Mazda 1990 323 Workshop Manual Supplement Download Page 1

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Summary of Contents for 1990 323

Page 1: ...manual Workshop Manual Form No 1 195 l O 89E All information in this supplement was the latest available at the time of printing all alter nations related to modifications will be notified by Service...

Page 2: ...VEHICLE IDENTIFICATION NUMBERS VIN JMl 86227 LO IOOOOl JMl 86228 LO 100001...

Page 3: ...ETY GI 5 PREPARATION OF TOOLS AND MEASURING EQUIPMENT GI 5 SPECIAL TOOLS GI 5 REMOVAL OF PARTS GI 5 DISASSEMBLY GI 5 REASSEMBLY GI 6 ADJUSTMENTS GI 7 RUBBER PARTS AND TUBING GI 7 JACK AND SAFETY STAND...

Page 4: ...jeopardized by the use of incorrect methods or tools POSSIBLE LOSS OF WARRANTY The manufacturer s warranty on Mazda vehicles and engines can be voided if improper service or repairs are performed by p...

Page 5: ...ns If a damaged or worn part is found repair or replace it as necessary 2 Expendable parts tightening torques and symbols for oil grease and sealant are shown in the overview illustration 3 Pages rela...

Page 6: ...this is shown in the illustration NOTES CAUTIONS AND WARNINGS As you read through the procedures you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES give y...

Page 7: ...e that all necessary tools and measuring equipment are available before starting any work SPECIAL TOOLS Use special tools when they are required REMOVAL OF PARTS While correcting a problem try also to...

Page 8: ...e carefully and thoroughly cleaned in the appropriate method REASSEMBLY Standard values such as torques and certain adjustments must be strictly observed in the reassembly of all parts Refer to STANDA...

Page 9: ...AMENTAL PROCEDURES GI 67UOGX 00 9MUGIX 00 ADJUSTMENTS Use suitable gauges and or testers when making adjustments RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing...

Page 10: ...IX 00 REAR END Jack position At the center of the rear crossmember w w At the rear differential 4WD 03UGIX 801 Safety stand positions On both sides of the body frame 03UGIX 008 Safety stand positions...

Page 11: ...e wheel dollies With either automatic or manual transaxle 1 Set the ignition switch in the ACC position 2 Place the selector lever or shift lever in N Neutral 3 Release the parking brake Caution l Do...

Page 12: ...p dead center ATF Automatic transmission fluid BAC Bypass air control BBDC Before bottom dead center BTDC Before top dead center CPU Central processing unit EC AT Electronically controlled automatic t...

Page 13: ...3 Ensure that the antenna and feeder are properly adjusted 4 Do not install a high powered mobile two way radio system CRUISE CONTROL UNIT FEEDyT7N T HARNESS I MOBIT WAY RADIO AT LEAST 30 cm i 1 8 in...

Page 14: ...r electronic com ponents Voltmeter The DC voltmeter is used to measure of circuit voltage A volt meter with a range of 15V or more is used by connecting the positive probe red lead wire to the point w...

Page 15: ...rs Removal of connector Never pull on the wiring harness when disconnecting con nectors Connectors can be removed by pressing or pulling the lock lever as shown Locking of connector When locking conne...

Page 16: ...inals Inspection Pull lightly on individual wires to check that they are secured in the terminal Replacement of terminals Use the appropriate tools to remove the terminal as shown When installing the...

Page 17: ...has a short circuit and the wiring should be checked 2 Be sure the negative battery terminal is disconnected be fore replacing a main fuse 80A 3 When replacing a pullout fuse use the fuse puller supp...

Page 18: ......

Page 19: ...AND SCHEDULED MAINTENANCE SERVICES PRE DELIVERY INSPECTION A 2 PRE DELIVERY INSPECTION TABLE A 2 SCHEDULED MAINTENANCE SERVICES A 3 SCHEDULE 1 NORMAL DRIVING CONDITION A 3 SCHEDULE 2 UNIQUE DRIVING C...

Page 20: ...d steering lock Inhibitor switch ATX only Starter interlock switch clutch pedal MTX only All lights including warning and indicator lights Sound warning system Horn wipers and washers front and rear i...

Page 21: ...x 1 000 miles 7 5 15 22 5 30 37 5 45 52 5 60 Service data and inspection points x1 000 km 12 24 36 48 60 72 84 96 I I l Cracks or damage l Tension Engine oil R R R R R R R R l Oil pan capacity All BP...

Page 22: ...d thickness Minimum Front 2 0mm 0 08 in P 18 Rear I Omm 0 04 in p 25 l Operation and looseness Steering operation and linkage I I l Fluid leakage or oozing N 18 l Free play O 30mm O l 18 in N 8 Front...

Page 23: ...nce chart note the following points l Replacement of the timing belt is required every 60 000 miles 96 000 km Failure to replace the timing belt may result in damage to the engine 2 This maintenance i...

Page 24: ...US qt 5 3 Imp qt ATX n 750 f 50 pm With parking brake applied R 1 F 71 F 107 l Fittings connections and components for leaks F 9 I f l Proper attachment and connections l Operation l Pedal height wit...

Page 25: ...mm O l 18 in N 8 Front suspension ball joint I I l Damage looseness and grease leakage Driveshaft dust boots I I l Cracking and damage M 7 Bolts and nuts on chassis and body T T T T l Retighten all lo...

Page 26: ...ce chart note the following points l Replacement of the timing belt is required every 60 000 miles 96 000 km Failure to replace the timing belt may result in damage to the engine 2 This maintenance is...

Page 27: ...INDEX B 2 1FEATURES 1 OUTLINE B 3 OUTLINE OF CONSTRUCTION B 3 SPECIFICATIONS B 3 INTERCHANGEABILITY FLYWHEEL I SUPPLEMENTAL SERVICE INFORMATION B 6 REMOVAL PROCEDURE z INSTALLATION a B 14 PROCEDURE B...

Page 28: ...TIGHTENING TORQUE 16 23 1 6 2 3 12 17 DEFLECTION AT 98 N 10 kg 22 lb mm linl DRIVE BELT NEW USED ALTERNATOR 8 0 9 0 0 31 0 35 9 0 10 0 0 35 0 39 PIS PIS A c 8 0 9 0 0 31 0 35 9 0 10 0 0 35 0 39 COMPRE...

Page 29: ...ression ratio Compression pressure cc cu in mm in kPa kg cm2 psi rpm 1 839 112 2 83 0 x 85 0 3 27 x 3 35 8 9 1 197 12 2 173 300 With parking brake applied Canada TEN terminal of diagnosis connector gr...

Page 30: ...0 Crankshaft related I Crankshaft I 0 I Main bearing 0 Thrust bearing 0 Connecting rod and cap 0 Connecting rod bearing 0 Piston 0 Piston pin 0 Piston ring 0 Crankshaft pulley 0 Rear cover 0 Flywheel...

Page 31: ...OUTLINE B FLYWHEEL I 4WD MODEL 2WD MODEL The flywheel is shaped differently to accommodate the redesigned clutch disc and clutch cover B 5...

Page 32: ...to Removal Note Step 1 ATX ONLY 1 Undercover 2 Side cover 12 Oil cooler hose ATX 13 Radiator bracket 03UOBX 808 3 Resonance chamber and air cleaner assembly 4 Battery bracket and battery 14 Radiator...

Page 33: ...ump away from the engine and affix it with wire A C compressor Caution l Do not damage the hoses 1 Remove the A C compressor with the hoses still connected 2 Position the compressor away from the engi...

Page 34: ...e B 8 Removal note Fuel hose Warning l Keep sparks and open flame away from the fuel area Caution l Cover the hose with a rag because fuel will spray out when disconnecting l Plug the disconnected hos...

Page 35: ...X 81 03UOBX 81 6 Tie rod end Removal Note page B 9 7 Driveshaft Removal Note page B 10 8 Propeller shaft Removal Note page L 5 Removal note Tie rod end 1 Remove the cotter pin and loosen the nut until...

Page 36: ...oint shaft 2 Remove the lower arm ball joint clinch bolt Caution l Do not damage the ball joint dust boots 3 Pry the lower arm downward to separate itfrom the knuckle Caution l Do not damage the oil s...

Page 37: ...l 2 3 Water inlet pipe and gasket 7 Dynamic damper 4 Engine mount member 8 No 3 engine mount rubber Removal Note page B l 1 9 No 4 engine mount rubber and bracket 5 No 2 engine mount rubber and brack...

Page 38: ...ing the member Clutch release cylinder MTX 1 Remove the release cylinder pipe bracket from the transaxle 2 Position the release cylinder with the hose connected away from the transaxle for easier remo...

Page 39: ...der shown in the fiaure yu UL I IV yJ _ _ MTX ATX 03UOBX 81 1 Intake manifold bracket 4 Throttle cable ATX 2 Center differential lock motor 5 Torque converter nuts ATX Removal Note page J3 99 6 Transa...

Page 40: ...bolts and nuts to the specified torques Step 1 1 Join the engine and transaxle Torque Specifications MTX 37 52 3 8 5 3 27 38 84 89 8 911 47 88 N m m kg ft lb ATX 37 52 3 8 5 3 27 38 37 52 3 8 5 3 27 5...

Page 41: ...6 2 41 59 x 74 103 7 5 10 5 54 76 1 9 2 6 14 19 AA v 43 61 4 4 6 2 32 45 67 93 6 6 Q 5 49 69 w a 6 9 9 6 N m 70 100 cm kg 61 67 in lb 16 23 3 6 5 3 27 36 I N m m kg tl I 03UOBX 82 1 Engine and transax...

Page 42: ...em bly MTX Tightening torque 16 23 N m 1 6 2 3 m kg 12 17 ft lb I 6 9 9 6 N m 70 l 00 cm kg 61 67 in lb 4 No 2 engine mount rubber and bracket assembly Tightening torque 37 52 N m 3 6 5 3 m kg 27 36 f...

Page 43: ...103 N m 7 5 10 5 m kg 54 76 ft lb 11 Tighten nut I Tightening torque 67 93 N m 6 8 9 5 m kg 49 69 ft lb 12 install the dynamic damper Tightening torque 55 80 Narn 5 6 8 2 m kg 41 59 ft lb 13 Remove a...

Page 44: ...he clip 2 Install the driveshaft and a new clip 3 Install the lower arm ball joint to the knuckle and tighten the clinch bolt Tightening torque 43 59 N m 4 4 6 0 m kg 31 43 ft lb 4 Install the joint s...

Page 45: ...6 N m 3 2 4 7 m kg 23 34 ft lb 4 Tighten the bracket nuts J Tightening torque 21 27 N m 2 1 2 8 m kg 15 20 ft lb Select and shift cable MTX 1 Install the select cable and the spring pin 2 Install the...

Page 46: ...ensure a good fit BRAKE VACUUM HOSE VACUUM HOSE CRUISE CONTROL Step 5 1 Connect the harness connectors shown in the figure OIL PRESSU RE SWITCH DIFFERENTIAL LOCK SENSOR DIFFERENTIAL I _ A DISTRIBUTOR...

Page 47: ...5 I 9 2 8 14 1 9 24 35 2 4 3 8 17 28 107 915 l 1 9 89 79 9 3 N m 65 95 cm kg 58 82 in lb 7 6 l 1 N m 80 I 10 kg 89 95 In lb 7 8 11 N m SO 15 cm kg 89 95 in lb N m m kg it lb 03UOBX 8 OZWOBX 839 Crossm...

Page 48: ...witch connector 5 Connect the oil cooler hose ATX 6 Connect the coolant reservoir hose 7 Connect the upper and lower radiator t Caution 03UOBX 842 ATXj loses l Position the hose clamp in the original...

Page 49: ...ps after installation 1 If the engine oil was drained fill with the specified amount and type of engine oil 2 Fill the radiator with the specified amount and type of engine coolant 3 Fill the transaxl...

Page 50: ......

Page 51: ...E COOLING SYSTEM OUTLINE E 2 OUTLINE OF CONSTRUCTION E 2 SPECIFICATIONS E 2 RADIATOR AND COOLING FAN E 3 03UOEX 801...

Page 52: ...Imp qt 5 0 5 3 4 4 6 0 6 3 5 3 Water pump Type Centrifugal Water seal Unified mechanical seal Thermostat Type Opening temperature Full open temperature Full open lift C OF C OF mm in Wax two stage Mai...

Page 53: ...5 0 049 1 3 0 051 e Heat dissipation capacity kcallh 38 500 43 800 38 800 43 800 Type Double tube Laminated Transaxle oil cooler Heat dissipation capacity 1 650 kcallh 1 700 Cooling fan Number of blad...

Page 54: ......

Page 55: ...M OUTLINE I FUEL TANK AND TRANSFER PUMP F 7 A C CUT OFF SYSTEM F 9 SUPPLEMENTAL SERVICE INFORMATION F 9 FUELSYSTEM F 9 PRECAUTION F 9 FUEL TANK F l 0 TRANSFER PUMP CONTROL SYSTEM F 11 SYSTEM OPERATION...

Page 56: ...nit Fuel pump control unit Inspection page F l 2 Replacement page F l 2 3 Transfer pump switch Removal Installation page F i 3 Inspection page F l 3 4 Transfer pump Inspection page F l 3 Replacement p...

Page 57: ...pump side section of the fuel tank A water thermoswitch is equipped for A C cut off system 03UOFX 803 SPECIFICATIONS Solenoid valve Purge control Resistance s2 1 23 27 Water themosensor 1 20 t 4OFj 14...

Page 58: ...T 1 LENOID VALVE RGECONTROL AIR CL FUEL FILTER HIGH PRESSURE VALVE RESONANCE AY CHAMBER I 5 THROTTLE SENSOR piiEq AIR VALVE Ne El DlSTRlI3UTOR I I FiJEL PUMP FUEL FILTER y 1 IiiANW til t UMY j 0 ENGIN...

Page 59: ...REGULATOR ELECTRICAL AK SWITCH ECU lnnul ILt WATER I SENSOR IMTX1 THERMO t 1 P S PRESSURE SWITCH 1 CANADA DRL DAYTIME RUNNING LIGHT I HAMSFER PI _ LJMP TRANdFER PUMP SWITCH...

Page 60: ...RANSFER PUMP F UEL PUMP L FILTEF III FUE TANK 4x4 CONTROL UNIT FliEL PUMP CONTROL UNIT The fuel system consists of the fuel tank the transfer pump the fuel pump the fuel filters the pressure regu lato...

Page 61: ...te right and left section due to the installation of the propeller shaft for the 4 wheel drive system A transfer pump is used to pump the fuel from the left to the right fuel pump side The transfer pu...

Page 62: ...a result current flows to the coil the switch is switched ON and the transfer pump is activated No fuel in left tank The transfer pump switch is ON and the transistor within the fuel pump control unit...

Page 63: ...m remains under high pressure when the engine is not running a Before disconnecting any fuel line release the fuel pres sure from the fuel system to reduce the possibility of injury or fire 1 Start th...

Page 64: ...keep sparks cigarettes and open flames away from it l Before repairing the fuel tank clean it throughly with steam to remove all explosive gas 1 Remove in the order shown in the figure 2 Inspect the f...

Page 65: ...uel tank fittings at least 25mm 1 0 in 2 Push the fuel filler hose onto the fuel tank pipe and filler pipe at least 35mm 1 4 in TRANSFER PUMP CONTROL SYSTEM SYSTEM OPERATION 1 Turn the ignition switch...

Page 66: ...d verify that the voltage at the 4x4 control unit terminal N is OV 3 Remove the jumper wire and verify that the voltage at the 4x4 control unit terminal N is approx 12V after approx 10 sec No continui...

Page 67: ...nd terminal Float position Continuity UP No Down Yes 2 If not as specified replace the transfer pump switch TRANSFER PUMP Inspection 1 Remove the rear seat cushion 2 Disconnect the transfer pump conne...

Page 68: ...bber 6 Install in the reverse order of removal Disassembly Assembly Caution l Prevent contaminants from entering into the transfer pump 1 Disassemble in the order shown in the figure 2 Assemble in the...

Page 69: ...kg 69 95 in lb GASKET YEPLACE GASKET REPLACE 46 56 4 1 5 6 30 41 0 40 65 4 1 5 6 30 41 N m m kg R lb 03UOFX 828 1 Main silencer Inspect for deterioration and restriction 2 Middle pipe assembly Inspect...

Page 70: ......

Page 71: ...G ENGINE ELECTRICAL SYSTEM INDEX G 2 OUTLINE OUTLINE OF CONSTRUCTION g SPECIFICATIONS G 3 SUPPLEMENTAL SERVICE INFORMATION G 4 STARTING SYSTEM STARTER z 03UOGX 801 i...

Page 72: ...G INDEX INDEX J 03UOGX 802 1 Starter Removal Installation page G 4 G 2...

Page 73: ...erminal of diagnosis connector grounded Primary Resistance coil winding Ignition coil at 20 68OF Secondary coil winding BP SOHC MTX ATX 12 55023L 60AH Max 20 0 A C 12 65 Transistorized built in IC reg...

Page 74: ...ARTING SYSTEM STARTER Removal Installation 1 Remove in the order shown in the figure 2 Inspect all parts and repair or replace as necessary 3 Install in the reverse order of removal 37 52 3 8 5 3 27 3...

Page 75: ...H CLUTCH OUTLINE OUTLINE OF CONSTRUCTION I SPECIFICATIONS INTERCHANGEABILITY OF H 2 I MAJOR COMPONENTS RELEASE BEARING I 03UOHX 801...

Page 76: ...er mm in Inner diameter mm in Pressure plate side mm in Thickness Flywheel side mm in Diaphragm spring 3 846 392 862 225 8 86 150 5 91 4 1 0 161 3 5 0 138 Type Suspended Clutch pedal Pedal ratio 6 55...

Page 77: ...life a newly designed friction plate with needle roll er bearings is used between the release fork and the release bearing With the inclusion of this friction plate the force required to depress the c...

Page 78: ......

Page 79: ...ACEMENT J3 11 TRANSAXLEAND TRANSFER UNIT J3 13 PREPARATION J3 13 REMOVAL J3 18 DISASSEMBLY J3 20 INSPECTION J3 45 ASSEMBLY J3 48 INSTALLATION J3 88 SHIFT MECHANISM OVERHAUL CENTER DIFFERENTIAL LOCK SY...

Page 80: ...2 Transfer carrier oil Inspection page J3 1 1 Replacement page J3 1 1 3 Transaxle and transfer unit Removal page J3 16 Disassembly page J3 20 Inspection page J3 45 Assembly page J3 48 Installation pa...

Page 81: ...enter differential employs a planetary carrier system and functions to distribute the driving force to the front and rear differentials Through the use of this center differential tire scuffing common...

Page 82: ...tary carrier i Center differential Number of ring Outer 79 78 gear teeth inner 66 Number of pinion Outer 14 t gear teeth Inner 14 Pinion gear I Number of sun c side gear teeth Idler gear side 43 50 Nu...

Page 83: ...omposed of three shift rods shift forks and shift rod ends For the manual transaxle of the 1989 323 4WD the l 2 and 3 4 shift forks were moved by one shift rod but for the 1990 323 4WD separate shift...

Page 84: ...type For the manual transaxle of the 1989 323 4WD the one shift rod was held by the other shift rod s interlock sleeve but for the manual transaxle of the 1990 323 4WD when one shift rod is caused to...

Page 85: ...UOJ3 Ot For improved transaxle reliability a tapered roller bearing is newly fitted at the ring gear end of the idler gear shaft for better support in addition the previously fitted bearing is changed...

Page 86: ...ary 2nd gear 3 Primary 3rd gear 9 Secondary 3rd gear 4 Primary 4th gear 10 Secondary 4th gear 5 Primary 5th gear 11 Secondary 5th gear 6 Primary reverse gear 12 Secondary reverse gear 13 Reverse idler...

Page 87: ...OUTLINE J3 POWERFLOW IST 3RD 5TH 2ND 4TH A 03UOJl 005 J3 9...

Page 88: ...f each gear Worn steel sliding groove of control end Weak spring pressing against steel ball Excessive thrust clearance Worn bearing Improperly installed or loose engine mount lnsuff icient oil Deteri...

Page 89: ...ary amount of the specified oil through the check plug port Specified oil All season ATF DEXRON It M III Above 18OC OOF SAE 75W 90 Grade API service GL4 Capacity 2 6 liters 2 7 US qt 2 2 Imp qt 4 Veri...

Page 90: ...mount of the specified oil through the check plug port Grade API servies GI 5 Specified oil Above 18 C O F SAE 90 Below 18 C O F SAE 80W Capacity 0 5 liter 0 53 US qt 0 44 Imp qt 4 Install the check p...

Page 91: ...PREPARATION SST 49 GO17 5A0 Support engine 49 0118 85OC support of engine 49 0107 680A Stand engine Transaxle hanger 49 GO30 440 49 0636 145 49 GO17 IA0 49 F401 366A 49 8092 373 Attachment G 49 0839 4...

Page 92: ...ment of bearing preload 19 F401 382A selector 452 Part of 19 GO30 380C For 49 F401 384 For adjustment of adjustment of bearing preload Collar Part of 49 GO30 380C bearing preioad Q 49 GO19 021 Set bol...

Page 93: ...TRANSAXLE AND TRANSFER UNIT J3 Gauge set pinion height adjustment 49 F401 337A Attachment C Part of 49 DO17 2Al 49 F027 005 Attachment 962 differential side 49 W023 785 Rubber bush 03UOJ3 01 J3 15...

Page 94: ...nnect the negative battery cable 2 Raise the vehicle and support it with safety stands 3 Drain the transaxle oil and transfer carrier oil into a suitable container 4 Remove in the order shown in the f...

Page 95: ...J3 18 23 Starter 24 Engine mount member Removal Note page J3 19 25 Engine mount No 2 26 Clutch release cylinder and clutch pipe Removal Note page J3 19 27 Transaxle and transfer carrier Removal Note...

Page 96: ...he transaxle case _I Caution l If the SST is not installed the differential side gears may become misaligned 4 Slide the SST into the differential side gear Center differential lock motor 1 Remove the...

Page 97: ...T before removing the en gine mounting member Clutch release cylinder Caution l Do not damage the clutch pipe 1 Remove the bolts shown 2 Lay aside the clutch release cylinder and the clutch pipe Trans...

Page 98: ...with compressed air Clean out all holes and passages with a compressed air and check that there are no obstructions 3 Wear eye protection when using compressed air to clean components 5th Reverse Gear...

Page 99: ...e J3 70 28 Interlock pin 29 Reverse idler gear shaft assembly 30 Reverse idler gear Inspection page J3 45 31 Reverse idler gear support 32 Reverse idler gear shaft 33 Bolt 34 Steel ball spring and bol...

Page 100: ...27mm 0 0108 in 4 If the clearance exceeds the maximum check the contact surfaces of 5th gear and the clutch hub Replace worn or damaged parts Disassembly note Clutch release bearing clutch release for...

Page 101: ...reuse the removed locknut 3 Uncrimp the tabs of the locknuts 4 Remove the locknuts from the primary and secondary shafts 5 Remove the shift fork together with the clutch hub assembly Top cover assembl...

Page 102: ...04 J3 24 2 Hold the front differential assembly and the idler gear as sembly so that primary shaft and secondary shaft can be removed 3 Remove the primary shaft assembly secondary shaft as sembly and...

Page 103: ...eld 5 Separate the front stabilizer from the lower arm Caution l Do not damage the dust boots 6 Remove the clinch bolt and pull the lower arm downward Separate the knuckle from the lower arm ball join...

Page 104: ...end gap of the clip facing upward 13 Install the joint shaft Tightening torque 42 62 N m 4 3 6 3 m kg 31 46 ft lb 14 install the lower arm ball joint to the knuckle and tighten Tightening torque 43 5...

Page 105: ...TRANSAXLE AND TRANSFER UNIT MEMO _ _ J3 27...

Page 106: ...Components Caution l Do not remove an oil seal if not necessary 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 34 R...

Page 107: ...nd air breather 24 Air breather 25 Baffle 26 Lever set spring and steel ball 27 Reverse lever support 28 Bearing outer race 29 Oil seal 30 31 32 33 Bearing outer race Disassembly Note page J3 30 Funne...

Page 108: ...3 057 Note l Remove the bearing outer race with a screwdriver if necessary 1 Insert a screwdriver between the clutch hous ing and bearing outer race 2 Pry the bearing outer race free 1 Remove the bear...

Page 109: ...CE 1 Inner select lever 2 Select lever 3 Roll pin Disassembly Note page J3 32 4 Retaining rings Disassembly Note page J3 32 5 Shift lever 6 Boot 7 Inner shift lever 8 Washer 9 Springs Disassembly Note...

Page 110: ...shift cover to the boot side 2 Remove the roll pin Retaining rings 1 Slide the guide spring and remove the retaining ring 2 Remove the inner shift lever Oil seal 1 Remove the oil seal with a screwdriv...

Page 111: ...ly Note page J3 34 2 4th gear Inspection page J3 45 3 Synchronizer ring 4th Inspection t page J3 45 4 Retaining ring 5 Clutch hub assembly 3rd 4th Disassembly Note page J3 34 Inspection page J3 45 6 S...

Page 112: ...UOJ3 061 03UOJ2 04 I 1 03UOJ2 045 J3 34 Disassembly note Bearing inner race 4th gear end Caution l Hold the shaft with one hand so that it does not fail 1 Remove the bearing inner race with the SST _...

Page 113: ...J3 45 3 Retaining ring 4 Secondary 3rd gear Preinspection page J3 36 Disassembly Note page J3 36 Inspection page J3 45 5 2nd gear Disassembly Note page J3 36 Inspection page J3 45 6 Synchronizer ring...

Page 114: ...ry 4th gear Caution l Hold the shaft with one hand so that It does not fall 1 Remove the bearing inner race and secondary 4th gear with the SST Secondary 3rd gear and 2nd gear 1 Remove the retaining r...

Page 115: ...TRANSAXLE AND TRANSFER UNIT 53 03UOJ2 04 Bearing inner race Secondary shaft end Caution l Hold the shaft with one hand so that it does not fall 1 Remove the bearing inner race with the SST J3 37...

Page 116: ...Assembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Inspect all bearings for damage and rough rotation and r...

Page 117: ...r wear and cracks 18 Gear case needle bearing 19 20 21 22 23 24 25 Planetary carrier Inspect gears for wear cracks and rough rotation Gear case needle bearings Differential gear case sleeve Disassembl...

Page 118: ...J3 40 2 Idler gear Inspect gear teeth for wear and cracks 3 O ring 4 Joint sleeve 5 Bearing inner race Joint sleeve side Disassembly Note page J3 40 I 03UOJ3 074 Bearing inner race Idler gear side 1...

Page 119: ...TRANSAXLE AND TRANSFER UNIT J3 MEMO J3 41...

Page 120: ...TRANSAXLE AND TRANSFER UNIT Transfer Carrier Assembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 InsDect all Darts and repair or replace as necessary 03UOJ3 07 J3...

Page 121: ...14 Collapsible spacer 15 Bearing inner race Disassembly Note page J3 44 Inspect for damage and rough rotation 16 Bearing inner race Disassembly Note page J3 44 Inspect for damage and rough rotation 1...

Page 122: ...ify the bearing outer races for proper reas sembly 1 Remove the bearing outer races by alternately tapping the races at the two grooves in the carrier Bearing inner race Drive pinion Note l Support th...

Page 123: ...nspect the individual synchronizer ring teeth for damage wear and cracks 2 Inspect the taper surface for wear and cracks Note l Set the synchronizer ring squarely in the gear then measure around the c...

Page 124: ...easure the clearance between the reverse idler gear bush ing and the reverse lever Standard clearance 0 095 0 345mm 0 0037 0 0136 in Maximum 0 645mm 0 0333 in Bearing 1 Inspect for damage and rough ro...

Page 125: ...34 970 35 000 35 025 _ 1 376 1 377 1 378 1 379 3rd 35 945 35 970 36 000 36 025 _ 0 03 0 08 1 415 1 416 1 417 1 418 0 001 0 003 4th 30 945 30 970 31 000 31 025 _ 1 218 1 219 1 220 1 221 5th 34 000 34...

Page 126: ...5TH REVERSE 03UOJ3 089 03UOJ3 22 SYNCHRONIZER RING CLUTCH HUB SLEEVE SYNCHRONIZER KEY 03UOJl 06 I Clutch hub assembly Note l Synchronizer ring diameters are as follows 1st and 2nd 3rd and 4th 5th and...

Page 127: ...TRANSAXLE AND TRANSFER UNIT MEMO J3 49...

Page 128: ...ND TRANSFER UNIT Transfer Carrier Assembly 1 Assemble in the reverse order of disassembly referring to Assembly Note N m m kg ft II 03UOJ3 C 117 176 12 18 86 130 I 68 89 6 9 9 1 50 66 18 25 1 8 2 6 13...

Page 129: ...52 9 Bearing inner race 10 Oil seal Assembly Note l page J3 54 11 Companion flange Assembly Note page J3 54 12 Washer 13 Nut Companion flange 14 Ring gear assembly 15 Bearing outer races Side bearing...

Page 130: ...Install the bearing inner race front companion flange washer and nut c Tighten the nut just enough so that the SST can be turned by hand d Place the SST on a surface plate and set the dial indicator...

Page 131: ...on height adjustment above being careful that the installa tion direction is correct l Press the bearing on until the force required sud denly increases 2 Press the bearing inner race rear bearing on...

Page 132: ...m kg 6 7 13 6 in lb Tightening torque 117 176 Nom 12 16 cm kg 66 130 in lb Adjustment of Backlash 1 Position the idler gear assembly in the carrier 03UOJ3 098 2 Install the differential bearing caps m...

Page 133: ...differential bearing preload be careful not to affect the backlash of the drive pin ion and ring gear Tightening torque 18 25 N m 1 8 2 8 m kg 13 19 ft lb Inspection and adjustment of teeth contact 1...

Page 134: ...race Joint sleeve side Assembly Note page J3 56 2 Joint sleeve 3 O ring 4 Idler gear 5 Bearing inner race Idler gear side Assembly Note page J3 56 M PLATE 03UOJ3 IO 03UOJ3 103 Assembly note Bearing in...

Page 135: ...TRANSAXLE AND TRANSFER UNIT J3 MEMO J3 57...

Page 136: ...rential gear case sleeve Assembly Note page J3 59 8 Needle bearings 9 Planetary carrier assembly 10 Needle bearing 11 Sun gear 12 Needle bearing 13 Washer 14 Spacer 15 Bearing inner race Sun gear side...

Page 137: ...and turn it 18OO Note l 00 not install the washer at this time 3 Install the other pinion gear and washer 4 Turn the pinion gear and washer 150 5 Install the washer under the opposite pinion gear 6 A...

Page 138: ...8 in 3 If the clearance is not within specification select the prop er washer from the chart below Measured clearance mm in 1 Washer thickness mm in 0 9 I I 0 0354 0 0433 I 3 5 0 137 0 7 0 9 0 02x5 0...

Page 139: ...OJ3 114 r Clearance 0 15 0 30mm 0 0059 0 0118 in 4 If the clearance is not within specification select the prop er washer from the chart below 03UOJ3 ll Adjustment of front ring gear clearance 1 Insta...

Page 140: ...2 Oil seal Select lever side 8 Washer 9 Inner shift lever _ Assembly Note page J3 63 10 tjoot 3 Oil seal Assembly Note page J3 63 Assembly Note page J3 63 11 Shift lever 4 Reverse gate spring Assembly...

Page 141: ...Install the new oil seal with a suitable pipe Oil seal Caution l Apply transaxle oil to the oil seal lip 1 Install the new oil seal with a suitable pipe Springs Caution l Do not misinstall the spring...

Page 142: ...ce Secondary shaft end Assembly Note page J3 65 7 1 st gear Assembly Note page J3 65 8 Synchronizer ring 1st Assembly Note page J3 65 9 Clutch hub assembly ist 2nd Assembly Note page J3 48 _I 10 Retai...

Page 143: ...ear synchronizer ring 1St and clutch hub assembly lstMnd as shown in the figure 2 Press the clutch hub assembly 1st Znd on with the SST Note l Press to 19 620 N 2 000 kg 4 400 lb Synchronizer ring 2nd...

Page 144: ...and differen tial drive gear Clearance 0 05 0 28mm 0 002 0 011 in Maximum 0 33mm 0 013 in 3 Measure the clearance between the 2nd gear and secon dary 3rd gear Clearance 0 175 0 455mm 0 0069 0 0179 in...

Page 145: ...ge J3 68 2 Synchronizer keys 3 Clutch hub sleeve Reverse gear 4 Synchronizer springs 5 Primary shaft 6 Bearing inner race Primary shaft end Assembly Note page J3 68 7 3rd gear Assembly Note page J3 68...

Page 146: ...stalling them The 2nd gear ring has the larger cut out as shown in the illustration l Align the synchronizer ring grooves and clutch housing hub keys when installing 1 Install the 3rd gear synchronize...

Page 147: ...UNIT 53 3 Measure the clearance between the 4th gear and bearing inner race Clearance 0 165 0 365mm 0 0064 0 0144 in Maximum 0 415mm 0 0163 in 4 If not as specified reassemble the primary shaft assem...

Page 148: ...the figure referring to Assembly Note 39 59 4 0 6 0 29 43 WASHER a LlC A 7 6 11 0 60 110 cm kg 69 95 in lb 46 3 2 4 7 23 34 7 n 11 n Ian lln nm kn 7 6 12 0 SC 120 cm kg 69 104 in lb 2 l 6 8 7 12 7 8...

Page 149: ...et 23 Plug 24 Ventilator covers 25 Dust cover 26 27 28 29 30 31 Transaxle case Adjustment shim Bearing outer race Adjustment shim Bearing outer race Oil seal Front and center differential 32 Assembly...

Page 150: ...03UOJ3 13 3 Set the idler gear assembly into the clutch housing 4 Turn the idler gear assembly to seat the bearing 5 Install the bearing outer race to the idler gear assembly 6 Measure from the top o...

Page 151: ...e primary shaft secondary shaft and front and center differential by select ina and installing the proper adjustment shim s 1 03UOJ3 13 TRANSAXLE CASE OUTER RACES OUTER RACE PRIMARY SHAFT ASSEMBLY FRO...

Page 152: ...Set the SST selectors in place 4 Mount the primary and secondary shaft gear assemblies onto the SST selectors 5 Set the SST collars between the transaxle case and the clutch housing and install the S...

Page 153: ...f the diaphragm spring which goes between the shim and the race from the meas ured value of the gap in the SST selector Example 0 94mm 0 0370 in 0 94mm 0 0370 in 0 70mm 0 0276 in Diaphragm spring 0 24...

Page 154: ...n place 4 Set the SST collars between the transaxle case and the clutch housing and install the SST bolts and tighten to the specified torque Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft lb 5 Sea...

Page 155: ...54mm 0 021 in So the nearest shim on thick side to 0 54mm 0 021 in is 0 6mm 0 014 in 10 Remove the SST bolts and collars and then remove trans axle case 11 Remove the SST selector bearing outer race a...

Page 156: ...ghten to the specified torque 37 52 N m 3 8 5 3 m kg 27 38 ft lb 9 Check the secondary shaft preload with the SST Preload 0 3 0 4 N m 3 0 4 3 cm kg 2 8 3 7 in lb 10 Remove the SST transaxle case and s...

Page 157: ...TRANSAXLE AND TRANSFER UNIT I 53 BEARING OUTER 03UOJ2 08 Diaphragm spring 1 Install the diaphragm spring as shown in the figure J3 79...

Page 158: ...arts 1 Assemble in the order shown in the figure referring to Assembly Note 7 6 l 1 O 60 l 10 cm kg 69 95 in lb 23 26 2 3 2 7 17 20 31 46 3 2 4 7 23 34 ROLL PIN NEW r Y 60 110 cm kg 69 96 in lb N m m...

Page 159: ...rod assembly 29 Bolt 30 Reverse idler gear shaft 31 Reverse idler gear support 32 Reverse idler gear 33 Reverse idler gear shaft assembly Assembly Note page J3 83 34 Interlock pin Assembly Note page...

Page 160: ...idler gear assembly Caution l Do not incision the hands to install time l Do not damage the oil seal 1 Lean the clutch housing 2 Install the front and center differential assembly idler gear and cent...

Page 161: ...nterlock pins as shown in the figure Top cover assembly 1 Install the steel balls and the springs 2 Install the top cover 3 Install the boot with the air bleed downward as shown in the figure Transaxl...

Page 162: ...he groove Primary 5th gear Note l After installation move the shift rod to verify that the gear change operation is smooth 1 Shift to neutral and install the roll pin Rear Cover Note l Clean the conta...

Page 163: ...rod 180 counterclockwise with a screwdriver and install the plug 3 Install the bolts Tightening torque 9 14 N m 90 140 cm kg 78 122 ft lb 4 Install the differential lock switch 03UOJ3 173 Tightening t...

Page 164: ...all in the order shown in the figure referring to Installation Note 3 Add the specified amount of the specified transaxle oil Refer to page J3 11 4 Warm up the engine and transaxle and inspect for oil...

Page 165: ...e page J3 89 17 Bolt 18 Differential lock motor connector 19 Back up light switch connector 20 Neutral switch connector Installation Note page J3 89 21 Shift cable 22 Speedometer cable Assembly Note p...

Page 166: ...h the driveshafts into the differential with the groove of the clips upward Note l Apply ATF to the oil seal lip 3 Install the driveshaft 4 Tighten the joint shaft mounting bolts in the order shown Ti...

Page 167: ...shaft Refer to Section L Control cable 1 Install the bracket Tightening torque 18 25 N m 1 9 2 8 m kg 13 18 ft lb 2 Attach the control cable to the bracket with the clip 3 Connect the control cable to...

Page 168: ...J3 TRANSAXLE AND TRANSFER UNIT Speedometer cable 1 Connect the speedometer cable 03UOJ3 181 J3 90...

Page 169: ...ly referring to Assembly Note I I 9 8 15 0 1 0 1 5 7 2 11 0 7 6 l 1 O 80 I 10 cm kg 89 95 in lb DO NOT INSTALL AS SHOWN N m m kg ft lb 03UOJ3 18 1 Rear console 7 Shift lever assembly Assembly Note pag...

Page 170: ...t console Shift lever assembly 1 Remove the nut and the clips 2 Disconnect the shift cable and select cable from the shift lever assembly 3 Remove the 4 mounting nuts 4 Remove the shift lever assembly...

Page 171: ...DIFFERENTIAL LOCK SYSTEM w 1 I I r A 2 1 S B 1 JB 07 0 CENTER DIF LOCK SWITCH ILLUMINATION LAMP REFER TO PAGE Z 78 t 9ir FI 01 JB 03 0 t 5 3 yEL PUMP METER I I CENTER I R 27 4x4 CONTROL UNIT 1 EM 19...

Page 172: ...that the indicator lamp in the instrument cluster is turned on and a beep is heard Note l The indicator lamp will flash until the center differential is fully engaged If necessary move the vehicle for...

Page 173: ...motor 3 Check resistance between terminals at the motor side con nectors Unit f Ohm Motor Free Lock B G D G W L 00 0 l 3 0 00 REPLACEMENT 1 Disconnect the negative battery terminal 2 Disconnect the co...

Page 174: ...nd transfer unit 8 Remove the O ring from the center differential lock motor 9 Measure the shift rod length in FREE and LOCK position Standard length FREE 75mm 2 95 in LOCK 83mm 3 26 in Note l Apply A...

Page 175: ...14 22 ft lb 15 Install the center differential lock sensor switch Tightening torque 20 29 Nsrn 2 0 3 0 m kg 14 22 ft lb 4x4 CONTROL UNIT INSPECTION Terminal Voltage 1 Turn the ignition switch ON 2 Mea...

Page 176: ...continuity in LOCK and FREE position Motor Free Lock a b c d e 0 0 M Indicates continuity v REPLACEMENT 1 Disconnect the negative battery terminal 2 Remove the switch 3 Replace the switch v CENTER DI...

Page 177: ...K2 143 EC AT CONTROL UNIT K2 144 WIRE HARNESS K2 146 TRANSAXLE AND TRANSFER K2 147 TRANSAXLE AND TRANSFER ASSEMBLY K2 147 TRANSAXLE AND TRANSFER UNIT DISASSEMBLY K2 152 TORQUE CONVERTER K2 167 OIL PUM...

Page 178: ...ction Replacement 03UOK2 OC Adjustment page K2 199 page K2 134 page K2 143 11 Control valve body assembly 2 Transfer carrier oil 6 Throttle sensor Disassembly Inspection Inspection Replacement 7 EC AT...

Page 179: ...as the 1989 626 EC AT G4A EL non turn0 model l The center differential employs a planetary carrier system and functions to distribute the driving force to the front and rear differentials l The elect...

Page 180: ...and right wheels Driving force for the rear axle is transmitted through the transfer unit the transfer carrier the propeller shaft and to the rear differential If the vehicle encounters very slippery...

Page 181: ...mp 40 6 6 7 0 5 8 Torque converter stall torque ratio 2 7 Forward clutch 313 Number of drivel driven plates Coasting clutch 3 4 clutch 212 414 1 Reverse clutch I 212 Low and reverse clutch 313 2 4 bra...

Page 182: ...OUTLINE STRUCTURAL VIEW REVERSE FOR WARD OUTPUT TORQUE CONVERTER OUTPUT GEAR TURBINE SHAFT IDLER GEAR K2 6...

Page 183: ...Brake band 4 Turbine shaft 12 Low and reverse brake 5 Oil pump shaft 13 One way clutch 1 6 Oil pump 14 One way clutch 2 7 Forward clutch 15 Large sun gear 8 Coasting clutch 16 Small sun gear 17 Long...

Page 184: ...0 0 0 S I e ngine A 1St Yes 0 0 0 Q3 No 0 0 0 oh I 0 0 0 2nd Below approx 110 km h 68 m Above aoorox 110 km h 68 mob Iyes v I L No 0 0 No 0 0 0 0 0 0 0 Below approx 5 km h 3 1 mph at operating 3rd te...

Page 185: ...LET TO OIL PUMP TRANSAXLECASE INLET CONTROL VALVE BODY 2 3 ACCUMULA COASTING CLUTCH TORQUE CONVERTER FRONT CHAMBER REVERSE CLUTCH TORQUECONVERTERREARCHAMBER FORWARD CLUTCH LOW AND REVERSE BRAKE u 2 4...

Page 186: ...NVERTER FRONT CHAMBER TORQUE CONVERTER REAR CHAMBER 3 4 CLUTCH TRANSAXLE HOUSING 03UOKX 00 Oil Pump OUTLET FOR LUBRICATION OUTLET TO FORWARD CLUTC UTLET TO REVERSE CLUTCH INLET TO UTLET TO CASTING CLU...

Page 187: ...ENT j HOLD SWITCH CM e V It 1 q 3 4 SOLENOID w LOCK UP JUDGMENT t ATF THERM0 SWITCH F m r LOCKUP SOLENOID INHIBIT WATER THERMOSIGNALtr JUDGMENT INHIBITOR SWITCH 0 LOCKUP F DIAGNOSIS AND c AVAILABLE FA...

Page 188: ...Detects throttle valve fully closed position Detects position range of gear selector Sets Hold mode Detects use of service brakes Indicates engine coolant temperature Detects automatic transaxle fluid...

Page 189: ...4WD G4AX EL BATTERY A GENERATOR Tmwt LE r MALFUNCTION INDICATOR v 1 I WATER SWITCH SWITCH SPEED SENSOR THERM0 SIGNAL BATTERY 1990 323 F4AzL a IGNITION 1 nll TPU lunl n 1 STOPL I Vbl INDICATOR n STARTE...

Page 190: ...OD Lockup OFF Lockup ON 1st 2nd 1 Below approx 5 km h 3 1 mph at operating I ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON ON S L HOLD D S 3rd temperature I I Above approx 5 km h 3 1 mph...

Page 191: ...l l 2 shift solenoid valve l 2 3 shift solenoid valve l 3 4 shift solenoid valve l Lockup solenoid valve If a condition as shown in the table below exists the EC AT control unit judges that the compon...

Page 192: ...as little interference as possible with driving performance If a malfunction occurs at all four solenoid valves 3rd 1st and reverse gears are obtained hydraulically Note l If all solenoid valves are...

Page 193: ...ator Vehicle speed sensor 06 Throttle sensor l2 JLMJ I I Pulse generator l 2 shift solenoid valve 60 I Z 3 shift solenoid valve 61 I I 2 3 shift solenoid valve 62 nn Lockup solenoid valve Note 63 1 2...

Page 194: ...ift Lockup Engine braking Shift Lockup Engine braking R Reverse 2 333 X X 1st 2nd 2 800 X 1 540 X X I I I I I I t Will not shift unless selector button depressed 03UOK2 01 t Will shift without selecto...

Page 195: ...ut regard to coolant signals The shift pattern is as shown below This function does not effect R or L range Shift Pattern at High ATF Temperature Normal mode Hold mode Range Gear Gear ratio Shift Lock...

Page 196: ...ote l Malfunction code s can also be checked for by the flashing sequence of the HOLD indicator lamp Refer to page K2 108 Step 2 Electric Signal Inspection Check the signals to from the EC AT control...

Page 197: ...lt of an incorrect adjustment Check the adjustment of each component and readjust if necessary 3 Input and outout signals of the EC AT control unit for the components indicated in the EC AT TESTER col...

Page 198: ...in N range Vehicle moves in P range or parking gear not disengaged when P dis 1 engaged 4 1 Excessive creep 8 Frequent shifting 9 1 Shift point hiah or low 10 No lockup 11 No kickdown 3 I I 2 Engine...

Page 199: ...TROUBLESHOOTING GUIDE K2 OFF VEHICLE c Powertrain e does not move in D S L and R ranges Refer to 1990 323 Workshop Manual 1O 89E 03UOK2 02 K2 23...

Page 200: ...tomer one can find out what the symptoms are and under what conditions they occur Work Flow CHECK IN I LISTEN TO CUSTOMER COMPLAINTS I REFER TO TROUBLESHOOTING PAGE THAT CORRESPONDS TO ACTUAL SYMPTOM...

Page 201: ...Check if ATF level is OK Yes Go to next step w page K2 134 Level Between notches on HOT side of level gauge at 65 149 F Add ATF to specified level OSJOFX 021 DESCRIPTION Further describes the symptom...

Page 202: ...41 K2 47 Shift schedule is as follows D range Normal mode Ist 2nd Srd OD Hold mode Ist 2nde3rd OD S range Normal mode lst 2nd 3rd OD Hold mode 2nd 3rd OD L range Normal mode 1st 2nd Hold mode 1st 2nd...

Page 203: ...verheats 21 Hold indicator lamp flashes Hold indicator flashes if a malfunction occurs of any of components as follows l Vehicle speed sensor l Throttle sensor l Pulse generator l Solenoid valves l 2...

Page 204: ...P INSPECTION ACTION 1 Check if ATF level is OK Yes Go to next step w page K2 134 Level Between notches on HOT side of level gauge at 65 149 F HOT RANGE No Add ATF to specified level w page K2 134 2 Ch...

Page 205: ...air of replace parking mechanism No Go to next step 5 Check if line pressure and throttle pressure are Yes Go to next step within specification c7 page K2 123 125 Line pressure Throttle pressure Range...

Page 206: ...Forward clutch or coasting clutch iTEC 1 2 3 Try known good EC AT control unit control valve body assembly or replace transaxle Refer to 1990 323 Workshop Manual 1195 I O 89E Check if selector lever...

Page 207: ...allation or adjustment incorrect 3 Parking mechanism malfunction TEP INSPECTION ACTION 1 Check if selector lever operation is OK Yes Go to next step w page K 264 No Adjust or repair selector lever w p...

Page 208: ...nge and N to D range shift shock felt TROUBLESHOOTING HINTS Engine idle speed misadjusted Throttle cable misadjusted Ignition timing BTDC 7 f lo Idle speed 750 f 50 rpm with parking brake applied inst...

Page 209: ...it clogged or leaking Forward clutch reverse clutch low and reverse brake one way clutch 1 or one way clutch 2 TEP INSPECTION ACTION 1 Check if ATF level is OK Yes Go to next step w page K2 134 Level...

Page 210: ...CT page K2 137 6 Check if line pressure at idle is OK Yes Go to next step w page K2 123 Line pressure 71 Adjust throttle cable No Line pressure kPa kg cm2 psi w page K2 137 3 6 4 4 51 63 8 9 10 6 127...

Page 211: ...e Oil pump worn Hydraulic circuit clogged or leaking w page K2 134 Between notches on HOT side of level CT page K2 134 Clear pink Normal condition Dark or black with friction material Worn powertrain...

Page 212: ...driven as follows R range Reverse D and S ranges 3rd L range 1st Note l Engine rpm at 40 km h 25 mph 1st gear 3 950 rpm 3rd gear 1 400 rpm Check if voltage at 2E 2G or 21 terminals of EC AT control un...

Page 213: ...1J or 2P 2G and IJ or 2P 21 and IJ or 2P Resistance 13 27Q Resistance 13 2752 If OK go to next step If not OK repair wiring Apply 12V to 2E 2G and 21 terminals and check if operation sound clicking o...

Page 214: ...ep 6 If not OK repair wiring w page F 143 nection at connectors Check if resistance between 2J terminal and 2L terminal of EC AT control unit is OK Resistance 200 4OOQ Resistance 200 4009 6 If OK go t...

Page 215: ...tion at connectors Continuity d If OK go to next step No If not OK repair wiring Yes No Replace selector lever knob assembly 25 Disconnect connectors from EC AT control unit Yes Try known good EC AT c...

Page 216: ...eck for cause Refer to Evaluation c7 page K2 121 22 Check if line pressure and throttle pressure are Yes Go to next step within specification c7 page K2 123 125 Line pressure Throttle pressure 4 8 6 0...

Page 217: ...2 4 brake band misadjusted P INSPECTION ACTION Check if ATF level is OK Yes Go to next step w page K2 134 Level Between notches on HOT side of level gauge at 65 149OF HOT RANGE No Add ATF to specified...

Page 218: ...unit Yes Check if all output and input component indica Go to Steps 6 11 13 16 19 20 and tions are correct Especially hold switch solenoid 21 in sequence valves throttle sensor voltage and drum speed...

Page 219: ...J or 2P 2G and 1J or 2P 21 and IJ or 2P Resistance 13 27Q Resistance 13 273 6 If OK go to next step c3 If not OK repair wiring Apply 12V to 2E 2G and 21 terminals and check if operation sound clicking...

Page 220: ...K Resistance 200 4OOQ w page K2 142 tors and go to next step minal of EC AT co unit and oscilloscope in put terminal to 2J terminal of EC AT control unit Check if pulse display is OK Very low voltage...

Page 221: ...ING GUIDE CT page K2 144 Voltage Approx 12V Hold switch released switch and 1H terminal of EC AT control unit is and poor connection at connectors If OK go to next step If not OK repair wiring a page...

Page 222: ...50 rpm No Check for cause Refer to Evaluation w page K2 121 Check if line pressure and throttle pressure are Yes Go to next step within specification w page K2 123 125 Line pressure Check for cause Re...

Page 223: ...for cause Refer to specified check sequence w page K2 108 No Code No displayed Check main relay and voltage of termi nals 2Q and 2s of EC AT control unit Voltage Approx 12V Ignition switch ON 88 flash...

Page 224: ...3 Check if engine stall speed is OK CD page K2 119 Engine stall speed 2 550 2 650 rpm Check for cause Refer to Evaluation c7 page K2 121 cc7 page K2 123 Throttle pressure 8 Try known good EC AT contro...

Page 225: ...l Between notches on HOT side of level gauge at 65 149OF HOT RANGE u page K2 134 TI No Add ATF to specified level 2 Check if ATF condition is OK Yes Go to next step w page K2 134 Clear pink Normal con...

Page 226: ...ecially idle switch throttle sensor voltage vehicle speed and drum speed Check for cause contra unit IS w page K2 144 Voltage Approx 12V Ignition switch ON w page K2 144 w page K2 144 2A No Check for...

Page 227: ...scope in put terminal to 2J terminal of EC AT control unit Check if pulse display is OK L I I l y I K No Adjust or replace throttle sensor Yes Go to Step 12 No Go to next step Yes No Yes No Check for...

Page 228: ...nd check for causev page K2 152 I I I 14 Check if engine stall speed is OK Yes Go to next step 0 page K2 119 Engine stall speed 2 550 2 850 rpm No Check for cause Refer to Evaluation v page K2 119 15...

Page 229: ...ON Check if malfunction indicator lamp MIL is illuminated Start engine and let it at idle Check if malfunction indicator lamp MIL goes 3FF Yes No Yes No Yes No Check for malfunction Code No r ACTION...

Page 230: ...TING GUIDE es not illuminate w page K2 144 Voltage Approx 12V Ignition switch ON oltage at terminal 2K of EC AT control w page K2 144 Voltage Approx 12V Lockup solenoid ON Lockup No Replace EC AT cont...

Page 231: ...not OK repair wiring 12V to 2E 2G 21 and 2K terminals and if operation sound clicking of solenoid is Apply 12V to 2K terminal of EC AT control unit start engine in P range and let it ide Shift to D ra...

Page 232: ...fter engine warmed up Check if operation of water thermosensor is OK w page F 142 Yes Go to Step 16 No Go to next step Yes No Go to next step Yes Replace engine control unit No Go to next step Yes Che...

Page 233: ...Yes Check for short or open circuit of wiring w page T 45 and poor connection at connector Switch Continuity If OK go to next step Depressed Yes 4 If not OK repair wiring Released No No Replace stopli...

Page 234: ...ors If OK go to next step If not OK repair wiring w page K2 144 c3 If OK go to next step If not OK repair or replace w page F 143 and poor connection at connectors Check if resistance between 2J and 2...

Page 235: ...l to 2L Yes Go to next step terminal of EC AT control unit and oscilloscope input terminal to 2J terminal of EC AT control unit Check if pulse display is OK No Very low voltage Replace pulse generator...

Page 236: ...if line pressure and throttle pressure are Yes Go to next step within specification m page K2 123 125 Line pressure Check for cause Refer to Evaluation c7 page K2 124 126 29 Try known good EC AT cont...

Page 237: ...ck main relay and voltage of termi nals 2Q and 2s of EC AT control unit Voltage Approx 12V Ignition switch ON 66 flashes Check wiring between 1C terminal of EC AT control unit and diagnosis con nector...

Page 238: ...f operation of hold switch is OK Yes Check for open or short circuit of wiring cc7page K2 140 and poor connection at connectors Switch Continuity If OK go to next step Depressed No If not OK repair wi...

Page 239: ...ulse generator II n 7 t n I 11 Connect oscilloscope ground terminal to 2L 1CD terminal of EC AT control unit and oscilloscope input terminal to 2J terminal of EC AT control n I I U L IIG L 3Lq3 12 Dis...

Page 240: ...SHOOTING GUIDE terminals of EC AT control unit and ground is Resistance 13 273 c3 If OK go to next step If not OK repair wiring 12V to 2E 2G and 21 terminals and if operation sound clicking of solenoi...

Page 241: ...level gauge at 65 149 F HOT RANGE No Add ATF to specified level w page K2 134 2 Check if ATF condition is OK Yes Go to next step w page K2 134 Clear pink Normal condition Dark or black with friction...

Page 242: ...and throttle pressure are Yes Go to next step within specification CT page K2 123 125 Line pressure No Check for cause Refer to Evaluation 3 page K2 124 126 Throttle pressure 5 Try known good EC AT c...

Page 243: ...ext step w page K2 134 Level Between notches on HOT side of level gauge at 65 149OF HOT RANGE No Add ATF to specified level w page K2 134 2 Check if ATF condition is OK Yes Go to next step w page K2 1...

Page 244: ...and throttle pressure are Yes Go to next step within specification w page K2 123 125 Line pressure Check for cause Refer to Evaluation c7 page K2 124 126 Throttle pressure 5 Try known good EC AT cont...

Page 245: ...is OK Yes Go to next step CT page K2 134 Level Between notches on HOT side of level gauge at 65 149 F HOT RANGE I _ No Add ATF to specified level w page K2 134 COOL RANGE 2 Check if ATF condition is...

Page 246: ...ure Line pressure kPa kg cm psi 111 No 1 Adjustthrottlecable 3 6 4 4 51 63 8 9 10 6 127 151 wpageK2 139 6 1 37 17 0120 5 2i2 292 6 Check if time lag is within specification at idle Yes Go to next step...

Page 247: ...and throttle pressure are Yes Go to next step within specification CT page K2 123 125 Line pressure Throttle pressure Check for cause Refer to Evaluation CY page K2 124 126 9 Try known good EC AT con...

Page 248: ...TF to specified level w page K2 134 2 Check if ATF condition is OK Yes Go to next step w page K2 134 Clear pink Normal condition Dark or black with friction material Worn powertrain components Milky p...

Page 249: ...K2 tions are correct es not illuminate w page K2 144 EC AT control unit is OK w page K2 144 Voltage Approx 12V W Solenoid valve 2E and 1J or 2P 2G and IJ or 2P 21 and 1J or 2P Resistance 13 27Cl No G...

Page 250: ...y known good EC AT control unit and unit go to next step Apply 12V to 2E 2G and 21 terminals and check if operation sound clicking of solenoid is heard No Replace solenoid valve 11 Check if throttle c...

Page 251: ...ISY IN N AND P RANGES JESCRIP 9 Noise corresponds to engine speed rlON TROUBLESHOOTING HINTS j ATF level low Oil pump worn TEP INSPECTION ACTION 1 Check if ATF level is OK Yes Go to next step CT page...

Page 252: ...epair or replace parts as necessary w page K2 134 No 3 or No 4 condition Replace ATF 3 Check if engine stall speed is OK Yes Go to next step w page K2 110 Engine stall speed 2 550 2 650 rpm No Check f...

Page 253: ...is OK w page K2 134 Clear pink Normal condition Dark or black with friction material Worn powertrain components Milky pink Water contamination I Light to dark brown Oxidation Overheated or old fluid C...

Page 254: ...if line pressure and throttle pressure are Yes Go to next step within specification w page K2 123 125 Line pressure Throttle pressure Check for cause Refer to Evaluation w page K2 124 126 5 Check oth...

Page 255: ...ATF to specified level c7 page K2 134 2 Check if ATF condition is OK Yes Go to next step w page K2 134 Clear pink Normal condition Dark or black with friction material Worn powertrain components Milk...

Page 256: ...K2 TROUBLESHOOTING GUIDE es not illuminate w page K2 144 Solenoid valve 2E and 1J or 2P 2G and 1J or 2P 21 and IJ or 2P Resistance 13 27Q K2 80...

Page 257: ...dle w page K2 122 Time lag N D 0 5 1 0 second N t R 0 6 1 0 second Check if engine stall speed is OK CT page K2 119 Engine stall speed 2 550 2 650 rpm Yes No Yes No Yes No Yes No ACTION Check for poor...

Page 258: ...hrottle pressure are Yes Go to next step within specification w page K2 123 125 Line pressure Check for cause Refer to Evaluation 17 page K2 124 126 Throttle pressure 13 Try known good EC AT control u...

Page 259: ...sequence CT page K2 106 No Code No displayed Check main relay and voltage of termi nals 20 and 2s of EC AT control unit Voltage Approx 12 Ignition switch ON 66 flashes Check wiring between IC terminal...

Page 260: ...K2 TROUBLESHOOTING GUIDE 4 If OK go to next step 6 If not OK repair wiring or 2P terminals of EC AT control unit is OK K2 84...

Page 261: ...2K terminal of EC AT control unit is OK D page K2 144 Approx 12V Lockup solenoid ON Lockup 2K 4 No Go to next step IO Check if continuity of transistors in EC AT control Yes Go to next step unit is O...

Page 262: ...V to 2K terminal of EC AT control unit Yes Go to next step Start engine in P range and let it idle Shift to D range and check if engine stalls No Replace lockup solenoid valve 15 Check if voltage at 2...

Page 263: ...EC AT control unit Check if pulse display is OK Yes No Yes No I ACTION Check for poor connection at connec tors and go to next step Replace pulse generator Check for open or short circuit of wiring a...

Page 264: ...s OK Yes Go to next step w page K2 134 Clear pink Normal condition Dark or black with friction material Worn powertrain components Milky pink Water contamination Light to dark brown Oxidation Overheat...

Page 265: ...Approx 12V Check if voltage at terminal 2K of EC AT control w page K2 144 Voltage Approx 12V Lockup solenoid ON Lockup 2Kand lJor2P ngine in P range and let it idle Shift to 0 range and check if engin...

Page 266: ...minals of EC AT control unit No Go to next step 9 Check for correct resistance between terminals Yes Check for poor connection at con of ATF thermosensor nectars D page K2 142 ti If OK try known good...

Page 267: ...in specification w page K2 123 125 T Line pressure 1 n 1 6 1 9 6 87 137 1 17 0 20 5 242 292 l No Throttle pressure Try known good EC AT control unit control valve assembly or replace transaxle Yes L G...

Page 268: ...TEST Check for cause Refer to specified Check if Malfunction Code No is displayed check sequence c7 page K2 108 Code No LOCATION OF MALFUNCTION 06 Vehicle speed sensor 12 Throttle sensor 55 Pulse gen...

Page 269: ...No displayed Check main relay and voltage of termi nals 2Q and 2s of EC AT control unit Voltage Approx 12V Ignition switch ON 66 flashes Check wiring between IC terminal of EC AT control unit and dia...

Page 270: ...for correct continuity between each Yes Go to next step terminal of inhibitor switch and terminal of EC AT control unit No Repair wiring 7 Check if operation of inhibitor switch is OK Yes Check for op...

Page 271: ...ect EC AT Tester to EC AT control unit Yes Go to Steps 3 6 9 12 15 and 16 in Check if all output and input component indica sequence tions are correct Especially inhibitor switch stop light switch loc...

Page 272: ...art engine in P range and let it idle Shift to D range and check if engine stalls No Replace solenoid valve 6 Disconnect 20 pin connector of EC AT control Yes Go to Step 8 unit Check if resistance bet...

Page 273: ...EC AT co unit and oscilloscope in put terminal to 2J terminal of EC AT control unit Check if pulse display is OK grounding of shield 6 If OK go to next step If not OK repair wiring Refer to 1990 323...

Page 274: ...of replace wiring 14 Check if operation of inhibitor switch is OK Yes Check for open or short circuit of wiring a page K2 140 and poor connection at connectors If OK go to next step c3 If not OK repai...

Page 275: ...tall speed is OK Yes Go to next step c7 page K2 119 Engine stall speed 2 550 2 650 rpm No Check for cause Refer to Evaluation v page K2 121 17 Check engine control system or Try known good EC AT contr...

Page 276: ...adjusted 3 ATF thermosensor malfunction 3 Pulse generator malfunction 3 Lockup solenoid stuck 3 Lockup control valve stuck 8 Torque converter worn 3 Hydraulic circuit clogged or leaking Ions are corre...

Page 277: ...ngine in P range and let it idle Shift to D range and check if engine stalls No Replace solenoid valve 6 Disconnect 20 pin connector of EC AT control Yes Go to Step 9 unit Check if resistance between...

Page 278: ...ion timing BTDC 7 f lo Idle speed 750 f 50 rpm with parking brake applied Check for correct resistance between IG termi nal and J or 2P terminals of EC AT control unit n good EC AT con thermosensor an...

Page 279: ...ck if engine stall speed is OK Yes Go to next step CT page K2 119 Engine stall speed 2 550 2 650 rpm No Check for cause Refer to Evaluation c7 page K2 121 13 Try known good EC AT control unit control...

Page 280: ...e memorized in the EC AT control unit to later be output as mal function codes The EC AT Tester and EC AT Selector are used to retrieve these malfunction codes Each malfunction is indicated by a code...

Page 281: ...e switch on the adapter unit to position A 4 Set the vehicle switch on the adapter unit to the 323 position 5 Set the vehicle switch on the EC AT selector to position 1 For EC AT tester body 49 GO19 9...

Page 282: ...heck that 88 flashes on the digital display and that the buzzer sounds for 3 seconds 7 If 88 does not flash check the diagnosis connector wiring 8 If 88 flashes and the buzzer sounds continuously for...

Page 283: ...onnector is not grounded the indicator flashes at a constant frequency until the malfunction recovers However the malfunction code is memorized in the EC AT control unit 3 The EC AT control unit has a...

Page 284: ...nput signal from speed sensor while driving at drum speed above 600 rpm in D S or L ranges Open circuit when accelerator depressed idle switch OFF or in correct adjustment No input signal from pulse g...

Page 285: ...play vehicle speed Yes Vehicle speed sensor OK Refer to page K2 116 Cancel memory of code number or replace EC AT control unit No Go to next step 3 Does vehicle speed sensor operate correctly Yes Chec...

Page 286: ...hrottle sensor volt Yes Throttle sensor OK age Refer to page K2 116 Cancel memory of code number or replace EC AT control unit No Go to next step 3 Is variable resistor of throttle sensor OK Yes Check...

Page 287: ...No Go to next step Does EC AT Tester display drum speed Yes Pulse generator OK Cancel memory of code number or replace EC AT control unit Is resistance of pulse generator OK Resistance 200 4OOfl No Go...

Page 288: ...pair connector No Go to next step Yes Replace EC AT control unit No Check for open circuit in wiring 03UOK2 058 CODE No 61 2 3 SHIFT SOLENOID VALVE iTEP INSPECTION ACTION 1 Are there any poor connecti...

Page 289: ...unit connector and ground Terminal 21 and ground Continuity Yes No Check for open circuit in wiring 03UOK2 Ot CODE No 63 LOCKUP SOLENOID VALVE STEP INSPECTION ACTION 1 Are there any poor connections...

Page 290: ...K2 SELF DIAGNOSIS FUNCTION Circuit Diagram ENGINE 03UOKX 07 K2 114...

Page 291: ...r as shown 5 Turn the ignition switch ON 6 Verify that no code numbers are displayed ELECTRICAL SIGNAL INSPECTION In this step the input and output signals are checked with the EC AT Tester The tester...

Page 292: ...F ATF temperature above 142 148OC 288 298OF ATF thermoswitch or wiring ATF temperature below 138OC 28OOF Hold switch released Hold switch or wiring Hold switch depressed Throttle valve fully closed Id...

Page 293: ...unit 2 3 shift solenoid or wiring EC AT control unit 3 4 shift solenoid or wiring LOCKUP SOLENOID VALVE ON OFF Lockup condition Non Lockup condition EC AT control unit lock up solenoid or wiring ISHI...

Page 294: ...pprox 4 km h 2 5 mph ON Above approx 5 km h 3 mph ON 3rd OD 1st 2nd Below approx 5 km h 3 1 mph at oper ating temperature Above approx 5 km h 3 1 mph or cold engine Lockup OFF Lockup ON 1st ON ON ON O...

Page 295: ...is slippage of the friction elements or malfunction of the hydraulic components Preparation 1 Check and correct as necessary the engine coolant engine oil and ATF levels before testing 2 Warm the eng...

Page 296: ...5 must be performed within 5 seconds to prevent possible transaxle damage 4 Firmly depress the foot brake with the left foot and gently depress the accelerator pedal with the right 5 When the engine...

Page 297: ...e In forward ranges Forward clutch slipping One way clutch 1 slipping Above specification In D range In S Hold and L Hold ranges In D Hold and S Hold ranges In R L and L Hold ranges One way clutch 2 s...

Page 298: ...he engine at idle speed for at least one minute Note l Make three measurements for each test and take the average value 5 Perform the test for the following shifts in the same manner 1 N D range 2 N t...

Page 299: ...G BRAKE 03UOK2 070 LINE PRESSURE AT IDLE LINE PRESSURE AT STALL 43 1 Start the engine and check the idle speed in P range Refer to Section F Idle speed 750 f 50 rpm with parking brake applied 2 Shift...

Page 300: ...head plug in the inspection port Tightening torque 4 9 9 8 N m 50 100 cm kg 43 87 in lb Evaluation of Line Pressure Test Line pressure Worn oil pump Possible location of problem Low pressure in every...

Page 301: ...IDLE SPEED THROTTLE AT IDLE PRESSURE THROTTLE PRESSURE AT STALL J L 1 Start the engine and check the idle speed in P range Refer to Section F Idle speed 750 f 50 rpm with parking brake applied 2 Shift...

Page 302: ...sure Range D Throttle pressure kPa kg cm2 psi Idle Stall 39 88 0 4 0 9 6 l 3 471 589 4 8 6 0 68 85 1 I 1 03UOK2 073 6 Install a new square head plug in the inspection port Tightening torque 4 9 9 8 N...

Page 303: ...Note l Drum speed rpm of the EC AT Tester represents the shift point l The vehicle s indicated speed as shown by the vehicle speedometer may not be accurate when the vehicle is on a chassis roller The...

Page 304: ...shift solenoid valve Stuck 3 4 shift valve No lockup shift Stuck lockup control solenoid valve Stuck lockup control valve IIncorrect shift point Misadjusted throttle sensor Stuck shift valves Stuck a...

Page 305: ...AND CRUISING SHIFT UP 100 120 140 160 63 75 87 99 VEHICLE SPEED km h mph I UJUUKZ U l b _ 3 While driving in S range and 3rd gear select the Hold mode and verify that 3rd gear is held until the 3 2 d...

Page 306: ...ector lever to L range 2 Accelerate the vehicle and verify that the l 2 upshifts and downshifts are obtained and that no 3rd gear OD or lockup is obtained 3 Check the upshifts for shift shock or slipp...

Page 307: ...E I I ii c 2 7 5 8 I z 2 2 3 4 8 I G 1 9 3 8 I 5 I is 1 4 2 8 0 I Y E 0 9 118 i B I E 0 4 018 I I I I 1 I I I I I I 1 I I 20 40 60 80 100 120 140 160 12 25 37 50 63 75 87 99 VEHICLE SPEED km h mph No...

Page 308: ...50 I 84 l IO 52 68 I I D3 02 Lockup ON fS3 J tlSU 4 lSU Kickdown Fully opened 4 OV I I s3 s2 E s2 Sl Sl s2 3 100 3 350 86 94 53 58 2 000 2 300 36 42 22 26 2 800 3 700 28 37 17 23 3 300 4 250 60 77 137...

Page 309: ...pm I 1 000 I 2 000 I 3 000 I 4 000 I Vehicle speed km h mph 10 6 20 12 36 19 40 25 10 6 20 12 30 19 40 25 18 11 36 22 55 34 73 45 28 17 1 56 35 1 84 52 1 112 69 40 25 1 80 50 1 120 74 1 160 99 6 OD D...

Page 310: ...he selector lever from P to L and back to P 4 Let the engine idle 5 Shift the selector lever to P Note l Only use the COOL 20 C 68OF range as a rough reference 6 Ensure that the ATF level is in the HO...

Page 311: ...luid leaks Check for fluid leaks of the transaxle at the points shown below and repair or replace as necessary 1 Gaskets O rings and plugs 2 Oil hoses oil pipes and connections 3 Oil cooler _ O RING _...

Page 312: ...specified oil from plug port 3 Install the check plug Tightening torque 39 58 N m 4 0 6 0 m kg 28 43 ft lb REPLACEMENT 1 Remove the drain plug Drain the oil into a suitable container 2 Install the dr...

Page 313: ...heck the inner and outer cable for damage 2 Verify that the accelerator operates smoothly I 03UOK2 087 03UOK2 088 Replacement 1 Disconnect the oil hose 2 Remove the throttle cable from the throttle le...

Page 314: ...e to the throttle lever 13 Install the control valve body cover and a new gasket Tightening torque 8 3 l 1 O N m 85 l 10 cm kg 74 l 00 in lb 14 Align the marks and slide the oil cooler hose onto the o...

Page 315: ...nuts to the correct position using the following procedure 1 Initially install the locknuts fully away from the throttle cam Loosen the cable all the way 2 Adjust the locknuts in a clockwise direction...

Page 316: ...voltage Switch Approx 12V Released Below 1 5V Depressed 4 If not correct go to the next step I OBUOKX 13 03UOKX 13 ENGINE START BACK UP LIGHTS ILLUMINATE I Continuity Switch Yes No Released Depressed...

Page 317: ...5 Install the new inhibitor switch and the manual shaft nuts Tightening torque 8 11 N m 80 110 cm kg 69 95 in lb 6 Align the holes of the inhibitor switch and the selector lever by inserting an appro...

Page 318: ...heat it up gradually 3 Check the continuity of the terminals If necessary replace the switch Connection guide Fluid temperature Continuity Above 150 f 3 C 302 f 37 F 1 Yes I Below 143T 289OF I No I P...

Page 319: ...cable SOLENOID VALVE Inspection 1 Disconnect the solenoid valve connector 2 Measure resistance between each terminal and a ground Resistance 13 27Q Note l 1 2 shift solenoid valve A l 2 3 shift solen...

Page 320: ...utput Hold indicator 1B Below 1 5V Hold mode I Approx 12V 1 Normal mode I Approx 12V Normal With EC AT Tester I Below 1 5V or Approx 12V If malfunction present With EC AT Tester fluctuating Code signa...

Page 321: ...n AC range Below 1 5V idle switch ON Throttle valve fully closed Ground Approx 3V 4V While driving Approx 3v 4v Vehicle stopped or below 1 5V Below 1 5V i Ignition switch OFF Ground Below 1 5V P and N...

Page 322: ...K2 ELECTRONIC SYSTEM COMPONENTS WIRE HARNESS diagram OBUOKX K2 146...

Page 323: ...rod end 49 GO17 502 Support Part of 49 GO17 5AO For 49 GO30 455 For support of engine holding side gear Holder differential side gear 03UOK2 1 C Removal 1 Disconnect the negative battery cable 2 Jack...

Page 324: ...K2 TRANSAXLE AND TRANSFER UNIT Y K2 148...

Page 325: ...2 Center differential lock motor Removal Note page K2 150 23 Starter 24 Engine mount member Removal Note page K2 151 25 Engine mount No 2 26 Oil hose In side 27 Oil hose Out side 28 Transaxle and tran...

Page 326: ...saxle case Caution 0 If the SST is not installed the differential side gears may become misaligned 4 Slide the SST into the differential side gear Center differential lock motor 1 Remove the set bolt...

Page 327: ...NIT K2 03UOK2 10 03UOK2 IC Engine mounting member 1 Suspend the engine with the SST before removing the en gine mounting member Transaxle and transfer 1 Use an engine hoist and remove the transaxle an...

Page 328: ...d throughly clean it when the clutch or brake band has burned or when the ATF has degenerated Cleaning Notes 1 Clean the transaxle exterior thoroughly with a steam cleaner or cleaning solvents before...

Page 329: ...e K2 173 10 Wave washer 4 2 4 brake band 11 Snap ring Disassembly Inspection I 12 Retaining plate Assembly page K2 197 13 Low and reverse brake Drive and driven plates 5 Small sun gear and one way clu...

Page 330: ...d O RING REPLACE I P 2 5 P O RING f REPLACE 2 O RING REPLACE 4 Q I I Q B SPRING CLIP REPLACE 1 Transaxle case 5 Manual shaft and manual plate 2 Output shell 6 Actuator support 3 Turbine shaft 7 Parkin...

Page 331: ...using 15 Idler gear assembly Transfer 5 Idler gear assembly Transaxle Disassembly Inspection Disassembly I Inspection I Assembly page K2 237 Assembly page K2 202 16 Transfer carrier assembly 6 Output...

Page 332: ...spill when removing the torque converter J 1 Remove the torque converter from the converter housing 2 Pull out the oil pump shaft by hand 86U07B 119 3 Remove the oil level gauge and oil filler tube 4...

Page 333: ...e hanger to the oil pump as shown 7 Lift the transaxle and mount it on the SST Warning l Avoid leaning the transaxle to one side during dis assembly it may turn quickly and cause injury 8 Remove the p...

Page 334: ...5 Remove the oil pan and gasket Examine any material found in the pan or on the magnet to determine the condition of the transaxle Clutch facing material Drive plate and brake band wear Steel magnetic...

Page 335: ...I 03UOK2 130 18 Remove the throttle cable 1 Remove the throttle cable attaching bolt and bracket 2 Remove the cable from the throttle lever of the valve body 19 Pinch the tangs of the solenoid connect...

Page 336: ...2 13 23 Remove the clutch assembly 1 Remove the turbine shaft snap ring 2 Pull the reverse and forward drum and remove the clutch assembly Note l Use a piece of wire to secure the brake band so that i...

Page 337: ...strut then remove the strut 27 Remove the servo 1 Remove the snap ring with the SST 2 Remove the servo and spring 28 Remove the one way clutch and carrier hub assembly 1 Remove the snap ring 2 Remove...

Page 338: ...d driven plates 30 Remove the internal gear 1 Remove the snap ring 2 Remove the internal gear from the 3 4 clutch drum 31 Remove the 3 4 clutch assembly 1 Remove the O ring from the turbine shaft at t...

Page 339: ...spring and detent ball 03UOK2 14 I 86UO7B I 5 I 86UO7B 159 I 03UOKZ142 I 03UOK2 14 I3 2 Remove the bracket 3 Loosen the nut and pull the manual shaft out 4 Remove the nut washer spacer and manual plat...

Page 340: ...own in the figure 38 Remove the transaxle case by tapping lightly with a plastic hammer 39 Remove the low and reverse brake piston 1 Install the SST 2 Compress the spring and retainer assembly 03UOK2...

Page 341: ...iers then remove the spring and retainer assembly 4 Remove the low and reverse brake piston by applying compressed air through the fluid passage 40 Remove the output shell from the output gear 41 Remo...

Page 342: ...lt indicated in the figure 2 Remove the roll pin with a pin punch 3 Remove the bearing housing by tapping lightly with a plastic hammer 48 Remove the idle gear assembly and output gear assembly by tap...

Page 343: ...surface of the converter for damage or cracks and replace it if necessary 2 Check whether there is any rust on the pilot hub of the con verter or on the boss If there is any remove it completely 3 Mea...

Page 344: ...N m m kg ft lb I mo 5 1 Bearing race 9 Cam ring 2 Seal rings 10 Pivot roller 3 Oil pump cover 11 Seal pin and spring 4 Pump flange 12 Plug and washer 5 Guide ring and guide spring 13 Spring Valve sid...

Page 345: ...Vane Oil pump cover Standard Standard 0 005 0 020mm 0 015 0 050mm 0 0002 0 0008 in 0 0006 0 0020 in Maximum Maximum 0 030mm 0 0012 in 0 080mm 0 003 in Wear limit Check each part for wear if not withi...

Page 346: ...the valve moves smoothly 2 Install the plug Tightening torque 24 35 N m 2 4 3 6 m kg 17 26 f lb 3 Install the cam ring and pivot roller onto the oil pump body 4 Install the rotor onto the oil pump bod...

Page 347: ...l Install the seal pins round end first 9 Install the seal pins and springs with the pins facing toward the oil pump body IO Install the new O rings 11 Install the oil pump cover to the oil pump body...

Page 348: ...ANSAXLE AND TRANSFER UNIT 86U07Eb18E 14 Apply petroleum jelly to the bearing race to secure it to the oil pump cover then install it on the oil pump cover Bearing race outer diameter 88 0mm 3 46 in K2...

Page 349: ...pump 2 Check the clutch operation by applying compressed air through the fluid passages shown Applied air pressure 392 kPa 4 0 kg cm2 57 psi Forward clutch 1 Measure the clearance between the retaini...

Page 350: ...aining plate 8 Drive and driven plate Inspect for wear and burning Inspection page K2 176 9 Dished plate 10 Snap ring Disassembly note page K2 176 11 Spring and retainer assembly Inspection page K2 17...

Page 351: ...tainer as sem bly Coasting clutch drum 1 Remove the coasting clutch drum from the reverse and for ward drum by applying compressed air through the fluid passage Coasting piston 1 Remove the coasting c...

Page 352: ...average of the three readings Standard 1 6mm 0 063 in Minimum 1 4mm 0 055 in 2 If not within specification replace the drive plates Spring and retainer assembly coasting clutch 1 Measure the spring f...

Page 353: ...Verify that there is air flow when applying compressed air through the oil hole on the return spring side Air pressure 392 kPa 4 0 kg cm2 57 psi max Assembly procedure Reverse clutch 1 Install the re...

Page 354: ...ve Il Install the retaining plate 12 Install the snap ring 13 Measure the reverse clutch clearance 1 Measure the clearance between the snap ring and the retaining plate of the reverse clutch 2 If the...

Page 355: ...inner and outer faces of the seals and in stall them onto the coasting piston 2 Face the outer seal lip toward the inside by gently roll ing it down around the circumference for easier instal lation...

Page 356: ...040 0 047 in Retaining plate sizes mm in 4 6 0 1811 4 8 0 1890 5 0 0 1969 5 2 0 2047 5 4 0 2126 5 6 0 2205 Forward clutch 1 Install the dished plate with the dished side downward Note l Installation...

Page 357: ...Pa 4 0 kg cm2 57 psi 03UOKX 24 Caution l The compressed air must be under 392 kPa 4 0 kg cm2 57 psi and should not applied for over 3 seconds 4 Verify that no bubbles come from between the piston and...

Page 358: ...in the reverse order of disassembly referring to Assembly Procedure APPLY PETROLEUM JELLY 1 Thrust bearing Inspect for damage and rough rotation 2 Snap ring 3 One wav clutch inner race 4 Thrust beari...

Page 359: ...eum jelly to the thrust bearing to secure it then install it to the one way clutch inner race Thrust bearing outer diameter 62 lmm 2 44 in Caution l Check that the spring cage of the one way clutch fa...

Page 360: ...bearing to secure it then install it to the one way clutch inner race Thrust bearing outer diameter 62 lmm 2 44 in Note l Align the splines of the one way clutch inner race and small sun gear clutch...

Page 361: ...f disassembly referring to Assembly Procedure 1 Snap ring 2 One way clutch Inspection page K2 185 3 Bearing races Inspect bearing for scoring and scratches 4 Snap ring 5 Carrier hub assembly Inspectio...

Page 362: ...r Clearance 0 2 0 7mm 0 008 0 028 in Assembly procedure 1 Assemble the carrier hub assembly to the inner race 2 Install the snap ring Note l Install the tangs of the bearing race into the align ment h...

Page 363: ...TCH Preparation SST 49 GO19 OA7A 49 GO19 026 49 GO19 029 Leak checker Preinspection Clutch operation 1 Install the SST as shown and check clutch operation by applying compressed air Air pressure 392 k...

Page 364: ...Disassembly Inspection Assembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of...

Page 365: ...the average of the three reading Standard 1 6mm 0 063 in Minimum 1 4mm 0 055 in 2 If not within specification replace the drive plate s Spring and retainer assembly 1 Measure the spring free length S...

Page 366: ...4 Compress the spring and retainer 5 Install the snap ring 6 Remove the SST Note l Installation order Driven Drive Driven Drive Driven Drive Driven Drive 7 Install the drive and driven plates 8 Instal...

Page 367: ...m2 57 psi Caution l The compressed air must be under 392 kPa 4 0 kg cm2 57 psi and not applied for over 3 seconds 2 Verify that no bubbles escape past the 3 4 clutch pis ton seal while applying compre...

Page 368: ...B019 002 Body Part of 49 GO19 OA7A For disassembly assembly of low and reverse brake For disassembly assembly of low and reverse brake For disassembly assembly of low and reverse brake 49 GO19 026 g...

Page 369: ...reverse order of disassemblv referring to Assembly Procedure 03UOK2 183 1 Snap ring 2 Retaining plate 3 Drive and driven plates Inspect for wear and burning Inspection page K2 194 4 Snap ring Disasse...

Page 370: ...ss in three places and deter mine the average of the three readings Standard 1 6mm 0 063 in Minimum 1 4mm 0 055 in 2 If not within specification replace the drive plates Spring and retainer assembly 1...

Page 371: ...rse brake piston by pushing even ly around the circumference being careful not to dam age the outer seal 19 2 Install the spring and retainer assembly 3 Install the SST in the transaxle case 4 Compres...

Page 372: ...clearance between the snap ring and the low and reverse brake retaining plate 2 If the clearance is not within specification adjust it by selecting a proper retaining plate Low and reverse brake clear...

Page 373: ...rt of 49 GO17 5AO 49 GO19 028 Bolt 49 GO19 030 Plate For support of engine For support of engine For adjustment of 2 4 brake band For adjustment of 2 4 brake band 49 GO17 501 For support of engine 7 5...

Page 374: ...arts and repair or replace as necessary 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Note 3 Assemble in the reverse order...

Page 375: ...ged or worn piston 2 Weakened return spring Free length of spring 42 0mm 1 654 in Assembly note Band servo 1 Install the servo to the transaxle case 1 Install the servo spring and servo 2 Compress the...

Page 376: ...ssemble in the reverse order of disassemblv referrinq to Assemble Procedure a REPLACE 1 Snap ring 5 2 3 accumulator piston 2 Stopper plug 6 Large seal ring 3 O ring 7 Small seal ring 4 2 3 accumulator...

Page 377: ...arge seal ring and small seal ring then install them to the accumulator piston 2 Install the 2 3 accumulator piston 3 Install the spring to the piston 4 Apply ATF to new O ring and install it onto the...

Page 378: ...e order of disassembly referring to Assembly Procedure For removal of bearing 03UOK2 196 For installation of bearing puter race REPLACE m 10 128 177 13 18 94 130 N m m kg ft lb 1 Locknut 7 Idler shaft...

Page 379: ...e the bearing outer race from the idler gear with the SST Assembly procedure 1 Press the bearing outer races in with the SST 2 Install the idler gear bearing onto the idler shaft then install the idle...

Page 380: ...le tightening the locknut Note l Read the preload when the idler shaft starts to turn Tightening torque 128 l 77 N m 13 18 m kg 94 l 30 f lb Preload 0 03 0 9 N m 0 3 9 0 cm kg 0 28 7 8 in lb Value ind...

Page 381: ...wn in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Procedure For removal of bear...

Page 382: ...RANSAXLE AND TRANSFER UNIT 03UOKX 331 03UOKX 33 Assembly Procedure Bearings 1 Press the output gear bearings onto the output gear with the SST Seal rings 1 Install the seal rings to the output gear K2...

Page 383: ...Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of diassembly referring to Assembly Procedure REPLACE 03UOK2 lS I Oil seal 2 Bearing outer race...

Page 384: ...XLE AND TRANSFER UNIT I I I I l I 1 I 03UOKX 33 5 03UOKX 336 Assembly procedure Bearing outer race 1 Press the bearing outer race into the cover Oil seal 1 Press the oil seal into the cover with the S...

Page 385: ...sassemble in the order shown in the figure referring to Disassembly Procedure 2 Inspect all parts and repair or replace as necessary 1 1 2 solenoid valve Inspection page K2 9 Front premain rear gasket...

Page 386: ...teel ball 22 Orifice check valve and spring 23 Main rear front gasket 24 Rear separator 25 Main rear rear gasket 26 Orfice check valve and spring 27 Orifice check valve and spring 28 Rear control valv...

Page 387: ...d oil strainers 3 Remove the 1 2 solenoid valve and 2 3 solenoid valve and wire harness 4 Remove the O rings and oil strainers 5 Remove the front indicated bolts and pull out the front con trol body w...

Page 388: ...10 Remove the orifice check valves 42 0mm 0 079 in 42 5mm 0 098 in and springs and the throttle relief ball and spring from the premain control body 11 Remove the converter relief ball and spring and...

Page 389: ...TRANSAXLE AND TRANSFER UNIT 03UOK2 31 15 Remove the orifice check valve q52 5mm 0 98 in and spring and the steel ball from the main control body K2 213...

Page 390: ...herwise damage a valve surface or bore l Do not drop or lose the valves or internal parts l Before assembly make sure all parts are thoroughly clean l Apply ATF to all parts and bores l Note the prope...

Page 391: ...ccumulator front spring Inspection page K2 215 22 N R accumulator piston 23 N R accumulator rear spring Inspection K2 215 24 N R accumulator seal rings 25 N D accumulator front spring Inspection page...

Page 392: ...on then insert the N R accumulator rear spring and N R accumula tor piston 5 Apply ATF to the O rings and install them to the piston then insert the N D accumulator piston and N D accumulator front sp...

Page 393: ...nstall the bypass spring bypass valve stopper plug and stopper pin 10 Install the servo control spring servo control valve stop per plug and stopper pin 11 Install the 2 3 timing valve 2 3 timing spri...

Page 394: ...valve surface or bore l Do not drop or lose the valves or internal parts l Before assembly make sure all parts are thoroughly clean l Apply ATF to all parts and bores l Note the proper direction of th...

Page 395: ...FREE LENGTH 1 WIRE DIAMETER 03UOKX 35t 3 18 3 4 shift valve Inspect for sticking scoring and scratches 19 3 4 shift spring Inspection page K2 2 19 20 Retainer 21 Throttle back up valve Inspect for sti...

Page 396: ...g as shown 3 Install the throttle lever assembly to the main control body Tightening torque 8 l 1 N m 80 I 10 cm kg 69 95 in lb 4 Install the throttle modulator spring throttle modulator valve stopper...

Page 397: ...TRANSAXLE AND TRANSFER UNIT K2 9 Install the low reducing valve low reducing spring and re tainer 10 Install the pressure modifier valve pressure modifier spring stopper plug and stopper pin K2 221...

Page 398: ...damage a valve surface or bore l Do not drop or lose the valves or internal parts l Before assembly make sure all parts are thoroughly clean l Apply ATF to all parts and bores l Note the proper direct...

Page 399: ...DIAMETER 03UOKX 35 8 Inspection 1 Measure the spring free length 2 If not within specification replace the spring s Spring Pressure regulator spring Lockup control spring Item Outer dia Free length Wi...

Page 400: ...K2 TRANSAXLE AND TRANSFER UNIT 3 Install the manual valve K2 224...

Page 401: ...ner 4 3 4 solenoid valve 5 Rear control valve body Bolt installation position page K2 229 6 Orifice check valve and spring Installation position page K2 228 7 Orifice check valve and spring Installati...

Page 402: ...on page K2 227 27 Front control body 20 Orifice check valve and spring Bolt installation position page K2 229 Installation position _ page K2 227 28 Bolts 21 Orifice check valve and spring 29 2 3 sole...

Page 403: ...TRANSAXLE AND TRANSFER UNIT Installation positions PREMAIN CONTROL VALVE BODY MAIN CONTROL VALVE BODY SIDE FRONT CONTROL BODY SIDE K2 227...

Page 404: ...TRANSAXLE AND TRANSFER UNIT MAIN CONTROL VALVE BODY PREMAIN CONTROL VALVE BODY SIDE K2 228 REAR CONTROL VALVE BODY SIDE REARCONTROLVALVE BODY...

Page 405: ...TRANSAXLE AND TRANSFER UNIT K2 Bolt installation positions and external parts locations K2 229...

Page 406: ...es 41 5mm 0 059 in 1 Omm 0 039 in and springs in the rear control body as shown 2 Install the gaskets on both sides of the rear separator then install it onto the rear control body 86UO7B301 Note l Th...

Page 407: ...urn the assembly over and install the orifice check valve 0 8mm 0 031 in and spring and the converter relief ball and spring in the main control body as shown 7 Install the orifice check valves 42 0mm...

Page 408: ...the premain control body onto the main control body 86UO7B 31 86UO7B 31 RING 0 8611078 312 Note l Match the bolt head letter as shown IO Loosely tighten the bolts 1 in and spring Il Install the orific...

Page 409: ...premain rear gasket are not interchangeable 13 Install the front control body on the premain control body Note l Match the bolt head letter as shown 14 Loosely tighten the bolts 15 Install the control...

Page 410: ...80 cm kg 57 69 in lb 17 Install the 3 4 solenoid valve and lock up solenoid valve along with new O rings and oil strainers Tightening torque 6 8 N m 66 80 cm kg 57 69 in lb 18 Install the I 2 solenoid...

Page 411: ...Disconnect the oil hose 2 Drain the ATF into a suitable container 3 Remove the control valve cover and the gasket 4 Remove the throttle cable from the throttle cam of the valve body 5 Disconnect the...

Page 412: ...ontrol valve body cover along with a new gasket Tightening torque 6 Align the marks and slide the oil cooler hose onto the oil cooler pipe until it is fully seated against the ridge 7 Install the hose...

Page 413: ...ly Note N m m kg ft lb 03UOK2 229 REPLACE 16 21 157 206 116 162 1 Locknut Disassembly Note page K2 237 Assembly Note page K2 238 2 Retaining ring 3 Side cover Disassembly Note Ia page K2 238 Assembly...

Page 414: ...the bearing and remove the side cover and the bearing 2 Remove the bearing from the side cover with a press Assembly Note Bearing 1 Install the bearing with a press Side cover 1 Install the top cover...

Page 415: ...TRANSAXLE AND TRANSFER UNIT MEMO K2 239...

Page 416: ...bearing 49 8027 004 Measuring plate 49 GO30 338 Attachment E Disassembly Inspection Assembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair...

Page 417: ...damage 13 Sun gear Inspect for wear or damage 14 Gear case needle bearing Inspect for wear or damage 15 Planetary carrier Inspect for engagement with pinion gears 16 Gear case needle bearing Inspect f...

Page 418: ...e with a press Assembly procedure Front differential 1 Install the side gears and washers and fix them with the SST 2 Install a pinion gear and turn it 18OO Note l Do not install the washer at this ti...

Page 419: ...and spacer 3 Install the planetary carrier assembly gear case needle bear ing sun gear gear case needle bearing and the SST Measuring plate thickness 4 3mm 0 169 in 4 Measure the clearance between th...

Page 420: ...bearing 8 Measure the clearance between the differential lock hub and the gear case needle bearing If the clearance is not within specification select the prop er differential lock thrust washer Stan...

Page 421: ...ER ASSEMBLY PREPARATION SST 49 0636 145 Installer oil seal 49 F027 OAO Gauge set pinion height adjustment 49 8531 565 Pinion model 49 DO17 2Al 49 F401 3368 Attachment I3 49 0839 425C companion flange...

Page 422: ...Differential gear assembly 8 Locknut Disassembly Note page K2 246 9 Washer IO Companion flange Disassembly Note page K2 246 11 Oil seal 12 Drive pinion Disassembly Note page K2 246 Inspect splines for...

Page 423: ...uts and the carrier Locknut 1 Hold the companion flange with the SST and remove the locknut Companion flange 1 Remove the companion flange with the SST Drive pinion 1 Push the drive pinion out by atta...

Page 424: ...h the SST Bearing inner race Differential gear Note l Do not disassemble the bearing inner race unless necessary l For proper reassembly identify the bearing inner race l Support the drive pinion by h...

Page 425: ...ll the spacer and bearing inner race to the SST b Assemble the spacer rear bearing and SST Secure the SST with the O ring Install the assembly in the carrier Note l Use the same spacer and nut removed...

Page 426: ...ure the lowest position on both the left and right sides i h Add the two left and right values obtained by the meas urements taken in step g and divide the total by 2 Standard Omm 0 in Note l The spac...

Page 427: ...ad 0 3 0 7 N m 3 7 cm kg 2 6 6 1 in lb Tightening torque 118 177 N m 12 18 m kg 87 130 ft lb 9 Remove the nut washer and companion flange 10 Tap a new oil seal into the differential carrier with the S...

Page 428: ...T 1 Toe and flank contact Replace the spacer with a thinner one to move the drive pinion outward I I 63609X 385 2 Heel and face contact HEEL CONTACT FACE CONTACT Replace the spacer with a thicker one...

Page 429: ...as described below 03UOKX 42 03UOKX 421 1 Align the bearing cover with guide bolts as shown and press it in Tighten the bearing cover bolts Tightening torque 1I 14 N m 1 l 1 4 m kg 8 10 ft lb 2 Instal...

Page 430: ...ll the four SST bolts then tighten them to the speci fied torque Tightening torque 19 26 N m 1 9 2 6 m kg 14 16 ft lb Note l Seat the bearing 8 Turn the SST selector to increase the clearance indi cat...

Page 431: ...shim s equivalent to the measured clearance 13 Remove the bearing housing and SST 14 Install the required shim s and press the bearing race into the bearing housing with the SST 15 Install the bearin...

Page 432: ...3UOKX 430 1 Remove the bearing outer race and adjustment shims from the transaxle case 2 Set the differential assembly into the converter housing 03UOKX 431 K2 256 Caution l Eliminate the gap arrow by...

Page 433: ...through the transaxle case and attach it to the side gear IO Mount the SST and pull scale or torque wrench Note l Read the preload when the differential starts to turn 11 Adjust the clearance between...

Page 434: ...cification If not within specification return to Step 1 Preload 2 9 3 9 N rn 30 40 cm kg 26 35 in lb 18 Remove the transaxle case 3 Install the idler gear and output gear as an assembly by tapping in...

Page 435: ...w part in ATF for at least 2 hours before installation 2 Before assembly apply ATF to all seal rings rotating parts O rings and sliding parts 3 All O rings seals and gaskets must be replaced with the...

Page 436: ...T Bearing and race locations 03UOKX 44 Outer diameter of bearing and race 1 2 3 4 5 6 7 Bearing mm in 86 0 3 39 56 1 2 21 62 1 2 44 62 1 2 44 72 0 2 83 56 1 2 21 72 1 2 84 Race mm in 88 0 3 46 72 0 2...

Page 437: ...03UOK2 25 1 Oil pump and gasket 5 Inhibitor switch 8 Oil level gauge and oil filler tube 2 Throttle cable 6 Oil strainer 9 Oil pump shaft 3 Control valve body assembly 7 Oil pan and gasket 10 Torque...

Page 438: ...2 Internal gear 11 Servo 3 Snap ring 12 2 4 brake band 4 Low and reverse brake Drive and drive plates 13 Anchor strut and shaft 5 Retaining plate 14 Small sun gear 6 Snap ring 15 One way clutch 7 Carr...

Page 439: ...NSFER UNIT K2 O RING NEW O RING NEW l lcLlp77 SPRIN G CLIP NEW 1 Parking paw1 2 Parking assist lever 3 Actuator support 4 Manual shaft and manual plate 5 Bracket 6 Turbine shaft 7 Output shell 8 Trans...

Page 440: ...aring cover 2 Oil seal Transaxle case 12 Oil seal 3 2 3 accumulator 13 Adjustment shim 4 Converter housing 14 Bearing outer race 5 Transfer carrier assembly 15 Output gear 6 Idler gear assembly Transf...

Page 441: ...embly into the clutch housing 2 Install the set bolt Note l Before coating with sealant clean the contact surfaces 3 Coat both surfaces with sealant 4 Install the transfer carrier assembly Tightening...

Page 442: ...37 52 N m 3 8 5 3 m kg 27 38 ft lb 10 Install the SST to hold the turbine shaft 11 Lift the idle gear slightly 12 Install a new oil seal Note l Before coating with sealant clean the contact surfaces 1...

Page 443: ...ll the internal gear to the 3 4 clutch drum 2 Install the snap ring 17 Install the carrier hub assembly 1 Verify that the thrust bearing and bearing race are properly installed 2 Hold the turbine shaf...

Page 444: ...taining plate sizes mm in 6 8 0 268 7 0 0 276 7 2 0 283 7 4 0 291 7 6 0 299 7 8 0 307 22 Check the low and reverse brake operation by applying compressed air through the fluid passage as shown in the...

Page 445: ...4 brake band in the transaxle case so that it is fully expanded 28 Install the small sun gear and one way clutch 1 Verify that the thrust bearing and bearing race are in stalled in the correct positio...

Page 446: ...he transaxle case Maximum 0 9mm 0 035 in 30 Install the snap ring into the bottom ring groove of the tur bine shaft 31 Use the following procedure to adjust the total end play and select a suitable be...

Page 447: ...mp 8 Place the selected bearing race and a new gasket onto the oil pump 9 Install the oil pump onto the clutch assembly Tightening torque 19 26 N m I 9 2 6 m kg 14 19 ft lb 32 Adjust the 2 4 brake ban...

Page 448: ...the transaxle case Tightening torque 1l 15 Nom 11 O 150 cm kg 95 130 in lb 36 Install the solenoid connector and a new O ring in the trans axle case 37 Install a new O ring on the bracket then feed t...

Page 449: ...ghtening torque Q 14 N m 90 l 40 cm kg 78 122 ft lb 43 Install the differential lock switch Tightening torque 20 29 N m 2 3 m kg 14 22 ft lb 44 Install the ball spring gasket and a plug Tightening tor...

Page 450: ...ue 0 4 0 7 N m 4 7 cm kg 4 6 in lb 48 Install the harness with the remaining clip Tightening torque 8 l 1 N m 80 l 10 cm kg 69 95 in lb 49 Remove the transaxle from the SST 50 Install a new O ring and...

Page 451: ...nsure that the torque converter is installed accurately measure distance A between the end of the torque con verter and the end of the converter housing A 13 6mm 0 535 in 56 Install engine mount No 1...

Page 452: ...everse order of removal referring to Installation 2 Fill the transaxle with the specified ATF after installation Note 80 110 cm kg 69 95 in lb l 27 2 1 2 8 15 20 7 52 3 8 5 3 A 64 89 6 5 9 1 47 66 TSd...

Page 453: ...tor 20 Inhibitor switch connector 21 Speedometer cable Installation Note page K2 279 22 Battery carrier 23 Battery 24 Air hose and air cleaner assembly 25 Splash shield 26 Wheel and tire 27 Throttle c...

Page 454: ...8 9 5 m kg 49 68 ft lb Driveshaft Caution l Do not damage the oil seal l After installation pull the front hub outward to verify that the driveshaft is secured 1 Replace the clips at the ends of the...

Page 455: ...3 58 N m 4 4 6 0 m kg 32 43 ft lb Stabilizer 1 lighten the stabilizer nut so that 17mm 0 67 in to 19mm 0 75 in of thread is exposed at the end of the bolt Propeller shaft 1 Align the marks and install...

Page 456: ...kg ft lb 1 Connector bolts Inspect for clogging 2 Packing 3 Oil pipes Inspect for damage or cracks I UP SIDE 03UOKX 503 K2 280 4 Oil hoses Inspect for damage or cracks Installation note page K2 253 5...

Page 457: ...i m Throttle m ure z Throttle modulate Tsgz Line pressure Z Z Torque converter II II L JP I I I x II pressure pressure...

Page 458: ...r Oil pump m Throttle pressure m Throttle modulate pressure x Line pressure Z 4 brake band SM Operating line pressure A Torque converter pressure...

Page 459: ...s Throttle pressure 3 Throttle modulate pressure g g Line pressure yyA Torque converter pressure i...

Page 460: ...HYDRAULIC CIRCUIT N RANGE ABOVE APPROX 18 km h 11 mph _ J K2 284...

Page 461: ...E Q Throttle pressure m Throttle modulate pressure m Line pressure Operating line pressure m Torque converter pressure 2 4 brake band Forward clutch Oil pump...

Page 462: ...K2 HYDRAULIC CIRCUIT D RANGE 2ND GEAR J hc JCJ K2 286...

Page 463: ...Throttle pressure i 2 Throttle modulate pressure g ss Line pressure m Operatmg line pressure ZZ Torque converter pressure 2 4 brake band Oil pump...

Page 464: ...ADDIV side F D Throttle pressure m Throttle modulate pressure m Line pressure Operating line pressure m Torque converter pressure 2 4 brake band Oil pump...

Page 465: ...ward clutc pressure Reverse clutc pressure 14 I l 2 accumulator w Throttle pressure 2 s Throttle modulate pressure F f Line pressure Operating line pressure Tm Torque converter pressure oasb g bypass...

Page 466: ...r m Throttle pressure X Throttle modulate pressure Operating lme pressure zfi Torque converter pressure 2 4 brake band Forward clutch Oil pump...

Page 467: ...f Oil pump Forward clutch pressure Reverse clutch pressure MQC Throttle pressure m Throttle modulate pressure gjgj Line pressure Operating line pressure m Torque converter pressure 2 4 brake band...

Page 468: ...K2 S RANGE HOLD 2ND GEAR HYDRAULIC CIRCUIT 03UOK2 33 K2 292...

Page 469: ...HYDRAULIC CIRCUIT K2 S RANGE 3RD GEAR BELOW APPROX 40 km h 25 mph aJ P L JJO K2 293...

Page 470: ...S RANGE 3RD GEAR ABOVE APPROX 40 km h 25 mph K2 HYDRAULIC CIRCUIT 03UOK2 33 K2 294...

Page 471: ...f 2 4 brake band m Throttle pressure SL Throttle modulate pressure Line pressure Operating line pressure T Z Low reducing preSSWe EY Operating low reducing pressure a Torque converter pressure Oil pum...

Page 472: ...clutch 1 pressure m Throttle pressure a Throttle modulate pressure m Line pressure a Operating line pressure y j Low reducing pressure y Operatmg low reducibg pressure Y IA Torque converter pressure O...

Page 473: ...clutch pressure reverse clutch pressure j Throttle pressure m Throttle modulate pressure m Line pressure Operating line pressure m Low reducing pressure Torque converter pressure LOW reduang i II II O...

Page 474: ...HYDRAULIC CIRCUIT L RANGE 2ND GEAR ABOVE APPROX 110 km h 68 mohl 03UOK2 341 K2 298...

Page 475: ...UTLINE OF CONSTRUCTION L 2 SPEClFlCATlONS L 2 PROPELLER SHAFT L 3 TROUBLESHOOTING GUIDE a n a a L 4 PROPELLER SHAFT a n m m a L 4 PREPARATION m m sm m m L 4 REMOVAL I INSPECTION I INSTALLATION L 5 OVE...

Page 476: ...our joint type with two center bearings for support 03UOLX 802 SPECIFICATIONS Item Length Outer diameter mm in mm in Model MTX ATX Ll 834 3 32 84 836 5 32 93 L2 634 0 24 96 l 3 437 0 17 20 Dt 75 0 2 9...

Page 477: ...high speed A constant velocity joint matched with either the automatic or manual transaxle is employed at the front of the front propeller shaft for smoother power flow and improved riding comfort A...

Page 478: ...7 Worn or damaged bearing cup Replace L 7 Improperly installed universal joint snap ring Repair L 7 Worn or damaged center bearing Replace L 7 Loose yoke mounting bolts Tighten L 5 Incorrect txooeller...

Page 479: ...moval referring to Installation Note t JJ 27 30 2 8 3 1 20 22 I 37 51 3 82 3 27 38 v 37 51 3 8 5 3 27 38 N m m kg B lb In 1 1 nn 1 Nut 8 Bolt 14 Washer Removal Note page L 6 9 Lock washer 15 Spacers 2...

Page 480: ...n the marks and install the propeller shaft 2 Verify that there is no abnormal noise or vibration when driv ing the vehicle Note l The spacer on each side must be the same size 3 If noise or vibration...

Page 481: ...ring 6 Yoke Diff side Disassembly Note page L 8 7 Nut Assembly Note I f I l page L 10 Disassembly Note I page L 8 2 Bearing cup Assembly Note I I page L 9 Disassembly Note page L 8 8 Lock washer Insp...

Page 482: ...tapping the propeller shaft yoke 2 Remove the opposite bearing cup in the same manner 3 Separate the propeller shaft and yoke 4 Clamp the yoke in a vise 5 Remove the bearing cups and the spider from t...

Page 483: ...center bearing support assembly with the SST Nut 1 Align the marks on the center propeller shaft and yoke 2 Install the nut Tightening torque 157 177 N m 16 18 m kg lf6 130 ft lb Bearing cup Caution l...

Page 484: ...t flanges with a plas tic hammer to seat the cups 4 Measure the starting torque of the spider Starting torque 0 29 0 98 Mm 3 10 cm kg 2 60 8 68 in lb 5 Install different snap rings to adjust the start...

Page 485: ...E INFORMATION M 5 TROUBLESHOOTING GUIDE s a M 5 REAR AXLE m s m M 5 DIFFERENTIAL STANDARD m m m s w M 5 REAR AXLE mI a m m m M 6 PREPARATION m a e M 6 DISC BRAKE TYPE I M 7 REAR DRIVESHAFT I m m M 12...

Page 486: ...e Removal I Inspection I Installation M 7 Disassembly Inspection Assembly M 8 2 Rear driveshaft Inspection I Removal I Installation M l 2 Disassembly Inspection Assembly M l 3 3 Rear differential Diff...

Page 487: ...employed for the rear wheel bearings for improved durability and serviceability 03UOMX 803 SPECIFICATlONS Model Item Rear axle h Wheel bearing axial play Maximum mm in Rear differential Reduction gear...

Page 488: ...REAR AXLE KNUCKLE I Wheel Bearings WHEEt BEARING Angular type ball bearings for which the bearing preload is set by tightening the driveshaft nut to the speci fied torque are employed for the wheel be...

Page 489: ...Oil leakage No differential operation Possible Cause Insufficient differential oil Incorrect differential oil Improperly adjusted ring gear backlash Poor contact of ring gear teeth Worn or damaged si...

Page 490: ...g For removal of wheel hub For removal of wheel bearing For installaton of wheel bearing For installatjon of wheel bearing For installation of wheel bearing 49 GO30 727 Attachment A Part of 49 6026 fA...

Page 491: ...el bearing if necessary Maximum wheel bearing play 0 05mm 0 002 in Removal I Inspection I Installation 1 Remove in the order shown in the figure referring to Removal Note 2 Inspect all parts and repai...

Page 492: ...to Assembly Note 4 I OWOMX 813 I UII sear Disassem bly Note m mI 1 1page M 9 Assembly Note page M l 1 2 Wheel hub Disassembly Note page M 9 Inspect for cracks and oth er damage Assembly Note page M l...

Page 493: ...uckle with the SST and Caution l Support the wheel hub by hand to prevent It from falling 2 Move the inner bearing race away from the axle with a ham mer and chisel 3 Set the SST between the wheel hub...

Page 494: ...he new dust cover as shown 3 lnstali the new dust cover Wheel bearing 1 Press the new wheel bearing in with the SST 03UOMX 82 Dust cover Caution l Do not remove the dust cover if not necessary l Do no...

Page 495: ...l hub 1 Press the wheel hub in with the SST Oil seal Caution l Use a new oil seal and apply grease to the lip of the seal l Install the oil seal flush with the knuckle 1 lnstal I the new oil sea I wit...

Page 496: ...318 24 0 32 5 88 l 18 9 0 12 173 235 O 85 87 N m m kg ft tb 03UOMX 826 1 Wheel nuts 2 Wheel and tire 5 Bolt Trailing link 3 Wheel hub nut 6 Bolt Lateral link 7 Rear driveshaft 4 Nut Driveshaft Removal...

Page 497: ...n the vise jaws l Be careful that dust or other foreign material does not enter the ball joint while the work is being performed l Do not disassemble the wheel side ball joint l Do not wash the ball j...

Page 498: ...eshaft the cage and the inner ring for proper reassembly 2 Remove the snap ring with snap ring ptiers Cage 1 Turn the cage approximately 3CP then puH it away from the inner ring 03UOMX 831 03UOMX 833...

Page 499: ...fferent A 89 9mm 3 54 in B 85 2mm 3 35 in 03UOMX 836 Caution l Do not use other than the specified grease 2 Apply molybdenum disulfide grease to the joint Quantity Differential side 75 g 2 64 oz Wheel...

Page 500: ...s1 20 710 Holder coupling 49 0839 425C 49 0710 520 Pulter bearing 49 F401 330B installation of 49 8531 565 Pinion mode1 Gauge block installation of oil 49 0259 720 Wrench diff side bearing adlusting...

Page 501: ...5 m kg 29 40 ft Ib Replacement 1I Remove the filler and drain plugs 2 Drain the differential oil into a suitable container 3 Wipe the plugs clean 4 Install the drain plug and washer Tightening torque...

Page 502: ...utput shaft flanges for proper reassembly 3 Separate the driveshaft from the differential and suspend it as shown in the figure 4 Remove the lateral link 5 Remove the trailing link 6 Pull the wheel hu...

Page 503: ...ng torque 63 75 N m 6 4 7 6 m kg 46 55 ft lb 14 Install the trailing link Tightening torque 49 59 N m 5 0 6 0 m kg 36 43 ft lb 15 Align the marks and reinstall the driveshaft Tightening torque 49 59 N...

Page 504: ...referring to Installation Note 27 N I 2 8 3 f 20 22 53 63 5 5 6 5 39 47 93 I 16 9 5 l 1 9 68 86 53 83 5 5 6 5 39 47 85 l 16 8 7 l 1 9 62 88 N m m kg f lb 03UOMX 851 1 Propeller shaft 4 Trailing link 6...

Page 505: ...shaft from the Rear differential 1 Support the differential with a jack while removing it Installation Note Rear differential 1 Support the differential with a jack while installing it Tightening torq...

Page 506: ...llation before filling the differential with the specified oil 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Ass...

Page 507: ...28 12 Drive pinion Assembly Note EII I I I page M 25 Inspect splines for cracks and other damage 13 Spacer 14 Bearing inner race Front bearing Inspect for rough rotation 15 CoHapsible spacer 16 Bearin...

Page 508: ...the SST Output shaft 1 Remove the output shaft with a pry bar as shown in the figure Bearing cap 1 Mark one bearing cap and the carrier Adjusting screw 1 Mark one adjusting screw and the carrier Nut...

Page 509: ...ces by alternately tappi races at the two grooves in the carrier Bearing inner race Rear bearing Note l Support the drive pinion by hand SO that it does not fall I Remove the rear bearing with the SST...

Page 510: ...t of pinion height 1 Adjust the drive pinion height as follows with the SST Note l Use the spacer that was removed l Do not install the collapsible spacer a Install the bearing inner race rear spacer...

Page 511: ...eft and right values obtained in Step f and divide the total by 2 Specification Omm 0 in h If it is not within specification adjust the pinion height by selection of a spacer Note l Spacers are availa...

Page 512: ...n flange Oil seal Companion flange Caution l Apply differential oil to the oil seal lip 1 Tap a new oil seal into the differential carrier with the SST Companion flange 1 Apply a light coat of grease...

Page 513: ...e gear case Tightening torque 69 83 Nm 7 0 8 5 m kg 51 61 ft ib 3 Press the new bearing inner race side gear on with the SST 4 Install the differential gear assembly in the carrier 5 Note the identifi...

Page 514: ...d ring gear GOOD CONTACT 03UOMX 882 RED LEAD I 03UOMX 883 TOE CONTACT FLANK CONTACT 1 I 63609X 385 HEEL CONTACT FACE CONTACT I SMUOMX 061 M 30 Inspection and adjustment of teeth contact 1 Coat both su...

Page 515: ...20 ft lb Oil seal Output shaft Caution l Apply lithium base grease to the new oil seal lip 1 Install the new oil sea I with the SST Output shaft 1 Install new clips 2 install the output shaft into the...

Page 516: ......

Page 517: ...N 3 SPECIFICATION N 3 1 SERVlCE 1 SUPPLEMENTAL SERVICE INFORMATION N 3 ENGINE SPEED SENSING POWER STEERING m N 4 PREPARATION t m N 4 POWER STEERING FLUID a N 6 STEERlNG GEAR AND LINKAGE l m N 7 POWER...

Page 518: ...gear and linkage Removal I Installation page N 7 Disassembly I Inspection I Assembly 1 I I page N 40 2 Power steering fluid Inspection V page N 6 3 Power steering oil pump Disassembly I Inspection I...

Page 519: ...Z cross joint 30 1 18 Steering gear Oil TYPO Gear ratio Rack stroke mm in Type Capacity liter US qt Imp qt Rack and pinion 00 Infinite 121 4 76 ATF M III or DEXRON II 0 9 1 0 0 95 1 06 0 79 0 88 03UO...

Page 520: ...on of seal 49 B032 327 Wrench outer box 49 8032 326 Protector outer installation of 49 8032 323 Remover body rod seal removal of oil 49 F032 303 installation of oil Handle 49 8032 309 Installer body 4...

Page 521: ...ad e 1 pinion torque locknut 49 BU32 321 Adapter For z kn 49 6032 305 Holder power steering pump 49 GO32 317 49 1232 670A For 49 1232 673 49 HO32 301 measurement of 49 1232 672 49 8032 304 measurement...

Page 522: ...y the oil pump If the pressure is below specification replace the oil pump assembly Oil pump fluid pressure 7 848 kPa 80 kg cm2 I 137 psi Caution l If the valve is left closed for more than 15 seconds...

Page 523: ...removal referring to Installation Note 8 After installation bleed air from the steering system 8 27 1 8 2 7 13 9 49 4 5 29 36 42 57 4 3 5 8 31 42 93 l 17 9 5 l l 9 69 86 93 117 9 5 11 9 69 86 N m m k...

Page 524: ...engine mount nuts 3 Remove the engine mount member 03UONX 81 A 3 03UONX 814 Removal note Bolt Steering gear mounting bolt 1 Set the SST as shown 4 Remove the No 4 engine mount mounting bolts 5 Remove...

Page 525: ...and the return pipe IO Remove the left bracket 11 I Pull the steering gear from the left side to remove it Installation note Bolt Steering gear mounting bolt Tightening torque Pressure pipe O ring re...

Page 526: ...e order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replace as necessary 3 Assemble in the reverse order of disassembly referring to Assembly Note 4 5 8 8 29 39...

Page 527: ...age N l 4 Assembly note l f II page N 15 17 U ring 18 Oil seal Disassembly note page N 13 19 Bearing Disassembly note m page N l 3 inspect for wear and operation 20 Pinion shaft assembly inspect for d...

Page 528: ...Caution l To avoid scratching the rack secure the rack in a vise protected with brass pads or cloth Locknut 1 Use the SST to remove the locknut Housing cover I1 Use a drill 1 5mm 0 06 in to make a rec...

Page 529: ...oil seal from the plug Caution l The oil seal can not be reused 93GONX 031 Outer box assembly 1 Use the SST to remove the outer box 93GONX 032 Oil seal and inner auide 1 Use the SST to re ove the oil...

Page 530: ...ering rack and out er box installed to the gear box check to confirm the air tightness of the cylinder part of the gear box Steering rack 1 Install a new oil seal and new seal ring to the rack s pisto...

Page 531: ...the SST to install a new seal ring to the valve part of the pinion shaft 2 After installing it use the SST to seat it properly 3 Use the SST to install the pinion shaft assembly to the gear housing P...

Page 532: ...ith the SST 5 Measure the pinion starting torque with the SST and a pull scale Starting torque At f 90 from the straight ahead position LO l 3 N m W 14 cm kg 8 7 12 in lb Pull scale reading 1 0 1 4 kg...

Page 533: ...g to Assembly Note m 5 9 9 8 10 6 1 0 4 3 7 2 t Suction pipe 2 O ring 3 Pressure switch assembly 4 O ring 5 Connector 6 O ring 7 Control valve inspect for damage and wear 8 Spring Inspect for damage 9...

Page 534: ...p in a vise be sure to use the SST so that force is not applied to the pulley or shaft Assembly note Rotor 1 Install the rotor to the shaft with the rotor s identification mark facing upward Cam ring...

Page 535: ...BRAKING SYSTEM INDEX P 2 OUTLINE P 3 OUTLINE OF CONSTRUCTION P 3 SPEClFICATIONS P 3 SUPPLEMENTAL SERVICE INFORMATION P 4 CONVENTIONAL BRAKE SYSTEM P 4 DUAL PROPORTIONING VALVE P 4 03UOPX 801...

Page 536: ...P INDEX 03UOPX 802 1 Dual proportioning valve Inspection page P 4 F 2...

Page 537: ...Diameter mm in Single diaphragm 214 8 43 239 9 41 Type Ventilated disc Cylinder bore mm in I 53 97 2 12 I Front disc brake Pad dimensions Area x Thickness mm2 x mm in2 x in 4 300 6 66 x 10 0 39 Disc p...

Page 538: ...1 422 psi to the brake pipes with adapters as shown in the figure Adapter and flare nut tightening torque 13 22 N rn 1 3 2 2 m kg 9 4 16 f lb Note l Disconnect and connect the brake pipes with SST 2...

Page 539: ...ONT WHEEL ALIGNMENT B m l R 6 REAR WHEEL ALIGNMENT l m m R 8 FRONT SUSPENSION STRUT a l R 9 PREPARATtON u 1 1 m w m R 9 FRONT SHOCK ABSORBER AND SPRING R 10 FRONT LOWER ARM se I a l R 5 FRONT STABILIZ...

Page 540: ..._ _C i Ct f _ I WUORX 002 1 Front shock absorber and spring Removal Installation I I lL page R 10 Disassembly Inspection page R l 1 Inspection 2 Front lower arm Removal I Inspection I lnstaifation pag...

Page 541: ...3UORX 00 1 Rear shock absorber and spring Removal Installation page R 20 Disassembly I Inspection I page R 21 Inspection I I I I1 I page R 22 Assembly page R 23 2 Lateral link and trailing link Remova...

Page 542: ...ee 1 2 f 3 0 08 f 0 12 0 2O f 3O Camber angle 0O20 f 45 03UORX 004 I Fuel tank full radiator coolant and engine oil at specified levels and spare tire jack and tools in designated positions Coil Sprin...

Page 543: ...g system Section N Damaged or unbalanced wheel s Section Q Heavy steering Poor lubrication or wear of lower arm ball joint Lubricate or replace R 15 Improperly adjusted wheel alignment Adjust R 6 Malf...

Page 544: ...cifications r Wheel alignment Unladen Item Maximum Inner steeringangle Outer Total mm in Specification 4u f 2O 33 f 2 2 f 3 0 08 f 0 12 Front toe in 1 degree 1 0 2 l 0 3 Camber angle 0005 f 45 Caster...

Page 545: ...Adjustments Total toe in To adjust the toe in loosen the left and right tie rod locknuts then turn the tie rods equally Caution l The left and right tie rods are both right threaded so to increase the...

Page 546: ...djust 03UORX 016 REAR WHEEL ALIGNMENT Adjustment Total toe in 1 Loosen the lateral link locknuts Note l One turn of the link changes 11 3 m 0 44 in 3 Tighten the lateral link locknuts to the specified...

Page 547: ...ling Lower the vehi cle and tighten all nuts and bolts to the specified torques with the vehicle unladen REFER 66 95 117 8 7 I l 9 63 86 I 68 95 6 4 9 5 50 70 N m m kg ft lb 1 Nut Stabilizer 9 Bolt La...

Page 548: ...Removal note Crossmember bushing 1 Remove the crossmember bushing in the direction of the arrow with the SST Installation note Crossmember bushing 1 Apply soapy water to the crossmember bushing and p...

Page 549: ...X s 2 OUTLINE s 2 OUTLINE OF CONSTRUCTION S 2 SERVICE 1 SUPPLEMENTAL SERVICE INFORMATION m S 2 UNDERSODY DlMENSlONS S 3 UNDERBODY PROJECTED DIMENSIONS S 3 UNDERBODY STRAIGHT LINE DIMENSIONS m 1 s 4 03...

Page 550: ...TLINE OF CONSTRUCTtON l The body for the 4WD model is basically the same as for the 2WD model however underbody is changed Refer to pages S 2 3 03UOSX 803 SUPPLEMENTAL SERVICE INFORMATION The followin...

Page 551: ...UNDERBODY DIMENSIONS s UNDERBODY DlMENSlONS I L C3t Li t wt d I al r6 3 78 67 2 64 65 2 561 570 18 5Oj I OWOSX 805 S 3...

Page 552: ...E REFERENCE HOLE 916 0 63 J REAR CROSSMEMBER MOUNTING BOLT 0 FRONT SUSPENSION MOUNTING BLOCK MOUNTING SURFACE K REAR SUSPENSION MOUNTING BLOCK MOUNTING SURFACE E STEERING GEAR MOUNTING BOLT L REAR CRO...

Page 553: ...2 OUTLlNE T 3 OUTLINE OF CONSTRUCTION T 3 FUSE AND JOINT BOX T 3 FUSE T 3 WARNING SYSTEM T 4 WARNING AND INDICATOR LAMPS T 4 SUPPLEMENTAL SERVICE INFORMATION T 6 INSTRUMENT CLUSTER T 6 FUEL GAUGE SEN...

Page 554: ...T INDEX INDEX 1 Fuel gauge sender unit in fuel tank Inspection I page T 6 T 2...

Page 555: ...Fuse REAR WIPER HAZARD ROOM ENGINE RADlO BELT METER WIPER STOP TAIL DIF LOCK DEFOG Circuit breaker HEATER Protected circuit IOA Rear wiper and washer 15A Hazard warning IOA Clock interior lamps Cargo...

Page 556: ...WARNING SYSTEM WARNING AND INDICATOR LAMP l With the addition of the center differential lock indicator the arrangement of the warning and indicator lamps is changed WITH TACHOMETER WITHOUT TACHOMETE...

Page 557: ...IC 1FUELTANK UNIT I 1 ID 4WD CONTROL UNIT I 1 TE 1WASHEk LEVEL SENSOR I I 1F 1FUEL TANK UNIT I I 1G EC AT CONTROL UNIT IH I II I 1 1 1J i I 2E GROUND 2F GROUND 3A 3B ALTERNATOR 3c 3D OILPRESSURE SWIT...

Page 558: ...gauge sender unit l Inspection l OWOTX 807 MAIN FUEL PUMP tNSTRUMENT CLUSTER METER I mm in 03UOTX 808 ISUB FUEL PUMP I FUEL GAUGE SENDER UNIT Inspection 1 Remove the fuel tank gauge unit Refer to Sec...

Page 559: ...U HEATER AND AIR CONDITIONER SYSTEM OUTLINE 1 u 2 OUTLINE OF CONSTRUCTION mm s ma U 2 03UOUX 801...

Page 560: ...basically the same as for the 2WD model however for EC AT equipped vehicles the cooling efficiency of the engine is improved by operating the additional fan independent of the A C switch Circuit Diag...

Page 561: ...AL SYSTEM a TD 7 CLUTCH TD 8 MANUAL TRANSAXLE AND TRANSFER TD 8 AUTOMATIC TRANSAXLE I l m m mmm m TD 10 PROPELLER SHAFT f m TD f 2 FRONT AND REAR AXLES B s STEERING SYSTEM 1 1 1 m s BRAKING SYSTEM l 1...

Page 562: ...VFIIVF clfvw nce mm iinl 0 Maintenance free 0 Maintenance free I _ Warm engine jCamside Cylinder head Height Distortion Grinding mm in mm in mm in 0 Maintenance free h w 1 I 0 10 0 004 max 0 10 0 004...

Page 563: ...435 I 7091 l 7100 Out of round 0 05 tO Ob2 max No 1 No 5 0 040 0 075 0 0016 0 0030 Camshaft bearing oil clearance mm in No 2 No 4 0 035 0 080 0 0014 0 0031 j No 3 0 050 0 095 0 0020 0 00371 Camshaft r...

Page 564: ...gth Center to center mm in 132 85 l 32 95 5 2303 5 2342 Bending mm in 0 075 0 0030 max 50 1 97 v Small end bore mm in1 19 943 19 961 0 7852 Om7859 1 Big end bore mm in 1 48 000 48 016 1 8898 l 8904 I...

Page 565: ...Oil pump I Type Relief pressure Regulated pressure Inner rotor tooth tip to outer rotor kPa kg cm2 psi kPa kg cm2 psi rpm 1 Standard Trochoid gear 343 441 3 5 4 5 50 64 294 392 3 O 4 0 43 57 3 000 0 0...

Page 566: ...w v 80 I 2 160 I 2 Current A 6 6 Hi 13 3 Low 8 8 Water thermoswitch UFF ON C OF 1 97 207 Radiator thermoswitch OFF ON C OF 1 105 221 Cootant Capacity liters US qt Imp qt 5 0 5 3 4 4 I 6 0 6 3 5 3 Coo...

Page 567: ...P SOHC 12 55023L 60AH Max 20 0 ATX Alternator YPe H L Output V A 12 65 Regulator type Regulated voltage v Brush length Standard mm in Minimum Transistorized built in IC regulator 14 1 14 7 21 5 0 846...

Page 568: ...ANSFER e Item Transmission Shift lever oosition Model BP SOHC GSMX R Floor shift Gear ratio First 3 307 Second 1 833 Third 1 233 Fourth 0 914 I 1 Fifth I 0 717 1 Reverse 3 166 ATF DEXRON II or M III O...

Page 569: ...ear teeth Bearing preload Nm cm kg in lb Bearing preload adjustment shim mm in End play of ring gear Ring gear end play adjustment washer End play of sun gear Sun adjustment wadher gear Transfer carri...

Page 570: ...Maximum 0 080 0 003 Seal pin and oil pump Standard 0 005 0 020 0 0002 0 0008 1 1 cover clearance mm in 1 Maximum 1 0 060 0 002 I Oil r3urnD Vane and rotor groove Standard 0 01 O 0 045 d 0004 clearance...

Page 571: ...when clutch fully disengaged mm in Minimum 41 O 1 61 Flywheel Rut tout limit Clutch disc We Runout limit Wear limit Outer diameter Inner diameter Facing thickness Clutch cover Type Set load mm in 0 2...

Page 572: ...SUHC FM R Floor shift 3 416 1 842 1 290 0 918 0 731 3 214 API service GL 4 or GL 5 DEXRON II M2C33 F or SAE 75W 90 SAE 8OW 90 2 68 2 83 2 36 0 10 0 32 0 004 0 013 0 37 0 015 0 1 O O 36 0 004 0 014 0...

Page 573: ...5 0 69 0 57 N STEERlNG SYSTEM POWER STEERING Steering wheel Outer diameter Free play Operation force Lock to lock mm in mm in N kg lb 370 14 57 O 30 O I I 8 29 3 0 6 6 or less 2 76 Type Steering gear...

Page 574: ...late mm in Cylinder bore mm in Parking brake Type Parking brake lever notches When tever is pulled at 98N IO kg 22 lb Power brake unit Drameter mm in Fluid pressure per treading force kPa kg cm2 psi N...

Page 575: ...0 030 0 80 O 032 0 85 O O34j mm in 0 90 0 035 0 95 0 037 1 00 O 039 1 05 0 041 1 10 0 043 1 15 0 0451 1 20 0 0471 I 25 0 049 1 30 o oslj 1 35 o o53j 1 40 o o55j 1 45 0 057j mm in I Sandard 0 025 0 1...

Page 576: ...5 60 65 OD 03 3 600 3 750 3 500 3 700 3 850 4 100 142 152 W 94 153 W 95 101 155 165 96 102 OD D2 2 000 2 200 2 000 2 200 2 300 2 500 82 90 51 56 88 96 55 60 94 102 58 63 Kickdown OD DI l OOO 1 150 950...

Page 577: ...irection mm in 0 050 0 002 Rear axle Bearing play axial direction mm in 0 050 0 002 I N STEERING SYSTEM Item Specifications Steering wheel Outer diameter Free play Operation force Lock to lock mm in 3...

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Summary of Contents for 1990 323

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Mazda 1990 323, Workshop Manual Supplement

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Summary of Contents for 1990 323

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