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Hyundai Sonata 1991, Shop Manual

The Hyundai Sonata 1991 Shop Manual is a comprehensive guide for owners looking to maintain or repair their vehicle. This manual covers all aspects of the car's servicing, with detailed instructions and diagrams. Available for free download from manualshive.com, this manual is essential for any Sonata owner.

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Summary of Contents for Sonata 1991

Page 1: ...HYUnCRI 1991 Shop Manual son...

Page 2: ...FOREWORD This shop manual is intended for use by service technicians of authorized Hyundai dealers to help them provide efficient and correct service and maintenance on Hyundai vehicle All the conten...

Page 3: ...HVunDR MOTOR COMPRnY Seoul Korea Printing APR 28 1990 Publication No YS 900406 Printed in Korea...

Page 4: ...GENERAL INFORMATION...

Page 5: ...epair for each possible cause is referenced in the remedy column to quickly lead you to the solution DEFINITION OF TERMS Standard Value Service standard YOOCBOA Indicates the value used as the standar...

Page 6: ...dentifier KMH Hyundai Motor Company s Passenger car 2HM Bromont Assembly Plant Canada 2 Line and drive type B Sonata LHD drive vehicle A Sonata RHO drive vehicle 3 Body type F 4 Door sedan 4 Series Bo...

Page 7: ...cylinder block ENGINE IDENTIFICATION NUMBER Engine identification number consists of 10 digits YOOCGOA TTTTT 1 2 3 4 5 1 Engine fuel G Gasoline G I 6 2 Engine range 4 In line 4 cycle 4 cylinder 3 Eng...

Page 8: ...g away The following precautions must be followed when jacking up the vehicle 1 Block wheels 2 Use only specified jacking positions 3 Support vehicle with safety stands rigid jacks Refer to the page 0...

Page 9: ...omplex requiring many parts to be disassembled all parts should be disassembled in a way that will not affect their performance or external appearance DISASSEMBLY YOOCNOA 2 Arrangement of parts All di...

Page 10: ...these parts should be replaced with new ones 1 Oil seals 2 Gaskets 3 a rings 4 Lock washers 5 Coller pins split pins 6 Plastic nuts Q o Depending on where they are 1 Sealant should be applied to gask...

Page 11: ...ire hazard To prevent this observe the following precautions and explain them to your customer 1 Use only unleaded gasoline 2 Avoid prolonged idling Avoid running the engine at fast idle speed for mor...

Page 12: ...ift Single post lift CAUTION 1 Never use a jack at the lateral rod or rear suspension assembly 2 In order to prevent scarring the centermember place a piece of cloth on the jack s contact surface to p...

Page 13: ...LUBRICATION AND II MAINTENANCE SCHEDULED MAINTENANCE TABLE 2 RECOMMENDED LUBRICANTS AND CAPACiTIES 6 MAINTENANCE SERViCE 7...

Page 14: ...36 48 60 72 84 96 MONTHS 5 10 20 30 40 50 60 70 EMISSION CONTROL ITEMS 1 ENGINE OIL AND FILTER R R R R R R R R 2 VALVE CLEARANCE JET VALVE ONLY I I I I 3 FUEL FILTER R 4 FUEL LINES AND CONNECTIONS I 5...

Page 15: ...requently C E SPARK PLUGS R Every 24 000 miles 40 000 km B H or 18 months BRAKE PADS CALIPERS ROTORS I More frequently C D G H REAR BRAKE DRUMS LININGS I More frequently C D G H STEERING GEAR RACK LIN...

Page 16: ...7 5 I 45 52 5 60 EMISSION CONTROL ITEMS 1 ENGINE OIL AND FILTER or every 6 months R R R R R R R R 2 JET VALVE CLEARANCE I I I I 3 FUEL FILTER R 4 FUEL LINES AND CONNECTIONS I 5 VACUUM CRANKCASE VENTIL...

Page 17: ...tly C E SPARK PLUGS R Every 24 000 miles 40 000 kml B H or 18 months BRAKE PADS CALIPERS ROTORS I More frequently C D G H REAR BRAKE DRUMS LININGS I More frequently C D G H STEERING GEAR RACK LINKAGE...

Page 18: ...de 2 or equivalent Coolant Ethylene glycol base for AI radiator Transaxle linkage parking SAE J310a Multipurpose grease brake cable mechanism hood NLGI grade 2 or equivalent lock and hook door latch s...

Page 19: ...ut oil filter 2 9 lit 3 06 U S qts 2 55 Imp qts With oil filter 3 3 lit 3 49 U S qts 2 90 Imp qts 5 Pull the dipstick out in order to check the oil level 6 Install the filler plug 7 Recheck the level...

Page 20: ...valve clearance adjustment is maintenance free For additional information regarding the auto lash adjuster refer to ENGINE section Jet Valve CAUTION 1 The cylinder head bolts should be retightened bef...

Page 21: ...it will not rotate and tighten locking nut No 1 No 2 No 3 No 4 Intake 10 Rotate the crankshaft one complete turn clockwise 360 degree 11 Check that valve clearance indicated in the diagram is at the...

Page 22: ...ncludes the air flow sensor CHECKING AND ADJUSTMENT OF V BELT TENSION Vl0EDOA COOLING SYSTEM Y10EFOA Check the cooling system for damaged hoses loose or seeping connections or other possible causes of...

Page 23: ...nt tighten the drain plug securely 6 Supply the coolant into the radiator until it is filled up to its filler neck 7 Supply the coolant into the reserve tank a After warming the engine until the therm...

Page 24: ...ij 7 zneclor 1 Check for damage or leakage in the fuel lines and connections 2 Inspect the surface or fuel hoses for heat and mechanical damage Hard and brittle rubber cracking checking tears cuts abr...

Page 25: ...as _ Fresh air _ Injector 4 Intake manifold 1 DisConnect the ventilation hose from the positive crankcase ventilation PCV valve Then remove PCV valve from the rocker cover and reconnect it to the vent...

Page 26: ...pipe 2 The overfill limiter 2 way valve installed on the vapor line between the canister inlet and fuel tank outlet should be checked for correct operation Air filter Fuel pump Filter Jr Fuel Filter F...

Page 27: ...has been corrected 1 Remove drain plug at differential bottom to let fluid drain 2 Place a drain container with large opening under the transaxle oil pan 3 Loosen oil pan bolts and tap pan at one cor...

Page 28: ...ck and service as required Y10 SOA Yl0ETOA 1 Inspect the belt for evidence of cuts and cracks Replace if necessary 2 Check belt for proper tension If necessary adjust the belt tension as follows 1 Pus...

Page 29: ...t leakage or contamination of the grease 2 Inspect the dust cover and boots for proper sealing leakage and damage Replace them if defective I J REAR WHEEL BEARINGS Inspect for grease leaks YlOEXOA Ins...

Page 30: ...ear Check the automatic brake adjusting system by hand to see if it operates smoothly Also see if the gears are in proper mesh with each other To assure smooth functioning apply a very thin coat of gr...

Page 31: ...Brake fluid DOT 3 or equivalent CHECKING OF THE TIRE INFLATION PRESSUE Check the Tire inflation Pressures as Follows Yl0FDOA TIRE INFLATION PRESSURE Check with Tires Cool Tire size Front Rear P185170...

Page 32: ...G BELT 26 ROCKER ARMS AND ROCKER ARM SHAFTS 33 CAMSHAFT 38 CYLINDER HEAD 39 VALVES AND VALVE SPRINGS 42 JET VALVE ASSEMBLy 47 FRONT CASE OIL PUMP AND COUNTER BALANCE SHAFT 50 PISTON AND CONNECTING ROD...

Page 33: ...ATDC Jet valve Opens BTDC Closes ABDC Valve overlap Intake valve duration Exhaust valve duration Jet valve duration Engine oil pressure At engine idle speed Compression pressure Between cylinder 20 2...

Page 34: ...m 0 744 0 745 in 0 01 0 04 mm 0 0004 0 0016 in Cogged type belt Cast iron Cam surface chilled 44 525 mm 1 753 in 33 935 33 950 mm 1 336 1 337 in 0 05 0 09 mm 0 0020 0 0035 in 0 1 0 2 mm 0 004 0 008 in...

Page 35: ...ERAL Specification 97 53 mm 3 840 in 4 3 mm 0 169 in 450 0 25 mm 0 0098 in 0 17 mm 0 0067 in 29 60 mm 1 165 in 3 5 kg 21 5 mm 7 7 Ib 0 846 in 1 50 Cogged type belt Steel 41 959 41 975 mm 1 6519 1 6526...

Page 36: ...al and pin Taper of journal and pin Oil clearance Main bearing journal Connecting rod journal Thrust taken by End play Bearings for service Connecting rod crankshaft Cylinder block Material Water jack...

Page 37: ...bolts 15 18 150 180 11 13 Oil filter 11 13 110 130 8 0 9 4 Oil filter bracket bolt 15 22 150 220 11 16 Oil pressure switch or gauge unit 7 8 12 80 120 5 8 8 7 Oil pan bolt 5 9 7 8 60 80 4 3 5 8 Oil pa...

Page 38: ...oil seal installer GENERAL Illustration Y20CCOA Use Removal of front bearing of counter bal ance shaft Removal of rear bearing of counter bal ance shaft use with 09212 32300 Installation of counter b...

Page 39: ...rankshaft rear oil seal installer 20 8 Use as a guide when pressing in the camshaft oil seal use with 09221 21000 1 Removal and installation of the intake or exhaust valve 2 Compression of spring when...

Page 40: ...6 32300 Leak down tester 09260 32000 Oil pressure switch wrench GENERAL Illustration Use Removal and installation of the piston pin Retaining of auto lash adjuster Air bleeding of auto lash adjuster u...

Page 41: ...screw Worn rocker face Worn valve guide Weakened valve spring Seized valve Cylinder head gasket blown Piston ring worn or damaged Piston or cylinder worn Valve seat worn or damaged Engine oil level t...

Page 42: ...ient oil supply Thin or diluted engine oil Excessive bearing clearance Shortage of engine oil Low oil pressure Poor quality engine oil Worn or out of round crankshaft journal Clogged oil passage in cr...

Page 43: ...to Page 20 13 2 Checking Air Filter Refer to Page 28 4 3 Checking Drive Belt Refer to Page 25 7 4 Checking Battery Refer to Page 27 17 5 Checking Spark Plugs Refer to page 27 35 6 Checking High Tensio...

Page 44: ...1 000 kg cm 65 72 Ib ft Hot At engine temperature is approximately 80 C 176 F 98 108 Nm 1 000 1 100 kg cm 72 80 Ib ft TIGHTENING CYLINDER HEAD BOLTS Y20CFOA 09221 32001 2 Be sure to follow the specif...

Page 45: ...CC OR SG Recommended SAE viscosity grades Y20CHOA Temperature range anticipated before Recommended SAE viscosity number next oil change 16 60 o 32 20W 50 10W 40 50 5W 20 40 40 20 30 20 23 10 1 Restric...

Page 46: ...il level Add oil if necessary All Hyundai Motor Company engines are equipped with high quality throw away oil filter This filter is recommended as a replacement filter on all vehicles The quality of r...

Page 47: ...hot engine 0 25 mm 0 010 in Timing mark Timing mark on camshaft sprocket on cylinder head 20Y007 Intake valve side NO 4 No 3 NO 2 NO 1 8 If jet valve clearance is not within specifications loosen roc...

Page 48: ...Timing mark C m h sprocket I 20Y012 4 Remove the two access covers These are easily removed by inserting a screwdriver into the slots from the direction of the embossed arrow and pry 5 Loosen the timi...

Page 49: ...sition Insert the screwdriver here 20Y015 20Y016 III Timing belt 1 l tensioner 8 First tighten the timing belt tensioner mounting bolt lower side and then tighten the mounting nut upper side CAUTION B...

Page 50: ...with your finger in the direction of the arrow place pressure on the timing belt so that the tension side of the belt is strerhed tight Now tighten the bolt to secure the tensioner CAUTION When tighte...

Page 51: ...nsaxle mounting bracket 29 39 300 400 22 29 Front roll stopper Engine mounting bracket 49 64 500 650 36 47 29 39 300 400 22 29 59 78 600 800 43 58 39 49 400 500 29 36 Rear roll stopper Crossmember Cen...

Page 52: ...bolts 2 Remove the engine mount bracket from the engine Transaxle Mounting 1 Remove the transaxle mount bolt Y20DAOA 2 Remove the plugs from the inside of the right fender shield and remove the remain...

Page 53: ...per roll stopper the rear member the bolt from f m the cross 1 Remove II stopper ro h rear ro Remove t e 2 INSPECTION ITEMS I mount Transax e One mount Eng 20Y028 er assembly Rear roll stopp er assemb...

Page 54: ...pill any of the oil or fluid out of the hoses plug the opening to prevent the entrance of foreign material 7 Disconnect the radiator upper and lower hoses on the engine side and then remove the radiat...

Page 55: ...the exhaust pipe from the bottom of the vehicle 24 Remove the lower arm ball joint bolts and the stabilizer bar at the point where it is mounted to the lower arm 25 Remove the drive shafts from the tr...

Page 56: ...portions and temporarily hold it in the raised condition CAUTION Confirm that all of the cables hoses harnesses connec tors etc are disconnected from the engine 33 Remove the blind plugs from the ins...

Page 57: ...1 14 49 59 500 600 36 43 Gasket Access cover Gasket Damper pulley 42 54 430 550 31 401 Tensioner spacer Timing belt front upper cover Tensioner spring 78 98 800 1 000 58 72 I Camshaft sprocket Timing...

Page 58: ...have a shaft 8 mm 0 3 in in diameter which can be inserted more than 60 mm 2 36 in 8 Remove the oil pump sprocket retaining nut and remove the oil pump sprocket 20Y040 Spring end Nut Fr L Bolt Screwd...

Page 59: ...and unclear canvas texture Last stage Canvas on load side tooth flank worn down and rubber exposed tooth width reduced 8 Missing tooth Separation Rounded belt side Abnormal wear Fluffy canvas fiber I...

Page 60: ...tion of flange If it is installed in wrong direction a broken belt could result 7 Install special washer and sprocket bolt to crankshaft and then tighten the sprocket bolt Tightening torque Crankshaft...

Page 61: ...ne 4 Align timing mark on the right counter balance shaft sprocket with the timing mark on the front case 5 Lift tensioner B to tighten timing belt B so that its tension side will be pulled tight In t...

Page 62: ...5 Timing mark punch on sprocket Timing mark notch in sprocket 20Y056 12 When timing mark on oil pump pulley is aligned with the timing mark on front case be sure to remove plug on left side of cylinde...

Page 63: ...tened earlier tension bracket will be turned together and belt will be overtensioned 17 Check to ensure that timing marks on all sprockets are in alignment with respective timing marks 18 Turn the cra...

Page 64: ...aft Adjusting screw 19 21 1190 210 14 1511 _ 7 8 9 8 180 100 5 8 7 2 20 26 200 270 14 20 if 7 l 2J RearbearingCap 1 i v 0 l l Fmnt bea n cap ROCke a m 8 Rocker arm D 0 Bearing cap No 4 Rocke a m C o j...

Page 65: ...ted several times replace the auto lash adjuster CAUTION The fully bleed auto lash adjuster should be held in an up right position to make sure that the Diesel fuel in the adjuster is not spilled Use...

Page 66: ...ny abnormal noise with the engine idling at normal operating temperature 2 If there is abnormal noise there may be a malfunction of the auto lash adjuster s air bleeding Bleed the air from the auto la...

Page 67: ...0GCOA Rocker Arms 1 Check rocker arms for wear or damage Replace if necessary 2 Check to ensure that oil holes are clear Oil hole 20Y066 Rocker Arm Shafts Oil holes _6 01 I Rocker arm mounting portion...

Page 68: ...Rocker Cover When rocker cover is installed apply sealant to semi circular packing and cylinder head top surfaces Sealant Rocker cover Three bond No 10 or equivalent CAUTION Make sure that rocker cov...

Page 69: ...owing areas of camshaft are badly worn or damaged replace 1 Journals 2 Cam lobes 3 Fuel pump drive dam 4 Distributor drive gear teeth 5 Oil seal contacting surface 2 If camshaft bearings are badly wor...

Page 70: ...14 Exhaust manifold Exhaust manifold gasket Cylinder head bolt Cold engine 88 98 900 1000 65 72 Hot engine 98 108 1000 1 100 72 82 Intake manifold gasket Cylinder head Cylinder head gasket Intake mani...

Page 71: ...mpressed air to make certain that the passages are not clogged 2 Visually check the cylinder head for cracks damage or water leakage 3 Check the cylinder head gasket surface for flatness with a straig...

Page 72: ...inder head bolts Cold At engine coolant temperature is approximately 20 C 68 F 88 98 Nm 900 1 000 kg cm 65 72 Ib ft Hot At engine coolant temperature is approximately 80 C 176 F 98 108 Nm 1 000 1 100...

Page 73: ...OMPONENTS Exhaust valve Exhaust valve seat Cylinder head e Intake valve guide Jetvalve assembly 18 22 180 220 13 16 v Intake valve seat Intakeval Retainer Retainer lock seal sp ng l Spring seat e Exha...

Page 74: ...2OJBOA A Check the valve stem to guide clearance If the clearance exceeds the service limit replace the valve guide with newover size part Size mm in Size mark Cylinder head hole size mm in Valve Guid...

Page 75: ...ss Max 4 Offset 1 5 1 IFree height _J 20Y085 Valve Seat Reconditioning 1 When correcting check valve guide for wear Replace worn guide and then correct seat ring 2 To correct valve seat use Valve Seat...

Page 76: ...Avoid insertion valve into seal with excessive force After insertion check to see if valve moves smoothly 4 Valve springs should be installed with the enamel coated side toward the valve spring retain...

Page 77: ...er head by hand Tighten the jet valve to the specified torque with special tool 09222 21300 and a torque wrench while holding the spe cial tool in line with the the centerline of jet valve Tightening...

Page 78: ...ft 20Y093 REMOVAL Y20KAOA 1 Remove the valve spring retainer lock using the special tool 09222 21400 2 Remove the valve spring retainer and valve spring CAUTION Do not mix up the combination of the j...

Page 79: ...5 mm 7 7 Ib 0 846 in 1 Using special tool 09222 21500 install the stem seal 2 Apply engine oil to the jet valve stem when installing it to the jet body Take care not to damage the valve stem seal lip...

Page 80: ...shaft clockwise and align with camshaft sprocket timing mark 7 Check that valve clearance indicated in the diagram is at the standard value JET VALVE CLEARANCE ADJUSTMENT Y20KDOA Exhaust No 1 No 2 No...

Page 81: ...11 13 110 130 8 0 9 4 Oil filter Oil filter bracket Gasket 15 22 150 220 11 16 Front case gasket Oil pump driven gear Oil pump drive gear Front case Oil plug cap Relief plug 39 49 400 500 29 36 Gasket...

Page 82: ...the oil filter bracket 5 Remove the four bracket securing bolts and remove the oil filter bracket and gasket 6 Remove the oil plug cap from the oil pump portion of front case 7 Remove the left side c...

Page 83: ...lace front case assembly 2 Check the oil passage of front case and oil pump cover for clogging and clean if necessary Counter Balance Shaft Check journals for wear or seizure If excessive wear or seiz...

Page 84: ...aft rear bearing from cylinder block At this time install special tool 09212 32300 on front surface of cylin der block to hold bearing puller 3 Using special tool 09212 32200 install left counter bal...

Page 85: ...has a conical periphery Install guide so that its smaller diameter end will face front of engine NOTE If crankshaft front oil seal is already mounted to front case use this special tool 09214 32100 fo...

Page 86: ...mm in Also tighten tensioner 20Yl20 11 Install the relief plug and gasket and tighten plug 12 Install the oil screen and gasket 13 Clean gasket surfaces of cylinder block and oil pan 14 Apply sealant...

Page 87: ...TING ROD COMPONENTS No 1 piston r i n g Q No 2 piston r i n g Q Oil ring Piston 4 Piston pin Connecting rod jllil Piston and connecting rod assembl I l Bearing connecting rod cap i 49 51 500 520 36 38...

Page 88: ...through the hole in the arch of the tool CAUTION Center the piston rod and pin assembly with the removal arbor 4 Press the piston pin out of the connecting rod Support fork_ Universal fork 20Y242 Remo...

Page 89: ...he sleeve on the installing arbor contacts the top of the tool arch The pin guide will fall out of the connecting rod as the piston pin is pressed in CAUTION Do not exceed 5000 pounds of force when st...

Page 90: ...ation mark of connecting rod are directed toward front of engine 10 When connecting rod cap is installed make sure that cylin der numbers put on rod and cap at disassembly match 11 When new connecting...

Page 91: ...PISTON AND CONNECTING ROD Connecting rod cap Bearing clearance 0 02 0 05 mm 0 0008 0 0020 in 14 Check connecting rod side clearance Side clearance 0 10 0 25 mm 0 004 0 010 in 20 60...

Page 92: ...ate 127 137 1 300 1 400 94 101 For A T Ring gear I Crankshaft bushing For MIT h f Bell housing cover Oil seal case Rear plate 10 12 100 120 7 2 8 7 Gasket 0 1 seal Oil separator _Crankshaft Lowerbeari...

Page 93: ...pins for damage uneven wear and cracks Also check oil holes for clogging Correct or replace any defective part 2 Inspect out of roundness and taper of crankshaft journal and pin INSPECTION Crankshaft...

Page 94: ...ven after bearing replacement the journal and pin should be ground to undersize and a bearing of the same size should be installed Oil Seal Check front and rear oil seals for damage or worn lips Repla...

Page 95: ...cial tool 09231 32000 install oil seal in oil seal case 09231 32000 20Y144 Oil seal case Oil pan mounting surface 10 With 4 mm 0 16 in diameter oil hole in the lower position oil pan mounting surface...

Page 96: ...ark Tightening torque Flywheel bolts 127 137 Nm 1 300 1 400 kg cm 94 101 Ib ft Runout 0 1 mm 0 004 in max 20Y146 14 With an Automatic Transaxle install adapter and drive plate and tighten bolts to spe...

Page 97: ...ft For further details refer to the respective chapters Level 1 No 1 piston ring position with piston at TOC Level 2 Center of cylinder Level 3 Bottom of cylinder 1 Visually check the cylinder block f...

Page 98: ...ze keep the specified clearance between the oversize piston and the bore and make sure that all pistons used are of the same oversize The standard measurement of the piston outside diameter is taken a...

Page 99: ...in clearance between 0 0 and cylinder 0 02 mm 0 008 in honing margin 4 Hone each of the cylinders to the calculated size CAUTION To prevent distortion that may result from temperature rise during hon...

Page 100: ...idle switch is good It switch is good check lamp and wiring Oil pressure switch operation pressure 20 39 kPa 0 2 0 4 kg cm2 2 9 5 7 psi Oil Pressure Sender Assy 1 Since bimetal type has constructiona...

Page 101: ...COOLING SYSTEM GENERAL 2 COOLING SySTEM 8 RADIATOR 10 RADIATOR FAN MOTOR ASSY 12 WATER PUMP 14 THERMOSTAT 16 WATER HOSE AND PiPE 17 WATER TEMPERATURE GAUGE UNIT AND SENSOR 18...

Page 102: ...radiator Type Operating temperature OFF ON ON OFF Coolant concentration 25 2 GENERAL Water cooling forced circulation with electric fan 7 0 lit 7 4 U S qts 6 2 Imp qts Wax pellet type with jiggle valv...

Page 103: ...ernator support bolt 20 25 200 250 14 18 Alternator brace bolt 12 15 120 150 8 7 11 Water pump to cylinder block bolt Head mark 4 bolt 12 15 120 150 8 7 11 Head mark 7 bolt 20 26 200 270 14 20 Water p...

Page 104: ...ature Faulty radiator cap Replace Restriction of flow in cooling system Replace Loose or missing drive belt Adjust or replace Faulty water pump Replace Faulty temperature gauge or wiring Repair or rep...

Page 105: ...e filler neck of the radiator 4 If there is leakage repair or replace the appropriate part Radiator cap tester 25YOOl RADIATOR CAP PRESSURE TEST Y25CHOA 1 Use an adapter to attach the cap to the teste...

Page 106: ...7 1 070 42 44 37 35 55 1 103 1 098 1 092 1 084 1 076 50 58 45 49 60 Example The safe operating temperature is 15 C 5 F when the measured specific gravity is 1 058 at coolant temperature of 20 C 68 F C...

Page 107: ...pe NIPPONDENSO BTG 2 Type Measuring Method 1 Press down on the tension gauge handle and insert the belt between the spindle and hook of the gauge 2 Release the handle and read the measurement on the g...

Page 108: ...COOLING SYSTEM COMPONENTS Cold Engine Hot Engine 25 8 Radiator Radiator COOLING SYSTEM Thermostat closed Water pump Thermostat opened Water pump 25YOO7...

Page 109: ...damage peeling or cracks 2 Check the belt surface for oil or grease 3 Check the rubber for worn or hardened areas 4 Check the surface of the pulley for cracks or damage Installation 1 Install the wate...

Page 110: ...cap Radiator upper hose Radiator fan motor connector Thermo sensor A 20 25 200 250 14 18 e 1 J _ Radiator lower hose Drain plug Lower insulator ri I 1 __ fr Reserve tank Thermo sensor B 20 25 200 250...

Page 111: ...motor 8 Remove the fan motor from the radiator 25Y011 INSPECTION Y25EBOA 1 Check for foreign material between radiator fins 2 Check the radiator fins for damage and straighten if necessary 3 Check the...

Page 112: ...ud 4 Remove the fan motor mounting bolts and detach the fan motor from the shroud 5 Detach the cooling fan from the fan motor by removing the clip Fan mounting clip Fan JIII Shroud lI1 REMOVAL INSPECT...

Page 113: ...4 L 1 Water temperature OFF 83 C 90 3 C 25Y020 Thermo Sensor B Operating temperature OFF ON 108 C or more 226 F or more ON OFF 112 118 C 234 244 F INSTALLATION Y25GCOA OFF ON 1 OFF 7 I I Water ON 108...

Page 114: ...WATER PUMP COMPONENTS Timing belt 7 8 9 8 80 100 5 8 7 2 Drive belt Power steering Water pump pulley Water pump pulley Power steering Drive belt Timing belt B TORQUE Nm kg em Ib ft 25 14 Water pump ga...

Page 115: ...leakage If water leaks from hole A seal unit is defective Replace water pump assembly 25Y023 INSTALLATION Y25HCOA L 20 0 79 L 30 1 18 1 Clean the gasket surfaces of the water pump body and the cylinde...

Page 116: ...3 Remove the thermostat 4 Heat the thermostat as shown in the illustration 5 Check to see if the valve operates properly 6 Check to determine the temperature at which the valve begins to open INSTALLA...

Page 117: ...S Connection for heater hose O ring Water inlet pipe 12 15 120 150 8 7 11 Connection for radiator lower hose TORQUE Nm kg em Ib ft 25Y028 INSPECTION Y25JAOA Check the water pipe and hose for cracks da...

Page 118: ...9 REMOVAL YB25KBOA 1 Drain the coolant down to the gauge unit level or below 2 Disconnect the battery ground cable 3 Remove the coolant temperature gauge unit sensor INSPECTION Y25KBOB Water Temperatu...

Page 119: ...eaded portion and tighten to the specified torque Water temperature gauge unit LOCTITE 962T or equivalent Water temperature sensor LOCTITE 962T or equivalent INSTALLATION Y25KCOB Li ant Tightening tor...

Page 120: ...ENGINE ELECTRICAL SYSTEM GENERAL 2 CHARGING SySTEM 4 STARTING SySTEM 22 IGNITION SySTEM 32 AUTOMATIC SPEED CONTROL CRUISE SySTEM 42 I...

Page 121: ...nder No 3 cylinder No 4 cylinder Contact pointless type 00 900 0 50 1800 0 50 2700 0 50 1 3 4 2 Controlled by electronic control unit 1EDOO31A MAN DO TO01542170 MELCO Mold coil 0 8 0 08 fl 12 1 1 21 K...

Page 122: ...48 AH 60 AH CANADA MF68 AH 540 A 122 min 1270 0 01 55 AH 68 AH NOTE 1 COLD CRANK AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal voltage of 7 2 or greater at a s...

Page 123: ...edy Charging warning Fuse blown Check fuses indicator does not Lamp burned Replace lamp light with ignition out switch ON and Wiring connection loose Tighten loose connections engine off Electronic vo...

Page 124: ...eason is that while checking a vehicle that has low output current due to a poor connection of the alternator B terminal when the terminal is loosened and a test ammeter is connected the poor connecti...

Page 125: ...2 Check the tension of the alternator drive belt 2 Turn off the ignition switch 3 Disconnect the battery ground cable 4 Disconnect the alternator output wire from the alternator B terminal 5 Connect a...

Page 126: ...k it Limit value 53A min 75A alternator NOTE The nominal output current value is shown on the nameplate affixed to the alternator body 2 The output current value changes with the electrical load and t...

Page 127: ...5 Disconnect the alternator output wire from the alternator B terminal 6 Connect a DC ammeter 0 to 1ooA in series between the B terminal and the disconnected output wire Connect the lead wire of the a...

Page 128: ...68 13 9 14 9 60 140 13 4 14 6 80 176 13 1 14 5 2 After the test lower the engine speed to idle speed and turn the ignition switch to OFF 3 Disconnect the battery ground cable 4 Remove the test voltmet...

Page 129: ...ot disconnect the oil pump hose 1 Remove the installation bolt of the power steering oil pump and hold the oil pump above the engine mount bracket Use rags etc to prevent scarring or scratching of the...

Page 130: ...CHARGING SYSTEM COMPONENTS Pulley Front bearing Bearing retainer Seal Rotor assembly Rear bracket Rectifier Slinger Brush spring Plate Voltage regulator and brush holder Terminal Stator 27 11...

Page 131: ...ear cover heat the bearing section with a 200 watt soldering iron Do not use a heat gun as it may damage the diode assembly 3 Secure the rotor in a vise with the pulley side up 21Y023 Bearing box 27Y0...

Page 132: ...tifier from the brush holder unsolder the two plates soldered to the rectifier Plate L fJ Plate B 1 Check the rotor coil for continuity Check to ensure that there is continuity between the slip rings...

Page 133: ...ween the positive rectifier and stator coil lead connection terminal with a ohmmeter The ohmmeter should rear continuity in only one direction If there is continuity in both directions diode is shorte...

Page 134: ...T CHARGING SYSTEM Y27BLOA Replace the brush by the following procedures if it has been worn to limit line BRUSH REPLACEMENT Y278MOA 0 l W imitline 2 Unsolder pigtail and remove old brush and spring 3...

Page 135: ...rse procedure of disassembly pay atten tion to the followings Before rotor is attached to rear bracket insert wire through small hole made in rear bracket to lock the brushs After the rotor has been i...

Page 136: ...age such as cracked or broken case or cover that could permit loss of electrolyte Determine cause of damage and correct as needed Clean corrosion with a soultion of baking soda and water Not O K I Rep...

Page 137: ...r no Refer to charging guide and safety more than 14 hrs and then precautions perform load test I Load test battery Apply 200A load for 15 sec then check battery voltage and compare below I Above 9 6...

Page 138: ...below 80 F Example The hydrometer reading is 1 280 and the electrolyte temperature reading is 10 F By using the chart the specific gravity must be lowered by 02B points The true corrected reading is 1...

Page 139: ...n in the event the battery case is cracked or leaking to protect your hands from the electrolye A suit able pair of rubber gloves not household type should be worn when this removing the battery by ha...

Page 140: ...l connections with light mineral grease after tightening CAUTION When batteries are being charged an explosive gas forms beneath the cover of each cell Do not smoke near batteries on charge or which h...

Page 141: ...al_ Y27CAOA STARTING SYSTEM GENERAL INFORMATION TROUBLESHOOTING Y27CBOA Symptom Probable cause Remedy Engine will not crank Battery charge low Charge or replace battery Battery cables loose corroded o...

Page 142: ...ith a feeler gauge Pinion gap 0 5 2 0 mm 0 02 0 079 in Stopper Pinion 27Y041 5 If the pinion gap is out of specification adjust by adding or removing gaskets between the solenoid and the front bracket...

Page 143: ...oltmeter 15 volt scale across the starter motor 4 Rotate the carbon pile to the off position 5 Connect a battery cable from the battery negative post to the starter motor body 6 Adjust the rheostat un...

Page 144: ...STARTER MOTOR STARTING SYSTEM REMOVAL AND INSTALLATION Starter motor 9 8 16 100 1607 3 11 7 TORQUE N m kg em Ib ft 27 25...

Page 145: ...agnetic switch Ball Packing A Screw Packing B Plate Lever Internal gear Overrunning Planetary gear Planetary gear clutch holder Stop ring Snap ring Front bracket Screw Rear bracket Brush holder Brush...

Page 146: ...e the parts in cleaning solvent Immersing the yoke and field coil assembly and or armature will damage the insulation Wipe these parts with a cloth only 2 Do not immerse the drive unit in cleaning sol...

Page 147: ...holder plate and the brush holder The normal condition is no continuity OVERRUNNING CLUTCH 27Y054 1 While holding the clutch housing rotate the pinion The drive pinion should rotate smoothly in one di...

Page 148: ...nsure a good solder joint 4 Insert the pigtail into the hole provided in the new brush and solder it Make sure that pigtail and excess solder are not on the brush surface 5 When replacing the ground b...

Page 149: ...ty 27Y059 CHECKING FOR ARMATURE COIL WIRING DAMAGE DISCONNECTION Check for continuity between the segments They are normal if there is continuity SERVICE POINTS OF ASSEMBLY Y27CP2A INSTALLATION OF THE...

Page 150: ...ove the starter relay and check continuity between the terminals If the continuity is not as specified replace the relay Terminal 3 L I 141 Condition 5 52 B When de energized When energized 1 Check ig...

Page 151: ...ust ignition timing hard to start Cranks Ignition coil faulty Inspect ignition coil OK Power transistor faulty Inspect power transistor Distributor faulty Inspect distributor High tension cord faulty...

Page 152: ...cable about 6 8 mm 0 24 0 31 in away from an engine ground and crank the engine I I I No spark produced I I Spark produced I I Check voltage at the negative side of the coil while cranking the engine...

Page 153: ...be produced in the gap In a defective spark plug no sparks will occur Ignition coil Spark plug Distributor CHECKING SPARK PLUG CABLES Y270EOA IGN SW 1 8 7 BAn Defective insulation Defection insulation...

Page 154: ...AUTION Use care not to allow foreign matter to enter through the spark plug holes 3 Check the spark plugs for the following 1 Broken insulator 2 Worn electrode 3 Carbon deposits 4 Damaged or broken ga...

Page 155: ...0 95 C 176 205 F All accessories Off Transaxle N Neutral Parking Brake ON 1 Connect timing light 2 Start engine and run at curb idle speed Curb idle speed 750 100 rpm 3 With the engine stopped connect...

Page 156: ...100 BTDC CHECKING IGNITION COILS Y27DHQA 1 Measurement of the primary coil resistance Measure the resistance of the positive terminal and neg ative terminal of the ignition coil Standard value 0 8 0 0...

Page 157: ...er is at top dead center 2 Align the distributor housing and gear mating marks INSTALLATION OF DISTRIBUTOR Y27DKOA _ Gear s mating a k l Housing s _mating mark 3 Install the distributor to engine whil...

Page 158: ...DISTRIBUTOR COMPONENTS IGNITION SYSTEM Plate Cover Packing Distributor shaft Bearing 0 lstributor ho uSIng Unit Lead wire 27 39...

Page 159: ...tor shaft 3 Remove the packing rubber 4 Lift off the cover 5 Remove the rotor shaft by using a driver DISASSEMBLY Y270MOA 7 Remove the disc and spacer 8 Disconnect the lead wire connector 9 Lift off t...

Page 160: ...e gear s mating mark ad the housing s mating mark sure that notch A at the shaft end is at the position shown in the figure and then align the roll pin hole and drive in a new roll pin CAUTION Drive i...

Page 161: ...orce Voltage drop Stop lamp switch Rated voltage Rated load Stop lamp Cruise control Insulating resistance Clutch switch Rated voltage Rated current SPECIAL SERVICE TOOL Specifications DC 11 16 V 30 8...

Page 162: ...me Symbol Accelerator switch vehicles with automatic A Reed switch Vehicle speed sensor E transaxle Actuator B Speed control switch F Clutch switch Vehicles with manual trans C Speed control unit crui...

Page 163: ...AUTOMATIC SPEED CONTROL CRUISE C E F Located into the cluster G 27 44...

Page 164: ...nic control unit ECU Recieves signals from sensor and control switches ECU controls all automatic speed control functions Actuator Regulates the throttle valve to the set opening by sig nals from the...

Page 165: ...hicles with automatic transmission overdrive ON and OFF signals from the ECU for the ASC Diagnosis connector By connecting the voltmeter or multi use tester control unit diagnosis codes can be read ou...

Page 166: ...elerator pedal is operated the rotation of intermediate pulley A which is connected to accelerator cable A accelerator pedal side causes intermediate pulley B to turn Then accelerator cable B which is...

Page 167: ...tor CIRCUIT DIAGRAM Electronic control unit ECU Actuator Variable voltage position sensor motor D C Clutch coil Pull Release Cruise MAIN switch Df D o j B rake Ir i 1__ 1 h __ v J I NC t _ _ I I I L _...

Page 168: ...shown in the figure above the rotation of the D C motor is transmitted to the speed reduction gears electromagnetic clutch coil gear final drive gear pinion gear rack gear 3 The selection of the direc...

Page 169: ...ection of current flow to the actuator motor windings ACTUATOR MOTOR ELECTRONIC CONTROL UNIT ECU The ECU incorporates circuity which provides the set coast resume acceleration cancel low speed limitat...

Page 170: ...e switch circuit normal close II Stop lamp I switch I I II Clutch 1 1 Input switch I circuit II Inhibitor 1 2 Alarm I Alarm switch I drive circuit I Accelerator T ELC 4 AIT switch N C ELC accelerator...

Page 171: ...r correcting the vehicle speed which is output is response to detected speed errors The output pulse width is determined based upon the amount of deviation between the current vehicle speed and the se...

Page 172: ...on at the fuse for the stop lamp CANCEL SWITCH CIRCUIT DIAGRAM Fuse Cruise control I C B 12V I Consta voltage c jc l l BV ECU Cruise MAIN I switch I r l J I w r l L __ Actuator I clutch coil Ignition...

Page 173: ...hes stop lamp switch clutch switch or inhibitor switch and command switches SETswitch or RESUME switch are switched on at the same time NOTE If the SET and RESUME switches are ON at the same time the...

Page 174: ...ain fixed value below the memorized vehicle speed and the actual vehicle speed continues at that reduced speed or during the resume operation described in item 3 or the acceleration operation describe...

Page 175: ...20 km h 12 mph or signal 0 5 OFF ON higher and before fixed speed driv sec 5 OV sec OFF ing has been set Actuator clutch Example Code No 13 Open brake switch or open ECU 11 coil drive circuit 05hf 5...

Page 176: ...using these function the time required check ing and repair can be shortened NOTE When the computer ECU power supply ignition switch and main switch is switched OFF the memorized diagnosis codes are...

Page 177: ...on code No 16 is entered in the memory as cancel switch ON sig nal input if the system is canceled by depressing the brake pedal and code No 13 or No 14 is entered when there is an automatic cancellat...

Page 178: ...If there is an automatic cancellation not intentionally made by the driver however excluding cancellations explicitly made by the cancel procedure there may be a temporary malfunction such as poor co...

Page 179: ...and the battery should not be disconnected 1 Make following preliminary inspections 1 Check to be sure that the installation of the actuator accelerator cables are correct and that the cables and link...

Page 180: ...set now I ignition switch and cruise main switch left ON I Yes No Yes Set the ASC system and Continue to Trouble conduct a road test Symptom 2 next page Did the problem reoccur Yes No now normal With...

Page 181: ...r disconnected wiring of the SET or RESUME Yes switch Check the input check items Input check items Probable ca use Remedy SET switch ON malfunction Replace the control switch SET switch input line sh...

Page 182: ...4 Trouble symptom Probable cause Remedy The ASC system is not canceled when Damaged or disconnected wir Repair the harness or replace the brake pedal is depressed ing of the stop lamp switch the stop...

Page 183: ...le cause Remedy Cannot decelerate coast by using the Temporary damaged or discon Repair the harness or replace SET switch nected wiring of SET switch the SET switch input circuit Actuator circuit poor...

Page 184: ...bulb Repair the harness or replace does not illuminate of cruise main switch indicator the part But ASC system is normaL lamp Harness damaged or discon nected Trouble Symptom 11 Trouble symptom Probab...

Page 185: ...ve is not canceled during fixed Malfunction of circuit related to Repair the harness or replace speed driving overdrive cancelation or mal the part Vehicles with an automatic transmis function of ECU...

Page 186: ...side Surge tank Reverse view shown for clarity Intermediate pulley C Actuator side Actuator Shown without mounting bracket attached Intermediate Pulley B Throttle valve side Insert 1 5 mm shim betwee...

Page 187: ...able Throttle valve side Y27EZOA 1 Assemble the accelerator cable to the intermediate pulley B 2 The locking nuts should be adjusted and tightened securely at approximately the mid point of the thread...

Page 188: ...tment Y27E2OA 1 5 mm Actuator cable Intermediate pulley 8 stop Accelerator cable 3 Adjust the cable casing at the rear side of the surge tank to allow ALL the slack to be removed from the inner cable...

Page 189: ...peed because of climbing a hill for example the automatic speed control will be can celled CHECKING SPEED INCREASE SETTING Y27E50A 1 Set to the desired speed 2 Press the RESUME button of the control s...

Page 190: ...transmission 3 The shift lever is moved to the N range Vehicles with an automatic transmission 4 The automatic speed control MAIN switch is switched OFF CHECKING RETURN TO THE SET SPEED BEFORE CANCELL...

Page 191: ...ing Continuity Not continuity Pushing 3 ON Max 1 OFF CHECKING INHIBITOR SWITCH N AND P POSI TIONS 1 Disconnect the connector 2 Check to be sure that there is continuity between connector E12 terminals...

Page 192: ...INTAKE EXHAUST SYSTEM GENERAL 2 AIR CLEANER 3 SURGE TANK AND INTAKE MANIFOLD 5 EXHAUST MANIFOLD 11 MUFFLERS 12...

Page 193: ...old cover to exhaust manifold 12 15 120 150 8 7 11 Oxygen sensor to exhaust manifold 39 49 400 500 29 36 Front exhaust pipe to exhaust manifold 29 39 300 400 22 29 Front exhaust pipe bracket 20 29 200...

Page 194: ...80 tOO 5 8 7 2 Air flow sensor Air cleanert element Air flow sensor gasket Air cleaner body TORQUE Nm kg em Ib ft 28YOO1 Remove the air intake hose and air duct connected to the air cleaner 2 Remove...

Page 195: ...over or packing for deformation corrosion or damage 2 Check the air duct for damage 3 Check the air cleaner element for restriction contamination or damage If element s lightly restricted remove dust...

Page 196: ...MANIFOLD 9 8 13 100 130 7 2 9 41 I Throttle body Intake manifold 9 8 13 100 130 7 2 9 4 i Fuel regulator y 15 20 150 200 11 141 a 25 1180 250 13 18 c IllOlllfOlU SHtv 1 Intake manifold gasket Fuel inj...

Page 197: ...body REMOVAL SURGE TANK AND INTAKE MANIFOLD Y28EAOA 2 Remove the accelerator and cruise control cables 3 Remove the water hose and throttle body 28Y058 4 Remove the P C v hose and brake booster vacuu...

Page 198: ...pipe line to prevent fuel overflow Refer to Fuel system 7 Remove the surge tank assembly and gasket 28Y012 8 Disconnect the fuel injector harness connector 9 Remove the delivery pipe with the fuel inj...

Page 199: ...ter hose Insulator 28V015 11 Disconnect the wiring harness connector between the water temperature gauge unit water temperature sensor 12 Remove the water outlet fitting and gasket 13 Remove the therm...

Page 200: ...cracking of any part 2 Check the cooling water and jet air passages for restrictions Clean if required 3 Check the deflection of the mounting surface with a straight edge and feeler gauge Standard val...

Page 201: ...SURGE TANK AND INTAKE MANIFOLD 2 Insert the insulators 4 il to the intake manifold 3 Ensure that the insulators are correctly inserted into the delivery pipe hole 28 10 lav023...

Page 202: ...Exhaust manifold 2eVQ2S Standard value 0 15 mm 0 006 in or less Service limit 0 3 mm 0 012 in or less 1 Check for damage or cracking 2 Using a straight edge and a feeler gauge check for distortion on...

Page 203: ...sconnect the main muffler from the center exhaust pipe 2 Remove the rubber hangers and take out the main muffler Caution Before removing or inspecting the exhaust system ensure that the exhaust system...

Page 204: ...haust Pipe 1 Remove the front exhaust pipe to catalytic converter mount ing bolts 2 Remove the front exhaust pipe clamp bolt and remove the exhaust manifold to front exhaust pipe mounting nuts 28Y032...

Page 205: ...catalytic con verter assembly the center exhaust pipe and the main muffler in that order 2 Install the rubber hangers so that they are identical left and right in length 3 Tighten the parts securely...

Page 206: ...EMISSION CONTROL SYSTEM GENERAL 2 CRANKCASE EMISSION CONTROL SySTEM 9 EVAPORATIVE EMISSION CONTROL SySTEM 11 EXHAUST EMISSION CONTROL SySTEM 16...

Page 207: ...duction Oxygen sensor feedback type 3 way catalytic converter CO HC NOx reduction Monolith type Exhaust gas recirculation system NOx reduction EGR valve Single type Thermo valve Bimetal type SERVICE S...

Page 208: ...Repair or replace Malfunction of the PCV valve Replace Malfunction of the purge control system Check the system if there is a pro blem check its component parts Engine hesitates or poor Malfunction o...

Page 209: ...N CONTROLS LOCATION GENERAL 29y001 A PCV valve B Purge control solenoid valve C EGR valve D EGR temperature sensor California only E Thermo valve F 2 way valve G Catalytic converter H Canister 29 4 F...

Page 210: ...e 29YOO4 Purge control solenoid valve PCV valve C EGR valve D EGR temperature sensor California 29YOO5 EGA temperature sensorr California only 1 29Y K 6 E Thermo valve 29YOO7 F 2 way valve 2 waV valve...

Page 211: ...FRONT U Purge control solenoid valve Fuel pressure regulator rl Bi Canister For California EGR control solenoid valve Throttle body EGR valve f y J FRONT U Fuel pressure regulator G Green Y Yellow L L...

Page 212: ...onditioner switch Inhibitor swilCh AIT only INPUT 1 Injector 2 ISC servo 3 Purge control solenoid valve Fuel pump control control relay Air conditioner power relay Ignition timing control ToC Top Dead...

Page 213: ...rol solenoid valve 4 EGA solenoid valve Fuel pump control control relay Air conditioner power relay Ignition liming COnlrol TOC Top Dead Center AIT Vehicles witch automatic Iransaxle DI YdSTRIBUTOR CR...

Page 214: ...plunger inside the PCV valve will move back and forth 3 If vacuum is not felt clean the PCV valve and ventilation hose in cleaning solvent or replace if necessary 1 Disconnect the ventilation hose fr...

Page 215: ...decelerating PCV valve Not operating PCV valve Fully operating Vacuum passage Clogged Vacuum pass ge Small rtf Intake manifold side mr Intake manifold side Moderate vacuuml Low vacuum I n ffIf Ir Roc...

Page 216: ...er Purge control solenoid I valve Engine Canister Charcoal H h Fuel injector Purge air Fuel vapour 29Y023 CANISTER Y29EAOA When the engine is not running fuel vapours generated inside the fuel tank ar...

Page 217: ...p during ordinary driving it opens to let stored vapors into the surge tank To canister r To throttle body l V 29Y026 Inspection NOTE When disconnecting the vacuum hose make an identification mark on...

Page 218: ...um valve opens when a vacuum has been produced in the tank To fuel check valve Pressure valve 29YOJO FUEL CHECK VALVE Y29EDQA The fuel check valve is used to prevent fuel leaks when the car suddenly r...

Page 219: ...he atmosphere Atmospheric pressure Fuel vapour pressure Fuel tank vacuum When pressure is in fuel tank When vacuum is in fuel tank 29Y032 CHECKING PURGE CONTROL SYSTEM Purge control solenoid valve Air...

Page 220: ...when it is warm coolant temperature 700 e 158 F or higher When engine is cold Engine operating condition Applying vacuum Result Idling 3 000 rpm When engine is warm Engine operating Apply vacuum Resu...

Page 221: ...ed by the same cam as the intake valve and by a common rocker arm so that the jet valve and intake valve open and close simultaneously The jet air flowing out of he jet valve scavenges the residual ga...

Page 222: ...d the catalytic con verter promotes both oxidation and reduction of resultant exhaust gas to make it clean before it is released to atmosphere CAUTION The catalytic converters require the use of unlea...

Page 223: ...vacuum hose green stripe from the EGR valve and connect a vacuum pump via the three way terminal 2 Check the following points when the engine is cold Coolant temperature 20 C 6BOF or below and when it...

Page 224: ...rough 26 kPa 7 5 in Hg or more Air blows through NOTE When installing the EGR valve use a new gasket and tighten to the specified torque Tightening torque EGR I 19 27 Nm 190 280 kg cm 14 20 Ib lt EGR...

Page 225: ...Engine coolant temperature 50 C 122 F or less 80 C 176 F or more Normal condition Vacuum is released Vacuum is held EGR Control Solenoid Valve California NOTE When disconnecting the vacuum hose make...

Page 226: ...FUEL SYSTEM GENERAL 2 MPI SySTEM 15 INJECTOR AND THROTILE BODy 64 THROTILE BODy 67 FUEL TANK 6911 FUEL PUMP 74 FUEL LINE AND VAPOUR LINE 76 ENGINE CONTROL 78...

Page 227: ...nce Coolant temperature sensor Type Resistance Oxygen sensor Type Output voltage Vehicle speed sensor Type 31 2 GENERAL 60 lit 15 9 U S gal 13 2 Imp gal High pressure type Electrical in tank type Elec...

Page 228: ...istance EGR control solenoid valve Only California Type Fuel pressure regulator Regulated pressure SEALANT Water temperature sensor GENERAL Photo diode sensor 0 2 1 2V Photo diode sensor 1 8 2 5V Elec...

Page 229: ...Oxygen sensor connector bracket bolt 7 8 12 80 120 5 8 B 7 Throllie position sensor TPS installation screw 1 5 2 5 15 25 1 1 1 8 Fuel pressure regulator lock nut 25 34 250 350 18 25 High pressure hos...

Page 230: ...y harness GENERAL Illustration 1 Use En9ine r p m check Diagnostic tester for MPI automatic transaxle and cruise control systems 09391 33600 4 Instruction manual 09391 33401 5 R O M Pack HMC 2 09391 3...

Page 231: ...ration Use 09353 24000 Connection of fuel pressure gauge to Fuel pressure gauge 1 delivery pipe for measurement of fuel connector pressure t1 t 09353 24100 r Fuel pressure gauge hose 09353 24200 Fuel...

Page 232: ...ems 1 Power supply 1 Battery 2 Fusible link 3 Fuse 2 Body ground 3 Fuel supply 1 Fuel line 2 Fuel filter 3 Fuel pump 4 Ignition system 1 Spark plug 2 High tension cable 3 Distributor 4 Ignition coil 5...

Page 233: ...leaks OK Check for ignition spark o Unplug injector connectors 0 Check for a strong spark by holding spark plug wire 8 10 mm 0 030 0 039 in away from engine block during cranking engine OK To be cont...

Page 234: ...0 kPa 150 psil 25D 400 rpm o Valve clearance Refer to page 10 61 OK II Check MPI electronic circuit GENERAL Wrong Wrong Wrong o Ignition timing adjust Refer to page 27 36 o Fuel line leakage deformati...

Page 235: ...ge 27 361 unction es Wrong Wrong J Element Clean or replace Wrong Wrong Wrong Check self diagnosis Refer to page 31 39 Malf cod Normal codes Check for vacuum leaks OK II Check fuel supply to injector...

Page 236: ...pressure regulator OK 1 Check injectors 4 Injection condition Wrong Check MPI electronic circuit 3 Wrong o Wiring connections o Power to ECU 1 Fusible links 2 Fuses 3 MPI control relay o Engine coolan...

Page 237: ...p o Brake drag 7 Wrong 7 Malfunction codes 7 Wrong 7 Wrong 7 Wrong Wrong L _ _ _ Check clutch or brakes OK 11 Check vacuum leaks in intake air line OK Check air cleaner element OK Check self diagnosis...

Page 238: ...valve clearance if necessary o Compression Limit 10 5 kg cm2 1050 KPa 150 psil 25D 400 rpm JOK Check MPI electronic circuit Wrong o Wiring connections o Power to ECU 1 Fusible links 2 Fuses 3 MPI con...

Page 239: ...Replace the fuel filter or clean the fuel tank and fuel lines Dirty or rusted fuel tank interior Clean or replace Malfunctioning fuel pump Restricted filter Replace in the pump Evaporative emission In...

Page 240: ...l injection takes place After pressure regulation excess fuel is returned to the fuel tank through the return hose When the injector is energized the valve inside the injector opens fully to inject th...

Page 241: ...19 514 817 16 13 II II II 31YOOS C02 3 C02 2 C02 1 1 N A NOT AVAILABLE 1 ISC MOTOR EXT 1 SPARK TIMING ADJUST 2 N SW 2 ISC MOTOR RET 2 NA 3 BAn BACK UP SOURCE 3 N A 3 AIR FLOW SENSOR 4 FUEL PUMP RELAY...

Page 242: ...on synchronous injection During engine starting cranking there are two fuel injections for each engine rpm for each of the four cylinders In addition on acceleration fuel in an amount proportionate to...

Page 243: ...310EOA Llnjection 31YQ07 Injector activation occurs one time per cycle for each cylinder and the injector activation time amount of fuel injection which is the theoretical air fuel mixture ratio relat...

Page 244: ...fference in intake air density caused by change in atmospheric pressure is corrected o Acceleration deceleration correction In accordance with the change in the amount of intake air fuel amount is cor...

Page 245: ...e starting there is synchronization to the crank shaft angle sensor s signals thus resulting in a fixed ignition timing 5 BTDC b Control During Ordinary Driving For each engine revolution and intake o...

Page 246: ...ion with the crankshaft angle sensor s signal thus resulting in the fixed ignition timing 5 BTDC and in this condition the reference ignition timing is adjusted Note however that the spark advance bec...

Page 247: ...ne speed is controlled to a target rpm according to the engine coolant temperature rpm feedback control When the idle switch is off the ISC servo is actuated to move the throttle valve to a target ope...

Page 248: ...even if the air conditioner switch is on the air compressor is not driven instantly preventing engine speed drop due to compressor load In addition for automatic transmission equipped models during a...

Page 249: ...t the fuel pump is driven Current als flows through coil L3 to close switch 5 As a result power is supplied to the ECU AF5 igniter and injectors o While the engine is running the ECU turns on the powe...

Page 250: ...sensor C ISC servo Motor position sensor D Throttle position sensor E Coolant temperature sensor F Power transistor G Crank angle sensor H Injector I Oxygen sensor J Inhibitor switch K MPI control rel...

Page 251: ...MPI SYSTEM B 31Y018 31Y260 LL r Idle speea control servo 1 If J t c l 7 Motor position sensor MPS c 31Y021 E L I Coolant _ temperature censor v lW Intake manifold G Crank 31 26...

Page 252: ...MPI SYSTEM 31Y026 In M Vehicle speed sensor 31YQ29 o EGR temperature sensor 31 27...

Page 253: ...ral P or N range for AIT vehicles o Steering wheel is a straight ahead position Vehicles with power steering 1 Install the tachometer and the timing light or connect the multi use tester to the diagno...

Page 254: ...ctric cooling fan and all accessories are off o Transaxle is in neutral P or N range for AIT vehicles o Steering wheel is a straight ahead position Vehicles with power steering 1 Loosen the accelerato...

Page 255: ...fied adjust the ISC adjusting screw to obtain the standard rpm 11 Tighten the fixed SAS until the engine speed starts to increase Then loosen it until the engine speed ceases to drop touch point and t...

Page 256: ...ation loosen TPS mounting screws and adjust by turning the TPS NOTE Turning the TPS clockwise increases the output voltage CAUTION Tighten the screws securely after adjustment 16 Turn the Ignotlon swi...

Page 257: ...ing speed becomes unstable or if the engine stalls slightly open the throttle valve to keep the engine running 5 Repeat steps 3 and 4 6 Attach the air intake hose 7 Adjust the idle speed control and t...

Page 258: ...e the fuel gauge unit from the fuel tank Overfill limiter Two way Valve Replacement Fuel Gauge Unit Replacement Y31DOQA Y310POA j 31Y045 Fuel Pump Operation Check Y31DQOA 1 Turn the ignition switch to...

Page 259: ...residual pressure in the fuel pipe line 3 Using the fuel pressure gauge adaptor 09353 24000 09353 24100 09353 24200 install the fuel pressure gauge to the delivery pipe Tighten the bolt to the specifi...

Page 260: ...eplace fuel pressure regulator regulator b Restricted or bent fuel return hose or pipe b Repair or replace hose or pipe There is no difference in a Restricted or damaged vacuum hose or a Repair or rep...

Page 261: ...r fuel leaks o Apply battery voltage to the fuel pump drive terminal to operate the fuel pump o With pressure check the fuel line for leaks NOTE If there is a problem with the change in vacuum it is p...

Page 262: ...onnect a hand vacuum pump Purge Port Vacuum Check MPI SYSTEM Y31DTOA 2 Start the engine and check to see that after raising the engine speed by racing the engine vacuum remains fairly constant NOTE If...

Page 263: ...ge to semiconductors 3 The control harnesses between the ECU and oxygen sen sor are shielded wires with the shield grounded to the body in order to prevent the influence of ignition noises and radio i...

Page 264: ...orization of the trouble codes is backed up directly by the battery the diagnosis results are memorized even if the ignition key is turned off The trouble codes will however be erased when the battery...

Page 265: ...l of the battery to erase any trouble codes 1 Turn OFF the ignition switch 2 Connect the the multi use tester to the diagnosis connector in the fuse box 3 Connect the power source terminal of the mult...

Page 266: ...n to make sure that the trouble code has been erased Inspection Procedure Using Voltmeter Y31DYOA MPI diagnosis Ground I I I I I I L 31Y061 Diagnosis Chart Y310Z0A Output Diagnosis Trouble code prefer...

Page 267: ...nector position 0 Motor position sensor sensor 31Y067 7 Engine 21 Retained o Harness and connector coolant o Engine coolant temperature tempera sensor ture sensor 31Y068 8 Crank angle 22 Retained o Ha...

Page 268: ...ce the engine control unit if a trouble code is read although the inspection reveals that there are no problems with the diagnosis item 2 The diagnosis item marked is applicable to California vehicles...

Page 269: ...e sure the problem has been corrected 7 Turn OFF the ignition switch 8 Disconnect the multi use tester 9 Disconnect the battery terminals for 15 seconds or longer This erases the self diagnosis code 1...

Page 270: ...e pulsations o Voltage is not supplied to the fuel o Actuator test conditions the return of the fuel flow pump o Item NO 7 o Engine cranking hose can be fell 1 Check the ignition switch IG and o Fuel...

Page 271: ...ctors can and control relay contacts be heard Engine Injector o Malfunction of the engine coolant coolant activation temperature sensor temperature time 2 o Malfunction of the ignition OC OF msec swit...

Page 272: ...k the oxygen sensor signal reduction and from 4 000 circuit rich by racing rpm o If the oxygen sensor output voltage is low during engine racing When engine 600 1 000 1 Check the oxygen sensor and is...

Page 273: ...Throttle position sensor or related o Item No 14 tion switch at Opens slowly Becomes circuitry malfunction ON higher in proportion to valve opening Fully open 4 500 5 500 Motor position sen o Engine i...

Page 274: ...switch Engine stopping OFF o Ignition switch ST signal circuit o Service data ON check o Item No 18 Engine cranking ON o Ignition switch check Engine coolant tem o Ignition switch Engine coolant Tempe...

Page 275: ...cel using the accel throttle valve erator cable or cruise control cable erator pedal sev slightly eral times o Malfunction of the setting of the fixed SAS Power steering o Engine idling Steering OFF o...

Page 276: ...table or 2 Check the spark plug and high after engine war engine stalls tension cable m up check the 4 3 Check the power transistor unit idling condition and control circuit Injector 0 Engine warmed E...

Page 277: ...r compressor clutch is not nor activation mal check the compressor clutch ON ON and the relay circuit compressor clutch activa tion Purge control sole o Ignition switch Actuator Operation o Check the...

Page 278: ...l 3 AFS output 2 Warm the engine and bring it to a normal idle 3 Measure the voltage of terminals Engine speed rpm Idling 3 000 Output voltage V 2 7 3 2 NOTE If the air flow sensor fails the intake ai...

Page 279: ...heric pressure sensor connector Terminal 5 Atmospheric sensor connector Terminal 6 Sensor ground 2 Warm the engine and bring it to a normal idle 3 Slowly cover about half of the air cleaner air intake...

Page 280: ...connector 3 2 1 I I 6 5 4 K If l 9 I I I 0 Intake aIr Ztemperature sensor 1 J1Y084 31YOBS Engine Coolant Temperature Sensor Y31EEOA The engine coolant temperature sensor installed in the engine coolan...

Page 281: ...ensor I I Standard value 3 5 6 5 KO 1 Disconnect the throttle position sensor connector 2 Measure the resistance between terminals 1 and 4 of the throttle position sensor connector Terminal 1 Sensor g...

Page 282: ...0 5 3 5 6 5 kO 5 If the resistance is out of specification or if the change is not smooth replace the throttle position sensor 312262 Tightening torque Throttle position sensor 1 5 2 5 Nm 15 25 kg cm...

Page 283: ...e terminals Motor Position Sensor IMPS Z31EHOA ISC servo assembly Forward Reverse Idle switch output Supply 5VI MPS output Sensor ground Sensor power I r J tl ISC Motor 2 L H1 3 Attach an ohmmeter bet...

Page 284: ...ure the output voltage of the terminals while cranking the engine Sensor Terminal Voltage No 1 cylinder Ground 0 2 1 2V TDC sensor The needle fluctuates Crankshaft Ground 1 8 2 5V angle sensor 3 When...

Page 285: ...s Y31EKOA Z31ELOA Z31EMOA I Rotor ffi t u I w 31Z044 Operation Check Using a multi use tester check as described below o Cut off the fuel injection of the injectors in sequence o Check the operation t...

Page 286: ...ward 2 Connect 6V DC to terminals 1 and 2 and check that the idle speed control servo extends and retracts by itself Idle speed control servo motion When terminal 2 is Retracts When terminal 1 is Exte...

Page 287: ...ils L and L NOTE Energized means voltage applied across terminals 6 and 7 o Coil L3 NOTE In the following tables the arrows indicate the direction of the current flow Confirm circuit tester polarity b...

Page 288: ...connect the power transistor connector 2 Connect a power supply of 1 5V one dry cell between the power transistor and then check for continuity between terminals 1 and 2 under power ON and power OFF c...

Page 289: ...6 0 rin9 I l tl Dellvery pipe Injector 71nsulator I I Grommet TORQUE Nm kg cm Ib ft COMPONENTS REMOVAL Y31FAOA 1 Release residual pressure from the fuel line to prevent fuel from spilling CAUTION Cov...

Page 290: ...e intake manifold Y31FCOA Insulator 31Y127 1 Grommet 2 Install a new grommet and O ring to the injector 3 Apply a coating of solvent spindle oil or gasoline to the O ring of the injector O ring 31 1 1...

Page 291: ...pe s instal lation hole 7 When installing the fuel pressure regulator apply a coating of spindle oil or gasoline to the O ring 8 Install the pressure regulator onto the delivery pipe Lock nut __L 9 Po...

Page 292: ...HROTTLE BODY COMPONENTS Throttle position sensor I Throttle valve set screw Throttle body TORQUE Nm kg em Ib ft Idle control servo assembly 31Z275 REMOVAL CAUTION The throttle valve must not be remove...

Page 293: ...disassembled 3 Use an open end wrench or box wrench to remove the adjust ment screw INSPECTION Cleaning Throttle Body Components Y31GBOA 1 Clean all components The following components must not be cl...

Page 294: ...Filler hose Leveling hose Fuel check valve Self locking nut 15 25 150 250 11 18 31Y137 NOTE Be sure to reduce the fuel pressure before disconnecting the fuel main pipe and hose otherwise fuel will sp...

Page 295: ...e fuel tank cap 4 Remove the drain plug and drain the fuel 5 Disconnect the return hose and vapour hose 6 Disconnect the fuel gauge unit connector 7 Disconnect the high pressure hose from the fuel tan...

Page 296: ...ks or damage 2 Check the fuel tank cap for proper operation 3 Check the fuel tank for deformation corrosion or cracking 4 Check the inside fuel tank for dirt or foreign material 5 Check the in tank fu...

Page 297: ...turn hose When attaching the fuel hose to the pipe be sure that the hose is attached as shown in the illustration 5 To connect the high pressure hose to the fuel pump temporarily tighten the flare nut...

Page 298: ...FUEL TANK 6 Connect the electrical fuel pump and fuel gauge unit connector 7 Tighten the drain plug to the specified torque Tightening torque Drain plug 15 25 Nm 150 250 kg cm 11 18 Ib lt 31 73...

Page 299: ...umped tothe injectors under pressure This fuel pump is installed within the fuel tank and is submerged in the fuel It features excellent performance while having low operating noise This pump is also...

Page 300: ...s way restarting of the engine becomes easier In addition vapour locks at high temperature are prevented REPLACEMENT 1 Disconnect the fuel pump connector 2 Remove the fuel tank cap 3 Drain the fuel 4...

Page 301: ...Holland For Aust Holland L Wlo 1 Remove the upper eye bolt while holding the fuel filter nut securely and remove the high pressure fuel hose CAUTION 1 Be sure to reduce the fuel pressure before discon...

Page 302: ...e illustration o If the fuel pipe does not have a stepped section connect the fuel hose to the pipe securely 2 Install the fuel filter and tighten the fuel filter bracket 3 Insert the main pipe on the...

Page 303: ...r AfT Return spring V J SPlitPin 78 12 80 120 5 8 87 Acceleratorpedal TORQUE Nm kg em Ib ft 31Y162 REMOVAL Y31KAOA 1 Remove the bushing and inner table of the accelerator arm side 2 Pull the left side...

Page 304: ...Y3 KCO 1 When installing the return spring and accelerator arm apply multi purpose grease around each moving point of the accelerator arm 2 Apply sealant to the bolt mounting hole and tighten the acce...

Page 305: ...CLUTCH GENERAL 2 CLUTCH PEDAL 10 CLUTCH MASTER CYLINDER AND TUBE 12 CLUTCH MASTER CyLINDER 15 CLUTCH RELEASE CyLINDER 18 CLUTCH COVER AND DiSC 21 II...

Page 306: ...tch assembly or components Do NOT create dust by sanding cleaning clutch parts with a dry brush or with compressed air A water dampened cloth should be used The clutch disc contains Asbestos Fibers wh...

Page 307: ...GHTENING TORQUE Clutch tube Clutch cover bolt Eye bolt to clutch release cylinder Clutch tube flare nut Clutch master cylinder to pedal support member Clutch pedal pivot bolt and nut Y41CBOA 8 5 9 1 m...

Page 308: ...Inner surface of clutch disc spline MOLYWHITE TA No 2 As required Inner surface of clutch master cylinder and outer circumference of piston assembly Brake fluid DOn As required Clutch master cylinder...

Page 309: ...SPECIAL TOOLS GENERAL Y41CFOA Tool Number and name Illustration Use 09411 11000 Centering flywheel and clutch disc Clutch disc guide 41 5...

Page 310: ...corrosion of clutch disc Replace spline Excessive vibration distortion of clutch Replace disc Clutch VVhen clutch is Insufficient play of clutch pedal Adjust noisy not used Replace Excessive wear of...

Page 311: ...draulic system Repair or replace parts Clutch disc lining oily or worn out Inspect clutch disc Pressure plate faulty Replace clutch cover Release fork binding Inspect release fork Clutch grabs chatter...

Page 312: ...ut Caution When adjusting the clutch pedal clevis pin play be care ful not to push the push rod toward the master cylin der 3 After completing the adjustments confirm that the clutch pedal free play m...

Page 313: ...rake fluid DOT3 Caution Use the specified brake fluid Whenever the clutch tube the clutch hose and or the clutch master cylinder have been removed or if the clutch pedal is spongy bleed the system Y41...

Page 314: ...tion lock sWitch I 0 G 8 10 80 100 58 J L J L WJ 8UShing I c S I J Return spring p It pin Clutch pedal mounting bolt TORQUE Nm kg cm Ib ft Removal 1 Remove the return spring 2 Remove the split pin was...

Page 315: ...re that there is continuity between connector terminals Ohmmeter EJ 1 2 D J INSTALLATION Y41DCOA 1 Apply the specified grease to the clutch pedal and bushings Specified grease Chassis grease SAE J310...

Page 316: ...Clutch master cylinder f Sealer Clutch tube Hose c1ip TORQUE Nm kg em Ib ft REMOVAL Y41EAOA 1 Drain the clutch fluid through bleeding plug 2 Remove clevis pin split pin washer 3 Disconnect the clutch...

Page 317: ...emove clutch hose from bracket 8 Remove the clutch tube rCIUIChtube f JJ Clutch hose 9 Disconnect the clutch tube release cylinder side INSPECTION Y41EBOA 1 Check the clutch hose or tube for cracks or...

Page 318: ...clutch hose does not become twisted Secure side 3 Install the clutch tube and clips 4 Install the master cylinder 5 Apply the specified grease to the clevis pin and washer Specified grease Wheel bear...

Page 319: ...servoir band Piston stop ring Piston assembly Boot Master cylinder body DISASSEMBLY Y41FAOA 1 Remove the piston stop ring 2 Pull out the push rod and piston assembly 3 Remove the reservoir cup band re...

Page 320: ...r directions 5 If the master cylinder to piston clearance exceeds the limit replace the master cylinder and or piston assembly Y41FBQA INSPECTION Specified fluid DOT 3 1 Apply the specified fluid to t...

Page 321: ...CLUTCH MASTER CYLINDER 4 Install the reservoir cap reservoir hose reservoir tank res ervoir tank bracket 41 17...

Page 322: ...R COMPONENTS Bleeder plug Piston and Cap 13 17 130 170 10 120 Conical spring 15 21 150 210 11 25 Boot Push rod 25 250 lB TORQUE Nm kg em Ib ft REMOVAL 1 Remove the clutch tube union 2 Remove the relea...

Page 323: ...release pressed air Y41GCOA INSPECTION Y41GDOA 1 Check the release cylinder bore for rust and damage 2 Measure the release cylinder bore at three locations bottom middle and top with a cylinder gauge...

Page 324: ...O 2 1 Apply a coating of the specified grease to the contact parts of the release fork and release cylinder push rod INSTALLATION CLUTCH RELEASE CYLINDER Y41GFOA Release fork 2 Install the clutch rele...

Page 325: ...rk Transaxle assembly Removal 41HAOA 1 Remove the transmission 2 Insert the special tool at the center spline in order to prevent the clutch disc from falling 3 Diagonally loosen bolts which attach cl...

Page 326: ...k 3 Check for torsion spring play and damage and if defective replace the clutch disc 4 Combine the clutch disc with the inpu shaft and check slid ing condition and check for play in the rotating dire...

Page 327: ...apply grease to each part but be careful not to apply excessive grease excessive grease will cause clutch slippage and shudder 2 Apply a coating of the specified grease to the end of the release cyli...

Page 328: ...clutch disc to the flywheel 6 Install the clutch cover assembly Tighten the bolts a little at a time working in a diagonal sequence finally tightening them to the specified torque 7 Before installing...

Page 329: ...ASSEMBly 14 MANUAL TRANSAXlE 16 MANUAL TRANSAXlE ASSEMBLY 19 5TH SPEED SYNCHRONIZER ASSEMBly 27 INPUT SHAFT 29 INTERMEDIATE SHAFT 37 III OUTPUT SHAFT 43 SHIFT FORK 44 DIFFERENTIAL 45 CLUTCH HOUSiNG 49...

Page 330: ...04 in 0 05 0 10 mm 0 002 0 004 in 0 025 0 150 mm 0 001 0 006 in 0 5 0 02 Y43CB2A Y43CClA Transaxle oil lit U S qts Imp qts Return spring and bracket sliding part Drive shaft oil seal lip Shift lever b...

Page 331: ...of intermediate shaft front bearing 1 50 0 0590 Blue end play 1 60 0 0630 Yellow 1 70 0 0669 Green Spacer 0 80 0 0315 80 for adjustment of intermediate shaft end play 0 83 0 0327 83 0 86 0 0338 86 0 8...

Page 332: ...07 0 0421 07 1 1 0 0 0433 J 1 13 0 0445 D 1 16 0 0457 K 1 19 0 0468 L 1 22 0 0480 G 1 25 0 0492 M 1 28 0 0504 N 1 31 0 0516 E 1 34 0 0527 0 Spacer 1 43 0 0563 Q for adjustment of differential case en...

Page 333: ...ransmission case tightening bolt Stopper bracket bolt Restriction ball assembly Reverse shift lever assembly installation bolt Bearing retainer bolt Differential drive gear bolt Interlock plate bolt Y...

Page 334: ...32 21300 Removing plate 43 6 GENERAL Illustration Y43CG2A Use Installation of the differential tapered roller bearing 1 Driving out the spring pin of the clutch shaft 2 Driving out the spring pin of t...

Page 335: ...Removing plate 1t 09432 33300 1 Installation of synchronizer assy Bearing installer 2 Installation of bearing sleeve and bearing 09432 33600 Installation of output shaft bearing outer Output shaft be...

Page 336: ...outer race Installation of differential bearing outer race and output shaft bearing outer race use with 09500 11500 Installation of output shaft bearing outer race use with 09432 33400 Removal of the...

Page 337: ...eed Adjust idle speed Oil leakage Broken or damaged oil seal or a ring Replace oil seal or a ring Hard shift Faulty control cable Replace control cable Poor contact or wear of synchronizer ring and Co...

Page 338: ...rough the filler plug part until the oil level is the same level as the plug hole Transaxle oil Hypoid gear oil SAE 75W 85W conforming to API GL 4 2 5 LIT 2 6 U S qts 2 2 Imp qtsl REPLACEMENT OF DRIVE...

Page 339: ...he meter side groove 3 Install the grommet so that as shown in the illustration the cable attachment part and the projecting part are horizontal Caution The cable arrangement should be made so that th...

Page 340: ...t cable Retainer Clip Shift lever side Cotter pin Shift lever assembly g Shift cable REMOVAL Y43DA2A 1 Remove the console box Refer to console box 2 Remove the cotter pins and clips shift lever side 3...

Page 341: ...2 The flange side of the resin bushing at the selector cable end should be at the lever B end surface 4 Remove the retainer and bolts 5 Remove the air cleaner 6 Remove the colter pins and clips Transa...

Page 342: ...SEMBLY COMPONENTS Bushing 19 28 190 285 14 20 llll Bracket assembly TORQUE Nm kg em Ib ft INSPECTION Shift lever Y43EA2A Lever Al 14 20 1 Cheek the bushing for wear or damage 2 Check the return spring...

Page 343: ...No 2 FORWARD Section A A 1 hnn II AI lI r Section B B C J W D Section C C Section D D 2 Install so that the return spring is in secure contact with the bracket end surface 3 Apply a coating of the sp...

Page 344: ...MANUAL TRANSAXlE COMPONENTS TORQUE Nm kg em Ib ft 43 16 MANUAL TRANSAXlE Select cable Shift cable Transaxle mount bracket 30 35 r 300 350 22 25 Drain plug...

Page 345: ...le Refer to MANUAL TRANSAXLE PART REMOVAL MANUAL TRANSAXLE Y4JFA2A 5 Remove the backup lamp switch connector 6 Remove the speedometer cable 7 Remove the starter motor 8 Remove the stabilizer bar tie r...

Page 346: ...MANUAL TRANSAXLE 10 Remove the cap and transaxle mounting bracket 11 Remove the transaxle assy 43 18...

Page 347: ...RANSAXlE ASSEMBLY COMPONENTS R ar Cover 15 22 150 220 i 30 35 300 350 22 35 Restriction ball assembly Poppet ball Poppet spring I Poppet plug I i oo Transmission case Oil guide Spring pin Shift rail a...

Page 348: ...nd rear cover DISASSEMBLY MANUAL TRANSAXlE ASSEMBLY Y43GA2A 2 Remove the backup light switch gasket and mounting bracket 3 Remove the poppet plugs poppet springs and poppet balls 4 Remove the speedome...

Page 349: ...t 2 Shift the shift lever in reverse using the control lever and select lever SeleCI lever Control lever o 3 Install the special tool 09432 21101 onto the input shaft 4 Screw a bolt 10 mm 0 39 in into...

Page 350: ...th speed synchronizer hub synchronizer ring 5th speed gear and needle bearing 9 Remove the intermediate gear using the special tool 09455 21000 09455 21000 09455 21000 10 Remove the reverse idler gear...

Page 351: ...ng outer race and spacer using the special tool 09455 32200 14 Remove the intermediate shaft bearing outer race and spacer 15 Remove the differential bearing outer race and spacer 16 Remove the revers...

Page 352: ...special tool 09414 11000 19 Disassembly of shift rail assembly 1 Shift the 1st 2nd speed shift fork to the 2nd speed 2 Shift the 3rd 4th speed shift fork to the 4th speed 3 Remove the shift rail assem...

Page 353: ...ly 22 Remove the output shaft assembly and differential gear assembly 23 Remove the intermediate shaft bearing outer race and spacer and oil guide using the special tool 09455 32200 24 Remove the outp...

Page 354: ...MANUAL TRANSAXLE ASSI MBLY 25 Remove the differential bearing oil seal and the differential bearing outer race 26 Remove the input shaft oil seal 43 26...

Page 355: ...hey slide smoothly 2 Check that the sleeve is free from damage at its inside front and rear ends 3 Check for wear of the hub front end surface in contact with the 5th speed gear INSPECTION SYNCHRONIZE...

Page 356: ...ons Assemble the hub to the sleeve in such a way that the center tooth T between two missing teeth wi touch the synchron izer key One loath skipped pans z 3 Install the synchronizer spring in such a w...

Page 357: ...COMPONENTS Snap ring Corn spring Sub gear Ball bearing Bearing sleeve gear Needle bearing Synchronizer ring I r spring Synchronize hub nchromzer 3rd 4th speed sy Input shaft Needle bearing Needle bea...

Page 358: ...Y INPUT SHAFT Y4JJA2A 09432 21201 2 Remove the front bearing using the special tool 09432 21300 3 Remove the bearing sleeve using the special tool 09455 21000 4 Remove the snap ring 9455 21 5 Remove t...

Page 359: ...e bearing is mounted for damage or abnormal wear portion A 2 Check the splines for damage or wear INSPECTION INPUT SHAFT NEEDLE BEARING Y43JB2A Y43JC2A Ill r L Spline 1 Combine the needle bearing with...

Page 360: ...s inside front and rear ends 3 Check for wear of the hub end surfaces in contact with each speed gear Caution Replace the synchronizer hub and sleeve as a set J 1 Check for wear of the synchronizer ke...

Page 361: ...six portions Assemble the hub to the sleeve in such a way that the center tooth T between two missing teeth will touch the synchron izer key 3 Install the synchronizer spring in such a way that its st...

Page 362: ...ng the synchronizer assembly make sure that three synchronizer keys are seated correctly in respective grooves of the synchronizer ring 2 After installing of the synchronizer assembly check that the 3...

Page 363: ...INPUT SHAFT 8 Install the rear bearing using the special tool 09432 21500 9 Install the snap ring 10 Install the rear bearing sleeve using the special tool 09432 21500 09432 21500 09432 2 500 43 35...

Page 364: ...INPUT SHAFT 11 Install the front bearing using the special tool 09432 33300 12 Install the snap ring 43 36 09432 33300...

Page 365: ...RMEDIATE SHAFT COMPONENTS Needle bearing 2nd speed gear Synchronizer spring Synchronizer ring Synchronizer spring Synchronizer key J 1sl 2nd speed synchronizer sleeve Synchronizer spnng Synchronizer r...

Page 366: ...ing removed from the shaft 2 Replace the inner and outer races of the tapered roller bearing as a set 3 Remove the 1st 2nd speed synchronize r assembly and 2nd speed gear needle roller bearing togethe...

Page 367: ...l noise or play 2 Check the needle bearing cage for deformation INSPECTION INTERMEDIATE SHAFT NEEDLE BEARING INTERMEDIATE SHAFT Y43KB2A Y43KC2A SYNCHRONIZER RING Y43KOZA Oamage and wear 1 Check the cl...

Page 368: ...or wear of the synchronizer key center protrusion 2 Check the spring for weakness deformation or breakage 1 Check the bevel gear and clutch gear teeth for damage and wear 2 Check the synchronizer cone...

Page 369: ...432 21500 Clutch housing side Identification 4 The synchronizer sleeve has teeth missing at six portions Assemble the hub to the sleeve in such a way that the center tooth r between two missing teeth...

Page 370: ...ly in respective grooves of the synchronizer ring 2 After installation of the synchronizer assembly check that the 3rd speed gear rotates smoothly 7 Install the needle roller bearing 1st speed gear be...

Page 371: ...cial tools 09432 21300 09433 21000 CAUTION Do not reuse the bearing removed from the shaft DISASSEMBLY Y43LA2A t 09432 21300 09433 21000 t 1 Install the tapered roller bearing using the special tool 0...

Page 372: ...ger 3rd 4th shift fork 1sl 2nd shift fork 1sl 2nd shift rail 5 r shift rail 3rdAth shift rail ASSEMBLY Insert the interlock speed shift rail Y43MA2A plunger as illustrated on the 3rd 4th Interlock plu...

Page 373: ...rential case Side gear Pinion Washer TORQUE Nm kg em Ib ft J DISASSEMBLY Y43NA2A 1 Clamp the differential case in a vise 2 Remove the differential drive gear retaining bolts and remove the differentia...

Page 374: ...32 11000 09532 11301 U9532 11100 9532 11000 R 09532 11301 F f O 9532 11100 Lock pin Pinion shaft Differential case 1 Install the spacer on the back of the side gear and then install the gear in the di...

Page 375: ...rect spacer reassemble and remeasure Caution Adjust the backlash of both side gears to the same spec ification 6 Align the pinion shaft lock pin hole with the case lock pin hole and insert the lock pi...

Page 376: ...and tighten in the order shown in figure to specified torque with the differential case clamped in a vise Specified sealant 3M Stud Locking No 4170 Caution If a bolt is reused remove the old sealant f...

Page 377: ...trol shaft ssembly Selee lever a r shoe r Select leve I r Coo m b S10ppe Oil seal t cont rOI flnge r t S tRo ptp nernrp ng 0 SP ng pin late Interlock P Spring pin Neutral return spring Neel bearing Cl...

Page 378: ...trol finger using the special tool 09414 11000 4 Drive out the spring pin from the stopper body using the spe cial tool 09414 11000 5 Pull out the control shaft and remove the control shaft boots and...

Page 379: ...g a socket wrench Oil seal Socket wrench 3 Install the neutral return spring assembly control finger interlock plate stopper body neutral return spring with the control shaft 4 Install new spring pins...

Page 380: ...CLUTCH HOUSING Slit 5 Install the interlock plate bolt and gasket 6 Install the select lever assembly and select shoe 43 52...

Page 381: ...AR ASSEMBLY COMPONENTS Oil seal I o Speedometer driven gear ASSEMBLY Y430A2A 1 Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft 2 Install the spring pin in such a way...

Page 382: ...RA2A 2 Install the input shaft front oil seal using the special tool 09431 21000 09431 21000 3 Install the differential gear bearing outer race and spacer using the special tool 09532 11500 09500 1100...

Page 383: ...1500 6 Install the differential gear assembly and output shaft assem bly 7 While lifting up the input shaft assembly install it simultane ously with the intermediate shaft assembly 8 Install the retai...

Page 384: ...pushed to 1st 2nd rail side 6 Turn the shift rail to engine shift lug 10 Reassembly of spring pin 1 Install the spring pins using the special tool 09414 111 2 When installing make sure that the slit o...

Page 385: ...ion case using the special tools 09500 21000 09532 32000 15 Install the output shaft bearing outer race and spacer to the transmission case using the special tools 09500 11000 09532 11500 09500 11 000...

Page 386: ...2 Install the transmission case and tighten the bolts to spec ified torque 3 Remove the transmission case 4 Remove the outer races and remove the solder Transaxle case o 00 5 Measure the thickness of...

Page 387: ...sealant go 21 Install the transaxle case to the clutch housing assembly and tighten the bolt 13 EA 22 Install the restriction ball and gasket 23 Center the shaft with a phillips screwdriver 24 Tighte...

Page 388: ...Install the spring pin using the special tool 09414 11100 09432 21500 09414 11100 31 When installing make sure that the slit of the spring pin is aligned with the shift rail center line Caution Do no...

Page 389: ...ghten the lock nut to specified torque 5 Stake the lock nut 33 Apply specified sealant to the rear cover and install the rear cover Specified sealant THREE BOND 1216 34 Install the mounting bracket 35...

Page 390: ...Y 59 AUTOMATIC TRANSAXLE ASSEMBLy 60 OIL PUMP ASSEMBLy 96 FRONT CLUTCH ASSEMBLy 100 REAR CLUTCH ASSEMBLy 103 END CLUTCH ASSEMBLy 106 PLANETARY GEAR SET 108 INTERNAL GEAR AND TRANSFER DRIVE GEARSET 112...

Page 391: ...Fourth Reverse Final gear ratio Speedometer gear ratio 45 2 GENERAL Automatic four speed with torque converter and integral differential KM175 With damper clutch 2 200 200 rpm 2 17 Electronically con...

Page 392: ...e gear bolt Manual control lever nut Manual control shaft set screw Inhibitor switch Sprag rod support bolt Pump housing to reaction shaft support bolt Oil pump assembly mounting bolt Valve body bolt...

Page 393: ...d lubricant GENUINE HYUNDAI ATF AUTOMATIC TRANSMISSION FLUID MOPAR ATF PLUS TYPE 7176 DIAMOND ATF SP BP AUTRAN MM SP For Australia Automatic transaxle fluid DEXRON II type Chassis grease SAE J310 NLGI...

Page 394: ...L IIIustration 2 6 Y45CE1B Use Removal and installation of the kickdown servo Diagnostic tester for MPI automatic transaxle and cruise control systems 09391 33401 5 R O M Pack HMC 2 09391 33700 6 Conn...

Page 395: ...aller 45 6 GENERAL IIIustration Use Removal of transfer shaft bearing outer race Installation of transfer shaft bearing Installation of transfer shaft bearing outer race use with 09500 21000 Removal o...

Page 396: ...pump 09453 24000 Spring compressor 09455 2100 Spring compressor Removal and installation of snap ring and return spring of front clutch use with 09453 21000 09453 21100 Spring compressor 09453 21200 S...

Page 397: ...r 09455 21100 Bearing installer 45 8 GENERAL Illustration i Use Installation of end clutch snap ring Measurement of the low and reverse brake end play use with a dial indicator and 09453 21400 Removal...

Page 398: ...of the transfer shaft rear side bearing 2 Installation of the transfer driven gear Supporting the transfer shaft Assembly of the valve body and transfer plate Removal and installation of kickdown ser...

Page 399: ...made of fluid levels and the condition of the ATF as well as the condition of the manual control cables adjustments should then be made if found to be necessary If a presumption has been made that th...

Page 400: ...h or piston al X X X l c 15 Malfunction of rear clutch or piston 9 X X X l t 16 Malfunction of kickdown band or piston al 17 Improper adjustment of kickdown servo C o c 18 Malfunction of low reverse b...

Page 401: ...en l l X X X X j shift 2 3 or 4 3 f en Excessive vibration shock during j X X X X X X 0 upshift Excessive vibration shock during iil X X XX X X X t 0 2 downshift Sudden engine rpm increase during X X...

Page 402: ...luid spongy Therefore pressure will be erratic Improper filling can also raise fluid level too high When transaxle has too much fluid gears churn up foam and cause same conditions which occur with low...

Page 403: ...properly adjusted if as described above the starter motor starts at both the P range and the N range 1 Connect the voltmeter or multi use tester to the connector for diagnosis 2 Read the output fault...

Page 404: ...ode Description will be stored in the RAM Three of these fault codes can be stored 4 The cancelation will occur if with the transaxle locked in 3rd gear the ignition key is turned to the OFF position...

Page 405: ...medy o Check the throttle position sensor connector o Check the throttle position sensor itself o Adjust the throttle position sen sor o Check the accelerator switch No 28 output or not o Check the th...

Page 406: ...oid valve con the shift control solenoid valve B nector system o Check shift control solenoid valve B itself 44 Short circuit of the shift control o Check the shift control solenoid J1fTIUlJ1L solenoi...

Page 407: ...he pulse generator output circuit harness o Check the pulse generator con nector o Check pulse generator A and pulse generator B themselves o Kickdown brake slippage o Check the pulse generator A outp...

Page 408: ...gear generated 4th time pulse generator B system 14 Damaged or discon Locked in 3rd gear When code No 41 or nected wiring or 42 is generated 4th short circuit of shift time control solenoid valve A 1...

Page 409: ...31 Upper 50 km h 31 mph mph driving 4 Throttle position sensor Accelerator fully open engine stopped Upper 4 5 5 0V o Upper No 21 ignition switch ON Lower OFF TPS output o Lower No 28 Accelerator ful...

Page 410: ...Power Economy select switch Select economy pattern Upper OFF o Lower no designation 12 Air conditioner relay Switch ON the air conditioner switch while Upper ON o Upper No 37 idling in 0 range Air co...

Page 411: ...ange TPS output Throttle position sensor output approx 2 5V according to load Lower 2 5V ELEMENT IN USE AT EACH POSITION OF SELECTOR LEVER Selector Overdrive Shifting Engine Parking Clutch Brake lever...

Page 412: ...select switch on the center console The solid lines shown in these shift patterns indicate up shifts and the broken lines indicate down shifts The reason why there is a difference between the shift po...

Page 413: ...__ _ j 0 o lJ L 20 f t r 7 J __ 1 __ __ _ ____I f 80 f __ i tL __ _ I__ __l Idle L _ l L_ _ L L 1000 60 f 7 l L f L if____ __ _ __I o Vehicle speed km h NORMAL RANGE 4600 4600 5400 Engine rpm 100 I 8...

Page 414: ...the positive and negative sides L r l of the connector terminal t 1 side 2 side _____t _ Replace the TPS resistance between Resistance Damaged or disconnected wir and 4 of the TPS high or infinite ing...

Page 415: ...se Very low i running at 1 000 rpm check the generator or malfunction of the voltage waveform between voltage pulse generator terminals 1 and 2 Correct the installation condition 1 000 mVp p or higher...

Page 416: ...ever to the R Stop the rl Improper adjustmnt of idling or 0 range engine Readjust the idling Let the engine continue idling Poor closure sticking of the I Normal I I damper clutch control solenoid val...

Page 417: ...operation noise Valve stroke 0 3 mm 0 012 in or less Replace the DCCSV Noise exists Sticking is usually at the Normal release side 8 Pressure Check the resistance between control sole I l terminal 2 o...

Page 418: ...of the solenoid valve and check the valve stroke Noise exists No operation noise stroke 0 25 mm O 010 in or less Residue accumulated in valve and core Replace the SCSV Normal I 10 Accelerator With the...

Page 419: ...ists In the N range check for conti nuity between terminals 3 and 5 I and terminals 10 and 11 Continuity exists 1No continuity Poor contact or damaged In the D range check for conti or disconnected wi...

Page 420: ...n servo switch terminal exists 1 and the transaxle case NOTE Be sure the brakes are Replace the KID servo applied during this check switch t No continuity Normal 13 Transaxle control unit TCU Disconne...

Page 421: ...il Pressure Table Conditions Standard oil pressure KPa psi No Reference Engine 1 2 3 4 5 6 Selector lever Shift Reducing Kickdown Front End clutch Low reverse Torque position vehicle speed speed posit...

Page 422: ...g e b Clogging of the filter L shaped type of b the reducing pressure circuit 2 Improper reducing pressure a Improper line pressure c Improper adjustment of the reducing pressure d Sticking of the red...

Page 423: ...ning b part c Functional malfunction of the valve c body assembly Disassemble the end clutch and check the seal ring O ring of the piston seal ring of the retainer O ring of the pipe etc replace if th...

Page 424: ...or the damper clutch system and the DCCSV clutch control valve b Clogging or leaking of the oil cooler b Repair or replace as necessary the and or piping cooler and or piping c Damaged seal ring of t...

Page 425: ...open any longer than is necessary to obtain maximum engine rpm reading and never longer than 5 seconds at a time If more than one stall test is required operate engine at approximately 1 000 rpm in n...

Page 426: ...ed and therefore can be distinguished from engine oil 2 Prior to removing transaxle perform following checks When leakage is determined to originate from transaxle check the fluid level prior to remov...

Page 427: ...Name Symbol E L C 4 speed automatic transaxle D control unit M P I control unit C Pulse generator A B Pulse generator B B Self diagnosis check connector G Solenoid A Throttle position sensor E Oil tem...

Page 428: ...Self diagnoSIS check connector GENERAL 45 39...

Page 429: ...uit forms bubbles which make fluid spongy Therefore pressures will be erratic causing delayed shift slippy clutch and brakes etc Improper filling can also raise fluid level too high When transaxle has...

Page 430: ...manual control lever aligns with switch body flange 12 mm 0 47 in wide portion Or turn switch body until 5 mm 0 20 in hole in manual control lever aligns with 5 mm 0 20 in hole in switch body 5 Tight...

Page 431: ...at the kickdown servo piston won t turn tighten the lock nut to the specified torque Loek nut 25 32 Nm 255 326 kg em 18 23 Ib ft 7 After fitting a new O ring in the groove around the cover install the...

Page 432: ...e figure Also be careful that the lead wiring isn t caught 9 Tighten valve body assembly mounting bolts 10 pieces to 10 12 Nm 100 120 kg cm 7 5 8 5 Ib ft A bolt 20 mm 0 787 in long B bolt 28 mm 1 102...

Page 433: ...as for adjustment of the line pressure 4 Make the oil pressure test Readjust if necessary ADJUSTMENT OF THROTTLE POSITION Y45C41A SENSOR TPS Refer to FUEL SYSTEM Service Adjustment Procedures REPLACEM...

Page 434: ...ble to the meter insert the cable until its stopper properly fits to the meter side groove 3 Install the grommet so that as shown in the illustration the cable attachment part and the projecting part...

Page 435: ...n the G wire and the ground wire at the accelerator switch connector 2 pin When the accelerator switch is ON 0 V When the accelerator switch is OFF 12 V ACCELERATOR SWITCH CHECK AND ADJUSTMENT 2 Measu...

Page 436: ...ONENTS Selector knob Overdrive switch connector J Position indicator I light connector I Control cable Shift lever assembly Shift lock solenoid assembly Cover Bush Parking position switch Nut Clip f _...

Page 437: ...overdrive switch connector and then remove the selector knob 4 Remove the indicator panel slider 5 Disconnect the position indicator light connector 6 Remove the indicator panel lower 7 Remove the sn...

Page 438: ...eck the bushing for wear or damage 3 Check the spring for damage or deterioration 4 Check the overdrive switch for continuity 0 0 Continuity 1 2 3 Switch position O 5 RW O 5 LR O 5 BrW Overdrive activ...

Page 439: ...r Push 0 D o o ILl IG SWITCH FREE TAILSW ILL PUSH PWR r r o I G _fr NORM IGNSW ILL I 1 Apply a coating of the specified grease to the interior of the bushing Specified grease Chassis grease SAE J310 N...

Page 440: ...tall the air cleaner assembly 6 Install the nut cable end pin snap ring 7 Connect the position indicator light connector the overdrive switch connector the parking position switch connector and the sh...

Page 441: ...face B of the adjusting cam to the push button driver s side 11 Install the selector knob 12 Install the console box Refer to BODY GROUP A Sleeve Lever assembly 1 Eliminate slack from the control cabl...

Page 442: ...0J QJ Bracket assembly TORQUE Nm kg cm Ib ft INSPECTION Y45EA1A o Check the detent place for wear o Check the bushing for wear or damage o Check the spring for damage or deterioration o Check the pin...

Page 443: ...SHIFT LEVER ASSEMBLY 2 Apply the specified grease at the places shown in the figure Specified grease Multipurpose grease SAE J310 NLGI No 2 45 54...

Page 444: ...ngth mm in Bolt identification A 43 55 430 550 31 40 7 10 x 40 1 6 J J AxB B 43 55 430 550 31 40 7 10 x 65 2 6 C 22 32 220 320 16 23 7 10 x 55 2 2 D 30 35 300 350 22 25 10 10 x 60 2 4 E 10 12 100 120...

Page 445: ...emove the control cable 4 Remove the speedometer cable 5 Disconnect the pulse generator connector inhibitor switch connector kickdown servo switch connector solenoid connector 6 Remove the starter mot...

Page 446: ...ine crankshaft with a box wrench to bring one of the bolts to the position appropriate for removal After removing the bolt turn the crankshaft in the same manner as above and remove all remaining bolt...

Page 447: ...12 Remove the transaxle assembly 45 58 AUTOMATIC TRANSAXLE 1...

Page 448: ...ssembly 3 Disconnect the automatic transaxle oil cooler hoses from the automatic transaxle CAUTION Plug the ends of the oil cooler hoses and the automatic transaxle port to prevent the transaxle fluid...

Page 449: ...dirt etc do not adhere If the transaxle main unit is damaged also disassemble and clean the cooler system 1 Clean away any sand mud etc adhered around the transaxle 2 Place the transaxle assembly on t...

Page 450: ...move manual control lever then remove inhibitor switch 7 Remove snap ring then remove kickdown servo switch 8 Remove the oil pan and gasket 9 Remove the oil filter from the valve body JI II s s c Kick...

Page 451: ...al from the bracket pull out from the connector side 11 Press the tabs of the solenoid valve harness grommet and then push into the case and remove the ELC connector 12 Remove 10 bolts and remove valv...

Page 452: ...AUTOMATIC TRANSAXLE ASSEMBLY 14 Remove the end clutch assembly 15 Remove the thrust plate 16 Remove the end clutch hub and thrust bearing 17 Pull out the end clutch shaft 45 63...

Page 453: ...multaneously and uniformly to remove oil pump assembly Oil pump may sometimes tilt to A side because straight line connecting oil pump removing holes does not pass center of pump If this is the case t...

Page 454: ...LE ASSEMBLY 23 Pull up the input shaft and then remove the front clutch assembly and the rear clutch assembly together 24 Remove the thrust bearing 25 Remove the clutch hub 26 Remove the thrust race a...

Page 455: ...E ASSEMBLY 27 Remove the kickdown drum 28 Remove the kickdown band 29 Using special tools 09222 21001 09456 21100 push in the kickdown servo and remove the snap ring 30 Remove the kickdown servo pisto...

Page 456: ...Remove the anchor rod UU U II c 32 Remove the snap ring 33 Attach special tool 09453 21310 on center support Holding handle of tool pull center support straight upward 34 Remove reverse sun gear and...

Page 457: ...r assembly and thrust bearing 36 Remove the wave spring return spring reaction plate brake disc and brake plate 37 Since screw lock paste is coated on the bolt threads tap the bolt head for easier rem...

Page 458: ...ot available use a punch or something similar 39 Remove idler shaft lock plate 40 Loosen transfer idler shaft with special tool 09454 21100 41 Pull out transfer idler shaft Remove transfer idle gear b...

Page 459: ...C TRANSAXlE ASSEMBLY 42 Remove the spacer 43 Remove snap ring from bearing 44 Remove internal gear output flange transfer drive gear and bearing as assembly from case 45 Remove the transfer shaft cove...

Page 460: ...and the transfer shaft lock nut rotation stopper up 47 Fix the transfer shaft converter housing side 48 Remove the locking nut NOTE The lock nut is left hand threaded 49 Knock off the transfer shaft t...

Page 461: ...driver remove the outer race 51 Remove two bolts and parking sprag rod 52 Remove the set screw and the manual control shaft assembly Remove the steel ball the seat and the spring together at this time...

Page 462: ...ler or adhesive to gaskets When bushing must be replaced replace assembly which includes it Do not use shop towels during disassembly and reassembly operation The oil in the cooler should also be repl...

Page 463: ...pecial tool 09453 21310 to the center support 5 Install the snap ring 6 Install the special tools 09453 21400 09453 33100 and a dial gauge at the rear side of the transaxle case Caution Install the di...

Page 464: ...manual control shaft into transaxle case and push it fully toward manual control lever At this time do not install O ring larger one of two O rings on manual control shaft NOTE If installed before in...

Page 465: ...Ib ft 6 Press fit the bearing inner race to the transfer driven gear and press fit the bearing outer race to the transaxle end clutch side 09432 21601 Transfer driven gear 7 Press fit the bearing inn...

Page 466: ...09455 21301 to the transaxle case to support the transfer shaft 10 Insert the thickest 1 80 mm 0 0709 in spacer 11 Attach the transfer driven gear 12 After removing the special tool affix the convert...

Page 467: ...cial tool measure the end play of the transfer shaft then select the spacer s needed to obtain the standard value and refit Transfer shaft end play 0 0 025 mm 0 0 0010 in 15 Using a punch lock the loc...

Page 468: ...t to the transaxle case 20 Install two taper roller bearings and spacer to transfer idle gear 21 Place the transfer idler gear assembled in the preceding section into the case and then insert the idle...

Page 469: ...is completed eliminate the backlash between the idler shaft and the lock plate by moving the idler shaft in the loosening direction Attach the lock plate and tighten the lock plate bolt Loek plate bo...

Page 470: ...827 2 4 0 094 5 1 70 2 756 55 7 2 193 2 2 0 087 42 6 1 677 28 1 102 6 70 2 756 55 7 2 193 2 6 0 102 54 2 126 38 7 1 524 1 6 0 063 7 70 2 756 55 7 2 193 1 8 0 071 2 52 2 047 36 4 1 433 8 48 9 1 925 37...

Page 471: ...e forward sun gear in the following order 1 Attach th e seal ring and the snap ring to the reverse sun gear When attaching squeeze the seal ring as shown in the figure 2 Attach the thrust race 9 to th...

Page 472: ...LE ASSEMBLY 30 Install both of the previously assembled sun gears inside the planetary carrier 31 Install the brake disc and brake plate 32 Install the selected brake pressure plate 33 Install the ret...

Page 473: ...er support Wave spring 36 After applying a coating of ATF to the O rings install the special tool 09453 21310 to the center support and install within the case Caution Be sure that the wave spring is...

Page 474: ...install a new O ring in the groove around the sleeve then assemble the kickdown servo spring piston and sleeve in the transaxle case 40 Press the kickdown servo and sleeve in by using special tools 0...

Page 475: ...on kickdown drum and tighten kickdown servo adjusting screw to keep band in position 43 Apply a coating of petrolatum to thrust bearing 8 and then attach to the kickdown drum 44 Apply a coating of pe...

Page 476: ...petrolatum 47 Apply a coating of petrolatum to thrust washer 2 and thrust bearing 4 and then attach to the rear clutch assembly Thrust bearing 4 48 Combine the rear clutch assembly and the front clut...

Page 477: ...h with washer of proper thickness corresponding to thrust race Find correct pair of thrust races metal and thrust washers fiber from following table Thrust washer 1 metal Thrust race 3 fiber Thickness...

Page 478: ...ump by USIn 51 to the 011 p assembly d the oil pump mp gasket an W oil pu 55 Install ne g and apply housln in groove of oil PU e surface of O ring 56 Install new o n efluid lightly to outs g six bolts...

Page 479: ...in the illustration 60 Install new case gasket to transaxle case 61 Install converter housing and tightening 14 bolts to 19 23 Nm 49O 2 0 kg cm 14 16 Ib ft 62 Remove the converter housing and gasket 6...

Page 480: ...tall new case gasket on transaxle case 67 Install converter housing and tighten 14 bolts to 19 23 Nm 190 230 kg cm 14 16 Ib ft 68 Install end clutch shaft Be sure to install the longest spring toward...

Page 481: ...ach by petrolatum thrust bearing 13 to the end clutch hub 72 Install end clutch assembly 73 Attach a new O ring and O ring to the end clutch cover Caution 1 Install so that the O ring is not twisted 2...

Page 482: ...r of top ot valve body assembly brake oil pressure passage 76 Install valve body assembly to case fitting detent plate manual control shaft pin in slot of manual valve 77 Replace the O ring of the sol...

Page 483: ...5 Ib ft 81 Install five magnets in the five depressions provided on the oil pan I 82 Install new oil pan gasket and oil pan y tightening 12 bolts to 10 12 Nm 100 120 kg em 7 5 8 5 Ib ft 83 Install a n...

Page 484: ...luid to outside surface of oil pump side cylindrical portion of torque converter install torque converter carefully so as not to damage oil seal lip Make certain that torque converter is in mesh with...

Page 485: ...ring from oil pump housing 2 Remove five bolts and remove reaction shaft support from housing 3 Remove oil pump drive and driven gears from pump housing 4 Make reassembly alignment marks on drive and...

Page 486: ...f the oil pump housing that contacts the oil pump gear reveals indications of interference replace the entire oil pump assembly Standard value 0 03 0 05 mm 0 0012 0020 in 2 Check the surface of the re...

Page 487: ...rings coated with automatic transaxle fluid to reaction shaft support 7 Make sure that oil pump gear turns freely 8 Install new O ring in groove provided in circumference of pump housing and apply pet...

Page 488: ...MENT 1 Pry off pump housing oil seal using a screwdriver 2 Using special tool 09452 21200 install oil seal to pump housing Apply thin coat of automatic transaxle fluid to oil seal lip before installat...

Page 489: ...FRONT CLUTCH ASSEMBLY FRONT CLUTCH ASSEMBLY COMPONENTS Clutch reaction plate 4 thickness 3 8 mm 150 in Snap ring select 45 100 O ring Clutch disc 3...

Page 490: ...box Radiator fan motor relay HIGH in the relay box Condenser fan motor relay HIGH in the relay box Blower relay Kick down switch A T Inhibitor switch A T Pulse generator A T Radiator fan motor relay L...

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