manualshive.com logo in svg

Mazda 1990 MX-5, Workshop Manual

The Mazda 1990 MX-5 Workshop Manual is available for free download on manualshive.com. This comprehensive manual provides detailed instructions and specifications for maintenance and repairs of the iconic sports car. Easily access this essential resource to keep your MX-5 in top condition. Download now for all the tools you need.

Share
Download
background image

Summary of Contents for 1990 MX-5

Page 1: ...erforming limited repair and maintenance on Mazda vehicles For proper repair and maintenance a thorough familiarisation with this manual is important and it should always be kept in a handy place for...

Page 2: ...VEHICLE IDENTIFICATION NUMBERS VIN JM1 NA351 LO 100001 JM1 NA352 LO 100001...

Page 3: ...I 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 POSITIONS GI 8 VEHICLE LIFT 2 SUPPORT TYPE POSiTIONS G...

Page 4: ...ty will be 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 per...

Page 5: ...lace it as necessary 2 Expendable parts tightening torques and symbols for oil grease and sealant are shown in the overview illustration 3 Pages related to service procedures are shown under the illus...

Page 6: ...d 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...

Page 7: ...ecessary 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 determine i...

Page 8: ...roughly 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 STANDARD BOLT AND NUT TIG...

Page 9: ...MENTAL PROCEDURES GI ADJUSTMENTS Use suitable gauges and or testers when making adjustments 67UOGX 002 RUBBER PARTS AND TUBING Prevent gasoline or oil from getting on rubber parts or tubing 9MUGIX 005...

Page 10: ...ND POSITIONS FRONT Jack position Safety stand positions At center of crossmember Side sills REAR Jack position Safety stand positions At center of differential Side sills VEHICLE LIFT 2 SUPPORT TYPE P...

Page 11: ...els off the ground WITH MANUAL tRANSMISSION If the transmissiori rear axle and steering system are not damaged the vehi cle may be towed on all four wheels If any of these components is damaged use a...

Page 12: ...ead center BTDC Before top dead center DRL Daytime running light ECU Engine control unit EGI Electronic gasoline injection ElL Electrical load EX Exhaust IC Integrated circuit IN Intake INT Intermitte...

Page 13: ...io observe the following precautions 1 Install the antenna at the farthest point from control units 2 Install the antenna feeder as far as possible from the control unit harnesses at least 30 em 11 8...

Page 14: ...ir bag system are not intended to be disassembled for service If a component failure is indicated by the diagnostic module replace the suspected component after verify ing the condition of the connect...

Page 15: ...eel is removed or the clock spring connector is replaced the clockspring connector must be properly aligned Align the clock spring connector as follows 1 Set the front wheels straight ahead 2 Turn the...

Page 16: ...e to harnesses or electronic com ponents Voltmeter The DC voltmeter is used to measure circuit voltage A volt meter with a range of 15V or more is used by connecting the positive probe red lead wire t...

Page 17: ...isconnecting connectors Never pull on the wire harness when disconnecting con nectors Connectors can be disconnected by pressing or pulling the lock lever as shown Locking connectors When locking conn...

Page 18: ...s 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 terminal be sure to insert it until it locks sec...

Page 19: ...R Black Brown Green Gray Blue Light Blue Light Green CODE COLOR 0 Orange P Pink R Red V Violet W White Y Yellow 1 When replacing a fuse be sure to replace it with one of the specified capacity If a fu...

Page 20: ...ND SCHEDULED MAINTENANCE SERVICES PRE DELIVERY INSPECTION A 2 PRE DELIVERY INSPECTION TABLE A 2 SCHEDULED MAINTENANCE SERViCES A 3 SCHEDULE 1 NORMAL DRIVING CONDITIONS A 3 SCHEDULE 2 UNIQUE DRIVING CO...

Page 21: ...and steering lock o Starter interlock switch clutch pedal D All lights including warning and indicator lights D Audible warning system o Horn wipers and washer D Audio system if equipped D Cigarette...

Page 22: ...CHEDULE 1 NORMAL DRIVING CONDITIONS Chart symbols I Inspect and if necessary correct clean or replace R Replace or change T Tighten Remarks After 60 months or 60 000 miles 96 000 km continue to follow...

Page 23: ...00 48 000 60 000 72 000 84 000 96 000 R R R R R R R R R R R R R R R R I I R R Replace every 60 000 miles 96 000 km R R 1 3 I R 1 2 I I I R R Service data and inspection point Oil pan capacity 3 2 lite...

Page 24: ...ount annually Compressor Inspect operation annually 55 60 55 60 88 96 I I I I R R T I Service data and inspection point Proper attachment and connections Disc plate thickness 16 0mm 0 63 in Minimum Pa...

Page 25: ...this maintenance chart note the following points 1 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...

Page 26: ...SYSTEM Idle speed Id Fuel filter Fuel lines 1 2 COOLING SYSTEM Cooling system I Engine coolant R 55 60 55 60 Service data and inspection point 88 96 R R Oil pan capacity 3 2 liters 3 4 US qt 2 8 Imp q...

Page 27: ...TIONER SYSTEM Refrigerant Inspect refrigerant amount annually Compressor Inspect operation annually Service data and inspection point Proper attachment and connections Disc plate thickness 16 0mm 0 63...

Page 28: ...B 11 TIMING BELT B 59 PREPARATION B 11 TENSIONER IDLER 8 59 TIMING B LT B 12 TENSIONER SPRING B 59 CYLINDER HEAD GASKET 6 16 PU LLEY 8 59 HLA 8 20 ASSEMBLV B 60 FRONT OIL SEAL 8 24 PREPARATION 8 60 R...

Page 29: ...asket Replacement page 8 16 3 HLA Removal Installation page 8 20 4 Front oil seal Replacement page 8 24 5 Rear oil seal Replacement page 8 26 8 2 COMPRESSION INSPECTION PAGE 6 10 STANDARD 1 324 kPa 13...

Page 30: ...E Problem Possible Cause Remedy Page Difficult starting Malfunction of engine related components Burned valve 1Replace B 49 Worn piston piston ring or cylinder Replace or repair 8 54 56 Failed cylinde...

Page 31: ...bearing related parts Excessive main bearing oil clearance Replace or repair 8 63 Main bearing seized or heat damaged Replace B 58 Excessive crankshaft end play Replace or repair 8 64 Excessive conne...

Page 32: ...F marks on the level gauge represents 0 8 liter 0 85 US qt 0 70 Imp qt ENGINE COOLANT Inspection Coolant level engine cold Warning Never remove the radiator cap while the engine is hot Wrap a thick cl...

Page 33: ...Used Alternator 491 589 422 491 50 60 110 132 43 50 95 110 PIS PIS A C 491 589 422 491 50 60 110 132 43 50 95 110 A C 491 589 422 491 50 60 110 132 43 50 95 110 6 Install the air intake pipe Adjustme...

Page 34: ...LA replaced 5 Tappet noise continues more than ten minutes 6 Tappet noise occurs at idle after high speed driving 3 Ale belt If necessary loosen the locknut and adjust the belt deflection by turning t...

Page 35: ...t a timing light and a tachometer to the diagnosis connector terminal IG Caution Be extremely careful when making connections to the diagnosis connector because a mistaken con nection will cause a mal...

Page 36: ...diagnosis connector 6 Increase the engine speed and verify that the ignition tim ing advances _ Idle Speed Inspection I Adjustment 1 Connect the SST or jumper wire to the diagnosis connec tor Refer to...

Page 37: ...heck each cylinder Compression 1 324 kPa 13 5 kg cm2 192 psi 300 rpm Minimum 932 kPa 9 5 kg cm2 135 pSi 300 rpm Differential limit between cylinders 196 kPa 2 0 kg cm2 28 psi 10 If the compression in...

Page 38: ...emoval and installation of tim ing belt pulley For prevention of engine rotation For prevention of S engine rotation 49 8011 102 Lock tool J0 f7 crankshaft 49 E301 061 J Body Part of 49 E301 060 49 8E...

Page 39: ...3 Water hoses Connect to thermostat housing 4 PIS andlor Ale drive belt Removal I Installation page B 6 5 Alternator drive belt Removal I Installation page B 6 6 Water pump pulley 7 Plate 8 Crankshaf...

Page 40: ...ner lock bolt Caution To prevent damage to the tensioner secure it with a rag 3 Temporarily secure the tensioner with the spring fully ex tended 4 Remove the timing belt Installation note Tensioner te...

Page 41: ...ks are aligned with the seal plate marks If not aligned remove the timing belt and repeat from ten sioner installation 6 Turn the crankshaft 1 and 5 6 turn clockwise and align the timing belt pulley m...

Page 42: ...lugs Tightening torque 15 23 N m 1 5 2 3 m kg 11 17 ft Ib Timing belt guide plate inner Caution Make sure the timing belt inner guide plate is in stalled in the proper direction 1 Install the timing b...

Page 43: ...ocation on the hose and squeeze the clamp lightly with large pliers to ensure a good fit 1 Disconnect the negative battery cable 2 Drain the engine coolant 3 Remove in the order shown in the figure re...

Page 44: ...shown in the figure 8 Front exhaust pipe 9 Manifold bracket 10 Cylinder head bolt Removal Note page 8 18 Installation Note page 8 19 11 Cylinder head Disassembly 00 000000 000000 000000 page 8 40 Ins...

Page 45: ...r bypass pipe IGNITION COIL OXYGEN gENSOR PIS PRESSURE SWITCH 05UOBX 040 1 Remove the exhaust manifold nut as shown in the figure 2 Remove the water bypass pipe from the cylinder head as sembly Cylind...

Page 46: ...t Ib Accelerator cable 1 Install the accelerator cable 2 Check the accelerator cable deflection If the deflection is not correct adjust by turning nut A De flection 1 3mm 0 04 0 12 in 1 Fill the radia...

Page 47: ...ain the engine coolant 3 Remove in the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal referring to Installation Note I l 1 Timing belt Removal Installati...

Page 48: ...e camshaft HLA Caution Mark the HLA with a felt pen so that they can be rein stalled in the position from which they were removed 1 Remove the HLA from the cylinder head Installation note HLA 1 Apply...

Page 49: ...in the figure Tightening torque 11 3 14 2 N m 1 15 1 45 m kg 100 126 in Ib 6 Apply a small amount of clean engine oil to the lip of a new camshaft oil seal 7 Push the oil seal slightly in by hand Cau...

Page 50: ...r 1 Apply grease to a new O ring and the blade 2 Install the crank angle sensor and loosely tighten the instal lation bolt 3 Connect the crank angle sensor connector 1 Fill the radiator with the speci...

Page 51: ...shown in the figure referring to Removal Note 4 Install in the reverse order of removal referring to Installation Note 1 I I I D I I I 2 106 116 11 0 12 0 60 67 ED 1 Timing belt 3 Timing belt pulley N...

Page 52: ...sh with the edge of the oil pump body 3 Tap the oil seal in evenly with a suitable pipe and a hammer Oil seal outer diameter 44mm 1 73 in Timing belt pulley 1 Install the timing belt pulley 2 Install...

Page 53: ...Removal Note 3 Install in the reverse order of removal referring to Installation Note REPLAC EDI 18 26 1 8 2 7 13 20 N m m kg ft Ib 05UOBX 067 1 Transmission 3 Flywheel Service page J 10 45 Removal No...

Page 54: ...oil seal in evenly with a suitable pipe and a hammer Oil seal outer diameter 100mm 3 94 in Flywheel 1 Remove the sealant from the flywheel bolt holes in the crank shaft and from the flywheel bolts Ca...

Page 55: ...2 Drain the engine coolant 3 Remove the under cover 4 Remove in the order shown in the figure referring to Removal Note Step 1 05UOBX 073 1 Air cleaner assembly 8 Alternator drive belt 2 Accelerator c...

Page 56: ...ion Do not damage the hoses 1 Remove the Ale compressor with the hoses still connected 2 Position the compressor away from the engine and affix it with wire 1 Disconnect the harness connectors shown i...

Page 57: ...ose 05UOBX 077 Removal Note page B 30 6 Heater hose 3 Vacuum hose Purge control 05UOBX 078 8 30 Removal note Fuel hose Warning Keep sparks and open flame away from the fuel area Caution Cover the hose...

Page 58: ...t frame 2 Clutch release cylinder 3 Transmission harness 05UOBX 080 Service page J 10 5 Engine mount nut 6 Engine and transmission assembly Removal Note page 8 31 Removal note Engine and transmission...

Page 59: ...B REMOVAL Step 5 05UOBX 081 1 Starter 3_ Transmission 2 Transmission mounting bolt 4 Engine assembly 6 32...

Page 60: ...2 For disassembly and assembly of and assembly of Plate engine Arms engine Part of Part of 49 L010 1AO 49 L010 1AO 49 L010 103 For disassembly 49 L010 104 For disassembly and assembly of 0 and assembl...

Page 61: ...1 Exhaust manifold insulator 2 Exhaust manifold 3 Water bypass pipe 4 Ale compressor bracket 05UOBX 084 8 34 7 05UOBX 083 5 Water inlet pipe 6 PIS oil pump bracket 7 Idler A C 8 Left engine mount Step...

Page 62: ...and plate in the specified po sition 3 Assemble the SST nuts hooks and bolts 4 Install the SST to the respective arms Note Adjust the SST bolts so that less than 20mm 0 79 in of thread is exposed Mak...

Page 63: ...s For removal and installation of pis ton pins Remover valve seal J til 1 For p revention of engine rotation For removal and installation of valves For removal of valve seals 05UOBX 090 1 Code all ide...

Page 64: ...Ignition coil and high tension lead 2 Crank angle sensor 3 Manifold bracket 4 Intake manifold assembly 5 Alternator 6 Alternator bracket 7 Right engine mount O RING REPLACE 05UOBX 092 8 Oil filter 9...

Page 65: ...ulley Disassembly Note page 8 39 8 Tensioner tensioner spring Inspection page B 59 9 Idler 3 Cylinder head cover 4 Timing belt cover upper Inspection page B 59 10 Timing belt pulley 5 Timing belt cove...

Page 66: ...ioner lock bolt Caution To prevent damage to the tensioner secure it with a rag 2 Temporarily secure the tensioner with the spring fully ex tended Note Mark the timing belt rotation for proper reinsta...

Page 67: ...ve spring seat upper Disassembly Note page 8 41 11 Valve spring Inspection page 8 52 Inspection page 8 52 3 HLA 12 Valve spring seat lower Disassembly Note page 8 41 13 Valve Inspection page 8 54 Insp...

Page 68: ...aft caps 3 Remove the camshaft 4 Remove the camshaft oil seal from the camshaft HLA Caution Mark the HLA with a felt pen so that they can be rein stalled in the position from which they were removed 1...

Page 69: ...B DISASSEMBLY Valve seal 1 Remove the valve seal with the SST 05UOBX 102 8 42...

Page 70: ...6 Oil pan baffle Service page H 14 2 Flywheel Disassembly Note page 6 44 Inspect for wear or damage 3 End plate 4 Oil pan Disassembly Note page 8 44 7 Water pump Service page E 9 8 Oil pump Service p...

Page 71: ...mage the con tact surfaces Do not damage or scratch the contact surfaces when removing the old sealant 2 Insert a screwdriver or a suitable tool only at the points shown in the figure 3 Remove the oil...

Page 72: ...ssembly Note page 8 46 Disassembly Note page 8 47 Inspection page 6 57 9 Crankshaft 3 Connecting rod bearing Inspection page 6 58 Disassembly Note page 8 47 Inspection page 6 58 4 Piston ring 10 Main...

Page 73: ...he Plastigage from the crankpin journals Caution Do not scratch the crankshaft journal or the cylin der wall 3 Use the handle of a hammer to remove the piston and con necting rod assembly through the...

Page 74: ...measure the crank shaft end play Refer to page 8 64 2 Loosen the main bearing cap bolts in two or three steps in the order shown in the figure 3 Remove the main bearing caps Crankshaft 1 Before removi...

Page 75: ...pecified Caution Do not damage the joints or friction surfaces of aluminum alloy components such as the cyl inder head or pistons 05UOBX 121 8 48 05UOBX 119 CYLINDER HEAD 1 Inspect the cylinder head f...

Page 76: ...necessary Margin thickness IN 1 0mm 0 039 in EX 1 0mm 0 039 in 3 Measure the length of each valve at the points shown Length Standard IN 105 29mm 4 1452 in EX 105 39mm 4 1492 in Minimum IN 104 79mm 4...

Page 77: ...haust valve guide on both sides as a replacement Removal 1 Remove the valve guide from the side opposite the com bustion chamber with the SST Installation 1 Assemble the SST so that depth L is as spec...

Page 78: ...lve against the seat 1 If blue does not appear 3600 around the valve face re place the valve 2 If blue does not appear 3600 around the valve seat resurface the seat 5 Measure the seat contact width Wi...

Page 79: ...mage 2 Measure the free length and out of square Replace the valve spring if necessary Free length Standard IN 48 0mm 1 890 in EX 48 3mm 1 902 in Minimum IN 47 0mm 1 850 in EX 47 3mm 1 862 in Out ot s...

Page 80: ...l clearance 1 Remove all foreign material and oil from the journals and bearing surface 2 Set the camshaft onto the cylinder head 3 Position Plastigage atop the journals in the axial direction 4 Insta...

Page 81: ...the HLA 1 Inspect the HLA friction surfaces for wear or damage Re place the HLA if necessary 2 Hold the bucket body and press the plunger by hand If the plunger moves replace the HLA CYLINDER BLOCK 1...

Page 82: ...ston and be the same for all cylinders 1 If the cylinder bore exceeds the maximum rebore the cylinder to oversize 2 If the difference between measurements A and C ex ceeds the maximum taper rebore the...

Page 83: ...0792 3 0794 0 50 0 020 oversize 78 461 78 467 3 0890 3 0892 3 Measure the piston to cylinder clearance Clearance 0 039 0 052mm 0 0015 0 0020 in Maximum 0 15mm 0 006 in 4 If the clearance exceeds the...

Page 84: ...h piston pin diameter in X and Y directions at four points Diameter 19 987 19 993mm 0 7869 0 7871 in 3 Calculate the piston pin to piston clearance Clearance 0 005 0 013mm 0 0002 0 0005 in 4 If the cl...

Page 85: ...5mm 0 0020 in max Caution Do not remove the fillet roll area R when grinding 5 If the diameter is less than the minimum grind the journals to match an undersize bearing Undersize bearing 0 25mm 0 010...

Page 86: ...tensioner or idler with cleaning fluids If necessary use a soft rag to wipe them clean and avoid scratching them 1 Check the tensioner and idler for smooth rotation and ab normal noise Replace the ten...

Page 87: ...guide Ill 49 L012 001 For installation of 49 L012 002 i For installation of Q 1 i valve seal a valve seal Installer Body Part of Part of 49 L012 OAO 49 L012 OAO 49 L012 005 For installation of 49 063...

Page 88: ...OBX 175 Connecting Rod 1 Install one piston pin clip into the clip groove in the piston 2 Assemble the piston and the connecting rod in the direc tion from which they were disassembled 3 Apply clean e...

Page 89: ...2 Install the oil ring spacer with the ends upward Note The upper rail and lower rail are the same The rails may be installed with either face upward 3 Install the upper rail and lower rail 2 Verify t...

Page 90: ...bearings Caution Install the grooved upper main bearings in the cyl inder block Install the thrust bearings with the oil groove fac ing the crankshaft 2 Install the upper main bearings and thrust bea...

Page 91: ...3 Install the crankshaft and the main bearing caps accord ing to the cap number and y o mark 4 Tighten the main bearing cap bolts in two or three steps in the order shown in the figure Tightening torq...

Page 92: ...mercially available Connecting Rod Cap 1 Measure the connecting rod bearing oil clearances using the same procedure as for the main bearing oil clearance Caution Align the matching marks on the cap an...

Page 93: ...rankpin journals and connecting rod bearings 6 Install the connecting rod caps with the matching marks aligned 7 Tighten the connecting rod cap nuts in two or three steps Tightening torque 50 54 N m 5...

Page 94: ...ilicone sealant to the shaded area shown in the figure 5 Install the rear cover Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib Oil Pump 1 Apply a small amount of clean engine oil to the lip of...

Page 95: ...ft Ib Oil Pan Baffle 1 Remove all foreign material from the contact surfaces Caution The oil pan must be secured within 30 minutes af ter the sealant is applied to the baffle 2 Apply a continuous bead...

Page 96: ...all the end plate Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib Flywheel 1 Remove the sealant from the flywheel bolt holes in the crank shaft and from the flywheel bolts Caution If all the pre...

Page 97: ...BLY Clutch Disc and Clutch Cover 1 Install the clutch disc and clutch cover using the SST Refer to page H 14 Tightening torque 18 26 N m 1 8 2 7 m kg 13 20 ft Ib OIL SEAL REPLAC ED 76 61 l2 7 7 8 3 56...

Page 98: ...mer B 4 Press the valve seal on until the SST contacts the cylinder head Valve and Valve Spring 1 Install the lower spring seat 2 Install the valve Caution Install the spring with the closer pitch tow...

Page 99: ...hown Tightening torque 76 81 N m 7 7 8 3 m kg 56 60 ft Ib Thermostat Housing 1 Remove all foreign material from the thermostat housing mounting surface 2 Install a new O ring and the thermostat housin...

Page 100: ...haft cap bolts and tighten them in two or three steps in the order shown Tightening torque 11 3 14 2 N m 1 15 1 45 m kg 100 126 in Ib 6 Apply a small amount of clean engine oil to the lip of a new cam...

Page 101: ...N m 05UOBX 058 1 25 1 75 m kg 109 152 In Ib GIl I ASSEMBLY 3 Install the camshaft pulley lock bolts 4 Hold the camshaft with a wrench 5 Tighten the camshaft pulley lock bolt Tightening torque 49 61 N...

Page 102: ...N m 11 0 12 0 m kg 80 87 ft Ib Idler 1 Install the idler Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 n Ib Tensioner and Tensioner Spring 1 Install the tensioner and the tensioner spring 2 Temporari...

Page 103: ...turn clockwise and align the timing belt pulley mark with the tension set mark 7 Loosen the tensioner lock bolt to apply tension to the tim ing belt 8 Tighten the tensioner lock bolt Tightening torqu...

Page 104: ...ming belt inner guide plate is in stalled in the proper direction 1 Install the timin belt inner guide plate 2 Install the timing belt outer guide plate 3 Install the crankshaft pulley 4 Install the p...

Page 105: ...L d 104 156In lb ASSEMBLY 36 54 3 7 5 5 27 40 19 25 1 9 2 6 14 19 O RING REPLACE I 19 25 1 9 2 6 14 19 37 52 3 6 5 3 27 36 N m m kg ft Ib 05UOBX 237 Engine Hanger 1 Install the front and rear engine...

Page 106: ...ft Ib Water Outlet Pipe 1 Remove all foreign material from the water outlet pipe mount ing surface 2 Install a new gasket and the water outlet pipe Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib...

Page 107: ...54 N m 3 7 5 5 m kg 27 40 ft Ib Alternator 1 Install the alternator and loosely tighten the mounting bolts Intake Manifold Assembly 1 Remove all foreign material from the intake manifold con tact sur...

Page 108: ...w O ring and the blade 2 Install the crank angle sensor and loosely tighten the instal lation bolt Ignition Coil and High tension Lead 1 Install the ignition coil Tightening torque 19 25 N m 1 9 2 6 m...

Page 109: ...the SST engine hanger from the engine 3 Install the parts shown in the figure Torque Specifications O RING REPLACE 19 25 1 9 2 6 14 19 7 8 11 N m 80 110 em kg 69 95 In lb N m m kg ft lb 05UOBX 251 Le...

Page 110: ...ipe Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft Ib 3 Apply a small amount of engine coolant to the new O ring 4 Install the water bypass pipe AIC Compressor Bracket 1 Install the Ale compressor...

Page 111: ...X 258 Transmission 1 Join the engine and transmission 2 Install the transmission mounting bolts Caution Install the exhaust pipe bracket as shown 3 Tighten the bolts Tightening torque 64 89 N m 6 5 9...

Page 112: ...and transmission assembly 1 Suspend the engine and transmission assembly Caution Do not damage any components in the engine com partment 2 Install the engine with the transmission tilting downward 3...

Page 113: ...42 58 ft Ib Propeller shaft speedometer cable and shift knob 1 Install the propeller shaft speedometer cable and shift knob Refer to page J 45 Transmission harness 1 Connect the transmission harness C...

Page 114: ...he hose clamp in the original location on the hose and squeeze the clamp lightly with large pliers to ensure a good fit Step 4 1 Connect the harness connectors shown in the figure GROUND INJECTOR BRAK...

Page 115: ...1 N m 80 110 em kg 69 95 in Ib 19 25 1 9 2 6 14 19 N m m kg ft Ib 05UOBX 269 Ale compressor 1 Install the Ale compressor Tightening torque 15 22 N m 1 5 2 2 m kg 11 16 ft Ib PIS oil pump 1 Install the...

Page 116: ...en the A C pipe bracket to the radiator Tightening torque 7 8 11 N m 80 110 em kg 69 95 in Ib 3 Connect the upper and lower radiator hoses Caution Position the hose clamp in the original location on t...

Page 117: ...efer to page E 5 4 If the transmission oil was drained fill with the specified amount and type of transmission oil Refer to page J 8 5 Connect the negative battery cable 6 Start the engine and check t...

Page 118: ...E D 3 OIL PRESSURE D 4 PREPARATION 0 4 INSPECTION D 4 ENGINE OIL 0 5 INSPECTION D 5 REPLACEMENT 0 5 OIL FILTER D 5 REPLACEMENT 0 5 OIL PAN D 6 REMOVAL INSPECTION INSTALLATION II 0 6 OIL PUMP D 9 PREPA...

Page 119: ...Oil filter Replacement page 0 5 0 2 HYDRAULIC LASH ADJUSTER HLA SERVICE SECTION B ENGINE OIL SPECIFICATION API SERVICE SF OR SG TOTAL CAPACITY 3 6 liters 3 8 US qt 3 2 Imp qt 4 Oil pan Removal Inspec...

Page 120: ...gine oil 10W 30 10W 40 1OW 50 20W 40 20W 50 Anticipated ambient temperature range before succeeding oil change c OF 05UODX 004 TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Engine hard star...

Page 121: ...3 Warm up the engine to normal operating temperature 4 Run the engine at 1 000 rpm and 3 000 rpm and note the gauge reading Oil pressure 196 294 kPa 2 0 3 0 kg cm2 28 43 psi l 000 rpm 294 392 kPa 3 0...

Page 122: ...4 Install a new gasket and the drain plug Tightening torque 29 41 N m 3 0 4 2 m kg 22 30 ft Ib 5 Refill the engine with the specified type and amount of en gine oil 6 Refit the oil filler cap Oil pan...

Page 123: ...the reverse order of removal referring to Installation Note 57 78 5 8 8 0 42 58 7 0 8 5 51 61 7 8 11 N m 80 110 em kg 69 95 In Ib 7 8 11 N m 80 110 em kg 69 95 in Ib l D RING REPLACE SEAT FACE N m m k...

Page 124: ...Remove the oil pan mounting bolts Caution Do not force a prying tool between the cylinder block and the oil pan which may damage the con tact surfaces Do not damage or scratch the contact surfaces whe...

Page 125: ...the projections in the notches shown in the figure 4 Apply a continuous bead of silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends 5 Install the oil pan Tightenin...

Page 126: ...cable 2 Drain the engine oil 3 Remove in the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal referring to Installation Note 1 1 I I I 1 Timing belt Servi...

Page 127: ...ley lock bolt 3_ Remove the pulley lock bolt Timing belt pulley Note If necessary remove the pulley with a steering wheel puller commercially available 1 Remove the timing belt pulley 2 Remove the pul...

Page 128: ...ASSEMBLY 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Assemble in the reverse order of disassembly referring to Assembly Note 2 9 1 Oil seal 6 Spring seat Disassembl...

Page 129: ...SPECTION Pressure Spring 1 Inspect the spring for weakness or breakage 2 Measure the free length Replace the spring if necessary Free length 45 5mm 1 791 in Rotor Clearance 1 Measure the following cle...

Page 130: ...lean engine oil to the lip of a new oil seal 2 Push the oil seal slightly in by hand Caution The oil seal must be pressed in until it is flush with the edge of the oil pump body 3 Press the oil seal i...

Page 131: ...CTION E 6 RADIATOR E 7 REMOVAL INSPECTION INSTALLATION E 7 THERMOSTAT E 8 REMOVAL INSPECTION INSTALLATION E 8 WATER PUMP E 9 REMOVAL INSTALLATION E 9 ELECTRIC COOLING FAN SYSTEM E 11 SYSTEM CiRCUiT E...

Page 132: ...n page E 8 5 Water pump Removal Installation page E 9 E 2 WATER THERMOSENSOR ENGINE CONTROL SERVICE SECTION F CD ENGINE COOLANT TOTAL CAPACITY 6 0 liters 6 3 US qt 5 3 Imp qt 6 Electric cooling fan sy...

Page 133: ...06 min Type Corrugated fin Radiator Cap valve opening pressure kPa kg cm2 psi 74 103 0 75 1 05 11 15 Type Electric Outer diameter mm in 320 12 6 Blade Cooling fan Number 5 Capacity W V 70 12 Motor Cur...

Page 134: ...released and then remove it 05UOEX 033 Coolant Level Engine cold 1 Verify that the coolant level is near the radiator filler neck 2 Verify that the coolant level in the coolant reservoir is be tween t...

Page 135: ...C 15 F 55 45 1 066 Above 40 C 40 F 45 55 1 078 05UOEX 010 REPLACEMENT Warning Never open the radiator cap while the engine is hot Wrap a thick cloth around the cap when loosening Use caution when dra...

Page 136: ...tween the radiator cap valve and the valve seat 2 Attach the radiator cap to a radiator cap tester commer cially available with the SST Appl pressure gradually to 74 103 kPa 0 75 1 05 kg em 11 15 psi...

Page 137: ...e 5 Install in the reverse order of removal 7 6 11 N m 80 110 em kg 69 95 In Ib 1 Radiator hose 2 Coolant reservoir hose 3 Cooling fan connector 05UOEX 017 N m m kg ft lb 05UOEX 016 4 Cooling fan and...

Page 138: ...e figure 4 Install in the reverse order of removal GASKET REPLACE INSTALL WITH PRINTED FACE GREEN TOWARD THERMOSTAT 1 Radiator hose upper 2 Water thermoswitch connector 3 Thermostat cover 05UOEX 019 E...

Page 139: ...system before disconnecting the battery Refer to page T 113 Do not disassemble the water pump If a problem is found replace the pump as a unit 1 Disconnect the negative battery cable 2 Drain the engi...

Page 140: ...move the PIS oil pump with the hoses still connected 2 Position the pump away from the engine and affix it with wire 1 Fill the radiator with the specified amount and type of engine coolant Refer to p...

Page 141: ...UOEX 024 05UOEX 023 SYSTEM INSPECTION 1 Jump across the fan test TFA terminal and the ground GNO terminal of the diagnosis connector 2 Turn the ignition switch ON and verify that the fan operates If t...

Page 142: ...within specification and or the fan does not turn smoothly replace the fan motor Obtain the code number and deactivate the audio anti theft system before disconnecting the battery Refer to page T 113...

Page 143: ...ermoswitch connector 05UOEX 031 05UOEX 029 2 Water thermoswitch Inspection page E 13 Installation Note page E 13 INSPECTION 1 Place the switch and a thermometer in water 2 Heat the water gradually and...

Page 144: ...1 Check continuity as shown with an ohmmeter Terminal Continuity A C No B O Yes 05UOEX 032 2 Apply 12V between terminals Band D Check for continuity between terminals A and C 3 If not as specified rep...

Page 145: ...TION F 101 SYSTEM OPERATION F 102 FUEL TANK F 104 FUEL FILTER F 106 FUEL PUMP F 107 CIRCUIT OPENING RELAy F 110 PRESSURE REGULATOR F 111 INJECTOR F 112 EXHAUST SySTEM F 115 COMPONENTS F 115 OUTLINE OF...

Page 146: ...PCV valve Inspection page F 94 Inspection page F 117 Installation page F 94 3 Intake manifold 8 Solenoid valve Purge control Inspection page F 119 Removal page F 95 9 Charcoal canister Installation p...

Page 147: ...eplacement page F 108 4 Circuit opening relay Inspection page F 11 0 Replacement page F 11 0 05UOFX 003 5 Pressure regulator Inspection page F 111 Replacement page F 112 6 Injector Inspection page F 1...

Page 148: ...F INDEX 1 Catalytic converter Inspection Replacement page F 122 F 4 2 Exhaust components Removal Inspection 05UOFX 004 Installation page F 115...

Page 149: ...SYSTEM DIAGRAM DYNAMIC CHAMBER THROTTLE SENSOR OUTLINE WATER THERMOSENSOR CATALYTIC CONVERTER FUEL FILTER HIGH PRESSURE SIDE PRESSURE REGULATOR TWO WAY CHECK VALVE FUEL VAPOR VALVE FUEL TANK F 05UOFX...

Page 150: ...F VACUUM HOSE ROUTING DIAGRAM CHARCOAL CANISTER F 6 OUTLINE BLACK ACTUATOR CRUISE CONTROL 05UOFX 006...

Page 151: ...SIS CONNECTOR I FROM IGNITION SWITCH FROM BATIERY 11L1R F FROM IGNITION SWITCH 11 F 14 paWER l CONNECTOR L F F 05 11 f 1W y 1 F i B W 18R Y 1W Rl Y R llLio 11 F F F Fl F F TO PLUG W R F t I TO PLUG B...

Page 152: ...t V GY I L r I lG W F 18 lG IRIL F F I 0 J ITHROTTLE SENSOR lG R BILG F F J J G B LG F l OXYGEN SENSOR FOR USA TNS RELAY Z 34 FOR CANADA COMBINATlON SWITCH Z 38 I I I IA AI F 15 CIRCUIT OPENING RE lAY...

Page 153: ...Below 400C 104 F Solenoid valve Purge contrOl Solenoid resistance 0 23 27 at 200C 68 F Crank angle sensor Type Optical pickup Airflow meter E2 VS Fully closed 200 600 Fully open 20 1 000 E2H VC 200 40...

Page 154: ...unit Ne signal Detects crank angle at 1800 intervals sends signal to control unit Dynamic chamber Interconnects all cylinders Engine control unit Detects the following ECU 1 AIC operation 1 AIC switc...

Page 155: ...minates when input device mal TEN terminal of diagnosis connector indicator lamp functions Lamp flashes to indicate malfunction code TEN terminal of diagnosis connector number of input and output devi...

Page 156: ...EFFECT ON ECU t SENSOR COLD TWO MINUTES I 1 1DROPPING LOW TO HIGH VOLTAGE O O 8V THREE MINUTES MORE THAN FOUR SENDS No 1 CYL INDER TDC SIG NAL TO ECU SENDS ENGINE SPEED SIGNAL TO ECU COOL TO WARM MEDI...

Page 157: ...APPROX OV OFF ED SENDS SIGNAL TO ECU APPROX 12V t OFF SWITCHES HEAD LIGHT SWITCH SIGNAL HAS NO EFFECT ON ECU HEAD LIGHT SWITCH ON HIGH VOLTAGE SIGNAL TO ECU APPROX 12V HEAD LIGHT SWITCH OFF LOW VOLTA...

Page 158: ...MINUTE TWO MINUTES THREE MINUTES RICH ALL CYLINDERS EACH Ne SIGNAL 2 GROUP LARGE AMOUNT OF BYPASS AIR OFF PURGE CUD RICH 4AND LEAN HOT CRUISE WARM AIR WARM COOLANT HOT ACCELERATION 60 THROTTLE HOT ACC...

Page 159: ...an Switch x x 0 x x x Blower Control Switch x x 0 x x x Headlight Switch x x 0 x x x Stoplight Switch 0 x x x x x Neutral and Clutch Switches 0 x 0 0 x 0 AIC Switch x x 0 x 0 x Idle Terminal 0 x 0 0 x...

Page 160: ...mptoms 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 CHECK FOR WHAT IS BAD IN SYSTEM Di...

Page 161: ...ause Refer to specified check sequence 00 flashes Check ECU terminal 1F voltage Voltage Approx 12V Ignition switch ON r r page F 78 r r page F 128 c If OK replace ECU r r page F 127 If not OK check wi...

Page 162: ...3 Rough idle just after starting Engine starts normally but vibrates excessively only F 39 just after starting 14 Idle moves up and down Engine speed up and down periodically at idle F 40 15 Engine st...

Page 163: ...e from the fuel system to reduce the possibility of injury or fire 1 Start the engine 2 Disconnect the circuit opening relay connector 3 After the engine stalls turn off the ignition switch 4 Reconnec...

Page 164: ...d while cranking engine 2 Check if 00 is displayed on Self Diagnosis Checker with ignition switch ON c r page F 76 SELECT SW A SYSTEM SELECT 1 o 3 ACTION Yes Go to Step 3 No Go to Step 2 Yes Check ign...

Page 165: ...ty of fuel pump No Check circuit opening relay Yes Go to Step 7 No Go to Step 6 Yes Check ECU terminals 2A 2U and 2V voltages No Check for open circuit in wiring be tween main relay and injector Yes G...

Page 166: ...46 psi kJJI GND F P 4 Check if ECU terminal voltages are OK 20 20 and 20 Low engine compression ACTION Yes Go to next step No Malfunction Code No displayed Check for cause Refer to specified check se...

Page 167: ...G CAP ii 1 0 1 1mm 0 039 0 043 in BURNS DAMAGE AND DETERIORATION DAMAGE 9 Try known good ECU and check if condition improves c r page F 127 ACTION Yes Repair or replace No Go to nest step Yes Go to ne...

Page 168: ...2 kg cm2 38 46 psi I GND F P Vapor lock Fuel pressure not held in fuel line after engine stops High RVP winter fuel used in warm weather ACTION Yes Go to next step No Malfunction Code No displayed Che...

Page 169: ...Gheck if fuel line pressure is held after ignition Yes Replace pressure regulator c T page F 112 switch is turned OFF and blocking outlet of pres No Check fuel pump hold pressure c r page F 107 sure r...

Page 170: ...e F 80 c r page F 128 If OK replace ECU c r page F 127 S If not OK check wiring between ECU and Self Diagnosis Checker c r page F 7 2 Check for correct intake manifold vacuum at idle Yes Go to next st...

Page 171: ...for correct engine compression c r page 9 10 Engine compression 1 324 932 kPa 13 5 9 5 kg cm2 192 135 psi 300 rpm 10 Check if spark plugs are OK WEAR AND CARBON BUILDUP PLUG GAP 1 0 1 1mm 0 039 0 043...

Page 172: ...Check for correct intake manifold vacuum at idle Vacuum More than 450 mmHg 17 7 inHg Check if air cleanerr element is clean c r page f 75 Try known good ECU and check if condition improves c r page F...

Page 173: ...d ECU and check if condition improves c r page F 127 Vapor lock Fuel pressure not held in fuel line after engine stops eHigh RVP winter fuel used in warm weather ACTION Yes Go to next step No Malfunct...

Page 174: ...iagnosis Checker Monitor Lamp and ignition switch ON 5 Check if ECU terminal voltages are OK 20 20 and 2Q No Check for air leakage of intake air sys tem components c t page F 93 Yes Go to next step No...

Page 175: ...U and injector If not OK replace injector c 7 page F 112 c r page F 7 CI page F 112 No Check wiring between ECU and injector c r page F 7 Yes Disconnect each injector connector at idle and check if en...

Page 176: ...unt Fuel injection control malfunction Correction for coolant temperature Poor atomization of fuel Low RVP summer fuel used in cold weather ACTION Yes Go to next step No Malfunction Code No displayed...

Page 177: ...e F 98 G g c4tEN QJIC1J 7 With condition of Step 5 check for correct igni tion timing at idle after warm up cr page F 75 Ignition timing 100 10 BTDC 8 Try known good ECU and check if condition improve...

Page 178: ...d Check for cause Refer to specified check sequence Yes No 88 flashes Check ECU terminal 1F voltage Voltage Approx 12V Ignition switch ON c t If OK replace ECU c If not OK check wiring between ECU and...

Page 179: ...k for correct engine compressicm CT page 8 10 Engine compression 1 324 932 kPa 13 5 9 5 kg cm 192 135 300 rpm 10 Check if spark plugs are OK WEAR AND CARBON BUILDUP PLUG GAP 1 0 1 1mm 0 039 0 043 in D...

Page 180: ...played on Self Diagnosis Checker with ignition switch ON c r page F 78 SELECT SW A 4 Check switches for correct operation with Self Diagnosis Checker Monitor Lamp and ignition switch ON c 7 page F 89...

Page 181: ...le and check if clicking is heard from ISC valve 7 Pinch PCV hose with pliers and check if engine speed decreases 8 Check if ECU terminal voltages are OK 20 20 and 2Q No Check air valve Yes Go to next...

Page 182: ...place ECU L7 page F 127 2 3 4 F 38 Check switches for correct operation with Self Diagnosis Checker Monitor Lamp and ignition switch ON L7 page F 89 SYSTEM SELECT 1 TEST SW SELF TEST Check if continui...

Page 183: ...l 1F voltage Voltage Approx 12V Ignition switch ON If OK replace ECU If not OK check wiring between ECU and Self Diagnosis Checker Yes Go to next step No Lamp not ON OFF with specified switch Check fo...

Page 184: ...N c r page F 78 SELECT SW A 2 Check for correct idle speed c r page F 76 Idle speed 850 I 50 rpm kD Lh1 3 Check for correct ignition timing at idle c r page F 75 Ignition timing 100 10 BTDC il kD Lh1...

Page 185: ...ATION DAMAGE Check if ECU terminal voltages are OK 20 2Q and 2X c r page F 128 11 Try known good ECU and check if condition im proves c r page F 127 Resistance Approx 140 c If OK check wiring between...

Page 186: ...tch ON c r page F 78 SELECT SW A SYSTEM SELECT 1 4 Check switches for correct operation with Self Diagnosis Checker Monitor Lamp and ignition switch ON CT page F 89 SELECT SW A F 42 No Check for air l...

Page 187: ...1mm 0 039 0 043 in I ____ BURNS DAMAGEAND DETERIORATION DAMAGE 10 Connect diagnosis connector terminals F P and GND with jumper wire and check for correct fuel line pressure with ignition switch ON c...

Page 188: ...if ECU terminal voltages are OK 20 20 and 2Q L7 page F 129 4 Check for correct intake manifold vacuum at idle Vacuum More than 450 mmHg 17 7 inHg F 44 No No ACTION Go to next step Malfunction Code No...

Page 189: ...TION Engine runs normally at idle during warm up but becomes rough and stalls after warm up TROUBLESHOOTING HINTS CD Air Fuel mixture too lean Air leakage of intake air system STEP INSPECTION Check i...

Page 190: ...next step No Go to next step No Malfunction Code No displayed Check for cause Refer to specified check sequence aa flashes Check ECU terminal 1F voltage Voltage Approx 12V Ignition switch ON If OK re...

Page 191: ...age of intake air system components c r page F 93 Yes Go to next step No Replace air cleaner element c r page F 92 Yes Check if ignition timing advances when accelerating c If advances go to next step...

Page 192: ...dition improves 4 Check if ECU terminal voltages are OK 2D 20 2U 2V and 20 Yes No Engine feedback control malfunction Idle speed misadjustment ACTION Go to next step Malfunction Code No displayed Chec...

Page 193: ...d from ISC valve 6 Check for correct idle speed cr page F 76 Idlle speed 850 50 rpm GND TI N bB UJ CONNECT TERMINALS 7 Try known good ECU and check if condition im proves L7 page F 127 Yes Go to next...

Page 194: ...m GND TEN bB LD CONNECT TERMINALS Disconnect ISC valve connector at idle and check if clicking is heard from ISC valve 6 Try known good ECU and check if condition im proves c r page F 127 F 50 ACTION...

Page 195: ...and wiggle harness and connector ACTION Yes Go to next step No Malfunction Code No displayed Check for cause Refer to specified check sequence Note When checking wiring harness and connectors tap mov...

Page 196: ...SW SELF TEST Yes No Check for cause Refer to specified check sequence L page F BO 88 flashes Check ECU terminal 1F voltage c r page F 128 Voltage Approx 12V Ignition switch ON r t If OK replace ECU I...

Page 197: ...page F 92 c r page F 127 c r page F 75 10 Check for correct fuel line pressure at idle Yes Check if fuel line pressure decreases when accelerating quickly L page F l03 Fuel line pressure 265 314 kPa 2...

Page 198: ...r to specified check sequence 88 flashes Check ECU terminal 1F voltage Voltage Approx 12V Ignition switch ON c If OK replace ECU c If not OK check wiring between ECU and Self Diagnosis Checker Yes Go...

Page 199: ...pressure at idle Yes Check if fuel line pressure decreases c J page F 103 when accelerating quickly Fuel line pressure If decreases check fuel line and fil 265 314 kPa 2 7 3 2 kg cm2 38 46 psi ter for...

Page 200: ...fully opens when depress Yes Go to next step ing accelerator fully 3 4 Check switches for correct operation with Self Diagnosis Checker Monitor Lamp and ignition switch ON F 56 No Check if accelerator...

Page 201: ...sion leads are OK Resistance 16 kG per 1m 3 28 ft 8 Check if resistance of ignition coil is OK c r page G 21 Resistance at 20 C 68 F G Primary coil 0 78 0 940 Cl Secondary coiL 11 2 15 2 kG ACTION Yes...

Page 202: ...clean c r page F 75 12 Check for injector operating sound at idle 13 Check if approx 12V exists at injector connector W R wire with ignition switch ON 14 Check if ECU terminal voltages are OK 20 20 an...

Page 203: ...r clogging be tween fuel pump and pressure regulator c r page F 112 If not clogged check fuel pump maximum pressure c page F 108 16 Run engine several minutes at idle and check if Yes fuel line pressu...

Page 204: ...step ing accelerator fully 3 Check if 00 is displayed on Self Diagnosis Checker with ignition switch ON U page F 78 4 Check switches for correct operation with Self Diagnosis Checker Monitor Lamp and...

Page 205: ...leads are OK Resistance 16 kn per 1m 3 28 tt 8 Check if resistance of ignition coil is OK c r page G 21 Resistance at 20 C 69 F CD Primary coil 0 78 0 940 Secondary coil 11 2 15 2 kO Yes ACTION Check...

Page 206: ...clean c r page F 75 12 Check for injector operating sound at idle 13 Check if approx 12V exists at injector connector W R wire with ignition switch ON 14 Check if ECU terminal voltages are OK 2D 20 a...

Page 207: ...ck for clogging be tween fuel pump and pressure regulator If no clogged check fuel pump maximum pressure c r page F 108 16 Run engine several minutes at idle and check if Yes High pressure fuel line p...

Page 208: ...F 89 ___ SYSTEM SELECT 1 TEST SW SELF TEST ACTION Yes Go to next step No Malfunction Code No displayed Check for cause Refer to specified check sequence Yes No 88 flashes Check ECU terminal 1F voltag...

Page 209: ...rned OFF 6 c 7 page F 1 02 Fuel line pressure More than 147 kPa 1 5 kg cm2 21 psi for 5 min Check if air cleaner element is clean c 7 page F 75 r I I I I 1 1 1 II I I rl 7 Try known good ECU and check...

Page 210: ...ming too advance Overheating Carbon deposits in engine ACTION Yes Go to next step No Malfunction Code No displayed Check for cause Refer to specified check sequence 88 flashes Check ECU terminal 1F vo...

Page 211: ...d pressure regulator 9 If no decrease go to next step Low pressure Check for fuel line pressure while pinch ing fuel return hose If fuel line pressure quickly in creases check pressure regulator c r p...

Page 212: ...lve purge control and check if air flows through valve 5 Try known good ECU c r page F 127 F 68 ACTION Yes Repair or replace No Go to next step Yes Go to next step No Malfunction Code No displayed Che...

Page 213: ...lation hose or their at taching nipples are separated damaged clogged or restricted c r page F 117 2 Check if air pressure or oil is present at ventila tion hose 3 Check if vacuum is felt at PCV valve...

Page 214: ...e pressure CT page Q 3 Unrecommended tire used u page 0 2 Clutch slipping L7 page H 3 No Repair Brake dragging c r page P 27 Exhaust component resticted CT page F 115 2 Check if air hoses are connecte...

Page 215: ...Check for correct fue Iine pressure at idle Yes Go to next step IT page F 111 Fuel line pressure 216 265 kPa 2 2 2 7 kg cm2 31 38 psi 10 Run engine several minutes at idle and check if fuel line pres...

Page 216: ...EVER ON DESCRIP I Self Diagnosis Checker indicates Malfunction code No of input device but MIL never ON TION Other indicator and warning lamps OK TROUBLESHOOTING HINTS Bulb burned out Open circuit in...

Page 217: ...and check if condenser fan operates when igni tion switch turned ON B t1 2 Ground LIB wire at ECU with jumper wire and check if condenser fan operates when ignition switch turned ON IrtttI I 1 I i I I...

Page 218: ...etween the Land F marks on the level gauge represents 0 8 liter 0 85 US qt 0 70 Imp qt Coolant Level Cold engine Warning Never remove the radiator cap while the radiator and engine are hot Wrap a thic...

Page 219: ...ower connec tor Blue l pin Warning Do not ground the power connector terminal Blue l pin the wiper 20A fuse will be burned 4 Connect a timing light and tachometer to the diagnosis con nector terminal...

Page 220: ...er wire from the diagnosis connector 7 Increase the engine speed and verify that the ignition tim ing advances Idle Speed 1 Connect the SST and set the TEST SW to SELF TEST or connect diagnosis connec...

Page 221: ...s malfunction code numbers Note The engine control unit constantly checks for malfunction of the input devices But the engine control unit checks for malfunction of output devices only in a 3 second p...

Page 222: ...1 and SELF TEST as shown SELF TEST J 05UOFX 069 05UOFX 070 4 Turn the ignition switch ON 5 Verify that 88 flashes on the digital display and that the buzz er sounds for 3 sec after turning the igniti...

Page 223: ...ber of times the buzzer sounds 0 4 second during one cycle N m ALFUNCTION CO D n n 5Ey TION O _jU 2 U 3 CYCLE BREAK IUU1 _____ U U I 1 4 0 SEC 0 4 SEC 0 4 SEC 3 First digit of malfunction code tens po...

Page 224: ...pressure Open or short circuit Maintains constant 14 sensor command of sea level OFF pressure UU Oxygen sensor Sensor output continues Cancels engine feedback 15 less than 0 45V 180 sec operation aft...

Page 225: ...y between igniter and ground 8 Check igniter Refer to page G 22 Circuit Diagram TO FROM IGNITION TACHOMETER SWITCH L F DIAGNOSIS CONNECTOR TERMINAL lG No Yes No Yes No Yes No Yes No Yes No Yes No Yes...

Page 226: ...discon Refer to page F 134 nected No Check for short circuit in wiring from crank angle sensor to ECU 05UOFX 078 CODE NO 03 G SIGNAL STEP INSPECTION ACTION 1 Are there any poor connections in crank an...

Page 227: ...SELF DIAGNOSIS FUNCTION Circuit Diagram ECU 30A W R F CRANK ANGLE SENSOR F B LG i 05UOFX 080 F 83...

Page 228: ...ges OK Refer to page F 129 Circuit Diagram WATER THERMOSENSOR F 84 B LG F ECU GY F B LG F B LG F RIG F Yes No Yes No Yes No Yes No Yes No ACTION Repair or replace connector Go to next step Check for o...

Page 229: ...ODE NO 10 INTAKE AIR THEAMOSENSOR IN AIRFLOW METER STEP INSPECTION ACTION 1 Are there any poor connections in intake air thermosen Yes Repair or replace connector sor circuit No Go to next step 2 Is t...

Page 230: ...tween oxygen sensor and ECU ter Yes minal2N No 7 Is ECU terminal 2N voltage OK Refer to page F 127 Yes No Circuit Diagram OXYGEN SENSOR F 86 B F GY F B LG F ACTION Repair or replace connector Go to ne...

Page 231: ...inal 2W voltage OK Refer to page F 130 Circuit Diagram FROM BATTERY FROM IGNITION SWITCH Yes No Yes No Yes No Yes I No Yes No Yes No Yes No Yes No Yes I No Yes No ACTION Repair or replace connector Go...

Page 232: ...tive battery cable and depressing the brake pedal for at least five seconds Reconnect the negative battery cable 2 Connect the SSTs to the diagnosis connector as shown 3 Turn the ignition switch ON bu...

Page 233: ...fully Stoplight switch Pedal depressed Headlight switch ON Blower switch ON Ale switch ON Water thermoswitch Fan operating SELECT SW A Light OFF Pedal depressed In gear Neutral Clutch pedal released...

Page 234: ...monitor lamp does not illuminate Refer to page F 139 Return transmission to neutral 05UOFX 098 Idle terminal Depress accelerator pedal less than full and verify that NO PC Idle terminal malfunction m...

Page 235: ...Set fan speed control to low position NO pc AIC switch malfunction Turn AIC switch ON and verify that monitor lamp Refer to Section U illuminates Blower switch malfunction YES Open circuit in wire ha...

Page 236: ...repair or replace as necessary 3 Install in the reverse order of removal 7 8 11 N m 7 6 11 N m 80 110 em kg 89 95 In Ib 60 110 em kg 69 95 in Ib fJ 9__25 9 r GASKET v REPLACE I 7 8 11 N m 80 110 em kg...

Page 237: ...Air Leakage INTAKE AIR SYST M Check for possible air leakage at the paints shown and repair or replace as necessary DYNAMIC CHAM R AND INTAKE MANIFOLD ASSEMBLY THROTTLE BODY L UU I I I uE CHAMBER AIR...

Page 238: ...he en gine coolant 4 Disconnect the water hoses 5 Disconnect the connectors for the ISC valve and the throt tle sensor 6 Remove the throttle body Inspection 1 Verify that the throttle valve is fully c...

Page 239: ...Remove the accelerator cable 5_ Disconnect the fuel hoses_ 6 Disconnect the connectors from the injectors 7_ Remove the delivery pipe and injectors_ 8 Remove the injector harness 8 Remove the intake...

Page 240: ...st with bolt B if necessary Replacement 1 Remove the accelerator cable from the throttle lever 2 Loosen the throttle adjustment nuts and remove the cable from the bracket 3 Compress the tabs of stay C...

Page 241: ...SSAGE F 05UOFX 118 To improve idle smoothness the ISC system controls the intake air amount by regulating amount of the by pass air that passes through the throttle valve This system consists of the a...

Page 242: ...aking connections to the diagnosis connector as a mistaken connection will cause a malfunction 2 Connect the SST and set the TEST SW to SELF TEST or connect diagnosis connector terminals TEN and GND w...

Page 243: ...69 in Ib ISC VALVE Inspection 1 Disconnect the ISC valve connector 2 Connect an ohmmeter between the terminals of the ISC valve and measure the resistance Resistance at 20 C 68 F 12 10 3 If not as sp...

Page 244: ...fuel pump the fuel filters the delivery pipe the pressure regulator the injectors and the circuit opening relay 1 Fuel tank Removal Inspection Installation page F 104 2 Fuel filter Replacement page F...

Page 245: ...as protection from fuel spray when disconnect ing the hoses c Plug the hoses after removal d When inspecting the fuel system use a suitable fuel pres sure gauge Caution Install hose clamps when securi...

Page 246: ...fuel pressure gauge between the fuel pipe and the fuel main hose Install clamps as shown 3 Connect the negative battery terminal 4 Connect diagnosis connector terminals F P and GND with a jumper wire...

Page 247: ...he fuel pipe and the fuel main hose Install clamps as shown 3 Connect the negative battery terminal 4 Connect diagnosis connector terminals F P and GND with a jumper wire 5 Turn the ignition switch ON...

Page 248: ...lean it thoroughly with steam to remove all explosive gas Note Drain the fuel from the fuel tank before removing the tank 1 Disconnect the negative battery terminal 2 Remove the main silenser Refer to...

Page 249: ...ts 1 Remove the fuel filter cover 2 Remove the fuel filter bolts 05UOFX 228 3 Remove the fuel filter with the fuel hoses still connected Brake pipe joint 1 Remove the brake pipe joint nuts 2 Remove th...

Page 250: ...OFX 140 The fuel filter must be replaced at the intervals outlined in the maintenance schedule Warning Before performing the following operation release the fuel pressure from the fuel system to reduc...

Page 251: ...ening relay and its cir cuits Refer to page F 109 05UOFX 145 05UOFX 146 8 If the voltage is normal check for continuity between fuel pump connector 8 and a ground 9 If there is continuity replace the...

Page 252: ...t the negative battery terminal 2 Connect a fuel pressure gauge to the fuel main pipe and plug the outlet of the fuel pressure gauge as shown Install clamps as shown 3 Connect the negative battery ter...

Page 253: ...the reverse order of removal referring to Installa tion Note Installation note O ring set 1 Use a new O ring set O ring cap and spacer 2 Apply oil or fuel to the O ring set before installing 3 To conf...

Page 254: ...rcuit Measure voltage between the terminals and a ground with a voltmeter Condition Fp Fe B STA E1 Ignition switch ON OV 12V 12V OV OV Ignition switch START 12V OV 12V 12V OV At idle 12V OV 12V OV OV...

Page 255: ...ssure Perform this inspection if the fuel pressure hold inspection is not as specified Refer to page F 102 Warning Before performing the following operation relase the fuel pressure from the fuel syst...

Page 256: ...system before disconnecting the battery Refer to page T 113 Inspection Operation check 1 Warm up the engine and run it at idle 2 Listen for operational sound of the injector with a screwdriver or a so...

Page 257: ...e the air valve 2 Firmly affix the injectors to the delivery pipe with wire 3 Disconnect the injector connectors 4 Remove the delivery pipe and injectors together with the fuel hoses connected 5 Conne...

Page 258: ...reverse order of removal referring to Installa tion Note Tightening torque Delivery pipe 19 25 N m 1 9 2 6 m kg 14 19 ft Ib Installation note 1 Use new injector O rings 2 Apply a small amount of clea...

Page 259: ...er of removal Note When installing the exhaust system components tighten all fasteners to the specified torque CD 64 69 6 5 9 1 47 66 31 46 3 2 4 7 23 34 7 6 11 N m 60 110 em kg 69 95 In lb 1 Main sil...

Page 260: ...ollowing systems are employed to reduce CO HC and NOx emissions 1 Positive crankcase ventilation PCV system 2 Evaporative emission control system 3 Catalytic converter 4 Deceleration control system F...

Page 261: ...larger amount of blowby gas to be drawn into the dynamic chamber 05UOFX 180 05UOFX 181 PCV VALVE Inspection 9MUOF2 182 1 Warm up the engine to the normal operating temperature and run it at idle 2 Di...

Page 262: ...lenoid valve is con trolled by the engine control unit THROTTLE SENSOR IDLE TERMINAL 8 OXYGEN SENSOR ATMOSPHERIC PRESSURE SENSOR WATER THERMOSENSOR ENGINE 1 CONTROL NEUTRAL CLUTCH SWITCH r AIRFLOW MET...

Page 263: ...vacuum hoses from the solenoid valve 2 Verify that no air flows through the valve 3 Disconnect the solenoid valve conneQtor and connect 12V and a ground to the terminals of the solenoid valve 4 Verif...

Page 264: ...ION CONTROL SYSTEM 3 Turn the valve over and blow through the valve Verify that no air flows 4 Replace the valve if necessary CHARCOAL CANISTER Inspection Visually check for damage and replace the cha...

Page 265: ...i INAL FUEL CUT SPEED NO 3 WATERTHE ENSORI________________ l tNo 4 NO 2 05UOFX 191 DASHPOT Inspection 05UOFX 239 1 Open the throttle valve fully Push the dashpot rod with a finger and verify that it...

Page 266: ...alytic converter for deterioration or restriction Check for damage to the insulation covers weld ed to the catalytic converter Replace the catalytic converter if necessary Note If the insulation cover...

Page 267: ...e Has Been Started The Ale is cut off for 2 sec just after the engine is started Acceleration The A C is cut off upon wide open throttle acceleration for approx 16 sec ffi TL pow 05UOFX 195 System Ope...

Page 268: ...n the engine is cold no fuel will be injected when the accelerator is held fully depressed while cranking the engine CRANK ANGLE SENSOR BATTERY 12V DETECTION OF CRANKING PRESSURE tGNITION SWITCH START...

Page 269: ...CONTROL SYSTEM For inspection of 49 G018 903 engine control unit Adapter harness For inspection of 49 8019 9AO oxygen sensor System Selector For inspection of 49 9200 166 oxygen sensor For inspection...

Page 270: ...on page F 136 Installation page F 136 5 Throttle sensor Inspection page F 136 Adjustment page F 137 Replacement page F 137 F 126 6 Oxygen sensor MIL SERVICE SECTION T 05UOFX 198 Inspection page F 138...

Page 271: ...ntrol unit and the wiring harness using the Adapter as shown 4 Place the SST Sheet on the SST 5 Measure the voltage at each terminal Refer to pages F 128 to F 130 5 If any engine control unit terminal...

Page 272: ...x 12V 1F 0 Self Diagnosis Buzzer sound for 3 sec after ignition With Self Checker Code switch OFF ON Below 2 5V Diagnosis number Checker and Buzzer not sounded after 3 sec Approx 12V System Selector W...

Page 273: ...OV 20 Ground Input Constant OV 1 0 Crank angle Ignition switch ON 2E Approx sensor Ne signal OV or 5V Idle Approx 2V 2F 2G 0 Crank angle Ignition switch ON Approx sensor G sgnal OV or 5V Approx 1 5V 2...

Page 274: ...from 3 000 rpm to 1 900 and red lights rpm After warm up Approx 12V flash 2W 0 ISC valve Ignition switch ON Approx 7V Idle Approx 9V 2X 0 Solenoid valve Ignition switch ON Approx 12V Purge control Idl...

Page 275: ...ctor terminal B Always below 2 5V Open or short circuit in wiring from diagnosis 88 is displayed and connector terminal FEN to ECU terminal 1F buzzer sounds continuously Always approx 12V Poor connect...

Page 276: ...er fan OK ECU terminal 1S Poor connection at ECU connector ECU malfunction Always approx 12V Open circuit in wiring from blower control switch to Blower fan OK ECU terminal 1S 1U Headlight switch Alwa...

Page 277: ...ing after warm up Refer to page F 86 20 Airflow meter Always approx OV or Refer to Code No OB troubleshooting approx 5V Refer to page F 84 2P Airflow meter Intake air Always approx OV or Refer to Code...

Page 278: ...k angle sensor Inspection 1 Visually check the crank angle sensor for damage 2 Replace if necessary Installation 1 Apply grease to the new O ring and the blade 2 Install the crank angle sensor Tighten...

Page 279: ...that the measuring plate moves smoothly 4 Disconnect the connector from the airflow meter S Move the measuring plate and check for resistance between the terminals with an ohmmeter Terminal Resistance...

Page 280: ...esistance of the sensor with an ohmmeter Coolant Resistance kO 20 C 4 F 14 6 17 8 20 C 68 F 2 2 2 7 80 C 176 F 0 29 0 35 3 If not as specified replace the water thermosensor Installation 1 Install the...

Page 281: ...hing screws 4 Rotate the throttle sensor clockwise approx 30 degrees then rotate it back counterclockwise until the buzzer sounds 5 Replace the feeler gauge with a 0 7mm 0 027 in gauge 6 Verify that t...

Page 282: ...sever al times Verify that when the speed is increased the meter reads O 5V 1 0V and when the speed is decreased it reads OV 0 4V 6 If not as specified replace the oxygen sensor Inspection of Sensiti...

Page 283: ...relay 3 Use an ohmmeter to check continuity of the terminals as shown_ Terminals 12V not applied 12Vapplied C D No continuity Continuity 4 If not as specified replace the main relay CLUTCH SWITCH Insp...

Page 284: ...tral switch Replacement Replace the neutral switch as shown in the figure POWER STEERING PRESSURE SWITCH Inspection 1 Disconnect the PIS pressure switch connector 2 Connect an ohmmeter to the switch 3...

Page 285: ...G 7 BATTERY G 8 ALTERNATOR I I I I I I I G 12 SELF DIAGNOSIS SYSTEM G 12 DRIVE BELT G 15 IGNITION SySTEM G 17 PREPARATION G 17 CIRCUIT DIAGRAM G 17 TROUBLESHOOTING G 18 IGNITION TIMING G 19 SPARK PLU...

Page 286: ...page G 16 G 2 INDEX 4 Spark plug Removal Installation page G 20 Spark test page G 20 Inspection page G 20 5 Ignition coil Inspection page G 21 Replacement page G 21 6 Igniter Inspection page G 22 7 Hi...

Page 287: ...ength Standard 17 0 0 67 mm in Minimum 11 5 0 45 Type Electronic spark advance ESA Ignition system Spark advance control Engine control unit controls spark advance Ignition timing BTDC Type Ignition c...

Page 288: ...to page G 7 NO Check if click is heard from starter magnetic switch when ignition turned to START NO I J Check starting s lstem Refer to page G 23 Check ignition switch Refer to page T 21 and starter...

Page 289: ...UIDE G Discharged battery IL _D_isc_h_a_rg_e_d_b_at_te_ry ___________ H Check charging system Refer to page G 7 05UOGX 006 Misfire I_M_is_fir_e_______________ H Check ignition system Refer to page G 1...

Page 290: ...RGING SYSTEM PREPARATION SST 49 9200 020 V ribbed belt tension gauge CIRCUIT DIAGRAM CHARGING SYSTEM For inspection of drive belt tension 05UOGX 008 I DIODE TRIO L _ Ie REGULATOR 05UOGX 009 B TERMINAL...

Page 291: ...ngine 2 Check if alternator warning lamp goes off I Check alternator Refer to page G 12 YES Check if drive belt tension is OK Refer to page 0 15 YES I J Adjust drive belt or replace Refer to page G 15...

Page 292: ...HECK Below 12 0V I 12 0 12 6V Above 12 6V I Quick charge 20A fo table below and rech r time specified in Batter eck voltage Battery voltage Charging time Below 11 0V 75 min 11 0 11 5V 50 min 11 5 12 0...

Page 293: ...ery turn off all accessories and stop the engine The negative battery cable must be removed first and installed last Caution Do not removed vent caps Follow carefully the instructions of the battery c...

Page 294: ...he Mazda genuine battery replace ment kit is as follows 1 Remove the battery cover Warning The negative battery cable must be removed first and installed last 2 Disconnect the battery cables from the...

Page 295: ...CHARGING SYSTEM G 05UOGX 022 11 Trim off the shadded area of the battery cover as shown for proper fitting to new battery 12 Install the battery over as shown G 11...

Page 296: ...nnected from the Land S terminals SELF DIAGNOSIS SYSTEM The alternator has a self diagnostic function to warn of prob lems in the charging system If any of the following problems arise the alternator...

Page 297: ...0 0 55 0 17 48 59 98 N m 6 0 10 0 m kg 43 72 ft lb 2 0 5 4 20 0_5 _4 1 9 2 0 5 4 20 0 55 0 17 48 N m em kg In Ib 05UOGX 027 1 Pulley nut 2 Pulley 3 Front cover 6 Brush holder assembly Inspection page...

Page 298: ...the core with an ohmmeter 2 Replace the rotor if there is continuity 3 Slip ring surface If the slip ring surface is rough use fine sandpaper to re pair it Stator 1 Wiring damage 1 Check for continui...

Page 299: ...the diodes with an ohmmeter Negative Black Positive Red E B P1 P2 P3 T E P1 P2 P3 B T 2 Replace the rectifier if necessary DRIVE BELT Inspection 1 Remove the air intake pipe Continuity Yes No No No Ye...

Page 300: ...n at the midpoint of new belt specification 1 Alternator belt If necessary loosen the alternator bolts and and adjust the belt deflection by turning the adjusting bolt Tightening torque 19 25 N m 1 9...

Page 301: ...selector CIRCUIT DIAGRAM TACHOMETER IGNITION SYSTEM For inspection of igniter For inspection of ignition timing 49 N018 001 Adapter harness ENGINE CONTROL UNIT IGNITER Li 4 IGNITION SWITCH 8 ffi 8 E8...

Page 302: ...80 Check if resistance of secondary windings is OK II NO f Check ignition coil Refer to page G 21 R e fe r to pa g e G 2 1 __ ________________ Check 2 lYES J J I Check if resistance of high tension l...

Page 303: ...ctions to the diagnosis connector as a mistaken connection will cause a malfunction 5 Connect the SST and set TEST SW to SELF TEST or con nect diagnosis connector terminals TEN and GNO with a jumper w...

Page 304: ...before installing 3_ Tighten the spark plugs to the specified torque_ Tightening torque 15 23 N m 1 5 2 3 m kg 11 17 ft Ib Spark Test 1_ Disconnect the high tension lead from the spark plug 2 Connect...

Page 305: ...ion replace the coil Primary coil winding resistance at 20 C 68 F 0 78 0 940 Secondary coil winding Measure resistance of the secondary coil winding of each coil with an ohmmeter If not within specifi...

Page 306: ...urn the ignition switch ON 6 Verify that there is approx 12V at the terminal If not as specified check related wiring Caution Do not activate the SW2 switch for more than 1 sec 7 Push the SW2 switch o...

Page 307: ...h to START position YES I Check starter motor magnetic switch 2 Check if voltage between S terminal and ground is I Refer to page G 25 approx 12V Check 2 NO 1 Depress clutch pedal 2 Check if voltage b...

Page 308: ...t the negative battery cable 2 Disconnect the wiring from the starter 3 Remove the starter bracket 4 Raise the front of the vehicle and support it with safety stands 5 Remove the bolts and the starter...

Page 309: ...if it is not with in specification Return test 1 Disconnect the motor wire from the M terminal 2 Connect 12V to the M terminal and ground to the body 3 Pullout the overrunning clutch with a screwdriv...

Page 310: ...necessary 3 Assemble in the reverse order of diassembly 4 1 7 5 42 77 36 67 1 Magnetic switch 7 Inspection page G 28 2 Rear housing 3 Front cover 4 Armature Inspection page G 27 G 26 5 Yoke assembly...

Page 311: ...the armature on V blocks and measure the runout with a dial gauge 2 Repair with a lathe if the runout is small or replace the armature if necesary Runout 0 03mm 0 001 in 4 Outer diameter of commutato...

Page 312: ...lation of field coil Replace the yoke assembly if the field coil is loose Magnetic Switch 1 Wiring damage S terminal M terminal Check for continuity between terminal S and terminal M with an ohmmeter...

Page 313: ...imit 11 5mm 0 45 in IGNITION SWITCH IG1 IG2 STA T BATTERY 1 ROD INTERLOCK SWITCH STARTER 05UOGX 074 The clutch pedal must be depressed during starting for battery power to be supplied to the starter I...

Page 314: ...REMOVAL INSTALLATION H 8 AIR BLEEDING H 9 OVERHAUL H 10 CLUTCH RELEASE CYLINDER H 12 PREPARATION H 12 REMOVAL INSTALLATION H 12 AIR BLEEDING REFER TO PAGE H 9 OVERHAUL H 13 CLUTCH UNIT I I I I I I I...

Page 315: ...page H 9 3 Clutch release cylinder Removal Installation page H 12 Overhaul page H 13 Air bleeding page H 9 H 2 4 Release bearing Removal Installation page H 14 Inspection page H 17 5 Release fork Remo...

Page 316: ...ywheel damaged Repair or replace H 14 Faulty dlsen Excessive runout or damaged clutch disc Replace H 14 gagement Clutch disc splines rusted or worn Remove rust or replace H 14 Oil on facing Repair or...

Page 317: ...h fluid which was drained out 1 Draw the fluid from the reserve tank with a suction pump 2 Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug 3 Place t...

Page 318: ...r adjustment inspect the pedal free play Clutch Pedal Free Play Inspection Depress the clutch pedal by hand until clutch resistance is felt Pedal free play 0 6 3 1 mm 0 02 0 12 in Total pedal free pla...

Page 319: ...ing 3 Install in the reverse order of removal referring to Installation Note 6 9 9 8 N m 70 100 em kg 61 67In lb 12 17 1 2 1 7 6 7 12 7 11 11 REPLACE o u_ Oll 6 I LITHIUM BASED GREASE N m m kg ft Ib 1...

Page 320: ...in the figure Installation Note Spring Note Use pads in the vise to prevent damaging the clutch master cylinder bracket 1 Place the clutch pedal assembly in the vise 2 Pry the spring on the clutch pe...

Page 321: ...val Note page H 8 Installation Note page H 8 2 Nut 4 REPLACE Ell 13 22 1 3 2 2 9 4 16 3 Clutch master cylinder Check for fluid leakage from cylinder bore Overhaul page H 10 Air bleeding page H 9 Remov...

Page 322: ...not reuse the clutch fluid which was drained out 1 Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug 2 Insert the other end of the vinyl hose in a cl...

Page 323: ...Assemble in the reverse order of disassembly referring to Assembly Note 1 Snap ring 9 REPLACE Disassembly Note page H 11 Assembly Note page H 11 2 Piston and secondary cup assembly Disassembly Note p...

Page 324: ...lation hole Assembly Note Caution Before assembly make sure all parts are completely clean Do not mix different brands of clutch fluid Do not reuse the clutch fluid which was drained out Apply the spe...

Page 325: ...ly with a rag 1 Remove in the order shown in the figure referring to Removal Note 2 Install in the reverse order of removal referring to Installation Note 13 22 1 3 2 2 9 4 16 1_ N m m kg ft Ib 05UOHX...

Page 326: ...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 disassembly 1 Boot 2 Push rod 3 Pi...

Page 327: ...l of pilot Puller bearing bearing Chuck Part of 49 1285 073 REMOVAL I INSTALLATION Note Remove the clutch release cylinder with the clutch pipe connected Do not remove the pilot bearing if not necessa...

Page 328: ...age H 16 Service Section J Inspection page H 17 3 Boot Installation Note page H 17 4 Release bearing 8 Pilot bearing Inspection page H 17 Inspection page H 18 5 Release fork Removal Note page H 16 6 C...

Page 329: ...nkshaft rear oil seal If necessary replace the oil seal Refer to Section B 1 Hold the flywheel with the SST 2 Remove the flywheel Pilot bearing Remove the pilot bearing with the SST if necessary Insta...

Page 330: ...not be washed in solvent Turn the bearing while applying force in the axial direction If the bearing sticks or has excessive resistance replace it CLUTCH COVER INSPECTION Note Minor scoring or burning...

Page 331: ...rce in the axial direction If the bearing sticks or has excessive resistance replace it FLYWHEEL INSPECTION Note Minor scoring or burning should be removed with emery paper 1 Inspect the contact surfa...

Page 332: ...FLYWHEEL H 3 Measure the flywheel runout with a dial indicator Replace the flywheel if runout is excessive Maximum runout 0 2mm 0 008 in 9MUOHX 048 H 19...

Page 333: ...RUCTURAL ViEW J 4 COMPONENTS J 5 POWERFLOW J 6 TROUBLESHOOTING GUiDE J 7 TRANSMISSION OIL J 8 INSPECTION J 8 REPLACEMENT J 8 TRANSMISSION J 9 PREPARATION J 9 REMOVAL I I I I I I II I I J 10 DISASSEMBL...

Page 334: ...13 Removal Disassembly J 2 HT SWITCH BACK UEP gCTION T SERVIC OIL SPECIFICA NOR GL 5 API SERVICE Y E SAE 75W 90 ALL SEAS 50 0 F SAE 80W 9 2 0 2 1 1 8 ABOVE 1 0 LITERS US qt Imp q CAPACITY 05UOJX 002...

Page 335: ...omesh Reverse Synchromesh Shift type 5 speed floor shift CD 3 Shift pattern 1 1st 3 136 2nd 1 888 3rd 1 330 Gear ratio 4th 1 000 5th 0 B14 Reverse 3 758 Grade API service GL 4 or GL 5 All season SAE 7...

Page 336: ...CTURAL VIEW VIEW A A 9MUOJX 004 1 Main drive gear 4th gear 7 Counter 5th gear 2 3rd gear 8 Mainshaft 3 2nd gear 9 Reverse gear 4 1st gear 10 Reverse idler gear 5 5th gear 11 Counter reverse gear 6 Cou...

Page 337: ...Shift fork and rod 5th Reverse I OUTLINE 6 Shift fork and rod 1 st 2nd 7 Shift fork and rod 3rd 4th 8 Mainshaft gear assembly 9 Main drive gear 10 Bearing housing 11 Countershaft J 05UOJX 004 12 Rever...

Page 338: ...J OUTLINE POWERFLOW 1ST 2ND 3RD 4TH 5TH REVERSE 9MUOJX 006 J 6...

Page 339: ...quality Replace with specified J 8 oil Worn synchronizer ring Replace J 24 Worn synchronizer cone of gear Replace J 24 Poor contact of synchronizer ring and gear cone Replace J 24 Excessive longitudi...

Page 340: ...g washer with a new one when ever the drain plug is removed 1 Remove the plugs and with washer 2 Drain the oil into a suitable container 3 Wipe all plugs clean 4 Apply sealant to plug thread 5 Install...

Page 341: ...of transmission case For installation of spring and ball For installation of clutch hub assembly For installation of oil seal 49 0500 330 Installer transmission bearing 49 0259 440 Holder mainshaft 4...

Page 342: ...y stands 3 Dr ain the transmission oil into a suitable container 4 Remove in the order shown in the figure referring to Removal Note 1 Shift lever knob 2 Rear console 3 Shift lever 4 Undercover J 10 V...

Page 343: ...correct installation 2 When the propeller shaft is removed from the extension housing immediately install the SST to prevent oil leakage Power plant frame PPF 1 Disconnect the wire harness from the P...

Page 344: ...e bolt downward 8 Install a bolt M6x1 into the hole in the block to hold the sleeve and remove the long bolt M 14x1 5 9 Remove the bolt M6x1 Caution Do not remove the spacers shown in the figure from...

Page 345: ...d rear oil seals if not necessary Disassemble in the order shown in the figure referring to Disassembly Note 1 8 REPLACE CVSELESTIVE REPLACE 5 REPLACE 1 Release bearing 2 Release fork 3 Boot 4 Front c...

Page 346: ...he vehicle and support it with safety stands 2 Drain the transmission oil into a suitable container 3 Remove the exhaust pipe 4 Remove the propeller shaft Refer to Section L 5 Remove the oil seal from...

Page 347: ...Spacer 5 Intermediate housing 13 3rd 4th shift rod 19 Spring Inspection page J 25 14 3rd 4th shift fork Inspection page J 25 6 Roll pin 7 Cap plug 8 Spring and ball Inspection page J 25 Inspection pa...

Page 348: ...J TRANSMISSION Mainshaft and Countershaft Parts Disassemble in the order shown in the figure referring to Disassembly Note J 16 EPLACE hi 5_ SELECITIVE I I j 1 lO_ II REPLACE 97UOJ1 017...

Page 349: ...J 18 Inspection page J 24 25 Snap ring Disassembly note Mainshaft rear bearing J 26 Countershaft front bearing Disassembly Note page J 18 Inspection page J 24 27 Bearing housing assembly Disassembly N...

Page 350: ...he mainshaft and clutch hub as sembly III 2 Use a suitable tool to uncrimp the tabs of the locknut Note Use pads in the vise to prevent damaging the bear ing housing II 3 Secure the bearing housing in...

Page 351: ...6 Clutch hub assembly 3rd 4th Disassembly Note page J 20 Inspection page J 23 7 Synchronizer ring 3rd Inspection page J 24 8 3rd gear Inspection page J 23 9 Clutch hub assembly 1 stl2nd Disassembly N...

Page 352: ...mainshaft out of the clutch hub assembly 1 st 2nd and 2nd gear 97UOJ1 029 Bearing Housing Parts Disassemble in the order shown in the figure referring to Disassembly Note 1 Snap ring 2 Adjustment wash...

Page 353: ...aft front bearing Caution Support the mainshaft front bearing with one hand so that it does not fall Remove the mainshaft front bearing with a suitable pipe Countershaft center bearing Caution Support...

Page 354: ...l spring and spring cap 2 Select lock spindle spring and spring cap 3 Plug spring and pushpin 4 Blind cover J 22 5 Roll pin 6 Control lever 7 Control lever end 8 Change bushing 9 Wave washer 05UOJX 02...

Page 355: ...main drive gear splines for damage and wear Mainshaft 1 Measure the mainshaft runout Maximum runout 0 03mm 0 0012 in 2 Inspect splines for damage or wear 3 Measure the clearance between mainshaft and...

Page 356: ...s Note Set the synchronizer ring squarely in the gear then measure around the circumference 3 Measure the clearance the between synchronizer ring and flank surface of gear Standard clearance 1 Smm 0 O...

Page 357: ...prings Standard free length Shift rod 5th Reverse spring 75mm 2 953 in Detent ball spring 1 stl2nd 3rd 4th 22 5mm 0 886 in Detent ball spring 5th Reverse 17 0mm 0 669 in Intermediate housing Measure t...

Page 358: ...8T REVERSE 5TH caJl II 1t 1 I IMP FRONT MAINSHAFT 97UOJ1 041 J 26 05UOJX 024 Clutch hub Caution Align the synchronizer ring grooves with the clutch hub keys during installation Note The synchronizer r...

Page 359: ...seal Assembly Note page J 28 2 Oil passage 3 Rod cover Assembly Note page J 28 4 Change control case I 5 Wave washer 6 Change bushing 7 Control lever 8 Control lever end 9 Roll pin DNEW Bill N m em kg...

Page 360: ......

Page 361: ...page J 29 4 Adjustment shim Assembly Note page J 30 SELECTIVE SELECTIVE I N m m kg tt lb 05UOJX 031 5 Mainshaft front bearing Assembly Note page J 30 10 Adjustment washer 6 Bearing cover 7 Reverse id...

Page 362: ...learance between the mainshaft front bearing and the bearing housing If not within specification adjust the clearance by installing the correct adjustment shim s Standard clearance 0 0 1 mm 0 0 004 in...

Page 363: ...mbly Note page J 32 7 Synchronizer ring CLUTCH HUB ASSEMLY ONT 4TH 3RD 2ND 1ST MAINSHAFT 8 Clutch hub assembly 1 stl2nd Assembly Note page J 32 9 3rd gear Assembly Note page J 32 10 Synchronizer ring...

Page 364: ...clutch hub assembly on the mainshaft then press in the mainshaft 2 Set the 3rd gear and 3rd 4th clutch hub assembly on the mainshaft then press on the 3rd 4th clutch hub assembly with the SST 3 Instal...

Page 365: ...TRANSMISSION J MEMO J 33...

Page 366: ...and Countershaft Parts Assemble in the order shown in the figure referring to Assembly Note J 34 I APPLY SPr CIFIr D OIL TO INDIVIDUAL PARTS r XCr PT LOCKNUTS I j 1ImDI NEW 28 196 13 20 94 145 m Q N...

Page 367: ...6 Mainshaft rear bearing Assembly Note page J 36 27 C washer Assembly Note page J 36 28 Retaining ring Assembly Note page J 36 29 Washer Assembly Note page J 36 30 Snap ring 31 Spacer 32 Counter 5th g...

Page 368: ...k washer Standard play 0 1 0 3mm 0 004 0 012 in Thrust lock washer thickness 6 2mm 0 244 in 6 4mm 0 252 in 6 5mm 0 256 in 6 6mm 0 260 in Mainshaft rear bearing 1 Drive on the mainshaft rear bearing wi...

Page 369: ...and reverse gear to put the gears in a double engaged condition Note Use pads in the vise to prevent damaging the SST 2 Connect the SST to the mainshaft and tighten it securely in a vise 3 Tighten a...

Page 370: ...y Note page J 40 6 3rd 4th shift fork Assembly Note page J 40 J 38 7 3rd 4th shift rod Assembly Note page J 40 8 Interlock pin Assembly Note page J 40 9 1st 2nd shift rod 10 Ball and spring 11 Cap plu...

Page 371: ...1 Insert the spring and ball 5th Reverse into the bearing housing 2 Press the spring and ball 5th Reverse with a screwdriver and the SST to install the shift rod Shift fork and rod Install the 5th Re...

Page 372: ...oll pin with the seam facing as shown in the figure Install a new roll pin into each shift fork Spring spacer clip 1 Slide the spring and spacer onto the 5th Reverse shift rod While pressing the space...

Page 373: ...6 in 3 2mm 0 1260 in 2 7mm 0 1063 in 3 7mm 0 1457 in 3 0mm 0 1181 in Intermediate housing I I 1 Apply sealant to the contacting surfaces of the intermedi ate housing and bearing housing 2 Mount the in...

Page 374: ...ble in the order shown in the figure referring to Assembly Note 2 Check the gearshift lever operation t 114 irf 31 46 19 25 3 2 4 7 1 9 2 6 23 34 A 14 19 1 I MORI WHITE TA NO 2 OR EQUIVALENT ORGANIC M...

Page 375: ...Release bearing Assembly Note page J 44 05UOJX 057 Assembly note Oil seal 1 Apply transmission oil to outer periphery 2 Install a new oil seal with the SST Extension housing 1 Apply sealant to the co...

Page 376: ...specified below of the thick ness corresponding to the value of A minus B so that bear ing end play will be within specification Bearing end play 0 0 1 mm 0 0 004 in Adjustment shim thickness 0 10mm 0...

Page 377: ...m kg 91 104 In Ib 1 Transmission 16 23 1 6 2 3 12 17 t I MOLYBDENUM DISULFIDE Installation Note page J 46 2 Power plant frame PPF Installation Note page J 46 3 Speedometer cable e 21 27 3 2 4 7 2 1 2...

Page 378: ...5 3 m kg 27 38 ftoulb 2 Support the transmission with a jack so that it is level 3 Position the PPF and snugly tighten the transmission side bolts by hand 4 Verify that the sleeve is installed into t...

Page 379: ...rque 27 30 N m 2 8 3 1 m kg 20 22 ft Ib Shift lever Note Add the specified oil whenever the extenSion hous ing has been removed or the transmission has been overhauled 1 Pour the specified amount of o...

Page 380: ...L PROPELLER SHAFT OUTLINE L 2 SPECIFICATIONS L 2 TROUBLESHOOTING GUiDE L 2 PROPELLER SHAFT L 2 PREPARATION L 2 REMOVAL INSPECTION INSTALLATION L 3 05UOLX 001...

Page 381: ...orn slip yoke splines Runout of propeller shaft Unbalanced propeller shaft Abnormal noise Worn or damaged universal joint Worn slip yoke splines PROPELLER SHAFT PREPARATION SST 49 0259 440 Holder main...

Page 382: ...ry 3 Install in the reverse order of removal referring to Installation Note 1 40 55 4 1 5 6 30 1 1 Exhaust pipe 2 Nut 3 Lock washer 4 Bolt Removal Note Propeller shaft N m m kg ft Ib 05UOLX 005 5 Prop...

Page 383: ...er shaft if runout is excessive Maximum runout 0 4mm 0 016 in 2 Move the universal joints in the directions shown and check for universal joint looseness If there is looseness replace the propeller sh...

Page 384: ...ITED SLIP M 4 FRONT AXLE M 5 PREPARATION M 5 WHEEL HUB STEERING KNUCKLE M 5 REAR AXLE M 9 PREPARATION M 9 DISC BRAKE TYPE M 10 DRIVESHAFT M 16 DOUBLE OFFSET JOINT M 16 DIFFERENTIAL M 22 PREPARATION M...

Page 385: ...Installation page M 5 Installation page M 16 Disassembly Inspection Overhaul page M 18 Assembly page M 8 4 Differential 2 Rear axle Standard Viscous limited slip differential Inspection Removal Diffe...

Page 386: ...e API service GL 5 Oil Viscosity Above 18 C OOF SAE 90 Below 1SoC OOF SAE SOW Capacity liter US qt Imp qt 0 65 0 69 0 57 Type Constant velocity double offset joint Driveshaft Length mm in 659 3 25 957...

Page 387: ...Improperly adjusted drive pinion gear preload Adjust M 38 Heat buildup Insufficient differential oil Add oil M 24 Insufficient gear backlash Adjust M 40 Excessive bearing preload Adjust M 38 40 Oil l...

Page 388: ...s necessary 4 Install in the reverse order of removal referring to Installation Note 1 Front wheel 2 Brake caliper assembly Removal Note page M 6 3 Hub cap 4 Disc plate 5 Locknut Installation Note pag...

Page 389: ...specification check and adjust the locknut torque or replace the wheel hub assembly if necessary Maximum wheel bearing play 0 05mm 0 002 in Removal note Brake caliper assembly Note For easier install...

Page 390: ...05UOMX 014 FRONT AXLE Installation note Locknut Install a new locknut and stake it Tightening torque 167 216 N m 17 22 m kg 123 159 ft Ib M M 7...

Page 391: ...disassembly referring to Assembly Note 3 1 DUST SEAL LIP CD 05UOMX 015 1 Front wheel hub assembly 4 Hub bolt 2 Dust cover Disassembly Note page M 8 3 Knuckle spindle 05UOMX 017 M 8 Assembly Note page...

Page 392: ...nstallation of oil removal and Installer oil seal seal Handle installation of Part of wheel bearing 49 G030 795 49 0636 145 For 49 G033 107 For removal of wheel installation of dust Puller fan bearing...

Page 393: ...erring to Installation Note 5 After installation adjust the rear wheel alignment Refer to Section R 49 69 5 7 36 51 1 Rear wheel 2 Brake caliper assembly Removal Note page M 11 3 Disc plate 4 Locknut...

Page 394: ...l bearing play If the bearing play exceeds specification check and adjust the locknut torque or replace the wheel bearing if necessary Maximum wheel bearing play 0 05mm 0 002 in Removal note Brake cal...

Page 395: ...107 OR EQUIVALENT 5 REPLACE ImII 6 05UOMX 023 1 Oil seal 5 Dust cover Assembly Note page M 15 Disassembly Note page M 13 2 Rear wheel hub assembly Assembly Note page M 14 Disassembly Note page M 12 6...

Page 396: ...el hub assembly remove as follows 1 Move the bearing inner race away from the rear wheel hub assembly with a chisel 2 Press the bearing inner race off the wheel hub with the SST Dust cover Caution Do...

Page 397: ...euse the removed hub bolts Press out the hub bolts Assembly note Hub bolt Press in new hub bolts Dust cover 1 Mark the new dust cover as the removed one 2 Align the marks of the new dust cover and the...

Page 398: ...eel hub assembly 1 Apply grease to the wheel bearing inner race 2 Press the rear wheel hub assembly in with the SST Oil seal 1 Apply grease to the new oil seal lip 2 Install the new oil seal with the...

Page 399: ...40 47 1 Rear wheel 2 Locknut J tf 46 7 4 7 6 4 49 rLx u REPLACE 30 15 21 N m m kg ft Ib 05UOMX 033 3 Driveshaft Installation Note page M 17 Removal Note page M 16 Overhaul page M 18 05UOMX 035 M 16 In...

Page 400: ...that it is flush with the end of the shaft and tap the nut with a plastic hammer Installation note Driveshaft Align the marks and install the driveshaft Tightening torque 54 64 N m 5 5 6 5 m kg 40 47...

Page 401: ...r of disassembly referring to Assembly Note 1 Boot bands Disassembly Note page M 19 Assembly Note page M 21 2 Clip Disassembly Note page M 19 3 Outer ring Inspect inside bore for wear corrosion and sc...

Page 402: ...proper reassembly 2 Remove the clip Snap ring Note Mark with paint do not use a punch 1 Mark the driveshaft end and inner ring 2 Remove the snap ring with snap ring pliers Cage inner ring and balls Di...

Page 403: ...boots at the wheel side and the differential side differ be careful not to in stall them incorrectly Outer diameter of large boot end Diffrential side 87 4mm 3 441 in Wheel side 90 8mm 3 575 in Cage i...

Page 404: ...s 2 Measure the driveshaft length Standard length 659 7 669 7mm 25 972 26 366 in If not within specification return to Step 1 Note Standard length On vehicle 659 3mm 25 957 in Note Always use a new ba...

Page 405: ...Handle Part of 49 G030 795 For 49 H033 101 installation of oil seal output shaft Remover bearing For 49 F027 005 installation of bearing Attachment c 62 Part of 49 F027 OA1 For 49 0727 570 adjustment...

Page 406: ...bearing inner Part of race rear Part of race side 49 0017 2A1 bearing 49 0017 2A1 bearing 49 S120 710 For 49 0839 425C For removal and removal and Holder coupling installation of Puller set 9 installa...

Page 407: ...n plug and washer Tightening torque 39 54 N m 4 0 5 5 m kg 29 40 ft Ib 5 Add the specified oil from the filler plug until the level reaches the bottom of the plug hole Specified oil Type Above 18 C OO...

Page 408: ...the new clips Caution With viscous L S D the right output shaft is longer than the left shaft 9 Install the output shaft into the side gears by lightly tapping with a plastic hammer 10 Verify that the...

Page 409: ...nd support the vehicle with safe ty stands 4 Release the parking brake 5 Using a torque wrench on a wheel lug nut measure the time it takes to turn the wheel 90 while applying the speci fied torque Sp...

Page 410: ...o the specified level 1 Rear wheel 2 Exhaust pipe GASKET REPLACE 3 Propeller shaft 27 30 2 8 3 1 20 22 V 40 55 4 1 5 6 30 41 Removal Note page M 28 Installation Note page M 31 4 Speedometer cable 5 Po...

Page 411: ...ges for correct Installation 2 Whe th prop lIer s haft is removed from the extension housing Immediately Install the SST to prevent oil leakage Po er plant frame PPF 1 Disconnect the wire harness from...

Page 412: ...olt M14x1 S 9 Remove the bolt M6x1 Caution Do not remove the spacers shown in the figure from the PPF If they are removed repalce the PPF as an as sembly 10 Remove the transmission side bolts and remo...

Page 413: ...the figure Installation note Differential 1 Connect the driveshaft to the output shaft with the marks aligned 2 Install the differential Tightening torque 83 98 N m 8 5 10 m kg 61 72 ft Ib 18 26 N m 1...

Page 414: ...side bolts Tightening torque 104 123 N m 10 6 12 6 m kg 77 91 ft Ib 8 Tighten the differential side bolts Tightening torque 104 123 N m 10 6 12 6 m kg 77 91 ft Ib 9 Install the power plant frame brac...

Page 415: ...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 disassembly referring to Assembl...

Page 416: ...aring inner race Rear bearing Disassembly Note page M 35 Inspect for damage and rowgh rotation Assembly Note page M 38 18 Bearing outer race Rear bearing Disassembly Note page M 35 Assembly Note page...

Page 417: ...m alloy differential case Strike the differential carrier with a copper hammer to sepa rate it from the case Differential gear assembly Mount the differential gear assembly on the SST Bearing caps Mar...

Page 418: ...ring inner race Rear bearing Note Support the drive pinion by hand so that it will not fall Remove the bearing inner race rear bearing with the SST Roll pin Note Use protective plates in the vise Tap...

Page 419: ...e of the differential mounting rubber to remove it Assembly note Differential mounting rubber Note Install the mounting rubber with the voids facing fore and aft Press in the new differential mounting...

Page 420: ...pacer and bearing inner race rear bearing onto the SST Note Use the same spacer and nut removed during dis assembly 5_ Assemble the spacer bearing inner race rear bearing and SST Secure the SST with t...

Page 421: ...r of the dial indicator so that it contacts where the bearing inner race side bearing is installed in the car rier Measure the lowest position on the left and right sides of the carrier 10 Add the two...

Page 422: ...m kg 87 ft Ib 7 Turn the companion flange several turns by hand to seat the bearing 8 Measure the drive pinion preload Adjust the preload by tightening the locknut and record the tightening torque Pre...

Page 423: ...shaft Stake the pin with a punch to prevent it from coming out of the case Adjustment of drive pinion and ring gear backlash Note Apply approx 0 04 cc 0 0024 cu in of thread locking compound at each...

Page 424: ...erential bearing preload be careful not to affect the backlash of the drive pin ion and ring gear 10 Tighten the adjusting nuts equally until the distance between the pilot sections on the bearing cap...

Page 425: ...lates on the bearing caps Tightening torque 18 25 N m 1 8 2 6 m kg 13 19 ft Ib Differential case 1 Apply sealant to the housing face 2 Tighten the bolts Tightening torque 23 26 N m 2 3 2 7 m kg 10 20...

Page 426: ...5 BOOT N 6 STEERING WHEEL AND COLUMN N 8 STEERING GEAR AND LINKAGE N 12 ENGINE SPEED SENSING POWER STEERING N 13 PREPARATION N 13 TROUBLESHOOTING GUIDE N 13 AIR BLEEDING N 15 POWER STEERING FLUiD N 16...

Page 427: ...ge N 6 2 Steering wheel and column On vehicle inspection page N 8 Removal Installation page N 9 Disassembly Assembly Inspection page N 10 N 2 STEERING WHEEL PLAY J 0 30mm 0 1 18 in 05UONX 002 3 Steeri...

Page 428: ...Removal Installation page N 9 Assembly Disassembly Inspection page N 10 3 Steering gear and linkage Removal Installation page N 1 9 Air bleeding page N 15 lSTEERING WHEEL PLAY 0 30mm 0 1 18 in 05UONX...

Page 429: ...ar ratio Rack stroke mm in Power steering fluid Fluid capacity liters US qt Imp qt MANUAL STEERING PREPARATION SST 490118850C Puller ball joint N 4 For removal of tie rod end 49 1243 785 Installer boo...

Page 430: ...racked or worn engine mount rubber Replace Section B Cracked or worn transmission mount rubber Replace Section J Shimmy Steering wheel Cracked or worn steering gear mount rubber Replace N 12 vibrates...

Page 431: ...e reverse order of removal referring to Installation Note 6 After installation check the steering angle and toe in and adjust if necessary Refer to Section R 29 44 3 0 4 5 22 33 REPLACE N m m kg ft Ib...

Page 432: ...nd make a mark for reference when tightening Tie rod end boot Caution Do not scar the part where the boot is attached to the tie rod end Secure the tie rod end in a vise Place a chisel against the boo...

Page 433: ...ng wheel in directions CD Cl and to check for column bearing wear steering shaft joint play steering wheel looseness and column looseness Steering wheel effort 1 Jack up the front of the vehicle 2 Tur...

Page 434: ...ecessary nuts and bolts to the specified torque 5 After installation check if the horn sounds If the horn does not sound remove the air bag module and connect the module connectors Refer to Section T...

Page 435: ...able puller Disassembly I Assembly I Inspection 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Assemble in the reverse order of disassembly referring to Assembly Note 1...

Page 436: ...er Re move the steering lock assembly Inspection Check for the following and replace the column assembly if necessary Steering shaft 1 Column bearing damage 2 Steering shaft length Length 583 3 1 5mm...

Page 437: ...adjust the clockspring connector U S spec Refer to Section T 1 Loosen the wheel lug nuts 2 Jack up the front of the vehicle and support it with safety stands 3 Remove the wheel 4 Remove the undercove...

Page 438: ...ONX 021 Page Section Steering feels heavy Poor lubrication foreign material or abnormal wear of Lubricate or replace N 19 steering ball joint Stuck or damaged lower arm ball joints Replace Section R I...

Page 439: ...just Section 0 Unevenly worn tires Replace Section Q Malfunctioning shock absorber Replace Section R Loose shock absorber mounting bolts Tighten Section R Stuck or damaged lower arm ball joint Replace...

Page 440: ...with the engine not running 3 Recheck the fluid level If it has dropped add fluid 4 Repeat Steps 2 and 3 until the fluid level stabilizes 5 Start the engine and let it idle 6 Turn the steering wheel f...

Page 441: ...ied power steering fluid Fluid specification ATF DEXRON ll or M ID To prevent damage to the steering system do not keep the steering wheel in the fully turned position for more than 15 seconds Start t...

Page 442: ...page N 15 4 Open the gauge valve fully Start the engine and turn the steering wheel fully left and right to raise the fluid tempera ture to 50 60o e 122 140 F Caution If the valve is left closed for m...

Page 443: ...tem Refer to page N 15 STEERING WHEEL AND COLUMN Caution Obtain the code number and deactivate the audio anti theft system before disconnecting the battery Refer to page T 113 On vehicle Inspection St...

Page 444: ...wn in the figure referring to Removal Note Note Use a container or rags to eolleet the power steering fluid when disconnecting the pressure pipe and return hose 5 Install in the reverse order of remov...

Page 445: ...N 20 ENGINE SPEED SENSING POWER STEERING 05UONX 035 Removal note Pressure pipe Before removing the pressure pipe make marks for reference during installation...

Page 446: ...urn hose 2 Install in the reverse order of removal referring to Installation Note 3 After installation 1 Check connections for fluid leakage Refer to page N 16 2 Bleed air from system Refer to page N...

Page 447: ...f necessary Deflection Depressed at 98 N 10 kg 22 Ib New 8 9mm 0 31 0 35 in Used 9 10mm 0 35 0 39 in Tension New 491 589 N 50 60 kg 110 132 Ib Used 422 491 N 43 50 kg 95 110 Ib Note Belt tension can b...

Page 448: ...AKE HYDRAULIC LINE P 6 BRAKE FLU 10 P 7 BRAKE PEDAL I I I I II I I I I II P 7 MASTER CYLINDER P 10 POWER BRAKE UNIT P 13 PROPORTIONING BYPASS VALVE P 16 FRONT BRAKE DISC P 18 CALIPER P 21 REAR BRAKE D...

Page 449: ...lation page P 15 6 Proportioning bypass valve PBV Inspection page P 16 Replacement page P 16 P 2 9 05UOPX 002 7 Front disc brake Quick Inspection On vehicle page P 18 Replacement pad page P 18 Removal...

Page 450: ...isc plate dimension mm in 235 x 18 9 25 x 0 71 effective diameter x thickness Type Disc solid Cylinder bore mm in 31 75 1 25 Rear disc brake Pad dimensions mm2 x mm 2 600 x 8 0 4 03 x 0 31 area x thic...

Page 451: ...or 49 F043 001 removal and Wrench flare nut installation brake Adjust gauge 49 0221 600C Expand tool disc brake P 4 pipes For installation of disc pads 49 0208 701A Boot air out tool For adjustment of...

Page 452: ...n of disc brake piston Repair or replace P 19 23 Worn or improperly adjusted wheel bearing preload Replace or adjust Section M Improper adjustment of wheel alignment Adjust Section R Unequal tire air...

Page 453: ...no air bubbles in the fluid 7 Check for correct brake operation 8 Check that there is no fluid leakage Be sure to clean away any spilled fluid with rags 9 After bleeding the air add brake fluid to the...

Page 454: ...the oth er end of the tube in a clear container 4 Pump out the old brake fluid by loosening the bleeder screws one by one and pumping the brake pedal until only clean fluid is expelled 5 Fill the res...

Page 455: ...7mm 0 16 0 28 in Adjustment 1 Loosen locknuts and turn rod to adjust the free play 2 Tighten locknuts Pedal to floor clearance Check that the distance from the floor panel to the center of the upper s...

Page 456: ...height and free play if necessary Caution Apply grease to the inner surface of the bushing and to the contact surfaces of the clevis pin and spring 1 Spring clip 2 Clevis pin 3 Nut 4 Spring washer 5...

Page 457: ...heck for fluid leakage Caution Brake fluid will damage painted surfaces If it does get on a painted surface wipe it off im mediately N m m kg tt lb 05UOPX 016 1 Fluid level sensor connector 4 Nut and...

Page 458: ...of the power brake unit If it is not Omm 0 in loosen the push rod locknut and turn the push rod to make the adjustment Reference By making the above adjustment the clearance between the push rod and...

Page 459: ...e when necessary Replace the piston assembly if necessary Do not let foreign material enter the cylinder and do not scratch the inside of the cylinder or the outer surface of the piston 1 Xf N 1 Fluid...

Page 460: ...force 3 Stop the engine with the pedal depressed 4 Hold the pedal down for about 30 seconds 5 If the pedal height does not change the unit is operating 6 If there is a problem check for damage or impr...

Page 461: ...e 196 N 20 kg 44 Ib Fluid pressure 1 079 1 177 kPa 11 12 kg cm2 156 171 psi 2 Start the engine Depress the brake pedal when the vacu um reaches 500 mmHg 19 7 inHg If the fluid pressure is within speci...

Page 462: ...r Refer to page P 6 3 Check all parts for fluid leakage 4 Make an on vehicle check of the unit Refer to page P 13 5 Check that the vacuum hose does not contact other parts Caution Apply grease to the...

Page 463: ...brake fluid and bleed the air Refer to page P 6 Check the brake lines for fluid leakage A 8 Master cylinder pressure kPa kg cm2 psi 05UOPX 031 Replacement 1 Remove in the order shown in the figure 2 I...

Page 464: ...05UOPX 033 BRAKE SYSTEM Removal I Installation Note Brake pipe Disconnect connect the brake pipes with the SST p P 17...

Page 465: ...aliper inspection hole and verify the re maining thickness of the pad Thickness 1 0mm 0 04 in min 2 Install in the reverse order of removal referring to Installation Note 1 78 88 8 0 9 0 58 65 1 Lock...

Page 466: ...tands 2 Remove the wheels then remove components in the order shown in the figure 3 Install in the reverse order of removal 4 Tighten all nuts and bolts to the specified torques referring to the figur...

Page 467: ...wear or cracks 3 Deterioration or damage by heat 4 Remaining lining thickness Thickness 1 0mm 0 04 in min Disc plate 1 Runout Runout 0 1 mm 0 004 in max Caution There must be no wheel bearing loosene...

Page 468: ...oor sealing 2 Piston s_ REPLACE 3 Piston seal 2 4 Bleeder screw 5 Caliper body 1 REPLACE 05UOPX 042 Disassembly page P 21 Inspect for damage and cracks Inspect for wear and rust 9MUOPX 075 Disassembly...

Page 469: ...1 Remove in the order shown in the figure referring to Removal Note 2 Install in the reverse order of removal referring to Installation Note 3 45 59 4 6 6 0 33 43 N m m kg ft Ib 05UOPX 044 1 Plug 4 M...

Page 470: ...move components in the order shown in the figure 3 Install in the reverse order of removal 4 Tighten all nuts and bolts to the specified torques referring t the figure 2 22 29 2 2 3 0 16 22 N m m kg f...

Page 471: ...or cracks 3 Deterioration or damage by heat 4 Remaining lining thickness Thickness 1 0mm 0 04 in min Disc plate 1 Runout Runout 0 1 mm 0 004 in max Caution There must be no wheel bearing looseness The...

Page 472: ...iston 7 Connecting link 8 Piston seal Disassembly below 9 Spring Assembly page P 25 10 Operating lever Inspect for wear and rust _ 3 Manual adjustment gear 4 Snap ring 5 Adjusting bolt 11 Cap and blee...

Page 473: ...ole to force the piston out of the caliper Caution Blow the compressed air slowly to prevent the pis ton from popping out Assembly Piston Insert the piston into the caliper and turn the adjustment gea...

Page 474: ...or replace P 18 22 05UOPX 056 05UOPX 057 PARKING BRAKE LEVER Inspection 1 Depress the brake pedal several times 05UOPX 055 2 Verify that the stroke is within specification when the park ing brake lev...

Page 475: ...stroke Refer to page P 27 r 1 Screw 6 Cap 2 Cover 7 Spring 3 Bolt Inspect for weakness 4 Parking brake switch 8 Bolt Installation page P 28 9 Parking brake lever 5 Adjusting nut and clip Inspect for d...

Page 476: ...ke cable in the order shown in the figure 6 Install in the reverse order of removal 7 After installation 1 Adjust the parking brake lever stroke 2 Depress the brake pedal a few times 3 Verify that the...

Page 477: ...IONS Q 2 TROUBLESHOOTING GUiDE Q 2 WHEELS AND TIRES Q 3 SPECIAL NOTES ABOUT WHEELS AND TIRES Q 3 NOTES REGARDING TIRE REPLACEMENT Q 3 INSPECTION ADJUSTMENT Q 3 REMOVAL INSTALLATION Q 4 TIRE ROTATION Q...

Page 478: ...teering gear mount rubber Replace Section N Steering wheel Loose steering gear mounting bolts Tighten Section N vibrates left right Stuck or damaged steering ball joint Replace Section N Excessive tir...

Page 479: ...ter mounting a tire onto a wheel inflate it to 250 300 kPa 2 55 3 06 kg cm2 35 55 42 66 psi Veri fy that the bead is seated correctly onto the rim and that there are no air leaks Then reduce the press...

Page 480: ...el Balance or replace Out of round brake drum or disc Correct or replace Other mechanical conditions Correct or replace Lack of rotation Rotate tires 4 Cracks damage and foreign matter such as metal p...

Page 481: ...n specification Maximum unbalance at rim edge 10 g 0 35 oz Caution Do not use more than two balance weights on the inner or outer side of the wheel if the total weight exceeds 100 g 3 5 oz rebalance a...

Page 482: ...R WHEEL ALIGNMENT R 9 FRONT SUSPENSION DOUBLE WISHBONE R ll PREPARATION R 11 SHOCK ABSORBER AND SPRING R 12 LOWER ARM R 15 UPPER ARM R 17 STABILIZER R 19 CROSSMEMBER R 20 REAR SUSPENSION DOUBLE WISHBO...

Page 483: ...e R 12 Disassembly Inspection Assembly page R 13 2 Lower arm Removal Inspection Installation page R 15 R 2 05UORX 002 3 Upper arm Removal Inspection Installation page R 17 4 Stabilizer Removal Inspect...

Page 484: ...R 22 Disassembly Inspection Assembly page R 13 2 Lower arm Removal Inspection Installation page R 23 05UORX 003 3 Upper arm Removal Inspection Installation page R 24 4 Stabilizer Removal Inspection In...

Page 485: ...color Wire diameter mm in Coil inner diameter mm in Free length mm in Coil number mm in Total toe in degree Camber angle Specifications Double wishbone Torsion bar 19 0 75 Cylindrical double acting l...

Page 486: ...n arm bushings Replace R 16 18 19 23 24 25 Section M Abnormal noise from Loose mounting component Tighten suspension system Poorly lubricated or worn upper or lower arm ball joint Replace R 15 17 Malf...

Page 487: ...n the vehicle height Refer to the following and to page R 9 for the specifications Inspection and adjustment of wheel alignment must be done with the vehicle unladed l Specifications 3 I 3 0 12 I 0 12...

Page 488: ...raduation on the scale changes the caster angle about 22 and the cam ber about 25 Turning the rear cam one graduation changes the caster angle about 22 and the cam ber about 2 3 Adjust the camber and...

Page 489: ...ts and turn the tie rods by the same amount Caution The left and right tie rods are both right threaded To increase the toe in turn the right tie rod toward the front of the vehicle and turn the left...

Page 490: ...fore adjusting the camber 1 Loosen the front and or rear cam nut 2 Turn the front and or rear adjusting cam bolt to provide the correct toe in Toe in Left wheel Right wheel Front cam Rear cam Front ca...

Page 491: ...ckwise clockwise clockwise Note Turning the front cam one graduation changes the camber about 15 and the toe in about 2 8mm 0 11 in Turning the rear cam one graduation changes the camber about 6 and t...

Page 492: ...eload measuring 49 G034 1AO For removal and 49 G034 101 rfrf installation of coil Compressor coil spring Body spring It IIii ii l iiiiliilli iIi II lIIi iiiiillii l i l ii l IIii Part of 49 G034 1AO 4...

Page 493: ...es referring to the figure Note Loosely tighten the shock absorber upper arm stabilizer control link and stabilizer bracket bolts Lower the vehicle and tighten all nuts and bolts to the specified torq...

Page 494: ...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 Tighten all nuts and bolt...

Page 495: ...press the coil spring with the SST and remove the up per nut 4_ Remove the coil spring Assembly note Coil spring and bound stopper 1 Set the shock absorber in a vise 2 Install the bound stopper on the...

Page 496: ...n the lower arm shock absorber and stabilizer control link bolts Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 7 Adjust the front wheel alignment R...

Page 497: ...tallation note Ball joint dust boot 1 Liberally coat the inside of the new dust boot with grease 2 Press the dust boot onto the ball joint with the SST Inspection Lower arm ball joint Ball joint rotat...

Page 498: ...erring the figure Note Loosely tighten the upper arm and shock absorber bolts Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 7 Adjust the front whee...

Page 499: ...ot contacts the seat Caution Install the dust boot squarely and do not press ex cessively the inner metal ring will be deformed if not done correctly 2 Verify that the clearance between the boot and t...

Page 500: ...orques referring to the figure Note I Loosely tighten the stabilizer control link and bracket bolts Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 1...

Page 501: ...ore installation lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 6 Install in the reverse order of removal 7 Adjust the front wheel alignment Refer t...

Page 502: ...l Compressor coil rfI spring Body spring Ii iijjjjiiiiiiiiiiiii ijjjjliiiiiiiiiiiiiiiiiii ii Part of 49 G030 1AO 49 G030 102 For removal and 49 G030 103 installation of coil Screw spring Arm Part of j...

Page 503: ...l link bolt Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 6 Adjust the rear wheel alignment Refer to page R 9 23 29 2 3 3 0 17 22 s 1 Filler pipe p...

Page 504: ...e R Loosely tighten the lower arm shock absorber and stabili2 er control link bolts Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 5 Adjust the rear...

Page 505: ...in the reverse of removal Note Loosely tighten the upper arm bolts Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 5 Adjust the rear wheel alignment...

Page 506: ...ghten the stabilizer bracket and control link bolts Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 18 26 1 8 2 7 13 20 _ _ N m m kg ft Ib 05UORX 054...

Page 507: ...tallation Lower the vehicle and tighten all nuts and bolts to the specified torques with the vehicle unladed 5 Inspect parts and repair or replace as necessary 6 Install in the reverse order of remova...

Page 508: ...ROUBLESHOOTING GUIDE S 20 EMERGENCY LOCKING RETRACTOR S 58 POWER WINDOW MAIN SWITCH 5 22 WEBBING 5 58 POWER WINDOW MOTOR S 22 BUCKLE SWiTCH S 58 FUEL FILLER LID OPENER 5 23 5EAT 5 59 COMPONENTS S 23 C...

Page 509: ...page S 15 5 Front bumper Removal Installation page S 24 6 Molding and garnish Removal Installation page S 27 S 2 05UOSX 002 7 Door mirror Removal Installation page S 30 8 Horn Removal Installation pag...

Page 510: ...ble top Removal Installation page S 18 Removal Installation page S 46 3 Fuel filler lid 8 Convertible top Removal Installation page S 23 Removal Installation page S 61 4 Rear bumper Disassembly Assemb...

Page 511: ...guide page S 20 6 Seat belt Inspection page 8 22 Removal Installation page 8 57 2 Fuel filler lid opener Inspection page S 58 Removal Installation page 8 23 7 8eat 3 Dashboard and console Removal Inst...

Page 512: ...the figure 2 Install in the reverse order of removal 7 8 11 0 8 1 1 5 8 8 0 1 Headlight seal 4 Hood 2 Side headlight seal 3 Washer pipe Adjustment page S 6 5 Hinge 6 Hood stay s 19 25 1 9 2 6 14 19 N...

Page 513: ...HOOD Adjustment Hood Adjust the hood laterally and vertically by loosening the hood to hinge mounting bolts and repositioning the hood Hood lock Adjust the hood lock after the hood has been aligned Lo...

Page 514: ...nnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal Note Remove the trim and door screen for removal of the door checker Refer to page...

Page 515: ...nting screws and adjust by moving the striker vertically 2 Verify the rear offset of the door to the body If there is a problem adjust by moving the door lock striker vertically Tightening torque 18 2...

Page 516: ...used Note Raise the door glass about 190mm 7 5 in from fully open position 1 Regulator handle Removal Note page S 10 Installation Note page S 10 2 Inner handle cover 3 Arm rest 4 Speaker grille Remova...

Page 517: ...ment of the door glass convertible top and detachable hard top is made as follows Adjust door Refer to page 8 8 OK Adjust weatherstrip alignment Convertible top only Refer to page 8 72 OK Adjust conve...

Page 518: ...When the door glass is raised both glass stop must contact the upper stop simultaneously Before an upper stop is moved for adjustment lower the door glass slightly SEC A A CONVERTIBLE TOP RETAINER MOU...

Page 519: ...ndow regulator and the glass guide should be tightened in approximately the same po sition in the slotted adjustment holes The door glass must raise and lower smoothly with the door closed 8 12 OUT TO...

Page 520: ...he correct position and then tighten the nuts 0 and E Note The window regulator and glass guide should be tightened in approximately the same posi tion in the slotted adjustment holes The door glass m...

Page 521: ...ent of the weatherstrip is correct Convertible top only CONVERTIBLE TOP RETAINER MOUNTING HOLE No 1 15 0 59 RETAINER E RETAINER MOUNTING HOLE NO 7 RETAINER MOUNTING HOLE No 6 C ____ DETACHABLE HARD TO...

Page 522: ...gure 3 Install in the reverse order of removal Caution Remove the door screen carefully so that it may be reused Note Raise the door glass fully to remove the door lock assembly 1 Regulator handle Rem...

Page 523: ...the order shown in the figure 2 Install in the reverse order of removal 1 Wire harness 2 Trunk lid Adjustment page 8 17 3 Rod holder 8 16 4 Balance spring Removal Note page S 17 Adjustment page S 17 5...

Page 524: ...oving the balance spring per sonal injury could result Adjustment Trunk lid Loosen the trunk lid mounting nuts and adjust as shown Balance spring Slide the balance spring to the desired position as de...

Page 525: ...1 0 8 1 1 5 8 8 0 7 8 11 0 8 1 1 5 8 8 0 5 N m m kg ft lb 05UOSX 023 4 Rear finisher Removal Note page S 28 Adjustment below 5 Key cylinder 3 Rear combination light 6 Striker Removal Section T r ___ _...

Page 526: ...WINDOW SYSTEM STRUCTURAL VIEW 05UOSX 025 1 Rear console 3 Power window regulator Removal Installation page 8 50 Removal Installation page S 9 2 Power window main switch Removal Installation page 8 50...

Page 527: ...15 POWER WINDOW MAIN SWITCH I DR2 0 i POWER WINDOW MOTOA A H DR2 ffi FI 01 FAONT F INSTRUMENT PANEL I 1 FOR CANADA FI 03 FAONT F INSTAUMENT PANEL I FDR1 o1 FAONT F OOOR NO 1 OR1 F OR i 0A1 01 POWER WI...

Page 528: ...to ground Repair harness Main switch Ground OK Check power window main switch Refer to page 8 22 05UOSX 027 lone power window does not operate II Turn ignition switch ON I Check for 12V at terminal w...

Page 529: ...Position UP 0 OFF 0 r o r o DOWN 0 0 0 Indicates continuity 2 If not as specified replace the switch POWER WINDOW MOTOR Inspection Passenger side a b e f 0 0 r o r o 0 1 Connect 12V to terminal a and...

Page 530: ...the opener lever s Remove the rear end mat rear package trim and bulkhead panel for removal of the cable 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 1 05UOSX 03...

Page 531: ...nect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 16 23 1 6 2 3 12 17 4 a N m m kg ft Ib 05UOSX 032 1 Front combination light 4 Mud gu...

Page 532: ...e disconnecting the battery Refer to Section T Removal Installation 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 16 23 1...

Page 533: ...ssembly I Assembly 1 Disassemble in the order shown in the figure 2 Assemble in the reverse order of disassembly N m m kg ft Ib 05UOSX 034 1 Rear fascia 4 Bumper stay 2 Retainer 5 Set plate 3 Bumper r...

Page 534: ...reverse order of removal 1 Windshield molding Installation Note page 3 28 2 Cowl grille Removal page 8 35 3 Front beltline molding Removal Note page 8 28 05UOSX 035 4 Beltline molding Removal Note pag...

Page 535: ...to the bonding area of the new upper molding and allow it to dry for approx 30 minutes Caution Keep the area free of dirt and grease Do not touch the surface If primer gets on the skin remove it im m...

Page 536: ...of dirt and grease Do not touch the surface If primer gets on the hand remove it immediately 4 Install the rear window molding to the glass as shown 5 If the molding is too long cut the excess molding...

Page 537: ...own in the figure 2 Install in the reverse order of removal 1 Mirror cover HORN COMPONENTS Removal I Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 1...

Page 538: ...ANADA MOTOR WASHER __________ F 27 r FOR USA 11 F 25 I I T r flT FOR I 1 CANADA I r I WIPER MOTOR iLI____ F 25 WIPER MOTOR F Llt L L Y FOR USA FOR CANADA F 26 WINDSHIELD WIPER SWITCH COMBINATION SWITC...

Page 539: ...wn Lo LlW 12V Hi L R 12V OK Check for continuity of motor terminal wire Bf to ground I Wiper automatic park function does not work I Turn ignition switch ON Check for 12V at terminal wire L of wiper m...

Page 540: ...T 05UOSX 051 Washer continues to operate when switch Is OFF II Check windshield washer switch Refer to Section T 05UOSX 052 Washer does not operate Wiper operates OK For USA II Turn ignition switch ON...

Page 541: ...X 057 8 34 NG I Replace washer motor I NG I Repair harness Motor Switch I NG i Repair harness Switch Ground I OK I Check windshield washer switch Refer to Section T I WIPER MOTOR Inspection 05UOSX 054...

Page 542: ...ation 1 Disconnect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 1 Wiper arm and blade Adjustment page S 36 2 Cowl grille 3 Baffle cove...

Page 543: ...18 0 20 187 129 200 220 7 36 5 08 7 87 8 66 mm in 05UOSX 059 05UOSX 060 Adjustment Arm height Set the arm height as shown Washer nozzle Insert a needle or similar object into the nozzle hole and move...

Page 544: ...INDSHIELD WIPER AND WASHER s Disassembly I Assembly 1 Disassemble in the order shown in the figure 2 Assemble in the reverse order of disassembly 05UOSX 061 1 Brush plate holder 2 Motor gear shaft 8 3...

Page 545: ...gure 2 Install in the reverse order of removal 1 Wiper arm and blade Adjustment page S 36 2 Cowl grille 3 Windshield molding Installation Note page S 28 4 Rearview mirror and cover 5 Striker 8 38 6 Su...

Page 546: ...eused a tool like that shown in the figure may be used Insert the blade in the sealant and pull on the bars Installation Note Windshield 1 Cut away the old sealant with a razor knife so that 1 to 2mm...

Page 547: ...fill the gap between the dam and the edge of the glass with a ridge of sealant 11 mm 0 43 in high Keep the bead of sealant smooth and even reshaping it where necessary with a spatula 7 If the protecto...

Page 548: ...ny points of poor contact 10 Install a new windshield molding Refer to page 8 28 11 Check for water leaks 12 If a leak is found wipe the water off well and remove the molding and windshield Reinstall...

Page 549: ...2 Use the SST 49 0305 870A to remove and install the rear window glass 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 1 Rear window molding 3 Dam Installation Note...

Page 550: ...careful that the wire does not rub on the top Use a razor knife to cut where the piano wire will not cut Installation Note Rear window glass 1 Cut away the old sealant with a razor knife so that 1to...

Page 551: ...alant smooth and even reshaping it where necessary with a spatula 6 If protector is damaged bond a new protector onto the detachable hard top as shown Caution Bond the protector securely and allow it...

Page 552: ...s 12 Check for water leaks 13 If a leak is found wiper the water off well and remove the molding and rear window glass Reinstall the glass and re place the molding with new molding Refer to page 8 29...

Page 553: ...the order shown in the figure 2 Install in the reverse order of removal 8 8 12 0 9 1 2 B 5 9 7 1 Rear package trim 2 Set plate 3 Beltline cover 4 Beltline protector 5 Rain rail 3 46 N m m kg ft Ib 05...

Page 554: ...ers 4 Remove the beltline protectors 5 Remove the rain rail mounting fasteners from the body Note Raise the convertible top completely Leave the top latch assemblies in the unlocked po sition 6 Remove...

Page 555: ...lw rear window 11 Peel apart the Velcro 12 Carefully remove the zipper stops from the rear window and top fabric and remove the rear window Note Save the zipper stops for reuse Installation Note Rear...

Page 556: ...Note Install the set plate beginning at the left side Note Unzip the rear window and lower the convertible top fully 12 Install the rain rail with the fasteners 13 Install the beltline protectors 14 I...

Page 557: ...nect the negative battery cable 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 1 Ashtray 2 Rear console assembly a Back plate b Shift lever boot c Power window swi...

Page 558: ...wn Center panel assembly The clips are where shown Adjustment Note Airflow mode wire 1 Set the airflow mode control lever to VENT position 2 Connect and clamp the wire with the shutter lever on the he...

Page 559: ...stallation move the REC FRESH lever to be sure the wire is securely attached and that it moves the full stroke from REC to FRESH Temperature blend wire 1 Set the temperature blend lever to MAX HOT pos...

Page 560: ...val 6 1 Front header trim Removal Note page S 54 2 A pillar trim Removal page S 54 3 Front side trim Removal Note page S 54 4 Scuff plate Removal Note page S 54 5 05UOSX 107 5 Quarter trim Removal Not...

Page 561: ...112 S 54 TRIM Removal Note Front header trim The clips and pin are where shown A pillar trim The clips and pin are where shown Front side trim The clip and pins are where shown Scuff plate The clips...

Page 562: ...I Door trim The clips and pin are where h sown aker grille clipS and pins are wh _ ere shown 8 55...

Page 563: ...ge 8 50 c Heater unit Refer to Section U I _ d Front side trim scuff plates quarter trim and rear package trim Refer to page S 53 e Front seat belts and buckles Refer to page 8 57 2 Remove the remaini...

Page 564: ...to page S 54 2 Remove in the order shown in the figure 3 Install in the reverse order of removal Caution Do not disassemble the buckle or retractor assembly _ _as 79 3 9 9 0 29 59 38 78 3 9 8 0 28 58...

Page 565: ...d the retractor as it would be installed 5 Slowly incline the retractor while pulling out the belt 6 Verify that the retractor locks at approx 30 degrees incli nation WEBBING Inspection Inspect the we...

Page 566: ...connector for removal of the seat with headrest speaker 38 51 3 9 5 2 28 38 IJ N m m kg ft Ib 05UOSX 120 1 Front seat Inspection below 05UOSX 121 SEAT Inspection 1 Verify that the seat adjuster lever...

Page 567: ...emble in the reverse order of disassembly 34 56 3 5 5 7 25 41 9 N m m kg ft Ib 05UOSX 122 1 Side cover 6 Pad 2 ReClining knuckle cover 7 Back frame 3 Reclining knuckle 8 Headrest speaker If equipped 4...

Page 568: ...gure 2 Install in the reverse order of removal 6 9 9 8 0 7 1 0 5 1 7 2 1 Beltline cover 4 Seaming welt 2 Beltline protector 5 Striker If equipped 3 Scuff plate 6 Quarter trim Removal Note page S 54 Re...

Page 569: ...uipped 6 Quarter trim 7 Stopper 8 Rear package trim 9 Set plate 10 Top handle 8 62 4 2 6 2 0 43 0 63 3 1 4 6 11 Top latch assembly Adjustment page S 71 12 Weatherstrip Adjustment page S 72 13 Retainer...

Page 570: ...on a clean surface 2 Remove the set plate weatherstrips and retainers 3 Remove the rivets from the link assembly with a drill Drill size 4 0mm O 16 in 4 Remove the rivets with a drill and remove the...

Page 571: ...from the link assembly with a drill and remove the cables from the link assembly Drill size 4 0mm 0 16 in 9 Peel off the Velcro at the rear bow 10 Pry back the bow retainers with a protected screwdri...

Page 572: ...Jded adhesive tape to the front header 4 Thread the cables into the top fabric 5 Place the link assembly over the top fabric Note Install the top fabric to the bows beginning from the rear bow Perform...

Page 573: ...t 11 Install the front of the top fabric to the front header Note Align the set plate and top fabric with the set plate mounting holes 12 Install the set plate to the link assembly 13 Pass the cables...

Page 574: ...to the link assembly 05UOSX 144 18 Install the retainers and weatherstrips to the link assembly 05UOSX 145 Adjusting Small Sag 1 Raise the convertible top and lock the latch assemblies 2 Use a steame...

Page 575: ...top fabric and the repair sheet with a razor knife 2 Cut another piece of repair sheet larger than the first for use as a back repair sheet 3 Trim the top fabric and the repair sheets with scissors 4...

Page 576: ...for use as a back repair sheet 2 Degrease the repair sheet with ethyl alcohol 3 Apply adhesive agent K180 WO 313 or equivalent to the part being repaired and to the back repair sheet Note Apply a subs...

Page 577: ...1 8triker 2 Top latch assembly Adjustment page 8 71 3 Side latch assembly Adjustment page 8 71 4 Weatherstrip Adjustment page 8 72 5 Retainer 6 Rear window molding Installation page S 29 8 70 9 8 15 1...

Page 578: ...ng any adjustment Detachable hard top If engagement of the striker and the side latch assembly is too tight or too loose adjustment is made through the latch assembly adjusting nut Adjustment procedur...

Page 579: ...r vertical adjust by following the steps below Adjustment procedure 1 Remove the weatherstrip in question 2 Loosen the retainer screw and adjust the retainer as necessary 3 Tighten the screw and reins...

Page 580: ...REFERENCE HOLE 12x18 G 47x0 71 J CROSSMEMBER MOUNTING NUT K FRAME REFERENCE HOLE 4 12 0 47 M o R s L FRAME REFERENCE HOLE cf 20 0 79 M FRAME REFERENCE HOLE 12x18 0 47xO 71 0 SUSPENSION MOUNTING BOLT R...

Page 581: ...SNOISN3WIC C31 3rOl ld ACOBl I3CNn SNOISN311 11C ACOBI I3CNn s...

Page 582: ...TING NUT I FRONT FENDER PANEL MOUNTING NUT J CROSSMEMBER MOUNTING NUT K FRAME REFERENCE HOLE jJ12 0 47 L FRAME REFERENCE HOLE cP20 0 79 M FRAME REFERENCE HOLE 12x18 0 47xO 71 N FRAME REFERENCE HOLE 12...

Page 583: ...38 CIRCUIT DIAGRAM T 39 TROUBLESHOOTING T 40 BRAKE FLUID LEVEL SENSOR T 43 PARKING BRAKE SWiTCH T 43 SEAT BELT BUCKLE SWITCH T 43 LIGHTING SySTEM T 44 STRUCTURAL ViEW T 44 HEADLIGHTS T 45 STOPLIGHTS...

Page 584: ...tch Inspection page T 88 Removal Installation page T 25 11 Interior lamp switch Inspection page T 25 12 Panel lamp control switch 4 Hazard warning switch Inspection page T 90 Removal Installation page...

Page 585: ...lay Inspection page T 19 4 TNS relay Inspection page T 19 7 Circuit opening relay 8 Cooling fan relay Inspection page T 19 9 Horn relay Inspection page T 19 10 Turn and hazard warning flasher unit Ins...

Page 586: ...l Installation page T 77 Removal Installation page T 54 8 Side marker light Inspection page T 56 Removal Installation page T 77 3 Stoplight 9 Taillight Removal Installation page T 60 Removal Installat...

Page 587: ...Installation page T 104 3 Actuator cable Removal Installation page T 106 Adjustment page T 106 r 05UOTX 005 4 Clutch switch Removal Installation page T 106 Adjustment page T 106 5 Brake switch Removal...

Page 588: ...SYSTEM 1 Audio unit Removal Installation page T 126 2 Door speakers Removal Installation page T 127 Inspection page T 128 T 6 05UOTX 006 3 Headrest spekkers Removal Ihstallation page T 127 Inspection...

Page 589: ...ion page T 150 2 Clock spring connector 4 Backup battery Removal Installation page T 151 5 Crash sensor Removal Installation page T 152 Inspection page T 159 3 Diagnostic module Removal Installation p...

Page 590: ...ts do not illuminate T 59 Stoplight does not illuminate T 60 Turn and hazard warning functions do not operate U S spec T 63 Turn and hazard warning function do not operate Canada spec T 65 Turn signal...

Page 591: ...short circuiting switch terminals and for verifying the condition of ground connections Caution Do not connect the jumper wire between a power source line and body ground because this may cause burni...

Page 592: ...connecting Battery Cables The optional audio unit has an anti theft function that is acti vated when the battery power is disconnected Obtain the code number and deactivate the audio anti theft system...

Page 593: ...Switch NO type relay NC type relay NO switch NC switch e 0 Not in operation No power supply X QX c STOP FLOW STOP FLOW In operation Power supply c X FLOW STOP FLOW STOP Other Electrical Symbols 10 1 H...

Page 594: ...located on the right side of the engine compartment and it contains nine fuses and two relays Fuse Box The fuse box is located above the dead pedal of the driver side The fuse box cover shows the spe...

Page 595: ...ay Headlight switch EGI main relay Cooling fan relay Backup battery for air bag system AIC relay Inhibitor relay Circuit opening relay Retractable headlight motors 05UOTX 506 Protected circuit EGI mai...

Page 596: ...e Plate type 1 Disconnect the negative battery cable 2 Using the fuse puller supplied in the fuse box removed re place the failed fuse 3 Reconnect the negative battery cable Cartridge type 80A fuse Bl...

Page 597: ...er to specified Section EGI main relay Refer to Section F Circuit opening relay Refer to Section F AIC relay Refer to Section U DESCRIPTION The DRL control unit which is equipped for Canada vehicles c...

Page 598: ...not as specified replace the retractor relay TURN AND HAZARD WARNING FLASHER UNIT Inspection 1 Check continuity between terminals of the flasher unit Note Set the ohmmeter to x 10000 range Terminal C...

Page 599: ...place the timer and buzzer unit Seat belt alarm test 1 Apply 12V to terminals f and h and ground terminal d and check if the buzzer sounds for approx 6 sec Terminal 12V I Ground Buzzer sounds f and h...

Page 600: ...3 Remove the 12V from terminal c 4 Apply 12V to terminals f and h and measure the voltage at terminals d and k Terminal Voltage d 12V k 12V 5 If not as specified replace the DRL unit 6 Remove the 12V...

Page 601: ...ot as specified replace the relay 3 If correct go to Step 4 4 Apply 12V to terminal 1 and ground terminal 2 Check for continuity between terminals 3 and 4 Terminal Continuity 3 4 Yes 5 If not as speci...

Page 602: ...bination switch equipped for U S specification vehicles includes a clock spring type electrical con nector for supplying electrical current to the air bag module and horn switches When installing the...

Page 603: ...ntinuity between terminals of the switch Position Terminal B1 B2 ACC IG1 IG2 5T K1 LOCK 0 ACC 0 0 0 0 ON 0 START 0 0 0 Indicates continuity T K2 ro 0 2 If not as specified replace the combination swit...

Page 604: ...spring connector adjustment 1 Set the front wheels straight ahead 05UOTX 035 2 Turn the clock spring connector clockwise until it stops 05UOTX 037 Do not force it 3 Return the connector 2 75 turns 4...

Page 605: ...ty or resistance is not as specified replace the combination switch as an assembly Lights dimmer and passing switch Position Terminal E HL HU TNS HEAD BA B 0 0 Low beam Headlight 0 0 High beam Passing...

Page 606: ...passing switch Position HS HL HU SA STN TNS Low beam 0 0 0 ro Headlight 0 0 r o High beam Passing 0 0 Tail Parking 0 f O 0 0 Indicates continuity Turn signal switch Position FU TL TR Left 0 D Right 0...

Page 607: ...h 1 Remove the retractor switch 2 Check for continuity between terminals of the switch Switch Terminal b d f Off On 0 D 0 0 Indicates continuity 3 If not as specified replace the retractor and hazard...

Page 608: ...pecification vehicles is MPH 0 130 MPH the main scale for Canada specification vehicles is KM H 0 210 KM H The odometer indication is the same as the main scale Tachometer The tachometer has a RED STR...

Page 609: ...HEADLIGHT RETRACTOR MOTOR Z 34 38 SlY U4 F 1E 1 01 TURN SIGNAL E HAZARD FLASHER UNIT Z 50 54 R I AIR BAG 30 CONTROL UNIT L Y Z 78 t ORL I CONTROL UNIT L Y Z 42 F l T n1 BLAKE FUILD LEVEL SENSOR PARKIN...

Page 610: ...fy that the speedometer cable is connected properly 2 If the connections are OK go to Step 2 Step 2 Check speedometer cable 1 Disconnect the speedometer cable from the instrument clus ter and transmis...

Page 611: ...he instrument cluster Refer to page T 33 2 Connect a test tachometer between terminals 1Hand 2J of the harness side connector Step 2 1 Start the engine 2 Check that the test tachometer indicates engin...

Page 612: ...ys correct Action Yes Replace water thermosensor No Go to Step 2 Caution Continue the above checks for at the least two minutes each to correctly judge the condition The allowable indication error is...

Page 613: ...ender unit in fuel tank No Go to Step 2 Caution Continue the above checks for at least two minutes each to correctly judge the condition The allowable indication error is twice the width of the needle...

Page 614: ...ace oil pressure sensor No Go to Step 2 Caution Continue the above checks for at least two minutes each to correctly judge the condition The allowable indication error is twice the width of the needle...

Page 615: ...NSTRUMENT CLUSTER REMOVAL I INSTALLATION Remove and install as shown in the figure INSTRUMENT CLUSTER DISASSEMBLY I ASSEMBLY Disassemble and assemble as shown in the figure T 05UOTX 058 05UOTX 059 T 3...

Page 616: ...error TACHOMETER Inspection 1 Connect a test tachometer to the engine and start the engine 2 Check the tachometer for allowable indication error Replace if necessary Caution WATER TEMPERATURE GAUGE In...

Page 617: ...ound terminal 2j 3 Connect the red lead of the SST to terminal 1a and the black lead to a ground 4 Set the SST to the resistance values shown in the figure 5 Verify that the needle indicates the corre...

Page 618: ...ent cluster 2 Check continuity between terminals 2d and 2f while rotat ing the speedometer cable shaft 3 If the correct number of pulsations fail to occur during each shaft rotation replace the speed...

Page 619: ...body ground as shown Condition Resistance Engine stopped 110 1300 Engine running 13 550 3 If not as specified replace the oil pressure sensor SPEEDOMETER CABLE Inspection 1 Disconnect the speedometer...

Page 620: ...g lamp 4 Headlight retractor motor indicator lamp 05UOTX 073 5 Alternator warning lamp 6 MIL Malfunction indicator lamp Refer to the following tables concerning warning lamps information Warning indic...

Page 621: ...A HEADLIGHT RETRACTOR MOTOR Z 34 38 B Y i4 F BLAKE FUILD LEVEL SENSOR lE TURN SIGNAL HAZARD FLASHER UNIT Z 50 54 1 01 R I A1R BAG L r CONTROL UNIT Z 7B L Y DRL F CONTROL UNIT PARKING BRAKE SWITCH Z 42...

Page 622: ...tem Refer to Section P Above MIN Go to Step 2 Step 2 Check parking brake switch 1 Disconnect the parking brake switch connector 2 Check continuity between the terminal of the switch and a body ground...

Page 623: ...Released No 3 If not as specified adjust or replace the parking brake switch 4 If the switch is OK repair the wiring harness Symptom Brake warning lamp does not come on when brake fluid in reservoir...

Page 624: ...g lamp does not illuminate when ignition switch first turned ON 0 D CHARGE BRAKE a CHECK BELTS 05UOTX 078 0 D CHARGE MAKE a CHECK BELTS 05UOTX 079 T 42 05UOTX 294 Step 1 1 Ground terminal J of the tim...

Page 625: ...ion 1 Disconnect the parking brake switch connector 2 Check for continuity between the switch connector and a body ground Lever Continuity Pulled one notch Yes Released No 3 If continuity is not as sp...

Page 626: ...05UOTX 083 1 Retractable headlight 7 License plate light 2 Headlight retractor motor 3 Stoplight 8 Side marker light 9 Taillight 4 High mount stoplight 10 Rear combination light lens 5 Turn and hazard...

Page 627: ...CTOR RELAY F 35 HEADLIGHT RETRACTOR MOTOR f GIL F 1 e __ I 1 HEADLIGHTS 1 FOR CANADA BATTERY BATTERY BTN 40A I R L F R W F RIB F F 29 I W R F F 37 R W F HEADLIGHTS 60W 40W L H 1 R L IF J 1 R H I FRONT...

Page 628: ...cable must be disconnected to pre vent accidental movement of the headlight and possible injury Troubleshooting W B R L o R L L Y T 46 05UOTX 085 Symptom Headlights do not operate U S spec MAIN FUSE B...

Page 629: ...ght switch ON and measure the voltage at the following terminal wires as shown Headlight Wire Headlight Voltage Remedical Action switch 12V Repair ground wire 8 RIB Low beam Repair wire RIB OV Headlig...

Page 630: ...e OK go to Step 3 Step 3 1 Turn the headlight switch ON 2 Disconnect the headlight connector and measure the volt age at the following terminal wires as shown Headlight Wire Headlight Voltage Action s...

Page 631: ...sition OV Repair wire W R 8TN 40A fuse Headlight switch R W ON 12V Next check wire R B High beam OV Go to Step 5 ON 12V Check for poor connection of RIB Low beam headlight switch connector OV Go to St...

Page 632: ...light switch ON and measure the voltage at the following terminal wires as shown Headlight Wire Headlight Voltage Action switch 12V Repair ground wire 8 RIB Low beam OV Repair wire RIB Left Headlight...

Page 633: ...ETRACT 30A and HEAD 30A fuses in the main fuse block 2 If a fuse is burned replace it Check and repair the wire harness if necessary 3 If the fuses are OK go to Step 2 Step 2 1 Retract the headlights...

Page 634: ...motor OV Replace retractor relay Canada spec Wire Voltage Action RIG 12V Next check wire W R OV Go to Step 5 12V Next check wire 8 W R OV Repair wire W R Headlight switch Retractor relay 8 12V Repair...

Page 635: ...uded in the instrument cluster The indicator lamp illuminates when the retractor motor is operating and should go out when the headlights are fully raised or retracted If the indicator lamp remains on...

Page 636: ...tallation Remove and install as shown in the figure 05UOTX 105 1 Bezel 4 Motor link 2 Headlight housing 5 Retractor hinge 3 Headlight 6 Retractor motor Caution Do not turn the adjusting screws during...

Page 637: ...cal regulations by turning the two adjusting screws Retractor hinge 1 Begin with the headlights fully retracted Caution Before disconnecting the negative battery cable verify the 10 code number of aud...

Page 638: ...Motor rotates to retracted position 5 If not as specified replace the retractor motor Retractor switch 1 Remove the retractor switch 2 Check for continuity between terminals of the switch Terminal Sw...

Page 639: ...3 4 No 2 If not as specified replace the headlight relay 3 If correct go to Step 4 4 Apply 12V to terminal 1 and ground terminal 2 Check for continuity between terminals 3 and 4 Terminal Continuity 3...

Page 640: ...Y E BACK UP LIGHTS SWITCH E 09 RIG F FR OI RIG A RIG RIG R IR BACK UP LIGHTS R 05 27W R H R 05 B Al STOP 15A WIG FI F 44 STOP LIGHT SWITCH F 44 G IF G IR G R G R I BULB TRADE NUMBER FRONT TURN LIGHTS...

Page 641: ...itch connector Inspection Wire Voltage Action condition 12V Next check wire G Constant WIG OV Repair wire WIG STOP 15A fuse Stoplight switch Brake pedal G 12V Go to Step 3 depressed OV Check stoplight...

Page 642: ...OK go to Step 2 Step 2 05UOTX 124 Measure the voltage at the following terminal wires of the faulty stoplight connector Inspection Wire Voltage Action condition 12V Next check wire 8 G OV Repair wire...

Page 643: ...t switch until it contacts the pedal arm Turn an additional 112 turn 5 Tighten the locknut Locknut tightening torque 14 18 N m 1 4 1 8 m kg 120 156 in Ib Inspection Stoplight switch 1 Disconnect the s...

Page 644: ...GHTS SWITCH E 09 RIG E FE O RIG IF FR 01 RIG R RIG RIG I l I ll BACK LP LIGHTS R OS 27W A H A 05 B IA STOP 15 1 WIG F F 44 STOP LIGHT SWITCH F 4 G IFI G R G R STOP 15A WIG F STOPLIGHT SWITCH G F FR O...

Page 645: ...nal Continuity Terminal Continuity I I I a c X d e X f 9 X a d X d f X f h X a e 0 d g X g a X a f 0 d h X g c X a g X e a X g d X a h X e c X g e X c a 0 e d X 9 f X c d 0 e f X g h X c e 0 e g X h a...

Page 646: ...Flasher unit Turn signal 12V Next check wire SIR GIY switch left OV Repair wire harness position Turn signal switch Flasher unit 12V Go to Step 7 SIR Constant OV Repair wire harness HAZARD 15A fuse Fl...

Page 647: ...a c X d e X f g X a d X d f X f h X a e 0 d g X g a X a f 0 d h X g c X a g X e a X g d X a h X e c X g e X c a 0 e d X g f X c d 0 e f X g h X c e 0 e g X h a 0 c f 0 e h X h c 0 c g 0 f a X h d 0 c...

Page 648: ...t check wire G R G R switch right OV Repair wire harness position Turn signal switch Flasher unit Turn Signal 12V Next check wire Y G G Y switch left OV Repair wire harness position Turn signal switch...

Page 649: ...unit Bulb Check DRL unit OV Refer to page T 18 12V Next check wire G O G 8 OV Repair wire G O Turn signal Flasher unit DRL unit switch left 12V Repair wire G O G O position DRL unit Bulb Check DRL un...

Page 650: ...e the right cluster switch assembly 4 If the cluster switch is OK go to Step 2 Step 2 Measure the voltage at the terminal wires of the hazard warn ing switch connector as shown Wire Voltage Action 0 1...

Page 651: ...Indicates continuity TR 4 If not as specified replace the combination switch as an assembly Canada spec 1 Remove the column cover then disconnect the turn signal switch connector 2 Check for continuit...

Page 652: ...Continuity Terminal Continuity I I I a c X d e X f g X a d X d f X f h X a e 0 d g X g a X a f 0 d h X g c X a g X e a X g d X a h X e c X g e X c a 0 e d X g f X c d 0 e f X g h X c e 0 e g X h a 0 c...

Page 653: ...DE NUMBER FRONT TURN LIGHTS 1157NA 27W REAR TURN LIGHTS 1156 27W BUCK up LIGHTS 1156 27101 STOP LIGHTS 1157 127W HIGH MOUNTED STOP LIGHT 921 19 4W G R STOPLIGHT SWITCH F 44 G F BULB TRADE NlMlER WIG W...

Page 654: ...If a bulb is burned replace it If the bulbs are OK go to Step 3 Step 3 1 Turn the ignition switch ON and shift the transmission to reverse 2 Measure the voltage at the terminal wires of the back up l...

Page 655: ...switch with the transmission in reverse Continuity Action Yes Repair wire harness METER 10A fuse Back ur light switch Back up light No Replace switch ro BACK UP LIGHT 05UOTX 146 Inspection Back up lig...

Page 656: ...FOR CANADA TNS RELAY COMBINATION SWITCH Z 34 Z 38 26 RIB F R B R LICENSE PLATE LIGHTS B R 11 R 8 R B R RIB F FR 01 RIB R r R B R RIB R L H 11 RIB R R H TAILLIGHTS B R B R l l 2 0 2 t fBR SIIE MARKER L...

Page 657: ...inal a W R 12V Next check wire W R Terminal b OV Repair wire W R Terminal a TAIL 15A fuse TNS relay W R 12V Replace TNS relay OV Repair wire W R Terminal b TAIL 15A fuse TNS relay Step 3 1 Check the b...

Page 658: ...Check and if necessary repair the wiring harness 3 If the fuses are OK go to Step 2 Step 2 1 Turn the headlight switch ON 2 Measure the voltage at the following terminal wires of the combination swit...

Page 659: ...ING SYSTEM Removal I Installation Remove and install as shown in the figures Taillights Side marker lights Parking lights License plate lights f TAILLIGHT T 05UOTX 149 05UOTX 150 05UOTX 151 05UOTX 152...

Page 660: ...T Z 54 11G 0 F FRONT TURN SIGNAL LIGHTS B F DAYTIME RUNNING LIGHT DRL CONTROL UNIT I G Y F B F 0 I F 38 DAYTIME RUNNING LIGHT DRL CONTROL UNIT F F 40 FRONT TURN SIGNAL LIGHT R H F YE JR B FI 01 FRONT...

Page 661: ...V Repair wire L WIPER 20A DRL unit Constant OV Repair wire B ORL unit Body ground Parking brake released 12V Go to Step 2 Headlight switch off OV Go to Step 3 05UOTX 159 05UOTX 160 05UOTX 158 Step 2 1...

Page 662: ...ke switch lever pulled one notch Next Step Step 2 Step 4 Step 4 Step 5 05UOTX 163 Step 2 1 Turn on the ignition switch 2 Turn on the headlight switch 3 Check the voltage at the terminal wire W R of th...

Page 663: ...ecified repair the wire harness Turn and hazard warning flasher unit DRL unit 5 If correct replace the DRL unit Step 5 1 Turn on the ignition switch 2 Pull the parking brake lever more than one notch...

Page 664: ...RL unit 3 Remove 12V from terminal c 4 Apply 12V to terminals f and h and measure the voltage at terminals d and k Terminal Voltage d 12V k 12V 5 If not as specified replace the DRL unit 6 Remove 12V...

Page 665: ...t housing by pushing the rear of the lens with a hammer handle or round bar 3 Heat the light housing and remove the hot melt and any fragments of the lens Note The hot melt should be reused if possibl...

Page 666: ...T LIGHTING SYSTEM 6 Immerse the combinatio n light in water to check for leaks T 84...

Page 667: ...F lI L R F F 51 l L W F R W F L H BUCKLE SWITCH B R FI 04 lIR W F FR 01 R W R R W W Rl Rl 09 R 10 DOOR SWITCH R H l L R I INTERIOR LAMPS l L R I 1 10 R H I 11 II U U B I B I IGNITION SWITCH ACC CIGAR...

Page 668: ...any position Step 2 Interior lamp s illuminate when control switches are in ON position but do not il Step 5 luminate with door open when switches are in DOOR position Interior lamp s illuminate when...

Page 669: ...mbly Step 5 1 Open both doors and set the control switches to DOOR position 2 Measure the voltage at terminal wire R W of each interior lamp connector Wire Voltage Action R W 12V Go to Step 6 OV Repla...

Page 670: ...replace the door switch 3 If the switches are OK go to Step 2 Step 2 1 Close both doors 2 Disconnect the interior lamp connectors and check con tinuity between terminal wire R W and a body ground Wire...

Page 671: ...AY I IR B I I ISE CONTROL MAIN SWITCH I ILLUMI I I 01 METER ILLUMI I nr _ J IBILIB Y I B I R IRIB II I G IR W I8 IG W IY R IG B I 2L 2K 2 21 2H 2G 2F 2E 20 2C 2B 2A WITH CRUISE CONTROL USA ONLY I 03 F...

Page 672: ...ir wire 8 Panel lamp control switch Body ground RIB 12V Next check wire R OV Repair wire RIB TAlL 15A fuse Panel lamp control switch R OV Repair wiring harness Panel lamp control switch Each lamp Othe...

Page 673: ...HORN STRUCTURAL VIEW CD 1 Horn HORN 2 Horn relay T 05UOTX 328 3 Horn switch T 91...

Page 674: ...LIGHTS SWITCH 1 04 HAZARD SWITCH 1 04 B II RIG IR RIG IR R 04 27 L H R 04 BACK U LIGHTS B R RIG IR R 05 27W R H R OS B RI G IAI r 7 7 4 MDt LICJ TS l G IR STOP 15A wiG F G IR BU B TRADE NU BER FRONT...

Page 675: ...ctor 3 If the horn sounds go to Step 4 4 If the horn does not sound go to Step 6 Step 4 U S spec Warning Before removal of the air bag module the negative battery cable must be disconnected to prevent...

Page 676: ...uity Action Yes Repair wire G O Horn relay Clock spring connector No Replace combination switch assembly Warning After installation of the air bag module verify that the air bag system is operating no...

Page 677: ...When carrying an air bag module make sure the trim cover is pointed away from your body to pre vent injury in the event of an accidental deployment When placing an air bag module on any surface place...

Page 678: ...HORN 4 Install the steering wheel and the air bag module Warning After installation of the air bag module verify that the air bag system is operating normally by monitor ing the air bag warning lamp R...

Page 679: ...CONTROL SYSTEM T CRUISE CONTROL SYSTEM STRUCTURAL VIEW 1 Cruise control unit 2 Actuator 3 Actuator cable 4 Clutch switch 0r 05UOTX 209 5 Brake switch 6 Cruise control main switch 7 Cruise control swit...

Page 680: ...H J F 56 BATTERY B F STOP 15A WIG F ENGINE CONTROL UNIT Z 22 24 llBR W F B F o 01 C o I CD CD F 54 CRUISE CONTROL UNIT F o F 55 ACTUATOR F F 57 CRUISE CONTROL SWITCH F sa Etijj FI 02 FRONT F INSTRUMEN...

Page 681: ...ontrol main switch Position Terminals a b d f g h Neutral 0 iD 0 Off 0 ro 0 0 f O 0 f O On 0 0 0 0 Indicates continuity 2 If not as specified replace the switch 3 If the switch is OK repair the wire h...

Page 682: ...onnector 2 Check continuity between terminals of the switch Pedal position Terminal a b Pedal released 0 0 Pedal depressed Indicates continuity 3 If not as specified replace the brake switch 4 If the...

Page 683: ...or 3 If continuity is OK go to Step 8 4 4 Disconnect the actuator cable from the accelerator pedal 5 Run the engine at idle speed 6 Apply 12V to the following terminals and check actuator operation Or...

Page 684: ...uise control unit connector as shown 3 Reconnect the cruise control unit connector Inspection 1 Turn the ignition switch ON 2 Turn the cruise main switch ON 3 Turn the cruise control switch to RESUME...

Page 685: ...position of the condition operation code represents the number of times the lamp is on 0 4 second during one cycle CONDITION OPERATION 1 CYCLE CODE JlJl CYCLE BREAK ffim_C_O_D_E_ 0_3___ 4 11 1 I 0 4...

Page 686: ...page T 99 05UOTX 226 If there is more than one malfunction the code numbers will be indicated in numerical order lowest number first 05UOTX 227 d b 05UOTX 459 9MUOTX 262 T 104 ACTUATOR Inspection 1 Me...

Page 687: ...ge T 107 Main switch ON 12V h Y Brake switch Brake pedal depressed OV Check brake switch Brake pedal released 9V Refer to page T 1 07 j BR W Clutch switch Clutch pedal depressed OV Check clutch switch...

Page 688: ...r cable free play is as shown when the cable is pressed lightly Cable play 1 3mm 0 04 0 12 in CLUTCH SWITCH Removal Loosen the locknut and remove the switch Installation Install in the reverse order o...

Page 689: ...arness Fuse Brake switch Control unit CRUISE CONTROL MAIN SWITCH Inspection 1 Check continuity between terminals of the cruise control main switch Position Terminal a b d f g h Neutral 0 f O 0 0 Off 0...

Page 690: ...AUDIO STRUCTURAL VIEW 1 Audio unit 2 Door speakers T 108 3 Headrest speakers...

Page 691: ...theft system is activated Three consective errors in inputting a code number to a unit that has had the anti theft sys tem activated will render the unit completely inoperable It must then be replace...

Page 692: ...PLAY MODE RADIO OR TIME VOLUME HEAD RESTRAINT BALANCE REWIND STOP FAST PLAY AUTOMATIC PROGRAM SPEAKER VOLUME EJECT FORWARD PROGRAM CONTROL TAPE BASS TREBLE ILLUMINATION ON OFF PUSHING THIS ALTERNATES...

Page 693: ...sample strong stations Scan ning stops at each station for about five seconds To hold station press SCAN again during five second in terval Channel preset tuning To set frequency To select band press...

Page 694: ...from radio or tape mode press PLAY STOP Ejecting Reloading CD To eject CD press EJECT RELOAD To reload ejected CD press EJECT RELOAD again Fast forwardlreverse To fast forward program press FF To rev...

Page 695: ...n the audio unit off with the ignition switch ACC 2 Push REW and FF simultaneously for approximately 2 sec onds until CODE is on the display 3 Again push REW and FF while CODE is displayed within 10 s...

Page 696: ...ars After 5 seconds CODE will disappear and the clock mode will appear This indicates the code number is canceled Note If Err appears on the display begin from Step 1 If anti theft system is activated...

Page 697: ...ion Go to Step 2 Step 2 1 Remove the audio unit Refer to page T 126 2 Check the connections of the ground wire and the short plug 3 If a connection is poor or loose repair or replace it 4 If the conne...

Page 698: ...is properly connected 3 If necessary repair or reconnect the connector 4 If the connection is OK go to Step 6 Step 6 1 Disconnect the connector from the suspected faulty speaker 2 Measure resistance b...

Page 699: ...2 Check the connections of the ground wire and the short plug 3 If a connection is poor or loose repair or replace it 4 If the connections are OK go to Step 3 Step 3 1 Turn the ignition switch to ACC...

Page 700: ...senger seat OK Left headrest speaker circuit pas No senger seat faulty Step 8 Yes Right headrest speaker circuit pas senger seat OK No Right headrest speaker circuit pas Step 8 senger seat faulty 05UO...

Page 701: ...not as specified replace the speaker 4_ If the resistance is OK go to Step 10 Step 10 1 Disconnect the 8 pin connector of the audio unit 2 Disconnect both headrest speaker connectors_ 3 Check for cont...

Page 702: ...compare the sound quality with another vehicle that has the same type audio unit 2 If the sound quality is inferior to the other unit the malfunc tion may be in the speaker circuit Go to Step 3 3 If...

Page 703: ...f the antenna mounting nut 2 If the nut is loose tighten it 3 If the nut is tight go to Step 6 Step 6 1 Remove the audio unit 2 Check for proper connection of the antenna connector 3 If necessary repa...

Page 704: ...OK 3 If sound quality is still poor go to Step 2 Step 2 1 Check for oxide or dirt on the head capstan and pinchroller 2 If oxide or dirt is found clean the parts with a head cleaner 3 If there is no o...

Page 705: ...If the tape loads the previous tape is defective The sys tem is OK 3 If the tape will not load go to Step 2 Step 2 1 Check if radio operation is OK 2 If radio operation is OK replace the audio unit 3...

Page 706: ...ads go to Step 2 Step 2 1 Playa known good tape and check the sound quality 2 If sound quality is normal the previous tape is defective The system is OK 3 If sound quality is still poor go to Step 3 S...

Page 707: ...he audio unit 3 If the radio does not operate there is defective in the power supply circuit Refer to Speaker s does not sound pages T 115 or 117 05UOTX 268 Symptom Compact disc skips 05UOTX 344 Note...

Page 708: ...T AUDIO VAL I INSTALLATION REMO d tall as shown in the figure Remove an Ins AUDIO UNIT 05UOTX 269 ANTENNA T 126...

Page 709: ...AUDIO T DOOR SPEAKERS DOOR SPEAKER HEADREST SPEAKERS HEADREST SPEAKER T 127...

Page 710: ...NAL SPECIFICATIONS Component Audio unit Compact disc player T 128 Connector Terminal a Headrest speaker left f b Headrest speaker left 8 h c NC i d NC j a ACC h b NC j c 8 k d NC I e TNS m for illumin...

Page 711: ...ATELLA AVENUE CYPRESS CA 90630 714 373 7419 MATSUSHITA ELECTRIC OF CANADA LIMITED 5770 AMBLER DRIVE MISSISSALlGA ONTARIO L4W2T3 416 624 5010 PANASONIC SALES COMPANY KM 97 AVE 65 INFANTERIA VICTORIA IN...

Page 712: ...e d S sensor 5 Crush sensor 6 Backup battery The MX 5 Miata is equipped with a driver side supplementary air bag system a first for Mazda vehicles The air bag system is designed to provide increased a...

Page 713: ...ackup battery Provides sufficient power to operate air bag sys tem if battery power lost during crash Clock spring Ensures uninterrupted electrical circuit to air bag One of part of combination switch...

Page 714: ...s shown in figure The battery S sensor air bag module and D sensors are con nected is series via diagnostic module When the S sensor and one of the D sensors are activated closed simultaneously electr...

Page 715: ...components of the air bag system are not in tended to be disassembled for service If a component failure is detected by the diagnos tic module replace the suspected component af ter checking the conne...

Page 716: ...H SENSOR INSTALLATION Crash sensor oreientation is very important for prop er operation If a vehicle is involved in a collision where its front sheet metal is damaged inspect the body structure at the...

Page 717: ...cted as below 1 Press the orange knob and disconnect the orange connector 2 Press the blue knob and disconnect the blue con nector 3 Connect the connectors in the reverse order of disconnecting 8 Afte...

Page 718: ...B F SIL F S SENSOR G B F F 60 F 60 R F tt I I I G W F F 48 G F AIR BAG CONTROL UNIT SR F llBR B F il G Y F RIB F FE 07 RIB E JOINT CONNECTOR NO 1 IIBR W llBR R F F IIBR Y 11BR G F F o SENSOR eNTER COM...

Page 719: ...e I RIW GIG ORANGE BLUE F 13 JOINT CONNECTOR F F 58 AIR BAG CONTROL UNIT F F 61 BACKUP BATTERY F F 65 COMBINATION SWITCH F 8 D I E BLUE F 48 COMBINATION SWITCH F rEI rfmr F 62 D SENSOR L H F t u CJ I...

Page 720: ...Open circuit between warning lamp and diagnostic module I t Repair as specified or replace Check out failed part by recommended procedure Note When the ignition switch is turned ON an audible alarm ma...

Page 721: ...leshooting read SERVICE PRECAUTION on page f 133 05UOTX 368 DIAGNOSTIC MODULE 05UOTX 369 Remedy 1 Disconnect the negative battery cable 2 Remove the knee protector and disconnect the clock spring conn...

Page 722: ...to Step 2 Less than 9V Charge battery by recomended procedure Refer to Section G Step 2 1 Check the following fuses Fuse Location INJ 30A Main fuse block AIR BAG 15A Fuse box AIR BAG 10A Main fuse bl...

Page 723: ...to Step 5 G R OV Replace wire harness assembly Step 5 1 Disconnect the negative battery cable 2 Disconnect the diagnostic module connector 3 Reconnect the negative battery cable 4 Measure the voltage...

Page 724: ...measure the resistance of each sensor Resistance Approx 1 2 kO 4 If not as specified replace the sensor 5 If correct go to Step 2 Step 2 1 Reconnect all D sensor connectors 2 Disconnect the diagnosti...

Page 725: ...sor connectors 2 Disconnect the diagnostic module connector 3 Measure the resistance between the following terminal wires of the diagnostic module connector and a body ground Terminal wire Resistance...

Page 726: ...gnostic module connector 4 Check continuity between terminal wires of the diagnostic module connector Terminal wire Continuity Action 28 G W Yes Go to Step 2 2D G W No Replace wire harness Step 2 1 Di...

Page 727: ...wire harness b e No Replace S sensor Step 5 1 Verify that the S sensor is installed properly 2 If the installation is poor clean the mounting and tighten the bolts 3 If correct go to Step 6 Step 6 1 D...

Page 728: ...air bag module installation nuts 2 Verify that the air bag module connector is properly con nected 3 If the connector is loose or disconnected reconnect it 4 If the connection is OK go to Step 3 Step...

Page 729: ...continuity between terminal wire 2F G Y of the di agnostic module connector and a body ground Terminal wire Continuity 2F G y Body ground No 2 If not as specified replace the wire harness assembly 3...

Page 730: ...ire Continuity Action 2J BRIY Yes Next check between 2H BR W and body ground Body ground No Go to Step 2 Yes Next check between 2E BR and 2H BR W body ground Body ground No Go to Step 3 2E BR Yes Repl...

Page 731: ...of the sensor connector and a body ground Terminal Continuity b Body ground Yes 2 If not as specified go to Step 5 3 If correct replace the wire harness assembly Step 5 1 Check that all D sensors CNT...

Page 732: ...ployment of the air bag When carrying a live unactivated air bag module make sure the trim cover is pointed away from your body to prevent personal injury in the event of an accidental deployment When...

Page 733: ...in the reverse order of removal Diangosis Module and Backup Battery 1 Disconnect the negative battery cable 2 Remove the knee protector and disconnect the clock spring connectors Orange and blue 3 Di...

Page 734: ...ct the negative battery cable 2 Remove the knee protector and disconnect the clock spring and combination switch connectors 3 Remove the nuts and remove the air bag module Refer to page T 150 Caution...

Page 735: ...tallation Note Installation note Before installing the steering wheel set the clock spring connector as follows 1 Set the front wheels straight ahead 2 Turn the clock spring connector clockwise until...

Page 736: ...Remove the nuts and the main fuse block 4 Disconnect the D sensor RH connectors 5 Remove the undercover 6 Remove the clips and remove the bolts and the D sensor RH 7 Install the D sensor RH in the rev...

Page 737: ...e relay box 4 Disconnect the D sensor LH connectors 5 Remove the undercover 6 Remove the clips and remove the bolts and the D sensor LH 7 Install the D sensor LH in the reverse order of removal referr...

Page 738: ...he arrow toward the front of the vehicle Tighten the mounting bolts to the specified torque Tightening torque 8 8 12 7 N m 90 130 cm kg 78 113 in Ib S sensor 1 Disconnect the negative battery cable 2...

Page 739: ...s Resistance a blue b orange Approx 1 2 kG 6 If not as specified replace the sensor Caution Do not try to repair the wire harness D sensor RH 1 Disconnect the negative battery cable 2 Remove the knee...

Page 740: ...tance a blue b orange Approx 1 2 kO 5 If not as specified replace the sensor Caution Do not try to repair the wire harness S sensor 1 Disconnect the negative battery cable 2 Remove the knee protector...

Page 741: ...the nuts and remove the air bag module 4 Check continuity between terminals of the clock spring con nectors blue as shown Terminals Continuity Connector A Connector B a A Yes b B Yes 5 If not as speci...

Page 742: ...r Bag Module To service a deployed air bag it must be replaced with an new module The deployed air bag module can be disposed of in the usual manner as any part to be scrapped Warning When handling a...

Page 743: ...attery to trigger the igniter 8 Allow at least 10 minutes before approaching the air bag to allow for cooling of the module and dissipation of the ef fluents Warning When handling a deployed air bag m...

Page 744: ...ERAL PRECAUTION U 6 HEATER U 18 STRUCTURAL ViEW U 18 HEATER UNIT U 19 BLOWER UNIT U 21 HEATER CONTROL SWITCH ASSEMBLy U 23 AIR CONDITIONER U 26 STRUCTURAL ViEW U 26 REFRIGERANT SySTEM U 27 COOLING UNI...

Page 745: ...Inspection page U 22 Resistor assembly in blower unit Heater core in heater unit Inspection page U 20 Inspection page U 22 3 Heater control switch assembly 2 Blower unit Removal Installation page U 23...

Page 746: ...netic clutch Removal Installation page U 32 Disassembly Assembly page U 33 Disassembly Assembly page U 41 4 Condenser 2 Compressor Removal Installation page U 35 Removal Installation page U 40 5 Recei...

Page 747: ...ON SWITCH WIPER 20A L F FI 01 L I IG1 I 13 LfF G R I FAC 01 ENGINE CONTROL UNIT Z 1S WATER THERMO SWITCH FAN 2 26 UAC HEATER CONTROL UNIT THERMO SWITCH ENGINE CONTROL UNIT 2 18 L B AC FROM SATTERY BIG...

Page 748: ...WINDOW FOR CANADA FAC 01 FRONT F A C AC F AC cE L F 53 MAGNETIC CLUTCH F IB Rlbd AC 01 AIC RELAY AC I I 12 THERMOSWITCH 1 1 13 HEATER CONTROL UNIT I gIG RI g AC 02 ADDITIONAL FAN AC 03 REFRIGERANT PR...

Page 749: ...ter is used for measurement of circuit voltage A voltmeter with a range of 15V or more must be used It is used by connecting the positive probe red lead to the point where voltage is to be measured an...

Page 750: ...to the second Mid third High or fourth Super high position causes the cir cuit resistance to decrease and the blower motor speed becomes correspondingly faster FUSE BOX 05UOUX 006 Step 1 1 Check the...

Page 751: ...Step 4 1 Turn the ignition switch ON 2 Turn the blower switch to the fourth position 3 Measure the voltage at terminal wire 8 of the blower switch connector Wire Voltage Action B OV Go to Step 5 12V...

Page 752: ...ration depending on engine load Refer to Section F c J GJG GiG 0 0 bolTIloO 0 8E O GE c J 100 WIPER 20A FUSE BOX AD FAN 20A MAIN FUSE BLOCK 05UOUX 084 05UOUX 013 05UOUX 011 Step 1 1 Check the followin...

Page 753: ...L Y 12V Next check wire L G OV Repair wire LlG AD FAN 20A fuse Ale relay L 12V Next check wire L B OV Repair wire L G WIPER 20A fuse A C relay L B 12V Check ECU terminal voltage OV Replace A C relay S...

Page 754: ...switches are ON and creates ground circuit 3 A C relay is magnetized and contact is closed 4 Battery voltage is applied to additional fan and fan operates Note The ECU also controls the additional fan...

Page 755: ...he related action as shown below Amount of refrigerant Action Insufficient refrigerant Check refrigerant pressure go to Step 2 Too much or proper amount of Turn air conditioner OFF and refrigerant wat...

Page 756: ...f Vacuum High side Below 589 kPa 6 kg cm2 85 psi Low side Above 245 kPa 2 5 kg cm2 35 6 psi High side 1 864 1 962 kPa 19 20 kg cm2 270 284 psi Low side 392 589 kPa 4 6 kg cm2 57 85 psi High side 687 9...

Page 757: ...go to Step 2 05UOUX 023 Step 2 1 Check for leakage from the following connections with a gas leak tester Inlet and outlet of condenser Inlet and outlet of receiver drier Inlet and outlet of compresso...

Page 758: ...denser is OK go to Step 2 Step 2 1 Discharge the excessive refrigerant Refer to page U 28 Warning Always wear gloves and eye protection when dis charging the refrigerant 2 Verify that the refrigerant...

Page 759: ...pressure sides are still too high replace the receiver drier Low pressure side 76 cmHg 3 0 inHg Vacuum High pressure side Below 589 kPa 6 kg cm2 85 psi Condition Refrigerant flow obstructed by moistur...

Page 760: ...either is found refer to Excessive refrigerant or insuffi cient condenser cooling page U 1S 3 If either is found replace the expansion valve Refer to page U 33 Case 7 Faulty compressor Measured pressu...

Page 761: ...ge U 20 Resistor assembly Heater core Inspection page U 22 Inspection page U 20 3 Heater control switch assembly 2 Blower unit Removal Installation page U 23 Removal Installation page U 21 Disassembly...

Page 762: ...nstallation 1 Remove the dashpanel Refer to Section S 2 Remove the heater unit as shown in the figure 3 Install the heater unit in the reverse order of removal 4 Install the dashpanel 1 Heater hose 2...

Page 763: ...e figure 1 Heater core 2 Temperature blend door U 20 3 Airflow mode door Inspection Heater core 1 Check the heater core fins for blockage 2 If the fins are clogged clean them 05UOUX 034 3 Check the fi...

Page 764: ...moval Installation 1 Remove the glove box HEATER 2 Remove the blower unit as shown in the figure 3 Install the blower unit in the reverse order of removal 4 Install the glove box 1 Blower unit u CD 05...

Page 765: ...37 1 Verify that the blower motor runs when connecting 12V to terminal a and grounding terminal b 2 If the blower motor does not run replace it Resistor assembly 1 Check for continuity between termina...

Page 766: ...all as shown in the fi gure 1 Center console 2 Vent outlet Installation note HEATER u CD 05UOUX 040 3 Switch panel 4 Rec Fresh wire When installing the heater control switch assembly adjust the airflo...

Page 767: ...sassemble and assemble as shown in the figure 05UOUX 041 1 Ree Fresh wire 6 Temperature blend lever 2 Airflow mode wire 7 Blower and Ale switch 3 Temperature blend wire 8 Panel 4 Rec Fresh lever 9 Swi...

Page 768: ...right Caution After installation move the temperature blend le ver to be sure the wire is securely attached and that it moves the full stroke from HOT to COLD Airflow mode wire 1 Set the airflow mode...

Page 769: ...t Removal Installation page U 32 Disassembly Assembly page U 33 2 Compressor Removal Installation page U 40 U 26 05UOUX 045 3 Magnetic clutch Disassembly Assembly page U 41 4 Condenser Removal Install...

Page 770: ...leakage Remember that R 12 upon com ing into contact with the flame produces phosgene a tox ic gas Always provide adequate ventilation Basic Procedure of Refrigerant System Service Refrigerant contai...

Page 771: ...he high pressure manual valve 4 Use a gas leak detector to check the system for leaks If a leak is found repair the faulty component or connection then evacuate the system again Discharging 1 Connect...

Page 772: ...al valves to obtain 760 mmHg 29 9 inHg 7 After the low pressure gauge shows lower than 760 mmHg 29 9 inHg continue evacuating for 20 minutes 8 Close both manual valves and stop the vacuum pump 9 Disco...

Page 773: ...dry bulb thermometer in the center ventilator outlet 6 Place a dry and wet thermometer close to the blower inlet 7 Wait until the air conditioner outlet temperature stabilizes Stabilized condition Blo...

Page 774: ...haded lone Checking refrigerant charge 1 Run the engine at a fast idle 2 Operate the air conditioner at maximum cooling for a few minutes 3 Determine the amount of refrigerant as shown below by ob ser...

Page 775: ...oval note Immediately plug all open fittings to keep moisture out of the system Installation note 05UOUX 053 Position the cooling unit so that its connections match those of the heater unit and the bl...

Page 776: ...cooling unit Refer to page U 32 2 Disassemble the cooling unit Remove the evaporator and expansion valve as an assembly 3 Disconnect the inlet and outlet pipes 4 Remove the capillary tube from the out...

Page 777: ...a b Yes 6 If not as specified replace the thermoswitch Note The thermoswitch contacts will be open if the evaporator temperature is below ooe 32 F Inspection Thermo5witch 1 Immerse the sensing bulb i...

Page 778: ...ir guide and splash shield 7 Charge the refrigerant system Refer to page U 29 05UOUX 061 1 Condenser 2 Receiver Drier Removal note Immediately plug any open fittings to keep moisture out of the system...

Page 779: ...If leakage is found at a fitting or the condenser replace parts as necessary 5 Check the condenser for the following and repair or replace as necessary 1 Cracks or damage 2 Bent fins 3 Distorted or d...

Page 780: ...Refer to page U 28 2 Replace the faulty pipe or hose Note Immediately plug any open fittings to keep moisture out of the system Tightening torque fittings Location Tightening torque CD 9 8 20 Nm 1 0 2...

Page 781: ...oling fan connector 3 Remove the bolts and cooling fan 4 Remove the condenser fan as shown in the figure S Install the condenser fan in the reverse order of removal 1 Cooling fan J 05UOUX 067 U 38 05U...

Page 782: ...als c e 1 1 Of I O 0 0 Indicates continuity 6 If not as specified replace the relay REFRIGERANT PRESSURE SWITCH Inspection 1 Turn the ignition switch OFF f 0 2 Connect the manifold gauge set and measu...

Page 783: ...6 Install the air guide and splash shield 7 Charge the refrigerant system Refer to page U 29 1 Suction hose 3 Compressor 2 Discharge hose Removal note Immediately plug any open fittings to keep moistu...

Page 784: ...ssembly I Assembly Magnetic clutch 1 Hold the clutch with the SST and remove the shaft nut 2 Remove the pressure plate with the SST 3 Remove the shims 4 Remove the snap ring 5 Remove the rotor by tapp...

Page 785: ...stator 8 Assemble in the reverse order of disassembly referring to Assembly note Assembly note Adjust the clearance between the pressure plate and the rotor after referring to the table and selecting...

Page 786: ...19 ft Ib Specification New Used Tension 491 589 N 422 491 N 50 60 kg 110 132 Ib 43 50 kg 95 110 Ib Deflection 8 0 9 0mm 9 0 10 0mm when applying moderate 0 31 0 35 in 0 35 0 39 in pressure 98 N 10 kg...

Page 787: ...6 ENGINE ELECTRICAL SySTEM TO 7 CLUTCH TO 7 MANUAL TRANSMiSSiON TO 8 PROPELLER SHAFT TO 8 FRONT AND REAR AXLES TO 9 STEERING SySTEM TO 9 BRAKING SySTEM TD 9 WHEELS ANO TIRES TO 10 SUSPENSION I I TO 10...

Page 788: ...clearance mm in IN 0 Maintenance free EX 0 Maintenance free Cylinder head Height mm in 133 8 134 0 5 268 5 276 Distortion mm in 0 15 0 006 max Grinding mm in 0 20 0 008 max Cylinder head to HLA cleara...

Page 789: ...dard size 78 006 78 013 3 0711 3 0714 mm in 0 25 0 010 oversize 78 256 78 263 3 0809 3 0812 0 50 0 020 oversize 78 506 78 513 3 0908 3 0911 Cylinder bore taper and out of round mm in 0 019 0 0007 max...

Page 790: ...undersize Minimum 44 658 1 7582 mm in 0 50 0 020 Standard 44 440 44 456 1 7496 1 7502 undersize Minimum 44 408 1 7483 0 75 0 030 Standard 44 190 44 206 1 7398 1 7404 undersize Minimum 44 158 1 7385 C...

Page 791: ...86 F SAE 10W 30 Above 25 C 13 F SAE 10W 40 or 1OW 50 Below OOC 32 F SAE 5W 30 Below 20 C 4 F SAE 5W 20 E COOLING SYSTEM Item Engine B6DOHC Cooling method Water cooled forced circulation Water pump Ty...

Page 792: ...pump Type Impeller in tank Output pressure kPa kg cm2 psi 441 589 4 5 6 0 64 85 Fuel filter Type Low pressure side Nylon element High pressure side Paper element Pressure regulator Type Diaphragm Reg...

Page 793: ...11 5 0 45 Type Electronic spark advance ESA Ignition system Spark advance control Engine control unit controls sparks advance Ignition timing BTDC 100 10 Test connector grounded Type Molded Ignition...

Page 794: ...verse Clearance between Idle gear reverse idle gear bushing Wear limit 0 15 0 006 and shaft mm in Clearance between shift fork and clutch sleeve Wear limit 0 5 0 020 Shift fork mm in and rod Clearance...

Page 795: ...2 5 913 2028 mm in Viscous L S D Viscous Limited Slip Differential N STEERING SYSTEM Type Manual steering J Power steering Item Steering wheel Outer diameter mm in 370 14 6 Free play mm in 0 30 0 1 18...

Page 796: ...force at 0 mmHg 0 inHg min kPa kg cm2 psi N kg Ib 5 199 5 494 53 56 754 796 196 20 44 at 500 mmHg 19 7 inHg min Rear wheel Type PBV hydraulic Bend portion Rear brake pressure 2 943 30 427 control sys...

Page 797: ...l Camber angle 0 43 30 1 Fuel tank full radiator coolant and engine oil at specified level and spare tire jack and tools in designated position 2 Difference between left and right must not exceed 10...

Page 798: ...5 0 7 2 7 8 11 8 0 8 1 2 5 8 8 8 8 0 315 1 25 0 049 9 8 14 7 1 0 1 5 7 2 10 8 16 23 1 6 2 3 12 17 18 26 1 8 2 7 13 20 10 0 394 1 25 0 049 20 28 2 0 2 9 14 21 31 46 3 2 4 7 23 34 36 54 3 7 5 5 27 40 12...

Page 799: ...I I I I I I I I I I I I I I I ST 3 CLUTCH AND MANUAL TRANSMISSION ST 4 DIFFERENTIAL I I I I I I I I I I I I I I I I I I I I ST 5 FRONT AND REAR AXLES ST 6 STEERING SySTEM ST 6 BRAKING SySTEM ST 7 FRON...

Page 800: ...isable that all service shops have these tools B Selective The tools ranked 8 are not as necessary as tools ranked A but all service shops should have them to per form repairs more easily and effiCien...

Page 801: ...E301 060 J Brake ring gear A 49 L010 1AO u f1 Hanger set A t engine stand 49 0636 100A Arm valve spring A lifter 49 B012 006 Pivot A valve spring lifter 49 8011 102 Lock tool A crankshaft 49 B012 005...

Page 802: ...5C Puller set bearing 49H017101 Hook 49 0180 321A Installer main drive gear bearing ST 4 PRIORITY A A A A A A A ILLUSTRATION OJ k TOOL NUMBER DESCRIPTION 49 1285 071 Puller bearing 49 0187 451A Guide...

Page 803: ...Installer rubber A Attachment A bushing 62 NEW SST 49 M005 561 49 H033 101 9 Hanger A Remover bearing A differential carrier 49 H027 002 49 F401 331 Remover A Body A bearing 49 8531 565 C 49 F401 336...

Page 804: ...Puller ball joint B 49 1243 785 Installer dust A boot 49 B032 302 Adapter power A steering gauge 8T 6 SPECIAL TOOLS ILLUSTRATION TOOL NUMBER PRIORITY ILLUSTRATION DESCRIPTION 49 G030 727 Attachment A...

Page 805: ...9 F043 001 Adjust gauge A 49 0208 701A Air out tool boot A FRONT AND REAR SUSPENSIONS TOOL NUMBER PRIORITY DESCRIPTION 49 G034 1AO Compressor coil B spring 49 0180 510B Attachment B preload measuring...

Page 806: ...gine Signal Monitor NEW SST 49 H018 9A1 Self Diagnosis Checker 49 9200 020 Tension gauge V ribbed belt 49 9200 162 Engine Signal Monitor ST 8 PRIORITY ILLUSTRATION A A A A A 8 A TOOL NUMBER DESCRIPTIO...

Page 807: ...CALIPER REAR P 25 CATALYTIC CONVERTER F 122 CHARCOAL CAN ISTER F 120 CIRCUIT OPENING RELAy F 110 CLOCK SPRING CONNECTOR T 130 152 159 WINDOW REGULATOR S 9 DOOR MIRROR S 30 DOOR SPEAKERS T 127 128 DOOR...

Page 808: ...1 FRONT COMBINATION LIGHT S 24 IGNITION SWITCH T 21 FRONT FASCiA S 24 INJECTOR F 112 FRONT SIDE MARKER LIGHT S 24 INSTRUMENT CLUSTER METER T 26 FRONT SUSPENSiON R 11 FUEL GAUGE T 35 CROSSMEMBER R 20 F...

Page 809: ...YTIME RUNNING LIGHTS DRL UNIT T 18 HEADLIGHT RETRACTOR RELAY T 16 57 TIMER AND BUZZER UNIT T 17 TURN AND HAZARD WARNING FLASHER UNIT T 16 p RELEASE BEARING H 15 17 RELEASE FORK H 15 PANEL LAMP CONTROL...

Page 810: ...D S 16 TRUNK LID LOCK ASSEMBLy S 18 WIRE HARNESS S 16 TWO WAY CHECK VALVE F 119 w WARNING LAMP AND SENDER UNIT T 38 BACK UP LIGHTS T 71 BRAKE FLUID LEVEL SENSOR T 43 DAYTIME RUNNING LIGHTS DRL T 78 HE...

Page 811: ......

Page 812: ......

Page 813: ......

Page 814: ......

Page 815: ......

Page 816: ......

Page 817: ......

Page 818: ......

Page 819: ......

Page 820: ......

Page 821: ......

Page 822: ......

Page 823: ......

Page 824: ......

Page 825: ......

Page 826: ......

Page 827: ......

Page 828: ......

Page 829: ......

Page 830: ......

Page 831: ......

Page 832: ......

Page 833: ......

Page 834: ......

Page 835: ......

Page 836: ......

Page 837: ......

Page 838: ......

Page 839: ......

Page 840: ......

Page 841: ......

Page 842: ......

Page 843: ......

Page 844: ......

Page 845: ......

Page 846: ......

Page 847: ......

Page 848: ......

Page 849: ......

Page 850: ......

Page 851: ......

Page 852: ......

Page 853: ......

Page 854: ......

Page 855: ......

Page 856: ......

Page 857: ......

Page 858: ......

Page 859: ......

Page 860: ......

Page 861: ......

Page 862: ......

Page 863: ......

Page 864: ......

Page 865: ......

Page 866: ......

Page 867: ......

Page 868: ......

Page 869: ......

Page 870: ......

Page 871: ......

Page 872: ......

Page 873: ......

Page 874: ......

Page 875: ......

Page 876: ......

Page 877: ......

Page 878: ......

Page 879: ......

Page 880: ......

Page 881: ......

Page 882: ......

Page 883: ......

Page 884: ......

Page 885: ......

Page 886: ......

Page 887: ......

Page 888: ......

Page 889: ......

Page 890: ......

Page 891: ......

Page 892: ......

Page 893: ......

Page 894: ......

Page 895: ......

Page 896: ......

Page 897: ...7 LAYOUT OF CONTENTS The followi q is d tYPlca I ltilmplf of the layout of r onUH1t J r Ilda microfiche parts caTd D Layout of contents Sl rlion o Inul t lI thp COIUI1HI 2 Alphal t lltdl 111 11 Pictor...

Page 898: ...1 1 _ _ _ _ _ _ _ _ _ im1950 IS 1940 Ii 1930 LO R VatSf PtSTOd UTOMATlC CLUTCH PLAH TAAY GEARS AUTOMAT1C kJbt to modIIr eome cIfIINnI In IC eCIll ef l l t from Dell 1ItI In INtI fWI lI r lIin 1 l C 1...

Page 899: ...m 1840 STARTE R AL TERNATOR OJ PICTORIAL INDEX 61310 1 1320 EXHAUST MANIFOLD rUEL SV oTHl FUEL DISTRIBUTOR ENGINE 2 2 o ENGINE ELECTRICAL SYSTEM AIR CLr ANER URAe T r 1I L l IH L 1 II 1364 THROTTLE BO...

Page 900: ...SPENSION MECHANISMS As 1hit 1 1 prepared 10 tit 10 t J tome Pllts dllfec N I In q ectf0Clti0ns flom 1M part5 Iistf 1 In thIs parts C 109 PICTORIAL IND X 2600 II 2610 19 2710 REAR AXLE nEAR DRAKE MECHA...

Page 901: ...ERS CLUTCH PIPINGS _________________ M A NU A L T R A N SM I S Sr O N L MANUAL TRANS_MISSION ACCELERATOR __ ______ CO N T RO L SY S T Mi ____ FUEL TANI CHASSIS 2 2 CLUTCH BRAKE PEDALS 9 4340 D BRAKE M...

Page 902: ...5105 v s rs HEAD LA HEAD LAMP RETRACTORS FRONT OMBINATlm4 LAM REAR COMBINATION LAMPS m l 6720 m6730 65120 WIRING HARNESS CLAMPS WINDSHIELD WASHER WINDSHIELD WIPERS LICENSE LAMPS IE 6703 BODY 1 4 m 1m...

Page 903: ...PANELS Al oIus tallOn ptepInd 10be I0 omc IS I spooK I o ftQm p u Ii t in I S PI CalalOg PICTORIAL INDEX 1 5010 115030 WINDOW GLASSES SUNROOF ACCESSORIES BODY 2 4 5180 RONNET 1m 5260 TRUNK LID 111534...

Page 904: ...8 OIl til r tH nc tff tTl If 1 I t hSled In Ihl 11_11 I lkHI II 5530 METER CdMPONENTg BODY 3 4 II o I 0 6 m m i 1 L lSI 5560 DASHBOARD AHAleO PARTS 1m 6611 j v COM81NATION SWIT ti iii 5570 CONSOLE D...

Page 905: ...n 6900 d fiIP VISORS ASSIST HANDLES MIRRORS PJ CTORIAL INDEX lEI 5790 BODY 4 4 _ d If m il rn 68 70 II 6680 AUDIO SYSTEMS RADIO TAPE DECK IE m6 82 tf AUDIO SYSTEMS I ANTENNA SPEAKER 6 6684 wf AIJIJIO...

Page 906: ...OCI OIL PAN TIMING COVER PISTON CRANKSHAFT FLYWHEEL VALVE SYSTEM INLET MANIFIJLC EXHAUST MANIFOLD FUEL SYSTEM FUEL DISTRIBUTOR AIR CLEANER THRI TTLE BODY EMISSION CONTROL SYSTEM INLET SIDE CAP HOSE CL...

Page 907: ...L I LI2 3210 STEERING COLUMN SHAFTS I MI2 3220 STEERING GEAR W O POWER STEERING l C13 3220 A STEERING GEAR W POWER STEERING I F13 3240 POWER STEERING SYSTEM I HI 330J FRONT AXLE 1 113 3310 FRONT BRAKE...

Page 908: ...F14 2 G14 2 H14 eODY PANELS DASH COWL PANEL 2 114 6630 6635 6640 6680 BODY PANELS SIDE BODv PANELS FLOOR FLOOR ATTACHMENTS HOLE COVERS FLOO ATTAC MENTS DASHBOARD EQUIPMENTS METER HOOD SPEEDOMETER CAB...

Page 909: ...KD7 1920 1 E08 1925 1 108 1910 1 009 1940 I G09 1950 1 109 1 0 THROiTLE BODV EMISSION CONTROL SVSTUM INLET SIDE CAP HOSE CLIP INLET EXHAU ST SIDE OIL PUMP FILTER COOLING SYSTEM BRACKET PULLEY BELT CL...

Page 910: ...I 20 GASKET ATER PUMP I 21 GASKET PUUP INLETH C I 22 RING 0 ATER BY PASS I 17 I I 201 j AUtlAOI I SEAL VALVE C S 2 GASKET_HEAD COVER I 3 GASKET CVLINDER HEAD II 4 GASKET IN UANIFOLD I S GASKET EX UAN...

Page 911: ...135 I BOL rI CYLINDER HEAD 8660 10 135A 10 10 138 I WASHER PLAIN CYL HE _ _ _ AD B630 10 138A 10 I 10 142 I STUD EX MANIFOLD B660 10 104A 9 _ I lO 22X I PLATE OIL BAFFLE IN SIDE B61P 10 2 ZX 1 _ _ I...

Page 912: ...1 I 10 271 I OASKET CYLlNOER HEAD B6F4 10 271A NON ASBESTOS 1 I 10 561 I HANOER ENGINE B660 10 561 2 9801 B660 1O 561 1 9B01 LllJ 110 138 I I 10 561B HANGER ENGINE REAR I B61P I0 565 1 9B01 I 10 9458...

Page 913: ...CTION FROM TO 13 740 HOSE VENT PUROE CON T V B61P 13 74DA 1 13 742B HOSE VENTILATION B61P U 742A 1 _ I 13 743 I HOSE ENtlLATlON 861P U 743A 1 13 890 VALVE P C V 8P05 U a90 1 13 8958 HOSE P C V 861P 13...

Page 914: ...I 10 3nSA PLUG 8366 1 305 1 9330 10 306 I PIN TUBULAR 8630 10 306 2 10 316 PLUG OIL CONTROL B630 10 305 1 9330 10 319 JOINT B630 10 319 1 10 3 5 I PIPE OIt LEVEL GAUGE B61P 10 440 1 I 10 327 I PLUG 8...

Page 915: ...L RESTRICTION HODEL RESTRICTION HODEL RESTRICTION nOH TO F O 450J _ I lO 730A I VALVE OIL JET SE01 10 730 4 _ I 15 612 I PLUG 99940 0600 SE01 15 612 1 18 291B CLAMP HOSE R230 15 538 1 110 325 I IIO 4...

Page 916: ...0C 1 0201 I 10 404 I PLUG DRAIN 86S7 10 404 1 0201 B6S7 10 404A B6S7 1O 404A 1 0201 I 10M 406A I PLATE OIL BAFFLE CYl ___M _____ BlK B61P I0 40YA 1 I 10 426 I BOLT B6S7 1O 465 2 I 10 427 I GASKET OIL...

Page 917: ...5218 1 9626 10 522 OASKET T BELT COVER C 8660 10 522 NON AS8ESTOS 1 ID 5liD I PLATE SEAL T BELT CO 0 _ _ _ _ _ _ VER U B61P 10 rI40B 1 10 544 RueaER SEAL S AL PLA TE 861P I0 544 1 _ 10 602A SEAL OlL F...

Page 918: ...30 11 317A 8630 11 317A 1 KE 1 1 I 11 321 I PU 8366 11 321A 1 _ I 11 371 I PU 86S7 1 401A 1 __ _ I 11 376 I 80 0631 11 405 4 Y WOODRUFF PULLEY LlEY TIMING 8ELT LLEY CRANKSHAFT LT PULLEY I 11 404 I PLA...

Page 919: ...11 SEO STD 1 B6Yl U SFX O S 0 50 1 B6Yl ll SFY O S 0 7S 1 86Yl 11 SFO O S 0 25 1 I 23 130 I RINJ SET PISTON _ 86Y3 11 SCO STD 1 AT B6Y3 11 SDX O S 0 50 1 AT 86Y3 11 SDO O S 0 25 1 AT B6 4 11 CO l jD...

Page 920: ...BXC 4 B6Z2 11 SBOB O S 0 25 A tB6Z2 11 SBOC 4 B6ZZ 11 SADC 5TD 4 MT 86Z2 11 S8XC 0 5 0 50 4 MT B6Z2 11 SBDC 0 5 0 25 4 eMT I 23 201 I METAL SET THRUST B6YD ll SJ0 STD A B6Yl 11 SJO 1 86YO ll SKX O S 0...

Page 921: ...111 I VALVE INLET 8657 12 111 8 I 12 112A I SEAT VALVE SPG UP 8J01 12 113 8 8660 12 113 8 I 12 11 I COTTER VALVE B660 12 114 32 I I 12 114A I SPRING QUT VALVE 861P 12 125 8 I 12 1148 I SPRING VALVE B...

Page 922: ...I COS 1500 I GOS 1580 l C06 1600 1 006 1700 1 E06 1710 IhJ06 J 720 I MO 1800 I C07 1830 l E07 1840 I G07 1850 1 H07 1910 I KD7 1920 I Eoe 1925 1 108 1930 1 009 1940 I G09 1950 I T09 19 0 SIDE CAP HOSE...

Page 923: ...141 e 112 112AI f __ 114BI e 10 155 jJ 116AI 1 12 1111 I I I I tOTY PART NO HODEL UESTRI T ON CONT D 861P 12 440 1 Mf I 12 700 TENSIONER T BELT B660 U 700C 1 _ I 12 711 I SPRlNO TENSlONER B660 12 711C...

Page 924: ...DEL RESTRICT1ON MODEL RESTRICTION FROH TO _ _ I 13 100 I MANIFOLD INLET B61P U lOOe A 861P 13 100C 1 9 17 861P 13 100C AN 861P 13 1000 1 9417 0404 861P 13 100D 1 06 04 _ I 13 111 I GASKET IN MANIFOLO...

Page 925: ...61P 13 450A 861 U 45OA 1 9714 I 13 456 I STUD 2306 1 456 I 13 461 I NUT EX MANIFOLD 8657 13 465 9 _ _ I 13 462 I GASKET EX MANIFOLD 8695 13 460 NON ASBESTOS A B695 13 460A I 9801 8695 l3 46DA NON ASBE...

Page 926: ...M PART HO loTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO I 13 ZEO I PUMP FUEL 861P U ZEO 1 _ I 13 ZEl I FILTER FUEL PUMP 861P U ZEl 1 13 ZE4 I WASHER LOCK PUMP FIL _ _ TER FEH2 13...

Page 927: ...13 145FJ 1320 2 FUEL SYSTEM i PART NO IOTY HODEL RESTRICTION 13 973 I HOSE DRAIN _ _ 861P U 97YA 1 1l 973A I HOSE EVAPORATION 861P 13 971A 1 20 l61A TUBE VACUUM 861P 20 361 1 66 773A GASKET NAOl 60 96...

Page 928: ...ICTION HODEL RESTRICTION FROM TO ____1_ _ _ _ _ I 13 150 I DISTRI8UTOR FUEL _ 861P 13 l50 1 I 13 158 I INSULATOR FUEL DIST B675 13 158 2 I 13 164 I BOLT FUEL DISTRIBUTO R F8e3 13 164 2 I 13 250A I INJ...

Page 929: ...206A 1 I 13 210A I METER AIR FLOW 86S7 13 210A 1 _ _ I 13 211 I GASKET B6S7 13 2UA NON ASBESTOS 1 ___00 _ _ _ _ _ I 13 221A I HOSE AIR B61P 13 221B 1 I I 13 225 I DUCT FRESH AIR 861P 13 200A 1 9926 A...

Page 930: ...329 3 I 13 345B I BRACKET AIR CLEANER 861P 20 211 1 I 13 3482 I SPACER AIR INT PIPE V1l5 13 348 1 SLAl 13 321 1 I 13 3492 I INSULATOR S501 13 349 1 I 13 363N I RUBBER MOUNTING FE51 13 363 3 I 13 765A...

Page 931: ...JUS _ _ T THR eS51 13 W75A 1 _ _ I 13 W8X I SCREW a W SHER SET 8551 13 W8X 1 _ I 13 W80 I 8RACKET SET DASH poor THRO 861p u wao 1 I 13 W89 I GAS ET THERMO 8551 13 wa9 1 13 104H I CAP BLIND 8551 U 104...

Page 932: ...IDE PAR T NO Ion HOD L RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROM TO _ _ _ I 13 ZC7 I RING O AIR VALVE _ _ 86S7 13 ZC7 1 I 13 190A I U l VE AIR 861P 13 190A 1 C I i R64J 13 190 1 CAT _ _ I 1...

Page 933: ...225 I ClAMP HOSE E5Al 13 225 1 1l3 157A B61P ll 73S 1 13 447C I CLAMP HOSE 3 157AI El B6l P 13 447 2 113 157AI I I 13 736A I CLAMP HOSE A I P A CLNR I 8630 13 736 1 REFER TO SECT NO 1370 A r 115 538 I...

Page 934: ...14 100 I PlIMP on 86 14 100E 1 _ t 14 113 GASKET OIL PL MP B63O 14 113 ASBESTOS 1 __ _ _ _ I 14 115 PLUNGER CONTROL 0221 14 115 1 I 14 116 I SPRING PRESSURE I 0324 14 116A 1 I 14 118 I SHEET SPRING 02...

Page 935: ...SION CONTROL SYSTEM INLET SIDE CAP HOSE CLIP INLET EXHAU ST SIDE OIL PUMP FILTER I COS 1500 COOLING SYSTEM I GaS 1580 BRACKET PULLEV BELT l C06 1600 CLUTCH DISC COVER ANUAL 1 006 1700 TMANSHISSION CAS...

Page 936: ...B61P 15 261A 1 I 15 106A I RING O WATER PUMP B61 15 106 1 I 15 116 I GASKET WATER PUMP _ B621 15 116A NON ASCtESTOS 1 I 15 131 I PULLEY WATER PUMP 8366 15 131 AN 8366 15 I31A 1 9901 B366 15 131A 1 990...

Page 937: ...cr VER B621 15 173 NON ASBESTOS 2 I 15 176B I CASE THERMOSTAT B 1P 15 176A 1 9401 A B61P 15 176B B61P 1S 176B 1 9401 I 15 179 DUTLET WATER B61P 15 179 1 9415 A B61P 15 179A 861P 15 179A 1 9415 15 184...

Page 938: ...15 287 1 I 15 290 I PIPE BY PASS B61P 15 290 1 9AOl ANCB61P 15 290A B61P 15 290A 1 9AOI 0301 AN B61P 15 29DB B61P 15 290B 1 O Ol I 15 350 I TANK SUB RADIATOR B61P 15 350A 1 9419 A B61P 15 350B B61P 1...

Page 939: ...87 ls al011 2I 1500 4 M COOLING SYSTEM PART NO IOTY HODEL RESTRlCTlON HODEL RESTRICTION HODEL RESYRICTION FROH TO I 15 538 I CLAMP WATER HOSE JF02 15 538 2 I 93 2401 I HOSE WATER 99324 07630 1 9419 99...

Page 940: ...26 861P l 5 907A L SSS 4PK RIB BELT 1 WI P S 9626 I 15 907 I BEL T V 86lH 1 5 909 L S55 4PK RIB V 1 I 15 920 I BRACKET COMPRESSOR B61P 15 IIOA CA 1 I 15 930 I BRACKET lDLE PULLEY BP01 15 951 A 1 I 15...

Page 941: ...TER V BEL T REFER TO SECT NO 1800 ALTERNATOR f DRIVE _ IDLE PULLEY AUlAe 1580 2 IRACKET PULLEY IELT PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO CONT D F201 11 363 1 WI P...

Page 942: ...PAN TIMING COVER PISTON CRANKSHAFT FLYWHEEL VALVE SYSTEM INLEl MANIFOLD EXHAUST MANIFOLD FUEL SYSTEM FUEL DISTRIBUTOR AIR CLEANER THROTTLE BODY EMISSION CONTROL SYSTEM INLET SIDE CAP H03E CLIP INLET E...

Page 943: ...REL FORK 0603 16 1028 1 I 16 214 I COVER DUST CLUTCH fO RK FE86 16 214 1 I 16 220 I COVE FRONT CLUTCH B622 16 220 1 I 16 225 I GASKET FRONT COVER FE50 16 225A 1 I 16 32A I SUPPORnR FDRK 1416 16 232A...

Page 944: ...0 I CASE T lMISSION M526 17 100 1 I 17 122 I PLUG MAGNET 0810 17 121 1 I 17 325 I COVER BEARING 8086 17 326 1 I 17 330 I HOUSING EXTENSION M5Yl 17 330 1 I 17 335 SEAL OIL 1 M i07 17 335 1 I 17 441 I G...

Page 945: ...L 2DS I R50Z 17 io6A BEARING ROLLER 1 17 20SF I RING RETAINING M501 17 20 1 I 17 221 I SHAFT MAIN M505 17 2218 1 I 17 225 I RING SNAP 031 17 225 1 L 30 I M513 17 iii GEAR 3RD 1 I 17 Z40 j Ms z i Z40e...

Page 946: ...17 261 1 I 17 262 I SLEEVE CLUTCH HUB MS03 17 262 1 I 17 264 I SPRING SYNCHRO KEY 0401 17 264 2 I 17 264A I SPRING SYNCRONIZER F401 17 264A 2 I 17 265 I RING SYNCHRONIZER G501 17 265A 2 M502 17 265A...

Page 947: ...259 17 279 17 28i HODEL RESTRICTION AM oi i728i 1 281A M50Q a 281A 1 I 17 i 87j _ _ SHI 99963 6iio M ADJUST 99963 6315 99963 6330 17 30i j M A 512 17 30 M512 17 302A M512 17 302A I 17 3ii M504 17 io L...

Page 948: ...I GEAR REVERSE IDLE M509 17 310 1 9801 A M509 17 310A M509 17 310A 1 Q Ol I 11 313 I WASHER THRUST REVERS E IDLE G M501 17 313 1 I 17 313B I WASHER THRUST 4077 17 314A Ta2 8fIfIt 1 4071 17 U5A T 3fIt...

Page 949: ...629 I NUT LOCK CLUTCH HUB 8601 17 629 1 I 17 631 I ASHER THRUST LOCK O VER TOP G 0884 17 6328 T 6 2f IIt 1 0 84 17 6338 T 6 4f0f4 1 0884 17 6348 T 6 Sf IIII 1 OaS4 U 6358 T 6 1 I 17 651 I WASHER THRU...

Page 950: ...17 351 2 I 17 402 I FORK SHIFTC1ST 2NO M503 11 402 1 I 17 404 I FORK SHIFT 3RO 4TH 501 17 4048 1 I I 17 406 I FORK SHIFT M504 17 406A 1 I 17 410 I ROO SHIFT 1STI2NO M503 17 411 1 I 17 410A I END S ROD...

Page 951: ...4328 I END SHIFT ROD O Topa REV M508 17 432 1 I 17 435E I RING RETAINING R502 17 435 3 I 17 461A I END CONTROL LEVER M508 17 461 1 I 17 461B I ROD CONTROL M516 17 450 1 I 17 462 I SHEET SPRING 0398 17...

Page 952: ...YSTeM MANUAL PART NO IOTY HODEL RESTRICTION HODEL RES TRIC TiON HODEL RESTRICTION FROH TO I 17 482 I WASHER WAVE CHANGE C ONT CASE M505 17 482 1 I 17 486A I COVER BLIND RSOl 17 47X 1 I 17 490A I COVER...

Page 953: ...15 966 1 I 18 10X I Call IGtUTER B61P 18 10XB 1 J521 AN B61P 15 10XC B61P 18 10XC 1 0521 I 18 110 I PLUG SPARK 8P01 18 1l0 BKRSEll NGK OPTION HOT TYPE 8P02 18 110 K16PR Ul1 DENSO 4 OPTION HOT TYPE BP...

Page 954: ...18 266A 061R US 266A 1 I 18 361 I STRAP ALTERNATOR B61P 18 360 1 A 661P 18 360A B61P 8 360A 1 I 18 363 I SPACER STRAP F201 18 363 1 _ I 18 3111 I BELT V _ B6S7 18 381A AUTO FLEX 3 A l4 7 A B6S7 18 38...

Page 955: ...DeR BLOCK OIL PAN TIMING COVER ISTON CRANKSHAFT FLYWHEEL VALVE SVSTEM INLET MANIFOLD EXHAUST MANIFOLD FUEL SYSTEM FUEL DISTRIBUlOR AIR CLEANER THROTTLE BODY EMISSION CONTROL SYSTEM INLET SIDE CAP HOSE...

Page 956: ...OVER REAR ALTERNATO R B366 18 W51 1 I 18 W59 I PLUG B675 18 WS9 1 4 533 I 12 1 118 i59 I 18 300 I ALTERNATOR 861P 16 300D 1 eMT B64J 18 300A 1 AT _ 24 501 STATOR 8366 18 W45 1 AT G608 1S W45 1 eMT I 2...

Page 957: ...24 526 I SCREW SET RF71 U W26 1 I 24 530 I PULLEY B366 18 W10 1 I 24 533 I NUT SET ot 8028 24 533 1 _ I 24 535 I SCREW SET RF71 18 W20 1 f 24 540 I ROTOR B61P ll W35 1 MT B366 18 W35 1 0601 A B366 1S...

Page 958: ...24 712 I STOPPER SET E356 18 X30 1 I 24 720 I ARMATURE F2lO la X60 ASBESTOS 1 B6S8 18 X60 NON ASBESTOS 1 I 24 722 I CLUTCH OVER RUNNING B630 18 X45 1 I 24 7222 I SLEEVE BEARING REAR E3S6 18 X81 1 I 2...

Page 959: ...TARTER PART NO Jon HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO I 24 7432 SLEEVE BEARINO FRONT F210 11 01 1 I 24 750 I HOLOER BRUSH 861R l 70 1 I 24 752 I SPRINO BRUSH 0222 24 752A 4...

Page 960: ...1R 1I 520B S46A24L S PANASONIC 1 0201 I 18 526 I CONNECTOR TUBE BATTE RY B61P 18 526 1 I 20 346 I TUBE VACUUM FE4J 20 l46 1 9901 861P 18 524 1 9901 I 56 030 CLAMP BATTERY NAOl 56 03XA 1 I 56 03 I BRAC...

Page 961: ...10 353 6 19 020 PLATE DRIVE 8U5S 19 020 1 19 025A I ADAPTER DRIVE PLATE FU60 19 025 1 19 063 PLATE BACKING FT31 19 063 1 19 065 NUT _ _ FU51 19 0 5 4 19 068 BOLT LOCK FT31 19 064 6 I 19 090A I T MISS...

Page 962: ...S 1 19 223A SEAL OIL O S S8 9 223A 1 I 19 240 COVER OIL P LiU55 19 240 1 I 19 255 I BOLT 03 S8 19 255 5 I 19 258 I SEAL CUT RING 0338 19 258 1 I 19 618 SHAFT INPUT 9U55 21 678 1 I 19 904 I HOSE VACUU...

Page 963: ...5 UI 660 w 8UI7 ZI 1186 992C7 160l1t AUIiAot 1 J I 1910 3 M TORQUE CONVERTER OIL PUMP PIPINGS AUTOMATIC PART NO lory HODrL eSTRICTION HODEL RESTRICTlON HODEL RESTRICTION FROH TO CONT D BU55 19 934A 1...

Page 964: ...E LIRE TRIC T1 0N I 10 460J I RING O 99541 01201 1 I 17 335 I SEAL OIL M507 17 335 1 I 17 441 I BI I55 17 441 GEAR DRIVEN 1 I 17 442 I SLEEVE SPEEDGMETER BU55 17 442 1 I 17 442J I lNG O 1011 17 443 1...

Page 965: ...TEM 1 121 212 1 I 19 381 I BU06 19 381 BV03 1Q 381 I 19 384A I PISTON 8AND ERVO I 1 I 1 I SEAL PISTON BU11J 19 384 BU5S 19 384 1 I 1 I I I I 19 385 I SEtlL I PISTON FT03 19 385 0 441 1 1 I 1 I 0842 19...

Page 966: ...19 39 RING O 0338 9 395 1 19 396A GASKET 1758 19 394A ASBESTOS 1 I 19 397 BOLT 1758 19 397 3 I 19 398 I BOLT 0338 19 398 3 I I 1 700 I HOUSING EXTENSION I BUYi2 19 7AO 1 19 710 HOUSING EXTENSION I BU5...

Page 967: ...2 I 19 833 I BOLT CONTROL VALVE O s8 19 8 s3 5 IGASKET OIL PAN I 19 8 5 I 0338 19 835B ASBESTOS 1 I 19 836 I PAN OIL 0338 19 836A 1 _ I 19 8 37 I BOLT QIL PAN O 38 19 837 17 I 19 870A I TUBE FILLER B...

Page 968: ...OCK rL PA TIMING COVE PISTON CRA XSH FT FLYWHEEL VALVE SYSTEM INLET MANIFOLD EXHAUST MANIFOLD FUEL SYSTEM FUEL DISTRIBUTOR AIR CLEANER THROTTLE BODY EMISSION CONTROL SYSTEM INLET SIDE CAP HOSE CLIP IN...

Page 969: ...OH FROI1 iO CONT D BVOl 19 986 1 I 21 182 I BRACKET BU5 i 21 182 1 I 21 212 I RING O BUOl 21 212 2 I 21 250 I SUPPORT DRUM BUSS 21 250 1 I 21 253 I GASKET DRUM SUPPDR r BU01 21 2 53 ASBESTOS 1 I I 21...

Page 970: ...8 J REFER OTE D ITt lid 1 OF AUUOI I I I I I I I 1920 6 M TRANSMISSION CASE MAIN CONTROL SYSTEM AUTOMATIC PART HO OTY HODEL RESTRICTION HOOEL Re TRICTION ODEl RESTRICTION FROtt TO 21 386 I STEM PISTON...

Page 971: ...774 I PLUG REOULATER _ I BU55 19 774 1 I 1q 775 t SlEEVE REGULATt PlU 0 8U55 19 775 1 t 19 777 I VALVE SECONO LOCK 0338 19 777 1 I 19 778 I SPRING SEtaND LOCK 0338 19 718 1 I 19 781 I PLATE SIOE O HSI...

Page 972: ...1A 1 I 19 792 I SPRING MOOIFIER FT37 19 792 1 I 19 793 I PLATE SIOE A 0338 19 793A 1 I 19 795 I VALVE rHROTTLE 0338 19 7958 1 I 19 797 I VALVE THROTTLE BACK _ UP 99222 0314 Q338 19 797 1 I 19 798 I SP...

Page 973: ...PRUNG 0338 19 814 1 I 19 815 I STRAINER OlL BU01 19 815 1 I 19 816 I SCREW 0338 19 816 7 I 19 817 I SCREW 0338 19 817 10 I I 19 818 I BOLT 19 815 0338 19 818 2 I 19 19 I NUT 0338 19 819 2 I 21 681 I V...

Page 974: ...RICTION FROH TO _ I 21 684A I SL EVE 3 4 SHIFT BU3 5 21 684 1 I 21 815 I SPRINB 3 2 TIMINO BUI7 21 815 1 t 19 815 a 19 5A3 D d IMM b mIi 8 1 D 2 0MU c 19 807 d 19 807 Ji1 e 19 8GS 4 77UU L 15 SUU f 19...

Page 975: ...121 567 I 12I _56 5J m s2D q 1_19 62l I 4I II9 639A AUMAOI AUTOMATIC THIS ILlUSTRAT 1 2 ION CONSISTS OF 2 PAGES I I I I I I I I I I I I 1910 I I I I I I I I I I I I I I I I I AlIMAOI CLUTCHES PLANETAR...

Page 976: ...ND BRAKE 0338 19 361 8 2 4 _ I 11 460 I CLUTCH FRONT 8U55 19 460 1 I 19 470 DRUM CLUTCH BU55 19 470 1 _ 19 475 SF AL O RING 0338 19 475 3 19 476 SEAl LATH CUT BVOl 19 476 1 0338 19 476 2 I 19 480 I PI...

Page 977: ...19 03 T 1 3959 19 504 T 5 2 1 3959 19 505 T 5 K1 1 3959 19 506 T 6f t1 2 3959 19 507 Ta5 8fIIIII 2 3959 19 508 T 6 2 3959 19 509 T 6 2f tt 3 I 19 503A I PLATE RETAINING 175 1 503 T 7 2r t1 1 1758 19...

Page 978: ...L RESTRICTION I 19 510 I CLUTCH REAR BV01 19 510 1 _ I 19 511 I DRUM REAR CLUTCH 1758 19 511 1 I 19 530 I HUB REAR CLUTCH BV04 19 530 1 I 19 531 I HUB REAR CLUTCH BVD4 19 153 1 I 19 533 I GEAR INTERNA...

Page 979: ...A O 38 19 623A 0338 19 623A 5 I 19 624 I BEARING NEEDLE _ _ 03 19 624 3 I 19 631 I RACE BRG PUMP COVER 0333 19 631 Tal f t1 1 0338 19 632 Ta l 4frt1 1 0338 19 633 Tal 6frt1 1 03 8 1q 634 T l 8frt1 1...

Page 980: ..._ CLUTCHES PLA ETARY GEARS A PART NO UTOHATlCI C OTY HOOE ONT D RESTRICTI0N wm Y r 0338 19 645 HOOE LlRE TRlCT10N 0338 19 646 __ rH n OE L R E 1 j TrRR IIC T I OIi 1 2 Io 0338 19 647 0338 19 648 BV01...

Page 981: ...IFOLD EXHAUST MANIFOLD FUEL SYSTEM FUS DISTRXBUTOR AIR CLEANER THROTTLE BODV EMISSION CONTROL SYSTEM INLET SIDE CAP HOSE CLIP lNLET EXHAU ST SIDE OIL PUMP FILTE COOLING SYSTEM BRACKET PULLEY BELT CLUT...

Page 982: ...0 6 M CLU fCHES a PLANETARY GEARS PART NO AU1DMATICl CONT O OT HODEL RESTRICTI BU 2__ 1 5 7 _ O N j MO O EL RE S TR I C TI O N f _ 1 OOEl RE lC7 r _ o i 1R CT ON BVOl 21 S3j CLUTCH ONE WAY l 31 BU01 2...

Page 983: ...8 19 337 a I 19 33 I BOLT 0338 19 338 8 I 19 397A I BOLT 0338 19 397 4 I 19 533 I GEAR INTERNAL BV04 19 533 1 I 19 534 I RING SNAP i 0338 19 534 1 I 19 650J I J I 19 580 I FLANGE I I BVOl 19 5KO 1 I 1...

Page 984: ...ON 0338 19 603 1 19 604 I SEAL O RING 0338 19 604 1 19 606 SPRING PISTON 0338 19 606 1 I 19 607 RINO SNAP 0338 19 607 1 I I 19 609 I PLATE DRIVEN 0338 19 609 4 I 19 610 I PI ATE DRIVEN BU17 19 610 4 I...

Page 985: ...BU55 19 650 1 I 19 655 I RING SEAL 0338 19 655 3 _ I 19 660A I VALVE GOVERNOR BU55 19 660 1 I 19 661 I BODY BU55 19 661 1 I 19 663 I VALVE 0338 19 663 1 I 19 664 I SPRING 0338 19 664 1 I 19 665 I VAL...

Page 986: ...ER SELECT BU55 19 031 1 19 431 SHAFT MANUAL BU67 19 431 1 I 19 432 I RING O 0338 19 432 1 I 19 440 PLATE MANUAI BU55 19 440 1 I 19 449 RING SNAP _ _ 0338 19 449 1 I 19 450 I ROD PARKING BU17 19 450 1...

Page 987: ...O 6600 m 431 J 119 432 rF JU CASE T MISSION REFER TO SECT NO 1920 I 1 JI AUItAOl HOUSING EXTENSION REFER TO SECT NO 1920 J 119 440 I v 1950 2 M MANUAL LINKAGE SYSTEM AUTOMATIC PART NO loTY HODEL RESTR...

Page 988: ...ISTON I 14 SEAL O RI NG I AUUOI IS GASKET EXTENSION 16 SEAL O RING 2 17 GASKET Oll PAN I la RING O l 19 GASKET DRUM SUPPORT I 2o SEAl O RING I 21 SEAL O RING I 22e RING O I 2J RING O I 24 RING O 25 GA...

Page 989: ......

Page 990: ......

Page 991: ......

Page 992: ......

Page 993: ......

Page 994: ......

Page 995: ......

Page 996: ......

Page 997: ......

Page 998: ......

Page 999: ......

Page 1000: ......

Page 1001: ......

Page 1002: ...RONT AXLE 1 113 3310 FRONT BRAKE MECHANISMS 1 K13 3400 FRONT SUSPENSION MECHANISMS I Ml3 3401 FRONT SPRING DAMPER 1 NI3 3410 CROSSMEMBER STABILIZER 1 C14 3700 TYRES JACK l C15 3900 ENGINE T MISSION MO...

Page 1003: ...I I REAR DIFFERENTIAL REFER TO SECT NO 2710 1 C1 1 L 2505 1 M EAR PROPELLER SHAFT l RT NO loTV HODEL RESTRICTIOH HODEL RESTRICTION HODEL RESTRICTION FROM TO 5 100A SHAFT PROPELLER M091 5 100 1 25 123...

Page 1004: ...AR DRIVE SHAFT PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO _ I 22 5108 I JOINT SET OUTER 090 22 510 2 _ I 22 S20e I JOINT SETCR lNNER M090 22 520 2 I 22 530 I BOOT SET O...

Page 1005: ...1 9901 I 26 251B I PLATE DISC 56 1030 MNA01 26 251A 2 I 26 261 I COVER DUST NAOl 26 261 2 9901 A CNAOl 26 261A NAOl 26 261A 2 9901 f8 I 33 042 I NUT NAOl 33 042A W wASHER 2 133 047 I I 33 047 I BEARIN...

Page 1006: ...6 668Z I SPRING L LEVER BWOH 26 669 1 i I 26 680 I BOLT BWOH 26 680 2 133 693AJ I 26 683A I PROTECTOR 133 691A BWOH 26 683 2 I 26 700 I PLUG SCREW eWOH 26 700 2 I 26 731 I SPINDLE ADJUSTER BWOH 26 131...

Page 1007: ...Ol 26 980A 1 I 26 980Z I CALIPERCL RR BRAKE NAOl 26 990A 1 I 26 998 I PIN GUIOE BW m 26 998A 2 I 33 691A I SCREW BLEEDER 133 693A1 BWOH 26 691 2 133 691AI I 33 693A I CAP BLEEDER SCREW 0259 33 693 2 I...

Page 1008: ...ET 0810 17 121 1 jellP I 25 421 I FCOl 2S 421A 2 I 26 060 I BREATHER U130 26 060 1 I 27 012 I WASHER 3919 27 012 1 I 27 018 I SEAL OIL T020 27 165 1 I 27 020 I FLANGE COMPANION T002 27 120A 1 ANCT002...

Page 1009: ...ART NO IOTY HODEL RESTRICTION CONTID A T020 27 1500 T020 27 1500 1 I 27 158 I SPACE T020 27 158A 1 I 27 15 I PIN TUBULAR T020 27 159A 1 I 27 171 I PIECE OISTANCE T020 27 171 1 I 27 230 I CASE T005 27...

Page 1010: ...HODEL RESTRICTION CONT D 0114 27 262 1 I 27 270A SHAFT OUT PUT T005 27 270B 2 I 27 301A SCREW ADJUST 0180 2l 301A 2 I 27 302 PLATE LOCK 0290 27 302 2 I 27 305 I BEARING 0249 27 350 2 I 27 401 I SPACER...

Page 1011: ...27 408A L S1 025 1 T020 27 it09A L Sl 0S0 1 _ _ I 27 431 I SPAC R T001 27 431 1 I 27 60D I CASING DIFF RNTIAL T020 27 6000 1 A T020 27 600E T020 27 600E 1 A T02D 27 600F T02D 27 600F 1 I 27 604 I BOLT...

Page 1012: ...____ GO O 27 60 A 9 07 8 1 2e J O 99796 1020 2710 A I REAR DIFFE LIMITED S pNTIALS DIFF PART NO OTY _____ HODEL RESTRICTION 2 26 060 j 0730 26 060 1 1 1 I 27 030 3919 27 130 1 l o i T025 2 i A T02S 2...

Page 1013: ...1S0C 1 A TO 0 27 150D i020 27 150D 1 I 27 158 I SPACE T020 27 15iSA 1 _ _ I 27 159 I PIN TUBULAR o T020 27 159A 1 I 27 171 I PIECE DISTANCE T020 27 171 1 I 27 200 I DIFFERENTIAL T016 27 200A 1 A T016...

Page 1014: ...EAR DIFFERENTIALS LIMITEO SLIP DIFf PART tlO loTY HODEL RESTRICTION _ _ I 2i 401 I SPACER _ _ 0259 27 401 T S O 1 0259 27 402 T 3 11 1 0259 27 403 T 3 1 1 0259 27 40 T 3 17 1 0259 21 405 T 3 2f0t4 1 0...

Page 1015: ...RAKE MECHANISMS l K13 3400 FRONT SUSPENSION MECHANISMS I MI3 3401 FRONT SPRING DAMPER I NI3 3410 CROSSMEMBER STABILIZER l Cl4 3700 TIRES JACK I CIS 3900 ENGINE T MISSIDN MOUNTINGS 1 015 4000 EXHAUST S...

Page 1016: ...ON CDNT D T020 27 409A L n 050 1 I 21 431 I SPACER TOOI 27 431 1 I 27 600 I CASING DIFFERNTIAL T020 27 6000 1 A T020 27 600E T020 27 600E 1 A T020 27 600F T020 27 600F 1 I 27 604 I BOLT CARRIER GOAO 2...

Page 1017: ...I I 1 I I I AUIAOI 2800 1 M REAR SUSPENSION MECHANISMS PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO 28 013A I SHEET RUBBER G030 28 013A 2 9330 I 28 1118 I STOPPcRpBUMP _...

Page 1018: ...AR SPRING DAMPER PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROM TO I 28 01OA I SPRING COIL REAR NAOl 21 011B 2 MY NA03 28 0 1 2 AT I 28 700 I DAMP R REAR _ NAOl 21 7DO 2 US OI...

Page 1019: ...TABILIZER PART NO Ion HODEL RESTRICTION HODEL RESTRICTION HOOEL RESTRICTIuN FROH TO i 28 101 I STAaILlZER RR NAOl 2a 151A 1 28 102 BUSH STABILIZER RR F801 2a 156 2 I 28 155 I PLATE STABILIZER RR FBOl...

Page 1020: ...2 I 28 113 I ROLT NAOl 2a U3 Z I 2a 2AO I ARM UPPER REAR NAOI ZI 2AOB 2 I 2 30D ARH R LOWER REAR NAOl 28 300 1 ________tr 2a sooz I ARM L LOWER REAR NAOl 21 350 1 _ _ I 28 4A BOLT ADJUST 0 NAOl 2a 4AO...

Page 1021: ...RAME 4 PART HO lorY HODEL RESTRICTION HODEL RESTRICTION HnOEl RESTRICTION FROH TO _ I 34 091 I NUT F801 34 091 4 I 34 170A I LINK CDNTROL STAI NAOl 34 170 2 I 34 222 I NUT _ 8871 34 222 NOT E D THE D...

Page 1022: ...BA LEATHER r 99940 0502 132 980 I THIS ILLUSTRATION CONSISTS OF _ AUMAOI 57 KIO i I57 K2Y 99186 0616 COiff D 3200 STEERING WHEEL 2 2 URETHANE o W O AIR BAG THIS ILLUSTRATI M crMSlSTS OF 2 PAGES i 9072...

Page 1023: ...L W lAIR 8AG I 32 040 I COVER ST WHEEL BOSS 8461 32 040 1 BASE 0701 W lO AIR BAG I 32 049 I COVER WHEEL CORE NAOl 32 049 1 PKG OPT V SPECIAL W lAIR BAG I 32 740C I PARTS SET ST WHEEL NAOl 32 750 1 PKG...

Page 1024: ...NAlll 57 K10H 1 W AIR BAG 9601 I 57 K2X I SENSOR R Al BAG NA01 7 1 2XJ 1 CW AIR BAG I 57 1 2Y I SENSORCL AIR BAG NA01 S7 K2YJ 1 W AIR BAG I 57 K40 I SENSOR AIR BAG INNER 132 04C 1 NAOl 57 K40D 1 CW A...

Page 1025: ...2 0908 1 W p S W AIR BAG NA07 32 090A 1 W O P S W O AIR 8A G NA08 32 o 090A 1 W P S WI D AIR BAG 1 32 099 1 BillT SHAFT B455 32 099 3 32 100 I SHAFT E GY ABSORBER NA01 32 1008 1 W AIR BAG NA07 32 100A...

Page 1026: ...GJ21 32 111 1 I I 32 115 I BEARING ST GEAR 0030 32 115 1 _ _ I 32 118F I COVER DUST ST GEAR _ NAOl 32 U8 1 I 32 1l9E I RACK STEERING GEAR NAOl 32 119 1 I 32 12X I BOOT SET ST GEAR i _ _ NAOl 3Z 12X 2...

Page 1027: ...TRICTION HODEL RESTRICTION FROM TO _ I 32 134 I PLATE CLAMP _ _ NAOl l2 134 1 _ I 32 136A I COVER REAR I GOlO S2 136 1 I 32 137 I NUT LOCK 030 32 137 1 I 32 146B I WASHER HA14 32 146 2 I 2 147A I BE o...

Page 1028: ...1 113 3310 l K13 3400 I MI3 3401 I NI3 3410 I Cllt 37 0 l C15 3901 1 015 4000 I F15 4140 1 G15 4145 I HIS 4160 1 115 4200 I MI5 4300 1 016 4300A 1 Flt 4340 1 H16 4360 FRONT BRAKE MECHANISMS FRONT SUS...

Page 1029: ...lZ 11r 1 32 110 I GEAR STEERING NA 32 110 1 _ I J2 112 I COVER DUST NA02 32 112 1 I 32 1140 I COVER DUST ST GEAR NA02 32 114 1 _ _ I 32 115 I BEARING ST GEAR NA02 32 115 1 I 32 117A I SPACER STEERING...

Page 1030: ...WASHER _ NA02 32 126 2 I 32 133 I PlATE CLAMP NA02 32 133 1 I 32 134 I PJ I TE LAMP NA02 32 134 1 I 32 14 IA I BEARING PINION _ NA02 32 147 1 I 32 148 I EY BOLT KIT ST GEA R 0002 32 148 1 I 32 151A I...

Page 1031: ...U 1I2 147AI 152A1 132 1rm 8 32 279 I __ 99924 1201 99221 3020 1 E13 3220 A 3 STEERING OEAR CW POWER STEERING PART NO Ion HODEL RESTRICTION HODEL RESTRICTION ODEL RfSTRICTION FROH TO I 52 452 I PIPE ST...

Page 1032: ...32 41I JA 1 0508 32 4oJO HOSE PRESSURE NA02 32 490A 1 0201 A NAC2 32 490B NA02 32 490B 1 0201 32 5 10 lPE SUCTlON _ _ NIlO2 32 10 1 _ _ I 32 600 PlI 1P VANE NOO2 32 600A 1 0301 AN NOO2 32 600 NOO2 J2...

Page 1033: ...L REZTRICTION FROH TO 32 80 I 8RACkET VANE PUMP NA02 32 6I0 1 _ 32 682 I HOS RETURN NOO 32 609 NA02 32 682 2 m 609 I r _ I 32 684 HOSE RETURN _ _ NA02 32 684B 1 32 690 TANK VANE PLW NA02 32 6C O 1 982...

Page 1034: ...TION FRO TO 26 071 CAP HUB B455 26 071 2 I 33 020 I KNUCKLE R STEERING NADl 33 020A 1 I 33 020Z I KNUCKLE L STEERlNO NAOl 33 030A 1 33 042 NUT NA01 3 042A W WASHER 2 I 33 061 I HUB WHEEL NAOl 33 04X 2...

Page 1035: ...3 280X I SUPPORTCL MDUNTINO NAOI 3J 291 1 I 33 610 I BODY a PISTON R L IPER NAOl 3J 61X 1 I 33 610Z I BODY a PISTON L CAL IPER NAOl 33 71X 1 I 33 691 I SCREW BLEEDER BOOl 33 691 2 I 33 693A I CAP BLEE...

Page 1036: ...HANISMS 310 FRONT BRAKE MECHANISMS p loTY PART NO HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO 49 240C SEAL KIT CALIPER FRT NAV1 33 24Z 1 49 250B I BOOT KIT FRT CALIPER NAYl 33 25Z 1...

Page 1037: ...1 I NUT 8037 28 091 6 LAOl 28 091 2 9405 _ I 28 1116 I STOPPER BUMP NA01 28 111 2 I i 8 533A I NUT FLANGE HOO1 28 333 it l _ _ I 28 380 I RUBBER MOUNTlNG NA01 28 380A 2 I I I 28 4AO I BOLT ADJUST NA01...

Page 1038: ...fRONT SUSPENSION MECHANISMS IOlY PART Nn OOEL RESTRICTION HODEL P ESTRICTION HOOEl RESTRtCT1ON FROM TO I 34 310Z I ARMCL LOWER NAOl 34 350A 1 I I 4 460 I BUSH RUaBER LWR ARM I NAOl 34 460A 2 I 34 480...

Page 1039: ...FRONT SPRING DAMPER r PART NO lOT HODEL RESTRICTION HODEL RESTRICTION HOOfL RESTRICT O FROH TO I 34 011 I SPRING COIL FRONT _ NAOl 34 01lA 2 M1 NA03 34 011 2 An I 34 700 I OAMPER F ONT NAOl 34 700 2...

Page 1040: ...SO T NAOl 34 09XA it I 34 091 I NUT FBOl 34 091 4 I 34 151 I STABILIZER FRON NAOl 34 151A 1 I 34 155 I PLATE STABILIZER FBOl 34 155 2 I 34 156A I RUBBER STA6 RT NAOl 34 156A 2 I 34 I70A I lINK CONTROL...

Page 1041: ...10 STEERING COLUMN SHAFTS I I Ml 3220 STEERING GEAR W O POWER STEERING I CI3 3220 A STEERING GEAR W POWER STeERING I F13 S240 POWER STEERING SYSTEM I HI 3300 I RONT AXLE 1 113 3310 F RONT BRAKE MECHAN...

Page 1042: ...OOEL kE TRltTION FROM TO I 26 161A I NUT HU8 _ _ 0603 26 161 NON 8RIGHT 16 B002 51 160 PLATED 16 I 37 190 I CAP CENTER 8455 37 190 4 NACU 37 190 If I I 37 192B I EM8LEM CENTI R 8001 37 192 4 _ I 7 600...

Page 1043: ...E WHL 4 99655 90015 ISO FOR I PIECE WHL 99655 90020 200 FOR I PIECE WHL 37 60 11 99655 90025 25G FOR l PlECE WilL 4 99655 90030 300 FOR I PIECE WHL 99655 90035 50 FOR I PIECE WHL _ _ _ 1 9965 90040 40...

Page 1044: ..._ _____ HOLOER JACK HANDLE REFER TO SECT 140 4200 p IIS SODAI I I I I 131 8om I I I I I I I 3700 J TIRES I JACK PART NO IOTY MDOEL RESTRICTION ODEL RESTRICTION HODEL RESTRICTION FROM TO I 56 170A I 10...

Page 1045: ...H13 3300 FRONT AXLE 1 113 3310 r RONT BRAKE MECHANISMS l K13 3400 FRONT SUSPENSION M CHANISMS I MI3 3401 FRONT SPRING DAMPER l N13 3410 CROSSMEMBER STABILIZER l C14 3700 TIitES JACK I CIS 3900 ENGINE...

Page 1046: ...UBBER ENGINE MT NAOl 39 040 2 I 3Q 045 I CASING STOPP R NAOl 39 041 2 S231 39 041 2 CAT I 39 710 I FRAME POWER PLANT 01 3 1 710 l CMT t lAO 5 39 710 1 AT 139 724 I 39 721 I BOLT PlANT FRAME NAOI 39 72...

Page 1047: ...LYST 861P 20 61J0 1 I 40 C DA I IPL E HAUST FRONT _ B690 40 500 1 ____ J _ _ _ _ t 40 i 61C I HANGER SlLENCER _ RF03 40 061 5 I 40 QC I lJRACKET HANGER _ 8690 40 OSOA 1 I 40 230 I BRACKET HANGER 8690...

Page 1048: ...TION HODEL RESTRICTION FROH TO CONT D 86e 40 100A 1 0401 A 8684 40 1008 8690 40 100E 1 9820 0401 A B690 40 100F 8684 40 1008 1 AT 0401 8690 40 100F 1 MY 0401 140 450 I 99716 0875 t too a5SAI 99971 100...

Page 1049: ...0259 33 691 1 33 693A CAP BLEEDER SCREW 0259 33 693 1 41 341 ROO PUSH H266 tt1 3 1 1 41 410 I SPRING 8312 41 4 0 l 41 920 I CVL CLUTCH RELEASE HE 29 41 920A 1 9701 NAOl 41 92G 1 9701 41 99C CVL CLUTCH...

Page 1050: ...L RESTRICTION FROH TO I 41 360 I HOLDER CLUTCH _ _ _ _ NAOl 41 370A SLltINO KOGYO 1 8871 41 370 1 0701 NA02 41 370 IOORI 1 0701 I 1 HO I PIPE CLUTCH NA01 41 3 A 1 I 41 380 I HOSE FLEXIBLE GK61 41 3aOI...

Page 1051: ...610 1 0701 A NAOZ 41 610A NAOI 41 lOA 1 8ASE 0701 W O AUTO CRUISE CON T NA02 41 61OA 1 PKG DPT 0701 W AUTO CRUISE CONT I 41 613 ROLLER 81Q4 41 114 1 PKG OPT W AUTO CRUISE CONT I 41 619 SPRING RETURN...

Page 1052: ...66 42 3668 1 I 42 243A I NAOI 42 233 1 I 42 249 I NAOl 12 249 4 AN NAOI 42 249A NA01 42 249A 4 ANCNAOl 42 2498 NAOl 42 2498 4 I 42 250 I NA02 42 250 1 NAtll 42 210 CO NAOl 42 210A O 42 270 HODE RESTRI...

Page 1053: ...LID FUEL FILLER NAOl 42 410 1 9801 AN NAOl 42 410A NAOl 42 41CIA 1 9B01 I 42 431 I SPRING LIFT LID H043 42 431D 1 I 42 441 I WASHER LID OPENER HAOl 56 896 1 I 42 480 I OPENER FILLER LIe NAOl 56 850A 1...

Page 1054: ...EL VAPOR FBrl 42 9ao 1 _ _ I 42 75X I REINF FUEL TANK NADl 42 77X 4 _ I 42 771 I RUBBER UP MOUNT TAN K NADl 42 771 4 I 42 772 I RU88ER lWR MOUNT TA NK NAOl 42 772 4 _ _ I 42 791 I PAD FUEL TANK _ __ _...

Page 1055: ...ROH TO j 67 052J I CLIP B001 67 051 1 67 054D I CLIP H260 67 054 2 I 69 061 I lABEl FUEL WARNING KA10 69 D61 1 93 5714 I HOSE 99357 14999 1 90786 061 9994r 142 90A 1 2 n 1 Jh 5 1992 02 d J o r 4 2 n J...

Page 1056: ...43 0 J 99921 1000 0 A 9981 1030 UTO CRUISE _ CaNT 67 210 I 90794 0820 I I I CLUT 8 ___ E PEDALS MANUAL T PART tlO p rni1 RAI N SM IS S l ON 4 OO 1 ____ OTY HODEL RESTRlrTIOH S ODEL REITRHTIO 1__ 1_15...

Page 1057: ...070 f BRACKET MASTER CYL NAOl 4 S 070A 1 eASE W O AUTO CRUISE CON T NA02 43 010A 1 PKG OPT W AUTO CRUISE CONT f tt3 0UA f SPRING RETURN BRAKE 92 1 081 1 I 43 140 I FORK BRAKE _ _ I 1524 43 1 0 1 I 43...

Page 1058: ...ING 3220 A STEERING GEAR W POWER STEERING 3240 PO ER STEERING SYSTEM 3300 FRONT A LE 3310 3400 3401 3410 3100 3900 4000 4140 4145 4160 4200 4300 FRONT BRAKE MECHANISMS FRONT SUSPENSION MECHANISMS FRON...

Page 1059: ...A6 O 85 111 168 61581 4FiTOl 99232 08229 41 131 J 1 _ 143 08JAI 99922 0800 n l GI 1iL1 99971 1000 1 AUUOI 99575 0600 99921 1000 99972 0800 r I _43 02 46 085 8001 43 029 99971 000 f6 08S I ill 081AI 14...

Page 1060: ...1 tf I 43 028 I PAD PEDAL 0268 43 028 1 I 43 029 I RU BER STOPPER 8001 43 029 I 43 U30 I PEDAL 8RAKE NA03 43 03J 1 I 43 041 I REST FOOT NAOl 43 041 1 _ I 43 0614 I PIPE PEDAL 0866 43 062 1 I 43 010 I...

Page 1061: ...O AuTO CRUISE CONT 167 210 I 9C794 082C 4300A 2 M BRAKE PEDALS AUTOMATIC TRANSMISSION PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODF l RESTR1CTION FROM TO CONT O 0001 43 152 1 I 46 035 I BUSH 1...

Page 1062: ...81 143 S52SI W023 43 505 1 I 43 540A I SENSOR RESERVE TANK GA91 43 S40 1 I 43 542 I FLOAT 3597 43 542 1 I I 4 S SS0S I TANK SET RESERVE 8216 49 680 1 0701 A BZ16 49 680A 216 49 6S0A 1 0701 I 43 S525 I...

Page 1063: ...43 OOD NAOl 43 400D 1 I 49 610 I PARTS KIT INN BKAKE GJ21 43 61Z 1 BWOA 43 61Z 1 I 49 620 PISTON PRIMARY OJ21 43 62Z 1 BWOA 43 62Z 1 _ __ I 49 630 I PISTON FLOATING BJ14 43 63Z 1 ElWOA 43 63l 1 49 67...

Page 1064: ...3 635 I 43 635 3 670 I _ _ 43 670A 3 694A I 43 694A 3 900 I 43 900 3 980A I 43 SIOA 3 9808 I 43 980 3 91S0X I 4 5 990 3 9aOY I _ _ t 3 820A 5 280 I 45 2808 5 320 I 45 3208 5 360 I NAOl 45 3608 4S 911...

Page 1065: ...99562 1000 4360 2 M BRAKE PIPINGS PART NO Jon HQOEl RESTRICTION HODEL RESTRICTION HODEl RE TRICTION fROM TO I 45 915A I HOLDER PlPE 8001 45 915 2 45 9158 HOLDER PIPE NAOI 45 U5A I 45 916 I HOLDER Plf...

Page 1066: ...E HOSE W023 43 6 SS 2 I 44 010 LEVER PARKING 8RAKE NAOl 44 01O 1 I 44 031 I SPRINO PARKING REVER G030 44 0 S1 1 I 44 032 I ROD RELEASE _ _ NAOI 44 032 1 I 44 033 I BUTTON RELEASE FBOl 44 0 S S 1 I 4 0...

Page 1067: ...UIIAOI 4400 2 M PARKING BRAkE SYSTEM PART NO lorY HODEL RESTRICTION I W tntl IRI TRlCTlON _ _ _ I 44 410A CA8LECL R PARK _ NAOl 44 4208 1 I 44 439 CLIP CABLE _ _ _ lQI1 44 439 1 I 66 40 I SWITCH PARKI...

Page 1068: ...4 13 157 6 _ _ 45 111 P E FUEL MAIN _ _ NAOl 45 111 1 I 45 112 1 PIPE FUEL MAIN _ 1 NAOl 45 112A 1 _ I 4S 125 I HOSE FUEL __ _ _ 99359 0815 2 99359 0815 1 _ __ 45 611 I PIPE FUEL RETURN 1 45 711 I PIP...

Page 1069: ...z r FILTER FUEL REFER TO SteT NO 1320 4S g 99351 0C999 L 80 W f 993S8 OB99g L 220UU UUOJ 4500 2 FUEt PlPINGS PA T NO lory HODEL RF S1Rl TlON HODEL RESTP ICTION I 45 921 I C 1 P1PE 1 8210 45 917 1 _ _...

Page 1070: ...Catalog No AU NA01 J7 1 r LAYOUT OF CONTENTS The followinq IS if tYIJIt r I ldmpll of th layout of contents In Jl iJ microfiche parts cata r 1 1 Lavout of contents St cl Ot 0 11 1l tv Ihl Col Illustr...

Page 1071: ...ISTON CRANKSHAFT FLYWHEEL VALVE SYSTEM L______________ B 1400 OIL PUMP FILTER D 1600 TRANSMISSION CASt MANUAL TRANSMISSION GEA MANUAL If _ lC 1720 p l im1950 1 MANUAL UHKAGE SYSTtM AOTOMAT1C 011940 m1...

Page 1072: ...SlARTEK m1830 ALTERNATOR III 61310 1320 EXHAUS T 1 1 ANI FCLD FUEL SVSTE FUEL DISTRIBUTOR AIR CLEANER ENGINE 2 2 o II 1111800 A f P t ENGINE ELECTRICAL Y5TrM BRArt d I 1 lIl L l Y II L T II 1364 THRO...

Page 1073: ...N R DIFFERENTIALS fa 1720 Engine Group CHANGE CONTROL SYSTEM MANUAL DiE D REAR SPRING OAMPE 2830 REAR LOWER ARMS SUB FRAME 3200 STE AING WHEEL 1 6 3210 STEERING COLUMN SHAFTS 1 m3310 I II 3300 fJ 3240...

Page 1074: ...I TIRES JACK MASTER CYLINDERS 1 ANUAL TRANSMISSION 1 CLUTCH PIPINGS MANUAL T AN1MISSION ACCELERATOR CONTROL SYSTEM FUEL TANK CHASSIS 2 2 __ L__ __ D Lu T lu KE P ED A LS o BRAKE MASTER CYLINDER POWER...

Page 1075: ...HER WINDSHIELD WIPERS IE 6703 ml6700 III 6640 17 WIRING HARNESSES BODY 1m 1m 1 4 m mm FAON7 R _____ A_U_TO_C_ A_U _SE CONTROL SYSTEM OOUH W I r Cit HORN 115103 UEAD LAMP RETRACTORS Ric LAY R lINI BUOY...

Page 1076: ...30 m_ REAR BUMPER fD S300 m6330 f IJ 7900 iJ Q A WINDOW GI ASSES SUNROOF ACCES ORIES BODY 2 4 m5180 m II I m5230 Bt tlNET II 5260 FLOOR ATTACHMENT5 f1 T _ TRUN LID m5370 m5340 m5330 m5320 m5310 SODY P...

Page 1077: ...ONENTS DASHBOARD to RELATED PART CONSOLE lSI o DO 6 6120 6100 t _ _ I _ t It I I J JO t l v tJor At tJII dlKt If II tf 1 1 Jly t p U1 dte JIr1e t nt t r ts h If f UIO I tr II 2 1 T 0 COMUINAiiON SWITC...

Page 1078: ...30 CAUTION PLA _s I AUEts I PICTORIAL INDEX fJ 5700 II 5790 SEATS BODY 4 4 rn 6900 1 r j VISORS ASSISl HANLJUS MIRRORS s nVICf lOOl S 2 J 1 or i _ t II 6680 m5682 II m6820 1i y fl FRONT HEADER TRIM PI...

Page 1079: ...UEL DISTRIBUTOR AIR CLEANER THROTTLE BODY EMISSION CONTROL SYSTEM INLET SIDE CAP HOSE CLIP INLET EXHAU ST SIDE OIL PUMP FILTER COOLING SYSTEM SRACKET PULLEY BELT CLUTCH DISC COVER MANUAL TRANSMrSSION...

Page 1080: ...REAR SPRING IJAMPER REAR STABILIZER REAR LOWER ARMS SUB FRAME STEERING WHEEL STEERING COLUMN SHAFTS STEERING GEAR W O POWER STEERING STEERING GEAR W POWE STEERING POWER STEERING SYSTEM FRONT AXLE FRON...

Page 1081: ...COOLING UNIT AIR CONDITIONER WINDOW GLASSES SUNROOF SWITCHES RELAYS ENGINE DASHBOARD SWITCHES COMBINATION SWITCH RELAYS UNIT SODY DOOR SWITCH HORNS AUTO CRUISE CONTROL SYSTEM AUDIO SYSTEMS RADIO TAPE...

Page 1082: ...EL I L12 3210 STEERING COLUMN SHAFTS 1 12 3220 STEERING GEAR W O POWER STEERING l e13 3220 A STEERING GEAR W POWER STEERING 1 Fl 3240 POWER STEERING SYSTEM I Hl3 3300 FRONT AXLE 1 113 3310 FRONT BRAKE...

Page 1083: ...lB 1 _ _ I 46 ATS I SCREW H338 46 AT8 2 I 46 AT9 I NUT H338 46 AT9 2 I 46 010 I LEVER SELECT NA03 46 100C 1 A NA03 46 100E NA03 46 100E 1 I 46 027 I _ _ H338 46 027 CAM CHANGE LEVER 1 I 46 030 I KN08...

Page 1084: ...TID NA03 46 300A 1 ANCNA03 46 300B NA03 46 300B 1 I 46 302 I CLIP NA03 46 302 1 NA16 46 302 1 I 46 510A I ROD SELECTOR REAR NA03 46 570 1 46 6 4 I BUSH 1015 46 684A 1 I 55 2 10A I BULB I c OCKET NA03...

Page 1085: ......

Page 1086: ......

Page 1087: ......

Page 1088: ......

Page 1089: ......

Page 1090: ......

Page 1091: ......

Page 1092: ......

Page 1093: ......

Page 1094: ......

Page 1095: ......

Page 1096: ......

Page 1097: ......

Page 1098: ...08 5380 BODY PANELS SIDE BODY PANELS FLOOR 2 K14 6682 2 L14 6700 FLOOR ATTACHMENTS HOLE COVEMS AUDIO SVSTEM ANTENNA SPEAK ER WIRING HARNESSES FP ONT REAR 2 G08 5390 FLOOR ATTACHMENTS 2 N14 6701 WIRING...

Page 1099: ...492AI 109 010 I NA03 09 010A 1 An O Ol 00 NAO NAl BLACK I 58 3150 I CLIP R G030 58 315 2 IS8 315DI I 58 492 I KEY PRIMARY BR75 58 492 KEY NO IS REQUIRED 2 I 58 492A I KEY SECONDARY LA02 S8 493 KEY NO...

Page 1100: ...B SET OLOVE NAOl 76 250 1 00 NAO BLACK I 75 990 I kEY SUB SET ST LOCK 15 910 I I 119 010J NAOl 76 290 1 0201 ANCNAOl 76 290A NA03 76 290 1 0201 AN NA03 76 290A NAOl 76 290A 1 MT 0201 NA03 76 290A 1 AT...

Page 1101: ...MPER NAOl 50 0Jl 1 AT I 50 0JS I RETAINERCL FRONT au MPER NAOI 50 0J5 1 I 50 0KO I RETAINER FASCIA Nl Ol 50 0KOB 1 I 50 015C I BOLT FBOl 50 132 2 I 50 015D I BOLT NAOI SO Ol2 8 I O O30 I HOLDER NO PL...

Page 1102: ...SO lAYA 1 9912 NAOl 50 1Aya 1 9912 I 50 180 I PLATE NO 2 R SET F BUMPER NAOl SO Ieo 1 I 50 l80A I PLATE ND 2 L SET F BUMPER NAQl 5C lCO 1 I SO lE2 I BOLT NAOI 50 1E2 2 NAOI SO IEl 4 I SO llY I BRACKE...

Page 1103: ...STRICTION HODEL RESTRICTION FROH TO CCNT D NAOl 50 2AOA 1 991 I 50 233C I FAST NER REAR BUM8 R _ _ IF82 50 233 s I 50 318 I TAPE ENGV A8S FO R RB NAOl iO SUS 2 _ I 50 335 I NUT CLIP FBOl 50 133 of I 5...

Page 1104: ...R BU Mt ER NAOl 50 2S4 1 I 50 2S4A I SHILO L SPLASH R BU MPER NAOl 50 2S5 1 I 50 221 I BLttPER REAR NAY1 50 220 1 9330 A NAY1 SO 220A NAYl SO 220A 1 9330 I 50 230 I REINFORCEMENT BUMPER NAOl 50 260 1...

Page 1105: ...RESTRICTION HODEL RESTRICTION HODEL RESTRICTION ROH TO I 50 28V I PLATE SET NAOl 50 28YC 2 I 50 335 I NUT CLIP NAOl 50 1l3 6 99940 0803 I _ _ _ I I 99910 0603 I I 0863 0516 L ________________________...

Page 1106: ...9701 A NAOl 50 792A NAOl 50 792A 1 9701 I 50 791 I ORlL LE COWL NAOl 50 790A 1 1 412 A NA01 50 790B NAOl 50 790B 1 9412 9701 A NAOI 50 790C NAOl 50 790C 1 9701 9912 A NAOl 50 7900 NAOl SO 790D 1 9912...

Page 1107: ...60 0612 W RC6 1 J I I 150 54AI 0 7968 r l 99864 0 2 5 fID ISO A41ID m 798 _ _ au AlIUOI 5030 2 M WINDOW MOULDING COWL GRILLES PART NO JOTY HODEL RESTRICTION HODEL RESTRICTION MODEL RE5TRICTION FROH TO...

Page 1108: ...MP SEHR IEAD 8BNl 51 030 1 I 51 030Z I LAMP SET L HEAD SBNl 51 040 1 I 51 032A I UNIT HEAD LAMP NA02 51 031 2 I 51 039 I SCREW B481 51 0E3 6 I Sl 046C I SPRING 1 NAOl 51 046 2 I 66 024 RING RETAINING...

Page 1109: ...6 I _ I 51 SBX I MOTORCLl RETRACTABlE HEA NA01 51ft S6X 1 I tl SC6 I NUT STOPPER lAMP HIN _ _ GE KAOl 51 SC6 it 1 ill SA7 I I _ _ PROTECTOR R RETRA H I I 5 SEl I L NAOl 51 SEl 1 _ _ PROTEClORCL RF TRA...

Page 1110: ...1 I A 1 OOB B li I 4 I t 4 1 I NAOl 51 S01A 1 _ I 51 513 NAOl 51 SC5 A UJAOl 51 S NAOl 51 SCS _ _ I 51 513Z NAOl 51 SD5 A NAOl 51 S NAOl 51 SD5 I 51 516A _ _ KAOl 51 S06 I A 1 C513 B 1 of I A 1 058 B...

Page 1111: ...ION NAME HEATER CONTROLS COMPONENTS HEATER BLOWER COMPONENTS AIR CONDITIONER o RING SET PIPING COMPRESSOR COMPONENTS AIR CON DITIONER COOLING UNIT AIR CONDITIONER WINDOW GLASSES SUNROOF SWITCHES RELAY...

Page 1112: ...RE5TRICTION FROH TO I 51 610A I BEZELCR HEAD LAMP NAOl 50 741 1 _ I 51 610Y I BfZEL L HEAD LAMP NAOl 50 751 1 I 51 61lA I SCREW HEAD LAMP BEZE L B481 50 75X a _ _ _ I 51 665 I BOLT MOTOR RETRACT H IL...

Page 1113: ...07 51 054 2 W O AIR BAtH 0701 I 51 060 I LAMP SETCR FRT COMB 8BNl 51 060 1 W AIR BAG 8BN2 51 U60 1 W O AIR BAG 0701 I 51 060Z I LAMP SE1CL FRT COMB 8BNl 51 070 1 Wl AIR BAG 88N2 51 070 1 W O AIR BAG 0...

Page 1114: ...UR IBN1 51 120 1 I 51 120X I LAMP SETCL SlDE TUR BBNI 51 l30 1 _ _ I 51 121 I LENS a aDDY R NA01 51 5E1B 1 9401 A NAOl 51 5EIC NAOI 51 5EIC 1 9401 9901 NAOl 51 5EX 1 9901 I S1 121Z I LENS a SOOY L HAO...

Page 1115: ...51 064J I SCREW TAPPING NAOl 51 1E6 2 I 51 0701C I BULB 99700 7110 Al2V 1I 4W 1 99701 3270 12V 27W 4 I 51 110J I BULB 99701 6038 12V 8W 2 o I 51 124A I SOCKET SIDE TURN BJ38 51 S84 1 _ I 51 150 I LAM...

Page 1116: ...RR CQM8 NAOl 51 1 S4 il I 51 169A I PROTECTOR L A NAOl 51 169 1 I 51 1728 I CAP 0030 51 172 5 _ I 51 1738 I PROTECTORCR 8 NAOI 51 17 5 1 I 51 183C I PROTECTOR l 8 c NAOl 51 113 1 I 51 5139 I CLIP NAOI...

Page 1117: ...1 5 508 I LAMP SETCR SIOE TUR N RR 8BNl 5 550 1 51 550C LAMP SETCL S10E TUR N RR 8BNl 51 S6U 1 51 580 LAMP STOP H1 MDUNT NA01 51 5S0B 1 I 51 582 I GASKET STOP LAMP HI MOUNT NAOl 51 592B 1 I 51 583 I L...

Page 1118: ...LAMPS PART NO Ion HODEL ReSTRICTION 51 270 LAMP LICENSE 8BFl 51 270 2 51 270J BUL8 99701 2070 12V 7 5W 2 I 51 2730 GASKET LICENSE LAMP FB67 S1 273 2 _ _ 51 276 SHAOE LAMP LICENSE F867 51 276 2 I 51 2...

Page 1119: ...WHITE 3L 3l SILVER STONE METALLI NAOl 50 8S0C 1 9901 99h A NAOl 50 8500 OU DU MARINER BLUE SU SU CLASSIC RED UC UC CRYSTAL WHITE 3L 3L SILVER STONE METALLI NA01 SO 8S00 1 9914 OU DU MARINER BLUE HU H...

Page 1120: ...EAR FINISHER PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROM TO 50 853E I BOLT GARNISH RR LAOl 50 153 4 50 8588 GASKET REAR FINISHER B388 S0 a 5 4 I 51 7116 I ORNAMENT MAKER NA...

Page 1121: ...460 HINGE U 110NNET NAOl 52 420A 1 2 510 I STAY BONNET I NAOl 56 650 1 I 52 514 I HOLDER ROD G030 56 693 1 I 56 620 I LO K BONNET I NAOl 56 620A 1 I 56 631 I FASTENER BONNET RELE ASE LAOl 56 6 51 1 I...

Page 1122: ...602B a _ _ n lIB 156 110 J 99709 3140 AUNAOI 2 M 6 J 5230 2 BONNET PART NO lory ODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO I 56 7958 I WEATHERSTRIP BONNET REAR NAOl 56 760 1 I 67 519...

Page 1123: ...2 710A 1 9901 I 52 720 I HINGE L TRUNK LID NAOl 52 720 1 9901 AN NAOl 52 720A NA01 S2 720A 1 9901 I 52 761 I SPRINQCR BALANCE NAOl 52 791A 1 I 2 771 I 5PRING L BALANCE NAOl 52 792A 1 _ _ __ I 56 615M...

Page 1124: ...00 6610 6611 6630 6635 82 2 L14 6700 2 N14 6701 2 015 6702 2 E15 70 2 F15 6704 2 115 6720 2 K15 67 50 2 M1S 6740 2 N15 6820 2 C16 6840 2 E16 6860 SECTION NAME HEATER CONTROLS COMPONENTS HEATEH BLUWER...

Page 1125: ...Br J 99940 0602 156 820 I 159 315 I 90786 06168 KEY SUB SET TRUNK REFER TO SECT NO 0900 J AIJIlAO I 5260 M2 M TRUNK LID PART NO IOTY HODEL RESTRICT ON HOOEl RESTRICTION HODEL RESTRICTiON FROH TO I 56...

Page 1126: ...D 1 9501 9B01 AN NAOl S3 1 OE NAOl 53 100E 1 9BOI 040 A CNAOl 53 100F NAOI 53 100F 1 0401 53 160B MEMBER CROSS NA01 53 16XA 1 9701 ANCNA01 53 16XB NAOl 53 loXB 1 9701 0701 A NAOl 53 16XCl NAOl 53 16XC...

Page 1127: ...NAYl 53 200B 1 0701 I 5 210e I PANEL R WHEEL APRON __ ____ l NA 2 JA 1 _r 11 C l 210B NAOI 53 210B 1 0701 _ I 53 210X I PANEl l WHEEL APRON JAOl 54 210A 1 0701 C NAOI 54 210B NAOI St 210B 1 0701 I 53...

Page 1128: ...S3 32XB NAOl 53 32XB 1 9701 I 54 210 I PANEL L WHEEL APRON NAYl 54 200 1 0601 AN NAYl 54 20DA I NAYl 54 200A 1 0601 0701 C NAYl 54 OOD NAY 54 200B 1 0701 I 54 330A I BRACKE1 L SYABILIZE R NAOl 54 330...

Page 1129: ..._ NAOJ 56 141A 1 0703 A NAOl 56 141C NAOl 56 141C 1 0703 _ _ 56 149 SCREW TAPPING HUD GU ARD 8455 56 149 10 9C20 g3 TaO 54 380 5 340A HOOK R TIE DOWN FRO NT NA01 56 34XA 1 9621 AN NAOl 5 34XC NAOl S6...

Page 1130: ...54 4000 1 9S01 I 53 S10 I PANEL DASH UPPER NAOl 53 510 1 9413 ANCNAOl 53 510A NA01 S3 510A 1 9413 9701 A NAOl 53 510D NA01 S3 510D 1 9701 I 54 480 I JUNCTION DASH SIDE S SILL NAOl S4 4aO 2 I 56 355 I...

Page 1131: ...BRACKET L INST NAOl 71 071 1 9901 G NA01 71 071A NAOl 71 071A 1 9901 I 54 96X I SILl FRT L SIDE INN ER NAOI 54 96XA 1 0101 A NAOl 54 96X8 NAOl 54 96XB 1 10101 I I 54 971 I SlLLCC SIDE INNER NAOl 54 9...

Page 1132: ...NAOl 70 l00 1 9701 9901 G eNAOl 70 l00F NAOl 70 100F 1 9901 9COI AN NA01 70 l00G NAOl 70 100G 1 1 geDl I 70 1ooB I PANELCR INSIDE I NAOl 70 19XB 1 I 70 1l3A I PLATE R SEAL NAO l 70 11Z 1 I 70 114 I P...

Page 1133: ...RIKER NAOl 70 460 1 70 445 GUSSETCR REAR FENDE R RR NAOl 70 445 1 I 70 451C I SILL R SIDE OUT _ _ NAOl 70 270A 1 M NA01 70 Z70B NAOI 70 270B 1 I 70 451E I OUSINO R LAMP RR F ENDER NADl 70 J30 1 I 70 4...

Page 1134: ...AN NAOl 70 7S0F NA01 70 7S0F 1 I 71 020 I PANELCL CQWL IDE NA01 71 020B 1 I 71 10X I PANEL L QUARTEn NA01 71 11X 1 ANCNAOl 71 11XA AOl 71 l1XA 1 I 71 100 I PANEL L QUARTER _ NAOl 71 100E 1 AN NA01 71...

Page 1135: ...71 260 I PILLARCL FRT INNER NAOl 71 240A 1 G NAOl 71 240B NAOl 71 240B 1 I 71 274 I GUSSETCU SIDE SILL OUTeR NA01 71 274 1 I 71 276 I REINF L SIDE SIll NAO 1 71 275 1 I 71 3908 I REINF L STRIKER NAOl...

Page 1136: ...T NA01 l0 280B 1 I 74 09JA I PILLAR R FRONT OUT NAOl 70 210 1 T 4 ioo j PANELCR FENDER REAR N Yl 70 OO 1 t NAYl 70 400A NAYl 70 400A 1 _ _ I 74 120 PILLAR L HINGE OUT NAOl 71 280B 1 _ _ I 74 120A I PI...

Page 1137: ...fEMS RAOIO TAPE DE CK BODY PANELS OASH COWL PANEL 2 114 6680 BODY PANELS SIDE BODY PANELS FLOOR FLOOR ATTACHMENTS HOLE FLOOR ATTACHMENTS 2 K14 6682 7Ul AUOIO SYSTEMS ANTENNA SPEAK ER WIRING HARNESSES...

Page 1138: ...1 I 53 670 I BRKTCR SEAT F FLOOR PAN NAOl S3 670 1 I 53 700 I PAN FLOOR REAR NAOl 53 710A 1 0701 C NAOl 53 710B NAOl 53 710B 1 0701 I 53 725A I GUSSET NO 3 R C FLO OR PAN NAOl 53 725A 1 I 53 7508 I P...

Page 1139: ...I 56 150A I NA01 53 602 I 56 2 OA I NA01 54 610 56 980 I NM1 S3 830A A NAOI 53 830C NAO l3 8l0C I 56 9908 I 9330 NA35 9901 HA3 CAT AUNAOI 07 I MeER O 4 CROSS 1 GUSSET FRONT FLOOR P AN 1 JUNCTIONCL FRT...

Page 1140: ...DEL RESTRICTION CDNT D NAOl 54 a sOA 1 A HAU1 14 a30e NAOl 54 830C 1 I 70 450B I PANELCR FLOOR SIDE 01 53 740a 1 I 71 450B I PANEL L FLOOR SIDE NA01 54 740 ANCNAOl 54 740A NA01 54 740A 1 9330 NA35MM I...

Page 1141: ...TION FROM HI _ _ I 56 051 I COVER HOLE 1011 56 0 1 4 _ _ I 56 052 I PLUG DRAIN 8092 56 052 D 12fIM 9 F801 56 056 4 0701 I 56 061A I COVER HOLE 8545 56 052 4 I 56 1128 I PLUG DRAIN B092 56 053 3 9516 I...

Page 1142: ...N NAOl 56 1118 NAOl 56 111e 1 9621 0701 AN NAOl 56 111C NA01 6 111C 1 0101 I 56 149 I SCREW TAPPING MUD GU ARC 8455 56 149 1 9601 I 56 111B I PROTECTOR R RR FEND ER NA01 56 171A 1 I I 56 11UK I CQVERC...

Page 1143: ...HMENTS PART NO IOTY HOOEl RESTRICTION HODEL RESTRICTION HODEL RESTRICTION n OH TO I 56 2911 I HOOK L TIE DOWN NAOl 56 Z10C 1 I 56 294 I SCREW TIE DOWN HOOK NAOl 5 294 4 I 56 410 I INSULATOR HEAT FRONT...

Page 1144: ...ATTACHMENTS HOLE COVERS FLOOR ATTACHMEhTS DASHBOARD EQUIPMENTS METER HOOD SPEEDOMETER CABLE 2 1 14 6682 2 L14 6700 2 N14 6701 HEATER OLOWER COMPONENTS AIR CONOITIONI R o RlNG SET PIPING COMPRESSOR COM...

Page 1145: ...00 NAO BLACK NADI 51 490B 2 9902 00 NAO BLACK I 51 491 I LENS PERSONAL LAMP H197 51 491A 2 00 BLACK I 55 220 I PANEL CENTER NA01 55 210 1 9801 A NA01 55 210A 00 NAO BLACK NAOI S5 21DA 1 9801 00 NAO B...

Page 1146: ...2 1 00 NAO HAl BLACK I 64 271 I PANEL CENTER LOWER NAOl 64 270B 1 9401 00 NAO BLACK NAOI 64 270C 1 9401 00 NAO BLACK I 64 2as I SPRING ASH TRAY NAOI 64 612 2 64 61 5 I SCREW ASH TRAY NAOl 64 f 4 I 64...

Page 1147: ...NO lorv HOUEL RESTRICTI0N HODEL RESTRICTION HODEL RESTRICTION FROM TO I 55 182 I RUBBER BLIND NAD1 55 182 1 9609 I 55 410 I HOOD METER NAOl 55 420A 1 9609 00 NAD NAI BLACK NAIl1 55 420B STO COAT BLAC...

Page 1148: ...T NO lorY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO I 60 070 I CABLE SPEEOOMSTER NA03 60 070 1 AT NAOl 60 070A 1 9613 G NAOl 60 0708 NAOl 60 0708 1 CM 9613 I 60 071C I CLIP UB40 60...

Page 1149: ...AT I 55 4AIA I METER OlL PRfSSURE t4AOl 55 4P l 1 I 55 430 I METER SET NAOl 55 430A 1 9820 AN NAOl 55 430B NA03 55 430A 1 0701 A NA03 55 430B NAOl 55 430B 1 9820 0701 A NA01 S5 430C NAOl 55 430C 1 MT...

Page 1150: ...8 I RESISTOR METER NAOI 5 S 476 1 Mn I 55 461 I TACHOMETER NAOI 55 461 1 G NAOI 55 461A NA03 55 461 1 G NA03 55 461A NAOI 55 461A 1 MT NAOJ 55 461A 1 AT I 5S 471 I SPEEDMETER _ NAOl 55 471 1 A NAOl 5S...

Page 1151: ...OI 55 24 A 3 00 NAO NAI BLACK _ I 55 561 I BOLT INST PANEL 8455 55 561 I I 56 905A I NUT SPRING 9092 60 408 4 I 58 612 I CUSHION RUBBER 8092 64 046 3 I 60 35X PAD INSTRUMENT PANEL NAOl 60 l5X I 00 NAO...

Page 1152: ...NAOl 60 462A NA01 60 462A 1 ORACKET MEMBER BRACKET INST PANH I 60 463 I BRACKEr CRUSH PAD NAOl 60 463 1 I 64 030 I BOX GLOVE NA01 64 030C 1 A NAOl 6 0300 00 NAOl 64 030D 00 I 64 032 I 1 NAOl 64 032A...

Page 1153: ...i3mJ I I J I 99863 0510 I I 60 463 IJQ 35X I AUJrAOI 2 K 9 I 5560 3 M DAS BOARO I RELATEO PARTS PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL ReSTRICTION FROM TO I 64 905B I COVER HOLE C NAOl...

Page 1154: ...N RUBBER _ _ 8092 64 046 2 I 60 376 I NUT TOP CRUSH PAD 8092 60 376 2 I 64 331 I BOOT CHA GE NAOl 64 331 1 MT 00 NAO BLACK I 64 344 I PLATE BACK BOOTS RIN G NAOl 64 344B 1 MT I 64 345A I BOX COIN CuNS...

Page 1155: ...260 64 419 1 I 64 425 I CASE LAMP NAOl 64 414 1 I 64 430A I LOCK CONSOLE REAR FBOl 64 43D 1 I 64 450 I LID CONSOLE _ _ NAOl 64 450A 1 00 NAO BLACK I 64 470 I HINGE NAOl 64 45XA 2 00 NAO BLACK I 64 481...

Page 1156: ...412B I 99863 0 12B Jr I _ 4 m IEff 90786 0616 1 1Il 4 4 1 AUJlAOI 5570 3 M CONSOLE T PART NQ IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO I 66 350 I NAOl 66 3S0A 00 t 03 66 350 0...

Page 1157: ...OOMET R CABLE METER COMPONENTS DASHBOA J RELATED P RTS CONSOLE VENT1LATOR SEATS Sr AT BELTS FRONT DOORS 66dZ 6700 Z N14 6701 2 015 6702 2 E15 6703 2 F15 6704 2 115 6720 16730 FRONT DO R MECHANXSHS 2 G...

Page 1158: ...0 161 1 STD COAT SLACtV8LAC I 00 NAG BLACK I 60 161Z I ORIlLE L DEMISTER NAOl 60 171 1 STD COAT BlACK BLAe 10 00 NAO BLACK I 60 UIA I UUCT R SlD DEMIST NAOI 60 183 1 I 60 UIY I DUCT L SlDE DEMIST N 40...

Page 1159: ...L US TR AT IOO CO N SI ST S OF 2 PA G ES 7H IS I LL OO T M TI C OOS I S O F 2 P ES 99849 040BB IS h 8E IS8 113AI IS8 110J AUNAOl f L Q 1RG J 188 105GI 188 117 I fr 8S 117 I r 88 10SGI chp8S 188AI if _...

Page 1160: ...1 A HA02 57 100E 00 NAO BLACK HAOl 57 100E 1 A HAOl 57 l00r 00 NAD BLACK NA02 57 100E 1 A NA02 57 100F 00 NAD BLACK NAOl 57 100F 1 BASE CLOTH W D HEAD SPK 00 M BLACK NA02 57H IOOF 1 PKO OPT CLOTH W H...

Page 1161: ...SE 0601 CClOTH W O HEAD SPK Oil NAO BLACK NAOZ 57 1S0F 1 PKG OPT 0601 CCLOTH W HEAD SPK 00 NAO BLACK I 66 960P I SPEAKER PIlLOW SEAT NA04 66 960A 2 PKG OPT W HEAD SPEAKER I 88 024 I PROTR R SEAT 8ELT...

Page 1162: ...NADl 8S 103 1 0201 A NAOl eft 103A NA01 S8 103A 1 11201 I 88 105B I BOLT LINK H260 8e l05 8 I 88 1050 I BUSH HINGE I H260 88 108 2 02 NAO BLACK _ I 88 106T I WIRE CONNECT NAO SS 106 1 I 88 108E I COVE...

Page 1163: ...T SEAT NAOI 88 130 1 BASE CLOTH W O HEAD SPK 00 NAD BLACK NAD2 8S 130 1 PKG OPT CCLOTH W HEAD SPK 00 NAO BLACK I 88 131 I TRIMlR SEAT BACK NAOI 8 l31 1 BASE PKG OPT CLOTH 00 NAO BLACK I 8S 132A I PADC...

Page 1164: ...PT CLOTH 99849 04088 00 NAO BLACK 18 pU I 88 161 I TRIMCL SEAl CUSHION NAOI U 161 1 BASE PKG OPT CLOTH 00 NAO BI ACK I 88 162A I PAOCL CUSHION FRT NAOl 88 162 1 BASE PICG OPT CLOTIH I 88 163A I FRAME...

Page 1165: ...81 I _ NA01 II Ul 00 _ _ I aa 18aA I NAOl 88 0a5 00 I 88 732A I NA01 U 732 I 88 782 I NAOl 88 782 188J8lBI Or14 c 0 99849 04086 2 J 1 0 CAT AUNA01 07 I 1 IOTY HODEL RESTRICTION TRIM L SEAT BACK 1 BASE...

Page 1166: ...8ELT B R FRT SEAt _ _ NA01 57 6 S0c 1 157 631 I DO NAO alACK _ _ I 57 631 I COVER ANCHOR NAOl 57 6318 2 00 NAO I ACK I 57 680 I BELT A RONT SEAT I NAOl 57 ao 1 00 NAO NAl BI ACK I 57 680A I EELT B L...

Page 1167: ...INGE DOOR _ _ B092 58 201 4 AN B092 58 201A B092 58 201A 4 I 58 210 I HINGECR DOOR UPPER FBOl 58 Z10 1 I 58 210Z I HINGECL DOOR UPPER FBOl 59 210 1 I 58 225 I BOLT SETTING HINGE L OWER B455 58 225 8 I...

Page 1168: ...4 I S8 S05e I SCREW WINOOW REGULAT OR 8092 58 505 6 I I I I 58 602 I GUIDE S R GLASS NAOl 58 603A 1 I 58 602Z I GUIDE B L GLASS _ _ NA01 59 603A 1 CHANNEL R DIVISION I I I 58 604 I I DOOR I NAOl 58 6...

Page 1169: ...58 760C 1 A NAOl 58 7600 NAOl 58 760D 1 I 58 760Z I WEATHERSTRIP L DOOR NAOl 59 760C 1 A NAOl 59 7600 NAOl 59 1600 1 58 762 I FASTENER 0031 58 162 42 _ _ I 58 772A I FASTENER _ _ _ 1011 58 772 4 I 58...

Page 1170: ...FLOOR ATTACHMENTS HOL COVERS 2 G08 5390 FLOOR ATTACHMENTS 2 C09 5500 DASHBOARD E UIPMENTS 2 ED9 5520 METiR HOOD 2 F09 5530 SPEFOOMETER CABLE 2 G09 5540 METER r OMPONENTS 2 109 5560 DASH90ARD RELATED P...

Page 1171: ...NER HANDLE NAOl 58 503 2 00 NAO HAl BLACK 58 310 I LOCK R DOOR NAOl S8 310B 1 I I 58 510Z LOCKCL OOOR I AOI 59 310B 1 _ 58 3148 JOINT H043 72 411 2 58 3150 I CLIP R GOlO 58 315 4 58 316A I CLIP BOOl 9...

Page 1172: ...C 1 58 420Z HANDLE L OUT NAOl S9 410A 1 ANCNAOl 59 410B NAOl 59 410B 1 A NAOl 59 410C NADl S9 410C 1 I 58 50SE I CAP 8092 58 355 2 BASE WI O POWER WIND 58 560 I REGULATOR R WINDOW _ NAOl 58 560B 1 BAS...

Page 1173: ...A 2 BASE W O POWER WINO I 58 861C SCREENCR FRONT DOOR NAOl 58 861A 1 BASE W lO POWER WINO NA02 58 861A 1 P G OPT V SPECIAL W lPOWER WIND I 59 315 I CLIP 0030 59 315 4 I 59 8 1 I SCREENCL FRONT DOOR NA...

Page 1174: ...WEATHERSTRIP L OUT NAOl 59 810B 1 9607 AN NAOl S9 810C NAOl 59 810C 1 9607 0306 ANCNAOI 59 810D NAOI 59 810D 1 J306 58 815A CLIP WEATHERSTRIP OU TER DI56 58 815 12 9607 NAOI 5S U5 12 9607 I 58 8158 I...

Page 1175: ...NO 00 NAD SLACK NA02 68 4208 1 PKO OPT V SPECIAL W IPOWER WIND 00 NAO BLACK I 6S 420Z I TRIM L DOOR _ _ NAPl 68 450B 1 BASE W IO POWER WIND 00 t lAO BLACK NA02 6B 450B 1 PKO OPT V SPECIAL W IPOWER WIN...

Page 1176: ...82 2 L14 6700 FLOOR ATTACHMENTS HOLE COVERS FLOOR ATTACHMENTS DASHBOARD EQUIPMENTS METER HOOD 2 N14 6701 2 D1S 6702 2 E1S 6703 2 F09 5530 SPEEDOMETER CABLE 2 G09 2 109 2 L J9 2 CIO 2 010 2 KIO 2 LlO 5...

Page 1177: ...SIIS I 6100 1 HEATER PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO 61 1 50 OUCT AIR _ _ NAOI 61 l50 1 9ADl G NAOl 61 150A NAOl 61 150A 1 9A01 I 61 211 I HOSE ND l WATER N...

Page 1178: ...RESTRICTION FROH TO _ I 6l AOl I CASE A HEATER UNIT NAOl 61 AOI 1 f 61 A02 I CASE B HEATER UNIT _ _ NAOl 61 A02 1 I 61 AIO I CORE HEATER UNIT NAOl 61 AlO 1 I 61 A20 I LINK SET n MP NAOl 61 A20 1 I 61...

Page 1179: ...5 1 I 6I C35 I WIRE MODE CONTROL e n6 S14 I NAOl 61 C35 1 I 61 C45 I WIRE RECYCLE I FRE H NAOl 61 C45 1 lSI COg 161 C30 I 6I CSO I SWITett FAN HEATER CO NTROL NAOl 61 C50 1 I 61 C95 I BUL8 MODE CONTRO...

Page 1180: ...N FROH TO t 90786 0612 I 61 801 I CASI A ILOW R UNIT NAOl 6l BOl 1 _ I 61 802 I CASE I ILOWER UNIT NAOl I a02 1 I 61 110 MOlOR FAN ILOWER UNI T NA01 61 810 1 I 61 815 I RESISTOR BLOWER UNIT NADl 6l B1...

Page 1181: ...TCH NAOl 61 193 1 I 61 197A I KNOB AIR CON _ NAOl 61 197 1 I 61 4H1 BRACKE1 HOSE NAOl 61 4Hl A 1 I 61 4J4 I RUBBER INS CONDR NAOl 61 4J4 CA 4 I 61 46Y I CLIP PIPE I 8Rll 61 46Y A 1 8R76 61 46Y A I 1 B...

Page 1182: ...l 61 467C 1 NAOl 61 467C A 1 I 61 467 I PIPE NO S COOlER NAOl 61 46a CA 1 I 61 470A I BRACKET HOSE NA02 61 470A 1 AN NA02 61 470B NA02 61 70B CA 1 I 61 471 I CLlP PIPE BF67 61 n1 CA 1 I 61 4721 I BAAC...

Page 1183: ...NAOI 61 487 1 I 61 486A I CLIP UB39 61 486A 2 I 61 500 I TANK LlQUID T NAOl 61 SOO A 1 f 61 526 f HOSE DRAIN NAOI 61 526 A 1 I 61 528E I BAND NAOI 61 43S 0 2 I 61 5358 I PLATE NO 1 SEAL NAOI 61 52YA A...

Page 1184: ...UN T 161 486AI ffi 466 1 REFER TO SECT NO 99796 061 6150 t I A U AO _ _ 2 J 12 130 4 M AIR CONDITIONER PART NO JOTY HOOEL RESTRI rl0N HODEL RESTRICTION HOOEL REZTRICTIOH FROM TO I 61 558A I ORCMlET 8...

Page 1185: ...HODEL RESTRICTION HODEL RESTRICTI N HODEL RESTRICTION FROM TO I 61 JIX I RINO O NO l OJY1 61 J1X A 1 I 61 J1XA I RINO O NO 2 OJY2 61 J1X A 1 I 61 JIX8 I RING O NO l OJY3 61 JIX A 1 I 76 700 I RING SET...

Page 1186: ...ll CA 1 I 61 K12 I HEAO CYL COMPRESSOR ot NA02 6l K12 CA 1 I 61 K19 I SEAL SHAFT COMPR F06 61 K19 1 I 61 1 20 I GASKET KIT CQMPRESSO R A 2 61 K2X CA 1 ISl K28 I l _ II 1 6T rrr 111 K391 rv I 61 K23 I...

Page 1187: ...Lll I ARMATURE MAGNET CLUT _ _ CH F06S 61 Lll 1 161 Ll4 I I 6l Ll2 I PULLEY MAGNET CI UTCH NAO 61 Ll2 A 1 I 61 Ll3 I COIL FIElD MAGNET CL UTCH F06 5 6l Ll3 1 I 61 Ll4 I BOlT MAGNET CLUrCH F065 61 L14...

Page 1188: ..._ NAOl 61 JOl A 1 I 61 J02 ct SE B COOLING UNIT NAOl 61 J02 CA 1 I 61 J04 I SEAL COOLING UNIT Ol 61 J04 A 1 I 61 JIO I EVAPORATOR _ NA01 61 JIO A 1 I 61 J14 I VALVE EXPANSION NAOl 61 J14 CA 1 _ I 61 J...

Page 1189: ...WITCHES RELAYS ENGINE 2 014 6 10 DASHBOARD SWITCHES 2 E14 6611 COMBINATION SWITCH 2 F14 6630 REL_YS UNIT BODY 2 G14 6635 ODOR SWITCH HORNS 2 H14 6640 AUTO CRUISE CONTROL SYSTEM BODV PANELS DASH COWL P...

Page 1190: ...NAOl 63 o95 1 OPTION W OETACHABLE TOP B COLOR r I 63 901 I GLASS WINDSHIELD NAOl 63 901 1 I 63 931 I GLASS BACK WINDOW NAOl 63 931C 1 OPTION W DETACHABLE TOP B COI OR I 63 936 I PROTR BACK WINDOW UP...

Page 1191: ...S OF 2 PAGES 6330 SUNROOF 2 2 W O DE T A CH A B LE T OP I R l_ 2 10 A I N AO 2 R I 36 la I S I TI I S O F 2 p r NA02 RI J7IB IB 1 81oI I 99174 04168 _ _ I dACK MINDO I REFER TO SECT NO bJOO I I I l __...

Page 1192: ...Rl 210E 1 A NAOI RI ZIOF NAOI RI ZIOF I AN NAOI Rl ZIOO NAOl RI 2100 1 I RI ZII I CLOTH REPAIR TOP NAYI RI 211 I I RI 240A I WINDOW BACK D TOP NAYI Rl 240C BLACK 1 I I RI 42 I TAPE SEAL RAIN RAIL NAYI...

Page 1193: ...01 W OETACHABLE TOP B COLOR Rl 33lA I HANOLE SOFT TOP NAD1 Rl 3oll 1 I Rl S8X I HOOK SOFT TOP REAR 0 Eel NAOl r 1 38XA 2 9801 A NA01 Rl 38XB NAOI RJ 38XB 2 9801 Ri 3SI I PLATE R HOOK REAR 0 ECK NAOI R...

Page 1194: ...1 I Rl 461 NAOI Rl 4218 1 I Rl 46 NAOI Rl 4 2B 1 I Rl 463 I NAOI Rl 4238 1 I Rl 491 I NAOI Rl 491 16 I Rl 560 NAOI Rl 560C 1 I Rl 5151 I NA01 Rl 5818 1 I Rl 5 2 I NArl Rl 582A 1 I Rl 592 NAOI Rl 59 A...

Page 1195: ...731B NAOI Rl 7318 1 0116 I Rl 741 I PROTRCR HOULD BELT LINE NAOI Rl 741A 1 9601 A NAOI Rl 741B NAOI RI 741B 1 9601 I RI 742 I PRDTRCL HQULD BELT LINE NAOI Rl 742A 1 9601 A CNAOI Rl 7428 NAOI RI 7428...

Page 1196: ...P BL UE NAD4 Rl 82X 1 OPTION 0401 W DETACHABLE TOP WH 11 I Rl ISlOC I ROOF OF TACHABLE TOP NA02 Rl 810C 1 0101 A NA02 RI 81DE NA02 Rl 810E 1 0101 0201 AN A02 RI 810F NA02 Rl 810F 1 OPTION 0201 W oETAC...

Page 1197: ...371A 0201 A CNA01 Rl 371B NA02 Rl 371A 1 0201 A NA02 Rl 371B NAOI RI 371B 1 0201 NA02 IU 3718 1 0201 I Rl 882A I RETAINER R WThSTP O TOP NAOI Rl 882 1 I I Rl S9X I WEATHERSTRIP O TOP R I EAR I NAOI RI...

Page 1198: ...5 Rl 953 4 I I Rl 958 I WASHER HOOK A 8 B B235 R1 958A 7 I Rl 96X I COVER TOP FABRIC NAOl Rl 96XA 1 9COl A NAOI R1 96XB NA01 Rl 96XB 9C01 I Rl 970 I HOOK REAR DECK NAOI R1 970 4 9701 A CNA01 Rl 970A I...

Page 1199: ..._ AUfUO I 2 L1 3 63 0 8 If SUNROOF PART NO IOTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRlrTION FROH Tn I 68 865C I FASTENER GU32 68 a65A 2 9301 00 r AO BLACK 68 86SQ I FAl fENER I OJ21 68 885A...

Page 1200: ...43 1 I 17 630 I SWITCH 8118 17 640A 1 9501 A 8118 17 6408 8118 17 640B 1 Mf 9501 1 7 640 I SWITCH BACK UP LAMP 1391 17 640 1 MT 9831 MS06 17 640 1 Mf 9851 I 18 T41 I RING IOI WATER THERM o SW F8B5 18...

Page 1201: ...D B61P 18 2FOB 1 9A01 I 18 811 I RELAY MAIN 66S8 18 811 1 I 18 821 I RElAY CIRCUIT OPEN _ _ 236 18 821 1 I I 18 840C I SENSOR WATER TEMP N350 18 840 DENse I 1 I 15574 1S 840 NIHON THERMOSTAT I 18 8619...

Page 1202: ...30 2 M13 6600 2 014 6610 2 E14 6611 2 F14 6630 2 G14 6635 2 Hl4 6640 2 114 6680 2 K14 6682 2 L14 6700 H14 6701 2 01 6702 2 1 15 6703 2 f15 6704 2 115 6720 2 K15 6730 2 M15 6740 2 N15 6820 2 C16 6840 2...

Page 1203: ...ER 1758 19 838 2 I 21 291 I SWITCH OIL PRESSURE 8U55 Z1 2Jl 1 AT I 21 292 I RIN 0 BU01 21 292A 1 AT I 21 293 I SOLENOID OVER DRIVE BIJSS 21 2J3 1 AT I 21 294 I RING 0 _ _ _ _ BU01 21 294 1 AT I 21 295...

Page 1204: ...R CLUSTER NA01 66 170 1 I 66 250 I LIGHTER ClOAR 8150 66 250 1 99863 05128 I 66 251 I RINQ ILLUMINATION 8001 66 251 1 I 66 340 I SWITC H MAIN NA01 66 340A 1 PK G OPT W AUTO CRUISE CaNT I 66 462 I BUL...

Page 1205: ...ers will be inforHd you by the Parts Ensineerina Chanae Bulletin as soon as established j j 6611 1 COMBINATION SWITCH PART HO loTY HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROH TO _ I 110...

Page 1206: ...O NAOl 67 700 1 ANCNAOl 67 700A NAOl 67 7GOA 1 I 67 720C I TIMER BUZZER NA02 67 720 1 I 67 1403 I RELAY N O H300 67 740 30A 1 HEAD LAMP RELAY LAIO 67 740 lOA 2 HORN RELAY SMALL LAMP RELAY CMT 3 HORN R...

Page 1207: ...1 I JJ 1 DOOR SWITCH HORNS I u ocuI PART NO _ I 66 546 I LAOl 66 54 _ I 66 790 I SA59 66 790 _ _ I 66 820 I B455 66 540 I CAT AUNAOl 07 lOTY HODEL RESTRICTION SCREW DOOR SWITCH 2 HORN LOW TONE 1 SWITC...

Page 1208: ...2 I BRACKET ACTIIATOR FRO NT NAOl 66 3A2A 1 I 66 310B I ACTUA1OP A C C LAOI 66 310A 1 I 66 311 I WIRE A e C NAOl 66 311A 1 I 66 320 I BOX A e C NAOl 66 320 1 Mf NA03 66 320 1 CAT I 66 361 I PIPE AUTO...

Page 1209: ...ASE 9801 WI O AUDIO I 55 235C I ORNAMENT STEREO LOWE R LA02 55 235 1 BASE WI O AUDIO I I 66 ACO I TUNER DECK COMB I NAOl 66 ACO 1 PKG OPT WI AUDIO I 66 AGO I PlAY R COMPACT DISC NAOl 66 AGO 1 OPTION W...

Page 1210: ...E DECK PART NO loTY HODEL RESTRICTION HODEL RES TRICT ION I HOOEl RESTRICTlO 1 FROH TO 66 904C BRACKET LOW NAOl 66 AT6 1 BASE PKG OPT WI Q C DISC _ _ I 66 912A I KNOB TONE TUt E R NAOl 6 BR2 1 PKG OPT...

Page 1211: ...LOW RADIO l NTEN N NAGl 66 A3X 1 P O OPT CW M TENNA I 66 9 5 I FEEDER ANTENNA NAOl 66 940 1 I 66 i41 I POL AtHENNA NCOl 66 A30 1 PKU O r _ _ I 66 950C I NAOl 66 900A I 66 91 1JM I _ _ NA03 66 960 A N...

Page 1212: ...66 732D I NAOl 66 731A COVER FUSE BLOCK FURUKAWA 1 I S6 732E I lABEI CAUTION FUSE C _ OVER 116 730 1 9 Bl1l NA01 6t 73ZA I 66 73 sA I HOOl 66 n3 _ I 66 740 I H001 66 739 I 67 671 I 1 BREAJo ER 1 HOLO...

Page 1213: ...NA04 67 010 1 9COl 0401 AN NA04 67 010A NA05 67 010 1 9C01 04Dl AN NA05 67 010A NA04 67 010A 1 BASE 0401 W O HEAD SPEAKER eMf NAOS 67 010A 1 PKG OPT 0401 W HEAD SPEAKER M NA06 67 010 1 W O AIR BAG 07...

Page 1214: ...NADl 66 7ciOB 1 I 66 761 I COVER MAIN FUSE BLDK NA02 66 762B YAZAK l I I 66 766 I COVER UNDER MAIN FUS E BLK B 65 66 767 1 I _ _ I 66 9912 I taRE EARTH I _ _ NAOl 67 EWIA 1 AN NAOl 67 EWIB NAOl 67 EW...

Page 1215: ...TEMS RADIO TAPE DE CK 2 107 5340 2 COa 5570 2 F08 5380 2 G08 5390 2 C09 5500 2 E09 5520 2 F09 5530 2 G09 5540 2 109 5560 2 L09 5570 2 CIO 5580 2 010 5100 2 K10 5790 2 L10 5800 BODY PANELS SIDE BODY PA...

Page 1216: ...99940 0603 67 D33A BRACKET WIIUNO NAOI 67 810e 1 I 67 070 HARNESS ENGINE NAOl 67 070C 1 W AIR BAG AT t OI 67 070F 1 9701 ANCNAOl 7 070H NAOl 67 070H 1 9701 9801 AN NAOI 67 070J NAOl 67 070J 1 W AIR BA...

Page 1217: ...NAOl 67 B31 1 eMf I 67 030 I HARNESS INSTRUMENT NA03 67 030C 1 CAT NAOl 67 0300 1 9101 A NAOl 67 0l0H NA02 67 030D 1 9701 A CNA02 67 030H 67 030 I NAOl 67 030H 1 9701 9AOI ANCNAOl 67 03OK NA02 67 030H...

Page 1218: ...RESTRICTION HODEL RESTRICTJON HODEL RESTRICTION FROH TO I 67 1900 I HARNESS DOOR _ _ _ t A01 67 190 2 9701 ANCNAOl 67 190A NA02 67 19D 2 9701 ANCNA02 67 190A NA01 7 190A 2 PKO OPT 9701 CW O POWER WIN...

Page 1219: ...013AJ 167 0illJ UHI4n 167 022 99786 0612 99786 0620 CVI67 026 I IS7 048AI 167 051 J 9 D167 0S1JI l67 0S2HI f 99786 0612 IS7 062BI 167 073 I l6 f073Al 167 073BI j IrJ7D 67 191 I I cf 1 2 ffP r 90845 06...

Page 1220: ...1 ANCN001 67 CS1C NOOl 67 CSIC 1 _ _ I 67 CT2 I CLIP HARNESS NAOl 67 CHS 1 I 67 011C I CLIP E356 15 141 1 _ 67 0 3A I CLIP UB42 67 013 1 I 67 013D I PROTECTOR HARNESS NAOl 67 P54 3 I 67 U14F I PROTECT...

Page 1221: ...A 3 9701 f J 99786 0612 1 I 67 06 B I CLIP HARNESS NA02 67 CS1A 1 I 67 072H I CLIP ENGINE HARNESS sj 062BI GIS7 073 167 073AI 167 073nl Qj167 070 IS7 191 I _ NAOI 67 CS6 1 k2 1 2 rttP 90845 0612 1 999...

Page 1222: ...HOSE LAOl 67 S0S4 1 66 941A I CLIP OB08 66 941 4 I 67 480 I TANK WASHER FRONT NADl 67 4ISD 1 BASE W WASHER TANK 2 2L NA04 67 4aOA 1 PKG OPT W WASHER TANK 4 SL 67 501E I PIPE NOZZLE FRONT WA SHER NA04...

Page 1223: ...ASHER PART NO JOTY HODEL RESTRICTION HOOEL RESTRICTION HODEL RESTRICTION FROH TO I 67 510 I NOZZL WASHER F WIND NAOl 67 510 2 I 67 521 I BRACKET WASHER TANK NA01 67 520 1 BASE W WASH R TANK 2 2L NA04...

Page 1224: ...A04 67 340A NA12 67 340A 1 67 4ia I 04 5 67 69 BLADE WIPER FRONT BlAO f WIP R FRON fliOTOR WIPER SPEC eye COLD 1 COLD SPEC C OLD SPEC EX p c AIR BAO COLD 1 W 0 SP AIR bAG COL W O EC lINK WIPER r16 6o...

Page 1225: ..._ 167 321DI 167 350 I AU OI 0 176 641 I 9S940 1 801 2 L1 5 76 657 I NAOI 67 363 I 76 658 I NAOl 67 364 I 76 659 I NADl 67 361 I 76 659A I NAOl 67 362 iI CAT AUNAOI 01 I SHA r D IVE NO 1 1 SHAFT DRIVE...

Page 1226: ...PEC NA17 67 l51 1 W O AIR BAG COlD SP EC NA23 67 351 1 EXC COLD SPEC NA26 67 351 1 W AI BAG COLD SPEC 76 619 I PARTS Sl T H043 76 619A 1 I 76 661 I GEAR SHAFT 8455 67 354 1 EXC COLD SPEC NA04 67 354 1...

Page 1227: ...8 090 1 9330 00 NAO BLACK NAOl 68 090A 1 1 9330 00 NAO BLACK 168 160J IS8 06101 _ _ _ _ I 68 160 I TRIM R A PILLAR NAOl 68 160 1 00 NAO BLACK c I 68 160l I lRIMCL A PILLAR NAOl 68 170 1 00 NAD BLACK I...

Page 1228: ...DY PANELS FENDER WHEEL AP RON 2 H14 6640 BODV PANELS DASH COWL PANEL 2 114 6680 BODY PANELS SIDE BODV PANELS FLOOR FLOOR ATTACHMENTS HOLE rlOOR ATTACHMENTS DASHBOARD EQUIPMENTS METER HOOD SPEEDOMETE C...

Page 1229: ...T SIDE NAOl 68 390 1 00 NAI BLACK I 68 4028 I GRDf MET SCREW FA54 68 719B I I 68 711 I PLATECR FRONT SCUFF NAOl 68 710 1 BASE PLASTIC TYPE 00 NAO BLACK I 68 71lZ I PLATE l FRO IT SCUFF NAOl 68 720 1 B...

Page 1230: ...I I I I I I I I 16 8 320 I AUUOJ 6840 2 M TRIMS SCUFF PLATES PART NO Jon HODEL RESTRICTION HODEL RESTRICTION HODEL RESTRICTION FROM TO CONT D 00 NAO BLACK I 68 865S I CLIP TRIM GJ12 61S 865 2 I 68 890...

Page 1231: ...R FENDER _ _ NAOI 68 6N 1 I 68 615B I NUT FLANGE CAP 8100 68 615 5 NAOl 68 615 1 I I 68 630A I INSULATOR DASHBOARD I NAC 68 631A 1 I 0701 A NAOI 68 631B 01 68 6318 1 0701 I 68 651F I PAD FRONT FLOOR _...

Page 1232: ...LACK I 8 81C I COVER BATTERY _ I NAOl 68 819B 1 OU NAO BLACK I68 6N4 I 0 I 0 J68 820AI 0 I 68 820A I COVER SPARE TIRE NAOl 68 8P9A 1 I 68 865 I FASTENER BOOl 68 865 2 00 NAO BLACK 1 8 6N21 t 68 865C t...

Page 1233: ...EL RESTRICTION I I I 68 070 I WRENCH HUa NUT _ _ 0810 68 070D 1 NAOl 6 070 1 I 8 660A i TOOL SET NA01 M 650 1 I 68 610 I 8AQ TODL _ _ _ _ 8173 69 670 1 NA01 69 670 1 I I 9421 HA35 M I01369 9601 NAl5NN...

Page 1234: ...ETALLl _ _ 110Y I MIRRDR L DOOP NAOS 69 180 1 DU OU MARINER BLue HU HU NED GREEN SU SU CLASSIC RED UC UC cnVSTAL WHITE 3L 3L SILVER STONE MET LLI I 69 170 I MIRROR INTERIOR NAOl 69 220 1 00 NAO BLACK...

Page 1235: ...NO lory HODEL RESTRICTICN MODF L RESrRICTION HODEL RESTRICTION FROH TO I 69 225 I COVER lNTERIOR MIRRa _ R OJ21 69 225 1 00 NAO I ACK I 69 240A I eASE INTERIOR MIRROR NAOl 69 240 1 99862 05208 I t 99...

Page 1236: ...ION A B NA01 S7 K91 1 W AIR BAG I 57 K92 I LABEL B CAUTION A B NA01 S7 K92 1 W AIR BAG _ I 67 1Xl I NA01 67 MX1 I 69 Al S I GJ21 69 A13 _ I 69 C i I UB40 69 C61 I 69 013 I 1 NAO 1 611 l lA A NAOl 69 D...

Page 1237: ...ODEL RESTrICTION HODEL RE5TRICTIOH FROM r 1 CONTIC NAOl 69 036A 9C2D A NAOl 6Q 036C NA04 69 036 1 9C2D A NA04 69 0366l 19c20 0701 NAOl 69 036C 1 CALIF NA04 69 036B 1 FED 9C20 Ui 01 NAOl 69 0360 1 AL I...

Page 1238: ...20A 00 I 6B S20Y I t NA01 i8 550A 00 TRIHC R QUARTER 1 eASI WID DETACHABLE TOP NAO NAl B ACK 1 OPlION W ol TACHABLE Tor INAO NAl BLACK TRIM L QUARTER 1 BASE 1 0 DE rACHA8l TOP NoAa NAl BLACK NA02 68 5...

Page 1239: ...orporation lAYOCT OF CONTENTS The followinq IS cI IYPlc lIlIpll f t lt layout of r ntc Jt Jr ijl iJ microfiche parts Cd 2 t 7 y 1 r FP7i 7 r I _ t J 1 u I I I _ _ 0 _ _ c l L3yout 01 contt nts St rIIO...

Page 1240: ...NE T MISSION MQUNTINGS GASKET SEAl KIT AUTOMATIC t im1950 01 I MANUA l UHKAGE SYSTEM o AUTOMAT1 1 OJ 1940 U GOVERNOR LOW PISTON AUTOM TIC ENGINE 1 2 o III 1930 ClUTCH PLANETARY GEAF S AUTOMATIC flmmmm...

Page 1241: ...61850 BA TTERY STARTER AL TER JA TOR 61310 EXHAUST ANIFaLD PICTORIAL INDEX FUEL SYSTEM FUEL DISTRIBUTOR ENGINE 2 2 o I m YSrfM AIR CLEANER BRAe I PUlLi S IH l T II 1364 THROTTl E BODY II 1370 EMISSION...

Page 1242: ...be 10 lome pariS I dolletenl n weor catiotls Irom 1M k led In Ihls e l_1og PICTORIAL INDf X 2600 II 2610 REAR AXLE REAR BRAKE MECHANISMS CHASSIS 1 2 I W II 2710 RE I FERENTIALS REAR SPRING DAMPER 2830...

Page 1243: ...TER CYLIHOERS CLUTCH PIPINGS TIRES JACK MANUAL TRANSMISSION MANUAL TRANSMISSION ACCELERATOR CONTROL SYSTEM FUEL TANK CLUTCH BRAKE P Uk S CHASSIS 2 2 B 4340 o BRAKE MASTER CYLINDER POWER BRAKE 6 4360 B...

Page 1244: ...6701 m6720 WI lDSHIElD WASHER WINDSHIELD WIPERS BODY 1 4 IE 1m m WIRING HARNESSES m ENGINE TIMISSION I n w m6700 m6640 m l35 IE 6630 WIRING HARNESSES J FRONT REAR AUTO CRUISE CONTROL SYSTEM DO lll SW...

Page 1245: ...on pe r IQ 1 am 1 part 5slerl to Ih s pat1 c t roq PICTORIAL INDEX g S010 05030 m OULOING REAR BUMPER COWL GR LLES m6300 f1l 6330 m iJ GD WINDOW GLASSES SUNROOF ACCESSOR rES BODY 2 4 IE 5180 REAR FINI...

Page 1246: ...INDEX D 5500 65520 II 5530 D 5540 _DA_S_HB_ _R_D_Ea_UI_PM_EN_T_S ____ __ PE ED O E METER COMPONENTS BODY 3 4 o 6 L_l DASHBOARD RELATErI PARTS CONSOLE 6115 HEATER m6130 61 V 614 6135 6150 AIR CONDITIO...

Page 1247: ...J 7 y 1 CAUl ON r LAlfS t lA Hl VISOn AS 151 HANOL S I MIRA II rn 6870 rn 6930 IlllOH MA f S PADS _ rI 1 f j i L l 4 J t Uf rItJW I J 1J4J fJJI I r U t i _________ J n JlC f TnOI 3 J 1 l I I t 1 i I I...

Page 1248: ...IP INLET EXHAU ST SIDE 1 N04 1400 OIL PUMP FILTER I COS 1500 COOLING SYSTEM I GOS 1580 BRACKET PULLEY BELT l C06 1600 CLUTCH DISC COVER MANUAL 1 006 1700 TRANSMISSION CASE O ANUAL 1 c06 1710 TRANSMISS...

Page 1249: ...10 STEERING COLUMN SHAFTS 1 M12 3220 STEERING GEAR W O POWER STEERINr l Cll 3220 A STEERING GEAR W POWER STEERING 1 F13 3240 POWER STEERING SVST M 1 HI3 3300 FRONT AXLE 1 Il3 3310 FRONT BRAKE MECHANIS...

Page 1250: ...NELS DASH COWL PANEL 2 I14 6680 AUDIO SYSTEMS RADIO TAPE DE CK 2 107 5340 BODY PANELS SIDE 2 K14 6682 AUDIO SYSTEMS ANTENNA SPEAK ER 2 COB 5310 BODY PANELS FLOOR 2 L14 6700 WIRING HARNESSES FRONT REAR...

Page 1251: ...2 012 5540 5560 5570 5580 5700 5790 5800 5830 5840 6100 6110 METER COMPONENTS DASHBOARD RELATED PARTS CONSOLE VEN ILATOR SEATS SEAT BELTS FRON DOORS FRONT ODOR MECHANISMS 2 F15 2 115 2 K15 2 M15 2 N15...

Page 1252: ...FLAP REAR MUD NA01 Vl 460 1 I V3 040 I TRIM RING SeT 0000 a8 0014 1 M5 V3 841 TRIM RING 0000 aa 0014 it 01 V4 1S30 DECK RACK 0000 U 5305 1 BK BLACK CM CHROME V4 900A AIRDAM SKIRT FRONT 00OO 86 5l0A 1...

Page 1253: ...S11 AUIlAOI o 0 93 841 I LY3 841 I I 3 41 I I IV3 41 11 I j3 840 I I I 1 00 2 ACCESSORIES PART NO lOTY HODEL RESTRICTION MODEL RESTRICTION HODEL RESTRICTION F llH YO I VIi 270 I CHROME VALVE COVER NA...

Page 1254: ...EZA Eill IMlce II Ofdena en 101 QUI n e lI4 ncl pros GENERALES I EJEMPLO o Tipo cit modelo Tercem en III lecuenc de Ii de modelo lentr laS clfta 1t0 4IO lugwl oGtupo Ptrmero en Ia lecUincl d4 Qf C O 1...

Page 1255: ...ll SHO I M3 B61P 13 1l1 B6YO ll SJO 100 M3 B61P 13 H 1 B6Yl 11 SJO 1 M3 B61P 13 140 B6YO ll SKX I M3 FE4J 13 146 B6Y1 11 SKX I M B61P 13 150 B6YO ll SKY I M3 8574 13 157 B6Yl ll SKY I M3 B6 0 11 51 0...

Page 1256: ...432 BU55 19 440 BU55 19 444A 0338 19 446 0338 1c 449 BUI7 I9 450 BUS5 19 460 BU55 19 470 0338 19 475 BVOl 19 476 0338 19 476 BVOl 19 480 033a 19 4BO 0338 19 486 0338 19 487 0338 19 488 BUI7 19 49a 03...

Page 1257: ...NAOl 34 S50 1 L13 NAOl 32 100B 1 L12 B461 32 800A I JI2 NAOI 34 700 I M13 NA07 32 100A I LIZ NAOl 32 850 l LI2 NAOl 34 800 1 N13 NA02 2 11X 1 C13 G030 32 961 l E13 NAOI 34 800A 1 N13 NAOl 32 110 I MI...

Page 1258: ...850D3L 2 J6 NAOl 50 852 2 J6 LA01 50 853 2 K6 B388 50 855 2 K6 GJ21 50 B91 2 C13 NAOl 50 894 2 C13 1f NM MMMM N MMM MM If 51 000 If If N M M H272 51 RC6 2 J5 NA01 51 AX 2 M5 NAOl 51 SA5 2 M5 NA01 51 S...

Page 1259: ...121 NAOl 60 141 NA01 60 161 00 NAO 60 171 00 NAOI 60 183 NAOl 60 19 S NAOl 60 220 00 NAOl 60 223 00 NAOl 60 230AOO NAOl 60 35X 00 NM1 60 350 00 B092 60 316 NAOl 60 401BOO NA01 60 401COO NAOl 60 407 6...

Page 1260: ...180 NAOl 69 220 GJ21 69 225 NAOl 69 240 NAOl 69 270A02 NAOl 69 270B02 OU 2 H16 HU 2 HH SU 2 H16 UC 2 H16 3L 2 H16 DU 2 H16 HU 2 H16 SU 2 H16 UC 2 H16 3L 2 H16 OJ 2 H16 00 2 Il6 NAOl 69 320B02 NAOl 69...

Page 1261: ...0050 99655 90055 99655 90060 99100 7180 99101 2010 99701 3210 99701 4278 99101 4278Y 99701 5050 99101 6030 99101 6038 99705 1130 99963 6310 99963 6315 99963 6330 l C14 1 014 1 014 1 014 1 014 1 014 1...

Page 1262: ...NEL BRKT OIAGNOSI5 UNIT BRKT DIAONOSIS POWER UNIT BRr T SURGE TANK BRACKET SET DA POT THRO BRACKET L CABLE BRACKETCL ENGINE BRACKE1 Ll F BUMPER SIDE BR CKETCL HrNGE LAMP LID JRACKET L INST B ACKET L R...

Page 1263: ...0 GEAR INTERNAl 1 09 1 H16 COVER 80x 2 J9 ORUM CONNECT NG I D9 rRAME R REAR SIDE 2 C8 I La 1 Il6 COVER CLUTCH l C6 DRUM OIRECT I N8 FRAMEeUp L FROtH FRT 2 F7 GEAR MAIN ORIVE l E6 l L16 COVER COlUMN lO...

Page 1264: ...l CORNER Q PANE 2 L7 JUNCT ONel FRT FLOOR 2 08 JU JCT ON R FRT FLOOR 2 C8 JUNCTION DASH SIDE SILL 2 H7 MM M M K M NMM KEY SET 2 C5 KEY UB SET L OOQR 2 C5 KEY sue SETeR OOOR 2 C5 KEf sue SET CONSOL 2 0...

Page 1265: ...PlATECR END 2 J7 POLE ANTENNA 2 K14 PlATECR FRONT SCUFF 2 C16 PRESSURE RG FUEL I H4 PLATECR HOOK REAR DECK 2 F13 PROTECTOR I F4 PLATECR SEAL 2 J7 I Fl1 PLATECR SET TOP FABRIC 2 G1 2 014 PLATECR SIDE R...

Page 1266: ...AR 2 G8 1 F7 SWITCH BACK JP LAMP Z M13 2 M5 SCREW WINDOW REGULATOR 2 MIO SHTELDCR SPLASH REAR 2 G8 SPRING COIL FRONT I MI3 SWITCH CLUTCH I MIS 2 03 SEAL KIT I F15 SHIELO SPLASH 2 G8 SPRING C01L REAR l...

Page 1267: ...L INDEX MM ENGLISH MMM MMMMMMMW MMMMWMM M M M W M M M MMMM MM MMM M M WASHER 1 013 I Hll I Ill l K13 I Lll I M8 I N8 I N12 2 MS 2 M1 2 M15 WASHER SET l E7 WASHER COMPRESSOR 2 L12 WASHER HOOK HOOO COVE...

Page 1268: ...CD g tI ell Ii l t D o 0 VI s VI c 5 s ceQ Fe GE 1 6 OH lorn AT He AT S 55 20 40 NO l S 2 HA01 Cl GE 1 6 OH NT 5S 20 4DS NO lW lbr Jul HA35 t 100001 89 80 200000 HA02 Cl GE 1 6 Dii NT 55 20 4DS L5 2...

Page 1269: ...LE TO FINU OUT NECESSARY COLOR CODE OF PART YOU NEED IN THE TEXT BODY PAIN INH AIOO COL CODE NAME CODe MAMINER BLUf au NAO J r_ __t _____ CLASSIC RED SU NAQ CRYSTAL WHITE uc NAO 1_S_I_LV_E_R_S_T_G_ _E...

Page 1270: ...2 AD3 CL GS 1 6 oK At lie 45 20 405 ND n HA04 D Gt U OK I T 55 20 OS NO 2w IUO 5 0 GS 1 6 DH iIlT 55 20 OS LS 2W H 06 0 08 1 8 OH J r f C 4S 20 4DS HO 2 AT Complete assemblies are available an j manuf...

Page 1271: ...t L __ Miscellaneous identification code 1 U S A 2 Canada SYdy style code i35 2 door L CM 0 INA_ MIAT ries I World manufacturer identifier All Mazda passenger cars under U SA Canada specifications are...

Page 1272: ...p ID l Il Or jTl St to D bot f l Dual I retlV iItIIl Top o l T UCk OarkYt fIO EWV Cc nrT 5 o0 I E CO O EI lCt CO Or 1 0_ s Q S sl E 1 G l D ljj ec toQf E r J GelS C O l S Y1 O S l l E r U dI f I J f S...

Page 1273: ...Shu 1t l S w 5 r 5 oe P St s o bti s 1 0 l Jr S q S IJ t l 0 Jc I 1 c t4P it N _ 6 4 W v a V 1i i r t r I t tr U k If tUII vA v C i l9f vGR i 11 11 ir JI W 0 i I lUAt w 4 1 liP iii r r t 1t J A ltt I...

Reviews:

No comments

Related manuals for 1990 MX-5

Harbor Freight Tools 92043 Assembly And Operating Instructions preview
92043
Brand: Harbor Freight Tools Pages: 4
Jeep 2009 Wrangler Quick Reference Manual preview
2009 Wrangler
Brand: Jeep Pages: 12
Jeep 2008 Liberty Installation Instructions Manual preview
2008 Liberty
Brand: Jeep Pages: 6
LAMBORGHINI URUS Quick Manual preview
URUS
Brand: LAMBORGHINI Pages: 48
Metra Electronics 95-6556 Installation Instructions preview
95-6556
Brand: Metra Electronics Pages: 4
Rostra REARSIGHT OnStar 250-8822 Installation Instructions preview
REARSIGHT OnStar 250-8822
Brand: Rostra Pages: 2
IBASE Technology MPT-3000V User Manual preview
MPT-3000V
Brand: IBASE Technology Pages: 100
Modifry Products S2000 Windscreen Camera Mount Quick Start Manual preview
S2000 Windscreen Camera Mount
Brand: Modifry Products Pages: 2
iArmor EDGE IA-N098 Quick Start Manual preview
EDGE IA-N098
Brand: iArmor Pages: 4
Waeco 8885100124 Operating Manual preview
8885100124
Brand: Waeco Pages: 172
VBG 56-201901 Mounting Instructions preview
56-201901
Brand: VBG Pages: 16
Whispbar K607W Fitting Instructions Manual preview
K607W
Brand: Whispbar Pages: 14
Prorack K544 Fitting Instructions Manual preview
K544
Brand: Prorack Pages: 20
Buick 2015 LaCrosse Getting To Know Manual preview
2015 LaCrosse
Brand: Buick Pages: 20
Volvo V70 2014 Quick Manual preview
V70 2014
Brand: Volvo Pages: 16
wtw spectroFlex Car Adapter Operating Manual preview
spectroFlex Car Adapter
Brand: wtw Pages: 4
KAP HK CARPLAY 10w Instruction Manual preview
HK CARPLAY 10w
Brand: KAP Pages: 22
Honda 2002 Accord Coupe Owner'S Manual preview
2002 Accord Coupe
Brand: Honda Pages: 367

Brands by name

Popular brands

Load more brands