTERIOR LAMP TIMER 1 o DOOR SWITCH RH FUSE o C j DOOR SWITCH L H FUSIBLE LINK LUGGAGE COMPARTMENT LAMP 1 o 0 1 BATTERY III L STEP LAMP L H n SEL3a7 EL 51 ...

Page 505: ...21 I i7I Y B B ib 1 k9 IrO jl a II CD a co a W White r9l 0 I I t I 00 a CD I i LUGGAGE COMPART MENT LAMP IHA TCHBACK RG B D 0 Q J i TRUNK ROOM LAMP HARDTOP RG ao t o L EL 52 lR lG i STEP LAMP A H 00 BR ro I A RG c J LUGGAGE COMPART MENT LAMP HATCHBACK eR RG DOOR nO fB O CH 4 TRUNK ROOM LAMP HARDTOP 1 RG 11 Rr I Whi 000 1 0 o hiB tSiB V R DOOR SWITCH LH BR W I 6 l iR tt ER STEP LAMP LH 00 BR c J RG...

Page 506: ...with a clothbefore insertion 2 Remove attaching bolts and de tach interior lamp assembly ELECTRICAL SYSTEM Lighting Systems DOOR SWITCH Inspection Door switch LR SEL391 I DOOR I CLOSE OPEN I 0 126 g I FOR USE KEY AND LIGHT WARNING INTERIOR LAMP INTERIOR LAMP TI MER Ic built In Location The interior lamp timer is attached to the upper side ofinstrument frame Refer to page EL 104 Inspection SEl393 C...

Page 507: ...T 2ND SWITCH ABC ABC ABC IUUMINATION I ROL RHEOSTAT Transistor bult ln 8pectlon fe Battery EL 54 J E SEL303 FUSE c COMBINATION METER OPTICAL FIBER r KEY ILLUMINATION o ILLUMINATION CONTROL RHEOSTAT 8 TEMPERATURE CONTROL PANEL A S C D MAIN SWITCH CIGARETTE LIGHTER LAMP 3 CIGARETTE LIGHTER LAMP 13 ASH TRAY LAMP 3 GLOVE BOX LAMP 13 RADIO ILLUMINATION 3 AfT POSITION INDICATOR LAMP SEL396 ...

Page 508: ...ILLUMINATION r r HEATER CONTROL PANEL ILLUMINATION B flJ Lgg Lv il I GW White LgB f Bluel A S C D equipped models IAO f C A T C A 2i a I q I q a l 6 06 0 aa LJ i nun LIGHTING SWITCH 0 fi I 0 I I GW METER I LgS AND KEY IllUMINATION COMBINATION METER CiD G ij D LgB ILLUMINATION CONTROL RHEOSTAT L Y ll B Jo GW B CIGARETTE LIGHTER LY S D GW GLOVEBOX LAMP GW I LgB B Gw e I ASH TRA Y LAMP GW II aa L9 V ...

Page 509: ...d Warning Systems ELECTRICAL SYSTEM METERS GAUGES AND WARNING SYSTEM CAUTION Before starting to work on eny part of electrical system disconnect battery ground cable COMBINATION METER R O A ANI 1 tTA TION SE L397 EL 56 ...

Page 510: ... n L ey 8 CD J 15 o u o 11 J c o i f c0 1 I L 1 A A l l 1 Temperature gauge 2 Seat belt warning lamp 4 Power source 5 Right twn indicator lamp 6 Fuel gauge 7 Beam indicator lamp 8 Tachometer Signal 10 Ground 12 Left turn indicator lamp 13 Charge WaIning lamp 14 Rear defogger indicator lamp IS IDumination lamps 16 Illumination lamps 17 Tail lamp monitor lamp 18 Headlamp monitor lamp 19 Stop lamp mo...

Page 511: ...o 0 W u Qi Q 1 n 6V I W z JCJ U J w Cl Cl Jc lLCJ aO JZ w 0 Z w Zo J ni I r 1 J 0 I J u w w a u 10 WIRING DIAGRAM TACHOMETER I Et e T l R G FUSIBLE LINK a a D BATTERY 0 0 IGNITION SWITCH a S1 ON ACe OFF i 0 B I I II BW IT WR IGNITION AND ACCESSORY RELAY CJ EL 58 WB FUSE BLOCK J 6f T IGNITIO N COIL RESIS TOR a CI Z a za 0 Oa r g f 1 y J 41 i 0 o i 0 J a Ot O 0 SE L399 GD L I J 2 3 0 TACtOYETER COMB...

Page 512: ...LY Y Green I 60 I s co V I OJ 1 U OIL PRESSURE THERMAL SENDING UNIT TRANSMITTER WR rn BW II II rn I I I 10 ACQON Sf 1 6 O I 6t S 6 1l J B y I IGNITION SWITCH IGNITION AND ACCESSORY RELAY FUEL TANK GAUGE UNIT J 0 I COMBINATION METER VOLTGAUGE OIL PRESSURE VOLTAGE GAUGE EGULATOR VOLTAGE REGULATOR 0 I LY 7 R C B 0 Y 8 1l u Iu 1ll n YW 362 J 4 5 o TEMPERATURE AUGE 6Hv FUEL GAUGE 0 OIL PRESSURE WARNING...

Page 513: ...WB BW I m r FUSE BLOCK I I lil 1Wh el jJ 00 00 00 is C BULB CHECK RELAY i BRAKE FLUID LEVEL SWITCH rr t B s 4 I R Br B I R G G BR L Qtl YG Green r OO BJ o WR gfgfllg l 8 White WR JI ill PARKING BRAKE SWITCH o DYG l ALTERNATOR L TERMINAL EL 60 G W wr BR d G IGNITION AND ACCESSORY RELAY DOOR SWITCH R H BR J4 04 1 DOOR SWITCH L H BR J e lI0 0 4 a J 2 3 COMBINATION METER w 2 a W a 0 J 0 a u 0 m SEL368...

Page 514: ...pressure sending unit or loose terminal connection Faulty oil pressure gauge unit Gauge pointer retums to original position when ignition switch is tumed off Faulty oil pressure gauge Gauge pointer indicates maximtim pressure even after igni tion switch is turned off Faulty fuel gauge tank unit Pointer deflects when fuel gauge tank unit yellow wire is grounded Faulty fuel level gauge Loose connect...

Page 515: ... with door opened and engine running Tachometer Condition Tachometer pointer deflects Tachometer pointer will not move EL 62 Probable cause Faulty oil pressure sending unit or loose terminal connectio r When lead wire connected to sending unit is grounded warning lamp lights Burnt bulb or looSe bulb Lack of engine oil Oil pressure too low Faulty oil pressure sending unit Faul1y door switch Burnt b...

Page 516: ...ged transmission speedometer pinion gear Faulty speedometer Improperly tightened or loose speedometer cable union nut Damaged speedometer cable Faulty speedometer Excessively bent or twisted speedometer cable inner wire or lack oflubrication Faulty speedometer Faulty speedometer Faulty speedometer a Float For fuel gauge Full Inapectlon Fuel tank gauge unit has two func tions II SEL311 1 4 nVi f Co...

Page 517: ...o the relay bracket Refer to pa EL 105 Inspection l f I t I i lll L w lI SEl406 DIODE For charge warning lamp Location The diode for charge warning lamp is fastened to harness with tape on the right side of the dash panel Refer to page EL 109 DOOR SWITCH Refer to page EL 53 TACHOMETER Removal d Installation 1 Remove combination meter 2 Remove tachometer attaching bolts 3 Remove tachometer from com...

Page 518: ... WARNING DISPLAY Ignition switch ON DESCRIPTION Warning lights come on to read aU items in succession one at a time for 2 seconds The warning display system con sists of a warning indicator a warning display amplifier and sensors When ignition switch is ON warn ing display operates as follows J YES NO I ight OFF I Abnormality I Abnormal indication I Eliminate abnormality I EL 65 ...

Page 519: ...rolyte level warning Coolant level warning Washer fluid level warning WASHER LEVEL SENSOR Ir b o WARNING DISPLAY AMPLIFIER FUSE Warning Indicates that fuel is less than v mately 10 liters 2 5 8 US gal 2 1 4 Imp gal Indicates that battery electrolyte is less than specified level Indicates that engine coolant in radiator reservoir tank is less than specified level Indicates that windshield washer fl...

Page 520: ...IATOR SENSOR tfW WR II FUSIBLE LINK FUSE eLOCK BL J 1 B J BATTERY SENSOR i L n C BY YL EYL 00 I g Black 00 J fj i IGNITION SWITCH WR BW 1ill 1 IGNITION AND ACCESSORY ffEU V t n I L LY Lvi lB LR f WARNING INDICATOR WARNING DISPLAY AMPLIFIER RY B BL LW LV LR LB L G YL BY o 0 0 0 0 0 YL B I ill FUEL TANK GAUGE UNIT SEL412 Et 67 ...

Page 521: ...euion one at a time for 2 seconds However warning lights will not come on even th ugh there i Ibnormality 1 Check sensor lOX Check for loose connection or open circuit lOX Check warning indicator for burnt bulb Replace warning display amplifier N G Re I pan or rep ace sensor N G Repair or replace N G Replace warning indicator I Warning light remain on even though th i no IbnormaJity 1 Check sensor...

Page 522: ...level sensor is located on the bottom of the washer tank InllPectlon Q SEl414 COOLANT LEVEL SENSOR Location The coolant level sensor is located on the bottom of the radiator reser voir tank InllPectlon Coolant level sensor is united with the reservoir tank and cannot be re moved alone w Empty Norm llev t on n SEL415 BATTERY LEVEL SENSOR Inspection Before inspection make sure that the battery is ch...

Page 523: ... glow with ignition switch on Either chime or warning lamp does not operate with proper condition EL 70 Probable cause Faulty warning chime Loose connection or open circuit Faulty door sWitch Faulty key warning chime switch Faulty lighting system Clearance lamp does not light Faulty eat belt switch Faulty seat belt warning timer Loose connection or open circuit Loose connection or open circuit Bur...

Page 524: ...GW I lVR GW GW SEAT BELT TIMER A YB WARNING CHIME R a SEAT BELT SWITCH gm 2k YB Br White 11 GW Lg 41 41 illY Blue il w l e rtfJ1 J t J fi l Whhe 1 1 IillJJ l 4 15 IGNITION SWITCH I I B iA IG IS Of aa ON S1 g o g IGNITION AND ACCESSORY REALY Ii O LIGHTING SWITCH I OFf r 1ST I 2ND ABCABCAB 9 0009 o oObo 888 g gg KEY WARNING SWITCH RG a iO oon w DlJ c U COMBINATION METER L9Y GD 2 2 B SEAT BELT WARNIN...

Page 525: ...at belt warning timer is located on the back side of the dash board on the right side Refer to page EL104 Inspection After about 6 secondl SEL41 WARNING CHIME Uc built In Location The warning chime is located on the back side of the dashboard on the right side Inspeictloil Battery w Battery w SEL420 DIODE For door awltch Location The diode for the door switch is fastened to body hamess with tape n...

Page 526: ...t battery ground cable SCHEMATIC WINDSHIELD WIPER AND WASHER With time control J C FUSIBLE LINK FUSIBLE LINK I SA TTERY L I WIPER SWITCH 11 WIPER f HI LO INIp o gg 8 JU 1r OACC f CON OJ IGNITION SWITCH 1 o c r c FUSE IGN ITlON AND ACCESSORY RELAY INTERMITTENT WIPER AMP WASHER MOTOR 1 WIPER MOTOR AUTO RETURN DEVICE SE L422 EL73 ...

Page 527: ...LOCK J WIPER MOTOR l o M L I I I Le 1 G GL INTERMITTENT WIPER AMPLI F I ER It ill I G ga I B 80 I LV 00 I LR L I LW WASHER MOTOR U W Ji EL 74 IGNITION SWITCH OfF iC i r rl lG 0 P I Sf 0 IGNITION AND ACCESSORY RELAV ld O WIP ER SWITCH WI PER W ffINIlO HI I L gg LJ T og9 llifl 5IJO l OOO LB j LR L LV LW L LI With time control SE L423 ...

Page 528: ...oper switch contact Faulty circuit breaker Motor brush for either low or high speed iswom Contaminated auto return relay co tacts or improper contact due to foreign mat ter Incomplete auto return operation Con tact is not interrupted Bumt fuse Faulty switch Faulty washer motor Loose or poor connection contact at motor or switch Clogged washer nozzle ELECTRICAL SYSTEM Wiperand wsher Corrective acti...

Page 529: ...h Faulty wiper motor Faulty intermittent amplifier Faulty wiper switch line voltage below 10 volts Faulty wiper switch Faulty wiring Faulty intermittent amplifier Faulty wiper switch Faulty wiper motor Faulty intermittent amplifier Faulty wiper switch Faulty wiring Faulty intermittent amplifier Excessive line voltage fluctuation Faulty wiper switch Faulty wiring Faulty wiper motor Faulty intermitt...

Page 530: ...LD WIPER Removal and Installation OJ SEL319 CAUTION Be careful not to bend linkage during removal Inspection 9 uL urff M P B Motor should run t low speed SEL321 Auto return deVicez Stop position I Ii M E Motor should runat high speC SEL322 EL77 ...

Page 531: ...WIPER Location The intennittent wiper amplil18r is attached to the relay bracket Refer to page EL 105 Inepectlon Be careful not to connect lead wir to incorrect te minals Connect test lead wire JIDECO BE L326 2 Make sure that test lamp comes oil when negative lead wire A is con nected 1 OnlY time control tYP D I e 1 A i B JIDECO Test lamp repeatedly comes OD SE 27 3 Disconnect lead wire B Test lam...

Page 532: ...INDOW WIPER AND WASHER Eflf L o 1 BATTERY FUSIBLE LINK Age Off J D ci o 6 IG I o S LB IGNITION SWITCH I r c B L o 0 0 o o 0 WR r o FUSE BLOC J Lvi 8 REAR WAS iER MOTOR LB to o U 5 L CD 1P1 LB REAR WINDOW WIPER ANO WASHER SWITCH lw RWIP V t l Ia f N I 1 i b 0 J L L Y LW L AUTO RETURN DEVICE WI PER WASHER ON OFF ON f b r o REAR WINDOW WIPER AND WASHER SEL434 E3 Uf W LB L B v 1 LB W LW L 19y 00 Lg r ...

Page 533: ... Installation r u i U 7 t 1 i i SEL367 I spectlon 0 I j I i t 1 J I B IO return device t Stop position BXP S E 1 Inspection REAR WINDOW WIPER SWITCH AND WASHER SWITCH Washer on Auto return Wi r EL 80 S PE SEL332 r I Washer I Wiper I OFF ON OFF I ON I X t tl SE L336 ...

Page 534: ...IGNITION AND ACCESSORY RELAY w u Q C REAR WINDOW 0 0 DEFOGGER FUSE 1 MON ITOR LAMP DEFOGGER 1 SWITCH 0 0 SEL436 WIRING DIAGRAM REAR WINDOW DEFOGGER iJ ig R FUSIBLE LINK BATTERY 0 I I FUSE BLOCK IGNITION SWITCH WR BW II 14 IGNITION AND ACCESSORY RELAY I W I WB BW Ji J LB LB r li gg White 8 e o 00 t 4 LB e LB L L e B le L White J 00 B 0 LB J co LB 00 d gg LB c J ocr iJ 2 4 190 I 1 DEFOGGER iN SW ITC...

Page 535: ...d its surrounding area clean with a cloth dampened in alcohol 2 AppJy snuillam t of c duc tive silver composition to tip of draw ing pen Shake silver on container belore use 3 Place ruler on glass along broken line Deposit conductive silver com position on break with drawing pen Slightly overlap existing heat wire on both sides preferably 5 mm 0 2 0 in ofthe break 00 Heat wire reak 1 Lf Drawing pe...

Page 536: ...tlon Remove door mirror securing bolt and disconnect harness connector S L442 I I R l I u 0 0000 9 0 uO 10 0 0 0 OQ r DOOR MIRROR RH ELECTRICAL SYST M Electrical Accessories 1 DOOR MIRROR SWITCH Inspection 4 5 a 1 R L U 0 I 11 9 I I I I 0 1 I I 6 c II 15 J 0 oJ I EL444 DOOR MIRROR SWITCH L H I R l U 0 oOOob J00bo0 i IQO r DOOR MIRROR L H SEL440 o Ell 8J ...

Page 537: ...RING DIAGRAM REMOTE CONTROL DOOR MIRROR 9 rrR o w FUSE BLOCK 1 BATTERY DOOR MIRROR SWITCH LH DOOR MIRROR SWITCH R H RLUD RLIUD rU U r tJ a a r11 CJ t CO 5 I ICO IIII II a Clco i rm il rTIl iil R J III DOOR MIRROR R H DOOR MIRROR LH SEL441 EL B4 ...

Page 538: ...ise for hour adjustment Turn it clockwise for minute adjustment Push it to set the time to the nearest hour For example when adjusting the time for 10 00 first set the time be tween 9 30 and 10 29 Then push the knob simuJt usly with the annou lcement of 10 00 To adjust the day first select MONTH DAY with the SE LECT knob then tum the AD JUST knob counterclockwise for MONTH adjustment or clockwise ...

Page 539: ...RAM CLOCK EL 86 I 1ll D FUSIBLE LINK WR W BATTERY I 1 WR LB ST ON lCCOff 000 B J 00 8 b I IGNITION SWITCH I J W W u i w C I IJ 1 j J I J L j Green J j White 1 Ii00 0 L 01 O L TO L1GHT SWITC H l iOOOOIIO ho oooo o J I e L og COMBINATION METER H G J 3 2 4 ...

Page 540: ...8 0 BATTERY HORN RELAY D G r HORN R H G HORN L H 0 FUSE ELECTRICAL S YSTEM EIectncal Accessories Surge killer HORN RELAY I o C 1 HOr B TN1 Q HORN Q HORN SEl445 6Bfl gW LINK i f I l D BG FUSE BLOCK 1 a J I l N D l l 3 I U HORN BUTTON 0 I COMBINATION SWITCH 2 SEL446 EL 87 ...

Page 541: ...ot stop to sound Short circuited horn button and or hom button lead wire When ins1rument harness is disconnected from combination switch horn stops sound ing Faulty hom relay Reduced volume and or tone quality Loose or poor connector contact Fuse relay horn and or horn button Faulty homo HORN Inspection rJ CD HI to SEL340 HORN RELAY Locstion The horn relay is located beneath the relay bracket Refe...

Page 542: ...ANTENNA 1 FUSIBLE LINK BATTERY I L RADIO IGNITION SWITCH C ACC CON OST ELECTRICAL SYSTEM Elecrrical Accessories y OST IGNITION SWITCH m I 000000 6 J01 V t POWER ANTENNA SWITCH I u N 0 o FUSE 0 0 u I I OeCK REAR SPEAKER R H II E REAR SPEAKER L H SEL447 l f t POWER ANTENNA 3 MOTOR SEL449 EL 89 ...

Page 543: ...E Y U FUSIBLE LINK Sf o LW illY 4YJ LyR B I a I J 0 01 IBlue I a m a 15i J 0 t J DOOR SPEAKER L H II II I YUi U Irml 9 0 0 FUSE RADIO EL 90 DWR Block J lgW J I v LR LB i l I L Green 0000 0000 00 DECK REAR SPEAKER RH 1J I I I tk Y m rT REAR SPEAKER L DOOR SPEAKER R H SE 1448 ...

Page 544: ...ITCH ST ON ACC Off I 8 g J I FUSIBLE LINK G D ftWR mtl 1 1WR LBi FUSE BLOCK s L n J Il l i White Ifg lIgg1gitl Whitel ill I s s Q l 0 a cO B I I i nht 0 Bluel Green 000000 1 1I000ill lIt o II I CD CD L1f3J I U N D Ig POWER ANTENNA SWITCH I s I I s RW B W s c a w r POWER ANTENNA MOTOR SEL450 EL 91 ...

Page 545: ...cable or radio receiver Before adju ingt be sure to check harness and antenna feeder cable con necton for proper connection 1 Extend antenna completely 2 Turn radio on and turn volume control to increase speaker volume 3 Tune in the weakest sta1ion bare ly audible on dial at the range around 14 1 400 kHz 4 Turn antenna trinuner to left or right slowly and set it in the position where reception is ...

Page 546: ...rIMMED1ATELY BACK ORDERED NO CLAIMSAI WED UNLESS MADE WITHIN 10 DAYS FROM DATE off INVOI CE rfo UNAUTHORIZED RETURNS ACCEPTED ThiS is to rtity that the 900ds herein were produced In ompllilnce with all provisions of the Fair Labor Standards Act of 1938 amended It is Intention o amply nd the prices here Invoiced do comply to tJ1e best of knowledge with sting price egulations SHIPPING 114l ...

Page 547: ...r Noisy radio reception 1 Stop engine and turn off all other I switches Revised 1 I Check ignition cables O KJ I N G I T gh I 1 ten secure y O K l Check antenna ground Adjust antenna trimmer O Kj Replace radio Revised 1 Faulty radio Check noise prevention parts Condenser bonding wire O K l Check spark plugs O K I Faulty speaker Unchanged O K Check feeder cable routing Replace radio Revised Faulty ...

Page 548: ...an electrical signal equivalent to the difference between the preset speed and the actual speed picked up by the speed sen or The rvo valve converts this signal into corre ponding vacuum and oper ates the actuator which adjusts the throttle valve opening IGNITION SWITCH ON r OFF I ON rc Y FUSIBLE LINK Y L FUSIBLE LINK BATTERY FUSIBLE LINK cY C 1 I OACC I Y g r L MAIN SWITCH Neutral xmtion I llRELA...

Page 549: ... controlled prop erly S ryo y ly TransdUc r The servo valve causes the vacuum valve and atmospheric valve to open or close according to the input current and adjusts the vacuum from the intake manifold Controll r The c ontroller compares the preset speed with the actual car speed and maintains the preset speed by in creasing or decreasing the current flowing through the servo valve 2 A S C D cable...

Page 550: ...tic transmission selector lever at any position other than Ip and I NW position YES to Open circuit I Faulty or unproperly adjuSted stop switch When set switch is depressed with main switch ON battery voltage 12V is present between terminals and V ofhamess connector YES 1 NO Faulty set switch With main switch ON manually rotate meter cable slowly Con1inuity between terminals CD and ofharness conne...

Page 551: ...le 1 With A closed no suction is possible at B 2 With A opened suction is begun at B YES to Faulty release valve It Servo valve operates normally Refer to Servo Valve for Inspection YES 1 NO Faulty servo valve Actuator operates smoothly when actuator vacuum port is suctioned TItis operation must be performed with A S CD cable released YES 1 Faulty controller lNO Faulty actuator tl LL I LJ A To ser...

Page 552: ...n vacuum hose Faulty actuator Faulty servo valve Faulty controller Faulty speed sensor Excessive play in A S C D cable Leakage or clogging in vacuum hose Faulty release valve Faulty servo valve Faulty controller Cancel circuit inoperative Faulty controller EL 98 Corrective act on Check and repair meter cable or renew cable Renew Adjust Check and repair piping route or renew hose Renew actuator Ren...

Page 553: ...ELECTRICAL SYSTEM Automatic Speed Control Device A S C D COMPONENT PARTS VACUUM ROUTING Adjusting nut Lock nut o f I Actuator To vacuum check valVe Air conditioner equipped model ToF I C D SEL392 EL 99 ...

Page 554: ... g g I s l o s tf IGNITION TCH r W we o 0 QI FUSE 0 BLOCK STcp LAMP 1 SWI STeP SWITCH C1 SET SWITCH RELEASE SERVO L U v V E A S C D CONTROLLER I r I II jG I J a J CD a J CD a C a J I I i 1 W VB A 5C D f m I INHIBITOR RELAY YL I I I L BL 1 i m vn I lOr LgB J m l iJ 1 m J CD C C I l I W XI Cl III 11 1 0 J A S C D MAIN SWITCH EUOO m Cl W Whits 171 Y 1r I SPEED SENSOR SEL3M ...

Page 555: ...ctuator If diaphragm moves to full position it is normal Plug hose with vacuum applied Make sure that act laJor remains in full position BE100D CAUTION When checking actuator by applying vacuum do not apply engina vacuum directly RELEASE VALVE Location Refer to page EL 99 In ction 1 Measure the resistance between terminals Circuit tester indication 25 30 n 2 Check to be sure that the valve opens o...

Page 556: ...sensor circuit Continuity existstwo times a turn O K A nro 9JD EL 102 0 IlL I I I l Servo valve MAIN SWITCH e Yacuumgauge 1 II 7 3 11 3 kP 55 85 mmHg 2 17 3 35 inHg Solenoid valve side To intake manifold BE730D Inspection Test continuity through switch or f 2Er Switch position Check terminal Q Q ID j j light with an ohmmeter in accordance with the following chart l 3 I I Off II lieAulSE CIN11lfi I...

Page 557: ... is located on the relay bracket Refer to page EL 105 Inspection a r c 1 a 0 o t L I Gr SEL433 Check terminals Normal condition l2V direct current is applied between terminals and CD Yes Yes No No Yes Yes Continuity should exist No Continuity should not exist A S C D CONTROLLER lC built In Location The controller is located on the left dash side panel Refer to page EL I04 Inspection Controller mus...

Page 558: ...Electrical Unit Location ELECTRICAL SYSTEM ELECTRICAL UNIT LOCATION Ignition arid accessory relay seatbelt timer HI control unit I to C v SE L432 EL 104 cJ ...

Page 559: ...elay III I Headlamp sensor Inhibitor relay Intermittent wiper amplifier Hatchback lamp nso I Tai1 and stop I Unit Location M Electrlca ELECTRICAL SYSTE Air conditioner relay alve Air con Magnet v H 7 lardtop 114 p sensor Tail nd lam EL 105 ...

Page 560: ...te R Red G Green Y Yellow Charging system lighting system Signal system Instrument system Others L 8r Lg Blue Brown light green B mack Grounding system HARNESS LAYOUT For easy identification connectors indicated in the system wiring diagram have the same numbers as those used in the har ness layout schematic I i YG CJ QO YG w Wiring diagram Main harness Instrument harness SEL461 SEL 2 EL 106 ...

Page 561: ...ICAL SYSTEM WiringHBrn8S SCHEMATIC Hatchback 4 1 Main harness 2 InstTumcnt harness 3 EFI harness 4 Body harness S Door harness 6 Console harness 7 Back door harness 8 Fuel pump harness SE L463 Hardtop EL 107 ...

Page 562: ...t t I1i ll t t li iJ s a a g g 9 e 5 iS u 11 l ii i t u ti a e II a d 0 i 5 t j i u Ii l s U et ooo g a rucn g9 l a i Ol c dod U 1l a t A l 0o 9 a 5e S6 j i a eil eJ d 0 a otIS i p p tt J i i a Po Po Po a IIi e 2l JJ t J 8c 4 58 Po e g e q s s 5 s i i s II PoPoal e i 5 1 l1 nl gi 1 i n SE d ...

Page 563: ...lue To l White To lID Black Parking brake switch 8 Seat belt switch Indicator lamp Am To console harness Heater control panel 1Jjl To door harness L H A S C D controller A S C D controller To EFI harness Hazard flasher unit Turn signal flasher unit Door mirror 5Witch L H i Door mirror switch R H A S C D main switch A Hazard switch r Ignition switch Windshield wiper switch m rm n l 0 n r Ul Ul l m ...

Page 564: ...tat To combination meter To combination meter To combination meter A S C D peed aenlOr Interior lamp timer Multi wambtg indicator ID Audio Power antenna switch garette Ughter Ash tray illumination Wamlns dl pby amplifier Glove box lamp To I Bbck To Blue To 8 Green To White ...

Page 565: ...p R H Back up lamp R H License lamp L U ill Rear combination lamp L R J Tr l m r m r In Rear combination lamp L n Back up lamp L U Power antenna ffi Side marker lamp L R Luggage ompartment lamp Rear speaker L U Door switch L R To fuel pump harness ill Fuel tank gauge unit Body earth Back door hameu To To Rear defogger Rear wiper motor Rear defogger Earth fr rr II o 0 azIIII mr mnt n r en CIl l m 3...

Page 566: ... top lamP aenlOr Y Tail and atop lamP senIOr ide marker lamp R a 1 Rw combbU tlon lamp R a Trunk room lamP lear speaker L a Fuel tank gauge unit Licon lamP R a Back up lamP R a Licen lampL a Back up lamP L a Rear combination lamp L a l Side marker lamp L a power antenna Door switch L a To fuel pump harness f i o r 1S mIm0 o r ...

Page 567: ...M Wiring Harness ENGINE ROOM HARNESS NO 2 Kickdown rwitch Arr Inhibitor switch Am Inhibitor rwitch Am Rever bmp rwitch Mm Starter motor Oil pressUIe sending unit To I To To I I I r f J 0 fr2 fr 11 1 II J SEL460 EL 113 ...

Page 568: ...4 i j f ...

Page 569: ... I Wn 1 1 fl lP J J l J llr k l g Hld YlOY H I m11111nr I r f fi III ii i r I IB 66 l a EJ III II o Il l Wi h Jt J 1 100 IlOl fl1 1I1 NlO l00 oo J L ISIS lI 1Lw cP1m J 1 f1 l 81 1s lt 1 tRI c a lInl ii ii f rWU f JI 1019 3sn r f o itri IT J Cl rno I i i E tEl 9 B 8 I r B n 0 I u iI I o Q KIII lIl ll J 1 l001 lMl bIl l I M ffi 1 IIM 3 l 300Q i J r jf I H y 1130 11 1 1 101 01 1 1 O A OS J d lmu J lO...

Page 570: ...W ld J REAR SPEAKEII 1 a 1 1 G a G BLACK WHITE co GREEN BLUE YELLOW LIGHT GREEN BROWN GREY IN THE CASE OF TWO TONE COLOR CABLE CABLE COLOR IS INDICATED BY BASE COLOR ONLY AND STRIPE COLOR IS NOT SHOWN GREEN w t WHITE SI BlU Wl n GREEN Sl p REAR WIPER I NTfNNA MOTORlIl MOTOR AUTOMATIC TRANSMISSION MQDELS 4 MANUAL TRANSMISSION MODELS CALIFORNIA MODELS NON CALlFORNIA MODELS i A SeD EQUIPPED MODELS HA...

Page 571: ...20 20 83 22 866 72 2 835 320 8 13 830 21 08 23 906 73 2 874 330 8 38 840 2134 24 945 74 2 913 340 8 64 850 2159 25 984 75 2 953 350 8 89 860 2184 26 1 024 76 2 992 360 9 14 870 22 10 27 1 063 77 3 031 370 9 40 880 22 35 28 1 102 78 3 071 380 9 65 890 22 61 29 1 142 79 3 110 I 390 9 91 900 22 86 30 1 181 80 3 150 I 400 10 16 910 23 11 31 1220 81 3 189 410 10 41 920 23 37 32 1 260 82 3 228 420 10 67...

Page 572: ...21 12 S1O 12 65 1 7 51 333 1250 9 rl1 600 07 1 1 Sl Y 58 7 2 11 15 Unit lIImlilt R 1AHl1tn I 2 010 0711 lLeath lO 2Io OCM7J 1 Leadl lO S O OO59I 1 F tNZ2 m Q 07 Q OClZll 10 51D 4111 U lo 338 EXPORT SERVICE DEPARTMENT NISSAN MOTOR CO LTD 17 1 Ginza 6Chome Chuo ku Tokyo 104 Jap Printed in Japan t J pq 119BI 1 Unit lin 161 174 1e81 e1SJ l StaOiI a2D I WHEEL ALlGNMEN U Iaden I I I 10 S rlS Tot in IlMP...

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