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Ford Corsar, Repair Manual

The Ford Corsar Repair Manual is a comprehensive guide for DIY enthusiasts looking to maintain or repair their vehicle. This manual covers everything from basic maintenance tasks to complex repairs, providing detailed instructions and diagrams. Download it for free from manualshive.com and keep your Corsar running smoothly.

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Summary of Contents for Corsar

Page 1: ...EPAlR MANUAL I l WM 31 l...

Page 2: ...you should follow when you work on a vehicle Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be surethat the ignitionswitch is...

Page 3: ...h3 cm3 16 387 Inch3 litres l 0 016 Inch3 litres l 0 946 Quart litres l 3 785 Gallon metres3 m3 0 764 Yard3 MASS kilograms kg 0 453 Pound kilograms kg 907 180 Ton tonne t 0 907 Ton FORCE newtons N 9 80...

Page 4: ...ual are based on the latest product information availableatthetimeof publication Ifyour I car differs from the specifications con tained in this manual consult your Ford dealer for information The rig...

Page 5: ...PRECAUTIONS GI 2 HOW TO USE THIS MANUAL GI 5 HOW TO READ WIRING DIAGRAMS GI 7 HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES GI l0 IDENTIFICATION INFORMATION GI 13 LIFTING POINTS AND TOW TRUCK TOWING G...

Page 6: ...r tire blocks to the wheels to prevent the vehicle from moving After jacking up the vehicle support the vehicle weight with safety stands at the points designated for proper lifting and towing before...

Page 7: ...ecting vacuum or air hoses attach a tag to indicate the proper connection 13 Use only the lubricants specified in MA section 14 Use approved bonding agent sealants or their equivalents when required 1...

Page 8: ...ff the exhaust pipe Precautions for Fuel Useonly unleadedpetrolwith aminimumoctaneratingof 92 R O N researchoctane number Precautionsfor starting with flat battery 1 No attempt should be made to start...

Page 9: ...ant steps such as inspection use of special tools knacks of work and hidden or tricky steps which are not shown in the previous large illustration Assembly inspection and adjustment proceduresfor the...

Page 10: ...ng with complicated components 10 SERVICE DATA AND SPECIFICATIONS is contained at the end of each section for quick reference of data 11 The captions WARNING and CAUTION warn you of steps that must bd...

Page 11: ...em k can be operated See POWER SUPPLY ROUTING in EL section for the detailed wiring diagram r MIT model This shows that conti nuity exists between terminals and 0 when the switch is turned to ON posit...

Page 12: ...WASH Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams MULTIPLE SWITCH The continuity of the multiple switch is identif...

Page 13: ...dicated in wiring diagrams is shown in a simplified form The terminal arrangement should therefore be referred to in the foldout at the end of the Service Manual The foldout should be spread to read t...

Page 14: ...ayoutinELsec tion for identificationof harnessconnectors 5 When checking circuit continuity ignition switch should be OFF 6 Before checking voltage at connectors check battery voltage 7 After accompli...

Page 15: ...1V l Cross reference of work symbols in the text and illustrations Illustrations are provided as visual aids for work procedures For example symbol indicated in the left upper portion of each illustr...

Page 16: ...th englne stopped Start englne or check wlth englne runnlng Apply parklng brake Release parklng brake Check after englne IS warmed up Symbol explanat on Current should be measured with an ammeter Proc...

Page 17: ...5JJ X 14 Alloy ModelCode 23941 ZK 23941 ZP 23943 FK 23943 FP ModelCoding 4 1 Z P Body Sedan GL 41 GHIA 43 Engine CA2OE KA24E P MANUALTRANSAXLE K AUTOMATIC TRANSAXLE Z 2 0LITRE F 2 4 LITRE Transaxle R...

Page 18: ...IDENTIFICATION INFORMATION Vehicle Identification Vehicle identification Compliance plat ENGINESERIALNUMBER MANUAL TRANSAXLE NUMBER AUTOMATIC TRANSAXLE NUMBER...

Page 19: ...gth Overall height Overall width Front track unladen Rear track unladen Wheelbase Minimum ground clearance Turning circle kerbt o kerb KERB WEIGHTS Nomina0 4523 mm 1375 mm 1690 mm 1460mm 1444 mm or 14...

Page 20: ...afety stands to support the frame when you have to get under the vehicle Place wheel chocks at the front wheels when the rear wheels are raised and place wheel chocks at the rear wheels when the front...

Page 21: ...g the towing operation must be obeyed It is necessary to use proper towing equipment to avoid possible damage to the vehicle during a towing operation When towing with the rear wheels on the ground re...

Page 22: ...ised with front wheels on ground as this may cause serious and expensive damage to the transaxle If it is necessary to tow it with rear wheels raised always use a towing dolly under the front wheels I...

Page 23: ...6 0 8 0 10 0 12 0 14 0 6 0 8 0 10 0 12 0 14 0 Tighteningtorque N m 5 1 13 13 25 25 42 46 74 8 4 21 22 41 43 71 77 127 12 29 31 59 62 98 108 177 Without lubricant N m 6 1 15 16 29 30 51 56 88 10 25 26...

Page 24: ...ENTS PREPARATION MA 2 MAINTENANCESCHEDULE MA 3 RECOMMENDEDFUEL LUBRICANTS MA 4 ENGINE MAINTENANCECA20E ENGINE MA 6 ENGINE MAINTENANCEKA24E ENGINE MA 11 CHASSIS AND BODY MAINTENANCE MA 16 SERVICE DATA...

Page 25: ...ption E7118 1 Adapter Harness KA24E Engine lgnition coil adapter to connect external tachometer E7118 2 Adapter Harness CA20EEngine lgnition coil adapter to connect external tachometer ESD28079 Diagno...

Page 26: ...C C C C C C C C C Power Steerina Fluid and line I I I I I I I I I I I Steering Operation and gear housing C C C C C C Steering linkages rack guide tie rod I C C C C C ends Steerina stoos L L L L L L...

Page 27: ...7 6 litres NOTE Engineand ManualTransaxle Oils The proper oil viscosity for your engine and manualtransaxleshould be determined by the average outside temperature Brake81ClutchSystem Heavy duty brakef...

Page 28: ...MAINTENANCE...

Page 29: ...xhaust G and 0 30 mm 0 012 in Adjusting screw lock nuts m 18 22 Nmm 1 8 2 2 kg m 13 16 ft lb Checking Drive Belts 1 Inspect for cracks fraying wear or oil adhesion If necessary replace with a new one...

Page 30: ...ools down 7 Repeat step 2 through step 6 until clear water begins to drain from radiator 8 Drain water Apply sealant to the thread of drain plug m 54 74 N m 5 5 7 5 kg m 40 54 ft lb 9 Fill radiator wi...

Page 31: ...nsure that screw does not contact adjacent parts Changing Fuel Filter 1 Remove fuse for fuel pump 2 Start engine 3 After engine stalls crank engine two or three times to make sure that fuel pressure i...

Page 32: ...lf a s the engine oil may be hot 3 Clean and install oil pan drain plug with washer Drain plug 29 39 N m 3 0 4 0 kg m 22 29 ft lb 4 Remove oil filter 5 Wipe oil filter mounting surface 6 Smear a littl...

Page 33: ...accordingto the numbersandcolours indicatedon them Grey Exhaustside Black Intakeside Spark Plug 20 29 N m 2 0 3 0 kg m 1 4 2 2 ft lb Checking lgnitionWiring 1 Check the ignition wires for cracks damag...

Page 34: ...between pulleys Adjust if belt deflections exceed the limit Belt deflection Inspect drive belt deflections when engine is cold Unit mm in Deflection of new belt 5 6 0 20 0 24 4 5 0 16 0 20 Used belt d...

Page 35: ...to the thread of drain plug m 34 44 N m 3 5 4 5 kg m 25 33 ft lb 5 Open air relief plug 6 Fill radiator with water and close air relief plug and radiator cap 7 Run engine and warm it up sufficiently 8...

Page 36: ...engine and warm it up sufficiently 18 Race engine 2 or 3 times under no load 19 Stop engine and cool it down then add coolant as neces sary Checking Fuel Lines Inspect fuel lines and tank for improper...

Page 37: ...up engine then stop it and check for oil leakage from engine components 2 Removeoil filler cap anddrain oil WARNING Becareful notto burnyourself asthe engine oil may be hot 3 Cleanand installoil pandr...

Page 38: ...039 0 043 in 5 Installspark plugs Reconnecthightension cables Spark Plug 20 29 N m 2 0 3 0kg m 14 22 ft lb Checking lgnitionWiring 1 Check the ignition wires for cracks damage burned terminals and pr...

Page 39: ...ck fluid lines and operating cylinder for improper attachment cracks damage loose connections chafing and deteriorat on Checking MIT Oil Never start engine while checking oil level 1 Check for oil lea...

Page 40: ...ck fluid level with engine idling If the vehicle has been driven for a long time at high speeds or in city traffic in hot weather or if it is being usedto pull a trailer the accuratefluid levelcannot...

Page 41: ...alve Use same procedure as in bleeding hydraulic system to refill brake fluid Refer to section BR a Refill with recommended brake fluid DOT4 a Never reuse drained brake fluid a Be careful not to splas...

Page 42: ...BODY MAINTENANCE CALIPER Check operation and for leakage PAD Check for wear or damage Frontdisc brake Standardthickness 11 0mm Minimumthickness2 0 mm Rear disc brake Standardthickness8 0 mm Minimumthi...

Page 43: ...At pullingforce of 196 N 20 kg 44 Ib 9 1 1 If not to specificationrefer Section Br Checking Steering Gear and Linkage STEERING GEAR Check gear housing and boots for looseness damage or grease leakage...

Page 44: ...and tongues when buckled and released CAUTION 2 If the condition of any component 4 Neveroil tongue or buckle 1 If the vehicle has been involved in of a seat belt is questionable do an accident replac...

Page 45: ...1 o 1 1 20 29 Set deflection of new belt 5 7 0 20 0 28 6 8 0 24 0 3 1 Alternator Power steering oil pump or idler KA24E Unit mm in Used belt deflection Set deflection of new belt 5 7 0 20 0 28 6 8 0...

Page 46: ...rotor Pedal mm in Free height M T A T Free play Depressedheight Underforce of 490 N 50 kg 110Ib with engine running mm in Parkingbrake Number of notches at pullingforce 196 N 20kg 44 Ib Standard thic...

Page 47: ...REPLACEMENT EM 16 CYLINDER HEAD EM 18 ENGINE REMOVAL EM 32 CYLINDER BLOCK EM 34 SERVICE DATA AND SPECIFICATIONS S D S EM 46 CA2OE 0 1 OUTER COMPONENT PARTS EM 56 COMPRESSIONPRESSURE EM 57 TIMING BELT...

Page 48: ...t to mating surfaces Use Genuine Liquid Gasket or equivalent m Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in wide for oil pan Be sure liquid gasket Is 2 0 to 3 0 mm 0 079 to 0 118 in wide i...

Page 49: ...mp seal cutter E7181A Camshaft pulley holder E7145 Chain stopper installer Tool Number Tool Name E7007 Valve spring compressor E7004 Valve stem seal X installer Intake only Description E7008 Camshaft...

Page 50: ...13 in1 dia B 6 6 mm installing valve 0 260 in1 dia guide Exhaust A 11 5 mm 0 453 in1 dia B 7 6 mm 0 299 in dia k Valve guide reamer Engine application Intake Exhaust CA 7 0 mm 0 276 in1 11 2 mm 0 441...

Page 51: ...PREPARATION...

Page 52: ...OUTER COMPONENT PARTS...

Page 53: ...m SEM596C A 0 Tightening Procedure of each Part INTAKE MANIFOLD nl 16 21 Nom 1 6 2 1 kg m 12 15 ft lb EXHAUST MANIFOLD nl 16 21 N m 1 6 2 1 kg m 12 15 ft lb INTAKE MANIFOLD COLLECTOR nl 16 21 Nom 1 6...

Page 54: ...rpm Standard 1 206 12 3 175 250 Minimum 1 010 10 3 146 250 Difference limit between cylinders 98 1 0 14 250 10 If cylinder compression in one or more cylinders is low pour a small amount of engine oil...

Page 55: ...n or aluminum mating face will be damaged Do not insert screwdriver or oil pan flange will be deformed 2 Slide Tool by tapping its side with a hammer and remove oil pan Installation 1 Before installin...

Page 56: ...Installation Cont d Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in wide 3 Apply liquid gasket to inner sealing surface as shown in figure Attaching should be done within 5 minutes after coat...

Page 57: ...Chain tensioner Oil pump drive boss kg m ft lb 12 16 87 116 0 7 0 8 5 1 5 8 y liquid gasket ql 16 21 1 6 2 1 12 1 To main bearing beam I SEM550C CAUTION After removing timing chain do not turn cranks...

Page 58: ...l 5 Set No 1 piston at T D C on its compression stroke 6 Remove the alternator and compressor drive belts 7 Remove the following parts Alternator and adjusting bar Oil separator Power steering pump pu...

Page 59: ...h hoist or chain block 13 Remove right side engine mounting bracket and lower the engine 14 Remove front cover 15 Remove the following parts Chain tensioner Chain guides Timing chain and sprocket Insp...

Page 60: ...ont 2 Install camshaft sprocket 3 Confirm that No 1 piston is set at T D C on its compression stroke 4 Install timing chain Set timing chain by aligning its mating marks with those of crankshaft sproc...

Page 61: ...cover 8 lnstall front cover a Be careful not to damage cylinder head gasket a Do not forget oil seal 9 Install rubber plug onto cylinder head Refer to Installation of CYLINDER HEAD 10 lnstall oil pan...

Page 62: ...1 Piston concerned should be set at T D C to prevent valve from falling 4 Apply engine oil to new valve oil seal and install it with Tool Before installing valve oil seal install valve spring seat Uni...

Page 63: ...R OIL 1 Remove 2 Remove 3 Remove 4 Remove 5 Remove SEAL transaxle flywheel or drive plate rear oil seal retainer traces of liquid gasket using scraper rear oil seal from retainer 6 Apply engine oil to...

Page 64: ...2 Refer t o Installation of CYLINDER HEAD Valve rocker cover Rocker cover gasket 3 8 4 2 27 30 Valve and spring Intake Valve cotter Cylinder head gasket For cylinder head bolt tightening procedure ref...

Page 65: ...ker arm there is a posslblllty of air entering it After removal always set rocker arm straight up or when laying it on its side have it soak in new englne oil a Do not disassemble hydraulic valve lift...

Page 66: ...move rocker cover When removing rocker cover do not knock rocker cover against rocker arms 8 Set No 1 piston at T D C on its compression stroke 9 Loosen camshaft sprocket bolt Support timing chain by...

Page 67: ...head bolts should be loosened in two or three steps Disassembly 1 Remove rocker shaft assembly a When loosening bolts evenly loosen from outside in sequence b Bolts should be loosened in two or three...

Page 68: ...cylinder head must be replaced Nominal cylinder head height 98 8 99 0 mm 3 890 3 898 in CAMSHAFT VISUAL CHECK Check camshaft for scratches seizure and wear CAMSHAFT RUNOUT 1 Measure camshaft runout at...

Page 69: ...ft sprocket runout Runout Total indicator reading Limit 0 12 mm 0 0047 in 3 If it exceeds the limit replace camshaft sprocket SEM232C VALVE GUIDE CLEARANCE 1 Measure valve deflection In a right angled...

Page 70: ...uitable tool 3 Ream cylinder head valve guide hole Valve guide hole diameter for service parts Intake 11 175 11 196 mm 0 4400 0 4408 in Exhaust 12 175 12 196 mm 0 4793 0 4802 in 4 Heat cylinder head t...

Page 71: ...ot continue beyond the bottom face of the seat recess in cylinder head 2 Ream cylinder head recess Reaming bore for service valve seat Oversize 0 5 mm 0 020 in Intake 36 500 36 516 mm 1 4370 1 4376 in...

Page 72: ...2 3 mm 0 091 in lnner lntake Less than 2 3 mm 0 091 in Exhaust Less than 2 1 mm 0 083 in 2 If it exceeds the limit replace spring Pressure Check valve spring pressure Pressure N kg Ib at height mm in...

Page 73: ...entering hydraulic valve lifter when checking Assembly 1 Install valve component parts Always use new valve oil seal Refer to OIL SEAL RE PLACEMENT Before installing valve oil seal install inner valv...

Page 74: ...Exhaust SEM579C 0 0 0 0 L0 0 0 0 010 l0 0 0 0 010 SEM560C Assembly Cont d 4 Install rocker shaft with rocker arms Fourtypes of rockersareused ldentificationandsubsequent locationisdeterminedfromtheid...

Page 75: ...ket and tighten cylinder head bolts in numerical order Do not rotate crankshaft and camshaft separately or valves will hit piston heads Tightening procedure 1 Tighten all bolts to 29 N m 3 0 kg m 22 R...

Page 76: ...lnstall rubber plugs as follows 1 Apply liquid gasket to rubber plugs Rubber plugs should be replaced with new ones a Rubber plugs should be installed within 5 minutes of applying liquid gasket 2 Inst...

Page 77: ...f hydraulic valve lifters are still noisy replace them and bleed air off again in the same manner as in step 3 9 Install any parts removed 0 0 L l0 6 6 SEM591C SEM592C 7 Install rocker cover m When in...

Page 78: ...ENGINE REMOVAL 1KA24E N m kg m ft lb...

Page 79: ...with engine slingers attach suit able slingers and bolts CAUTION When lifting engine be careful not to strike adjacent parts especially accelerator wire casing brake lines and brake master cylinder In...

Page 80: ...nap Oil seal Piston rings Rear oil seal retainer TRear oil seal 0 Drive plate reinforcement 7 1 01Tighten in two stager 2nd 60 65 deg 1st l4 16 1 4 1 6 10 12 Main bearing Drain plug 0129 39 3 0 4 0 22...

Page 81: ...d connecting rod remove snap rings then heat piston to 60 to 70 C 140 to 158OF or use piston pin press stand at room temperature 8 Remove main bearing beam and crankshaft Before removing main bearing...

Page 82: ...piston andlor piston ring assembly PISTON RING END GAP End gap Top ring 0 28 0 43 mm 0 0110 0 0169 in 2nd ring 0 45 0 60 mm 0 0177 0 0236 in For rings punched with R or T 0 55 0 70 mm 0 0217 0 0276 i...

Page 83: ...in Nominal cylinder block height from crankshaft center 246 95 247 05 mm 9 7224 9 7264 in 3 If necessary replace cylinder block PISTON TO BORE CLEARANCE 1 Using a bore gauge measure cylinder bore for...

Page 84: ...l main bearing caps and tighten to the specified torque to prevent distortion of cylinder bores in final assembly 8 Cut cylinder bores When any cylinder needs boring all other cylinders must also be b...

Page 85: ...ce A Dm Standard 0 020 0 047 mm 0 0008 0 0019 in Limit 0 1 mm 0 004 in 6 If it exceeds the limit replace bearing 7 If clearance cannot be adjusted within the standard of any bearing grind crankshaft j...

Page 86: ...1 Install connecting rod bearing to connecting rod and cap 2 Install connecting rod cap to connecting rod Tighten bolts to the specified torque 3 Measure inner diameter C of each bearing 4 Measure ou...

Page 87: ...proper bearing has been installed Then if excessive bearing clearance exists use a thicker main bearing or undersized bearing so that the specified bear ing clearance is obtained Crank pin grade numbe...

Page 88: ...small end bushing and piston pin 0 005 0 017 mm 0 0002 0 0007 in FLYWHEELIDRIVE PLATE RUNOUT Runout Total indicator reading Flywheel MIT model Less than 0 1 mm 0 004 in Drive plate AIT model Less tha...

Page 89: ...and main bearing beam and tighten bolts to the specified torque Prior to tightening bearing cap bolts place bearing cap in its proper position by shifting crankshaft in the axial direction Tighten be...

Page 90: ...ecting rod bearing cap nuts to the specified torque Connecting rod bearing nut 1 Tighten to 14 to 16 N m 1 4 to 1 6 kg m 10 to 12 ft lb 2 Tighten bolts 60 to 65 degrees clockwise with an angle wrench...

Page 91: ...CYLINDER BLOCK 1 2 4 1 Assembly Cont d 2 Install pilot bushing MIT or pilot convertor AIT 4 Crankshaft side AIT SEMI636 I l l l l l l I...

Page 92: ...in Valve arrangement Firing order Number of piston rings Compression Oil Number of main bearing Compression ratio Differential limit between cylinders 1 98 1 0 14 250 KA24E 4 in line 2 389 145 78 89...

Page 93: ...47 3 5051 Less than 0 0 15 0 0006 Less than 0 010 0 0004 Less than 0 05 0 0020 0 020 0 040 0 0008 0 0016 246 95 247 05 9 7224 9 7264 Inner diameter Height HI Limit 0 1 0 004 0 2 0 008 0 2 0 008 0 2 0...

Page 94: ...000 7 018 0 2756 0 2763 11 175 11 196 0 4400 0 4408 Standard Exhaust 56 0 2 205 12 223 12 234 0 4812 0 4817 8 000 8 018 0 3150 0 3157 12 175 12 196 0 4793 0 4802 Intake 52 6 2 071 11 023 11 034 0 4340...

Page 95: ...a Contacting width W Standard Intake 36 000 36 016 1 4173 1 4179 36 080 36 096 1 4205 1 4211 4 5 O 1 6 1 7 0 063 0 067 Service Exhaust 42 000 42 016 1 6535 1 6542 42 080 42 096 1 6567 1 6573 45 1 7 2...

Page 96: ...6 965 6 980 0 2742 0 2748 7 948 7 960 0 3129 0 3134 45O30 45 30 1 15 1 45 10 0453 0 057 1 1 35 1 65 0 0531 0 0650 Free height H Outer Inner Standard Out of square Intake 57 44 2 2614 53 34 2 1000 604...

Page 97: ...o f camshaft journal D Camshaft runout Camshaft end play Standard 44 839 45 029 1 7653 1 7728 10 4 0 409 0 045 0 090 0 0018 0 0035 33 000 33 025 1 2992 1 3002 32 935 32 955 1 2967 1 2974 0 0 02 0 0 00...

Page 98: ...0009 Piston pin outer diameter Interferencefit of piston pin to piston pin hole Pistonpin to connecting rod bearing clearance CONNECTING ROD Side clearance Ring gap Standard 20 989 21 001 0 8263 0 826...

Page 99: ...n I Pin Runwt T I R Freeend play Fillet roil Unit mm in 59 967 59 975 2 3609 2 3612 59 959 59 967 2 3606 2 3609 59 951 59 959 2 3603 2 3606 49 968 49 974 19672 1 9675 49 962 49 968 19670 1 g6721 49 95...

Page 100: ...t mm in ldentification color Brown Green Grade number 0 1 2 Thickness mm in 1 505 1 508 0 0593 0 0594 1 508 1 511 0 0594 0 0595 1 511 1 514 0 0595 0 0596 MISCELLANEOUS COMPONENTS Unit mm in 0 08 0 003...

Page 101: ...NOTES...

Page 102: ...or 1 8 2 2 1 8 2 2 13 16 n Manifold stay A i LL La Oil filter 7 Water pump pulley I L a t e r pump belt M 16 20 1 6 2 0 12 14 Water pump Oil level gaugeJ Idle pulley With air conditioner h CI1 44 54 4...

Page 103: ...i a t 350 rpm Standard 1 196 11 96 12 2 173 Minimum 902 9 02 9 2 131 Differential limit between cylinders kPa bar kg cm2 psi at 350 rpm 98 0 98 1 O 14 7 If cylinder compression in one or more cylinder...

Page 104: ...timing pulley and belt tensioner are clean and free from oil or water d Before installingtiming belt confirm that No 1cylinder is set at T D C on compression stroke e Align arrow on timing belt forwa...

Page 105: ...following belts I Power steering oil pump drive belt Compressor drive belt Alternator drive belt Set No 1 cylinder a t T D C on its compression stroke 5 Remove front upper and lower belt covers 6 Loos...

Page 106: ...dling Poor belt cover sealing Coolant leakageat water pump Camshaft jamming Distributor jamming Oil leakage at camshaftlcrankshaft oil seal Tensioner jamming Overheated engine Interferencewith belt co...

Page 107: ...cess Belt corners are worn and round Wicks are frayed and coming out SEM396A C Canvas on tooth face is worn down Canvas on tooth is fluffy rubber layer is worn down and faded white or canvas texture i...

Page 108: ...ming belt b Align white lines on timing belt with punch mark on cam shaft pulleys and crankshaft pulley c Have arrow on timing belt pointing toward front belt covers 4 Tighten belt tensioner and assem...

Page 109: ...cover gasket Valve and sprlng Intake Front 011seal N m kg m ft lb When installingsliding parts such as rocker arms and camshaft be sure to apply engine oil on the sliding surfaces Use new gaskets and...

Page 110: ...ith rocker arms and securing bolts Before removal fully loosen valve clearance adjusting screws The bolts should be loosened in two or three stages 3 Loosen camshaft bolt whilst holding sprocket with...

Page 111: ...CYLINDER HEAD Disassembly 1 Remove camshaft locate plate 2 Remove camshaft and camshaft oil seal 3 Remove valve component parts using E7007tool 4 Remove valve oil seals...

Page 112: ...s A Amount of cylinder block resurfacing is B The maximum limit is as follows A B 0 2 mm 0 008 in After resurfacing the cylinder head check that camshaft rotates freely by hand If resistance is felt t...

Page 113: ...er a 20 kN 2t 2 2 US ton 2 0 Imp ton pressure or hammer and suitable tool 3 Ream cylinder head valve guide hole Cylinder head valve guide hole diameter a For service parts mm in 11 l 85 11 l96 0 4404...

Page 114: ...ylinder head 2 Ream the cylinder head recess Reaming bore for service valve seat Oversize 0 5 mm 0 020 in Intake 43 500 43 516 mm 1 7126 1 7132 in dia Exhaust 37 500 37 516 mm 1 4764 1 4770 in dia 3 H...

Page 115: ...is greater than the maximum replace cam shaft andlor cylinder head Maximum clearance 0 10mm 0 0039in CAMSHAFT RUNOUT CamshaftRunout T I R Total Indicator Reading Limit 0 05mm 0 0020 in If beyond the...

Page 116: ...m tip is 0 2 mm 0 008in or less VALVE SPRING SQUARENESS Out of square Outer Less than 2 2mm 0 087in Inner Less than l 9mm 0 075in VALVE SPRING PRESSURE LOAD Refer to S D S ROCKER SHAFT AND ROCKER ARM...

Page 117: ...alve oil seal install inner valve spring seat lnstall outer valve spring uneven pitch type with its narrow pitch side toward cylinder head side 2 lnstall camshaft 3 Install camshaft locate plate n Loc...

Page 118: ...N m 3 0 kg m 22 ft lb 2nd Tighten all bolts to 78 N m 8 0 kg m 58 ft lb 3rd Loosen all bolts completely 4th Tighten all bolts to 29 N m 3 0 kg m 22 ft lb 5th Using an angle wrench turn bolt 83 to 88 d...

Page 119: ...llation 6 Install rocker shaft with rocker arms To prevent rocker shaft springs from slipping out of rocker shafts insert bracket bolts into shaft 7 Tighten rocker shaft bolts Tighten bolts gradually...

Page 120: ...rance and Valve clearance Unit mm in At temperature 2 0 68 F Intake Exhaust Adjusting screw lock nuts a 18 22 N m 1 8 2 2 kg m 13 16 ft lb 9 Install intake and exhaust manifolds n lntake manifold 20 2...

Page 121: ...l pump assembly Inspection Refer to LC section lnstallation Always install with new oil seal 1 Install oil pump assembly 4 Refer page LC 13 2 Apply sealant to oil pan and oil pan gasket 3 Install gask...

Page 122: ...SEAL 1 Remove flywheel and rear oil seal retainer 2 Remove rear oil seal from the retainer 3 Apply engine oil to oil seal and install it in place 4 Install rear oil seal retainer with gasket 4 4 6 N m...

Page 123: ...OIL SEAL REPLACEMENT W Unit mm in SEM791A 6 Apply engine oil to valve oil seal and install it in place using tool no E7003 Beforeinstalling valve oil seal install inner valve spring seat...

Page 124: ...ENGINE REMOVAL 1 CAPOE l...

Page 125: ...edwith engine slingers attach suit able slingers and bolts CAUTION When lifting engine be careful not to strike adjacent parts especially accelerator wire casing brake lines and brake master cylinder...

Page 126: ...M T C1 32 36 3 3 3 7 24 271 Main bearing cap Oil pan gasket Front oil seal 015 7 0 5 0 7 3 6 5 11 1 0 1 4 7 101 Drain Plug R29 39 3 0 4 0 22 29 When installing sliding parts such as bearings be sure t...

Page 127: ...ork stand 2 Remove timing belt 3 Drain coolant and oil 4 Remove water pump 5 Remove oil pan and oil pump 6 Remove cylinder head 7 Remove pistons 8 Remove bearingcap and crankshaft Place the bearingsan...

Page 128: ...0098 0 0201 2nd ring 0 15 0 31 0 0059 0 0122 Oil ring Rail ring 0 20 0 76 0 0079 0 0299 Max limit of ring gap l 0 mm 0 039 in BEARING CLEARANCE Bearing clearance Main bearing 0 020 0 047 mm 0 0008 0 0...

Page 129: ...4 Measure outside diameter Dm of main journal in crank shaft 5 Calculate main bearingclearance Main bearing clearance A Dm CONNECTING ROD BEARING 1 Install connecting rod bearing to connecting rod an...

Page 130: ...r cracks 2 Check journals with a micrometer for taper and out of round Out of round X Y1 Less than 0 03 mm 0 0012 in Taper A B Lessthan 0 03 mm 0 0012 in a Fillet roll should not be reground L Pin jou...

Page 131: ...der head resurfacing is A Amount of cylinder block resurfacing is B The maximum limit is a s follows A B 0 2 mm 0 008 in 2 Using a bore gauge measuce cylinder bore for wear out of round or taper Stand...

Page 132: ...of the cylinder bore at a time Cut only 0 05 mm 0 0020 in or so in diameter at a time 5 Hone the cylinders to the required size referring to S D S 6 Measure the finished cylinder bore for out of roun...

Page 133: ...avoid a wrong com bination includingbearing b When pressing piston pin in connecting rod apply engine oil to pin and small end of connecting rod c After assembling ascertain that piston swings smooth...

Page 134: ...ng bearing cap bolts place bearing cap in proper position by shifting crankshaft in the axial direction Tighten bearing cap bolts gradually in two or three stages in the sequence shown After s e c u r...

Page 135: ...HAUL Assembly R 2 Install connecting rod bearing caps 01 Connecting rod bearing nut 32 36 N m 3 3 3 7 kg m 24 27 ft lb 6 Measureconnecting rod side clearance Connecting rod side clearance Limit 0 30 m...

Page 136: ...gs Compression Oil Number of main bearings Compression ratio CA20 4 in l ne 1 974 120 45 84 5 X 88 0 3 327 X 3 465 O H C 1 34 2 2 1 5 8 5 Inspection and Adjustment Compression pressure Standard Minimu...

Page 137: ...In Ex Valve ster 1end surface grindins limit VALVE SPRING S SEM567A Unit mm in CA20 40 0 40 2 1 575 1 583 35 0 35 2 1 378 1 386 105 25 105 55 4 1437 4 1555 107 79 108 21 4 2437 4 2602 6 965 6 980 0 27...

Page 138: ...em to guide clearance Ex Valvr deflection Rocker shaft Outer diameter Rocker arm lnner diameter Clearancebetween rocker arm and rocker shaft Standard 19 979 20 000 0 7866 0 78741 20 007 20 028 0 7877...

Page 139: ...n Standard 43 000 43 016 1 6929 1 6935 37 000 37 016 1 4567 1 4573 Service 43 500 43 516 1 7126 1 7132 37 500 37 516 1 4764 1 4770 0 081 0 1 13 0 0032 0 0044 0 064 0 096 0 0025 0 0038 43 097 43 1 13 1...

Page 140: ...223 35 o 2 o oo81 Height H 8 7894 8 79331 U n t m m in Surface flatness 1 0 03 0 00121 0 1 0 0041 Cylinder bore Inner diameter Standard L m l t W e a r limit Engine model 84 50 84 51 Grade No 1 1 3 32...

Page 141: ...5 3 3254 3 3258 84 475 84 485 3 3258 3 32621 84 485 84 495 3 3262 3 3266 84 495 84 505 3 3266 3 3270 84 505 84 515 3 3270 3 3274 84 485 84 635 3 3262 3 3281 84 965 85 01 5 3 3451 3 3470 85 465 85 51 5...

Page 142: ...25 149 35 5 8760 5 8799 Less than 0 05 0 00201 Less than 0 05 0 0020 19 965 19 978 0 7860 0 78651 48 000 48 013 1 8898 1 8903 0 2 0 3 0 008 0 012 L mit 0 10 0 0039 0 10 0 0039 0 3 0 012 Engine model...

Page 143: ...0 10 0197 Undersize Crankshaft journal diameter 52 951 52 964 2 0847 2 0852 52 701 52 714 2 0748 2 0754 52 451 52 464 12 0650 2 0655 MISCELLANEOUS COMPONENTS Engine model Standard 0 08 0 0031 Undersiz...

Page 144: ...ION LC 2 PRECAUTION LC 3 7 1 KA24E I ENGINELUBRICATION SYSTEM LC 4 ENGINECOOLING SYSTEM LC 7 SERVICE DATA AND SPECIFICATIONS S D S LC 11 1CA2OE A ENGINELUBRICATION SYSTEM LC 12 ENGINECOOLINGSYSTEM LC...

Page 145: ...S Tool number Tool name Description Radiatorcap tester adapter 8 10991 Repco Use with 810200 or 810300 Repcotester Testing radiator leakage COMMERCIAL TOOLS Oil pressuregauge Hose Adapting oil pressur...

Page 146: ...id gasket to mating surfaces Use Genuine Liquid Gasket or equivalent m Be sure liquid gasket is 3 5 to 4 5 mm 0 138 to 0 177 in wide for oil pan a Be sure liquid gasket is 2 0 to 3 0 mm 0 079 to 0 118...

Page 147: ...sage Intermittently Chain tensioner Center cam bracket SEF115I Oil Pressure Check WARNING m Be careful not to burn yourself as the engine and oil may be hot m Oil pressure check should be done in Neut...

Page 148: ...than 78 0 8 11 If difference is extreme check oil passage and oil pump for oil leaks 6 Install oil pressure switch with sealant Oil Pump REMOVAL 1 Drain oil 2 Remove front cover Refer to EM section 3...

Page 149: ...eeds the limit replace gear set or entire oil pump assembly REGULATOR VALVE INSPECTION 1 Visually inspect components for wear and damage 2 Check oil pressure regulator valve sliding surface and valve...

Page 150: ...caused by high pressure fluid escap ing from the radiator Wrap a thick cloth around the cap and carefully remove by turning it a quarter turn to allow built up pressure to escape Then continue to turn...

Page 151: ...0 kg cm2 14 psi CAUTION Higher than the specified pressure may cause radiator dam age CHECKING RADIATOR CAP To check radiator cap apply pressure to cap with a tester Radiator cap relief pressure 78 9...

Page 152: ...eck for badly rusted or corroded vanes and body as sembly 2 Check for rough operation due to excessive end play Thermostat INSPECTION 1 Check valve seating condition at ordinary room tempera tures lt...

Page 153: ...away or bend fins to exposeaffected area Donot cut awaywhat isnot necessary and do not remove more than 25mm total finning from the radiator 3 Dryaffected tube andarea with an air drier 4 Lightly surf...

Page 154: ...0043 0 0079 Inner gear to crescent clearance 0 22 0 33 0 0087 0 0130 Outer gear to crescent clearance l 0 21 0 32 0 0083 0 0126 Housingto inner gear side clearance 0 05 0 09 0 0020 0 0035 Housing to...

Page 155: ...I Main bearing Cylinder head 011gallery 0 Connecting rod bearing Ir No 4 cam bracket Connecting rod 6 Camshaft d5 Cam surface 0 v Rocker s h a f t 1 Rocker arm z Oil Pressure Check WARNING Be careful...

Page 156: ...ure rpm kPa bar kg cm2 psi Idle speed More than 59 0 59 0 6 9 3 200 333 510 3 3 5 10 3 4 5 2 48 74 If difference is extreme check oil passage and oil pump for oil leaks 6 Install oil pressure switch w...

Page 157: ...ECTION Using a feeler gauge check the following clearances Unit m m in Body to outer gear clearance 0 11 0 20 0 0043 0 0079 Inner gear to crescent clearance 0 12 0 23 0 0047 0 0091 Outer gear to cresc...

Page 158: ...d valve spring 3 Coat regulator valve with engine oil and check that it falls smoothly into the valve hole by its own weight If damaged replace regulator valve set or oil pump assembly OIL PRESSURE RE...

Page 159: ...m 20 25 2 0 2 5 14 18 Oil cooler cover C1J N m kg m ft lb C1J 29 34 3 0 3 5 22 25 Oil cooler stud Oil cooler a 011 cooler support INSPECTION 011 cooler 1 Check oil cooler element and housing for crac...

Page 160: ...ENGINE COOLING SYSTEM CAZOE Cooling Circuit P q Reservoir tank Radiator Water pump Oil cooler For A T model Water outlet Thermostat...

Page 161: ...olant CAUTION When removing water pump assembly be careful not to get coolant on timing belt e Water pump cannot be disassembled and should be replaced as a unit After installing water pump connect ho...

Page 162: ...minutes and check for leaks Always replace with new gasket 2 Check valve opening temperature and maximum valve lift Standard Valve opening temperature C F Max valve lift 8 95 rnm C in F 0 311203 3 The...

Page 163: ...Do not cut away what is not necessary and do not remove more than 25mm total finning from the radiator 3 Dry affected tube and area with an air drier 4 Lightly surface damaged area with suitable scrap...

Page 164: ...0091 Outer gear to crescent clearance 0 21 0 32 0 0083 0 01 26 Idlespeed More than 59 0 59 0 6 9 Housing to inner gear clearance 0 59 0 09 0 0020 0 0035 3 200 333 510 3 3 5 1 3 4 5 2 48 74 Housing to...

Page 165: ...omponent Parts Description ES 9 ES 91 E C C S Control Functions ES 14 ES 96 E C C S Control Unit Systems ES 20 ES 105 E C C S Control Unit Modes ES 22 Idle Speed lgnition Timinglldle Mix Ratio Inspect...

Page 166: ...external CA20EOnly tachometer E7118 1 Ignition coil adapter Adapter Harness to connect external KA24EOnly tachometer DIGITALMULTlMlTER General Fault Finding Commercial Supplier 10M fl minimum 0 500 k...

Page 167: ...ting in damage to ICs pedal when starting Do not disassemblethe E C M Keep the E C C S harness a t least immediately after do ElectronicControl Module 10 cm 3 9 in away from adjacent rev U P the engin...

Page 168: ...E C C S CAZOE I COMPONENT PARTS LOCATION Air regulator Throttle chamber Fuel filter Air flow meter Injector Hall effect sensor Distributor Ignition coil and power transistor...

Page 169: ...tributor Water temperaturesensor EngineSpeed Enginetemperature Vehicle speed sensor Throttle position sensor Start signal lgnition switch Throttle valve position Rateof throttle valve movement Air con...

Page 170: ...air control valve position sensor xhaust gas sensor Hall effect sensor built in distributor er temperature sensor Catalytic Converter Air flow meter Hot wire type Air conditioner compressor where fit...

Page 171: ...fold vacuum pressure The E C M controls only the injection pulse duration For this reason the pressure difference between the fuel pressure and intake manifiold vacuum pressure should be maintained at...

Page 172: ...AIR FLOW SYSTEM DESCRIPTION 1 Throttle valve Intake air flow c Exhaust gas flow 6 t Air cleaner Air flow meter SEF606D...

Page 173: ...tabs that rotate past the stator assembly hall effect switch The stator assembly consists of a hall effect device and a magnet As the rotor rotates alternatively ametaltab then awindow passbetweenthe...

Page 174: ...rent I in relation to the varying resistance value R so that V always equals V The air flow meter transmits an output for voltage V to the control unit where the out put is converted into an intake ai...

Page 175: ...r Note If power transistors are removed from their mounting brackets heat sink compound must be used on reassembly IGNITION COILS The ignition coils are a moulded type IDLEAIR CONTROL IAC VALVE The IA...

Page 176: ...pen As the engine starts and electric currentflows throughaheater the bimetalbeginsto rotatethe shut ter to close off the by pass port The air passage remains closed until the engine is stopped and th...

Page 177: ...ure ratio feedback system does not operate under the following conditions when starting the engine when the exhaust gas is cold when the engine coolant is below 60 C when the engine speed is above 380...

Page 178: ...t off during deceleration Fuel shut off occurs under certain conditions defined by water temperature engine and vehicle speed and throttle closure Additionally fuel shut off to all cylinders occurs at...

Page 179: ...M via a fuel pump relay Fuel pump and air regulator ON OFF control Hall effect sensor Fuel pump lgnition switch position 1 Engine I i i r regulator condition o eration E C M Engine speed b Operates f...

Page 180: ...E C M is transmitted to power transistor and con trols ignition timing Spark Plug Switching Control Distributor Hall effect sensor Water temperature sensor E C M Engine speed b The spark plug switchi...

Page 181: ...que converter lock up is only available in 4th gear above approximately 70 75 kph hydraulic pressure available Torque converter lock up operation is then controlled by the E C M turning OFF the lock u...

Page 182: ...tion received from vehicle speed sensor water temperature sensor and air conditioner switch wherefitted The fans are operatedvia cooling fan relays high and low at either low speed high speed or off a...

Page 183: ...has been reached will cause the E C M to de activate the air conditioner Additionally if the throttle is opened more than 60 and acceler ation enrichment is triggered the E C M will de activate the c...

Page 184: ...ult occurs with the water temperature and or its sensor the control unit will substitute a value equivalentto engine operation of 90 C Main Processor Failure The E C C S control unit incorporates a ba...

Page 185: ...lfunction has been detected If a malfunction occurs whilst driving the lamp will illumi nateandamalfunctioncodewill berecordedinthe control unitmem ory If the problem goes away e g intermittent the la...

Page 186: ...cond pause indicatesthe ten digits whilst the number of half secondflashes fol lowing the one second pause indicates the unit digits Codes are repeatedafter a three second pause If no malfunctionsare...

Page 187: ...P N and shifting into gear while in Field Service Mode Air flow meter Voltagetoo low Air flow meter Voltagetoo high Burn off air flow meter Vehicle speed NOTE This code is set in FieldService Mode an...

Page 188: ...cluding the Vehicle Speed and Park Neutralfault codes unlessthey were clearedwhile in the Field Ser vice Mode will be displayed While in this mode i e ignition ON radiator fans ON and the engine havin...

Page 189: ...Code 13 Oxygen Sensor Diagnostic Procedure 12 Code 14 Water Temperature Sensor Voltage Low Diagnostic Procedure 13 Code 15 Water Temperature Sensor Voltage High Diagnostic Procedure 14 Code 2 1 Throt...

Page 190: ...ontinuously Most intermittent problems are caused by poor electric connections or faulty wiring In this case careful checking of suspicious circuits may help prevent the replacement of good parts A vi...

Page 191: ...stic results exist l Yes INSPECTION ON THE BASIS OF EACH MAL FUNCTION INSPECTION ON THE BASIS OF EACH SYMPTOMX2 I FINAL CHECK Confirm that the trouble is completely fixed by performing Basic Inspectio...

Page 192: ...tion Partial combustion NOT affected by throttle position C1 Possible but hard to start U Others 1 No fast idle U Unstable High idle U Low idle U Others 1 Stumble U Surge U Detonation U Lack of power...

Page 193: ...if the torque reaction of the engine unit causes electric breaks Cool with an icing spray or similar device Heat with a hair drier WARNING Do not overheat the unit Wet WARNING Do not directly pour wat...

Page 194: ...TROUBLE DIAGNOSES...

Page 195: ...Seeapplicablechart If morethanone code Diagnosticcircuitcheck ok isstored Startwith the lowestcode If engine if enginecranksbut will not run goto DiagnosticProcedure2 cranksbut i l l not run goto i pr...

Page 196: ...TROUBLE DIAGNOSES DIAGNOSTIC PROCEDURE 1 ECM LAMP WON T FLASHANY CODE LAMP ON STEADY OR NO LIGHT l2V INSTR CLUSTER ECM LAMP A N 100 p 1 2U BULB INPUT...

Page 197: ...ort to voltage on circuit with light Reconnect ECM connectors back probe ECM connector terminal 44 with test light to earth and note ECM light I Check for and repair open circuit in either Diagnostic...

Page 198: ...TROUBLE DIAGNOSES M DIAGNOSTIC PROCEDURE 2 ENGINE CRANKS BUT WILL NOT RUN NOTE THIS CHART SHOULD ONLY BE CONSULTED AFTER PERFORMING SELF DIAGNOSIS SYSTEM CHECK 5 W L 6...

Page 199: ...ugs to engine earth Lead Positive to AN01 or AN02 I Repair power circuit AN63 I Voltage over 0 8 r Ignition off After at least 10 seconds key off check AF66 pump power line with test lamp or multirnet...

Page 200: ...listen for fuel pump run running at fuel tank I I 1 Running Not Running Check for Fouled spark plugs Proper TPS circuit operation Restricted exhaust Improper airflow meter operation Improper coolant...

Page 201: ...TROUBLE DIAGNOSES...

Page 202: ...TROUBLE DIAGNOSES DIAGNOSTIC PROCEDURE 3 FUEL PUMP ELECTRICALCIRCUIT...

Page 203: ...h I Check for Open in circuit AF66 Open pump earth circuit 970 on steady Both Ok p p l y l2 volts to fuel I Reconnect fuel pump relay back probe circuit AF66 with test light still connected to battery...

Page 204: ...on It should light for 3 seconds Then go out Does it Ignition off Disconnect fuel pump relay and ECM connectors Check ckt AF67 for being open or shorted to earth I Circuit AF67 I I I Yes No I I I l C...

Page 205: ...TROUBLE DIAGNOSES Notes...

Page 206: ...0 kPa not continue to d r o after pump stops runnin Pump should run about 3 seconds then shut off See NoteAbove Ok I Ilgnition on7 connect l2 volts to fuel pump Pressure but continues to drop after pu...

Page 207: ...to fuel rail Attach a piece of fuel hose to the Return fuel pipe Insert other end of hose into an ao roved aasoline container Apply l2volts to fuel pump Bridge Relay and note fuel pressure Pressure st...

Page 208: ...TROUBLE DIAGNOSES DIAGNOSTIC PROCEDURE 5 IDLE AIR CONTROL IAC SYSTEM r F In 42 41 IDLE AIR mVUVE 44 16 ECM l L d 15 52 PIri CONNECTOR 1 1 11s...

Page 209: ...r resistance I is in the range 30 to 50 ohms I Remove the auxillary air valve and i check that the blade is closed 1 before the valve cools down I I A I For vacuum leaks causes fast idle speeds I 1 T...

Page 210: ...EDURE 6 IGNITION SYSTEM NOTE THIS CHART SHOULD ONLY BE CONSULTEDAFTER PERFORMING DIAGNOSTICPROCEDURE2 5 E g W r n m I U 2E m I E D n LD L 2 ze l l A p H 0 5 I L Pd 5 I I L m 7 m 7 0 W m r X P t I I I...

Page 211: ...th not AEO1 Do not use a test lamp I Check voltage on OC terminal of each driver module I Check voltage at pin 9 of the ECM Should be battery voltage Check and repair AN01 or AN02 as applicable or I 1...

Page 212: ...TROUBLE DIAGNOSES DIAGNOSTIC PROCEDURE 7 RADIATOR FAN CONTROL NOTE IF CODES 14 15 OR 55 ARE DISPLAYED ATTEND TO THEM FIRST...

Page 213: ...relays both high and low speed and replace if necessary Remove diagnostic plug reconnect temperature sender Check the wiring to 12 volts on the relays the wiring from relaysto the fans and from the fa...

Page 214: ...lock up solenoid for connection to 12volts I I Apply accelerator to run 1 l Check solenoid for shorted the engine at 2000 rpm winding and replace if faulty 1 Check for short circuit on AR15 Check AR15...

Page 215: ...volts If not check ignition fuse Now switch AIC on and measure ECU I I I More than 2 volts Less than 2 volts with AIC switch on Check AIC fuse Check Hi and Lo pressure switch Check thermo amp More tha...

Page 216: ...lt WC range Code 11 The voltage should read more than 0 7 volts AC whilst cranking and normally reads 1 4 volts AC I No Code 1 1 Possibly intermittent Check for poor electrical connection I I I I Volt...

Page 217: ...conds But should then go out Error code 44 lean could be set by this test Does it I earth Light stays off Code 13 is intermittent If no other codes were stored Check for an intermittent fault 1 I Ligh...

Page 218: ...or temp to resistancevalues approximate I I OHMS 146 188 247 444 1 191 1 716 2 523 5 860 9 307 15 258 Disconnectcoolant sensor connector lgnition on engine stopped I I Clear codes run engine for 2 min...

Page 219: ...nnection in WTS circuit m m I Check resistance across coolant sensor terminals See table for a roximate I Repairshortto voltage 1 oncircuit AN17 Should be 4 6 volts I Probe coolant sensor harness conn...

Page 220: ...terminal and note codes Code 21 is intermittent Look for poor electrical connection in TPS circuit Any other code See applicable chart Diagnostic bridge removed Ignition off DisconnectTPS sensor Start...

Page 221: ...codes I Disconnect TPS then I Start engine With engine running jumper AN43 and AN44 Together at TPS harness connector I Ignition on Engine stopped I Bridge diagnostic terminal and note codes I I Code...

Page 222: ...ush started Ignition off clear codes Bridge diagnostic plug I Start engine I I Check ECM terminals and harness terminals Code 23 I l Check harness for open circuit or short circuit No Code 23 Voltage...

Page 223: ...running I Ignition off clear codes I I Bridge diagnostic plug I Run engine switch ignition off Code 31 I Disconnect connector at transmission connect a jumper between AN36 and Possibly intermittent l...

Page 224: ...sert diagnostic bridge lgnition on engine stopped read code I Code 32 I I Leave idling engine Check voltage on AN16 to AN15 using multimeter at AFM terminals 3 and 2 Is the voltaae Problem is intermit...

Page 225: ...odes lgnition off Removediagnostic bridge DisconnectAFM sensor connector Start engine and idle for 1 minute or until ECM lamp comes on Stop engine Insert diagnostic bridge lgnition on Note code Proble...

Page 226: ...TROUBLE DIAGNOSES DIAGNOSTIC PROCEDURE 20 CODE 34 AIR FLOW METER BURN OFF VOLTAGE LOW...

Page 227: ...seconds of switching the ignition off I Continue measuring the air flow meter voltage ECM pin 32 when the ignition is switched off in the last step above I Repeat the force a burn offprocedure and mea...

Page 228: ...at least 10 kmlhr Turn off engine and when engine stops turn key to on position Code 43 a Connect a voltmeter across pins 8 and 35 of ECM 8 is signal Put the car in neutral and observe the voltage of...

Page 229: ...isconnect ECM Probe circuit AF178 1 Repair ckt AF178 z 5 I 2 volts I 1 Approx 12 volts I Reconnect smallest plug to ECM Probe across ECM pins 8 and 35 I 2 volts Approx 12 volts Clear codes run engine...

Page 230: ...w Checkthefollowing I I Low fuel pressure Contaminated fuel Vacuum leak on inlet system Exhaust manifold leaks Ahead of O2Sensor Flashing open loop Faulty airflow sensor O2sensor metal vent covered wi...

Page 231: ...pen Loop I A rich exhaust condition exists Check for the following High fuel pressure Leaking injector Air flow meter Canister purge Coolant sensor circuit TPS sensor operation I Ignition off Disconne...

Page 232: ...1 minute or until ECM light comes on or code 12 Check relevant chart or code 12 indicates no fault recorded Note When a Code 55 is present 1 Air conditioner will not operate 2 Fans will be on after th...

Page 233: ...TROUBLE DIAGNOSES Notes...

Page 234: ...nition Switch ON Remove fuel pump fuse and crank engine Drivevehicleslowly or raise vehicle and rotate bothfront wheels Ignition ON Engine running both A C and fan switch ON either A C or fan switch O...

Page 235: ...cted Condition Enginerunning Ignition ON Ignition ON Not applicable Ignition ON Ignition ON lgnition ON in NeutralJPark except NeutralJPark Ignition ON Ignition ON Ignition ON engine stationary engine...

Page 236: ...tem IAC valve output Diagnostic request ground Diagnosticrequest Not connected Not connected Not connected Not connected ECM earth Ignition Battery input Injector driver Condition Engine running Ignit...

Page 237: ...Place rotor trigger vane inside air gap Voltmeter must register at least 11 0 at 20 C Air Flow Meter With ignition OFF disconnect and remove air flow meter from vehicle 1 Apply battery voltage to ter...

Page 238: ...and terminal 0 58 to 0 74 ohms at 20 C Secondary winding resistance etween and HT terminal 8 000 to 11 000 ohms at 20 C Note Resistancewill vary with coil temperature L J 7 l HT A B C Throttle Positi...

Page 239: ...nition OFF disconnect injectors and check resistance as shown Resistance between terminals 15 5 to 1 6 5 ohms at 20 C Note Resistance will vary with throttle body temperature Fuel Pump and lnjector Sy...

Page 240: ...circuit for continuity 4 With voltmeter connected to signal line rotate the pinion and confirm voltage changes from Ov to 7 5 approx 10times per sensor revolution Temperature C 100 9 0 70 40 3 0 20 A...

Page 241: ...Removefuse for fuel pump 2 Start engine 3 After enginestalls crankenginetwo or threetimes to makesure that fuel pressure is released 4 Turn ignition switch off and installfuse for fuel pump Checking a...

Page 242: ...E C C S SYSTEM Wiring Schematic c m IS E LIR VNYE I Yl lW ECU I...

Page 243: ...E C C S SYSTEM Wiring Schematic Cont d ECU I I NR INJECTORS AIR R W 501MR...

Page 244: ...E C C S SYSTEM Wiring Diagram Engine ManagementSystem ENGINE CONTROL UNIT...

Page 245: ...E C C S SYSTEM p i j Wiring Diagram Cont d IgnitionSystem ENGINE CONTROL UNIT...

Page 246: ...icle body ness connectors with engine running m Do not apply battery power di rectly to injectors otherwise m Do not operate fuel pump when there is no fuel in lines uel hose clamps to the specified t...

Page 247: ...E C C S DESCRIPTION E C C S Components m E C C S Component Parts Location 1 Electrical fuel pump In tank type E C C S control unit...

Page 248: ...N E C C S Components F 1 E C C S Component Parts Location Cont d Ignition coil 8 power transistor Throttle sensor throttle valve switch A A C valve S C V actuator meter From power I valve housing L Ve...

Page 249: ...E C C S DESCRIPTION IKA24E System Diagram...

Page 250: ...Fuel pump control E C C S control unit Acceleration cut Air conditioner relay control S C V Swirl control S C V control I valve control solenoid valve ECM lamp Exhaustgas sensor Inspection lamp Onthe...

Page 251: ...r Throttle chamber Swlrl control valve Swlrl control and fuel pressure regulator vacuum supply Swirl control solenold Fuel pressure regulator solenold Carbon canlster purge solenoid Carbon canister di...

Page 252: ...SEE LAST PGEI 00 START INHIBIT R E U Y m Dw DQ 1701 1 1901 20EI W W W W...

Page 253: ......

Page 254: ...NTROL UNIT ENG EARTH...

Page 255: ...n the wave forming circuit When the rotor plate passes between the L E D and the photo diode the slits in the rotor plate continually cut the light being transmitted to the photo diode from the L E D...

Page 256: ...ve and feeds the voltage signal to the E C U ldle position of the throttle valve is determined by the E C U receiving the signal from the throttle sensor This system is called soft idle switch and con...

Page 257: ...conia its tube is coated with platinum The voltage is approximately 1V in a richer condition of the mixture ratio than the ideal air fuel ratio while approximately O V in leaner condi tions The radica...

Page 258: ...ceived the larger the amount of air that will flow through the A A C valve This air flow also varies with the temperature of the engine coolant flowing through the A A C valve The higher the coolant t...

Page 259: ...vacuum signal from the intake manifold is cut When the control unit sends an ON signal the coil pulls the plunger and feeds the vacuum signal to the swirl control valve actuator Fuel Filter The specia...

Page 260: ...ength of time the valve remains open is determined by the E C U The basic amount of fuel injected is a programmable value mapped in the E C U ROM memory In other words the programmable value is preset...

Page 261: ...Engine starting MIXTURE RATIO SELF LEARNING CONTROL The mixture ratio feedback control system monitors the mixture ratio signal transmitted from the exhaust gas sensor This feedback signal is then se...

Page 262: ...Timing Control INPUTIOUTPUT SIGNAL LINE Engine speed and piston position Crank angle sensor Amount of intake air b Engine temperature b Throttle valve idle position Idle switch Throttle valve opening...

Page 263: ...ec tion pulse width and crank angle sensor signal which varies every moment Then responding to this information ignition signals are transmitted to the power transistor A B T D c In addition to this 1...

Page 264: ...hich by passes the throttle valve via A A C valve The A A C valve repeats ONIOFF opera tion according to the signal sent from the E C U The crank angle sensor detects the actual engine speed and sends...

Page 265: ...rform If the 1 signal is not received when the ignition switch is on the engine stalls The E C U stops pump operation and prevents battery discharging thereby improving safety The E C U does not direc...

Page 266: ...DESCRIPTION The E C U controls the operation of the C C P system by c When starting the engine turning ON or OFF the C C P solenoid valve thereby When idling controlling the vacuum signalto inhibit C...

Page 267: ...olenoid valve is operated by the This system has a swirl control valve S C V in E C U the intake passage of each cylinder Water temperature is above 35 C 95 F with While idling the S C V closes Thus t...

Page 268: ...ol of the radiator fan corre sponding to the vehicle speed engine temperature and air conditioner ON signal Throttle valve opening angle relay unit E C C S control Vehicle speed Vehicle speed sensor F...

Page 269: ...w or above the specified value water temperature is fixed at the preset value as follows But engine speed will not rise more than 2 400 Fuel injection control system rpm in order to inform the driver...

Page 270: ...ecking or adjustment move selector Oil filler cap oil level gauge etc lever to N position set parking brake and a Fuel pressure chock rear wheels a Engine compression b After the adjustment has been m...

Page 271: ...warm it up until water temperature SE F457C indicator points to the middle of qauqe Open engine hood and run engine at about 2 000 rpm for about 2 minutes under no load 4 Perform E C C S self diagnosi...

Page 272: ...sensor harness connector 1 1 Ensurethat engine speed is below 800 rpm 1 4 l Connect throttle sensor harness connector A 4N G A m I I I I Adjust idle speed to less than 800 rpm by turning idle speed a...

Page 273: ...umping wire from exhaust gas sensor I O K I Note Do not reconnect exhaust gas sensor at this stage I N G Disconnect enaine temperature sensor harness Repair or replace E C C S harness and connect batt...

Page 274: ...inspection lamp on E C U goes on and off more than 5 times during 10seconds a t 2 000 rpm under no load I O K Check fuel pressure regulator I Check air flow meter I Seepage 174 Check injector Seepage...

Page 275: ...IDLE SPEED IGNITION TIMINGIIDLE MIXTURE RATIO INSPECTION I KA24EI Notes...

Page 276: ...dure 12 EngineStallswhen the Engineis Cold Diagnostic Procedure 13 EngineStalls when Stepping on the Accelerator Momentarily Diagnostic Procedure 14 Engine Stalls after Decelerating Diagnostic Procedu...

Page 277: ...DiagnosticProcedure 3 4 P R V R CONTROL Diagnostic Procedure 35 INJECTOR Diagnostic Procedure 36 FUELPUMP DiagnosticProcedure 3 7 S C V CONTROL DiagnosticProcedure 3 8 A A C VALVE Diagnostic Procedure...

Page 278: ...tinuously Most intermittent prob lems are caused by poor electric connections or faulty wiring In this case careful checking of suspicious circuits may help prevent the replacement of good parts A vis...

Page 279: ...ECK IN 1 DIAGNOSTIC WORKSHEET 1 LISTEN TO CUSTOMER COMPLAINTS 1 Basis Inspection I BASIC INSPECTION t 2 Do self diagnostic results exist l 1 INSPECTION ON THE FUNCTION Diagnostic Procedures INSPECTION...

Page 280: ...ing Startability No fast idle U Unstable High idle D Low idle Others 1 Partial combustion affected by throttle position Cl Partial combustion NOT affected by throttle position Cl Possible but hard to...

Page 281: ...rapidly See if the torque reac tion of the engine unit causes electric breaks Cool with an icing spray or similar device Target condition Made lean Made rich Advanced Retarded Suspended Operation che...

Page 282: ...ks simultaneouslywith the RED L E D on the E C U E C U L E D In the E C U the Green and Red L E D s have now been permanently changed to one RED L E D SELF DIAGNOSTIC FUNCTION Mode 1 1 SELF DIAGNOSTIC...

Page 283: ...S Start engine SENSOR MONITOR TO ERASE E C U MEMORY Change control unit from Mode II to Mode I I Turndiaanostic mode selector I on E C U UII clockwise I I Wait at least 2 seconds 1 Do not changecontro...

Page 284: ...ber of single digits For example the red L E D flashes once for 0 6 seconds and then it flashes twice for 0 3 seconds This indicates the number 12 and refers to a malfunction in the air flow meter In...

Page 285: ...8 0 signal is not entered for the first few seconds during engine crank ing Either 1 or 1 8 0 signal is not input often enough while the engine speed is higher than the specified rpm The air flow met...

Page 286: ...TO ERASE SELF DIAGNOSTIC RESULTS RETENTION TERM CHART Example The malfunction code is erased from the backup memory on the E C U when the diagnostic mode is changed from Mode II to Mode I Refer to HOW...

Page 287: ...gas I ON OFF HOW TO CHECK EXHAUST GAS SENSOR 1 Set Mode II Refer to HOW TO SWITCH MODES 2 Start engine and warm it up until engine coolant tempera ture indicator points to the middle of the gauge 3 Ru...

Page 288: ...onnect CONSULT to diagnostic connector Diagnostic connector is located behind left dash side panel 3 Turn on ignition switch 4 Touch START 5 Touch ENGINE 6 Perform each diagnostic mode according to th...

Page 289: ...tment or A A C valve WORK SUPPORT SELF DIAGNOSTIC RESULTS X X X X X X X X X X X 2 z l 3 a l 2 DATA X X X X X Crank angle sensor A I flow meter Engine temperature sensor Exhaust gas sensors Vehicle spe...

Page 290: ...FOLLOWING CONDITIONS l IGN SW ON l ENG NOT RUNNING ACCPEDALNOTPRESSED l IGNITION TIMING FEEDBACK CONTROL WILL BE HELD BY TOUCHING START AFTER DOING SO ADJUST IGNITIONTIMING WITH A TIMING LIGHT BY TUR...

Page 291: ...hicle speed sensor Battery E C U power supply circuit Harness and connector Throttle sensor Throttle sensor adjust ment Harness and connector Fuel temp sensor Harness and connector Starter switch Harn...

Page 292: ...ne stopped a Turn the fuel pump relay ON and OFF with the CONSULT and listen to operating sound a lgnition switch ON a Turn solenoid valve ON and OFF with the CONSULT and listen to operating sound a I...

Page 293: ...splits kinks and proper connections Wiring for proper connections pinches and cuts H CONNECT CONSULT TO THE VEHICLE Connect CONSULT to the diagnostic connector and select ENGINE from the menu Refer t...

Page 294: ...ing idle adjusting screw 2 When touching START does engine rpm fall to the following values MIT 650f 50 rpm AIT 650f50 rpm N position OR When disconnecting throttle sen sor harness connector does en g...

Page 295: ...Condition I Voltage V Repair or replace the malfunctioning switch or its circuit Start i n Ib Em Ivo tage O Id I wsition I FAILURE DETEC TED TIPlE E Il IE E TEMP SENSciR Ci Neutral Parking switch sult...

Page 296: ...by touching SEF294 J Exhrrrst gas CLEAR 3 Does the engine speed drop OR 1 Disconnect exhaust gas sen sor harness connectors 2 After racing engine at 1 500 rpm under no load for about 30 seconds does...

Page 297: ...not produce a momen tary engine speed drop OR When disconnecting each spark plug cap one at a time is there any cylinder which does not pro duce a momentary engine speed CHECK SPARK PLU GS Repair or r...

Page 298: ...from Check injector s and circuit s I I engine Harness connector should I L I remain connected 2 Disconnect each ignition wire 3 Turn ignition switch ON Do not start engine 4 When rotating crank angle...

Page 299: ...FUEL PRESSURE RELEASE7 in WORK SUPPORT mode in order to release fuel pressure to zero 2 Install fuel pressure gauge and check fuel pressure At idle Approx 226 kPa 2 3 kglcm2 33 psi OR fuel pump and c...

Page 300: ...CH more than 5 times during 10 seconds RICH LEAN R H 1 time 2 times LEAN RICH OR 1 Set Exhaust gas sensor monitor in the self diagnostic Mode II See page ES 123 2 Maintaining engine at 2 000 1 rpm und...

Page 301: ...ck for IAS clogging or throttle valve clogging CHECK IDLE ADJ SCREW CLOGGING 1 Perform AAC VALVE ADJ No in WORK SUPPORTs mode 2 Can you set engine rpm as follows by turning idle adjust ing screw MIT 8...

Page 302: ...not start engine 4 When rotating crank angle sensor shaft does each injector make an operating sound Yes Check ignition coil power 1 Disconnect each spark plug cap transistor unit and their 2 Connect...

Page 303: ...d H CHECKSPARKPLUGS Remove the spark plugs and check for fouling etc u CHECK E C U HARNESS CONNECTOR Repair or replace Check the E C U pin terminals for dam I age or poor connection of E C U har ness...

Page 304: ...ect fuel pressure reg ulator vacuum hose and plug hose 2 Can you start engine No Check injector s and circuit s CHECK INJECTOR 1 Remove crank angle sensor from No englne Harness connector should remai...

Page 305: ...t when the Engine is U b lfi b9A f nut U I I LUI B 4 CHECK E C U HARNESS CONNECTOR Repair or replace Check the E C U pin terminals for dam age or poor connection of E C U har ness connector Repair or...

Page 306: ...ccelerator pedal fully Check injector s for leak age can you start the engine B CHECK INJECTOR 1 Remove crank angle sensor from Check injectors and cir cuits engine Harness connector should remain con...

Page 307: ...poor connection of E C U har ness connector Repair or replace GROUND CIRCUIT Referto page ES 170 Repair or r r P I U CHECK SPARK PLUGS Remove the spark plugs and check for l CHECK E C U HARNESS CONNEC...

Page 308: ...operties I l Select PRVR CONT SOL VALVE in ACTIVE TEST mode 2 After touching ON perform cruise test 3 Does the hesitation disap pear O R 1 Disconnect fuel pressure reg ulator vacuum hose and plug hose...

Page 309: ...ouling etc R CHECK FOR INTAKE AIR LEAK When pinching blow by hose lowering and repair the blow by air supply does the en gine speed rise No El Trouble is fixed TRY A KNOWN GOOD AIR FLOW METER Replace...

Page 310: ...under no load with en gine warmed up sufficiently check to make sure that the monitor fluctuates between LEAN and RICH more than 5 times during 10 sec onds RlCH LEAN RlFH l time 2 times LEAN RICH I O...

Page 311: ...Procedure 9 Hesitation under Normal Conditions Cont d INSPECTION END l a p CHECK FOR INTAKE AIR LEAK When pinching blow by hose lowering the blow by air supply does the en gine speed rise Discover air...

Page 312: ...t produce a momentary engine speed drop Yes B 1 CHECK INJECTOR 1 Remove crank angle sensor from engine Harness connector should remain connected 2 Disconnect each ignition wire 3 Turn ignition switch...

Page 313: ...kPa 3 0 kglcm2 43 psi OR 1 Release fuel pressure to zero Referto pageES 219 2 Install fuel pressure gauge and check fuel pressure a ICHECK E C U HA Repair or replace ICheck the E C U pin terminals fo...

Page 314: ......

Page 315: ...ent throttle valve is fully open Approx 294 kPa 3 0 kglcm2 43 psi transistor unit and their circuits Seepage ES 179 A S j 1 ulator diaphragm 1 Release fuel pressure to zero Referto page ES 219 2 Insta...

Page 316: ...71 engine speed drop CHECK INJECTOR Check injector s and I 1 Remove crank angle sensor from I I circuit s I I engine Harness connector should I I I I remain connected 1 2 Disconnect each ignition wire...

Page 317: ...E Ir4Ef HF l TEP EtlliIt4E H L L i _TLFT 1 CAUTION When servicing fuel system after performing Fuel Pressure Release in Work Support mode turn off ignition key with CONSULT set in Work Support mode 2...

Page 318: ...NCE TEST 1 Perform POWER BALANCE in ACTIVE TEST mode 2 Is there any cylinder which does not produce a momen tary engine speed drop t t t POI EE ALAt II E r t t R Ilot lITfiR When disconnecting each in...

Page 319: ...19 2 Install fuel pressure gauge and check fuel pressure i C CHECK E C U HARNESS CONNECTOR Repair or replace Check the E C U pin terminals for darn age or poor connection of E C U har ness connector m...

Page 320: ...gears to Neutral When disconnecting throttle sen sor harness connector does the engine speed drop CHECK IDLE ADJ SCREW CLOGGING Check for IAS clogging or throttle chamber clog ging 2 Can you set engin...

Page 321: ...rn ignition switch ON Do not start engine 4 When rotating crank angle sensor shaft does each injector make an operating sound lYes PERFORM POWER BALANCE TEST 1 Perform POWER BALANCE in ACTIVE TEST mod...

Page 322: ...ssure gauge and check fuel pressure U CHECK EXHAUST GAS SENSOR Replace exhaust gas 5 1 See MIR FIC MNT in DATA MONITOR mode 2 Maintaining engine at 2 000 Check fuel pressure reg ulator diaphragm rpm u...

Page 323: ...edure 14 Engine Stalls after Decelerating Cont d Repair or replace Check the E C U pin terminals for dam 1 age or poor connection of E C U har Repair or replace GROUND CIRCUIT Referto pageES 170 m l T...

Page 324: ...Remove crank angle sensor from circuit s engine Harness connector should remain connected 2 Disconnect each ignition wire 3 Turn ignition switch ON Do not start engine 4 When rotating crank angle sens...

Page 325: ...ES F ELEQ E H N G Check fuel pump circuit _l 8 I I When servicing fuel system after performing Fuel Pressure Release in Work Support mode turn off ignition key with CONSULT set in Work Support mode 3...

Page 326: ...en Driving at 9 Constant Speed Cont d Repair or replace GROUND CIRCUIT H i Referto page ES 170 No I TRY A KNOWN GOOD E C U I Repair or replace CHECK E C U HARNESS CONNECTOR I INSPECTION END I Check th...

Page 327: ...mentary engine speed drop SEF1571 El CHECK INJECTOR 1 Remove crank angle sensor from circuit s engine Harness connector should remain connected 2 Disconnect each ignition wire 3 Turn ignition switch O...

Page 328: ...oment throttle valve Is fully open Approx 294 kPa 3 0 kg cm2 43 psi OR 1 Release fuel pressure to zero Referto page ES 2 19 2 Install fuel pressure gauge and check fuel pressure ulator diaphragm Repai...

Page 329: ...PRESSURE 1 Perform FUEL PRESSURE ulator diaphragm SUPPORT mode in order to release fuel pressure to zero 2 Install fuel pressure gauge and check fuel pressure At idle Approx 226 kPa 2 3 kglcm2 33 psi...

Page 330: ...s for clogging cracks and poor connection a Vacuum hose between E G R con trol valve and E G R control sole noid valve b Vacuum hose between E G R control solenoid valve and throttle chamber Repair or...

Page 331: ...under no load with en gine warmed up sufficiently check to make sure that the monitor fluctuates between LEAN and RICH more than 5 times during 10 sec onds R I F H L E A N t R I e 1 time 2 times I LEA...

Page 332: ...BacKtlre rnrougn the Intake CHECK INTAKE AIR LEAK When pinching blow by hose lowering and repair the blow by air supply does the en gine speed rise El CHECK FOR INTAKE VALVE DEPOSITS If there are dep...

Page 333: ...ROUBLE DIAGNOSES Diagnostic Procedure 21 Backfire through the Exhaust CHECK ENGINE TEMPERATURE SEN Replace or repair SOR l Check engine temperature sensor and its circuit Seepage ES 176 INSPECTION END...

Page 334: ...ch ON 2 Check voltage between E C U terminals a and 5 Check the following Harness connectors Harness continuity between E C U and E C C S relay If N G repair harness or con nectors Voltage ground Batt...

Page 335: ...ignition switch ON Harness connectors tween E C U terminals and engine ground Continuity should exist I3 P CHECK GROUND CIRCUIT 1 Check harness continuity be 2 Check voltage between E C U I IT 101 w c...

Page 336: ...D CIRCUIT 1 Turn ignition switch OFF 2 Check harness continuity be tween terminal and engine ground Continuity should exist N G Repair harness or connectors 2 Start engine c F M PG 3 g g 2r pnl 3 Read...

Page 337: ...ical Components Inspection See page ES 2 13 damage or the connection of E C U harness connector Perform FINAL CHECK by the following procedure after repair is completed FINAL CHECK 1 Erase the self di...

Page 338: ...1 h 1 i 1 l i i i i 1 i 1 I I F pr 1 I L SEF5851 ME I IT 101 COIWECT I SEF91g1 CHECK GROUND CIRCUIT 1 Turn ignition switch OFF 2 Disconnect EC U harness connector 3 Check harness continuity be tween t...

Page 339: ...tic Procedure 24 Cont d Perform FINAL CHECK by the following procedure after repair Is completed FINAL CHECK 1 Erase the self diagnosis mem ory Perform driving test damage or the connection of E C U h...

Page 340: ...t engine temperature sensor harness connector 2 Turn ignition switch ON 3 Check voltage be tween terminal and ground Voltage Approximately 5V ITurn ignition switch OFF Disconnect engine tem connector...

Page 341: ...ostic Procedure 25 Cont d Perform FINAL CHECK by the following procedure after repair is completed FINAL CHECK Erase the self diagnosis mem lOrY Perform driving test damage or the connection of E C U...

Page 342: ...value should be the same as the speedome Check vehicle speed sensor and its circuit ter indication 1 Turn ignition switch 2 Disconnect E C U harness connector and combination meter harness connector...

Page 343: ...IT N G Repair harness or connectors 1 Turn ignition switch OFF 2 Disconnectpower transistor harness connector and resistor and condenser harness connector 3 Check harness continuity between terminal a...

Page 344: ...age or the connection of E C U harness connector C Perform FINAL CHECK by the following procedure after repair CHECK COMPONENTS Ignition coil power transistor resistor and condenser Refer to Electrica...

Page 345: ...con nection i Check E C U pin terminals for damage or the connection of E C U harness connector m 0 N CUIT IRepair harness or connectors 1 1 Turn ignition switch OFF 2 Disconnect E C U harness connect...

Page 346: ...nectors it up sufficiently Harness continuity between 2 Make sure that MIR E C U and exhaust gas sensor 1 WIT 101 romcm 1 1 Disconnect E C U har 1 exhaust gas sensor RECORD harness connector 2 Check h...

Page 347: ...tor 2 Turn ignition switch ON 3 Check voltage between air temDeraturesensor terminal and ground Voltage Approximately 5v Turn ignition switch OFF l Disconnect air tempera ture sensor harness con necto...

Page 348: ...erform FINAL CHECK by the following procedure after repair is completed I FINAL CHECK I Erase the self diagnosis mem ory Perform driving test I INSPECTION END C N G Recheck E C U pin terminals for dam...

Page 349: ...r terminal and engine ground Continuity shouldexist Repair harness or connectors SEC4616 1 Reconnect throttle sen sor harness connector M 2 Turn ignition switch I I TYF T LE EL i ON I fi it 4 F i i II...

Page 350: ...Procedure 31 Cont d CHECK COMPONENT Throttle sensor Refer to Electrical Components Inspection See page ES 2 16 4 Check E C U pin terminals for I damage or the connection of I E C U harness connector...

Page 351: ......

Page 352: ...ttery voltage Except above Approximately O V INSPECTION END I Check the following m Harness connectors 10A fuse m Harness continuitv between CHECK SIGNAL CIRCUIT 1 Turn ignition switch OFF 2 Disconnec...

Page 353: ...ng cracks and proper con nections After a few minutes SEF9671 See pageES 2 19 2 Start engine and warm it up until engine temperature exceeds 90 C or see NOTEat procedure end 3 Stop engine 4 After a fe...

Page 354: ...switch OFF 2 Disconnect E C U harness connector 3 Check harness continuity be tween E C U t e r m i n a l m a n d Solenoid terminal Continuity should exist SEF9701 I i iIi E TE i T I a CHECK COMPONEN...

Page 355: ...cold etc disconnect englnetemperaturesensor harnessconnector andconnect a resistor 0 1 kSZ to engine temperature sensor harness connector 1 Do not perform this test for a long time m 2 Perform self di...

Page 356: ...ector harness a Fusible link connector and E C U harness connector Harness continuity between 3 Check voltage between battery and injector injector terminal and sound E C U terminal a Harness continui...

Page 357: ...or con nectors CHECK POWER SUPPLY 1 Turn ignition switch OFFsr 2 Disconnect fuel pump relay 3 Turn ignition switch ON 4 Check voltage between termi nals and ground Voltage Battery voltage N G CHECK G...

Page 358: ...ently 2 Stop engine 3 After a few seconds discon nect vacuum hose to swirl control valve and restart en gine 4 Make sure that vacuum exists under the following condi tions Engine speed is less than 1...

Page 359: ...on switch OFF 2 Disconnect E C U harness connector 3 Check harness continuity be tween E C U terminal and terminal B Continuity should exid N 6 S C V control solenoid valve Replace S C V control solen...

Page 360: ...16 CHECK POWER SUPPLY E R 1 stop engine 5 Check the following Harness connectors 2 Disconnect A A C valve har e 10A fuse ness connector 8 Harness continuity between 3 Turn ignition switch ON A A C val...

Page 361: ...ve I I I 1 Reconnect E C U har ness connector and A A C valve harness connector 2 Start engine 3 Perform AAC VALVE OPENING TEST in ACTIVE TEST mode with CONSULT R Refer to Electrical Com ponents Inspe...

Page 362: ...for a few minutes with air conditioner operating 6 Make sure that radiator fan operates at low speed Without air conditioner I 1 Start engine 2 Keep engine speed at about 2 000 rpm until engine is war...

Page 363: ...relay l and 2 3 Turn ignition ON 4 Check relay l voltage between terminals and ground 5 Check rela 2 voltage between terminals6 and ground Voltage Battery voltage N G 0 K v CHECK GROUND CIRCUIT 1 Tur...

Page 364: ...I f a o t o j fan motor9 0 C fan motor l 4 relay 2 I Repair harnessor connectors I 3 Check continuity from radiator fan relay l terminal with fan motor 2 terminal D and fan motor 1 terminal8 H 4 Chec...

Page 365: ...e Approximately OV 1 Turn ignition switch OFF 2 Disconnect E C U harness connector 3 Check harness continuity between E C U terminal 9 with relay 1 terminal 1 and E C U terminal with relay 2 8 termina...

Page 366: ...Cont d CHECK COMPONENTS Radiatorfan relay l 2 radiator fan motor l and 2 Refer to Electrical Components Inspection See page ES 2 14 Check E C U pin terminals for damage or the connection of E C U harn...

Page 367: ...d ground 0 5 INSPECTION END Voltage When steering wheel is turned quickly Approximately O V Except above Approximately 8 l3 9v CHECK GROUND CIRCUIT 1 Stop engine 2 Disconnect power steering oil pressu...

Page 368: ...0 Cont d CHECK COMPONENT Power steering oil pressure switch Refer to Electrical Components Inspection See page ES 215 Check E C U pin terminals for I damage or the connection of I E C U harness connec...

Page 369: ...and body ground Continuity should exist Turn ignition switch OFF harness connector 2 Check harness continuity be tween terminal and body ground Continuity should exist CHECK GROUND CIRCUIT 1 Disconnec...

Page 370: ...gnostic Procedure41 Cont d CHECK COMPONENT Neutral switch Refer to Electrical Components Inspection See page ES 218 Check E C U pin terminals for damage or the connection of E C U harness connector N...

Page 371: ...r 3 Turn ignltlon swltch ON 4 Check harness continu S E F O J t y between E C U term nal and body ground Continuity should exist 5 Shlft selector lever to N range 6 Check harness contlnu t y between E...

Page 372: ...1 Check the following a Harness connectors a Harness continuity between E C U and inhibitor relay If N G repair harness or con 35 m E CHECK INPUT SIGNAL CIRCUIT 1 Check harness continuity be tween E C...

Page 373: ...e speed IEngine is running Engine speed is 2 000 rpm ldle speed Within approximately 1 second after turning ignition switch OFF For approximately 1 second after turning ignition switch OFF IEngine is...

Page 374: ...ngine at high speed under no load Temperature of intake air is 20 C 68 F Temperature of intake air is 80 C 176 F IEngine is running Do not run engine at high speed under no load Throttle valve idle po...

Page 375: ...VOLTAGE 11 14V Idle switch side Lhrottle valve I 1 Except idle position 1 turned Throttle valve idle position Ignition switch ON I I I l ngine is running Approximately 9 10V ir conditioner is 0 eratin...

Page 376: ...on switch ON IEngine is running 1 Within 5 seconds after turning ignition switch ON ngine IS running F Engine is cold Water temperature is below 60 C 140 F 1 After warning up Water temperature is betw...

Page 377: ...gine crank angle sensor har ness connector is connected 2 Turn ignition switch ON 3 Rotate crank angle sensor shaft slowly and check voltage between terminals and ground Voltage fluctuates between 5V...

Page 378: ...pproximately 0 7Q FUEL PUMP RELAY RADIATOR FAN RELAYS 1 2 Check continuity between terminals and Terminal No 02 0 0 0 Check continuity between terminals and and and a Tester polarity 0 0 0 0 0 0 0 0 C...

Page 379: ...See page ES 182 Condition 12V direct current supply between terminals and No supply AIR TEMPERATURE SENSOR Check air temperature sensor resistance Air passage continuity between and Yes No POWER STEE...

Page 380: ...eleased Partially released Completely depressed 1 Install throttle sensor body in throttle chamber Do not tighten bolts 2 Connect throttle sensor and idle switch harness connector 3 Start engine and w...

Page 381: ...or and check nozzle for clogging SWIRL CONTROL VALVE Supply vacuum to actuator and check swirl control valve operation A A C VALVE a Check A A C valve resistance Resistance Approximately 10R at 20 C 6...

Page 382: ...ion Fully closed Open Continuity Yes No INHIBITOR SWITCH Check continuity between terminals and Conditions Shift to Neutral Shift to other position Continuity Yes No INHIBITOR RELAY Check continuity b...

Page 383: ...essure regulator control system is operating otherwise fuel pres sure gauge might indicate incorrect readings Release fuel pressure to zero Remove air duct Disconnect fuel hose between fuel filter and...

Page 384: ...OVAL 1 Release fuel pressure to zero 2 Remove or disconnect the following m Air duct m Fuel hoses m Fuel pressure regulator m Accelerator wire bracket m Fuel injector harness connectors 3 Remove fuel...

Page 385: ...d Installation Cont d INSTALLATION Y 4 1 Clean exterior of injector tail piece 2 Replace 0 rings and insulators with new ones 3 lnstall injectors 4 Install any parts removed CAUTION After properly con...

Page 386: ...TEMPERATURE SENSOR Resistance L 2 1 Approximately 10 FUEL PRESSURE at idling Unit kPa kg cm2 psi IDLE SWITCH Measuring point between fuel filter and fuel pipe Vacuum hose is connected Vacuum hose is...

Page 387: ...SECTION EC CONTENTS CRANKCASE EMISSIONCONTROL SYSTEM EVAPORATIVE EMISSIONCONTROL SYSTEM EXHAUST EMISSIONCONTROL SYSTEM EC 3 EC 5...

Page 388: ...crankcase Under full throttle condition the manifold vacuum is insufficient to draw the blow by flow through the valve and its flow goes through the hose connection in the reverse direction On vehicle...

Page 389: ...he purge control valve is closed Only a small amount of stored vapor flows into the intake manifold through the constant purge orifice As the engine speed increases and the throttle vacuum increases t...

Page 390: ...the top section of the canister i e around the tubes or lid the canister must be replaced FuelTank Vacuum ReliefValve Inspection 1 Wipe clean valve housing 2 Apply vacuum A slight resistance indicates...

Page 391: ...atalytic converter activates to oxidizeandreduce harmfulgases HC C OandNOx intoharmless gases CO H O and N Inthis way the catalytic converter cleans the exhaust gas and emits C O 0 and N into the atmo...

Page 392: ...ENGINE CONTROL FUEL EXHAUST SYSTEMS SECTION FE CONTENTS ENGINECONTROL SYSTEM FUELSYSTEM FE 3 EXHAUST SYSTEM FE 4...

Page 393: ...g procedure Tighten adjusting nut until throttle drum starts to move From that position turn back adjusting nut 1 5 to 2 turns and fasten it with a lock nut f a Check accelerator control parts for imp...

Page 394: ...ion proof container and put lid on securely CAUTION Do not disconnect fuel line unless absolutely necessary Plug up hose and pipe openings to prevent entry of dust or dirt Always replace 0 ring and cl...

Page 395: ...ire system for unusual noises After installation checkto assurethat mountingbracketsand mounting insulator are free from undue stress Ifany of above partsare not installedproperly excessivenoiseor vib...

Page 396: ...TS PRECAUTIONS AND PREPARATION CLUTCHSYSTEM INSPECTIONAND ADJUSTMENT HYDRAULIC CLUTCH CONTROL CLUTCH RELEASE MECHANISM CLUTCH DISC AND CLUTCH COVER SERVICE DATA AND SPECIFICATIONS S D S CL 2 CL 3 CL 4...

Page 397: ...d 8 Never use mineral oils such as gasoline or kerosene They will ruin rubber parts of the hydraulic system 8 Usesuitabletool when removingandinstallingclutch hose Always tension clutch hose and fitti...

Page 398: ...ster cylinder Pedalbracket 16 22 1 6 2 2 12 Pedal stopper Fulcrum Assist spring Pin m Clevis pin m Pin Clutc Pedal Clutch Operating cylinder Air bleeder screw m Apply lithium based grease including mo...

Page 399: ...cylinder push rod Then tighten lock nut Pedal free play AI 1 0 3 0 mm 0 039 0 118 in Pedal free play means the follwing total measured at position of pedal pad Play due to clevis pin and clevis pin h...

Page 400: ...is stopper when m Contact surface to piston assembly removing piston and return spring m Apply rubber grease N m kgm ft lb SCL348 DISASSEMBLY AND ASSEMBLY Push piston into cylinder body with screwdriv...

Page 401: ...tems and replace if necessary a Rubbing surface of cylinder and piston for uneven wear rust or damage a Piston with piston cup for wear or damage a Piston spring for wear or damage a Dust cover for cr...

Page 402: ...thium based grease including molybdenum INSPECTION Check the following items and replace if necessary a Release bearing to see that it rolls freely and is free from noise cracks pitting or wear a Rel...

Page 403: ...N Check the following items and replace if necessary m Clutch disc for burns discoloration oil or grease leakage Backlash of spline Clutch disc for wear of facing Wear limit of facing surface to rivet...

Page 404: ...tering noise or lightly ham mering on rivets for a slightly cracked noise Replace clutch cover assembly if necessary Check pressure plate and clutch disc contact surface for slight burns or discolorat...

Page 405: ...CLUTCH DISC AND CLUTCH COVER Clutch Cover and Flywheel Cont d INSTALLATION Align clutch disc with Tool when installing clutch cover and disc...

Page 406: ...m in CLUTCH COVER Full load N kg Ib 1 3 923 400 882 1 4410 450 990 7 8 8 2 0 307 0 323 with 3 923N 400 kg 882 Ib Model Engine Inspection and Adjustment CLUTCH DlSC 8 0 8 4 0 315 0 331 with 3 923N 400...

Page 407: ...ONTENTS PREPARATION MT 2 ON VEHICLE SERVICE MT 4 REMOVALAND INSTALLATION MT 6 MAJOR OVERHAUL MT 8 DISASSEMBLY MT 11 REPAIR FOR COMPONENT PARTS MT 14 ADJUSTMENT ASSEMBLY MT 27 E m MT 30 SERVICE DATA AN...

Page 408: ...l oil seal E7128 Removing mainshaftfront bearing Bearing raceloil seal outer race remover Removing differential side bearing outer race E6673 Disassemblinginput main Bearinglgear remover shafts E1673C...

Page 409: ...earingpuller Removing mainshaftfront bearing Usewith E1673MT E7177 5 Bearingpuller Removing differential side bearings E7008 Installer differential Installer differential side bearings side bearing E1...

Page 410: ...vel Filler plug S M A l 4 4 A 1 SMT346B Checking M T Oil Check manual transaxle for leakage Checkoil level BACK UP LAMP SWITCH AND NEUTRAL SWITCH Check continuity Gear position Reverse Neutral Except...

Page 411: ...tial oil seal Apply multi purpose grease to seal lip of oil seal before installing 5 Install drive shafts Refer to section FA STRIKING ROD OIL SEAL 1 Remove transaxle control rod from yoke 2 Remove re...

Page 412: ...ansaxle bolts CA2OE Engine KA24E Engine Bolt No 1 2 3 4 Front gusset to engine Rear gusset to engine Bolt No I Tightening torque N m kg m ft lb Tightening torque N m kg m ft lb 43 58 4 4 5 9 32 43 43...

Page 413: ...TRANSAXLE GEAR CONTROL Control lever knob 1 2 1 5 9 11 0 22 29 2 2 3 0 16 22 rn spring bracket 14 18 1 4 1 8 10 13 A O N m kg m ft lb SMT341 B...

Page 414: ......

Page 415: ...MAJOR OVERHAUL Gear Components...

Page 416: ...bolt 5th shift fork lst 2nd fork rod l st 2nd bracket Interlock plunger 3rd 814th bracket eturn bearing m bracket Select check spring Reverse lever assembly Reversecheck cam Reversearm shaft fi 7nti i...

Page 417: ...case Caution Do not lever on transmission case mating surfaces 3 Remove position switch Remove switch contact assembly from selector Remove oil gutter 4 Mesh 4th gear and then remove reverse idler sh...

Page 418: ...ball 8 Remove lower stopper rings and retaining pins from 5th reverse 3rd 4th and 1st 2nd shift fork rods 9 Remove 5th reverse and 3rd 4th fork rods Then remove forks and brackets 10 Remove both input...

Page 419: ...retaining rolled pin and detachthe selector Removedetent balls 4 and rod 14 Remove drain plug for convenience in removing retaining pin which holds striking lever to striking rod 15 Remove retaining...

Page 420: ...m in 2 Remove oil channeland shim from rear bearing Remove input shaft rear bearingusing E6673 press plates I 5th input gear 3 Remove 5th synchronizer and 5th input gear usingE7199press plates 0 23 0...

Page 421: ...s 7 Removeinput shaft front bearingusingE6673press plates INSPECTION Gear and shaft Check shaft for cracks wear or bending Check gears for excessive wear chips or cracks Synchronizer Check spline port...

Page 422: ...etween baulk ring and gear Clearance between baulk ring and gear Standard 1 0 1 35 mm 0 0394 0 0531 in Wear limit 0 7 mm 0 028 in Bearing Make sure bearings roll freely and are free from noise cracks...

Page 423: ...f groove and then install it Allowable clearance of groove 0 0 1 mm 0 0 004 in Snap ring of 3rd 4th synchronizer hub Refer to S D S 5 Install 4th input gear 6 Select proper thrust washers to minimize...

Page 424: ...SEMBLY 1 Before disassembly check 1st and 2nd main gear end plays Gear end play If not within specification disassemble and check contact surface of gear shaft and hub Then check clearance of snap rin...

Page 425: ...5th main gear and 4th main gear using E6673 press plates 5 Press out 3rd main gear and 2nd main gear using E6673 press plates 6 Remove snap ring 7 Remove 1st 2nd synchronizer and 1st main gear 8 Remo...

Page 426: ...coupling sleeves hubs and gears for wear or cracks Check baulk rings for cracks or deformation Check insert springs for deformation Measure clearance between baulk ring and gear Clearance between bau...

Page 427: ...2 Install 1st main gear and 1st baulk ring 3 Press on 1st 2nd synchrbnizer hub Pay attention to its direction 4 Install coupling sleeve with three inserts and 2nd baulk ring 5 Select proper snap ring...

Page 428: ...ring of 5th main gear to minimize clearance of groove and then install it Allowable clearance of groove 0 0 15 mm 0 0 0059 in Snap ring of 5 t h main gear Refer to S D S 11 Pressonthrust washerandpres...

Page 429: ...pin and draw out pinion mate shaft 4 Remove pinion mate gears and side gears INSPECTION Gear washer shaft and case Check mating surfaces of differential case side gears and pinion mate gears Check was...

Page 430: ...ngpin 4 Measureclearance betweenside gear and differentialcase with washersfollowing the procedurebelow a Set Tool and dial indicator on side gear b Move side gear up and down to measure dial indicato...

Page 431: ...Install retaining pin Make sure that retaining pin is flush with case 6 Install final gear 7 Install speedometer drive gear 8 Presson differential side bearingusingtool E7008 Shift Control Components...

Page 432: ...AND INSTALLATION Input shaft oil seal Apply multi purpose grease to seal lip of oil seal before installing Mainshaft front bearing outer race Mainshaft rear bearing outer race Refer to ADJUSTMENT Diff...

Page 433: ...ferential side beacing outer race transmission case side and shim s using E7128puller Remove input shaft case welch plug 2 Reinstall differential side bearing outer race without shim s 3 Install input...

Page 434: ...bearing outer race 8 Check differential side bearing turning torque a Install final drive assembly on clutch housing b Install transmission case on clutch housing Tighten transmission case fixing bol...

Page 435: ...dge to surface of the bearing outer race using a depth micrometer m Measure at three places on bearing outer race and take the average 6 Determine dimension A to be used by the following equation Dime...

Page 436: ...and striking rod 2 lnstall selector and retaining pin 3 lnstall reverse gate assembly 4 lnstall final drive assembly 5 lnstall input shaft and mainshaft with 1st 2nd shift fork assembly Be careful no...

Page 437: ...lunger 5th shift fork Fork rod 3rd 4th 7 Install 3rd 4th shift fork and bracket then install 3rd 4th shift rod stopper ring and retaining pin 8 Install interlock balls 9 Install 5th shift fork and bra...

Page 438: ...th reverse check plug spring and ball 11 Install reverse lever assembly a Apply multi purpose grease to check ball 12 Install reverse arm shaft and retaining pin 13 Mesh 4th gear Then install reverse...

Page 439: ...2nd bracket and 3rd and 4th bracket 16 Apply sealant to mating surface of transmission case and install it 17 Install position switch 18 Apply sealant to threads of check plugs Install balls springs...

Page 440: ...9 45 49 14 46 37 35 4 1 39 48 29 4 7 KA24E RS5F50A 5 Warner p 11 2 4 R 3 285 1 850 1 272 0 954 0 740 3 428 14 20 33 44 50 14 46 37 42 42 37 48 29 4 7 lst 2nd 3rd 4th 5th Rev lst 2nd 3rd 4th 5th Rev ls...

Page 441: ...0 0281 Thickness mm in 4 500 0 17721 4 525 0 1781 4 550 0 17911 4 575 0 1801 1st 2nd 3rd 4th 5th 3rd 4th synchronizer hub Allowable clearancebetweenside gear and differential case with 0 1 0 2 mm At i...

Page 442: ...0307 0 0323 0 82 0 86 0 0323 0 0339 0 86 0 90 0 0339 0 0354 0 90 0 94 0 0354 0 0370 0 94 0 98 0 0370 0 0386 0 98 1 02 0 0386 0 0402 1 02 1 06 0 0402 0 0417 1 06 l lO O 0417 0 0433 1 l0 1 l4 0 0433 0...

Page 443: ...40 0 44 0 0157 0 0173 0 44 0 44 0 0173 0 0173 0 44 0 48 0 0173 0 0189 0 48 0 48 0 0189 0 0189 0 48 0 52 0 0189 0 0205 0 52 0 52 0 0205 0 0205 0 52 0 56 0 0205 0 0220 0 56 0 56 0 0220 0 0220 0 56 0 60...

Page 444: ...SERVICE DATAAND SPECIFICATIONS S D S NOTES...

Page 445: ...RE4F02A AT 92 REMOVALAND INSTALLATION AT 94 DISASSEMBLY AT 96 REPAIR FOR COMPONENT PARTS RL4F02A AT 102 REPAIR FOR COMPONENT PARTS RE4F02A AT 126 ASSEMBLY AT 155 SERVICE DATA AND SPECIFICATIONS S D S...

Page 446: ...sure Measuringoil pressure E7128 Side bearingouter race puller E7187 Preloadadapter E7 192 Height Gauge Checkingdifferential side bearing preload Removingdifferential side bearing Aad A Selecting thru...

Page 447: ...ionsand sequences Care Use lint free cloth or towels for wiping parts will also prevent springs and small parts from clean Common shop rags can leave fibers that becomingscattered or lost could interf...

Page 448: ...AIT CONTROL DIAGRAM RE4F02A I Hydraulic Control Circuits...

Page 449: ...A T CONTROL DIAGRAM I RL4F02A I Hydraulic Control Circuits Cont d...

Page 450: ...A T mode SAT158C Mechanical Operation Range Reverse clutch Park I Reverse I On Neutral I Drive 1 High 1 Low 1 Bandy0 1 0 1Parking c utch lutchOperation Release pawl on on on on on on on on on on l l...

Page 451: ...A T CONTROL DIAGRAM I RE4F02A 1 Cross sectional View AT 7...

Page 452: ...stalling control valve to transmission case make sure that selector lever can be moved to all positions Inhibitor Switch Adjustment 1 Remove control cable from manual shaft 2 Set manual shaft in NWpos...

Page 453: ...in direction U 3 Reverse nut B by NW revolutions in direction T then tighten nut A securely Throttle drum should be held at P1 Number of revolutions N 2 75 3 25 turns 4 Ensure that throttle wire strok...

Page 454: ...s for Quick and Accurate Repair WORK FLOW CHECK IN LISTEN TO CUSTOMER COMPLAINTS I CHECK A T FLUID LEVEL AND CONDITION I PERFORM ROAD TESTING r I INSPECT MALFUNCTION ON THE BASIS OF EACH COM PONENT S...

Page 455: ...foot brake place selector lever in D range and wait a few minutes 3 Stop engine 4 Check for fresh leakage FLUID CONDITION CHECK FLUID LEVEL CHECK Refer to section MA Fluid color Dark or black with bu...

Page 456: ...ity 2 Release parking brake with selector lever in N range Lightly depress accelerator pedal to make sure vehicle does not move When vehicle is new or soon after clutches have been replaced vehicle ma...

Page 457: ...se vehicle speed Make sure it does not upshift to 3rd gear 4 While driving vehicle at the 25 to 35 km h with throttle at half to light position 2 range fully depress accelerator pedal to make sure it...

Page 458: ...hen oil temperature is between 50 to 80 C 122 to 176 F after the vehicle has been driven approx 10minutes SHIFT SCHEDULE Upshift Downshift Kickdown range in 4 4Lockup 0 10 20 30 40 50 60 70 80 90 100...

Page 459: ...TROUBLE SHOOTING AND DIAGNOSES I RL4F02A I Road Testing Cont d ROAD TEST SYMPTOM CHART FOR RL4F02A Numbers in chart below correspond with those indicated in Trouble shooting chart...

Page 460: ...TING CHART OFF VEHICLE FOR RL4F02A Numbers are arranged in order of probability Perform inspections starting with number one and working up Circled numbers indicate that the transaxle must be removed...

Page 461: ...3rd to 2nd or from 4th to 2nd Failure to change gear from 2nd to 1st or from 3rd to 1st Gear change shock felt during deceleration by releasing accelerator pedal Too high a change point from 4th t o 3...

Page 462: ...to 1st in l range Large shock changing from 2nd t o 1st in l range Transaxle overheats Oil shoots out during operation White smoke emitted from exhaust pipe during operation Offensive smell at oil ch...

Page 463: ...It is good practice to put a mark on point of specified engine rpm on indicator 5 Start engine apply foot brake and place selector lever in D range 6 Accelerate to wide open throttle gradually while a...

Page 464: ...roperly l Reverse clutch or l Lock upclutch is dragging 1 range test 0 K l L I N One way Low clutch clutch slips slips low rev brake converter one way clutch is slips faulty slipping or engine l Perfo...

Page 465: ...TEST PROCEDURE 1 Check AIT and engine fluid levels If necessary add fluid 2 Warm up engine until engine oil and A T F reach operating temperature after vehicle has been driven approx 10 min utes A T...

Page 466: ...oil pump Oil leakage at or around oil pump control valve body transmission case or governor Sticking pressure regulator valve Sticking pressure modifier valve 2 When line pressure while idling is low...

Page 467: ...ns refer Trouble shooting chart a Component Check OVERDRIVE CONTROL SWITCH Check continuity between two terminals Condition Lock up ON Lock up OFF Switch position Continuity ON OVERDRIVE OFF CANCEL To...

Page 468: ...lock up is disabled When solenoid is OFF the drain is closed and lock up is enabled The E C C S control unit will switch the lock up solenoid according to the table below The circuit from the ECMis sh...

Page 469: ...TROUBLE SHOOTING AND DIAGNOSES Notes...

Page 470: ...ppropriate position AT 60 Diagnostic Procedure3 SYMPTOM O D OFF indicator lamp doess not come on when setting overdrive switch to OFF position AT 60 Diagnostic Procedure4 SYMPTOM Power indicator lamp...

Page 471: ...MPTOM Lock up is not released when accelerator pedal is released AT 71 Diagnostic Procedure 18 SYMPTOM A T does not shift from D to D when changing overdrive switch to OFF position AT 72 Diagnostic Pr...

Page 472: ...LAINTS I CHECK A T FLUID LEVEL AND CONDITION I PERFORM ROAD TESTING PERFORM SELF DIAGNOSIS l INSPECT MALFUNCTION ON THE BASIS OF EACH COM PONENT S CONDITION 4 FINAL CHECK I Reference item 1 See page A...

Page 473: ...rpose of this road test is to determine overall performance of automatic transmission and analyze causes of problems a The road test consists of the following three parts 1 Check before engine is star...

Page 474: ...de switch to B 1 Does power indicator lamp flicker for about 8 seconds Does power indicator lamp come on for about 2 seconds come on 1 I I No Go to Diagnostic Procedure 1 2 Does power indicator lamp Y...

Page 475: ...indicator lamp GOto Diagnostic Procedure3 come on B o Go to Diagnostic Procedure4 on for about 3 seconds after accelerator pedal is depressed m Yes Refer to SELF DIAGNOSIS PROCEDURE and note N G l it...

Page 476: ...flat surface 1 Move selector lever to P or Is engine started Go to Diagnostic Procedure 5 Move selector lever to D l 4 Is engine started 7 Go to DiagnosticProcedure5 1 l No I Move selector lever to P...

Page 477: ...ot brake I 1 H 4 I Move selector lever to R ranae 1 Go t o Diagnostic Procedure 8 changing from N to R range H 1yes I Release foot brake for several I seconds I 1Yes Move selector lever t o D 2 and 1...

Page 478: ...cross termi nals and of A T control unit Cruise test Part 1 Warm up engine until engine oil and A T F reach operating tem perature after vehicle has been driven approx 10 minutes AT F operatingtempera...

Page 479: ...m 1 yes W Does A T shift from D3to D4 Go to iagnostic Procedure 14 at the specifiedspeed Specified speed when shifting from D3to D4 Refer to Shift schedule Does A T perform lock upat Go to Diagnostic...

Page 480: ...m h using half throttle then quickly depress it fully Does A T shift from D4 to Da GOto Diagnostic Procedure 12 a s soon a s accelerator pedal is depressed fully B Yes No Does AIT shift from D2 to D3...

Page 481: ...switch to OF F I position while driving in D4 I range l ksshift f o m l NO iGo to DiagnosticProcedure 18 1yes I Moveselector lever from D to 1 2 range while driving in DJ I I 1 H 4 Yes I Does A T shi...

Page 482: ...TROUBLE SHOOTING AND DIAGNOSES RE4F02A I PreliminaryCheck Cont d SHIFT SCHEDULE Hold pattern Upshift Vehicle speed kmlh MPH I SHIFT SCHEDULE Power pattern I Uphift Downshift i Veh cle speed kmlh MPH l...

Page 483: ...A T Electrical Parts Location Located on...

Page 484: ...To Illumination s y s t e m tt IGNI T I ON SW1TCH I ON o r START FUSE I G N I T I O N CO1L I G N I T I O N SW1 TCH To d l s t r l b u t o r ON o r START TOR 7 i W T CONTROL U N I T...

Page 485: ......

Page 486: ...TROUBLE SHOOTING AND DIAGNOSES r iizq NOTES...

Page 487: ...r lever to P range I Doespower indicator lamp come on for about 2 seconds 4Yes I 4No l 1 J I Move selector lever to D range 1 I Go to Diagnostic r o c e d u r e l I Set overdrive switch in CANCEL posi...

Page 488: ...NOSES 1 RE4F02A Self diagnosis Cont d JUDGEMENT OF SELF DIAGNOSIS CODE All judgement flickers are same All circuitsthat can be confirmed by self diagnosis are A T control unit ti 2 5 seconds t2 2 0 se...

Page 489: ...TROUBLE SHOOTING AND DIAGNOSES p G i q Self diagnosis Cont d ft solenoid B circuit is short circuited or disconnected Shift solenoid B A T control unit solenoid AIT control unit...

Page 490: ...NOSES p G 6 q Self diagnosis Cont d Fluid temperature A T control unit II Go to fluid temperaturesensor and A T control onnected for a long time When reconnectingA T control unit connectors This is no...

Page 491: ...or lamp Does not come on Selfdirgnosis Start Light Shade SAT1466 Damaged circuit Inhibitor switch overdrive switch or throttle valve switch circuit is disconnected or AIT control unit is damaged Go to...

Page 492: ...Voltage At 0 km h OV At 30 km h 1V or more Voltage rises gradually in 2 Check voltage between AIT Harness continuity between control unit terminal and A T control unit and speed ground while drivinga...

Page 493: ...ge Fully clodthrottle Depress slowly 0 2 0 6V Fullyopenthrottle 2 9 3 9V Voltage rises gradually in 34 35 responseto throttle valve opening Perform selfdiagnosisagain after 1 Perform A T control unit...

Page 494: ...sembly CHECK POWER SOURCE ClRCUIT 1 terminal cord assembly I 1 Remove control valve assem bly Refer to ON VEHI CLE SERVICE 2 Check the following items Shift solenoid A Refer to Electrical Components I...

Page 495: ...d assembly CHECK GROUND CIRCUIT l 2 Disconnect terminal cord assembly connector in engine compartment 3 Check resistance between terminal and ground connector 3 Check resistance between terminal and A...

Page 496: ...ms Timing solenoid Refer to Electrical Components Inspection Harness continuity of terminal cord assembly m I O K Repair or replace harness CIRCUIT 1 1 2 Disconnect A T control unit I I between A T co...

Page 497: ...ms Lock upsolenoid Refer to Electrical Components Inspection Harness continuity of terminal cord assembly Resistance 10 20Q O K CHECK POWER SOURCE 5 CIRCUIT Repair or replace harness betweenA T cont r...

Page 498: ...T CONTROL UNIT POWER SOURCE O K I Check the following items Harness continuity between CHECK FLUID TEMPERA TURE SENSOR WITH TERMINAL CORD ASSEMBLY 2 Disconnectterminal cord assembly connector in engin...

Page 499: ...ile inputloutput signal inspection O K 2 If N G recheck A D control unit pin terminals for damage INSPECTION END or connection of A T control SAT991B unit harnessconnector m l 11 IT 101oO cDm1 33 E G...

Page 500: ...ne pressure solenoid Refer to Electrical Com ponents Inspection Harness continuity of terminal cord assembly Performself diagnosisafter driving for a while 0 K lNSPECTlON END l PerformAIT control unit...

Page 501: ...through each range Check the following items Inhibitor switch Refer to Electrical Components Inspection Harness continuity b e e n ignition switch and inhibitor switch Harnesscontinuity between inhib...

Page 502: ...t harness connector 4 a E GIR CHECK IDLE SWITCH N G CIRCUIT 1 LGM Performself diagnosis for engine control Check idle switch circuit J J SATQ96B 2 Check voltage between A T control unit terminal and g...

Page 503: ...nition 1 Perform AIT control unit input output signal inspection 2 If N G recheck AIT control unit pin terminals for damage or connection of AIT control unit harness connector 2 DisconnectA T control...

Page 504: ...re 1 Check the following items Repair or replacedamaged parts A T mode switch Comfort indicator lamp Harness continuity between ignition switch and A T mode switch Harnesscontinuity between A T mode s...

Page 505: ...elf diagnosis Doesself diagnosisshow damage to throttle sensor circuit Check throttle sensor Refer Repair or replacethrottle sensor to section ES O K 1 Perform AIT control unit inputloutput signal ins...

Page 506: ......

Page 507: ...mperature sensor circuit Check throttle sensor Refer Repair or replacethrpttle sensor to section ES 1 Check line pressureat idlewith 1 Removecontrol valve assem selector lever in D range bly Refer to...

Page 508: ...onwith bly Refer to ON VEHI selector lever in 1 and R CLE SERVICE range 2 Check the following items Valves to control line pressure O K in l range Pressureregulator valve pilot N G in R range a valve...

Page 509: ...SERVICE 2 Check the following items Valvesto control line pressure Pressureregulator valve pilot valve and oil filter Line pressuresolenoid 3 DisassembleA T 4 Check the following items Oil pump assem...

Page 510: ...oint 5 with selector lever in D range Refer to PRESSURE TEST1NG El O K Check A T fluid condition b N G I Yes Removeeomrolvalve bly Refer to ON VEHI CLE SERVICE 2 Check the following items 1 2shift val...

Page 511: ...o sensor Repair or replace revolution sensor and speed knsor circuits Check revolutionsensor and N G 25 35 27 H O K A T control unit Check throttle sensor Refer N G Repair or replace throttle sensor t...

Page 512: ...r to Self diagnosis Repair or replacethrottle sensor to section ES Go to Diagnostic Procedure 10 or 11 O K O K Yes 1 1 Removecontrol valve assem bly Refer to ON VEHI CLE SERVICE 2 Check the following...

Page 513: ...nsor speed sensor or fluid temperature sensor circuit after cruise test Repair or replacethrottle sensor to section ES O K O K O K 1 Removecontrol valve assem bly Refer to ON VEHI CLE SERVICE 2 Check...

Page 514: ...eck throttle sensor Refer to section ES Repair or replace throttle sensor O K Repair or replace damaged Parts 1 Removecontrol valve Refer to ON VEHICLE SERVICE 2 Check following items Lock upcontrol v...

Page 515: ...4 Check torque converter and oil pump assembly SAT638A t 1 Perform A T control unit input output signal inspection 2 If N G recheck A T control unit pin terminals for damage or connectionof A T contro...

Page 516: ...YMPTOM AIT does not shift from D to DJ when changing overdrive switch to OFF position Does self diagnosisshow damage to overdrive switch circuit after cruise test Yes Check overdrive switch circuit Re...

Page 517: ...test NO SelfdirgnoSiS nart Light Go to Diagnostic Procedure 12 Diagnostic Procedure 20 SYMPTOM A T does not shift from 2 2 to 11 when changing selector lever from 2 to 1 range Vehicle does not deceler...

Page 518: ...spection INSPECTION OF AIT CONTROL UNlT Measure voltage between each terminal and terminal or by following AIT CONTROL UNlT INSPECTION TABLE a Pin connector terminal layout I 1 1 2 1 3 1 4 1 9 1 1 0 1...

Page 519: ...performs lock up When A T does not perform lock up When shift solenoid A operates Whendriving in D1 or D4 When shift solenoid A does not operate Whendriving in D2 or D3 When shift solenoid B operates...

Page 520: ...tage When setting selector lever t o other 1V or less ranges Battery voltage range When setting selector lever t o 2 range Battery voltage When setting selector lever t o N Battery voltage range When...

Page 521: ...Ground AIT mode switch POWER When turning ignition switch to OFF When turning ignition switch to ON 2 t o 3 km h for 1m or more Vary from 0 to 5v 4 5 5 5v When A T F temperature is 2 0 1 56V When A T...

Page 522: ...oltage 1V or less Condition When setting overdrive switch in OVERDRIVE position When setting overdrive switch in CANCEL position When setting A T mode switch in HOLD position When setting A T mode swi...

Page 523: ...continuity between terminals and and between terminals and 0 0 0 while moving selector lever through each range 3 If N G adjust inhibitor switch 4 Check terminal continuity again 5 If N G replace inh...

Page 524: ...iming solenoid 20 4052 4 UNIT SOLENOID ASSEMBLY Shift solenoid A B lock up solenoid and line pressure solenoid For removal and installation refer to ON VEHICLE SERV ICE Check resistance between termin...

Page 525: ...le has been driven approx 10 min utes A T F operating temperature 50 80 C 3 Set parking brake and block wheels 4 Install a tachometer where it can be seen by driver during test It is good practice to...

Page 526: ...clutch is dragging Too hi Too low converter one way clutch is malfunctioning slipping or engine is not performing l Reverseclutch or l Lock upclutch is dragging properly low rev brake converter one wa...

Page 527: ...ressure test procedure 1 Check A T and engine fluid levels If necessary add 2 Warm up engine until engine oil and A T F reach operating temperature after vehicle has been driven approx 10 min utes A T...

Page 528: ...regulator valve Fluid pressure leakage between manual valve and particularclutch m For example If line pressure is low in R and 1 ranges but is normal in D and 2 range fluid leakageexists at or aroun...

Page 529: ...pressure gauge to lock up pressure port Shift selector lever in D range If lock up pressure is not within specifications refer to Diag nostic Procedures 15 and 16 Condition Lock up ON Lock up OFF Tor...

Page 530: ...2 rang but runs in 1 and R ranges Vehicle will not run in D l 2 n n g but runs in R range Clutch slips Very poor acwhration Clutcha or brake slip wm8whm in starting Excariw crwp No crwp at all Feilun...

Page 531: ...change point from D to D from D to D from D to D Kickdowndoes not operate when depressing pedal in D within kickdown cpw Kickdown operates or engineowrruns when depressingpedal in D beyond kickdown v...

Page 532: ...anmxle overheats A T F shoou out during operation White smoke emitted frqm exhaust pipe during operation Offensive smell et fluid chargingpipe Toque converter is not locked up Lockup piston slip Locku...

Page 533: ...TROUBLE SHOOTING AND DIAGNOSES Notes...

Page 534: ...ferential spacer Pinion mate thrust was oear 1 everse clutch assembly Pinion mate shaft LPinion mate L Control cylinder Needle bearing Thrust washer Governor valve and shaft Speedometer case Converter...

Page 535: ...7 14 20 l 5 7 0 5 0 7 3 6 5 1 6 3 8 3 0 64 0 85 4 6 6 1 74 88 7 5 9 0 54 65 16 21 1 6 2 1 12 15 0 31 37 3 2 3 8 23 27 16 21 1 6 2 1 12 15 0 l 6 21 1 6 2 1 12 15 5 7 0 5 0 7 3 6 5 1 3 7 5 0 0 38 0 51...

Page 536: ...tial side bearing Reverse clutch assembly Differential side bearing Thrust washer Speedometercase Converter housing Torque converter High clutch assembly L Needle bearing Always replace when disauembl...

Page 537: ...y 20 26 2 0 217 14 20 l 5 7 0 5 0 7 3 6 5 1 6 3 8 3 0 64 0 85 4 6 6 1 l 74 88 7 5 9 0 54 65 l l 6 21 1 6 2 1 12 15 31 42 3 2 4 3 23 31 7 9 0 7 0 9 5 1 6 5 3 7 5 0 0 38 0 51 2 7 3 7 5 7 0 5 0 7 3 6 5 1...

Page 538: ...ce A to be certain that they are correctly assembled Distance A 19 0m m or more Install converter to drive plate After converter is installed to drive plate rotate crankshaft several turns and check t...

Page 539: ...E Engine Bolt No 1 2 3 4 5 Front gusset to engine Rear gusset to engine Tightening torque N m kg m ft lb 29 39 3 0 4 0 22 29 39 49 4 0 5 0 29 36 39 49 4 0 5 0 29 36 29 39 3 0 4 0 22 29 6 8 0 6 0 8 4 3...

Page 540: ...h drain hole 2 Remove torque converter 3 Remove control cylinder 4 Remove control valve cover i Remove throttle lever RL4F02A Only ii Remove control valve cover 5 Disconnect harness connectors on cont...

Page 541: ...sembly The terminal retrieving hooks will break if they are forced inward too far Bend them gently inward while pulling carefully outward on the terminal Do not pull on the wires 7 Remove accumulator...

Page 542: ...overnor bolt then pin using 4mm10 75 pitch screw or equivalent c Removegovernor shaft RL4F02A Removespeedometer shaft RE4F02A 14 Support transaxle assembly on wooden blocks and remove converter housin...

Page 543: ...stem lock nut then back off piston stem 20 Remove brake band and high clutch reverse clutch pack with high clutch hub and front sun gear as a unit To prevent brake linings from cracking or peeling do...

Page 544: ...low reverse brake clutches and detach low reverse brake retainer snap ring pushing retainer 23 Removelow and reversebrake piston by applying low pressure compressed air as shown 24 Remove bearing ret...

Page 545: ...LY Disassembly Cont d 26 Remove band brake servo piston snap ring and remove piston and return spring 27 Loosen manual shaft lock nuts and remove manual plate 28 Pull out retaining pin then remove man...

Page 546: ...pport ring 7 Return spring 7 Oil pump spring retainer h o t o r Vane ring L Seal ring DISASSEMBLY 1 Remove oil pump cover Remove differential lubricationtube SAT806 2 Remove cam ring spring taking car...

Page 547: ...d vane ring when measuring clearance Standard clearance 0 010 0 024 mm 0 0004 0 0009 in Wear limit 0 034 mm 0 0013 in If the clearance is out of wear limit replace oil pump as an assembly a Measure cl...

Page 548: ...cross type pattern 4 Rotate pump when it has been assembled to ensure that all parts have been correctly assembled 5 Install seal rings Refer to figure at left for proper locations of two different ty...

Page 549: ...PARTS 1 RL4F02A I Control Cylinder Inspect control cylinder body control piston and cylinder plug for scratches or damage Replace if necessary Pay attention to direction of lip seal After assembling...

Page 550: ...REPAIR FOR COMPONENT PARTS RL4F02A 1 Control Valve Body Cont d Spring seat 7 Lock up control valve AT 106...

Page 551: ...lve 3rd 2ndtiming valve 2nd 4th timing valve 4th 2nd timing valve lst reducingvalve Torque converter regulator valve Low clutch timing valve Lock up control valve Lock up timing valve 2nd 3rd throttle...

Page 552: ...k valves for burning Replace if necessary Check separator plate for scratches or damage Replace if necessary Scratches or score marks can cause oil to by pass correct oil passages and result in system...

Page 553: ...1 Reinstall steel balls in valve body Caution Ballshown insectionA A issmaller thanthe other balls 2 Assemble separator plate and lower valve body on upper valve body and lock up body m Dip gasket in...

Page 554: ...S 1 RL4F02A 1 8 Use two reamer bolts as a guide while assembling upper and lower bodies 8 Pay attention to the position of harness clamps when installing control valve bolts 3 Install lock up solenoid...

Page 555: ...plate and driven plate refer to the below cross section High clutch piston High clutch drum SAT362A DISASSEMBLY 1 Compress clutch springs using E7179 spring compressor and removesnap ringfrom spring...

Page 556: ...clutch drum bushing and install inner seal and piston seal Be careful not to stretch seals during installation Never assemble clutch dry always lubricate its compo nents thoroughly Pay attention to d...

Page 557: ...ing is a wave type Specified clearance between retaining plate and snap ring Standard 1 8 2 2 mm 0 071 0 087 in Allowable limit 2 8 mm 0 110 in Available retaining plate Refer to S D S 7 Check high cl...

Page 558: ...entially the same as those for high clutch with the following exception Specified clearance between retaining plate and snap ring Standard 0 5 0 8 mm 0 020 0 031 in Allowable limit 1 6 mm 0 063 in Ava...

Page 559: ...lutch piston Reverse clutch drum L L Snap ring n m o Spring retainer li Spring LRetaining plate Driven plate Select with proper thickness SAT6598 Service procedures for reverse clutch are essentially...

Page 560: ...Cont d After a s s e m b l y check operation of c l u t c h Low Reverse Brake For the number of clutch sheets drive plate and driven plate refer to the below cross section Low reverse clutch piston R...

Page 561: ...e for damaged clutch drive plate facing and worn snap ring Check drive plate facing for wear or damage if necessary replace Drive plate thickness Standard 2 0 mm 0 079 in Allowable limit 1 8 mm 0 071...

Page 562: ...ner 3 8 5 1 N m 0 39 0 52 kg m 2 8 3 8 ft lbl cumulator piston Servo piston retainer Servo piston assembly Servo cushion spring SAT397A INSPECTION Check band friction material for wear If there are cr...

Page 563: ...ssure inlet Governor plunger View A SAT683A The governor plunger and the valve are moved upward by the return spring force and the line pressure circuit is shut by the governor valve when driving at l...

Page 564: ...y Carrier INSPECTION m Check clearance between pinion washer and planetary carrier with a feeler gauge Standard clearance 0 15 0 70 mm 0 0059 0 0276 in Allowable limit 0 80 mm 0 0315 in m If not withi...

Page 565: ...tallreductionpiniongearfront bearingouter raceusingE7008 installer Differential side bearing outer race Note The remaining differential side bearing components are covered in Final Drive and Assembly...

Page 566: ...g Removal Use E1673MTpuller in conjunctionwith E1673C20 plates lnstallation Use E7008to installbearing Output Gear Bearings Removal Use E1673MTpuller in conjunctionwith E1673C20plates Installation Use...

Page 567: ...REPAIR FOR COMPONENT PARTS 1 RL4FOZA I SAT841 DISASSEMBLY 1 Remove final gear 2 Drive out pinion mate shaft lock pin and draw out pinion mate shaft...

Page 568: ...ide gears and pinion mate gears Replace as required a Check tapered roller bearings for wear scratches pitching or flaking ASSEMBLY 1 Install side gear and thrust washer in differential case 2 Install...

Page 569: ...en side gear and differential case with washer 0 1 0 2 mm 0 004 0 008 in c If not within specification adjust clearance by changing thickness of side gear washers Side gear thrust washer Refer to S D...

Page 570: ...support ring Oil pump spring retainer SAT043C DISASSEMBLY 1 Remove oil pump cover Remove differential lubrication tube 2 Remove return spring taking care not to damage converter housing Remove oil pu...

Page 571: ...ximum measured value should be within the specified range Be sure to remove friction ring and vane ring when measuring clearance Standard clearance 0 010 0 024 mm 0 0004 0 0009 in Wear limit 0 034 mm...

Page 572: ...rn 5 Rotate the pump when it has been assembled to ensure that all parts have been correctly assembled 6 Install seal rings Refer to the figure at left for proper locations of the two different types...

Page 573: ...cylinder Gasket 0 SAT8696 INSPECTION AND ASSEMBLY Inspect control cylinder body control piston and cylinder plug for scratches or damage Replace if necessary When assembling pay attention to the direc...

Page 574: ...ly Solenoid separator gasket Separator plate Solenoid separator gasket Solenoid body 0 ring 4unit rolelioid assembly line pressure solenoid lockup solenoid and shift solenoids A and B Lower b o d y 1...

Page 575: ...solenoid d Remove 0 rings from solenoids 2 Remove solenoid body a Place lower body facedown and remove bolts Be careful not to drop solenoid body b Place upper body face down and remove solenoid body...

Page 576: ...body downward Remove lower body with separator plate and separator gasket attached to upper body c Remove oil filter separator gaskets and separator plate from upper body d Check to see that steel ba...

Page 577: ...REPAIR FOR COMPONENT PARTS RE4F02A I Control Valve Upper Body 3 2 timing valve This valve is fixed Lock up shuttle valve Pressure modifier accumulator valve...

Page 578: ...lot valve Manual valve Lock up shuttle valve Pressure modifier accumulator valve Pressure regulator valve 1 2 shift valve This Lock upcontrol valve Feedbeck accumulator valve 1st reducing valve Torque...

Page 579: ...valve facedown and remove internal parts a If a valve Is hard to remove place valve body facedown and lightly tap It with a soft hammer a Be careful not to drop or damge valves and sleeves 2 Remove va...

Page 580: ...lve spring 0 Torque converter relief valve spring 1st reducing valve spring Feedback accumulator valve spring Lock up control valve spring Control valves Check sliding surfaces of valves sleeves and p...

Page 581: ...l tape and use it to insert the valves into proper position Pressure regulator valve Position plug in sleeve and install pressure regulator valve on upper body 2 Install parallel pins and retainer pla...

Page 582: ...t filter is not clogged or damaged Timing solenoid Measure resistance Refer to Electrical Components In spection 4 unit solenoid assembly Line pressure solenoid lock up solenoid and shift solenoids A...

Page 583: ...face up Install steel balls in their proper positions b Install upper body separator gasket separator plate and lower body separator gasket on upper body c Fit oil filter and install lower body on upp...

Page 584: ...dy on control valve body and temporarily tighten bolts c Install accumulator support plate and harness clips in thier proper locations and tighten all bolts Bolt nl 3 4 4 4 Nom 0 35 0 45 kg m 2 5 3 3...

Page 585: ...and driven plate refer to the below cross section Driven plate 31536 21XW High clutch drum Retaining plate DISASSEMBLY 1 Compress clutch springs using E7179 spring compressor and removesnap ringfrom...

Page 586: ...g and install inner seal and piston seal Be careful not to stretch seals during installation Never assemble clutch dry always lubricate its compo nents thoroughly Pay attention to direction of piston...

Page 587: ...a wave type Specified clearance Standard 1 4 1 8 mm 0 055 0 071 in Allowable limit 2 6 mm 0 102 in Retaining plate of high clutch 7 Check high clutch operation using compressed air Thickness mm in 3 6...

Page 588: ...clutch hub driven plate refer to the below cross section 7 Lathe cut seal ring Spring retainer Snap ring LDished plate Retaining plate LSnap ring ive plate A Driven plal Dished plate 1 Retaining plate...

Page 589: ...n Specified clearance between retaining plate and snap ring Standard 0 5 0 8 mm 0 020 0 031 in Allowable limit 2 0 mm 0 079 in Retaining plate of low clutch After assembly check the operation of clutc...

Page 590: ...te y Driven plate LDrive plate Snap ring Driven plate 7 snap ring Q LReverse clutch drum SAT9186 Service procedures for reverse clutch are essentially the same as those for high clutch with the follow...

Page 591: ...6 0 220 5 8 0 228 6 0 0 236 Low Reverse Brake Part number 31537 21x10 31537 21x11 31537 21x12 31537 21x13 31537 21x14 or the number of clutch sheets drive plate and driven late refer to the below cros...

Page 592: ...mm 0 118 in Retaining plate of low reverse brake Part A Driven plate or SAT039C Thickness mm in 3 4 0 134 3 6 0 142 3 8 0 150 4 0 0 157 4 2 0 165 4 4 0 173 4 6 0 181 4 8 0 189 5 0 0 197 If clearance...

Page 593: ...d and Band Servo r Spring retainer I Accumulator Snap ringQ SAT920B INSPECTION 8 Inspect band friction material for wear If cracked chipped or burnt spots are apparent replace the band 8 Check band se...

Page 594: ...5 in Check planetary gear sets and bearings for damaged or worn gears Bearing Retainer and Output Shaft INSPECTION Measure clearance between seal ring and ring groove Standard clearance 0 10 0 25 mm 0...

Page 595: ...bearing outer race OIL SEAL Torque converter oil seal Differential side oil seal BEARINGS Idler Gear Bearing Remove using E1673MT puller with E1673C20 plates Refit using E7008 to install bearing Outp...

Page 596: ...side bearing 74 88 N m 7 5 9 0 kg m 54 65 ft lb Differential case Governor shaft drive gear Pinion mate thrust washer Pinion mate gear Pinion mate shaft SAT841 SMT6lO DISASSEMBLY 1 Removefinal gear Wh...

Page 597: ...viscous coupling where fitted for cracks silicone leakage etc 2 Check clearance between side gear and differential case with washer following the procedure below a Set Tool and dial gauge on side gear...

Page 598: ...en inserting be careful not to damage pinion mate wash ers 4 Measure clearance between side gear and pinion mate gear referring to Inspection If necessary adjust Side gear to pinion mate clearance 0 1...

Page 599: ...ASSEMBLY When installing assembling needle bearing and bearing race use the following illustrations as a guide to installation procedures and locations SAT860...

Page 600: ...ial gutter to converter housing 2 Install oil strainer 3 Install detent spring assembly 4 Pass parking rod into the hole in the manual plate and then install manual plate on manual shaft 5 Install ban...

Page 601: ...gear 7 lnstall bearing retainer assembly a lnstall seal rings onto bearing retainer with great care Clean the grooves and liberally apply petroleum jelly to hold the rings in place Otherwise they cou...

Page 602: ...y tapping it evenly with Tool 11 Install low and reverse brake retainer and secure with snap ring 12 Install low and reverse brake driven drive plates and retaining plate then secure with snap ring Us...

Page 603: ...ickness Low and reverse brake clearance Standard 1 2 1 6 mm 0 047 0 063 in Allowable limit 3 0 mm 0 118 in Retaining plate of low reverse brake Check low reverse brake operation using air Thickness mm...

Page 604: ...priorto installingthe carrierset to the transaxle r 17 Install carrier set Front carrier assembly Rear carrier assembly Low clutch assembly SAT856 18 lnstall one way clutch assembly while rotating fr...

Page 605: ...bly Sun gear assembly SAT860 Transmission 20 Assemble reverse clutch and high clutch 21 lnstsll reverse and high clutph as a pack 22 Install brake band and anchor pin Temporarily tighten anchor bolt b...

Page 606: ...mm 3 921 in Specified total end play 0 25 0 55 mm 0 0098 0 0217 in Total end play can be adjusted with oil pump bearing races Available oil pump bearing races Refer to S D S I Clutch pack end play a...

Page 607: ...ss oncase SAT870 20 Adjust differential side bearing preload as follows a Remove left side bearing inner cone from transmission case b Measure dimension E from transmission case surface to the mating...

Page 608: ...nverter housing and place a straightedge on tools e Measure dimension F from straightedge to top of side bearing inner cone Clearance G E F 60 mm 2 36 in f Select shim s of appropriate thickness using...

Page 609: ...are self sealing bolts Apply A T F to thread of other bolts by that fix converter housing to transmission case when install ing them Bolt 0 0 0 0 0 63 0 0 28 Install 0 ring onto input shaft Tightenin...

Page 610: ...imension H and K between mating surface of side cover and fitting surface of bearing c Put bearing outer races on output gear and idler gear d Place Tool on transmission case and place a straightedge...

Page 611: ...ly A T F to thread of other bolts by that fix side cover to transmission case when installing them Bolts and 0 1 9 23 N m 1 9 2 3 kg m 14 17 ft lb Bolts and 0 21 23 N m 2 1 2 3 kg m 15 17 ft lb Identi...

Page 612: ...e reversed from the illustration Installthrottle shaft and return spring RL4F02A only 36 Insert manual valve to control valve body then assemble them to transmission case Bolt nl 3 7 5 0 Nom 0 38 0 5...

Page 613: ...case and install valve cover Always use new bolts as they are self sealing bolts lnstall throttle lever RL4F02A 39 lnstall control cylinder 40 lnstall revolution sensor RE4F02A only 41 lnstall govern...

Page 614: ...e converter to converter housing Be careful not to scratch front oil seal 45 Apply sealant to threads of drain plug and install it in place 46 Install inhibitor switch to transmission case 47 Adjust i...

Page 615: ...ate 1 Number of drive plates Number of driven plates Thicknessof drive plate mm in Standard Allowable limit Clearance mm in Standard Allowable limit Thicknessof retainingplate 3 5 2 0 0 079 1 8 0 071...

Page 616: ...tial side bearing adjusting shim Unit mm in I Part number 31429 21x00 3 1429 21X01 31429 21X02 31429 21x03 31429 21X04 31429 21x05 31429 21X06 0 4 0 8 mm 0 016 0 031 mm washer and planetarycarrier Sta...

Page 617: ...1 96 0 0772 Allowable clearancebetween side gear and differential case with washer Thickness mm in 0 75 0 80 0 0295 0 03 15 0 80 0 85 0 0315 0 0335 0 85 0 90 0 0335 0 0354 0 90 0 95 0 0354 0 0374 Par...

Page 618: ...late Numberof driven plates I 6 Numberof drive plates 5 4 4 1 4 1 8 0 055 0 071 2 6 0 102 1 6 0 039 1 4 0 055 I Clearance mm in Standard Allowable limit Thickness mm in 3 6 0 142 3 8 0 150 4 0 0 157 4...

Page 619: ...ndard Allowable limit E l Oil pump clearance mm in Cam ring oil pump cover Standard Allowable limit Rotor oil pump cover Standard Allowable limit Vane oil pump cover Standard Allowable limit Seal ring...

Page 620: ...AND DIFFERENTIALCASE WITH WASHER 0 1 0 2 mm 0 004 0 008 in 0 16 0 0063 31499 21X01 0 20 0 0079 31499 21X02 Idler gear preload adjusting shim I Thicknessmm in I Pannumber SlDE GEAR THRUST WASHER PARKIN...

Page 621: ...ELECTRICALCOMPONENTS...

Page 622: ...RONT AXLE FA 9 FRONT AXLE Wheel Hub and Knuckle FA 10 FRONT AXLE Drive Shaft FA 15 FRONT SUSPENSION FA 23 FRONT SUSPENSION Coil Spring and Strut Assembly FA 24 FRONT SUSPENSION Stabilizer Bar FA 26 FR...

Page 623: ...used they must be renewed Preparation SPECIAL SERVICE TOOLS Tool sup lier Litchfield I Tool number Tool name Description E2237 Balljoint remover Removing tie rod outer end and lower ball joint E2M1OF...

Page 624: ...adjustments Toe in 1 3 mm 0 04 0 12 in Totaltoe in 6 18 Strut mounting insulator assembly7 Front 2 6 3 6 18 26 Support bearing 4 2 5 2 30 38 1 3 1 9 9 14 1 6 2 2 12 16 118 147 12 15 87 108 When insta...

Page 625: ...Shake each front wheel 2 Retightenall nuts and bolts to the specified torque Tightening torque Refer to FA 23 3 Check front axle and front suspension parts for wear cracks or other damage Check strut...

Page 626: ...ts in designated positions PRELIMINARY INSPECTION 1 Check tires for wear and improper inflation 2 Check wheel runout 1 Alloy 0 5mm I 0 3mm 3 Check front wheel bearings for looseness 4 Check front susp...

Page 627: ...ve the adjusting pin Adjusting pin is factory installed with the flat portion facing down 2 Install adjusting pin with the flat portion facing up 3 Turn the adjusting pin to adjust Camber changes abou...

Page 628: ...L shouldbeapproximately equal L H to R H sides Maximumvariance 2mm 3 Tighten lock nuts then torque them Refer to ST section 1 3 0 04 0 12 6 18 FRONT WHEEL TURNING ANGLE 1 Set wheels in straight ahead...

Page 629: ...CHECK AND ADJUSTMENT Front Wheel Alignment Cont d 3 Adjust by stopper bolt if necessary Standardlength L 31 3mm Drive Shaft Check for grease leakage or other damage...

Page 630: ...p al 98 118 10 12 72 87 Cotter pin 0 CAUTION When replacing wheel bearing replace inner and outer wheel bearings at the same time t o prevent mix use of bearings of different brands install inner race...

Page 631: ...brake pedal or piston will pop out Make sure brake hose is not twisted Separate tie rod from knuckle with Tool Install stud nut conversely on stud bolt to prevent damage to stud bolt Loosendrive shaf...

Page 632: ...eel bearing from knuckle replace wheel bearing assembly outer race inner race and grease seals with new parts WHEEL HUB m DriveouthubwithinnerraceAfrom knucklewithtoolasshown m Refer to FRONT AXLE WHE...

Page 633: ...r cracks Check snap ring for wear or cracks Replace if necessary WHEEL BEARING GREASE SEAL Removalof wheel bearingand greaseseal necessitatesreplace ment with new parts Assembly 1 Install snap ring in...

Page 634: ...od A In cases where drive shaft is not removed from transaxle Spin knuckle several turns in both directions and then measure bearing preload If a loadof approximately49 kN 5tonne 5 5 USton 4 9 Impton...

Page 635: ...cedure 3 Spin wheel hub several turns in both direction and then measure bearing preload Rotation running torque 0 3 2 5 Nom 3 26 kg cm 2 6 22 6 in lb As measured at wheel bolt 5 10 44 62 N 0 52 4 55...

Page 636: ...removing drive shaft cover boots with waste cloth to prevent damage to them Refer to FRONT AXLE Wheel Hub and Knuckle For A T models remove left drive shaft after removing right drive shaft Caution W...

Page 637: ...aw Tool 4 L Hshaft Pushdrive shaft then press fit circularcliponthe driveshaft into circular clip groove of side gear m After its insertion try to pull the flange out of the slide joint by hand If it...

Page 638: ...1 4 1 22 30 rA 2s 3 I2 6 3 6 19 28 Ba careful not to damage boots Use suitable protector or cloth during removal and installation Support bearing retainer 0 13 19 1 3 1 9 9 14 I S n a p ring Do Dust...

Page 639: ...e cannot be disassembled Before separating joint assembly put matching marks on drive shaft and joint assembly Separate joint assembly with suitable tool Be careful not to damage threads on drive shaf...

Page 640: ...er damage Replace if necessary Check roller surfaces for scratches wear or other damage Replace if necessary 8 Check serration for deformation Replace if necessary 8 Check slide joint housing for any...

Page 641: ...y lightly tapping it with a hammer Install joint assembly securely ensuring that marks made during disassembly are properly aligned 3 Pack drive shaft with specified amount of grease Specified amount...

Page 642: ...aking sure the marks which were made during disassembly are properly aligned 3 Install new snap ring 4 Pack drive shaft with specified amount of grease Specified amount of grease 220 240 g 7 76 8 46 O...

Page 643: ...FRONT AXLE Drive Shaft S F A 6 1 8 Transaxle side Assembly Cont d SUPPORT BEARING a Press bearing into retainer a Press drive shaft into bearing a Install snap ring a Install new dust shields...

Page 644: ...ing final tightening needs to be carried out at curb weight with tires on ground R 39 54 4 0 5 5 29 40 Spacer 59 78 16 8 43 58 Strut insulator Lower rubber 11 4 16 2 62 117 Wheel bearing lock nut 235...

Page 645: ...e Do not remove piston rod lock nut on vehicle Put matching marks on strut lower bracket Disassembly 1 Set strut assemblyon vise with suitabletool then loosen piston1 rod lock nut Do not remove piston...

Page 646: ...cemented rubber to metal portion for melting or cracks Check rubber parts for deterioration THRUST SEAT Check for cracks deformation or other damage Replace if necessary COIL SPRING Check for cracks...

Page 647: ...Removal and Installation Remove stabilizer bar When installing stabilizer make sure that paint mark and clamp face in their correct directions When removing and installing stabilizer bar fix portion A...

Page 648: ...r to page FA 23 During installation final tightening must be carried out at curb weight with tires on the ground After installation check wheel alignment Refer to CHECK AND ADJUSTMENT Inspection Check...

Page 649: ...er boots with waste cloth so as not to damage them when removing drive shaft 6 Remove lower ball joint from knuckle with Tool Inspection Check ball joint for play If ball stud is worn play in axial di...

Page 650: ...tip on lower edge of brake caliper 3 Make sure front wheels are straight and brake pedal is depressed 4 Place a pry bar between transverse link and stopper road wheel 5 While raising and releasing pry...

Page 651: ...Oil capacity CC CA20E CA2OE KA24E Hydraulic 30 0 20 0 143 490k 3 1136 116 255 264 27 59 215 5 DRIVE SHAFT KA24E Applied model Bar diameter mm M T All 22 Wheel side M T A T L H 12 7 130 358 21 6 Red W...

Page 652: ...turn degree Insideloutside WHEEL BEARING CAPOE KA24E 195 65R14 0 25 to 1 05 0 25 to 2 05 13 25 15 05 1 3 0 04 0 12 6 18 34 38 27 31 22 20 200 Axial end play mm in Lock nut tightening torque N m kg m...

Page 653: ...AND PREPARATION RA 2 REAR AXLE AND REAR SUSPENSION RA 3 CHECK AND ADJUSTMENT RA 4 REAR AXLE AND REAR SUSPENSIONASSEMBLY RA 7 REAR AXLE Wheel Hub RA 8 REAR SUSPENSION RA 10 REAR SUSPENSION Coil andStru...

Page 654: ...s tension brake pipes and fittings to specified torques refer S D S When removing each suspension part check wheel align ment and adjust if necessary Do not jack up at the parallel links Where fitted...

Page 655: ...0 45 Vehicle requiresonly toe in adjustment 1 3 mm 0 04 0 12 in Wheel bearing m Axial end play 0 05 mmor less 4 3 5 5 31 40 6 0 8 0 43 58 Upper spring seat Front Front parallel link 0 41 47 4 2 4 8 3...

Page 656: ...n Parts Check axle and suspension parts for looseness wear or damage 1 Shake each rear wheel 2 Retighten all nuts and bolts to the specified torque Tightening torque Refer to RA 16 I Front 3 Check str...

Page 657: ...TION Make following checks Adjust repair or replace if necessary Check tires for wear and for improper inflation Check rear wheel bearings for looseness Check wheel runout 1 Steel Check that rear stru...

Page 658: ...nce A and B at the same height as hub center Toe in A B 1 3 mm 0 04 0 12 in 2 6 18 to 6 3 Adjust toe in by varying the lengths of rear parallel links a Adjust left and right rear parallel links to the...

Page 659: ...ne and parking brake cable at equalizer Remove suspension assembly one side 1 Remove parallel link fixing bolt radius rod fixing bolt stabilizer fixing bolt stabilizer connecting rod brackets and park...

Page 660: ...peration Wheelhubbearingdragsorturns roughlywhen hubisturned withyour handafter bearinglocknutistightenedtospecified torque After wheel hub bearing is removedfrom knuckles spindle Remove wheel bearing...

Page 661: ...allation Install wheel hub bearing Tighten wheel bearing lock nut m 186 255 N m 19 26 kg m 137 188 ft lb Check that wheel bearings operate smoothly Check wheel bearing axial end play Axial end play 0...

Page 662: ...pare tire jack hand tools and mats in designated positions CAUTION Do not jack up at the parallel links radius rods Strut cover ql 59 78 6 0 8 0 43 58 Strut mounting tube a 42 54 Spacer 4 3 5 5 31 40...

Page 663: ...n rod lock nut 2 Compress spring with tool as shown so that the strut mounting insulatorcan beturned by hand 3 Remove piston rod lock nu 4 Remove gland packing with Tool Avoid getting dirt and dust in...

Page 664: ...rber kit cartridge GLAND PACKING Check gland packing for oil leakage Replace gland packing if necessary INNER CYLINDER Check inner cylinder for cracks deformation or other dam age For inner cylinder d...

Page 665: ...Except shock absorber kit cartridge Use GENUINE STRUT FLUID or equivalent Oil capacity isvery important since performance of strutvaries with amount of fluid in strut Capacity 310 7cc Lubricate sealin...

Page 666: ...ly Assembly Cont d 1 0 1 5 Z O ft L Effective length of torque wrench FA280 Hepeat proceaures as snown ar IeTrj several rimes so rnat air will be thoroughly bled from strut Except shock ab sorber kit...

Page 667: ...REAR SUSPENSION Coil Spring and Strut Assembly Assembly Cont d After placing coil spring in position on lower spring seat release spring compressor gradually Lower spring seat...

Page 668: ...Springconstant N mm Identification color All CA20E KA24E M T A T 12 0 130 305 21 6 White Orange Model All Engine Strut type CA20E KA24E Hydraulic Piston rod diameter mm Inner cylinder bore dia mm Stro...

Page 669: ...d Adjustment STABILIZER BAR Eng ne Bar diameter mm WHEEL ALIGNMENT Unladen 1 Total toe in dearee 1 18 to 6 I CAPOE 15 Engine Camber degree Toe in mm Tank full of fuel radiator coolant engine oil full...

Page 670: ...EDAL AND BRACKET BRAKE BOOSTER VACUUM PIPING MASTER CYLINDER FRONT DlSC BRAKE CL25VA Caliper FRONT DlSC BRAKE CL25VA Rotor REAR DlSC BRAKE CL9H Caliper REAR DlSC BRAKE CL9H Rotor PARKING BRAKE CONTROL...

Page 671: ...e fluid a Never use mineral oils such as gasoline or kerosene They will ruin rubber parts of the hydraulic system Usesuitable tool when removing and installing brake tube Always tension brake pipes an...

Page 672: ...amaged parts If leakage occurs around joints retighten or if necessary replace damaged parts a Check for oil leakage by fully depressing brake pedal Changing Brake Fluid 1 Drain brake fluid from each...

Page 673: ...eeding Procedure CAUTION Carefully monitor brake fluld level at master cylinder during bleeding operation Fill reservoir with recommended brake fluld Make sure it is full at all times while bleeding a...

Page 674: ...e fluid comes out of air bleeder valve Removal and Installation 1 To remove brake hose first remove flare nut securing brake tube to hose then withdraw lock spring 2 Cover openings to prevent entrance...

Page 675: ...0 8 1 1 5 8 8 0 0 8 1 1 5 8 8 0 neplacc r l v i s pin if plastic stopper w r ch IS located at the end of clevis n deformed or damaged J N m kg m rr ib SBt c t3A Inspection Check brake pedal for the f...

Page 676: ...012 0 039 in A Pedal free play 1 3 mm 0 04 0 12 in 1 Adjust pedal free height with brake booster input rod Then tighten lock nut Make sure that tip of input rod stays inside 2 Adjust clearance C with...

Page 677: ...e is running and stop engine with pedal depressed If there is no change in pedal stroke after holding pedal down 30 seconds brake booster is airtight SBROOZA OUTPUT ROD LENGTH CHECK 1 Supply brake boo...

Page 678: ...BRAKE BOOSTER Inspection Cont d 3 Adjust rod length if necessary 4 If rod length is without specification replace brake booster...

Page 679: ...check valve SB R450A I __ U I Mora than 24 mm 0 94 in SBR004A Brake booster Intake manifold s de or vacuum pump side SBR202A Insert vacuum tube into vgcuum hose more than 24 mm 0 94 in Install check...

Page 680: ...UUM PIPING Manifold side Brake booster side SBR846 Inspection Cont d CHECK VALVE m When pressure is applied to brake booster side of check valve and valve does not open replace check valve with a new...

Page 681: ...se when assemblingmaster cylinder Dual proportioning valve Do not disassemble SBR451A SBROl l A Secondary piston SBROl2A m Replace stopper cap if claw is damaged or deformed m Bend claws inward when i...

Page 682: ...int m Rubber grease point m Brake fluid C1 N rn kgm ft lb SBR453A Pad Replacement 1 Remove pin bolt 2 Swing cylinder body upward Then remove pad and inner and outer shims CAUTION When cylinder body is...

Page 683: ...ecting bolt Install brake hose to caliper at protrusions securely Disassembly Push out piston with dust seal using compressed air Inspection INSPECTION OF BRAKE DRAG FORCE 1 Swing cvlinder body upward...

Page 684: ...Check Inside surface of cyllnder for scorlng rust wear damage or fore gnmater als Replace f any such cor ditior ex sts Ellmlnate mlnor damage from rust or forelgn mater a c pollshlng surface with flne...

Page 685: ...ng preload Check runout using a dial indicator Rotor repair limit Maximum runout Total indicator reading at center of rotor pad contact surface 0 07 mm 0 0028 in THICKNESS Measure thickness of brake d...

Page 686: ...FRONT DISC BRAKE CL25VA Caliper Notes...

Page 687: ...REAR DISC BRAKE CLSH Caliper Notes...

Page 688: ...iper Pad re Outer Brake hose connector contact area q 22 31 2 2 3 2 16 23 Pad retalner m L Piston boot pJ N m kgm ft lb m P B C Poly Butyl Cuprys l grease or silicon based grease point m Rubber grease...

Page 689: ...ylinder body by turn ing piston clockwise with service tool CAUTION Be careful not to damage piston boot or get oil on rotor Always replace shims when replacing pads Removal and Installation Dissconne...

Page 690: ...damage cylinder body 4 Remove return spring and lever Inspection CAUTION Use brake fluid to clean cylinder Never use mineral oil CYLINDER BODY m Check inside surface of cylinder for score rust wear d...

Page 691: ...N Piston sliding surface is plated Do not polish with emery paper even if rust or foreign matter is stuck to sliding surface PIN AND PIN BOOT Check for wear cracks or other damage Replace if any of th...

Page 692: ...REAR DISC BRAKE CLSH Caliper Press R n g B Spr ng Seat 4 SBR879 Assembly Cont d 4 Install seat spring spring cover and ring B with suitable press and drift...

Page 693: ...sure that axial end play is within the specifications before measuring Refer to section RA Then check runout with a dial indicator Rotor repair limit Maximum runout Total indicator reading at center o...

Page 694: ...console box Make sure there is no free play after installing Inspection 1 Check control lever for wear or other damage Replace if necessary 2 Check parking brake cables and lamp switch Replace if nece...

Page 695: ...y before carrying out the adjustment parking brake warning 1 1 Adjust control lever by turning adjusting nut Pull control lever with specified amount of force Check lever stroke and ensure smooth oper...

Page 696: ...X 0 87 Rear brake I Brake model I CL9H disc brake Cylinder bore diameter 33 96 1 3370 mm in Rotorouter diameter 1 258 10 16 mm in Liningor pad mm in LengthX width X thickness Mastercylinder I 75 X 40...

Page 697: ...A T Depressed height D mm in under force of 490 N 50 kg 110 Ib with engine running Clearance between switches and pedal stopper bracket C mm in Pedalfree play A mm in CL25VA 185 195 7 28 7 68 175 185...

Page 698: ...VEHICLE INSPECTION ON VEHICLE INSPECTION Power Steering STEERING WHEEL AND STEERING COLUMN MANUALSTEERINGGEAR AND LINKAGE POWER STEERINGGEAR AND LINKAGE POWER STEERINGOIL PUMP SERVICEDATA AND SPECIFI...

Page 699: ...ositions Use nylon cloths or paper towels to clean the parts common shopragscanleavelintthat might interferewiththeir operation Before inspection or reassembly carefully clean all parts with a general...

Page 700: ...et E9254A 1 E8802 6 Balljoint wrench Inner ball joint removal and installatidn E7110 1 Pinionplug socket Pinion plug removal and installation E7115 Angle Torque Gauge E8802 1 Yoke plug removal Yoke pl...

Page 701: ...y lnner seal installer Rack tube end bush Removing installing rack tube end bush E1404 Protector Rackprotection Tool number Oil pump attachment COMMERCIAL SERVICETOOLS Application Power steering model...

Page 702: ...rack is centred i e same number of turns to each side lock If not centre steeringrack a If it is not in the neutral position remove the steering wheei and re install it correctly in the neutral positi...

Page 703: ...Belt Inspection Checking Fluid Level Check the level when the fluid is cold CAUTION Do not overfill Recommended fluid is Automatic Transmission Fluid Dexron Type Checking Fluid Leakage Check the lines...

Page 704: ...ing noise inoil pump Excessivebuzzingin oil pump Whilethevehicleisstationary orwhile movingthe steeringwheel slowIy fluid noise may occur inthe valve or oil pump This noiseisinherentinthis steeringsys...

Page 705: ...pressure with steering wheel fully turned to left and right positions at 1 000 rpm CAUTION Do not hold the steering wheel in a locked position for more than 15 seconds Oil pump maximum standard pressu...

Page 706: ...ING WHEEL AND STEERING COLUMN Removal 3 0 4 0 22 29 m13 18 1 3 1 8 9 13 o 13 18 1 3 1 8 9 13 o N m kg m ft lb 0 35 0 45 2 5 3 3 STEERING WHEEL 1 Pull out horn pad l 2 Remove steering wheel with tool E...

Page 707: ...steering column fingertighten all lower bracket and clamp retaining bolts then tighten them se curely Do not apply undue stress to steering column When attaching coupling joint be sure tightening bolt...

Page 708: ...CAUTION After installing turn steering wheel to make sure it moves smoothly and that the number of turns from the straight forward position to left and right locks are equal When disassembling and ass...

Page 709: ...smoothly without binding 3 Return tilt lever to position 0 Make sure there is no free play O of steering column when steering wheel is pushed down by force 4 Install lock washer and E ring m Steering...

Page 710: ...ease or replace steering column as an assembly if necessary 2 Check jacket tube for deformation or breakage Replace if necessary When the vehicle is involved in a light collision check column length I...

Page 711: ...uckle arms with Tool Installation Initially tighten nut on tie rod outer socket and knuckle arm to 54 to 59 Nm 5 5 to 6 0 kg m 40 to 43 ft lb Tighten nut further to align nut groove with the first pin...

Page 712: ...the crimping 6 Remove inner ball joint assemblies using special tool Litch field No 8802 6 CAUTION When removing ball housings use an adjustable wrench on the flat teeth of the rack to prevent rotati...

Page 713: ...coring wear and damage Assembly 1 Placesteeringgear inasoft jawed vice or suitable fixture 2 Fit left hand rack bushingwith asuitable pieceof tube ensuring tabs on bushingare correctly located inhousi...

Page 714: ...wear and damage 10 Fillthe internal lip cavity of the pinion seal with grease and fit the seal over the pinionshaft intothe top of the pinion plug 11 Assemble ball housing to rack then using special t...

Page 715: ...RW Removaland Installation Front suspension member 10 0 40 72 Knuckle arm Power steerlng Low pressure s d e gear assembly 2 5 3 0 18 22 H gh pressureslde 8 6 11 0 62 80 g N m kg m ft lb Gear houslng c...

Page 716: ...ith a 4 mm drill to a depth sufficient to break the crimping 7 Before removing inner balljoint assemblies remove pinionend cover and loosen pinion lock nut 8 Remove inner ball joint assemblies usingsp...

Page 717: ...card 19 Using special tool E1401 tap out the seal and spacer from the inner end of the rack tube Discard seal and de burr the spacer which may have been marked during this removal 20 Drive out lower p...

Page 718: ...of the rack 6 Whilst holding R H end of rack slide rack end bush along the cover untilit clearsthe machinedshoulder at the endof the rack Remove cover 7 Gently tap end bush home into rack housing 8 U...

Page 719: ...tted to the vehicle 20 Fit lower pinion nut andtighten 40 45 Nm Fit lower pinion end cover and tighten 2 1 Loosenyoke plug 22 With rackinstraight aheadposition tightenyoke plugto 4 5 Nm ten back off 1...

Page 720: ...Pay attention to its direction 31 42 3 2 4 3 23 31 31 42 3 2 4 3 23 311 C1 N m kg m ft lb m Lubrication points With automatic transmission fluid Dexron Type R31 42 3 2 4 3 23 31 Pre disassembly Inspe...

Page 721: ...cautions in the Service Manual a When disassembling and reassembling do not let foreign matter enter or contact the parts a Remove snap ring then draw pulley shaft out Be careful not to drop pulley s...

Page 722: ...s and oil seal are properly installed m When assembling vanes to rotor rounded surfaces of vanes must face cam case side Always install new 0 rings and oil seal Be careful of oil seal direction Automa...

Page 723: ...TEERING OIL PUMP Front housing side Rear housing side B SST497A SST077B Assembly Cont d Insert pin into pin groove of front housing and rotor Then install cam ring as shown at left Install connector p...

Page 724: ...less Manual Steering STEERING COLUMN Power Steering Collapsible Tilt type Steeringcolumn length Piniongear and rackgear Powersteering 3 6 Steeringgeartype Tie rod outer balljoint swingingforce N kg I...

Page 725: ...ure kPa bat kg crn2 psi Unit N m kg m ft lb Steeringwheel nut 29 39 3 0 4 0 22 29 Lowerjoint to column 24 29 2 4 3 0 17 22 Lowerjoint to gear 24 29 2 4 3 0 17 22 Holecover to dash panel 8 10 0 8 1 O 5...

Page 726: ...Power Window INSTRUMENT PANEL INTERIOR AND EXTERIOR in EXTERIOR Including Weatherstrips SEAT WINDSHIELD AND WINDOWS MIRROR REAR COMBINATIONLAMP BODY ALIGNMENT BF 2 BF 6 When you readwiring diagrams R...

Page 727: ...protrude from parts When replacing any metal parts for example body outer panel members etc be sure to take rust prevention measures Clip and Fastener m Clips and fasteners in BF section correspond t...

Page 728: ...No I Symbol Clip and Fastener Cont d Shape Removal Installation Removal Tilt dip m indicatedby arrow then draw out Removal Remove by bendingup with flat bladed screwdrivers Removal Removal Push SBF02...

Page 729: ...ers or pliers Clip and Fastener Cont d I I Litchfieldtool No E7184 Removal Installation No Symbol Removal Holdbr portion of clip mud be spread out to remove rod I Shape Molded intogrille corners I I I...

Page 730: ...GENERAL SERVICING NOTE...

Page 731: ...pply a coat of grease to hood locks engaging mechanism Hood opener Do not attempt to bend cable forcibly Doing so increaseseffort required to unlock hood rBumper reinforcement After removingbumper ass...

Page 732: ...h fender At that time deflec After hood lock adjustment adjust bumper tion is approx 0 5 mm 0 020in rubber Bumper rubber free height is approx When securing hood lock ensure it does 22 0mm 0 866 in no...

Page 733: ...ystem adjustment Adjust striker so that it is in the center of the lock After adjustment check trunk lid lock operation Opener cable Do not attempt to bend cable using excessive force After installati...

Page 734: ...BODY END Body Rear End and Opener Cont d 6 lid lock Type l Fuel filler lid opener control After removing bumper assembly from body disassemble fascia and reinforcement Fascia SBFlOOE...

Page 735: ...side handle installation Door glass adjustment Door glass adjustment Adjust guide rail mounting position by rotating it Striker adjustment m Door inner panel Pawl L Inside handle Escutcheon a N m kg m...

Page 736: ...n adjuster as the clearance between outside handle At this time outside handle play is approx 2 mm 0 08 in Door inner panel 7 Pawl l 1 P Q Inside handle l p Pawl L n k m y Escutcheon Striker adjustmen...

Page 737: ...CIRCUIT BREAKER EARTH 34Ml SMJ CONNECTOR SEE LAST PAGE1 BATTERY yj R 4 Iz I LH REAR IFDc 9FDL LH FRONT MAIN SWITCH DOOR LOCK SW DOOR LOW SWITCH DRIVERS...

Page 738: ...e GOto TROUBLE SHOOTING PROCEDURE 1 PRIORITY SYMPTOM I I This trouble shooting must be applied accordingto priority Driver s door lock does not operate by this system HOW TO REPAIR L Either one or two...

Page 739: ...als and and 0 Check continuity betweenter and body ground minalaand body ground For auto door lock switch conti Auto door lock switch nuity should exist when Check continuity between and a and body Co...

Page 740: ...ing Cont d TROUBLE SHOOTING PROCEDURE 2 c 7 Disconnect door lock timer and actuator connectors B 4 N G Check continuity between ter r n g 1 timer and 1 actuator and timer and 2 actuator Repair harness...

Page 741: ...DOOR PowerWindow WIRING DIAGRAM...

Page 742: ...main switch harness connector HOW TO REPAIR GOto TROUBLE SHOOTING PROCEDURE 1 GOto TROUBLE SHOOTING CEDURE 2 Go to TROUBLE SHOOTING PROCEDURE 3 GOto TROUBLE SHOOTING PROCEDURE 4 Check harness continu...

Page 743: ...tor or ani body ground with p lo K L ignition switch ON Check fuse Body ground 12V Body ground 12V Blown L I O K J Reoai har 1 m nector I l 1 Disconnect main switch con R 1 Check continuity l ness bet...

Page 744: ...shooting Cont d TROUBLE SHOOTING PROCEDURE 3 I Disconnect inoperative window I sub switch connector I I m 1 Check voltage terminal and body ground with ignition switch ON 1 I Body ground 12V I I I O K...

Page 745: ...I Y M S qns aaeldat I MSqns y3aq3 3 0 1 El AZL punofi Apoa NO 43l MS UO I U I M pun0 6 Apoq pue t a eu wJai uaawaq ssau JO OW...

Page 746: ...PANEL When removing instrument panel assembly remove defroster grille combination meter AIC or heater control cluster lid C and S M J first Defroster grille t Instrument panel assembly mounting bolts...

Page 747: ...INSTRUMENT PANEL...

Page 748: ...cluster lid and pull firmly towards rear of car cluster lid is retained by metal spring clips at top edge to remove 8 Disconnect cigarette lighter wires and tilt cluster lid bottom edge up to disconne...

Page 749: ...wherefitted connector plugs are not reversedon reassembly 8 DisconnectSMJ located near fuse holder assembly 9 Remove glovebox left hand dash cover and glovebox support bar 10 Remove radio with mount b...

Page 750: ...INTERIOR AND EXTERIOR Interior SIDE AND FLOOR TRIM Passenger room Metal clip Metal clip Garnish...

Page 751: ...INTERIOR AND EXTERIOR Interior Cont d 1 Type I1 Door trim and remove it D screw 0 Plug...

Page 752: ...INTERIOR AND EXTERIOR Interior Cont d LUGGAGE ROOM TR lM Trunk space I 1...

Page 753: ...INTERIOR AND EXTERIOR Interior Cont d ROOF TRIM W n d s h e l d o r rear w n d o w glass garn sh Garnish...

Page 754: ...INTERIOR AND EXTERIOR Exterior Apply sealing compound where necessary while installing parts When applying sealing compound be careful that the sealing compound does not protrudefrom parts...

Page 755: ...ces Finish well to give it a good appearance Method 2 1 cut off sealant a t glass end Hood moldingand hood front seal 2 Clean the side on which panel was mounted 3 Set molding fastener and apply seala...

Page 756: ...ape I Removal 1 Heat molding portion to 30 to 40 C 86 to 104 F with a heat gun Heat gun SBF455A 2 Raise end of molding and while cutting off bondingagent detach molding Installation 1 Remove all trace...

Page 757: ...windshield upper molding Refer to Windshield upper molding Rear window lower molding It is mounted with screws Trunk lid weatherstrip Door outside rnolding Front door Door outer panel SBF114E Vehicle...

Page 758: ...SEAT BELT Front Seat Mounting...

Page 759: ...SEAT Rear Seat...

Page 760: ...mponent 1 If the vehicle has been involved in of a seat belt is questionable do an accident replacethe entire belt not repair seat belt but replace it assembly regardless of nature of as abeltassembly...

Page 761: ...Keep primers and sealant in a cool dry place Ideally they should be stored in a refrigerator WARNING Keep heat or open flames away a s Glass side primersare flammable o d y side CAUTION Be careful not...

Page 762: ...indshield More than 7 0 28 r X N C 5 C e P Rear window C m r Dam rubber l2 0 47 Unit mm ill SBF118E Set glass in position and press glass lightly and evenly I Check for water leakage CAUTION Windshiel...

Page 763: ...ks can be repaired without removing and reinstalling glass If water is leaking between caulking material and body or between glass and caulking material determine the extent of the leak b y applying w...

Page 764: ...MIRROR Door Mirror WIRING DIAGRAM...

Page 765: ...REAR COMBINATION LAMP Rear combination lamps are installed with nuts and butyl sealant I...

Page 766: ...asurements should be taken a t the center of the mounting holes An asterisk following the value a t the measuring point indicates that the measuring point on the other side is symmetrically the same v...

Page 767: ...BODY ALIGNMENT...

Page 768: ...16 1 1 0 43 11 0 43 8 0 31 2 7561 26 83 124 92 0 0 694 0 2400 0 00 2732 945 1 l l l 490 0 606 9 5150 1929 23 89 1 20 28 l Coordinates mm Y 30 0 1 181 260 0 10 24 527 0 20 75 635 0 25 00 I SBF085E SBF0...

Page 769: ...BODY ALIGNMENT MEASUREMENT 111 E 3 C v C c 2 5 E U B z m C U 0 U L C g E g C E m E u m w L a St Underbody a e...

Page 770: ...BODY ALIGNMENT Underbody Cont d MEASUREMENT POINTS...

Page 771: ...22 44 575 0 22 64 570 0 22 44 575 0 22 64 Front bumper mounting hole on underside of front side member Locating hole on underside of front side member center extension Locating hole on underside of fr...

Page 772: ...n sion mounting Front lower member on front suspen sionmounting lower member Transverse link 17 0 67 on dash lower 353 0 13 90 342 5 13 48 402 0 15 83 496 0 19 53 0 s 106 2 4 18 139 5 5 49 378 9 14 92...

Page 773: ...BODY ALIGNMENT Underbody Cont d Hole dia Coordinates mm in Points Detailed points Rear suspension...

Page 774: ...EFRIGERANT CONNECTION HA 9 DISCHARGING EVACUATING CHARG NG AND CHECKING HA 10 SERVICE PROCEDURES HA 16 A C PERFORMANCE TEST HA 20 ELECTRICALCOMPONENTS Inspection HA 26 TROUBLE DIAGNOSES HA 28 SERVICED...

Page 775: ...efroster Ventilation Intake lever A C switch Air control lever Floor and defroster Temperature L Fan lever control lever I r Bi level Defroster I I mT o ventilator T o defroster 1 Air passed through h...

Page 776: ...AYOUT I Component Layout Heater duct Heater Defroster ductC7 Center ventilator duct Air conditioner Control assembly Side ventilator ductC A C switch1 L Control finisher For removal it is necessary to...

Page 777: ...k control rod first disconnect temperature control cable from air mix door lever Re connect and readjust temperature control cable 1 Push air mix door lever in direction of arrow 2 Pull control rod of...

Page 778: ...OR START IGN S W ON OR ACC I F SMJ CONNECTOR SEE LAST PAGE1 IIREF FUSE POWER BLOCK SUPPLY 0 i B c m t 0 B 2 3 E i IGNITION SWITCH ON OR ACCESSORY RAD FAN MOTOR X I I 0 m 7 I l L 1 BLGWR RA0 FAN MOTOR...

Page 779: ...IGN S W ON O R START IGN S W ON OR ACC RAD FAN RELAY l SMJ CGWECTOR REF LAST PAGE 1 FUSE BLOCK d R CIO REF POWER SUPPLY1 rIGNITION SWITCH O N OR ACCESSORY I I IM RAD FAN MOTOR 12 HEATER SWITCH...

Page 780: ...charge refrigerant into system a 3 To discharge and charge refrigerant into Charge valve To discharge and charge refrigerant into system Thermometer To check temperature Vacuum pump Electric leak dete...

Page 781: ...e lack of oxygen m Keep refrigerant away from open flames because poison ous gas will be produced if it burns m Do not increase can temperature beyond 40 C 104OF in charging m Do not heat refrigerant...

Page 782: ...wrench After disconnecting tubes plug all openings immediately to prevent entrance of dirt and moisture Always replace used 0 rings When connecting tube apply compressor oil to portions shown in illu...

Page 783: ...ating the System Charging Charge refrigerant into system When low pressure gauge reading is 98 kPa 0 98 bar 1 0 kg cm2 14 psi completely close high pressure valve of rnani fold gauge and stop charging...

Page 784: ...valves of gauge and stop vacuum pump Let it stand for 5 to 10 minutes in this state and confirm that the reading does not rise a The low pressure gauge reads lower by 3 3 kPa 33 mbar 25 mmHg 0 98 inH...

Page 785: ...pletely close high pressure valve of manifold gauge and stop charging Evacuating the s t e r n m 1 Close manifold gauge valve securely and disconnect charg ing hose from refrigerant can 2 Connect cent...

Page 786: ...ing charged refrigerant with scale Overcharging will cause discharge pressure to rise Refrigerant amount 0 8 0 9 kg 1 8 2 0 Ib The state of the bubbles in sight glass should only be used for checking...

Page 787: ...seen Suitable High pressure side is hot and low pressure side is cold Almost transparent Bubbles may appear when engine speed is raised and lowered refrigerant is nearly gone lnsuff icient High pressu...

Page 788: ...f the fitting MEASUREMENT STANDARD If any leak is noted with a detector having a nominal sensitivity of 15 to 25 g 0 53 to 0 88 oz year that leak must be repaired The nominal sensitivity of the detect...

Page 789: ...o control amplifier interrupts the compressor operation When the evaporator coil temperature rises above the specification the thermo control amplifier allows compressor operation REFRIGERANT SYSTEM P...

Page 790: ...SERVICE PROCEDURES Refrigerant Lines High pressure Discharge service valve Cooling unit N m kg m ft lb RHA296A...

Page 791: ...er system has beenflushed with parts chargingamount refrigerant replace receiver drier Then pour in All oil cannot be drained from system 200 m 1of oil into air conditioner system CHECKINGAND ADJUSTIN...

Page 792: ...rainedis muchgreater than under normalcircum t i stances flush air conditioner system with refrigerant Then install new compressor 200 ml of oil is charged compressor service L parts l l Example 1 t U...

Page 793: ...r air conditioner starts operating More than 10 minutes TEST READING Recirculating to discharge air temperature table Ambient air temperature to compressor pressuretable I I Discharge air temperature...

Page 794: ...xpansion valve restricts refrigerant flow Expansion valve is clogged Expansion valve is in operative Valve stuck closed Thermal bulb has lost charge AC353A Corrective action 1 Leak test 2 Repair leak...

Page 795: ...ates around 39 kPa 0 39 bar 0 4 Expansionvalve allows too much refrigerant through evaporator Faulty expansion valve Air mixed with refrigerant in system Drier is saturated with moisture Moisture has...

Page 796: ...e remains high in spite of all above actions taken remove and inspect the condenser for possible oil clogging l HIGH PRESSURE LINE BLOCKED l n I Insufficient cooling Frosted high pressure liquid line...

Page 797: ...es Cont d Corrective action Refer to COMPRESSOR OIL for correcting oil level Probable cause Too much oil circulates with refrigerant causing the cooling capacity of the system to be reduced Condition...

Page 798: ...A C PERFORMANCE TEST Notes...

Page 799: ...Inspection BLOWER RESISTOR Check continuity between terminals FAN SWITCH Check continuity between terminals at each lever position shown in the table AIC SWITCH Check continuity between terminals at...

Page 800: ...3 Check thermo control amp operation shown in the table THERMAL PROTECTOR Evaporator outlet air temperature c Decreasing to 1 5 k0 7 Increasing to 2 8 k 0 3 Thermo amp operation Turn OFF Turn ON Temp...

Page 801: ...ir TROUBLE SHOOTING PROCEDURE 3 HA 34 INCIDENT Magnet clutch does not operate HOW TO READ SYMBOLS Symbolsare shown in the illustrations to clarify the checking conditions The checking conditions indic...

Page 802: ...PRELIMINARY CHECK PRELIMINARY CHECK Compressor belt tension check Check compressor belt deflection Adjust if belt deflection exceeds the limit Refer to Checking Drive Belts in MA section Power supply...

Page 803: ...control amp harness connector 2 Connect voltmeter from harness side 3 Measure voltage across terminal No and body ground Voltmeter terminal Voltage Body ground Approx 12V I Check body ground circuit...

Page 804: ...d 2 A Q x r F at left B r E Check power supply for blower motor B voltmeter Blower motor connector RHA30 A El ground Ohmmeter 0 K Blower motor connector Continuity exists O K v B Check blower motor ci...

Page 805: ...tor I 1 L O R B terminal and body ground tween each fan switch harness Flowchart Voltage O K a 3 7 4 1N G Note Check circuit continuity be tween fan switch and resistor I l Check fan switch after disc...

Page 806: ...onnect manifold gauge then check system pressures Measure temperature of dis charge air Refer to A C PERFORMANCE TEST 1 O K f Check air a mix door adjustment Check evaporator outlet air t e m N G C pe...

Page 807: ...1R A l A l Check power supply for compressor Disconnect compressor harness R H A I A connector Do approx 12 volts exist be tween compressor harness connector terminal No and body ground N G b v 0 l I...

Page 808: ...inal No and body Do approx 12 volts exist be ground tween A C relay harness terminals No 0and body O K ground Disconnect A C relay harness O K N G connector Check power supply and 10A fuse at fuse blo...

Page 809: ...y ground Ohmmeter O K Check power supply for thermo B O K Therrno control amp Go to Preliminary Check connector Check dual pressure switch O K Does continuity exist between Voltmeter N G Check refrige...

Page 810: ...and fan switch harness terminal No 1O K Note Check circuit continuity be tween fan switch harness terminal N o a a n d body ground O K r I Check fan switch Refer to A C ELECTRICAL COMPONENTS l Replac...

Page 811: ...ained Compressor Service parts charging amount DIESELKlKl DKV14C Vane rotary 140 8 54 Clockwise Viewedfrom drive end Poly V DIESELKlKl DKV14C FREOL D 9OPX 200 7 O Approx 100 3 5 200 7 0 REFRIGERANT In...

Page 812: ...AUGES WIPER AND WASHER HORN CIGARETTE LIGHTER AND REAR WINDOW DEMISTER REAR WINDOW DEMISTER AUDIO LOCATION OF ELECTRICALUNITS HARNESS LAYOUT SUPER MULTIPLEJUNCTION S M J WIRING DIAGRAM REFERENCE CHART...

Page 813: ...accidental looseness or disconnection The connector can be disconnected by pushing or lifting the locking section CAUTION Do not pull the harnesswhen disconnectingthe connector Example PUSH Terrn nal...

Page 814: ...closed and mixed type relays NORMAL OPEN RELAY Does not SW l BATTERY Flows SW 1 BATTERY SW 1 BATTERY NORMAL CLOSED RELAY Flows Does not flow MIXED TYPE RELAY Flows 1 BATTERY Does not SW 1 BATTERY Does...

Page 815: ...STANDARDIZED RELAY...

Page 816: ...l POWER SUPPLY ROUTING l Wiring Diagram...

Page 817: ...holder properly b Remove fuse for clock if vehicle is not used for a long period of time Fusible Link A melted fusible link can be detected either by visual inspection or by feeling with finger tip I...

Page 818: ...r motor from engine and ring gear Replace if necessary terminal of starter motor and battery a Check armature assembly field coil terminal to starter motor body and brush Yer Replace if necessary N G...

Page 819: ...TING SYSTEM IGNITION SWITCH ON OR START I SMJ CONNECTORS SEE LAST PAGE REF POWER SUPPLY1 G O W B R FUSIBLE LINKS G B R G G P 5z1 E g q MANUAL 128 1281 STARTER MOTOR EARTH y U INHIBIT SWITCH NEUTRAL Pr...

Page 820: ...movecover plateon ringgearandremoveplanetarygeartrain together with over runningclutchandfork leverfrom housingby gently tapping end of output shaft with soft mallet Inspect and put aside 7 To disasse...

Page 821: ...consists of a thermo set plastic with the detachable brush cages The brushes are manufactured from two 2 carbon compounds with the leading edge being of a harder brush compound Specialattention must...

Page 822: ...r seat of brush holders in anchor points lightly oil felt ring and insert in recess on commutator end of armature Placeend shield on shaft andset armaturelength playwith shim and fit clip Lightly grea...

Page 823: ...m PositiveCable Nut I 6 0 8 0 Nm SolenoidScrews Through Bolts Rear Cap Screws Lubrication Specifications Coarse thread of armature shaft Bosch Grease Part Number Helix of drive assembly 7 6 1 l O Nm 4...

Page 824: ...STARTING SYSTEM 1 Wiring Diagram...

Page 825: ...STARTING SYSTEM Starter Construction...

Page 826: ...STARTING SYSTEM S t a r t e r Construction Cont d...

Page 827: ...2 Remove harness clamps For A T model remove harness connectors from harness connector bracket 3 Remove starter cable from starter 4 Remove starter fixing bolts INSTALLATION a Installation is in reve...

Page 828: ...check condition of ring gear teeth 2 Check to see if pinion locks in one direction and rotates smoothly in the opposite direction If it does not lock or locks in either direction or unusual resistance...

Page 829: ...dirty clean Pole PieceCheck Mitsubishi type Pole piece is secured to yoke by bonding agent Check pole piece to see that it is secured to yoke and for any cracks Replace malfunctioning parts as an asse...

Page 830: ...en each commutator bar and shaft Continuity exists Replace 3 Check commutator surface Rough Sand lightly with No 500 600 sandpaper 4 Check diameter of commutator Commutator minimum diameter Refer to S...

Page 831: ...ION LENGTH ADJUSTMENT Hitachi With pinion driven out by magnetic switch push pinion back to remove slack and measure clearance Q between the front edge of the pinion and the pinion stopper Clearance Q...

Page 832: ...472 13 7 25 5 1 4 2 6 3 1 5 7 28 8 1 134 0 5 2 0 0 020 0 079 Minimum length of brush mm in Brush spring tension N kg Ib With new brush Minimum diameter of commutator mm in Clearance Q between pinion f...

Page 833: ...CHARGING SYSTEM ICAZOE 2 4 1 Wiring Diagram...

Page 834: ...CHARGING SYSTEM Alternator CAZOEI S c a S a m m t c c a C C 0 m m m c 2 a a am a 3 r n r n c o c o a...

Page 835: ...e claw poles and has its ends connected to the slip rings SUPPRCSSOR r I I l I I 0 REGULATOR I 1 OF 1 l I I X09 1 Fig I 9 diode alternator with built in regulator Connect on Current Anode Housing Anod...

Page 836: ...switctung off T2 and T1 w h c h are arranged In a Darlington pair With tlus s w t c h n gaction the cur rent flow through the exclter winding and T I to ground is interrupted With The alternator may o...

Page 837: ...Rectifier connections Power diodes test probes polarity whether the diodes are functioning properly If Apply test probes as described above diodes C B F C or E D are short to points B C D or E F G see...

Page 838: ...Applied Model Nominal rating V A Ground polarity Hot output current Alalternator rpm Regulated output voltage V Torque pulley nut Nm ft lb Through bolts Nm in lb B O S C CA2OE 12 70 Negative More tha...

Page 839: ...ainer 4 0 6 0 29 43 Front beer ng Diode assembly Q Q 0 32 0 40 2 3 2 9 Brush assembly q N m kg m ft lb SEL936J Rear bearing CAUTION Rear cover may be hard to remove becausea ring is used to lock outer...

Page 840: ...Replace rotor 2 lnsulator test m Continuity exists Replace rotor 3 Check slip ringfor wear Slip ring minimum outer diameter Refer to S D S Brush Check 1 Check smooth movement of brush m Not smooth Ch...

Page 841: ...or diode separate them by unsoldering the connectingwires CAUTION Use only as much heat as required to melt solder Otherwise diodeswill be damaged by excessive heat 1 Continuity test No continuity Rep...

Page 842: ...ositivediode plate SE L768D Continuity Yes No No Yes Ohmmeter probes SUB DIODES Attach ohmmeter s probe to each end of diode to check for continuity Continuity is N G Replace diode assembly Negative D...

Page 843: ...terminal WHEN SOLDERING BRUSH LEAD WIRE 1 Position brush so that it extends 10 5 to 11 5 mm 0 413 to 0 453 in from brush holder 2 Coil lead wire 1 5 times around terminal groove Solder out side of ter...

Page 844: ...cover push brush up with fingers and retain brush by inserting brush lift wire into brush lift hole from outside 2 After installing front and rear sides of alternator pull brush lift wire by pushing...

Page 845: ...der no load When 13 5 volts is applied rpm Hot output current Alrpm Regulatedoutput voltage V Minimum length of brush mm in Brush spring pressure N g 0 2 Slip ring minimum outer diameter mm in LR180 7...

Page 846: ...ghting switch and turn signal switch LIGHTING SWITCH WIPER SWITCH T U R N SIGNAL SWITCH VARIABLE INTERMITTENT WIPER VOLUME wherefitted HORN SWITCH E E NOTE Pin numbersare only for referenceto switchin...

Page 847: ...base Lighting switch SEL967K rotrusion guide SEL989C Replacement Each switch can be replaced without removing combination switch base To remove combination switch base remove base attaching screw and...

Page 848: ......

Page 849: ...HEADLAMP Wiring Diagram...

Page 850: ...as dust moisture smoke etc may enter the headlamp body and affect the performance of the headlamp Thus the headlamp bulb should not be removed from the headlamp reflector until just before a replacem...

Page 851: ...ust headlamps so that main axis of light is parallel to center line of body and is aligned with point P shown in illustration b Dotted lines in illustration show centre of headlamp H Horizontal center...

Page 852: ...I AITION SWITCH ON OR S T M T I STOP L A W SWITCH n RH COMBINATION LAW n STOP TAIL LAMP STDP TAIL LAMP I REVERS L A W...

Page 853: ...EXTERIOR LAMP Turn Signal and HazardWarning Lamps Wiring Diagram...

Page 854: ...sher Unit Check Before checking ensure that bulbs meet specifications Connect a battery and test lamp to the combination flasher unit as shown Combination flasher unit is properly func tioning if it b...

Page 855: ...INTERIOR LAMP IIlumination Wiring Diagram GL Models...

Page 856: ...N HEATER CONTROL A C SWITCH SHJ CONNCTOR SEE LAST PAGE aU ZN4ECTCn SEE LAST PAGE U O V E BOX CLOCK RR DEFDG SWITCH ILLWINATION IUUMINATION HAZARD WITCH ILLUMINATICN E T E R ILLUMINATION IUUMINAT ICN C...

Page 857: ...38W l H SEL987K Illumination Control Unit Check GHIA Model Connect as shown in figure at left If test lamp darkens when connecting terminal to battery 0 terminal and if test lamp brightens when conne...

Page 858: ...INTERIOR LAMP Interior Spot and Trunk Room LampsIWiring Diagram GL Model T 3 g W Q L 2 g U 8gl...

Page 859: ...REAR CMPARTPENT I REAR LH W O W SWITCH HEADLAMPS FRONT LH DOOR SWITCH REAR RH WoR SWITCH l SPOT FRONT STEP FRONT STEP REM STEP REAR STEP LAMP LAW LH LAW RH L W LH LAMP RH...

Page 860: ...METER AND GAUGES Combination Meter RearView of Combination Meter Plug 1 Plug 2 Plug 3...

Page 861: ...TER AND GAUGES Wiring Circuit Speedometer Tachometer Water Temp Clock FuelLevel Low Fuel ECM Lamp NOTE The circuit shown covers all models Ignorethe circuits which do not apply to the model in questio...

Page 862: ...M P S M M RELAY COMBINATION METER IB ILLUM GLOBES 3K IC 1 OXE D R I E R S DOOR W I T C H O l FR WT LH W D R ITCH l BRAKE PRESSWE PARK BRAKE L 0 r DIFFER W I T W SWITCH 8DO O I L P CHIME e...

Page 863: ...ides of S M J plug and pushfirmly Caution Take care to align connector and plug correctly 8 Tighten connector bolt and replacefuse cover Note The gauechecker E7126 can beusedby itselftotestfuel water...

Page 864: ...Check the resistance between the terminals of thermal trans mitter and body ground Oil Pressure Switch Check Check the continuity between the terminals of oil pressure switch and body ground Water te...

Page 865: ...METER AND GAUGES Vehicle Speed Sensor V S S To fault diagnose the vehicle speed sensor or sensor circuit refer section ES...

Page 866: ...R AND WASHER Wiper and WasherIWiring Diagram mONT WIPER SWITCH GHlA ONLY EARTH FUSE BLOCK 4 REF POYER SLPPLY I I I I I I I FRT WAS MOTCR LG 145E l33El EARTH I IGNITION SWITWLlN 5 4CC F R O G W 0 1 BA...

Page 867: ...then turn it OFF 4 Ensure that wiper blades stop within clearance C or D Clearance C 20 35 mm 0 79 1 38 in Clearance D 25 35 mm 0 98 1 38 in Tighten windshield wiper arm nuts to specified torque Fron...

Page 868: ...85 0 0335 SEL0881 From Check valve reservolr To nozzle D SEL411H Check Valve A check valve is provided in the washer fluid line Be careful not to connect check valve to washer tube in the wrong direct...

Page 869: ...HORN CIGARETTE LIGHTER AND REAR WINDOW DEMISTER Wiring Diagram...

Page 870: ...V1 0 volts SE L265 SE L266 Filament Check 1 Attach probe circuit tester in volt range to middle portion of each filament 2 If a filament is burned out circuit tester registers 0 or 12 volts 3 To loca...

Page 871: ...tive silver composition on break with drawing pen Slightly overlap existing heat wire on both sides preferably 5 mm 0 20 in of the break Heat wlre 4 After repair has been completed check repaired wire...

Page 872: ...AUDIO Wiring Diagram GL Model IIGNITION SWITCH ACCESSW OR ON I RH FRONT SPEAKER FUSE BLOW WA EARTH IREF POWER SUPPLY R G BR I B A m Y A N X W BR CASSETTE L R G...

Page 873: ...IGNITION SWITCH ACCESSORY OR ON G EARTH EARTH 9 9 2T RH FRONl SPEAKER LH FRONT SPEAKER SPEAKER RH REAR e SPEAKER LH REAR...

Page 874: ...relay Brown CA2OE engine Grey K A 2 4 E engine Fuel pump relay Green Horn relay Grey Radiator fan relay Blue Low speed Bulb check relay Blue iator fan relay 2 Brown High speed ECCS relay KA24E Green L...

Page 875: ...LOCATION OF ELECTRICALUNITS Passenger Compartment...

Page 876: ...HARNESSLAYOUT Main Harness GL Models For harness plug description refer page EL 69 EL 65...

Page 877: ...HARNESS LAYOUT Main Harness GL Models Cont d For harness plug description refer page EL 69...

Page 878: ...HARNESS LAYOUT Main Harness GHlA Models For harness plug description refer page EL 69 EL 67...

Page 879: ...HARNESSLAYOUT Main Harness GHlA Models Cont d For harness plug description refer page EL 69 EL 68...

Page 880: ...ESSR H ILLUMINATIONCONTROLUNlT E C C S HARNESS 80M 8 1M 82M 84M 85M 86M 87M 88M 89M 90M 9 1M 92M AUTOMATIC TRANSMISSIONDEVICE MODESWITCH HANDBRAKESWITCH FRONT DOOR SWITCH L H REAR DOOR HARNESSL H FRON...

Page 881: ...19G 20G 21G 22G MainHarness ECM ECM ECM Diagnostic Connector Air Flow Meter Radio Condenser IgnitionCoil Engine RoomHarness EngineRoom Harness OxygenSensor Distributor Earth Engine Earth Distributor I...

Page 882: ...HARNESS LAYOUT E C C S Harness KA24E Engine ManualVariant...

Page 883: ...GNITIONCOlL EARTH RESISTOR CONDENSOR DROP RESISTOR AUTO 38G THROTTLE VALVE SENSOR 39G ENGINE EARTH 40G ENGINE EARTH 50G 5 1G 52G 53G 54G 55G 56G 57G 58G 59G IDLESPEED CONTROLSOLENOID CRANK ANGLE SENSO...

Page 884: ...B 208 2 1B 22M 23M I TO SPEED SENDER TO OIL PRESSURE SWITCH TO ENGINE ROOMHARNESS TO ENGINE ROOMHARNESS TO ALTERNATOR TO ALTERNATOR TO THERMAL TRANSMITTER TO STARTER MOTOR TO INHIBITORSWITCH AUTO TO L...

Page 885: ...8 68 78 88 9B 100 llB 238 Automatic Transaxle TO E C C S HARNESS TO E C C S HARNESS TO E C C S HARNESS TO STARTER MOTOR TO SPEED SENDER TO OIL PRESSURE SWITCH TO OIL PRESSURE SWITCH TO INHIBITSWITCH T...

Page 886: ...HARNESS LAYOUT Engine Room Harness CA20E Engine...

Page 887: ...HARNESS LAYOUT Engine Room Harness KA24EEngine For harness plug description refer page EL 77 EL 76...

Page 888: ...47E FRONT TURN LAMP L H...

Page 889: ...lI INSTRUMENTHARNESS 21 ILLUMINATIONCONTROLSWITCH G L 31 ILLUMINATIONCONTROLSWITCH GHlA 51 REAR DEFOGSWITCH 71 HAZARD SWITCH 81 GLOVE BOX SWITCH 91 101 111 121 CLOCK EXCEPTGL METER l METER 2 METER 3...

Page 890: ...HARNESS TO SPEAKER TO MIRROR TO POWER WINDOW MOTOR TO POWER WINDOW ONETOUCH TO POWER WINDOW SWITCHAUTO TO STEP LAMP TO STEP LAMP TO DOOR UNLOCK SWITCH 12FD 13FD L H Front Door GHlA Model lFDL 2FDL 3F...

Page 891: ...UT Rear Door Harness GHIA Model Left hand shown right hand is the same 1RD 2RD 3RD 4RD 5RD 6RD TO MAIN HARNESS TO POWER WINDOW MOTOR RR TO POWER WINDOW SWITCH RR TO STEP LAMP TO STEP LAMP TO DOOR LOCK...

Page 892: ...HARNESS LAYOUT Room Lamp Harness I 1RL MAIN HARNESS Ii 1 ROOM LAMP MAP LAMP GHIA ONLY...

Page 893: ...T 9T 12T 16T 17T TO MAIN HARNESS EARTH TRUNK ROOM LAMP SWITCH REAR SPEAKER RH EXCEPTGL TRUNK ROOM LAMP HIGH MOUNTINGSTOP LAMP REAR SPEAKER LH EXCEPTGL REAR DOOR SWITCH LH TRUNK ROOM LAMP SWITCH REAR C...

Page 894: ...bolts until orange full tight mark appears and then retighten to specified torque as required tn 3 5N m 0 3 0 5 kg m 2 2 3 6 ft lb CAUTION Do not overtighten bolts otherwise they may be damaged Termin...

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