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Mazda 323 1988, Workshop Manual

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Summary of Contents for 323 1988

Page 1: ...323 1988 Workshop Manual...

Page 2: ...ll be made available at Mazda deal ers This manual should be kept up to date Mazda Motor Corporation reserves the right to alter the specifications and contents of this manual without obligation or ad...

Page 3: ...TAL PROCEDURES G 2 JACK AND SAFETY STAND RIGID RACK POSITIONS G 6 VEHICLE LIFT 2 SUPPORT TYPE POSITIONS G 6 TOWING G 7 MAINTENANCE NOTES 4WD MODEL G 8 CHASSIS NUMBER LOCATION I G 8 ENGINE MODEL AND NU...

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

Page 5: ...orrecting a problem try also to determine the cause Begin work only after first learning which parts and subassemblies must be removed and disassem bled for replacement or repair DISASSEMBLY If the di...

Page 6: ...parate or otherwise identify the parts to be replaced from those that will be reused 3 Cleaning parts for reuse All parts to be reused should be carefully and thoroughly cleaned by the appropriate met...

Page 7: ...and testers to make adjustments to stan dard values ELECTRICAL SYSTEM Be sure to disconnect the battery cable from the nega tive terminal of the battery Never pull on the wiring when disconnecting co...

Page 8: ...of the engine mount member afety stand positions n both side sills front REAR Jack position safety stand positions At the center of the rear crossmember 2WD On both side sills rear At the rear differ...

Page 9: ...ng 56 km h 35 mph for more than 80 km 50 miles without danger of damaging the transaxle If the towing speed will exceed 56 km h 35 mph or if the towing distance will exceed 80 km 50 miles use either o...

Page 10: ...also note the fol lowings Speedometer Tester l Place the rear wheels on the rollers l Be sure to block the front wheels l Shift to 2nd gear carefully engage the clutch at low engine rpm and increase e...

Page 11: ...ency locking retractor EX Exhaust Fig Figure IC Integrated circuit IGilGN Ignition IN intake INT Intermittent ISC Idle speed control JB Joint Box LH Len hand M Motor MAS Mixture adjust screw MIL Malfu...

Page 12: ...0 PRE DELIVERY INSPECTION AND SCHEDULED MAINTENANCE SERVICES PRE DELIVERY INSPECTION 0 2 SCHEDULED MAINTENANCE SERWCES 0 3 63uoox o 5...

Page 13: ...cator lights 0 Ignition key reminder buzzer if equipped 0 Horn wipers and washers front and rear if equipped 0 Radio and antenna if equipped 0 Center differential lock switch 0 Cigarette lighter and c...

Page 14: ...ing in extended use of brakes l Driving in areas using road salt or other corrosive materials l Driving on rough and or muddy road l Extended periods of idling and or low speed operation l Driving for...

Page 15: ...Properattachmentand connections l Operation l Pedalheight I 214 5 Ii mm 6 44 t in 2WD modd 229 ti mm 9 02 O in 4WDmodel 6 5 l Freeolav 6 9 Q lg m m 0 35 0 59 in 2WDmodel 0 6 3 0 mm 0 02 0 12 in 4WDmod...

Page 16: ...o the following points l Replacement of timing belt is required at every 60 000 miles 96 000 km Failure to replace the timing belt may result in damage to the engine 2 This maintenance operation is re...

Page 17: ...for damage l Tension l Oil pan capacity B6 EGI engine 3 0 liters 3 2 US qt 2 6 Imp qt 66 DOHC engine 3 2 liters 3 4 US qt 2 8 Imp qtj l Oil filter capacity 0 3 liter 0 32 US qt 0 26 Imp qt lA 6 w lA 5...

Page 18: ...in 2WD model 0 6 3 0 mm 0 02 0 12 in 4WD model l Wheel cylinder operation and leakage l Lining for wear or damage l Thickness of lining minimum 1 O mm 0 039 in l Drum inner diameter maximum 201 mm 7 9...

Page 19: ...to the following points l Replacement of the timing belt is required at every 60 000 miles 96 000 km Failure to replace the timing belt may result in damage to the engine 2 This maintenance operation...

Page 20: ...IFICATIONS lA 3 TROUBLESHOOTING GUIDE 1A 3 TUNE UP PROCEDURE lA 5 ON VEHICLE MAINTENANCE IA I 1 TIMING BELT lA 11 CYLINDER HEAD lA 15 VALVE SEAL lA 21 REMOVAL AND INSTALLATION IA 25 DISASSEMBLY 1A 28...

Page 21: ...IA OUTLINE OUTLINE STRUCTURAL VIEW 1A Z...

Page 22: ...1 Firing order 1 3 4 z 83lJ01A4302 TROUBLESHOOTING GUIDE Problem Difficult starting Poor idling Excessive oil consumption Possible Cause Malfunction of engine related components Burned valve Worn pist...

Page 23: ...ance Replace or repair 1A 53 Main bearing seized or heat damaged Replace lA 53 Excessive crankshaft end play Replace or repair 1A 54 Excessive connecting rod bearing oil clearance 1A 55 Connecting rod...

Page 24: ...cording to the procedures described in Section 5 4 Check the tightness of the terminals to ensure good electrical connections Clean the terminals and coat the terminals with grease 5 Inspect for corro...

Page 25: ...ley groove 2 Check the drive belt for wear cracks or fraying 3 Check the pulley for damage Inspection of belt tension Check the drive belt tension by using the tension gauge Standard tension N kg lb...

Page 26: ...0 31 0 35 in Used 9 10 mm 0 35 0 39 in A C and P S oil pump drive belt New 8 Q mm 0 31 0 35 in Used 9 10 mm 0 35 0 39 in Adjustment of belt deflection Alternator drive belt 1 Loosen the alternator mo...

Page 27: ...he belt tension and deflection by turning the adjusting bolt C 3 Tighten the adjusting bolt lock nut B and mount ing bolt A Tightening torque Bolt A 31 46 N m 3 2 4 7 m kg 24 34 ft lb Nut B 36 54 N m...

Page 28: ...ure 1 Check for tappet noise if noise exsists check the followings 1 Engine oil condition and level 2 Engine oil pressure Refer to section 2A 2 If the noise does not disappear check for move ment of t...

Page 29: ...onnect a timing light tester 4 Disconnect the vaccum hose from the vacuum control and plug the hose 5 Disconnect the black connector at distributor 6 Check that the ignition timing mark yellow on the...

Page 30: ...figure I Engine side cover 2 A C and P S drive belt and pulley 3 Alternator and alternator drive belt 4 Water pump pulley Note 5 Crankshaft pulley and baffle plate 6 Upper and lower timing belt cover...

Page 31: ...tion of rotation on the timing belt Note The direction arrow is so the belt can be rein stalled in the same direction 3 Remove the timing belt Caution Do not allow any oil or grease on the timing belt...

Page 32: ...spring is fully extended 4 Install the timing belt Caution a The timing belt must be reinstalled in the same direction of previous rotation if it is reused b Be Sure that there is no oil grease or di...

Page 33: ...ensioner spring Timing belt deflection 12 13 mm 0 47 0 51 in I98 N 10 kg 22 lb Caution Be sure not to apply tension other than that of the tensioner spring 11 Install the lower and upper timing belt c...

Page 34: ...Exhaust manifold insulator 2 Oil level gauge IO Distributor 17 Exhaust manifold 3 Accelerator cable and 11 Spark plugs 18 Water pump pulley cruise control cable 12 Engine hanger and ground 19 Upper ti...

Page 35: ...ft pul ley with the matching mark on the cylinder head cover 2 Loosen the timing belt tensioner lock bolt 3 Pull the tensioner in the direction indicated by ar row and temporarily tighten the lock bol...

Page 36: ...der Head Refer to page l A 32 Inspection Refer to page IA 37 Assembly Refer to page l A 59 Installation I Thoroughly remove all dirt and grease from the top of the cylinder block with a rag 2 Place th...

Page 37: ...hing mark straight up so that the timing marks on the camshaft pulley and cyl inder head align Tightening torque 49 61 N m 5 0 6 2 m kg 36 45 ft lb 5 Apply a coat of sealant to the cylinder head cover...

Page 38: ...ft lb Rear 19 30 N m 1 9 3 1 m kg 14 22 ft lb 11 Install the exhaust manifold Tightening torque 16 23 N m 1 6 2 3 m kg 12 17 ft lb 12 Install the exhaust manifold insulator 13 Install the water bypass...

Page 39: ...h tension leads Y Y 83 01A 036 71 20 Install the engine harness connectors 21 Install the canister hoses 22 Install the vacuum hoses 23 Install the brake vacuum hose 24 Install the heater hoses 25 Ins...

Page 40: ...over 4 Rocker arm and rocker shaft assembly 5 Thrust plate Front Rear 6 Spring retainer 7 Upper valve spring seat 8 Valve spring 9 Lower valve spring seat 10 Valve seal Rocker arm and rocker shaft ass...

Page 41: ...he crankshaft pulley 4 Remove the spring retainer by pressing down on the SST 5 Remove the valve spring and spring seats upper and lower 6 Remove the valve seal from the valve guide with pliers or the...

Page 42: ...69 96 in lb 6 Install the rocker arm and rocker shaft assembly on the cylinder head and tighten it gradually in the order shown in the figure Note Use the installation bolts for alignment when instal...

Page 43: ...1 A ON VEHICLE MAINTENANCE VALVE SEAL 9 Install the upper timing belt cover bolt Tightening torque 8 11 N m 0 8 1 1 m kg 69 95 in lb 10 Install the air intake pipe lA 24...

Page 44: ...r 2 Air cleaner assembly 3 Oil level gauge 4 Cooling fan and radiator assembly 5 Accelerator cable and cruise control cable if equiped 6 Speedometer cable 7 Fuel hoses 8 Heater hoses 9 Brake vacuum ho...

Page 45: ...igh pressure and low pressure hoses still connected to it secure the compressor as shown in the figure PIS Pump Secure the P S pump as shown in the figure Be care ful not to damage the pipe when the e...

Page 46: ...ecified torque Steps After Installation 1 Adjust the drive belt tension Refer to IA 6 2 Fill the radiator and sub tank with coolant 3 Fill the engine with engine oil 4 Fill the transaxle with transaxl...

Page 47: ...ge also should be noted 2 Code all identical parts such as pistons piston rings connecting rods and valve springs so that they can be reinstalled in the position from which they were removed 3 After s...

Page 48: ...High tension leads spark plugs and dis 3 P S pump bracket tributor 4 Alternator 9 Intake manifold assembly and gasket 5 Coolant bypass pipe and hose 10 Oil filter 6 Thermostat cover and thermostat 11...

Page 49: ...nt of Engine 1 Waterpump pulley 2 Crankshaft pulley and baffle plate 3 Upper timing belt cover 4 Lower timing belt cover 5 Timing belt tensioner and spring 6 Timing belt 7 Timing belt pulley 8 Water p...

Page 50: ...osening the tensioner lock bolt 2 Mark the direction of rotation on the timing belt 3 Remove the timing belt Caution Do not allow any oil or grease on the timing belt Crankshaft pulley and timing belt...

Page 51: ...earance refer ring to INSPECTION AND REPAIR section 1 Cylinder head cover 8 Spring retainers 2 Rocker arm and rocker shaft assembly 9 Upper spring seats 3 Thrust plate 10 Valve springs 4 Camshafl pull...

Page 52: ...with bolts Caution Do not mix up the various parts of the rocker arm and rocker shaft assembly Camshaft pulley 1 Hold the camshaft using a suitable wrench on the cast hexagon 2 Remove the camshaft pul...

Page 53: ...el Clutch cover MTX Backing plate ATX Clutch disc IMTXI Drive alate CATXl 3 Flywheel Mix Adaptor ATX 4 End plate 5 Oil pan 6 Oil strainer 7 Rear cover 8 Oil pump Clutch cover and flywheel Remove the c...

Page 54: ...end play main journal bearing oil clearance connecting rod bearing oil clearance connecting rod side clearance referring to ASSEM BLY section 1 Connecting rod caps 5 Main bearmg caps 2 Connecting rod...

Page 55: ...od as shown in the figue If the large end does not drop by its own weight replace the piston and or piston pin r0 remove 2 Remove the piston pin with the SST as shown Flywheel pilot bearing Use suitab...

Page 56: ...six directions shown in the figure Distortion 0 15 mm 0 006 in max 3 If the cylinder head distortion exceeds specifica tion grind the cylinder head surface If the cylinder head height is not within s...

Page 57: ...thickness IN 0 5 mm 0 020 in min EX 1 0 mm 0 039 in min 3 Measure the valve length Length IN 103 77 mm 4 0854 in EX 102 67 mm 4 0421 in 4 Measure the valve stem diameter Diameter IN 8 970 6 985 mm 0 2...

Page 58: ...valve and or valve guide Replacement of valve guide Removal 1 Gradually heat the cylinder head in water to ap prox 90 C IgOOF 2 Remove the valve guide from the side opposite the combustion chamber wi...

Page 59: ...replacement Valve Seat 1 Inspect the contact surface of the valve seat and valve face 1 Rouahness 2 Damage 2 If necessary resurface the valve seat using a 45O valve seat cutter and or resurface the va...

Page 60: ...ve to the valve seat using a lapping compound 8 Check the sinking of the valve seat Measure protruding length dimension L of the valve stem Dimension L 39 0 mm 1 535 in 1 If L is as below it can be us...

Page 61: ...or damage replace if necessary 3 Check the cam lobe height at the two places as shown Height IN 36 38 38 53 mm 1 432 1 438 in EX 36 38 36 53 mm 1 432 l 438 in Minimum IN 36 23 mm 1 426 in EX 36 23 mm...

Page 62: ...in Maximum 0 15 mm 0 0059 in 4 If the clearance exceeds the maximum replace the camshaft or cylinder head 83U01A 078 6 Measure the camshaft end play If it exceeds the maximum replace the thrust plate...

Page 63: ...for wear or damage replace if necessary Caution Do not remove the HLA unless necessary to prevent damage to the 0 ring Cylinder l3lock 1 Check the cylinder block repair or replace if necessary 1 Leaka...

Page 64: ...the measurement A and C exceeds the maximum taper rebore the cylinder to oversize Taper 0 019 mm 0 0007 in max 2 If the difference between the measurement X and Y exceeds the maximum out of round re...

Page 65: ...clearance exceeds the maximum replace the piston or rebore the cylinder to oversize Note If the piston is replaced replace the piston rings also Piston and Piston Ring 1 Measure the piston ring to ri...

Page 66: ...r places Diameter 19 988 20 000 mm 0 7869 0 7874 in 2 Measure the piston pin diameter in the same manner Diameter 19 974 19 980 mm 0 7884 0 7866 in 3 Check the piston pin to piston clearance Clearance...

Page 67: ...et the crankshaft on V blocks 3 Check the crankshaft runout at the center journal replace if necessary Runout 0 04 mm 0 0016 in max 4 Measure each journal diameter in X and Y direc tions at two places...

Page 68: ...Crankpin journal diameter undersize mm in Bearingsize Journal diameter 0 25 undersize 1 44 690 44 706 1 7594 1 7601 0 50 undersize 1 44 440 44 456 1 7496 1 7502 Caution Do not grind the fillet roll Ma...

Page 69: ...oner with cleaning fluids If necessary use a soft rag to wipe it clean and avoid scratching it Timing Belt Tensioner Spring Check the free length of the tensioner spring replace if necessary Free leng...

Page 70: ...o the circumference of each piston pin and to the small end of each con necting rod 3 Set the SST in position as shown in the figure 4 Insert the piston pin from the direction of the F mark on the pis...

Page 71: ...3 Install the upper rail and lower rail Caution a After installation of the upper and lower side rails make certain they turn smoothly in both directions b Do not align the end gaps stagger them 2 In...

Page 72: ...le 4 Set the main bearing caps according to the cap number and m mark and trghten it Note Do not rotate the crankshaft when measuring the oil clearances Tightening torque 54 59 N m 5 5 6 0 m kg 40 43...

Page 73: ...h thrust bearings Standard thickness 2 50 2 55 mm 0 0984 0 1004 in Undersize width 0 25 mm 0 010 in 2 625 2 675 mm 0 1033 0 1053 in 0 50 mm 0 020 in 2 750 2 600 mm 0 1083 0 1102 in Note Oil groove of...

Page 74: ...0 in Caution Be sure to align the matching marks on the cap and on the connecting rod when instail ing the connecting rod cap 2 Check the side clearance of the connecting rod Clearance 0 30 mm 0 012 i...

Page 75: ...he rear cover assembly Caution Do not scratch the rear cover assembly End Plate Install the end plate Tightening torque S 11 N m 0 8 1 1 m kg 69 95 in lb Oil Pump 1 Remove any dirt or grease from the...

Page 76: ...ealant which is squeezed out Oil Strainer Install the oil strainer along with a new gasket Tightening torque 8 11 N m 0 8 1 1 m kg 69 95 in lb Oil Pan 1 Apply sealant to the shaded areas as in the fig...

Page 77: ...N m 9 6 10 6 m kg 71 76 ft lb Drive Plate ATX Install the drive plate along with the adapter and back ing plate with the SST Tightening torque 96 103 N m 9 6 10 6 m kg 71 76 ft lb Clutch Disc and Clut...

Page 78: ...rd the cylinder head 4 Install the spring retainer after compressing the valve spring with the SST Cylinder Head 1 Thoroughly remove all dirt and grease from the top of the cylinder block with a rag 2...

Page 79: ...then insert the camshaft in position with the thrust plate Tightening torque 8 111 N m 0 8 1 1 m kg 69 95 in lb Camshaft Pulley 1 Install the camshaft pulley onto the dowell pin with the pin groove fa...

Page 80: ...nstall the HLA in the rocker arm Caution a Do not remove the HLA from the rocker arm unless necessary b Be careful not to damage the O ring when installing Rocker Arm and Rocker Shaft Assembly 1 Assem...

Page 81: ...1 ft lb Cylinder Head Cover 1 Apply a coat of sealant in the groove as shown 2 Place the gasket in position 3 Install the cylinder head cover with new seal washers Tightening torque 5 9 N m 0 5 0 9 m...

Page 82: ...3 Apply sealant to the timing belt pulley bolt then tighten it Tightening torque 106 126 N m 11 0 13 0 m kg 80 94 ft lb 4 Release the SST 49 E301 060 5 Turn the crankshaft so that the timing mark on...

Page 83: ...oil grease or dirt on the timing belt side 3 Turn the crankshaft twice in the direction of rota tion Clockwise 4 Check that the timing marks are correctly aligned If not repeat the above mentioned pr...

Page 84: ...mm 0 47 0 51 in 98 N 10 kg 22 lb Timing Belt Cover install the lower and upper timing belt covers and new gaskets Tightening torque 8 11 N m 0 8 1 1 m kg 69 95 in lb Crankshaft Pulley Install the cran...

Page 85: ...7 ft lb Thermostat and Thermostat Cover 1 Install the thermostat with the jiggle pin facing upward 2 Install the thermostat cover and gasket Tightening torque 19 26 N m 1 9 2 6 m kg 14 19 ft lb Cautio...

Page 86: ...r install ing bolt Spark Plug and High Tension Lead 1 Install the spark plugs Tightening torque 15 23 N m 1 5 2 3 m kg 11 17 ft lb 2 Connect the high tension leads intake Manifold Assembly 1 Install t...

Page 87: ...ft lb 2 Install the alternator and alternator drive belt Loosely tighten the alternator installation bolt 3 Adjust the drive belt deflection by referring to page 1A 6 Tightening torque Alternator ins...

Page 88: ...IB 2 SPECIFICATIONS IB TROUBLESHOOTING GUIDE 3 1B TUNE UP PROCEDURE 3 lB ON VEHICLE 5 MAINTENANCE TIMING BELT I IB 11 78 11 CYLINDER HEAD REMOVAL AND 18 15 INSTALLATION DISASSEMBLY 18 22 1 B 26 INSPE...

Page 89: ...16 OUTLINE OUTLINE STRUCTURAL VIEW 1 18 Z 63UOlX 002 _...

Page 90: ...Poor idling Excessive oil consumption Possible Cause Malfunction of engine related components Burned valve Worn piston piston ring or cylinder Failedcylinder head gasket Malfunction of fuel system Mal...

Page 91: ...n ring Bent connectina rod Valves or timlng related parts Malfunction of HLA Broken valve spring Excessive valve guide clearance Malfunction of timing belt tensioner Malfunctlon of coolino svstem Malf...

Page 92: ...ing to the procedures described in Section 5 4 Check the tightness of the terminals to ensure good electrical connections Clean the terminals and coat the terminals with grease 5 Inspect for corroded...

Page 93: ...drive belt is positioned in the pui ley groove 2 Check the drive belt for wear cracks or fraying 3 Check the pulley for damage Inspection of belt tension Check the drive belt tension by using the tens...

Page 94: ...m 0 31 0 35 in Used 9 10 mm 0 35 0 39 in A C and P S oil pump drive belt New 8 9 mm 0 31 0 35 in Used 9 10 mm 0 35 0 39 in Adjustment of belt deflection Alternator drive belt 1 Loosen the alternator m...

Page 95: ...belt tension and deflection by turning the adjusting bolt C 3 Tighten the adjusting bolt lock nut B and mount ing bolt A Tightening torque Bolt A 31 46 N m 3 2 4 7 m kg 24 34 ft lb Nut 8 36 54 N m 3...

Page 96: ...temperature 1 Check for tappet noise if noise exsists check the followings 1 Engine oil condition and level 2 Cylinder head oil pressure Refer to section 26 2 If the noise does not disappear check for...

Page 97: ...lectric loads OFF 3 Connect a timing light tester 4 Disconnect the vaccum hose from the vacuum control and plug the hose 5 Disconnect the black connector at distributor 6 Check that the ignition timin...

Page 98: ...e numbered sequence shown in the figure 1 Side cover 2 Water pump pulley 3 Drive belt 4 Crankshaft pulley Note 5 Timing belt cover upper middle lower 6 Baffle plate 7 Timing belt tensioner and spring...

Page 99: ...oil or grease on the timing belt Inspection Refering to page 1B 49 inspect the following parts 1 Timing belt 2 Timing belt tensioner and spring 3 Timing belt pulley 4 Camshaft pulley Installation 1 Be...

Page 100: ...Be sure that there is no oil grease or dirt on the timing belt Note Remove all spark plugs for easier rotation 5 Turn the crankshaft twice in the direction of rota tion Clockwise 6 Check that the timi...

Page 101: ...other than that of the tensioner spring 1 Install the lower and upper timing belt cover Tightening torque 8 11 N m 0 8 1 1 m kg 89 95 in lb 12 Install the spark plugs Tightening torque 15 23 N m 1 5...

Page 102: ...1 B CYLINDER HEAD Removal Warning Release the fuel pressure Refer to FUEL PRESSURE RELEASE of FUEL SYSTEM section 1 Disconnect the battery negative cable 2 Drain the coolant 3 Remove the parts in the...

Page 103: ...s 17 Engine harness connectors 18 Surge tank bracket 19 Cylinder head cover 20 Timing belt Refer to 1B l 1 21 Cylinder head bolts 22 Cylinder head and intake manifold assembly 23 Intake manifold assem...

Page 104: ...gasket must face the thermostat 3 Install the intake manifold assembly and new gasket Tightening torque 19 26 N m 1 9 2 6 m kg 14 19 ft lb 4 Thoroughly remove all dirt and grease from the top of the c...

Page 105: ...1 1 m kg 69 95 in lb 9 Install the water pump pulley Tightening torque 8 i 1 N m 0 8 l l m kg 69 95 in lb 10 Install the crankshaft pulley pulley and baffle plate Tightening torque 12 17 N m l 25 1 7...

Page 106: ...nnect the vacuum hoses 15 Connect the Fuel hoses 16 Install the accelerator cable 17 Install the exhaust manifold and turbocharger as sembly along with new gasket Tightening torque 39 57 N m 4 0 6 8 m...

Page 107: ...12 17 ft lb 21 install the exhaust manifold insulator Tightening torque 19 26 N m 1 9 2 6 m kg 14 19 ft lb 22 Install the turbocharger insulator Tightening torque 19 26 N m 1 9 2 6 m kg 14 19 ft lb 2...

Page 108: ...grooved match ing mark on the body then install the distributor by referring to Section 5 29 install the spark plugs Tightening torque 15 23 N m 1 5 2 3 m kg 11 17 ft lb 30 Install the high tension l...

Page 109: ...the fuel pressure Refer to FUEL PRESSURE RELEASE of FUEL SYS TEM section I_ Disconnect the battery negative cable 2 Drain the engine oil transaxle oil and coolant 3 Remove the parts in the numbered s...

Page 110: ...bles cover for 4WD IO Heater hoses 19 Connectors starter motor 11 Speedometer cable oil pressure switch al ternator lntercooler 1 Disconnect the air hose from intercooler Caution Cover the end of air...

Page 111: ...connected to it secure the compressor as shown in the figure PIS Pump Secure the P S pump as shown in the figure Be care ful not to damage the pipe when the engine is re moved and installed Hose Clamp...

Page 112: ...19 26 Nm 1 9 2 6 m kg 14 19 lb For 2WD u 46 r Steps After Installation 1 Adjust the drive belt tension Refer to 1B 6 2 Fill the radiator and sub tank with coolant 3 Fill the engine with engine oil 4...

Page 113: ...amage also should be noted 2 Code all identical parts such as pistons piston rings connecting rods and valve springs so that they can be reinstalled in the position from which they were removed 3 Afte...

Page 114: ...hoses 11 Hose 12 Air intake pipe 13 Surge tank bracket 14 Intake manifold assembly 15 Oil filter 16 Oil cooler 17 Oil pressure switch and knock sensor 18 Distributor and high tension leads 19 Aiterna...

Page 115: ...Water pump pulley 7 Timing belt tensioner 2 Drive pulley 8 Idler pulley 3 Baffle plate 9 Tensioner spring 4 Upper timing belt cover IO Timing belt 5 Middle timing belt cover 11 Timing belt drive pulle...

Page 116: ...osening the tensioner lock bolt 2 Mark the direction of rotation on the timing belt 3 Remove the timing belt Caution Do not allow any oil or grease on the timing belt Crankshaft pulley and timing belt...

Page 117: ...IR section 1 Spark plug 2 Cylinder head cover bolt 3 Cylinder head cover 4 Camshaft pulley 5 Seal plate 6 Camshaft cap 7 Camshaft IN 8 Camshaft EX 9 Hydraulic lash adjuster IO Cylinder head bolts 1B 3...

Page 118: ...Remove the HLA from the cylinder head Note Mark all HLA so that they can be reinstalled in the position from which they were removed Cylinder heed bolt Remove the cylinder head bolts in the numbered o...

Page 119: ...d Flywheel 1 Clutch cover 6 Engine bracket and mount arm 2 Clutch disc 7 Oil pan 3 Flywheel 8 Oil strainer 4 End plate 9 011 pump 5 Rear cover 10 Oil jet Clutch cover and flywheel Remove the clutch co...

Page 120: ...on a Do not force a pry tool between the block and pan to prevent damaging the contact surfaces b Do not damage or scratch the contact sur face when removing the oil sealant Flywheel pilot bearing Use...

Page 121: ...in journal bearing oil clearance connecting rod bearing oil clearance connecting rod side clearance reffering to ASSEM BLY section 1 Connecting rod caps 2 Connecting rod bearings 3 Clips 4 Connecting...

Page 122: ...nd connecting rod 1 Check the oscillation torque of the connecting rod as shown in the figure If the large end does not drop by its own weight replace the piston and or piston pin 2 Use the SST to rem...

Page 123: ...six directions shown in the figure Distortion 0 15 mm 0 006 in max 3 If the cylinder head distortion exceeds specifica tion grind the cylinder head surface If the cylinder head height is not within s...

Page 124: ...Margin thickness IN 0 5 mm 0 020 in min EX 0 5 mm 0 020 in min 3 Measure the valve length Length IN 105 29 mm 4 1452 in EX 105 39 mm 4 1492 in 4 Measure the valve stem diameter Diameter IN 5 970 5 98...

Page 125: ...lace the valve and or valve guide Replacement of valve guide Removal 1 Gradually heat the cylinder head in water to ap prox 90 19O F 2 Remove the valve guide from the side opposite the combustion cham...

Page 126: ...placement Valve Seat 1 Inspect the contact surface of the valve seat and valve face 1 Roughness 2 Damage 2 If necessary resurface the valve seat using a 45O valve seat cutter and or resurface the valv...

Page 127: ...o the valve seat using a lapping compound 8 Check the sinking of the valve seat Measure protruding length dimension L of the valve stem Dimension IL 43 5 mm 1 713 in 1 If L is as below it can be used...

Page 128: ...age replace if necessary 3 Check the cam lobe height at the two places as shown Height IN 40 888 mm 1 6098 in EX 40 888 mm 1 6019 In Minimum IN 40 889 mm 1 8098 in EX 40 689 mm 1 6019 in 4 Measure wea...

Page 129: ...r head Note Do not install the HLA when measuring the oil clearance 3 Position the plastic gauge on top of the jour nal in the journal axial direction 4 Install the camshaft caps according to the cap...

Page 130: ...haft or the cylinder head End play 0 07 0 19 mm 0 0028 0 0075 in Maximum 0 20 mm 0 008 in HLA 1 Check the HLA for wear or damage 2 Hold the HLA between your fingers and press it If the HLA moves repla...

Page 131: ...at three levels in each cylinder as shown Cylinder bore mm in 1 If the difference between the measurement A and C exceeds the maximum taper rebore the cylinder to oversize Taper 0 019 mm 0 0007 in max...

Page 132: ...ing replace if necessary 2 Measure the outer diameter of each piston at a right angle 90 to the piston pin 16 5 mm 0 650 in below the oil ring land lower edge Piston diameter mm in L Size Diameter 1 7...

Page 133: ...ssary 4 Insert the piston ring into the cylinder by hand and push it to the bttom of the ring travel in using the piston 5 Measure each piston ring end gap using a feeler gauge replace if necessary En...

Page 134: ...nd or piston pin Connecting Rod 1 Measure the connecting rod small end bore Diameter 20 003 20 014 mm 0 7875 0 7880 in 2 Check the clearance between the small end bore and piston pin Clearance 0 010 0...

Page 135: ...mm 1 9661 l 9668 in Minimum 49 89 mm 1 964 in Out of round 0 05 mm 0 0020 in max Crankpin journal Diameter 44 940 44 956 mm 1 7693 l 7699 in Minimum 44 89 mm i 7673 in Out of round 0 05 mm 0 0020 in...

Page 136: ...for damage wear peeling cracks or hardening replace if necessary Caution a Never forcefully twist the timing belt Do not turn it inside out or bend it b Be careful not to allow oil or grease on the b...

Page 137: ...Timing Belt Pulley and Camshaft Pulley Inspect the pulley teeth for wear deformation or other damage replace the pulley if necessary Caution Do not clean the pulley with cleaning fluids If necessary u...

Page 138: ...maged cap identification mark Mark Connecting Rod 1 Align the identification mark to the cap of lage end of connecting rod and F mark on the piston as shown in the figure 2 Apply a coat of engine oil...

Page 139: ...iece oil rings on the pistons 1 Apply engine oil to the oil ring spacer and rails 2 Install the oil ring spacer 3 Install the upper rail and lower rail Caution After installation of the upper and lowe...

Page 140: ...ore installation make sure that the oil pas sage is not clogged Crankshaft I Inspect the oil clearances of the crankshaft and main bearings 1 Remove any foreign material and oil from the journal and b...

Page 141: ...oint for the largest clearance Oil clearance 0 024 0 042 mm 0 0010 0 0017 in Maximum 0 08 mm 0 0031 in 6 If the oil clearance exceeds the limit grind the crankshaft and use undersize main bearings Und...

Page 142: ...block by using a piston insertion tool com mercially available Caution The pistons must be inserted so that the F marks face the front of the cylinder block Connecting Rod Cap 1 Inspect and adjust the...

Page 143: ...ing rod cap to align the match ing mark and tighten it Tightening torque 65 69 N m 6 6 7 0 m kg 48 51 ft lb Rear Cover 1 Apply engine oil to the rear cover oil seal and oil seal lip 2 Press the oil se...

Page 144: ...and oil pump with a rag 2 Apply engine oil to the oil seal lip 3 Install new gasket Caution Do not allow any sealant in the oil hole 4 Install the oil pump Tightening torque 19 28 N m 1 9 2 8 m kg 14...

Page 145: ...n Do not leave any dirt or oil on it 4 Apply silicone sealant to the oil pan continuously with the bead of 2 5 3 5 mm 0 0984 0 1378 in rimming the surface inside the bolt holes as shown Caution After...

Page 146: ...76 ft lb Clutch Disc and Clutch Cover Install the clutch disc and clutch cover with the SST and tighten the clutch cover Tightening torque 18 26 N m 1 8 2 7 m kg 13 20 ft lb Note Follow the clutch di...

Page 147: ...e SST HLA 1 Apply engine oil to the sliding surface 2 install the HLA in the position from which they were removed 3 Check for free movement Cylinder Head 1 Thoroughly remove all dirt and grease from...

Page 148: ...ngine bracket and mount arm Tightening torque Bolt 0 47 66 N m 4 8 6 7 m kg 35 48 ft lb Bolt 0 60 85 N m 6 1 8 7 m kg 44 63 ft lb Bolt 0 93 l 17 N m 9 5 t 1 9 m kg 69 86 ft lb Bolt 37 52 N m 3 8 5 3 m...

Page 149: ...oat of engine oil to the camshaft oil seal and cylinder head 2 Install the camshaft oil seal 3 Apply a thin coat of sealant to the front camshaft cap surface 4 Install the camshaft caps tighten the ca...

Page 150: ...aft Pulley 1 Install the camshaft pulley Caution For the exhaust side camshaft pulley install the pulley with the E mark straight up For the intake side camshaft pulley install the pulley with the I m...

Page 151: ...3 0 4 m kg 26 35 in lb 4 Install the filler cap and the ventilation hose Timing Belt Pulley 1 Reverse the direction of the SST 49 E301 060 2 Install the timing belt pulley and key 3 Apply sealant to t...

Page 152: ...Fight as possible Caution a The timing belt must be reinstalled in the direction of previous rotation if it is reused b Be sure that there is no oil grease or dirt on the timing belt 3 Turn the crank...

Page 153: ...ve or replace the tensioner spring Deflection 8 5 l 1 5 mm 0 33 0 45 in IS5 N 10 kg 22 lb Timing Belt Cover Install the lower middle and upper timing belt cover and a new gasket Tightening torque 8 11...

Page 154: ...lternator 1 Install the alternator strap Tightening torque 37 62 N m 3 8 5 3 m kg 27 38 ft lb 2 install the alternator and alternator drive belt Loosely tighten the alternator installation bolt 3 Adju...

Page 155: ...e oil filter 0 ring and install the filter tighten throughiy by hand Distributor 1 Apply engine oil to the 0 ring and position it on the distributor 2 Apply engine oil to the drive gear 3 Install the...

Page 156: ...es 2 Air hose 3 Ventilation hose 4 Vacuum hose Caution Hose clamp must be reinstalled in the orignal position on the hose Surge Tank Bracket Install the surge tank brakcket Tightening torque 31 46 N m...

Page 157: ...g torque 19 26 N m 1 9 2 6 m kg 14 19 A lb Coolant Bypass Hose 1 Apply a coat of long life coolant to the 0 ring 2 Install the coolant bypass hose Power Steering Pump Bracket Install the power steerin...

Page 158: ...ylinder head side 3 Install the exhaust manifold and turbo charger as sembly Tightening torque 39 57 N m 4 0 5 8 m kg 29 42 ft lb 4 Install the turbocharger bracket Tightening torque Bolt A 25 32 N m...

Page 159: ..._ Exhaust Manifold insulator Install the exhaust manifold insulator and wire clip Tightening torque 19 26 N m 1 9 2 6 m kg 14 19 ft lb Turbocharger Insulator Install the turbocharger insulator Tighten...

Page 160: ...2 SPECIFICATIONS 2A 3 TROUBLESHOOTING GUIDE 2A 3 OIL FILTER 2A 4 REPLACEMENT 2A 4 OIL PAN 2A 5 REMOVAL AND INSTALLATION 2A 5 INSPECTION OIL PUMP r REMOVAL AND INSTALLATION 2A 7 DISASSEMBLY AND ASSEMB...

Page 161: ...2A OUTLINE OUTLINE STRUCTURAL VIEW j ZA 2...

Page 162: ...ssible Cause Remedy Page Loose drain plug Tighten or replace 2A 6 Faulty seal at oil pan and cylinder block Repair 2A 6 Damaged cylinder head cover Refer to Section 1A Loose oil pump body bolt cylinde...

Page 163: ...a small amount of engine oil to the O ring of the new oil fiiter 3 Fully tighten the oil filter by hand 4 Add engine oil to the correct level 5 After installing the filter check to be sure that there...

Page 164: ...3 Remove the parts in the numbered sequence shown in the figure 4 install in the reverse order of removal 83U02A 0c II 3 I Steps after installation 1 Add the prescribed amount of oil 2 Check for oil...

Page 165: ...d drain plug threads _ Installation Note 1 Apply sealant to the places indicated by the arrows in the figure after cleaning the surface 2 Apply sealant to the shaded area as shown in the figure after...

Page 166: ...ove each part in the numbered sequence shown in the figure 4 Install in the reverse order of removal 1 Timing belt cover 2 Timing belt pulley 3 Oil pan Refer to 2A 6 4 Oil strainer 5 011pump Timing Be...

Page 167: ...6 Pump body Oil Pump Cover Removal Loosen the screws by an impact driver so that the oil pump body is not damaged installation 1 Coat locking agent on the screw threads 2 Install the pump cover to the...

Page 168: ...n max Side clearance 0 14 mm 0 0055 in max 5 Replace the gear assembly or oil pump body if the clearances are not within the limits OIL PRESSURE INSPECTION 1 Remove the oil pressure switch 2 Connect t...

Page 169: ...2B 4 REPLACEMENT 2B 4 OIL COOLER 2B 5 REMOVAL 2B 5 INSTALLATION 2B 5 OIL PAN 2B 6 REMOVAL 2B 6 INSPECTION 2B 7 INSTALLATION 2B 7 OIL PUMP 26 9 REMOVAL AND INSTALLATION 2B 9 DISASSEMBLY AND ASSEMBLY 2...

Page 170: ...2B OUTLINE OUTLINE STRUCTURAL VIEW 28 Z...

Page 171: ..._ _ l sIIYle slurr nemeoy rage Loose drain plug Tighten or replace 2B 7 Faulty seal at oil pan and cylinder block Repair 2B 7 Damaged cylinder head cover Refer to Section 1B Loose oil pump body bolt c...

Page 172: ...y a small amount of engine oil to the O ring of the new oil filter 3 Fully tighten the oil filter by hand 4 Add engine oil to the correct level 5 After installing the filter check to be sure that ther...

Page 173: ...Remove the oil cooler INSTALLATION 1 Install the oil cooler Tightening torque 29 39 N m 3 0 4 0 m kg 22 29 ft lb 2 Install the oil filter Refer to page 28 4 3 Install the under cover 4 Add engine oil...

Page 174: ...under covers 2 Exhaust pipe bracket 3 Exhaust pipe 4 Turbocharger bracket 5 Oil pan 6 Gasket Removal Note 1 Remove the oil pan by prying only at the points shown in the figure 2 Loosen the mounting me...

Page 175: ...arrows in the figure after cleaning the cylinder block surface 2 Install the gaskets onto the oil pump body and rear cover with the projections in the notches as shown 3 Clean the oil pan contact sur...

Page 176: ...Bolt A 37 52 N m 3 8 5 3 m kg 27 38 ft lb Bolt B 19 26 N m 1 9 2 6 m kg 14 19 ft lb 6 Tighten the bolts gradually in three steps Tightening torque 8 11 N m 0 8 1 1 m kg 69 95 in lb Steps After Install...

Page 177: ...each part in the numbered sequence shown in the figure 4 install in the reverse order of removal 1 Timing belt cover 2 Timing belt pulley 3 Oil pan Refer to page 28 6 4 Oil strainer 5 Oil pump Timing...

Page 178: ...8 Pump body Oil Pump Cover Removal Loosen the screws by an impact driver so that the oil pump body is not damaged Installation 1 Coat locking agent on the screw threads 2 Install the pump cover to the...

Page 179: ...max Side clearance 0 14 mm 0 0055 in max 5 Replace the gear assembly or oil pump body if the clearances are not within the limits OIL PRESSURE INSPECTION 1 Remove the oil pressure switch 2 Connect th...

Page 180: ...000 rpm and note the gauge reading Standard oil pressure 98 198 kPa 1 0 2 0 kg cm2 14 28 psi 3 000 rpm 5 If oil pressure is lower than specifications check and repair as necessary 6 After checking th...

Page 181: ...SPECTION 3A 5 ELECTRIC FAN MOTOR 3A 5 INSPECTION 3A 5 WATER THERM0 SWITCH 3A 6 INSPECTION 3A 6 ELECTRIC FAN RELAY 3A 6 INSPECTION 3A 6 WATER PUMP DRIVE BELT 3A 6 INSPECTION AND ADJUSTMENT 3A 6 THERMOS...

Page 182: ...3A OUTLINE OUTLINE STRUCTURAL VIEW Throttle body I 3A 2...

Page 183: ...r head bolt Damaged cylinder head gasket Cracked cylinder block Cracked cylinder head Replace Repair or replace Repair or replace Replace Repair or replace Refer to Section IA Refer to Section 1A Refe...

Page 184: ...pressure of 103 kPa 1 05 kg cm 15 psi to the tester 3 Note if the tester indicator shows a reduction of pressure If it does there may be a coolant leak Check for leaks 2 Close the plug tightly 3 Afte...

Page 185: ...re is maintained for about 10 seconds Negative Pressure Valve 1 Pull the negative pressure valve to open it Check that it closes completely when released 2 Check for damage on the contact surfaces cra...

Page 186: ...ing the water thermo switch Do not use seal tape on the threads of the therm0 switch b Check for water leakage after installation ELECTRIC FAN RELAY INSPECTION 1 Disconnect the water therm0 switch con...

Page 187: ...eeze it lightly with large pliers to ensure a good fit INSPECTION Check the operation Replace if necessary 1 Visually check the valve to be sure it is air tight 2 Place the thermostat and a thermomete...

Page 188: ...Cooling fan 3 Cooling fan motor Note 4 Radiator hose 5 Reserve tank hose 6 Radiator Position the hose clamp in the original location on the hose and squeeze it lightly with large pliers to ensure a go...

Page 189: ...gure 4 Install in the reverse order of removal 1 Water pump pulley 2 Crankshaft pulley 3 Timing belt cover 4 Timing belt tensioner and spring 5 Timing belt 6 Coolant inlet pipe and gasket 7 Water pump...

Page 190: ...INSPECTION FOR ZWD 3B 5 INSPECTION FOR 4WD 3B 6 WATER THERM0 SWITCH 3B 6 INSPECTION 3B 6 RADIATOR SWITCH 3B 7 INSPECTION 3B 7 ELECTRIC FAN RELAY 3B 7 INSPECTION 3B 7 WATER PUMP DRIVE BELT 3B 8 INSPEC...

Page 191: ...3B OUTLINE OUTLINE STRUCTURAL VIEW ISC valve 3B 2...

Page 192: ...r core seam Replace 38 l 0 Leakage from radiator hose or heater hose Repair or replace 38 10 Leakagefrom water thermo switch or radiator switch Repair or replace 3B 6 7 Malfunction of water pump seal...

Page 193: ...tor shows a reduction of pressure if it does there may be a coolant leak Check for leaks Warning When removing either the radiator cap or the tester with adapter loosen it slowly until the pressure in...

Page 194: ...d for about IO seconds RR I Y 3 Negative Pressure Valve I Pull the negative pressure valve to open it Check that it closes completely when released 2 Check for damage on the contact surfaces cracked o...

Page 195: ...nt 13 3 14 6 Amperes 7 If the fan motor is faulty replace it WATER THERM0 SWITCH INSPECTION 1 Remove the electric fan water therm0 switch Warning Do not disconnect the water therm0 switch connector wh...

Page 196: ...oil above 120 C 248OF 5 If the radiator switch is faulty replace it Note Clean the engine oil on the switch when the switch is reused ELECTRIC FAN RELAY INSPECTION 1 Disconnect the water therm0 switc...

Page 197: ...ter minals c and 9 terminals 2 Check that there is no continuity between c and fJ terminals when 12V battery is applied across a and b terminals 3 If the relay is faulty replace if not check the fuse...

Page 198: ...ueeze it lightly with large pliers to ensure a good fit INSPECTION Check the operation Replace if necessary 1 Visually check the valve to be sure it is air tight 2 Place the thermostat and a thermomet...

Page 199: ...g 2 Cooling fan 3 Cooling fan motor Note 4 Radiator hose 5 Reserve tank hose 6 Radiator Position the hose clamp in the original location on the hose and squeeze it lightly with large pliers to ensure...

Page 200: ...th P S and or A C 2 Drive belt 3 Water pump pulley 4 Crankshaft pulley 5 Baffle plate 6 Timing belt cover upper 7 Timing belt cover middle 8 Timing belt cover lower 9 Timing belt tensioner 10 Tensione...

Page 201: ...TER 49 9200 750A 4A 35 TROUBLESHOOTING CHART 44 37 FUEL PRESSURE 4A 38 INSPECTION 4A 40 REPLACEMENT 4A 44 FUEL TANK 4A 46 DECELERATION CONTROL SYSTEM 4A 47 HIGH ALTITUDE COMPENSATION SYSTEM a 4A 50 EV...

Page 202: ...4A OUTLINE OUTLINE SYSTEM DIAGRAM 4A 2...

Page 203: ...OUTLINE 4A EMISSION COMPONENT LOCATION Throttle sensor Atmospheric pressure sensor Pressure regulator Water therm0 Water therm0 switch Catalytic converter...

Page 204: ...4A OUTLINE VACUUM HOSE ROUTING DIAGRAM cuum switch valve Solenoid valve for vacuum switch valve Solenoid valve for No 1 purge control valve 4A 4...

Page 205: ...rols operation of the following 1 Fuel injection amount 2 Idle speed control system 3 Fail safe system 4 Monitor switch function radually allows throttle valve clos ng during deceleration ilters parti...

Page 206: ...4A OUTLINE I I REMARKS nds signal to control ensates fuel in ection sure valves operate in accordance 4A 6 323 Revised IO 87...

Page 207: ...441 566 4 5 6 0 64 0 85 3 cc win 1 0 set 220 360 13 G23 23 2 when fuel pressureat 250 kPa 2 55 kgicm 36 3 psi Type Low pressure side Nylon 6 250 mesh element High pressure side Paper element Pressure...

Page 208: ...T SWITCH WATER THERM0 SWITCH NEUTRAL AND CLUTCH SWITCH STARTER SWITCH ZITCH AC SWITCH P S SWITCH TEST cONNECTOR INJECTOR 0 I x 0 I x 0 I x 0 X 0 I x 0 X 0 I X 0 I X 0 I x 2 t SOLENOID SAC VALVE PURGE...

Page 209: ...Group Above 6 400 rpm TIMING fUd cut off SAC AIR open VALVE VALVE Closed Coolant temp below 60 1409 ISC Large amount of Small amount of bypass air VALVE Large and bypass air Does not Test connector s...

Page 210: ...ts may be at fault by se of the SST Eielf Dlagnosls checker 49 HOW 9Al 1st Check input sensorsand output solenoidvalves with SST Referto page 4A 12 2nd Check other switcheswith SST Refer to aae 4A 20...

Page 211: ...5 I 4 b t 5 1 6 7 4 2 1 2 2 2 1 I 6 I 9 t 3 4 2 1 5 6 3 2 4 Note The number of the list such shown a priorities of inspection from the most possible to that with the lowest possibility These were dete...

Page 212: ...rom the control unit as warning code numbers Note Note The control unit constantly checks for malfunction of the Input devices But the control The control unit constantly checks for malfunction of the...

Page 213: ...t a jumper wire between the test connec tor Green lpin and a ground 4 Turn the ignition switch ON then check for any code number Note The SST buzzer should sound for 3 sec after the ignition switch Is...

Page 214: ...engine control unit iM terminal YE8 Is engine control unit 1 M terminal voltage OK Refer to page 4A 61 PC Engine control unit malfunction No 08 Code Illumination Airflow Meter ssUO4A 120 Are there an...

Page 215: ...69 W Replace water thermo sen sor 1 0 l 3 kQ 1 0 49 0 67 kQ 0 29 0 35 kQ I I YES Is there continuity between water thermo sensor and engine control unit Water thermo sensor 1 Engine control unit A LR...

Page 216: ...ere continuity between intake air thermo sensor in air flow meter and engine control unit Intake air thermo sensor Engine control in air flow meter unit THA BrY wire 2J Ez LY wire 2c NO Replace air fl...

Page 217: ...ttage not 4 5 5 5 Is voltage at L wire of atmospheric pressure sensor connector OK Voltage 3 5 4 5V at sea level 2 5 3 5V at high elevation 2 000 m 6 500 ft NO Replace atmospheric pressure sensor J 1Y...

Page 218: ...No 17 Code illumination Feedback System Doesmonitor lamp of Sel luminateat idle PC Air leak in vacuum hosesor engine components Contaminatedoxygen sensor Clogged fuel jet s Are spark plugs clean Clean...

Page 219: ...34 Code Illumination SAC valve Repair or replace connector 1NO Is the resistance of the BAC valve OK Resistance 5 20 Q Replace BAC valve Is there battery voltage at B valve connector PC Open or short...

Page 220: ...e stopped to check the switches Disconnected terminal Connected terminal OXYGEN SENSOR MONITOR FUNCTION The oxvaen sensor and feedback mode are monitored as follows I I Engine Condition Test connector...

Page 221: ...on b Do not start the englne Check each switch and related wiring harness l Clutch and Neutral Refer to page 4A 63 switch Idle switch throttle Refer to page 4A 66 sensor l Brake light switch Refer to...

Page 222: ...check that monitor lamp il l Brake light switch malfunction Referto paw 4A 63 1 YES I I l bpen cirduit in wiring harnessfrom brake switch to engine control unit I I Brake light switch is OK Releasebr...

Page 223: ...ion 15 l Open circuit in wiring harnessfrom rear defroster switch to E L control unit l Engine control unit 1I terminal malfunction I PC l Inhibitor switch malfunction Refer to page 4A 63 l Open or sh...

Page 224: ...iming l Connect a jump wire between the test connec tor Green 1 pin and ground idle speedy 1 Check the idle speed Idle speed 850 50 rpm MTX Neutral ATX in P range 2 If the idle speed is not within spe...

Page 225: ...Air flow I BAG valve I I _ ___ _ The intake air system supplies air required by the engine for the formation of the air fuel mixture and measures the air flow and air temperature It consists of the ai...

Page 226: ...e the intake air system in the sequence shown in the figure 3 Install in the reverse order of removal 1 Accelerator cable 6 Water hoses 2 Air funnel 7 Throttle body 3 Air cleaner with Air flow meter 8...

Page 227: ...taching nuts 5 Remove the air flow meter Install in the reverse order of removal Throttle Body Removal and Installation 1 Drain the water from radiator 2 Disconnect the accelerator cable from the thro...

Page 228: ...mm 0 04 0 12 in ad just by using nuts A 2 Depress the accelerator pedal to the floor and con firm that the throttle valve is fully opened Adjust by using bolt B if necessary Throttle Body 1 Check that...

Page 229: ...the intake air amount detected by the air flow meter by regulating the bypass air amount that passes through the throttle body and thereby helps the engine to maintain a steady idle speed This system...

Page 230: ...4A IDLE SPEED CONTROL ISC SYSTEM TROUBLESHOOTING CHART Before performing the following troubleshooting check the condition of the wiring harness and connector After wermin 4A 30 323 Revised 10187...

Page 231: ...the engine speed Cold engine Engine speed drops Warm engine Engine speed unchanged 5 Connect the EAC valve connector 6 Disconnect the test connector 7 Warm up the engine to normal operating temper atu...

Page 232: ...does not flow ISC valve 1 Disconnect the BAC valve connector 2 Connect an ohmmeter to the terminals of the BAC valve 3 Check the resistance Resistance 5 20 n Removal and installation 1 Drain the wate...

Page 233: ...sure Low pressure 3 J Injector The fuel system supplies the injectors with fuel necessary for combustion at a constant pressure Fuel is metered and injected into the intake manifold and intake ports a...

Page 234: ...e fuel pressure from the fuel line to reduce the possibili ty of injury or fire 1 Start the engine 2 Disconnect the circuit opening relay connector 3 After the engine stalls turn OFF the ignition swit...

Page 235: ...LTCPRESSURE TESTER 49 9200 75OA The MULTI PRESSURE TESTER 49 9200 750A has been developed to check the fuel pressure and intake manifold vacuum These can easily be inspected by setting the buttons on...

Page 236: ...sure side 3 Connect SST between fuel main hose and pres sure regulator using the adapter Caution Do not reverse the adapter connection 4 Disconnect the vacuum hose from the pressure regulator control...

Page 237: ...ming the following troubleshooting check the condition of the wiring harnessand connector 4 E R P 0 A A P F fterburn In exhaust system 3 4 5 12 6 7 0 fuel consumption 3 4 5 6 7 8 12 B 10 sils erniedon...

Page 238: ...re and injector Refer to page 4A 41 Fuel Pump Pressure 1 Connect the terminals of the test connector yel low connector with a jumper wire 2 Turn the ignition switch ON to operate the fuel pump 3 Move...

Page 239: ...ne pressure Approx 177 216 kPa 1 8 2 2 kg cm 24 6 31 3 psi 4 If not within specification check the vacuum hose 5 Pinch a vaccum hose of pressure regulator 6 Check the fuel line pressure Fuel line pres...

Page 240: ...connected 7 If the voltage normal replace the fuel pump Fuel pump Volume test Warning Before performing following procedures re lease the fuel pressure to reduce the possi bility of injury or fire Ref...

Page 241: ...tor from the engine Refer to page 4A 44 2 Check that the resistance of the injector Resistance 11 l 5 61 Injector Leak test Warning Before performing following procedures re lease the fuel pressure to...

Page 242: ...t 1 Connect a suitable vinyl hose to the injector and place the hose in the container or graduated glass etc Note The hose should be 2 m 78 in or more 2 Connect the terminals of the fuel pump check co...

Page 243: ...el system keep sparks cigarettes and open flames away from the fuel Fuel Pump 1 Remove the rear seat 2 Remove the filler cap 3 Disconnect the fuel pump connector 4 Remove the fuel pump cover 5 Disconn...

Page 244: ...of removal Pressure Regulator 1 Remove the dynamic chamber Refer to page 4A 26 2 Disconnect the fuel return hose 3 Remove the pressure regulator 4 Install the pressure regulator and dynamic cham ber i...

Page 245: ...g torque 16 6 26 5 N m 9 2 6 m kg 13 7 16 6 ft lb Note a O ring of injector is not reuseable b When install the injector apply the gasoline on O ring Fuel Filter High Pressure The fuel filter should b...

Page 246: ...ses 4 Raise the vehicle on a jack and support it with safe ty stands 5 Remove the drain plug and drain the fuel Warning a When repairing the fuel tank clean the fuel tank thoroughly with steam to remo...

Page 247: ...CONTROL SYSTEM 4A DECELERATION CONTROL SYSTEM Throttle en sOr Injector I Mater therm0 sensor The fuel cut function is provided in the deceleration control system This function is to improve fuel consu...

Page 248: ...In exhaust system 0 0 0 0 iiK7 8 3Lu System Inspection Electrical Slgnal 1 Connect SST between the wiring harness and en gine control unit 2 Warm up the engine and run at idle 3 Set 3C and 3E position...

Page 249: ...dashpot slowly 2 Release the finger and make sure the rod comes out quickly Adjustment 1 Warm up the engine to the normal operation tem perature and run it at idle speed 2 Attach a tachometer 3 Incre...

Page 250: ...4A HIGH ALTITUDE COMPENSATION SYSTEM HIGH ALTITUDE COMPENSATION SYSTEM pressure sensor I 19 Ignition coil 4A 50 323 Revised IO 87...

Page 251: ...approx 7 BTDC vacuum connected 3 Connect a vacuum pump to the atmospheric pres sure sensor 4 Apply a vacuum of 120 mmHg 4 72 InHg by us ing the vacuum pump and check the ignition timing Ignition timin...

Page 252: ...water therm0 sensor intake air therm0 sensor air flow sensor and engine speed sensor ignition coil The engine control unit determined the engine operating conditions from the signals and control the e...

Page 253: ...l switch connector MTX Disconnect the inhibitor switch connector ATX 6 Check the terminal voltage BY Voltage below 1 W 7 Place finger over the hose opening 8 Increase the engine speed to about 2 000 r...

Page 254: ...m the evaporation pipe 2 Blow into the hose and check that air flows freely SOLENOID VALVE 1 Disconnect vacuum tube A from the servo di aphragm 2 W nnect vacuum tube B from the solenoid 3 Disconnect t...

Page 255: ...en applied vacu um is more than the specified vacuum amount Specltied vacuum 70 100 mmHg 2 76 2 94 InHg THREE WAY CHECK VALVE 1 Remove the three way check valve 2 Blow through the valve from port A an...

Page 256: ...lightly opened and small amount of blow by gas is drawn into the dynamic chamber At high engine speed the PCV valve is further opened and large amount of blow by gas drawn into the dynamic chamber PCV...

Page 257: ...Injector pheric pressure sensor Clutch switcl Air flow meter Water therm0 switch The control system consists of the input devices and control unit The control unit controls the injection amount monit...

Page 258: ...rness Contlnultv 1 Apply 12V to and a ground terminals of the main relay 2 Check continuity at terminals using an ohmmeter 12V Not applied 12V Applied NO Yes NO Yes 3 If not correct replace it CIRCUIT...

Page 259: ...CONTROL SYSTEM 4A Resistance 1 Check the resistance between the terminals using an ohmmeter Between terminals Resistance 4 STA El B P Fc B e Fp It not correct replace it 15 30 80 l 50 OD 2 4A 59...

Page 260: ...oped to check the engine control unit terminal voltages This monitor easily inspects the terminal voltage by setting the monitor switch How to Use the Engine Signal Monitor 1 Connect the Englne Signal...

Page 261: ...ped Brake ped Power steering s Power steering s A C A C JWI U Ignition switch ON Approx 12V 1M Input Ignition coil Approx 12V I At idle 1 Green ani red liaht flash 1 1N 10 IP IQ 1R j IT I I I I nition...

Page 262: ...ntake air t emp more than In gear condition Below 1 5V I 50 1122on t rn than 50 Y2 Y l Jumm wire connect to the lj tral switch MTX Approx 12V I w I I c 44 CL Idle speed control valve I V I I Ground 1...

Page 263: ...n the pedal is released Yes INHIBITOR SWITCH ATX Inspection 1 Disconnect the inhibitor switch connector 2 Connect an ohmmeter to the switch 3 Check continuity of the terminal Position Continuity P and...

Page 264: ...A YG Main relay Approx 12V Approx 12V Electrical fan relay Below 1sv 6 Ground ov 0 I Below 1 5v 0 Contrrgl unit 1 H Approx 12V FL O Combination switch Approx 12V B w 1 5v Below 1 5V 0 Blower motor swi...

Page 265: ...ance 0 20 to 400 100 to 300 200 to 400 20 4 10 000 to 20 000 0 32OF 4 000 to 7 000 20 68OF 2 000 to 3 000 40 104vq 900 to 1 300 60 14OOF 400 to 700 I F1 a Fr I OL I 3 Press open the measuring plate wi...

Page 266: ...onnect an ohmmeter i 3 insert athickness gauge between the throtUe stop screw and stop letier 4 Note the operation of the buzzer or continuity be tween terminals Adjustment 1 Disconnect the connector...

Page 267: ...thickness gauge with a 0 7 mm 0 027 in gauge 6 Check that the buzzer does not sound 7 If it sounds repeat steps 3 to 6 8 Tighten the two attaching screws Note Be careful not to move the throttle senso...

Page 268: ...n replace the air flow meter assembly 5 If the resistance is within specification check the wiring harnesses WATER THERM0 SENSOR Inspection of Resistance 1 Remove the water therm0 sensor 2 Place the s...

Page 269: ...he engine and run it at idle speed 2 Disconnect the oxygen sensor wiring harness con nector 3 Attach a voltmeter between the oxygen sensor con nector oxygen sensor side and ground 4 Run the engine at...

Page 270: ...es ON and OFF more than 8 timed10 set ATMOSPHERIC PRESSURE SENSOR Inspection of Terminal Voltage 1 Remove the rubber cap and connect a vacuum pump to the port of the sensor 2 Turn the ignition switch...

Page 271: ...STEM 4A EXHAUST SYSTEM REMOVAL Remove in the sequence shown in the figure 1 Main silencer 2 Catalytic converter 3 Front exhaust pipe INSPECTION Visually check the exhaust system parts for cracks or da...

Page 272: ...4A EXHAUST SYSTEM INSTALLATION Install in the reverse order of removal Note When installing the exhaust system parts tighten to the specified torque Catalytic converter 4A 72...

Page 273: ...8 49 FUEL TANK 2WD 48 52 FUEL TANK 4WD 48 53 PRESSURE REGULATORCONTROL PRC SYSTEM 4B 54 TURBOCHARGING SYSTEM 4B 66 TROUBLESHOOTING CHART 48 69 REMOVAL AND INSTALLATION 4B 60 INSPECTION 48 62 DECELERAT...

Page 274: ...ckvalve Distributor I I I n I I I II Pressure d __ I II Fuel filter RIII In 1 I I II II II 1 Fudl pump n rm r r II 1 Dash switch switch switch Wate throttle sensor sensor EMI 1 I I II Turbochar J Neut...

Page 275: ...NE 4B EMISSION COMPONENT LOCATION Throttle sensor Dashpot Knock control unct CSolenoid valve ressure switch mospherio pressure sensor cuit opening relay E L control unit Intake air thermo sensor Main...

Page 276: ...nt temperature 4 Engine load condition 5 OXyQen concentration 6 In gear condition 7 Intake air temperature 8 Atmospheric pressure 9 AK operation 10 P S operation 11 E L operation 12 Starting signal 13...

Page 277: ...Control Valve No 2 Purge Control Valve 26 27 e 29 30 31 32 33 Throttle Sensor Variable reeiater type Solenoid Valve for No 1 purge control valve Solenoid Valve for vacuum switch valve Solenoid valve...

Page 278: ...UUM ROUTING DIAGRAM Vacuum switch valve PCV valve Solenoid valve for No 1 purge control valve Solenoid ialve for vacuum switch valve Solenoid valve F for pressure regulator Distributor vacuum control...

Page 279: ...Resistance PUC lnn Ez L s Es Vc n Ez Ve Ez THA 1TYPO output pressure Feeding capacity nanatmr q umn impeller in tatIK kPa kg cm psi 441 568 4 5 6 0 64 85 cc cu in 10 sec 1 220 380 13 4 23 2 when fuel...

Page 280: ...B TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE RELATIONSHIP CHART Input Devices and Output Devices OUTPUT INJECTOR DEVICE I PRCV SOLENOID BAC VALVE I PURGE SOLENOID 1 No 1 No 2 1 48 8 323 Revised 10187...

Page 281: ...cut OFF Vacuum to pressure regulator After start Does not During hot ON operate starting Vacuum cut SAC AIR Open CbXe VALVE VALVE Coolant temp below 60 C 140 F ISC VALVE PURGE No SOLEN VID No 2 Large...

Page 282: ...fault using the self Diagnosis Checker 49 HO18 9Al Ist Check input sensors and switches and output sdenoid valves self diagnosed with Self Dlagnosls checker Refer to page 46 12 3rd Check the followin...

Page 283: ...10 1 11 12 13 14 15 16 2 3 5 2 6 3 The number of the list show the priorities of inspections from the most possible to that with the lowest possibility These were determined on the following basis l E...

Page 284: ...utput devices check for the cause using SST Using the SST failures of each input and output device are indicated and retrieved from the control unit as malfunction code numbers Note The control unit c...

Page 285: ...2 Connect SST to the check connector Green Gpin and the battery negative cable 3 Connect a jumper wire between the test connec tor Green 1pin and a ground 4 Turn the ignition switch ON then check for...

Page 286: ...and engine control unit 1M terminal PC Open circuit in wiring harness from ignition coil to engine control unit 1 M terminal iYES Is engine control unit 1M terminal voltage OK Refer to page 48 76 PC...

Page 287: ...Is there continuity between air flow meter and engine control unit Air flow meter Engine control unit Ye YG wire 31 Vc LgR wire 28 Vs LgB wire 2E E2 LY wire 2c IYES NO Repair air flow meter go PC Ope...

Page 288: ...NO Replace water therm0 sensor Is there continuity between water therm0 sensor and engine control unit Water thermo sensor 1 Engine control unit NO PC Open circuit in tiring harness from water therm0...

Page 289: ...4 k I 20 C EW F 2 21 2 69 kn 6OT 14Wfl 0 493 0 667 kfI IYES Is there continuity between intake air thermo sensor in air flow meter and engine control unit NO Replace air Row meter NO PC Open circuit...

Page 290: ...ge 48 76 YES No PC Open or short circuit in the wiring harness from the IC terminal to the throttle senser to engine control unit Engine control unit defective More than Measure ZG terminal voltage of...

Page 291: ...t 4 5 5 5VJ 1 Is voltage t LO wire of atmospheric pressure sen _ so cOnnectOr Iv 1 Voltage 3 5 4 5v at sea level 2 5 3 5V at high elevation 2 000 m 6 500 ft NO Replace atmospheric pressure sensor YES...

Page 292: ...mination Feedback System Does monitor lamp of S luminate at idle PC Air leak in vacuum hoses or emission compo nents Contaminated oxygen sensor Clogged fuel jet s YES t Are spark plugs clean Clean or...

Page 293: ...mination BAC Valve Are there any poor c connectors Repair or replace connector NO Is the resistance of the BAC Resistance 5 20 0 Replace BAC valve Is there battery voltage at YG wire of the BAC valve...

Page 294: ...opped to check the switches Blower switch OXYGEN SENSOR MONITOR FUNCTION The oxygen sensor and feedback mode are monitored as follows Engine Running Condition Item monitored Function Test connector ox...

Page 295: ...k that the monitor lamp does not illuminate t 1YES Check each switch in accordance with following procedures I Check each switch and related wiring harness l Clutch and Neutral switch Refer to page 4A...

Page 296: ...rake zi Fz unit l Engine control unit 1 J terminal malfunction Release brake pedal Blower switch Turn blower switch to 3rd position and check that monitor lamp illuminates YES Blbwer switch is OK A C...

Page 297: ...unit malfunction Refer to page 46 85 l Rear defroster switch malfunction Refer to Section 15 l Open circuit in wiring harness from rear defroster switch to E L control unit l Engine control unit 1 I t...

Page 298: ...the ignition timing l Connect a jump wire between the test connec tor and ground Idle speed 1 Check the idle speed Idle speed 850 50 rpm 2 If the idle speed is not within specification remove the blin...

Page 299: ...alve Air valve Air fynnel Intake manifold assemblv Turbocharger Intercooler This system is comprised of the air cleaner air flow meter turbocharger intercooler air bypass valve air funnel throttle bod...

Page 300: ...emove the intake air system in accordance with the following order 3 Install in the reverse order of removal 1 Accelerator cable 2 Air hoses and vacuum hoses 3 Air funnel 4 Air cleaner 5 Water hoses 6...

Page 301: ...attaching nuts of air flow meter 5 Remove the air flow meter Install in the reverse order of removal Throttle Body Removal and Installation 1 Drain the water from radiator 2 Disconnect the accelerato...

Page 302: ...n ad just by using nuts A 2 Depress the accelerator pedal to the floor and con firm that the throttle valve is fully opened Adjust by using bolt Et if necessary Throttle Body 1 Check that the throttle...

Page 303: ...to port of the valve 3 Apply vacuum and check that the air flow through the valve from port to port at loo 370 mmHg 3 94 14 58 inHg of the vacuum 4 Replace the valve if necessary INTERCOOLER lnspectlo...

Page 304: ...ake air amount detected by the air flow meter by regulating the bypass air amount that passes through the throttle body and thereby helps the engine to maintain a steady idle speed This system consist...

Page 305: ...M 4B TROUBLESHOOTING CHART Before performing the following troubleshooting check the condition of the wiring harness and connector While warming up 4Rerburn In exhawt system all emission test 4 5 3 1...

Page 306: ...4 Pinch the air hose and note the engine speed Cold engine Engine speed drops Warm engine Engine speed unchanged 5 Connect the BAC valve connector 6 Disconnect the jumper wire 7 Warm up the engine to...

Page 307: ...air funnel 2 Blow through the BAC valve from port Check the air flow Cold engine Air flows Warm englne Air does not flow ISC valve 1 Disconnect the BAC valve connector 2 Connect an ohmmeter to the ter...

Page 308: ...High pressure Distribution pipe Injector Fuel filter v w Pressure t regulator 1 This system supplies fuel for engine and controls the fuel pressure to maintain the required fuel injec tion amount to...

Page 309: ...release the fuel pressure from the fuel line to reduce the possibili ty of injury or fire 1 Start the engine 2 Disconnect the circuit opening relay connector 3 After the engine stalls turn OFF the ig...

Page 310: ...LTI PRESSURE TESTER 49 9200 750A The MULTI PRESSURE TESTER 49 9200 750A has been developed to check the fuel pressure and intake manifold vacuum These can easily be inspected by setting the buttons on...

Page 311: ...adapter Caution Do not reverse the adapter connection 4 Disconnect the vacuum hose from the pressure regulator control solenoid valve and connect SST vacuum hose using a three way joint 5 Connect the...

Page 312: ...FUEL SYSTEM TROUBLESHOOTING CHART Before performing the following troubleshooting check the condition of the wiring harness and connector POSSIBLE CAUSE Engine stall Rough idle 48 40 323 Revised lo 8...

Page 313: ...and injector Refer to page 48 47 Fuel Pump Pressure 1 Connect the terminals of the test connector yel low connector with a jumper wire 2 Turn the ignition switch ON to operate the fuel pump 3 Move th...

Page 314: ...pressure Approx 167 216 kPa 1 7 2 2 kg cm 24 1 31 3 psi 4 If not within specification check the vacuum hose 5 Disconnect a vaccum hose of pressure regulator 6 Check the fuel line pressure Fuel line pr...

Page 315: ...ed 7 If the voltage is normal replace the fuel pump Fuel pump Volume test Warning Before performing following procedures re lease the fuel pressure to reduce the possi bility of injury or fire Refer t...

Page 316: ...or then short or open the BG and B terminals of the fuel tank gauge unit connector using a jumper wire and check the transfer pump operation Terminals Transfer pump dperation Short stop Open Run Note...

Page 317: ...ctor 4 Remove attaching screws and cover 5 Turn the ignition switch ON 6 Short or open the BG and B terminals of the fuel tank gauge unit connector and check the voltage B and BY terminals of the fuel...

Page 318: ...possi bility of injury or fire Refer to page 4B 37 1 Remove the filler cap 2 Remdve the rear seat cushion 3 Remove attaching screws and cover 4 Disconnect the fuel hoses and plug them 5 Remove the fu...

Page 319: ...r from the engine Refer to page 48 50 2 Check the resistance of the injector Resistance 12 16 il Injector Leak test Warning Before performing following procedures re lease the fuel pressure to reduce...

Page 320: ...ct a suitable vinyl hose to the injector and place the hose in the container or graduated glass etc Note The hose should be 2 m 78 in or more 2 Connect the terminals of the fuel pump service con necto...

Page 321: ...shion 3 Remove attaching screws and cover 3 Disconnect the fuel main and return hoses and plug them to prevent fuel leakage 4 Remove the fuel pump and fuel tank gauge unit assembly Warning Use of fire...

Page 322: ...pump bracket under the vehicle 3 Disconnect the fuel hoses 4 Disconnect the connector 5 Install in the reverse order of removal Pressure Regulator 1 Remove the throttle body Refer to page 48 29 2 Dis...

Page 323: ...16 6 25 5 N m 1 9 2 6 m kg 13 7 16 8 ft lb Note a O ring of injector is not reuseable b When install the injector apply the gasoline on the O ring Fuel Filter High Pressure The fuel filter should be r...

Page 324: ...other hoses 7 Remove the fuel tank 63 048 06 8 Installation Install in reverse order of removal and be careful of the following 1 Make sure to connect the hoses in the correct po sitions 2 Fill tank w...

Page 325: ...ibited while working on the fuel tank Removal and Installation 1 Remove in the sequence shown in the figure 2 Install in the reverse order of removal and be careful of the following a Be sure to conne...

Page 326: ...e air therm0 sensor To prevent percolation of the fuel during idle for a specified period after the engine is restarted vacu um is cut to pressure regulator and the fuel pressure is increased Specifie...

Page 327: ...ection 1 Connect SST to the engine Refer to page 48 38 2 Start the engine 3 Warm up the engine to normal operating temper ature and stop the engine 4 Disconnect the water therm0 sensor connector then...

Page 328: ...ensor connector then connect a resistor 200 0 to the sensor con nector 2 Remove the air cleaner upper cover assembly and heat up the intake air therm0 sensor above 60 1409 3 Disconnect the vacuum hose...

Page 329: ...olenoid valve and vacuum pipe 2 Blow through the solenoid valve from vacuum hose 0 3 Check that air passes through the solenoid valve and flows from port Apply battery power 4 Disconnect the solenoid...

Page 330: ...ich pressurizes the intake air full floating bearings which support the compressor and turbine wheels seal rings which prevent oil leakage housing actuator which controls the waste gate valve and wast...

Page 331: ...TURBOCHARGING SYSTEM 46 TROUBLESHOOTING CHART POSSIBLE CAUSE oor acceleration hesftatlon and ack of power 48 63 48 63 48 62 5 43 5 44 48 X 4B 7 323 Revised IO 87 48 59...

Page 332: ...actuator mounting or rod c Cover the intake exhaust and oil passages to prevent dirt or other particles from entering 3 When reinstalling the turbocharger perform the fol lowing a Remove all the gaske...

Page 333: ...e order of removal 1 Under cover 2 Radiator 3 Air pipe and air hose 4 Insulator covers 5 Water hoses Caution 6 Oil pipe 7 Oil return pipe 8 Attaching nuts 9 Attaching bolts IO Turbocharger a Before re...

Page 334: ...er Inspection of wheel assembly 1 Cool the engine 2 Remove the air hose 3 Check that the rotor assembly turns smoothly 4 If there is excessive load or noise replace the tur bocharger Inspection of whe...

Page 335: ...applying the compressed air 5 If the warning buzzer does not sound inspect as described below Inspection of voltage 1 Turn the ignition switch ON 2 Apply air pressure of 71 8 79 8kPa 0 73 0 81 kg cm 1...

Page 336: ...LERATION CONTROL SYSTEM DECELERATION CONTROL SYSTEM Throttle sensor The fuel cut function is provided in the deceleration control system This function is to improve fuel consumption _ 48 64 323 Revise...

Page 337: ...Electrical Signal 1 Connect SST between the wiring harness and en gine control unit 2 Warm up the engine and run at idle 3 Set 3C and 3E position on SST Note 3C For No 2 and No 4 injectors 3E For No...

Page 338: ...s into the dashpot slowly 2 Release the finger and make sure the rod comes out quickly Adiustment 1 Garm up the engine to the normal operation tem perature and run it at idle speed 2 Connect tachomete...

Page 339: ...meter and the engine speed sensor ignition coil The control unit determines the engine operating conditions from the signals and control the evaporative emis sion control system by operating the solen...

Page 340: ...o the neutral switch connector 6 Disconnect the throttle sensor connector vacuum hose disconnected 7 Check the terminal voltage C G Voltage below 1 W 8 Place finger over the hose opening 9 Increase th...

Page 341: ...he evaporation pipe 2 Blow into the hose and check that air flows freely SOLENOID VALVE 1 Disconnect vacuum hose A from the servo di aphragm 2 Disconnect vacuum hose B from the solenoid valve 3 Discon...

Page 342: ...applied vacu um is more than the specified vacuum amount Specified vacuum 70 100 mmHg 2 76 3 94 inHg THREE WAY CHECK VALVE 1 Remove the three way check valve 2 Blow through the valve from port A and...

Page 343: ...ow by gas is drawn into the dvnamic chamber t high engine speed the PCV valve is further opened and large amount of blow by gas drawn into the dynamic chamber PCV VALVE inspection 1 Warm up the engine...

Page 344: ...48 CONTROL SYSTEM CONTROL SYSTEM Throttle sensor Pressure switch Water therm0 sensor Ignition coil 48 72 323 Revised IO 87...

Page 345: ...tinuity at terminals using an ohmmeter and wiring harness Continuity 1 Apply 12V to I and a ground terminals of the main relay 2 Check continuity at terminals using an ohmmeter 12V Not applied IZV Ap...

Page 346: ...ONTROL SYSTEM I Resistance 1 Check the resistance between the terminals using an ohmmeter Between terminals Resistance fQ1 I STA El m a C I Y _ IL I 80 150 0 Fp 00 2 It not correct replace the relay 4...

Page 347: ...ges This monitor easily inspects the terminal voltage by setting the monitor switch How to Use the Engine Signal Monitor 1 Connect the Engine Signal Monitor 49 9200 162 between the engine control unit...

Page 348: ...witch Oh Below 1 5v A C switch ON al 1G Input Neutral clutch switch Approx 12V Clutch pedal depressed In gear condition Neu Below 1 5v c tcf m h relaa ad trai constant 12V r 1H Input Water thermo swit...

Page 349: ...oolant temp More va va so en01 mper VW connect to a Neutral switch Engine control unit connector 31 3G13E 3C13A ZQ 2012M 2KI 21 2G 2E 2C 2A lW lU lS 1Q 1OI1M 1KI II IIG IEIIC IA J H F D B ZR P N L J H...

Page 350: ...h switch and check the continuity between the switch terminals Condition Continuity When the pedal is depressed NO When the pedal is released Yes BRAKE LIGHT SWITCH Inspection 1 Disconnect the brake s...

Page 351: ...iver measure the resistance between El and FC fuel pump switch and between E2 and VS Measuring Plate EI B Fc co 0 Ez Vs 20 to 4coD 20 to 1 ooon 4 If not correct replace it INTAKE AIR THERHO SENSOR Ins...

Page 352: ...ch terminal and ground 4 Open the throttle valve and check the voltage be tween each terminal and ground 5 If not correct on D terminal only check the throt tle sensor setting 6 If not correct at othe...

Page 353: ...the operation of the buzzer or continuity be tween terminals Thickness gauge Buzzing of Continuity between terminals the tester B D 0 5mm 0 020 in YSS YE3 0 7mm 0 027 in NO NO If necessary adjust the...

Page 354: ...Tighten the two attaching screws Note Be careful not to move the throttle sensor from the set position when fightening the screws IO Open the throttle valve fully a few times then check the adjustmen...

Page 355: ...the engine and run it at idle 2 Disconnect the oxygen sensor wiring harness con nector 3 Attach a voltmeter between the oxygen sensor con nector oxygen sensor side and ground 4 Run the engine speed a...

Page 356: ...set ATMOSPHERIC PRESSURE SENSOR inspection of Terminal Voltage 1 Remove the rubber cap and connect a vacuum pump to the port of the sensor 2 Turn the ignition switch ON 3 Check voltage between each t...

Page 357: ...ntte _ below 97 C 206 PF Coolant temp above 97 206 6T I I i I Below 1sv E L ON Control unit 1H Ar orox 12V 1 E L OFF Combination switch Blower motor switch Rear defroster switch Approx 12V Below 1 5V...

Page 358: ...SYSTEM EXHAUST SYSTEM REMOVAL Remove in the sequence shown in the figure 1 Main silencer 2 Catalytic converter 3 Front exhaust pipe INSPECTION Visually check the exhaust system parts for cracks or dam...

Page 359: ...EXHAUST SYSTEM 4B INSTALLATION Install in the reverse order of removal Note When installing the exhaust system parts tighten to the specified torque 31 4 46 1 N rn X2 4 7 m kg 23 1 34 5 ft lb 48 87...

Page 360: ...STALLATION 5 29 INSPECTION 5 29 HIGH TENSION LEADS 5 29 INSPECTION 5 29 IGNITION COIL 5 30 REMOVAL AND INSTALLATION 5 30 INSPECTION 5 30 DISTRIBUTOR NON TURBO 5 31 SPARK TEST 5 31 IGNITION TIMING 5 31...

Page 361: ...5 OUTLINE OUTLINE STRUCTURAL VIEW NON TURBO 83 05X 002 1 Alternator 5 2 Spark plug Ignition coil 6 Main fuse block 3 Distributor 7 4 Starter Battery 5 2...

Page 362: ...OUTLINE 5 STRUCTURAL VIEW TURBO 1 Alternator 6 Battery 2 Spark plug 7 Main fuse block 3 Distributor 8 High tension lead 4 Starter 9 Knock sensor 5 Ignition coil 10 Knock control unit 5 3...

Page 363: ...1 C 2 10 Vacuum host Approx 7O 00 l 19 M 190 5 A chamber Oni mmHg 2 95 inHg 28 1450 mmlig 17 72inHQ 300 501 OOl Vacuum ho rpm 3 rpm 1 rpm Bchamber 0 175 mmHg 2 95 inHQ 5W50 mmHQ 5 91 inHQ i j 0 T 3 1...

Page 364: ...n magnetic switch pull in coil Broken wire in magnetic switch holding coil Starting motor and related parts Poor contact of brushes Fatigued brush spring Poor ground of field coil Poor soldering of fi...

Page 365: ...brush and slip ring Malfunction of rectifier Malfunction of IC regulator Insufficient battery electrolyte Malfunction of battery electrode internal short circuit Poq contact of battery terminal s Exce...

Page 366: ...the terminals to ensure good electrical connections Clean the terminals and coat them with grease 2 Inspect for corroded or frayed battery cables 3 Check the rubber protector on the positive termi nal...

Page 367: ...e rec tifier b Do not use high voltage testers such as a megger because they will damage the rec tifler c Remember that battery voltages is always applied tom the alternator B terminal d Do not ground...

Page 368: ...lternator warning light goes off 1 Alternator warning light always not illuminate Fuse or wiring harness malfunction OK Perform TEST 1 Refer to p IC regulator or field coil malfunction 1OK Alternator...

Page 369: ...he other electrical components IC regulator brush or field coil malfunction Refer to page 5 l 6 or 5 l 7 a Poor connection between B terminal and the positive battery terminal b Poor connection of the...

Page 370: ...ness to the battery and check that the red lamp and green lamp illuminate 4 Start the engine and check that both lamps go off TEST 2 1 Connect an ammeter 60A min between the wire and the B terminal 2...

Page 371: ...speed Voltage 14 1 14 7V TEST 4 1 Turn all electric loads off and release the brake pedal 2 Check that output voltage between S terminal and ground is within specification at 2 500 3 000 rpm of the e...

Page 372: ...ALTERNATOR 5 TEST 6 1 Turn the ignition switch ON 2 Turn all electric loads off and release the brake pedal 3 Check that voltage between S terminal and ground is battery voltage 5 13...

Page 373: ...n the reverse order of removal Tightening torque Adjusting bolt 19 24 N m 1 9 2 6 m kg 14 19 ft lb Installation bolt 37 52 N m 3 6 5 3 m kg 27 36 f lb 7 Adjust the tension of the V belt Deflection New...

Page 374: ...te a If the bearing box is not heated the bear ing cannot be pulled out because the rear bearing and rear bracket fit together very tightly b Be careful not to force the screwdriver in too far because...

Page 375: ...aring circumference is at the slip ring side Bearing puller 6 Remove the nut of the B terminal and the insula tion bushing 7 Remove the rectifier holding screws and the brush holder holding screw 8 Se...

Page 376: ...Brush holder end line IO Replace the brushes Remove the solder from the pigtail and then re move the brush 11 When soldering the brush solder the pigtail so that the wear limit line of the brush proje...

Page 377: ...he core by using a circuit tester 2 Replace the rotor if there is continuity 3 Slip ring surface If the slip ring surface is rough use a lathe or fine sandpaper to repair it Stator 1 Wiring damage 1 C...

Page 378: ...h the brush into the brush holder until the tip projects 2 mm 0 079 in and read the force at that time Note For a new brush the force is 2 9 4 3 N 300 4409 10 6 15 6 02 Bearing 1 Check for abnormal no...

Page 379: ...een the diode lead and the heat sink at the negative side There should be continuity only in the direction from the heat sink to the diode 3 Trio diode Check for continuity by using a circuit tester T...

Page 380: ...spring protruding from the groove is lessened so that assembly becomes easi er In addition no strain is exerted on the spring and thus Its stopping effect becomes greater 2 Brush lifting Before assemb...

Page 381: ...und If it is 8V or more there is a starter mal function if it is less than 8V there is a malfunction in the wiring Caution If the magnetic switch is hot it may not func tion even though the voltage is...

Page 382: ...rter install in the reverse order of removal Tightening torque 31 41 N m 3 2 4 7 m kg 23 34 ft lb DISASSEMBLY AND ASSEMBLY Disassemble in the numbered order shown in the figure Assemble in the reverse...

Page 383: ...he pinion will eject out ward and then stop Then measure the clearance pinion gap between the pinion and the stopper Do not operate the starter for more than 20 seconds Pinion gap 0 5 2 0 mm 0 020 0 0...

Page 384: ...by using a lathe or replace the armature Note Before checking be sure that there is no play in the bearings 3 Outer diameter of the commutator Replace the armature if the outer diameter of the commut...

Page 385: ...using a circuit tester Replace the yoke assembly if there is no continuity 2 Ground of the field coil Check for continuity between the connector and yoke by using a circuit tester Repair or replace th...

Page 386: ...nuity between the insulated brush and the plate by using a circuit tester Repair or replace if there is continuity Also check that the brush slides smoothly inside the brush holder Drive pinion and ho...

Page 387: ...t the battery between terminal M of the magnetic switch and the body as shown in the figure 2 Pull the pinion out manually to the pinion stopper position 3 The pinion should immediately return to its...

Page 388: ...k the following points If a problem is found re place the spark plug 1 Damaged insulation 2 Worn electrodes 3 Carbon deposits If cleaning is necessary use a plug cleaner or a wire brush Clean the uppe...

Page 389: ...uity in the pri mary coil If there is no continuity replace the coil Secondary coil Use a tester to measure the resistance of the secon dary coil Secondary coil resistance 6 30 kO Insulation of case U...

Page 390: ...e bad Check once again after replacing the ignition coil or pick up coil IGNITION TIMING NON TURBO 1 Warm up the engine to the normal operating tem perature 2 Turn all electric loads OFF 3 Disconnect...

Page 391: ...g are correct 3 Disconnect the vacuum hoses from the vacuum control and plug the ends of the hoses 4 While gradually increasing the engine speed use a timing light to checksthe advance angle on the pu...

Page 392: ...of compression 4 Remove the distributor Note Do not turn the crankshaft after the distribu tor has been removed INSTALLATION Install in the reverse order of removal Note the following points 1 Coat t...

Page 393: ...SSEMBLY 1 Disassemble in the numbered order shown in the figure 2 Assemble in the reverse order of disassembly l Cap 2 Rotor 3 Pick up set 4 Vacuum control unit 5 Breaker plate assembly 6 Governor set...

Page 394: ...out turning the ignition to IG position E 2 Faulty ignition stitch 12V is indicated 3 Wiring between positive terminal of ignition coil and ignition switch is interrupted OK I I 1 Check for voltage a...

Page 395: ...up coil IGNITION TIMING 1 Warm up the engine to operating temperature 2 Turn all electric loads OFF 3 Disconnect the vacuum hose from the vacuum control unit and plug the hose 4 Connect a tachometer t...

Page 396: ...vance Excess advance weak governor spring if the governor spring is broken the advance will rise very high Insufficient advance governor weight or cam malfunction Vacuum 1 Warm up the engine to operat...

Page 397: ...4 35 2 701 1 45 r I I I 10 2O 10 8 kPa l REMOVAL 1 Remove the high tension leads 2 Disconnect the vacuum hoses and wiring con nectors 3 Turn the crankshaft so that No 1 cylinder is at top dead center...

Page 398: ...mble in the numbered order shown in the figure 2 Assemble in the reverse order of disassembly 1 Cap 5 Pick up coil and igniter 9 Coupling set 2 Rotor 6 Vacuum control unit IO Governer set 3 Cover 7 Br...

Page 399: ...2 Defective ignition switch 3 Wiring between positive terminal of ignition coil and ignition switch open 1 Replace main fuse 2 Replace igni tion switch 3 Repair wiring OK Check for voltage at negativ...

Page 400: ...KNOCK CONTROL SYSTEM 5 KNOCK CONTROL SYSTEM TURBO...

Page 401: ...ect the service connector 5 Tap the intake manifold assembly with a wrench as shown in the figure and check that the ignition timing retards 6 Stop tapping the surge tank bracket and confirm that the...

Page 402: ...t the ignition timing returns to specification Specification 12 lo BTDC INSPECTION OF KNOCK SENSOR 1 Check the retard function 2 If the ignition timing does not retard go to next step 3 Disconnect the...

Page 403: ...minal to knock control unit I terminal Check ignition timing at idle and then disconnect the senAce connector from the engine control unit I Tap the surge tank bracket lightly and make SUE ignition ti...

Page 404: ...0 HYDRAULIC type OUTLINE 6 3 STRUCTURAL VIEW 3 SPECIFICATIONS 4 TROUBLESHOOTING GUIDE 6 4 ON VEHICLE MAINTENANCE 6 9 INSPECTION AND ADJUSTMENT 6 9 CLUTCH PEDAL HEIGHT 6 9 CLUTCH PEDAL PLAY 6 9 CLUTCHP...

Page 405: ...OUTLINE OUTLINE STRUCTURAL VIEW 2WD 1 Adjusting nut 7 Release fork 2 Pin 8 Return spring 3 Clutch cable 9 Release bearing 4 Transaxle 10 Clutch cover 5 Clutch pedal 11 Clutch disc 6 Release lever 6 2...

Page 406: ...OUTLINE 6 OUTLINE STRUCTURAL VIEW 4WD 1 Clutch pedal 5 Clutch cwer 2 Master cylinder 6 3 Pipe Release bearing 7 4 Clutch disc Release cylinder 6 3...

Page 407: ...ufficient clutch pedal play Clutch pedal sticking Flywheel damaged Excessive run out or damaged of clutch disc Clutch disc splines rusted or worn Oil on facing Diaphragm spring weakened Excessive clut...

Page 408: ...eration PEDALFREEPLAY Inspection Depress the pedal lightly by hand and measure the freeplay ensure that it is within specification Pedal freeplay 9 15 mm 0 35 0 59 in Adjustment 1 Depress the clutch p...

Page 409: ...uence shown in the figure 1 Retaining ring 2 Lever 3 Bushing 4 Return spring 5 Bushing 6 Nut 7 Spring washer 8 Flat washer 9 Spacer IO Through bolt 11 Clutch pedal 12 Bushing 13 Clutch cable INSPECTIO...

Page 410: ...s of the pedal bushing pedal cable and hook unit 2 Install the return spring to the bushing and apply lithum grease Note install spring in position shown 3 Install the clutch pedal and tighten the nut...

Page 411: ...N Check the following and replace if necessary 1 Damage to the inner or outer cable 2 Function of the cable INSTALLATION Install in the reverse order of removal and note the following 1 Apply lithium...

Page 412: ...ng the carpet Standard height 229 2 mm 9 02 2 k Oin Adjustment 1 Adjust the clutch pedal height by loosening lock nut and turning clutch switch I 2 After the adjustment tighten lock nut CLUTCHPEDAL PL...

Page 413: ...tch pedal free play I 1 Clip 6 Cover 2 Push rod 7 Nut 3 Clip bushing and washer a Bolt 4 Spring 9 Bushing and washer 5 Nut IO Clutch pedal Caution Apply grease lithium base NLGI No 2 to the bushings a...

Page 414: ...rder of removal 3 After installation perform air bleeding r 1 Clutch pipe 2 Nut 3 Master cylinder 4 Gaskst 5 Spacer Clutch Pipe Use SST to disconnect and connect the clutch pipe Caution Clutch fluid w...

Page 415: ...and dust 4 Use clutch fluid to wash the inner parts 67 OW01 i 1 Snap ring 2 Piston and secondary cup assembly 3 Protector 4 Primary cup 5 Return spring 6 Joint bolt 7 Gasket 8 One way valve piston 9...

Page 416: ...condary Cup Assembly Remove the piston and secondary cup assembly by compressed air One way Valve 1 Remove the joint bolt 2 Remove the one way valve piston and spring by compressed air Reservoir Pry t...

Page 417: ...spring 3 Wear or damage to primary or secondary cups ASSEMBLY Assemble the clutch master cylinder in the reverse order of disassembly Note a Before assembling coat the edges of the piston and cups wi...

Page 418: ...flare nut of the clutch pipe Note After disconnecting the clutch pipe plug it to avoid fluid leakage Caution Clutch fluid will damage painted surfaces Use a container or rags to collect the fluid If...

Page 419: ...st be bled to remove air which has entered when the pipes are disconnect ed for repairs etc This bleeding is done as described below Cautlon a The fluid in the reservoir tank must be main tained at th...

Page 420: ...l 49 SE01 310 3 Remove the flywheel mounting bolts and then re move the flywheel 4 Remove the pilot bearing from the flywheel with a suitable rod and a hammer Note Do not remove the bearing If it is n...

Page 421: ...Note Use sandpaper if the trouble is minor 2 Loose facing rivets 3 Worn clutch disc Measure the depth to the rivet heads with a slide caliper Depth 0 3 mm 0 012 in min 4 Run out of clutch disc Lateral...

Page 422: ...ry replace the ring gear as follows 1 Heat the ring gear with a blowtorch and then tap around the gear to remove it from the flywheel 2 Heat the new ring gear to 250 300 C 450 570 F and then fit it on...

Page 423: ...Tightening torque 96 103 N m 9 9 10 5 m kg 71 75 ft lb Note If reinstalling flywheel bolts clean threads to remove old sealant apply new sealant and tighten to specification If old sealant can not be...

Page 424: ...No 2 or equivalent organic molybdenum grease 6 Install the clutch disc by using the SST Note Install the clutch so that It faces in the direc tion shown in the figure 7 Tighten the pressure plate grad...

Page 425: ...A 30 DIFFERENTIAL 7A 30 STEP 1 7A 32 STEP 2 7A 42 STEP 3 7A 44 INSTALLATION 7A 76 TRANSAXLE CONTROL 7A 61 REMOVAL 7A 61 INSPECTION 7A 62 INSTALLATION 7A 62 OUTLINE 7A 3 STRUCTURAL VIEW 7A 3 CROSS SECT...

Page 426: ...ry shaft gear as sembly 2 Secondary shaft gear as sembly 3 Clutch housing 4 Transaxle case 5 Differential assembly 6 Shift fork and shift rod as sembly 7 Transaxle control assembly 8 Rear cover 9 5th...

Page 427: ...STRUCTURAL VIEW Primary shaft gear assembly Secondary shaft gear assembly Differential assembly Clutch housing 5 Primary reverse synchronizer gear 6 Secondary reverse synchronizer gear 7 Reverse idle...

Page 428: ...7A OUTLINE CROSS SECTIONAL VIEW F type 7A 4...

Page 429: ...OUTLINE 7A CROSS SECTIONAL VIEW G type 7A 5...

Page 430: ...7A OUTLINE SPECIFICATIONS Gear ratio Oil Above 18 0 F API GL 4 or GL 5 ATF M2C33 F or DEXRON II SAE80W 90 or SAE 90 7A 6 323 Revised 10187...

Page 431: ...bushing Weak change iever ball spring Improperly installed extension bar Worn shift fork Worn clutch hub Worn clutch hub sleeve Worn secondary shaft gear Worn sliding surface of gear Worn steel ball s...

Page 432: ...necessary amount of the specified oil through the gear case hole Replacement 1 Park the vehicle on a level area 2 Remove the speedometer driven gear See inspection section above 3 Remove the drain plu...

Page 433: ...tabilizer from the lower arm 5 Remove the clinch bolt and pull the lower arm downward Separate the knuckle from the lower arm Caution Be careful not to damage the ball joint dust boot 6 Separate the d...

Page 434: ...IO Install the driveshaft as follows 1 Pull the front hub outward and then fit the driveshaft into the transaxle 2 Insert the driveshaft into the transaxle by push ing on the wheel hub assembly Cautio...

Page 435: ...t Tightening torque 12 18 N m 1 2 1 8 m kg 9 13 ft lb Dimension A 10 8 mm 0 43 in 13 install the side cover 14 Install the undercover 15 Mount the front wheel s 16 Remove the safety stands 17 Add the...

Page 436: ...emove the ground wire installation bolt 7 Remove water pipe bracket 8 Remove the secondary air pipe and E G R pipe bracket 9 Remove the wire harness clip 0 Disconnect the coupler for the neutral switc...

Page 437: ...arm ball joints and the knuckle clinch bolts pull the lower arms downward and separate the lower arms from the knuckles Caution Be careful not to damage the ball joint dust boot 20 Separate the drives...

Page 438: ...wires from the starter motor and re move the starter motor i I 29 25 Remove the end plate 26 Lean the engine toward the transaxle side by loosening the engine support hook bolt 27 Support the transax...

Page 439: ...b assembly 7 Synchronizer ring 8 5th gear 9 Gear sleeve 10 Lock nut 11 Primary gear 12 Lock bolt 13 Guide bolt 14 Transaxle case 15 Reverse idle shaft 16 Reverse idle gear 17 Lock bolt hii rod 5th and...

Page 440: ...with the SST and remove the lock nut Note Shift to 1st or 2nd Shift Fork 5th Remove the shit fork 5th together with the clutch hub assembly Shift rod 5th and reverse 1 Insert a pin punch or suitable...

Page 441: ...ansaxle in neutral Spring Pin The spring pin used for attaching the control rod and control end can easily be removed by the following procedure 1 Make sure the transaxle is in neutral and the inter l...

Page 442: ...Assembly Lift the primary shaft secondary shaft and shift fork assemblies out as a unit Control End Pull the change rod rearward and remove the con trol end and ball and spring Caution Be careful not...

Page 443: ...rse gate 11 Spring 12 Selector 13 Oil seal 25 Lever set spring 14 Breather cover 26 Bearing outer race 15 Breather 27 Bearing outer race 16 Speedometer driven gear 28 Diaphragm spring assembly 29 Adju...

Page 444: ...the pin out with a pin punch and hammer Bearing Outer Race differential clutch housing and transaxle case Remove the bearing outer races with the SST and hammer Do not remove the oil seals unless repl...

Page 445: ...emove the bearing outer races gradually with the SST or a screwdriver with a bent end Oil Seal differential Check the oil seals and if necessary replace them Use a pipe of the proper size to tap the s...

Page 446: ...15 Synchronizer spring 4 Spring pin 16 Synchronizer key 5 Control lever 17 Clutch hub 6 Control rod 18 Clutch hub sleeve 7 Bearing inner race 19 Synchronizer ring 8 Bearing inner race 20 3rd gear 9 P...

Page 447: ...aft with the SST Caution Hold the shaft with one hand so that it does not fall Bearing Inner Race 4th gear end of primary shaft aeart Press e dearing inner race from the shaft with the SST Caution Hol...

Page 448: ...t with one hand so that it does not fall Clutch Hub Assembly 1st 2nd gear Support the 1st gear and press it and the clutch hub assembly off the secondary shaft Caution Hold the shaft with one hand so...

Page 449: ...washer 6 Side gear 7 Thrust washer 8 Side bearing in ner race 9 Speedometer drive gear IO Gear case Backlash Before disassembly check the backlash of side gears and pinion gears Refer to page 7A 31 St...

Page 450: ...com bination of parts from the SST INSPECTION Check the following parts and replace if necessary lst 2nd 3rd 4th and 5th gears 1 Worn or damaged synchronizer cone 2 Worn or damaged hub sleeve coupling...

Page 451: ...sure around the circumference b If the measured value is less than the limit replace the synchronizer ring or gear Secondary Shaft Gear 1 Worn or damaged gear contact surface 2 Worn or damaged spiines...

Page 452: ...d hub splines 2 Worn or damaged sleeve fork groove 3 Clearance between sleeve and shift fork Standard 0 2 0 458 mm 0 008 0 018 in Limit 0 5 mm 0 020 in Synchronizer Key and Spring 1 Worn key 2 Bent sp...

Page 453: ...s and the preload of the differential side bearings Bearing 1 Roughness or noise while turning 2 Worn or damaged outer race or rollers Caution a Replace the bearing the outer race and the inner race a...

Page 454: ...in the numbered order shown in the figure 1 Gear case 6 Thrust washer 2 Speedometer drive gear 7 Pinion gear 3 Side bearing inner race 8 Pinion shaft 4 Thrust washer 9 Knock pin 5 Side gear 10 Ring g...

Page 455: ...cannot come out of the gear case Backlash of Side Gear and Pinion Gear Check and adjust by the following procedures 1 Install the left and right driveshafts on the differen tial assembly 2 Support the...

Page 456: ...ar 18 Thrust washer 7 Bearing inner race 19 Ring 8 1st gear 20 3rd gear 9 Synchronizer ring 21 Synchronizer ring 10 Clutch hub sleeve reverse 22 Clutch hub sleeve g 9 23 Clutch hub 11 Clutch hub 24 Sy...

Page 457: ...on The wider side face of the synchronizer key must be install to reverse gear direction 0 0 0 1atQnd 19 0 7480 4 25 0 1673 4 25 0 1673 3rd 4th 17 0 6693 4 25 0 1673 4 25 0 1673 5th Rev 17 0 6639 4 25...

Page 458: ...into the holes in the groove Bearing Inner Race 4th gear end of secondary shaft gear Press the inner race on the end of the secondary shaft with SST Note Press to 19 620N 2 000 kg 4 400 lb Thrust Cle...

Page 459: ...and the thrust washer Standard 0 095 9 38 mm 0 004 0 015 in Limit 0 43 mm 0 017 in Thrust Clearance of 4th Gear Measure the clearance between the 4th gear and the bearing inner race Standard 0 09 0 4...

Page 460: ...A ASSEMBLY Bearing Preload Adjust the bearing preload by selecting adjustment shim s Transaxle case Secondary shaft Primary shaft assal 323 Revised IO k37...

Page 461: ...ut the outer races into the SST for primary 49 F401 383 for secondary 49 F401 382A Caution Turn the SST to eliminate the gap indicated by the arrow in the figure 4 Set the differential assembly into t...

Page 462: ...gure 1 7 To seat the bearings mount the SST on parts A and B of the selector and then turn the selector so the gap shown by the arrow in the figure is widened _ Move the bar by hand until the selector...

Page 463: ...the shim and the race from the meas ured value of the gap in the selector Example 0 94 mm 0 0370 in 0 94 mm 0 0370 in 0 70 mm 0 0276 in Diaphragm spring 0 24 mm 0 009 in So the nearest shim on the lar...

Page 464: ...Qn mm 0 036 in t 12 Adjust the selector with the SST until the preload specification is obtained Preload OS o 75 N m 5 7 6 cm kg 4 3 6 6 in lb 13 Use a thickness gauge to measure the gap in the select...

Page 465: ...then remove the transaxle case Remove the shaft gears selectors and the differential 16 Remove the bearing outer races for both shafts from the transaxle case Leave the differential side bearing outer...

Page 466: ...shim 9 Diaphragm spring 10 Bearing outer race 11 Bearing outer race 12 Lever set spring 13 Reverse lever 14 Reverse lever shaft 15 Spring pin 16 Gear case 17 Oil seal 18 Driven gear 19 Spring pin 20 O...

Page 467: ...ter Race 1 Install the selected adjustment shims and the di aphragm spring into the transaxle case Caution Install the diaphragm spring as shown in the figure l I n 2 Install the bearing outer races i...

Page 468: ...Gear sleeve 4 Crank lever assembly 13 Gate 25 5th gear 5 O ring 14 Shift rod 5th and reverse 26 Crank lever shaft Synchronizer ring 6 15 Lock bolt 27 Clutch hub assembly 7 Differential assembly 16 Re...

Page 469: ...0 3 7 6 cm kg 0 26 6 8 in lb 5 Remove the adaoter and the attachment 6 With the transaxle facing in the direction shown in the figure install the SST to the primary shaft gear Hook the spring scale to...

Page 470: ...Install the differential assembly 4 Unite the primary shaft gear secondary shaft gear and shift fork assembly Install the control rod into the control end as the unit is lowered into place Note Keep...

Page 471: ...the cor rect position Interlock Sleeve and Reverse Idle Shaft Before installing the transaxle case make sure the control lever arrow is kept flush with the surface of the end of the interlock sleeve P...

Page 472: ...as sem bly Lock Nut 5th clutch hub Put the transaxle in 1st or 2nd aear and lock the pri mary shaft with the SST and tighten the locknut on the secondary shaft to the specified torque Stake the lockn...

Page 473: ...17 Magnet synchronizer gear 18 Reverse idle shaft 6 Spring pin 19 Reverse idle gear 7 Shift fork 20 Lock bolt 8 Clutch hub assembly 21 Shift rod 5th and reverse 9 Synchronizer ring and clip 10 5th gea...

Page 474: ...nd remove the lock nut Note a Turn the transaxle on its side b Shift to 1st or 2nd gear Secondary 5th Gear Remove the secondary 5th gear Crankshaft Lever Shaft The crankshaft lever shaft can be remove...

Page 475: ...rod counter clockwise 2 While holding the 1st 2nd shift fork with one hand and the 3rd 4th shift fork with the other raise them both at the same time and shift each of the clutch hub sleeves 3 Lift t...

Page 476: ...e 7A 52 15 Selector 16 Oil seal 17 Bolts 18 Bleeder cover 19 Bleeder 20 Bolt 21 Speedometer driven gear assembly 22 O ring 23 Spring pin I 24 Driven gear 25 Gear case 26 Oil seal 27 Bearing outer race...

Page 477: ...Outer Race between secondary shaft and engine Remove the bearing outer race by lifting out the fun nel and the race together Spring Pin Align the groove for removal of the clutch housing pin with the...

Page 478: ...nd 18 Synchronizer keys gears 19 Clutch hub 6 Spring pin 20 Clutch hub sleeve reverse 7 Control lever gear 8 Control rod 21 Synchronizer ring 9 Bearing outer race 22 1st gear 10 4th gear 23 Bearing in...

Page 479: ...hown Note The clutch hub sleeve must be meshed with 1st gear Warning Hold the shaft with one hand so that it doesn t fall Clutch Hub Assembly 1st and 2nd gears Press off the 7st and 2nd clutch hub ass...

Page 480: ...SST onto the 3rd gear and press off the clutch hub assembly together with the gear Caution Hold the shaft with one hand so that it doesn t fall DIFFERENTIAL Disassemble in the sequence shown in the fi...

Page 481: ...in a vice use a pin punch to tap out the spring pin Side bearing inner race side opposite the ring gear Remove the bearing inner race from the gear case using the SST Caution Hold the gear case with o...

Page 482: ...e 4 Clogged oil passage Note When the shaft gear is replaced adjust the bearing preload Synchronizer Ring 1 Engagement with gear Caution If meshing is not good coat the gear and the synchronizer ring...

Page 483: ...or damaged bushing 2 Worn or damaged teeth 3 Worn or damaged release lever coupling groove Clutch housing Transaxle case Rear cover and Differential Gear Case 1 Cracks or damage Note Note If the clut...

Page 484: ...stall the driveshaft and the joint shaft onto the differential assembly 2 Support the shafts on V blocks as shown 3 Measure the backlash of both pinion gears Backlash O O 1 mm O 0 0039 in 4 If the bac...

Page 485: ...0 0069 0 0179 in Max 0 505 mm 0 0199 in 3 Measure the clearance between 3rd gear and 2nd gear Standard 0 05 0 20 mm 0 0020 0 0079 in Max 0 25 mm 0 0098 in 4 Measure the clearance between 4th gear and...

Page 486: ...tween the bearing and the gear case 3 Install the thrust washer onto the pinion gear then install both into the gear case and install the pin ion shaft 4 Tap the spring pin into the gear case from the...

Page 487: ...figure and press on the shaft gear Note Install the clutch hub sleeve as shown Caution Begin pressing only after confirming that the splines of the shaft gear and the clutch hub are properly positione...

Page 488: ...7 Press the clutch hub assembly onto the shaft gear using SST Note Begin pressing only after confirming that the splines of the shaft gear and the clutch hub are properly positioned and press until th...

Page 489: ...ess on the bearing inner race and 4th gear at the same time Note a Install 4th gear so that it faces in the direc tion shown in the figure b1Begin pressing only after confirming that Isolines of the s...

Page 490: ...earing out er race and tap with a hammer until it contacts the clutch housing Outer race Differential Outer races z Secondary shaft aseem bly Transaxle case Outer rases Primary shaft assembly Outer ra...

Page 491: ...differential selector as shown 9 Set the SST between the transaxle case and the clutch housing then install the SST and tighten to the specified torque Tightening torque 18 20 N m 1 8 2 0 m kg 13 14 f...

Page 492: ...circumfer ence of the selector 14 Select an appropriate adjust shim 1 The shim to be used at the primary shaft gear side should be selected by referring to the ta ble and selecting the shim which is...

Page 493: ...ust the selector with the SST until the preload specification is obtained Preload 0 5 N m 5 cm kg 4 3 in lb 17 Measure the clearance between A and B with a feeler gauge 16 Add 0 15 mm 0 0059 in to the...

Page 494: ...lutch housing 3 Tap in a new spring pin 4 Tap in the oil seal differential side using the SST 5 Install the bleeder 6 Install the bleeder cover 7 Install the oil seal change rod side 6 Install the cha...

Page 495: ...ve the control rod ball spring and pin Remove the crankshaft lever shaft and the crank shaft lever 15 Install the funnel and the bearing outer race into the secondary shaft gear bearing bore of the cl...

Page 496: ...es and tap in new spring pins 2 Install the shift fork 1st and 2nd gears and the con trol end onto the control rod so that they face in the direction shown in the figure align the control end and the...

Page 497: ...1A 2 0 N m 14 20 cm kg 12 2 17 5 in lb 5 Remove the SST 6 With the transaxle facing in the direction shown in the figure install the SST to the primary shaft gear 7 Measure the preload Preload 0 1 0...

Page 498: ...the direction of the arrow in the figure so that the ball goes into the shaft the rod will at the same time line up with the shift rod coupling hole in the clutch housing 7A 74 6 Set each clutch hub...

Page 499: ...direction shown in the figure 14 Apply a thin coat of sealant to the contact surfaces of the clutch housing and transmission case tight en the transaxle case installation bolts to the speci fied torqu...

Page 500: ...tion the secondary 5th gear on the secondary shaft gear in the direction shown in the figure 3 Install the clutch hub and the 3 synchronizer keys to the clutch hub sleeve 5th gear 4 Insert the hook pa...

Page 501: ...94 145 ft lb Il Coat the surface of the transaxle case which faces the rear cover vith sealant then install the rear cov er and tighten the bolts to the specified torque Tightening torque 8 11 N m 0...

Page 502: ...ecified torque Tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft lb Extension Bar and Change Control Rod Install the extension bar and the change control rod and tighten them to the specified torque T...

Page 503: ...riveshaft be careful not to damage the oil seal b After installtion pull the front hub outward to confirm that the driveshaft is securely held by the clip Ball Joint Install the lower arm ball joint t...

Page 504: ...uts to the specified torque Tightening torque 23 29 N m 2 3 3 0 m kg 17 22 R lb Transaxle Oil 1 Add the specified amount of the specified trans axle oil through the speedometer driven gear in stallati...

Page 505: ...n in the figure 63 07 149 Change lever knob 1Center console 3 Side wall 4 Change boot 5 Bolt and nut 6 Mounting rubber 7 Spring 8 Change lever 9 Ball seat upper IO Boot 11 Holder 12 Ball seat lower 13...

Page 506: ...n of any joint 3 Damaged change lever ball 4 Weak spring 5 Wear or damage of bushing INSTALLATION Install in the reverse order of removal and note the following Extension Bar First install the extensi...

Page 507: ...grease to all joints Spring Make sure that the hooked part of spring is properly seated in the bracket groove as shown in the figure Bracket Cavity Put grease in the bracket cavity Change Control Rod...

Page 508: ...CATIONS 7C 4 TROUBLESHOOTING GUIDE 5 C VEE LE MAINTENANCE E 6 7c 11 DISASSEMBLY 7C 15 STEPI 7C 15 STEP2 7C 22 STEP3 7C 25 STEP4 7C 30 STEP5 7C 35 INSPECTION 7C 38 ASSEMBLY 7c 45 STEP1 7C 45 STEP2 7C 4...

Page 509: ...sembly 6 Idle gear 7 Center differential lock shift fork assembly 8 Primary shaft gear assembly 9 Secondary shaft gear assembly IO Shift fork and shift rod assembly 11 5th gear 12 Reverse idle gear 13...

Page 510: ...OUTLINE u CROSS SECTIONAL VIEW...

Page 511: ...st 3 307 Gear ratio Third 1 233 Fourth 0 970 Front final gear ratio Speedomete Oil zear ratio Transaxle TYPO 1 045 ATF DEXRON II API GL 4 or GL 5 SAE r ow go or SAE go Above 160c 0 Capacity TVDe 3 6 l...

Page 512: ...e primary shaft gear bearing preload Improperly adjusted change guide plate Bent shift control rod Worn shift control rod bushing Weak shift lever ball spring Improperly installed extension bar Worn s...

Page 513: ...ed oil OIL SEAL Transfer Carrier Replacement 1 Remove the drain plug and oil 2 Remove the propeller shaft 3 Before loosening the lock nut measure the rota tion starting torque of the drive pinion Note...

Page 514: ...ferential oil 8 Coat companion flange seal surface with differen tial oil and install the washer and companion flange 9 Tighten the bolt with the SST Note Check the drive pinion preload 10 Install the...

Page 515: ...h the SST 2 Remove the clinch bolt and pull the lower arm downward Separate the knuckle from the lower arm ball joint Note Be careful not to damage the ball joint dust boot 3 Remove the drain plug and...

Page 516: ...l seal 8 Fit a new clip on driveshaft 9 install the driveshaft to transaxle and transfer carrier IO Install the joint shaft Tightening torque 42 62 N m 4 3 6 3 m kg 31 46 ft lb 11 Install the lower ar...

Page 517: ...tall the tie rod end to the knuckle and tighten it Tightening torque 29 44 N m 3 0 4 5 m kg 22 33 ft lb _ 13 Install the drain plug and add the specified oil from oil supply port plug Tightening torqu...

Page 518: ...ilizer 3 Speedometer cable IO Mount bracket No 4 17 Tie rod end 4 Clutch release cylinder 11 Tire and wheel 1a Lower arm 5 Neutral switch 12 Side cover and undercover 19 Joint shaft 6 Backup lamp swit...

Page 519: ...ve the bolt and clip and remove the clutch release cylinder 3 Disconnect the neutral switch backup lamp switch differential lock sensor switch and differential lock motor connector 4 Remove the body g...

Page 520: ...7c 7 Mount the SST to the engine hanger 8 Remove mount bracket No 4 9 Remove the wheels IO Remove the side cover and undercover 11 Remove the oil filter differential lock assembly starter and stabiliz...

Page 521: ...AL 12 Remove the tie rod end and lower arm 13 Remove the driveshaft 14 Insert the SST to hold the side gear 1 15 Remove the end plate bolts 16 Use an engine hoist and remove the transaxle and transfer...

Page 522: ...sembly 17 Bolt 5 Side cover 18 Transaxle case 6 Rear cover 19 Magnet 7 Lock nut s 20 Reverse idle shaft 8 Primary reverse synchroniz 21 Reverse idle gear er gear and gear sleeve 22 Idle gear 9 Synchr...

Page 523: ...transaxle on the SST Switch Remove the neutral switch center differential lock sen sor switch and backup lamp switch Center Differential Lock Assembly 1 Remove the bolt 2 Turn the differential lock sh...

Page 524: ...DISASSEMBLY 7c 3 Remove the differential lock assembly Cover 1 Remove the side cover 2 Remove the rear cover 5th Gear 1 Shift the lever into 1st gear 7c 17...

Page 525: ...remove the lock nuts 4 Drive the spring pin out and remove the primary reverse synchronizer gear gear sleeve and syn chronizer ring 5 Remove the secondary reverse synchronizer gear 6 Remove the shift...

Page 526: ...bolt and inter lock sleeve mount bolt 2 Disconnect the idle gear from the transaxle case by tapping lightly with a plastic hammer 3 Remove the transaxle case 4 Remove the magnet Reverse Idle Gear Rem...

Page 527: ...bly and Shift Fork Assembly 1 Remove the set bolt 2 To remove the reverse shift rod wrap it with a cloth and turn it with pliers while pulling out 7C 20 3 Remove the shift gate and reverse lever suppo...

Page 528: ...hift fork assemblies out as a unit Center Differential 1 Remove the set bolt and remove the center dif ferential assembly 2 Remove the center differential lock shift fork Transfer Carrier 1 Remove the...

Page 529: ...Oil passage 4 Baffle plate 5 Bearing outer race 6 Diaphragm spring 7 Washer s 8 Funnel 9 Oil seal 10 Clutch lever 11 Clutch release fork 12 Clutch release shaft 13 Clutch release collar 14 Spring pin...

Page 530: ...the oil seals unless replace ment is necessary due to damage 3 Remove the bearing outer race by lifting the fun nel and the race out together Oil Seal Check the oil seals and if necessary replace the...

Page 531: ...7c DISASSEMBLY Clutch Housing 1 Remove the spring pin and crank lever 2 Remove the spring pin and inner shift lever 3 Remove the base plate 7C 24...

Page 532: ...sas sembled b Before disassembly check the thrust clearance of all gears Refer to page 7C 62 63G07C 30 1 Bearing inner race 8 Primary shaft gear 2 4th gear 9 Bearing inner race 3 Synchronizer ring 10...

Page 533: ...a press Caution Hold the shaft with one hand so that it does not fall 4th Gear Remove the 4th gear and synchronizer ring Clutch Hub Assembly 3rd 4th gear 1 Remove the retaining ring 2 Set the SST onto...

Page 534: ...Hold the shaft with one hand so that it does not fall SECONDARY SHAFT GEAR Bearing Inner Race and Secondary 4th Gear 1 Set the SST onto the secondary 4th gear 2 Remove the bearing inner race and the s...

Page 535: ...b sleeve into 1st gear 3 Set the SST onto the 2nd gear 4 Remove the 2nd gear and secondary 3rd gear with a press Caution Hold the shaft with one hand so that it does not fall Clutch Hub Assembly and 1...

Page 536: ...1st gear with a press Caution Hold the shaft with one hand so that it does not fall Bearing Inner Race Remove the bearing inner race from the shaft with the SST and press against the shaft with a pro...

Page 537: ...t screw 3 Side cover 8 IO Washer and lock nut 4 Bearing 11 Companion flange 5 Idle gear 12 Oil seal 6 Lock plate and bolt 13 Bearing inner race 7 Bolt 14 Collapsible spacer 15 Bearing inner face 16 Sp...

Page 538: ...in a vise 2 Uncrimp the tab of the lock nut 3 Remove the lock nut Note Use pads in the vise 4 Remove the retaining ring 5 Tap the bearing and remove the side cover 6 and bearing 6 Remove the bearing f...

Page 539: ...n the SST and mount the transfer carrier Adjustment Screw 1 Make matching marks on the carrier and caps 2 Remove the bolts lock plates and the bearing caps 3 Remove the adjustment screw Differential G...

Page 540: ...ove the lock nut with the SST 2 Remove the companion flange with the SST 3 Push the drive pinion out by attaching a miscel laneous lock nut to the drive pinion and tapping it with a copper hammer 4 Re...

Page 541: ...mer drive out the bearing 2 Remove the bearing outer races by using the two grooves in the carrier and tapping the races alter nately Bearing Inner Race Differential gear 1 Remove the bearing inner ra...

Page 542: ...bearing 7 Gear case needle bearing 8 Differential lock thrust washer 9 Gear case needle bearing 10 Bearing inner race 11 Thrust washer 12 Gear case needle bearing 13 Sun gear 14 Gear case needle bear...

Page 543: ...leeve differen tial lock hub and gear case needle bearing 3 Remove the gear case needle bearings and differential lock thrust washer 4 Remove the bearing inner race using a press then remove the washe...

Page 544: ...DISASSEMBLY 7c Front Differential I Remove the pinion shaft 2 Remove the side gears and pinion gears 3 Remove the washers 7c 37...

Page 545: ...gear run out Maximum run out 0 03 mm 0 001 in Note If the shaft gear is replaced adjust the bear ing preload Refer to Page 7C 65 Synchronizer Ring 1 Engagement with gear 2 Worn or damaged teeth 3 Worn...

Page 546: ...ars Standard 0 03 0 08 mm 0 001 0 003 in Note if the shaft gear is replaced adjust the bear ing preload Clutch Hub 1 Worn or damaged splines 2 Worn or damaged synchronizer key groove 3 Worn end surfac...

Page 547: ...Worn bearing Reverse idle Gear and Shaft 1 Worn or damaged Qear 2 Worn shaft Standard clearance 0 1 0 32 mm 0 004 0 013 in Maximum 0 5 mm 0 02 in Clutch Housing and Trannaxle Case Cracks or damage No...

Page 548: ...Worn or damaged teeth 2 Worn or damaged 0 ring Ring Geai Speedometer Drive Gear Worn or damaged teeth Oil Seal Damaged or worn lip Retaining Ring Bent ring Idle Gear Worn or damaged teeth Drive Pinio...

Page 549: ...dard length 43 35 43 66 mm 1 701 1 719 in Companion Flange and Oil Seal 1 Check the oil seal for wear or damage 2 Check the companion flange for cracks worn splines or rough oil seal contact surface T...

Page 550: ...ECTION c Planetary Carrier Assembly Engagement with pinion gears Differential Lock Gear Sleeve Worn or damaged Differential Lock Hub Worn or damaged Side Gear Pinion Gear and Washer Worn or damaged 7c...

Page 551: ...7c iNSPECTION Differential Gear Case Worn or damaged Differential Gear Case Sleeve Worn or damaged Gear Case Needle Bearing Worn or damaged 7c 44...

Page 552: ...ng 9 Spacer IO Gear case needle bearing 11 Planetary carrier 12 Gear case needle bearing 13 Sun gear 14 Gear case needle bearing 1 6 Thrust washer 16 Bearing inner race 17 Gear case needle bearing 18...

Page 553: ...2 Install a pinion gear and turn it 180 Note Do not install the washer at this time 3 Install the other pinion gear and washer 4 Turn the pinion gear and washer 150 5 Install the washer on opposite pi...

Page 554: ...ar case needle bear ing and the SST Note Apply transaxle oil to the needle bearings Measuring plate thickness 4 3 mm 0 169 in 4 Measure the clearance between the SST and gear case needle bearing If th...

Page 555: ...and the gear case needle bearing If the clearance is not within specification select the proper differential lock thrust washer Standard 0 15 0 30 mm 0 006 0 012 in Available washer thickness 1 20 mm...

Page 556: ...5 Side cover B 6 Idle gear 7 Lock nut 8 Transfer carrier 9 Bearing outer race 10 Bearing outer race 11 Drive pinion 12 Spacer 13 Bearing inner race 14 Collapsible spacer 15 Bearing inner race 16 Oil...

Page 557: ...rential gear 2 Install the bearing inner race to the differential gear Idle Gear 1 Install the retaining ring to the bearing 2 Install the side cover B and bearing to the idle gear using a press 3 Use...

Page 558: ...the SST 2 Install the bearing outer race with the SST 3 Install the bearing outer race using a brass drift 4 Install the spacer and bearing inner race to the SST Note Use the spacer which was removed...

Page 559: ...moved b Tighten the nut enough so that the drive pinion model can still be turned by hand 7 Place the SST on the surface plate and set the dial indicator to Zero 8 Set the SST on top of the gauge bloc...

Page 560: ...3 29 mm lo 1295 in 3 32 mm 10 1307 inl Specification 0 mm 0 in 11 If it is not to the specification adjust the pinion height by selection of a spacer Note The spacer thicknesses are available in 0 03...

Page 561: ...inner race and companion flange and tighten the lock nut Note Do not install the oil seal 4 Turn the companion flange by hand to seat the bearing 5 Measure the drive pinion preload Preload l l 6 N m...

Page 562: ...ferential carrier with the SST 9 Coat companion flange with oil IO Install the companion flange and washer Il Install and tighten a new lock nut with the SST Tightening torque 118 177 N m 12 18 m kg 8...

Page 563: ...pecifications with the SST Standard backlash 0 09 0 11 mm 0 0035 0 0043 in 6 After adjusting the backlash tighten the adjustment screws equally until the distance between the pi lot sections on the be...

Page 564: ...ar back and forth by hand rotate the drive pinion several times and check the tooth contact 3 If the tooth contact is correct wipe off the red lead 4 If it is not correct adjust the pinion height and...

Page 565: ...3rd gear 14 Reverse gear 4 Synchronizer ring 1 5 Clutch hub assembly 5 Clutch hub assembly 16 Retaining ring 6 Retaining ring 17 Synchronizer ring 7 Synchronizer ring 18 2nd gear 8 4th gear 19 Second...

Page 566: ...0 19 0 7480 14 2 0 5591 17 0 6693 12 2 0 4803 Note Align the synchronizer ring groove and clutch hub key when installing PRIMARY SHAFT GEAR Bearing Inner Race 1 install the bearing inner race with the...

Page 567: ...sembly with the SST 4 Install the retaining ring 4th Gear 1 Install the 4th gear and synchronizer ring 2 Install the bearing inner race with the SST SECONDARY SHAFT GEAR Bearing Inner Race Install the...

Page 568: ...chronizer rings are different as shown in the illustration 1 Install the 1st gear and synchronizer ring 2 Install the clutch hub assembly with the SST 3 Install the retaining ring 2nd Gear 1 Install t...

Page 569: ...st Clearance of 3rd Gear Measure the clearance between the 3rd gear and the primary shaft gear Standard 0 050 0 200 mm 0 002 0 008 in Maximum 0 250 mm 0 038 in Thrust Clearance of 4th Gear Measure the...

Page 570: ...dary shaft Standard 0 050 0 280 mm 0 002 0 011 in Maximum 0 330 mm 0 013 in L Thrust Clearance of 2nd Gear Measure the clearance between the 2nd gear and the secondary 3rd gear Standard 0 175 0 455 mm...

Page 571: ...tch housing 12 Inner shift lever 3 Oil seal 13 4 Washer s Spring pin 14 Crank lever shaft 5 Diaphragm spring 15 Crank lever 6 Bearing outer race 16 7 Funnel Spring pin 17 Clutch release shaft 8 Oil pa...

Page 572: ...ASSEMBLY 7c Bearing preload Adjust the bearing preload by selecting and installing the proper adjust shim s Transaxle Case Center differential Primary shaft assembly Secondary shaft assembly...

Page 573: ...ipe against the outer race and tap in with a hammer until it con tacts the clutch housing __ Primary and Secondary Shaft Gear 1 As shown in the figure put the outer races into the SST Note Turm the se...

Page 574: ...re that each shaft turns smoothly 7 Use a thickness gauge to measure the gap of the selector for both gears Note Measure the gap around the entire circumfer ence of the selector 8 Select an appropriat...

Page 575: ...ctor Example 0 94 mm 0 0370 in 0 94 mm 0 0370 in 0 70 mm 0 0276 in Dlaphragm spring 0 24 mm 0 009 in So the nearest shim on thick side to 0 24 mm 0 009 in is 0 26 mm 0 010 In Note The number of shims...

Page 576: ...5 3 m kg 27 38 ft lb 4 To seat bearings turn the SST so the gap is widened 5 Insert the SST 6 Expand the SST until preload specification is ob tained Preload 0 3 l 2 N m 3 12 cm kg 2 6 10 4 in lb 7 Us...

Page 577: ...red val ue of the gap in the selector Example 0 54 mm 0 021 in So the nearest shim on thick side to 0 54 mm 0 021 in is 0 6 mm 0 014 in Note The number ot shims to be used must not be more than three...

Page 578: ...pe and a hammer to tap the out er races in until they are seated Baffle Plate and Oil Passage 1 install the baffle plate and oil passage Tightening torque 7 9 10 8 N m 0 8 1 1 m kg 5 79 7 98 ft lb Bas...

Page 579: ...LY I 2 Install the crank lever shaft and crank lever 3 Install the spring pin 4 Install the inner shift lever to shift lever assembly and then install them to crank lever assembly 5 Install the spring...

Page 580: ...o the attachment and meas ure the preload Note Extend the handle fully and hook the pull scale to the end of the handle Preload 1 4 2 0 N m 14 20 cm kg 12 2 17 5 In lb 5 Remove the SST 6 Connect the S...

Page 581: ...shift rod as 19 0 ring sem bly 20 Transaxle case 8 Primary shaft as gear 21 Bolt sembly 22 Side cover 9 Secondary shaft gear as 23 Secondary 5th gear sem bly 24 Gear sleeve and 5th gear IO Reverse lev...

Page 582: ...all the center differential assembly into the clutch housing 2 install the set bolt Shaft Gear and Shift Fork Assembly Install the primary shaft gear secondary shaft gear and shift fork assembly accor...

Page 583: ...ft Gate 1 Install the reverse lever support and shift gate 2 Install the shift rod 5thlreverse Tightening torque 11 8 15 7 N m 1 2 l 6 m kg 8 7 i 1 6 ft lb 3 Assemble the shift gate and install the sh...

Page 584: ...t surfaces 3 Install the transaxle case 4 Install the detent ball spring and bolt 8 set bolts 0 and case bolt Note Coat the threads of I bolts with seal ant before installing Tightening torque 8 15 21...

Page 585: ...Note Before coating with sealant clean the contact surfaces 4 Install the side cover Tightening torque A 37 52 N m 3 8 5 3 m kg 27 5 38 3 ft lb B 19 25 N m 1 9 2 8 m kg 14 19 ft lb 5th Gear 1 Install...

Page 586: ...nchronizer gears 7 Shift the lever into 1st gear 8 Lock the primary shaft with the SST 9 Use new lock nuts and tighten it to the specified torque Tightening torque 127 206 N m 13 21 m kg 94 152 ft lb...

Page 587: ...how n in the figure 2 Install the center differential lock assembly Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft lb Rear Cover Note Switch 323 Revised 10187 3 Turn the rod 90 counterclockwise wit...

Page 588: ......

Page 589: ......

Page 590: ...er and undercover right side Wheel 1 Install the wheels Tightening torque 88 118 N m 9 12 m kg 65 67 ft lb 2 Install mount bracket No 4 Tightening torque 0 50 61 N m 5 1 6 2 m kg 37 45 ft lb 19 26 N m...

Page 591: ...Speedometer Cables 1 Connect the speedometer cable 2 Install the air cleaner Transaxle Oil 1 Add the specified amount of the specified trans axle oil through the speedometer driven gear in stallation...

Page 592: ...Remove the parts in the sequence shown in the figure Y Install in the reverse order of removal 1 Shift lever knob 2 Center console 3 Side wall 5 b fl lever boot 6 Flat washer 7 Clip 8 Nut 9 Shift lev...

Page 593: ...defor mation 5 Check that the select cable end hole aligns per fectly with the select lever pin 6 If not aligned loosen nut and turn the adjust nut to align 7 Position the transaxle shift lever at th...

Page 594: ...removal 1 Bolt 9 Support plate 17 Select stopper 2 Ball seat cover 10 Return spring 18 Bushing 3 Spring 11 Assist spring 19 Select lever 4 Ball seat No 2 12 Retaining ring 20 Crank lever sleeve 5 Shif...

Page 595: ...NE 2 OUTLINE OF CONSTRUCTION L 2 STRUCTURAL VIEW 8 2 SPECIFICATIONS 8 3 TROUBLESHOOTING GUIDE 8 3 ON VEHICLE CHECK 8 4 PROPELLER SHAFT 8 5 REMOVAL 8 5 DISASSEMBLY 8 6 INSPECTION 8 8 ASSEMBLY 8 9 INSTA...

Page 596: ...NE OUTLINE OUTLINE OF CONSTRUCTION Standard universal joints are installed on the propeller shaft STRUCTURAL VIEW 1 Propeller shaft 2 Driveshaft front 3 Joint shaft 4 Driveshaft rear 5 Rear differenta...

Page 597: ...UBLESHOOTING GUIDE Problem Vibration Noise Possible Cause Bent propeller shaft Left right universal joint snap rings not symmetrical Loosen yoke installation Worn or damaged universal joint bearing Un...

Page 598: ...he necessary part 1 Check for backlash by moving the parts as shown in the figure 2 Check for looseness of bolts and nuts and tight en if necessary 3 Check for cracks or damage of dust boot 4 Check fo...

Page 599: ...2 Remove the parts in the sequence shown in the figure 1 Bolts and nuts front 2 Bolts and nuts rear 3 Nuts and washers 4 Bushings washers and shims 5 Propeller shaft Propeller Shaft Before removing t...

Page 600: ...Lock nut 9 Dust seal front IO Dust seal rear 11 Snap ring 12 Bearing 13 Rear propeller shaft 14 Rear yoke Yoke 1 Place the propeller shaft in a vise Caution Use pads in the vise so as not to dimage th...

Page 601: ...by lightly tapping the yoke with a brass hammer as shown in the figure 5 Remove the yoke Spider 1 Remove the bearings as shown in the figure 2 Remove the spider Center Yoke 1 Make mating makes on the...

Page 602: ...ls Bearing 1 Remove the snap ring using snap ring pliers 2 Remove the bearing using suitable pipe INSPECTION Check the following points If a problem is found re place the necessary part 1 Runout of pr...

Page 603: ...e in both direc tions to the inner race and check for binding or ab normal noise ASSEMBLY Assemble in the reverse order of disassembly Bearlng 1 Install the bearing using suitable pipe 2 Install the s...

Page 604: ...rea indicated by the oblique lines Center Bearing Support Assembly Install the center bearing support assembly using SST Center Yoke 1 Align the matching marks on the yoke and shaft 2 install the cent...

Page 605: ...enter yoke using a plas tic hammer Caution Align the spider and yoke mating marks 2 Install new snap rings Caution a The snap rlngs cannot be reused b All 4 snap rings must be the same thickness c Che...

Page 606: ...ightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft lb 4 Align the mating marks on the companion flange of the transfer unit and yoke and install the front of propeller shaft Tightening torque 27 30 N m...

Page 607: ...PECTION 9 26 ASSEMBLY Q 26 INSTALLATION 9 29 REAR AXLE Q 30 REMOVAL DRUM BRAKE Q 30 REMOVAL DISC BRAKE 9 31 INSPECTION 9 32 INSTALLATION Q 33 OUTLINE Q 36 OUTLINE OF CONSTRUCTION Q 36 STRUCTURAL VIEW...

Page 608: ...INE STRUCTURAL VIEW Driveshaft fTurbol 1 Locknut 6 Dynamic damper right side only 2 Washer 7 Ball joint assembly differential side 3 Ball joint wheel side 6 Clip 4 Boot band 9 Clip 5 Boot IO Snap ring...

Page 609: ...INE 9 Driveshaft Non Turbo I Locknut 6 Dynamic damper right side only 2 Washer 7 Tri pod joint differential side 3 Ball joint wheel side 8 Clip 4 Boot band 9 Clip 5 Boot 10 Snap ring 323 Revised 10187...

Page 610: ...ock nut 6 Outer wheel bearing 11 inner wheel bearing 2 Washer 7 Spacer 12 Inner oil seal 3 Wheel hub 8 Dust cover 13 Lower arm ball joint 4 Disc plate 9 Knuckle 14 Caliper and pad assembly 5 Outer oil...

Page 611: ...l seal 12 Caliper and pad assembly SPECIFICATIONS Engine type 66 DOHC Item 66 EGI 2WD 4WD 1 Length of driveshaft Driveshaft diameter Len h of iointshaft ATX Right sidemm in 907 7 35 74 Leit side mm in...

Page 612: ...tires Brake dragging Refer to Section 11 Unstable handling Incorrect wheel bearing preload adjustment Adjust or replace Bent steering linkage Refer to Section 10 Joint in steering system worn or dama...

Page 613: ...grease or loose boot bands If any damage is found replace the boot Spline Looseness Turn the driveshaft by hand and make sure the spline and joint are not excessively loose If damage is found or join...

Page 614: ...care not to be confused by the looseness of the lower arm ball joint If any abnormal looseness or noise is found disassemble the hub and knuckle and adjust the preload 3 Remove the wheel and remove th...

Page 615: ...pins smoothly and that there is no abnormal noise from the bearing If any problem is found adjust or replace the bearing Bearing Preload 1 Remove the wheel and tire 2 Hook a spring scale on a hub bolt...

Page 616: ...he transaxle oil 3 Remove the front wheels 4 Remove the side covers 5 Raise the nut tab and loosen the driveshaft lock nut but do not remove it Note When loosening the nut lock the hub by ap plying th...

Page 617: ...y be damaged If it is difficult to separate do as follows Insert a bar between the driveshaft and the trans axle case as shown in the figure lightly tap the end of the bar Note Do not insert the bar t...

Page 618: ...o the front hub and cannot be removed use the SST to push the shaft out 12 Pull the driveshaft out of the transaxle 13 After removing the driveshaft install the SST the transaxle thus preventing dirt...

Page 619: ...e shown in the figure 1 Clip 2 Joint shaft 3 Oil seal 4 Oil seal 5 Bearing 6 Bracket Jointshaft Support the bearing and remove the jointshaft us ing a press Caution Hold the shaft by hand do no let it...

Page 620: ...sed to secure the outer ring to the ball joint at the differential side if there Is no problem If the clio is removed replace it with a new one 1 Boot band 8 Boot band 2 Clip for locking the ball join...

Page 621: ...on the driveshaft end and inner ring 2 Remove the snap ring with snap ring pliers Bails Inner ring and Cage Disassemble in the following order 1 Insert a flat tipped screwdriver between the inner rin...

Page 622: ...on right hand side drlveshaft before assembling jolnt to drlveshaft Ball Joint 1 Apply the specified grease molybdenum disulfide to the joint Do not use any other type of grease Note The color of thl...

Page 623: ...the shaft and outer ring Boot Band Tighten the boot band according to the following procedure Note a Always use a new band b The band should be folded in the direction opposite to the forward revolvin...

Page 624: ...bly c Do not disassemble the ball joint at the wheel side Do not wipe off the grease it there is no problem d Do not remove the clip which Is used to secure the outer ring to the ball joint at the dif...

Page 625: ...he snap ring 2 Make matching marks on the driveshaft end and tri pod joint 3 Tap the boss with a hammer and rod to remove the tri pod joint Caution Do not tap on the rollers INSPECTION Non Turbo Check...

Page 626: ...8 mm 2 39 in 90 4 mm 3 56 in T pod Joint 1 Before inserting the boot onto the shaft put tape on the shaft splines 2 Align the matching marks and install the Vi pod joint with a rod and a hammer 3 Ins...

Page 627: ...directions indicated by the arrows 2 Check the boots for grease leaks or damage INSTALLATION install in the reverse order of removal and be careful of the following points Note MTX and ATX are the Sam...

Page 628: ...abilizer bar control link Ti te s rque k 1 i m kg 8 7 13 0 ft lb Driveshaft Locknut Use a new driveshaft locknut tighten and stake the locknut ensuring that it seats into the groove in the driveshaft...

Page 629: ...split pin from the tie rod end locknut 5 Separate the tie rod end from the knuckle with the SST Note If it is difficult to separate tap the knuckle and ball joint with a hammer 6 Remove the caliper as...

Page 630: ...ASSEMBLY Disassemble in the order shown in the figure Note a Do not remove the dust cover unless necessary for repairs b Do not confuse the inner bearing with the outer bearing 63 09X 070 1 Wheel hub...

Page 631: ...Note Hold the hub to prevent it from falling 2 Remove the outer oil seal from the front hub 3 Remove the bearing outer race with SST and a press Note a Do not remove the bearing unless it is b e race...

Page 632: ...bly and note the following Dust Cover Press fit the dust cover with a pipe and a hammer Disc Plate Align the disc plate and wheel hub matching marks assemble the plate and the hub and tighten the moun...

Page 633: ...Note Use the removed spacer 2 Measure the bearing preload after the SST is tightened Tightening torque 196 N m I20 m ka 145 g lb Bearing p load Rztation starting torque 0 25 l 18 N m 2 5 12 0 cm kg 2...

Page 634: ...to the lip of the seal b Make sure the oil seal is installed flush with the knuckle Install the inner oil seal with SST and a hammer Note a Use a new oil seal and apply grease to the lip of the seal b...

Page 635: ...ft lb 2 Install the disc brake caliper assembly Tightening torque 39 49 N m 4 0 5 0 m kg 29 36 ft lb 3 Use a new driveshaft locknut tighten it to the speci fied torque and stake it into the groove se...

Page 636: ...Brake drum Note If it is difficult to remove the brake drum in crease the shoe clearance Refer to Section 11 5 Oil seal 6 Bearing inner race 7 Bearing outer race Note a Check the bearing races and di...

Page 637: ...by lifting up on the hub spindle 4 Remove the hub spindle to shock absorber through bolts 5 Remove the hub spindle Disc Brake 1 Jack up the rear of the vehicle and support it with safety stands 2 Rem...

Page 638: ...bearing if it is not necessary b Set a brass rod on the race through the grooves in the hub and remove the race with a hammer INSPECTION Rear Hub Spindle Check the following and if there is any proble...

Page 639: ...ng 1 To install bearing outer race use a hammer and a brass rod Note Tap in until the outer race is fully seated in the hub 2 Completely fill the area shaded in the figure with lithium grease NLGI No...

Page 640: ...rum brake 1 Install the back plate and brake assembly to the hub spindle Tightening torque 45 67 N m 4 6 6 6 m kg 33 49 ft lb Disc brake 1 Install the dust cover on the hub spindle Tightening torque 4...

Page 641: ...al drag value in the previous step to the specified value of 2 6 6 5 N 0 26 0 67 kg 0 6 l 9 lb This is regarded as the standard bearing preload Bearing preload Rotation starting torque 0 15 0 49 N m 1...

Page 642: ...OUTLINE OF CONSTRUCTION 4 wheel drive 4WD is used the newly established parts for 4WD are as follows l The jointshaft of front driveshaft l The rear differential l The rear driveshaft STRUCTURAL VIEW...

Page 643: ...OUTLINE 9 Rear Differential...

Page 644: ...9 OUTLINE 1 9 38...

Page 645: ...OUTLINE 9 Rear Axle...

Page 646: ...wheel bearing ReplaCe Pulls or one sided improperly adjustedwheel bearing Adjust baking Worn or damaged wheel bearing ReplaCe Excessive steering Improperly adjustedwheel bearing Adjust wheel olav REA...

Page 647: ...load Worn output shaft spline R WS Heat build up Insufficient differential oil Add oil Insufficient gear backlash Adjust Excessive bearing preload Adjust Oil leakage Excessive differential oil Remove...

Page 648: ...1 Jack up the vehicle and support it with safety stands 2 Drain the differential gear oil Companion flange oil seal 1 Remove the propeller shaft Refer to Section 8 2 Before loosening the lock nut meas...

Page 649: ...Note Apply a thin coat of grease lithium base NLGI No 2 to the oil seal lip 6 Install the companion flange and tighten the lock nutto get the specified starting torque above step 2 7 Install the prope...

Page 650: ...Caution Be careful that when disconnect the bolt and nut the lateral link will be bounded 3 Remove the trailing link 4 Remove the parking brake cable from trailing link 5 Pull the wheel hub out and s...

Page 651: ...the removal operation be cause the shaft may suddenly jump out 7 Replace the oil seal using the SST Note Apply a thin coat of grease lithium base NLGI No 2 to the oil seal lip 8 Install the output sh...

Page 652: ...the trailing link Tightening torque 93 l 17 N m 9 5 l 1 9 m kg 69 66 ft lb 13 Tighten the driveshaft Tightening torque 49 59 N m 5 0 6 0 m kg 36 43 ft lb 14 Fill the differential with the correct gra...

Page 653: ...r of the vehicle and support it with safety stands 2 Drain the differential gear oil 3 Remove the parts in the sequence shown in the figure 1 Propeller shaft 5 Lateral link 2 Wheel 6 Trailing link 3 N...

Page 654: ...the stabilizer from crossmember Caution Never remove the both ends of the stabilizer 5 Remove the lateral link Caution Be careful that when disconnect the bolt and nut the lateral link will be bounded...

Page 655: ...plate X seal 13 Lock plate 14 Bolt 15 Bearing cap 16 Adjust screw 17 Bearing outer race 18 Differential gear ass y 19 Lock nut 20 Washer 21 Companion flange 22 Drive pinion 23 Collapsible spacer 24 B...

Page 656: ......

Page 657: ......

Page 658: ...g parts in the SST remove the side bearings from the gear case Caution Identify each one of the bearings so that they can later be re installed in the same position Ring Gear Remove the ring gear usin...

Page 659: ...ifferential Gear 1 Check the differential side gears and pinion gears for cracks chipped teeth or damage 2 Check the differential bearings and pinion bearings for wear flaking or damage Bearing Check...

Page 660: ...Assemble in the reverse order of disassembly Side Gear and Pinion Gear 1 Install the thrust washers on the side gears and in stall them in the gear case 2 Through the openings of the gear case insert...

Page 661: ...ickness Identification mark 0 1 2 Thickness 2 00 mm 0 0767 in 2 10 mm 0 0627 in 2 20 mm 0 0666 in Knock Pin Install the knock pin to secure the pinion shaft Stake the knock pin into position with a pu...

Page 662: ...stall this to the collar with the 0 ring Then install this to the carrier carrier 4 Attach the front bearing SST companion flange 4 Attach the front bearing SST companion flange washer and nut to the...

Page 663: ...position on both the left and the right sides Mark OS 11 14 17 20 23 26 Thickness 3 29 mm 9 Add the two left and right values obtained by the measurements taken in step 8 and divide the total by 2 St...

Page 664: ...irection is correct 3 Install the collapsible spacer 4 Install the drive pinion assembly 5 Install the companion flange and tighten the lock nut Caution Do not install the oil seal Tightening torque 1...

Page 665: ...dentification marks on the caps correspond with those on the carrier 4 Mark the ring at four points at approx 90 inter vals Mount a dial indicator to the carrier so that the feeler comes in contact at...

Page 666: ...ft lb 9 Install the adjuster lock plates on the bearing caps to prevent the adjusters from loosening Tightening torque 19 28 N m 1 9 2 8 m kg 14 19 ft lb Inspection and Adjustment of Teeth Contact 1 C...

Page 667: ...Replace the spacer with a thicker one to bring the drive ion in Differential Housing 1 Coat both surfaces with a sealing compound 2 Install the differential housing Tightening torque 23 26 N m 2 3 2...

Page 668: ...ial assembly Tightening torque Front 45 68 N m 4 6 6 9 m kg 33 50 ft lb Rear 108 131 N m 11 0 l 3 4 m kg 80 97 ft lb 2 Align the mating marks on the driveshaft and out put shaft then install the drive...

Page 669: ...ue 12 16 N m 1 2 l 8 m kg 9 13 ft lb 6 Install the propeller shaft Tightening torque 27 30 N m 2 8 3 1 m kg 20 22 ft lb 7 Install the tires Tightening torque 88 l 18 N m 9 12 m kg 65 87 ft lb 6 Fill t...

Page 670: ...ts if a problem is found re place the part 1 Check the dust boot on the driveshaft for cracks damage leaking grease or a loose boot band 2 Check the driveshaft bearing for cracking and wear of the spl...

Page 671: ...t it with safety stands 2 Remove the parts in the sequence shown in the figure 3 Install in the reverse order of removal 1 Tire 4 Lateral link 2 Lock nut 5 Trailing link 3 Nut 6 Driveshaft Wheel Hub I...

Page 672: ...careful that dust or other foreign material does not enter the joint while the work is being performed c Do not disassemble the wheel side ball joint d Do not wash the ioint unless it is being disass...

Page 673: ...nd that the tire rotates smoothly when rotated by hand 3 Remove the caliper assembly and support it from the shock absorber 4 Set a dial gauge against the axle flange Then push and pull the axle hub b...

Page 674: ...e the parts in the sequence shown in the figure 3 Install in the reverse order of removal 1 Tire 5 Trailing link 2 Lock nut 6 Bolt 3 Disc caliper assembly 7 Bolt 4 Lateral link 8 Hub and knuckle assem...

Page 675: ...ghten the shock absorber through bolt Tightening torque 78 l 17 N m 8 0 l 1 9 m kg 58 88 ft lb 2 Tighten the disc caliper assembly Tightening torque 49 89 N m 5 0 7 0 m kg 36 51 ft lb 3 Tighten the lo...

Page 676: ...2 Spacer 3 Disc plate 4 Wheel hub 5 Bearing Outer 6 Oil seal Outer 7 Oil seal Inner 8 Bearing Inner 9 Bearing outer race Outer IO Bearing outer race Inner 11 Dust cover 12 Wheel lug bolt Knuckle 1 Re...

Page 677: ...alling Wheel Hub Put mating marks on the disc plate and the wheel hub then remove the wheel hub Bearing and Oil Seal Outer Set the SST between the oil seal and wheel hub and remove the bearing and oil...

Page 678: ...e races alternately Dust Cover Remove the dust cover Note Never remove the dust cover from the knuckle except when replacing it INSPECTION Check the following points if a problem is found re place the...

Page 679: ...dust cover for deformation or damage Wheel Hub Check the wheel hub for cracking or damage ASSEMBLY Assemble in the reverse order of removal Wheel Lug Bolt Remove and replace the wheel lug bolt using...

Page 680: ...1 Install the inner bearing spacer and outer bear ing and set the SST as shown in the figure Note Use the same spacer which was removed at disassembly 2 Measure the bearing preload with the spacer sel...

Page 681: ...a spacer Note a If bearing preload is excessive use a thicker spacer If bearing preload is less than specified use a thin spacer b If the spacer is thinner changed by one 1 rank the bearing preload I...

Page 682: ...the area indicated by the oblique lines Wheel Hub Align the mating marks of the wheel hub and the disc plates and tighten Tightening torque 44 54 N m 4 5 5 5 m kg 33 40 ft lb Knuckle Install the knuck...

Page 683: ...F POWER STEERING SYSTEM IO 10 POWER STEERING PRESSURE 10 l 1 FRONT WHEEL ALIGNMENT TIE ROD END BOOT it REMOVAL AND INSTALLATION lo 15 STEERING WHEEL AND COLUMN lo 17 REMOVAL AND INSTALLATION INSPECTIO...

Page 684: ...10 OUTLINE OUTLINE STRUCTURAL VIEW Manual Steering r 1 Steering wheel 3 Intermediate shaft 5 Tie rod end 2 Steering shaft 4 Steering gear 6 Tilt steering lock lever 1O 2...

Page 685: ...OUTLINE 10 Power 1 Steering wheel 4 Steering gear 7 Return hose 2 Steering shaft 5 Tie rod end 8 Oil pump 3 Intermediate shaft 6 Pressure hose 9 Tilt steering lock lever 1o 3...

Page 686: ...infinite Rack stroke mm I 136 5 35 140 5 51 Oil Capacity liter US qt Imp qt 6 0 63 0 53 0 6 0 63 0 53 Type ATF DEXRON II or MZC33 F 1Maximum steering 1 Inner 1 40 00 20 39000 20 Wheel alignment angle...

Page 687: ...of front wheel bearing preload Adjust Fatigued front spring Replace Malfunction of shock absorber Replace Incorrect wheel alignment toe in Adjust 10112 Incorrect tire pressure Adjust Wheels are defor...

Page 688: ...ring shaft is restricted looseinstallationbolt s Steering linkagedoes not operate smoothly Malfunction of steerinoclear Incorrect tire pressure Improper preload adjustment or wear of wheel bearing Imp...

Page 689: ...aring wear steering shaft joint play steering wheel looseness or column looseness STEERING WHEEL EFFORT Manual Steering 1 Jack up the vehicle Move the steering wheel to put the wheels in the straight...

Page 690: ...g wheel effort 40 N 4 1 kg 9 lb or less during one turn of the steering wheel 4 If measured value exceeds standard value range check the following fluid level air in system fluid leakage at hose or co...

Page 691: ...kg 27 40 ft lb Nut tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft lb LEAKAGE OF POWER STEERING FLUID Check for fluid leakage in the places shown by arrows below Note Start the engine and check for...

Page 692: ...sition and 5 Put the wheels in the straight ahead position and turn off the engine The fluid level in the pump turn off the engine The fluid level in the pump should not increase if it does air is pre...

Page 693: ...mperature will increase ex cessively and adversely affect the oil pump If the fluid pressure is low replace the oil pump as sembly 5 To measure the fluid pressure generated at the gear housing first o...

Page 694: ...the fender brim between the left and right sides should be within 15 mm 0 59 in Toe in Inspection 1 Raise the front end of the vehicle until the wheels clear the ground 2 Turn the wheels by hand mark...

Page 695: ...4 0 m kg 25 29 ft lb 4WD 34 50 N m 3 5 5 1 m kg 25 37 ft lb Steering Angle Maximum Angle to the Left and Riaht lnGpe ion The steering angle is measured by placing the front wheels on a turning radius...

Page 696: ...ve side the caster Is not ad justable 1 Jack up the front of the vehicle and support itwith safety stands 2 Open the hood 3 Remove the two nuts mounting the shock absorber mounting block to the fender...

Page 697: ...e and support it with safety stands 2 Remove in the sequence shown in the figure 3 Install in the reverse order of removal 1 Cotter pin and nut 3 Locknut 2 Tie rod end knuckle 4 Tie rod end 5 Boot Tie...

Page 698: ...od end in a vise 2 Place a chisel against the boot and hold it at the angle shown in the figure 3 Remove the boot by tapping the chisel with a hammer Caution Be careful not to scar the part where the...

Page 699: ...e battery negative cable 3 Remove in the sequence shown in the figure 4 Install in the reverse order of removal 1 Horn cap 6 Harness couplers 11 Under cover 2 Lock nut 7 Combination switch 12 Dust boo...

Page 700: ...a groove in the head of the steering lock installation screw Remove the screw by using a flat tipped screwdriver and then remove the steering lock 2 After installing the steering lock to the jacket us...

Page 701: ...d set the steering lock lever so that it touches the stopper plate and then tighten the lock lever bolt Tightening torque 18 27 N m 1 8 2 7 m kg 13 0 19 5 ft lb 3 Check that the lock lever operates sm...

Page 702: ...10 STEERING WHEEL AND COLUMN 4 Joint for excessive play 5 Dust boot for damage 10 20...

Page 703: ...e cable 4 Remove the wheels 5 Remove the under cover 6 Remove the parts in the sequence shown in the figure 7 Install in the reverse order of removal 8 After installation add the power steering fluid...

Page 704: ...om the knuck le with the SST Oil Pipes Make marks on the pressure pipe nuts for proper rein stallation and then disconnect it Note Power steering fluid will leak out when the pressure pipe or the retu...

Page 705: ...ttery tray and carrier 6 Remove the under covers 7 Remove in the sequence shown in the figure 8 install in the reverse order of removal 9 After installation add power steering fluid and bleed air then...

Page 706: ...e nuts for proper rein stallation and then disconnect it Note Power steering fluid will leak out when the pressure pipe or the return hose is discon nected so prepare a suitable container for it to dr...

Page 707: ...move the transmission control cable clip 5 Remove the nuts mounting the transfer unit to en gine mount No 4 6 Lower the engine gradually until bolt can be removed Caution Do not lower the engine too m...

Page 708: ...No 4 to Transfer Tightening torque 19 25 N m 1 9 2 6 m kg 14 19 ft lb Engine Mount No 1 and No 2 to Engine Mount Member Tightening torque 84 89 N m 6 5 9 1 m kg 47 88 ft lb Engine Mount Member to Bod...

Page 709: ...left right 8 Locknut 15 2 Nuts left right Stop ring 9 Adjust Bolt 16 3 Boots clip left right Snap ring 10 Adjust cover 17 Pinion 4 Boot wire left right 11 Yoke spring 18 Rack 5 Boot left right 12 Spa...

Page 710: ...s of the vise Tie rod ends Before removing the tie rod ends Imake a mark on the threaded part of the tie rods to use as a guide for installation Tie rods When removing each of the tie rods from the ra...

Page 711: ......

Page 712: ......

Page 713: ...l noise or rough movement of the bearing c If pinion bearing replacement is necessary replace the pinion and bearing as an as sembly 5 Wear of contact surface of pressure pad which con tacts rack 6 Cr...

Page 714: ...slit of the rack housing Note Apply grease lithium base NLGI No 2 to the inside of the bushing 3 Push the rubber mount on until it just contacts the end of the housing 4 Attach the rubber mount to the...

Page 715: ...ed as shown in the figure when the rack is positioned at the center of the rack housing 7 Install the oil seal as follows 1 install the snap ring Caution a Use a new snap ring b The snap ring tapered...

Page 716: ...m kg 58 72 ft lb 10 Align the washer with the rack groove and crimp the washer il Install the boot and then wrap a new wire two times around it and twist it 4 or 4 5 times Caution Check that the boot...

Page 717: ...que with the SST and a pull scale Pinion torque Neutral position 90 0 9 1 3 N m S 13 cm kg 7 81 l 1 26 in lb Pull scale reading 900 1300 g 31 7 45 9 02 Any other position 1 5 N m or less 15 cm kg 13 0...

Page 718: ...10 MANUAL STEERING GEAR AND LINKAGE 14 Install the tie rod ends and align them with the marks made before disassembly 1O 36...

Page 719: ...nd clean thoroughly 1 Tie rod ends left right 8 Adjust cover 2 Boot wires left right 9 Spring 3 Boot clips left right 10 Pressure pad plate 4 Boot left right 11 Pressure pad 5 Tie rod left right 12 Du...

Page 720: ...insert a soft protective material be tween the part and the jaws of the vise Tie rod ends Before removing the tie rod ends make a mark on the threaded part of the tie rods to use as a guide for insta...

Page 721: ...plug oil seal Remove the oil seal from the pinion plug with the SST Pinion Gently grasp the serrated part of the pinion and pull it out Rack Remove the rack by taking it out in the direction indi cat...

Page 722: ...th a flat blade screwdriver 3 Remove the bushing with SST Note After removing the bushing clean the inside of the housing INSPECTION Check the following points replace the part if a problem is found I...

Page 723: ...f sliding surface of pressure pad which con tacts rack 6 Cracking or deformation of gear housing 7 Looseness or lack of smoothness in tie rod ball joint operation 8 Bent tie rods or tie rod ends 9 Dam...

Page 724: ...slit of the rack housing Align the three lock points and tap in with the old bushing and a piece of wood Note Apply grease lithium base NLGI No 2 to the inside of the bushing 4 Push the mounting rubbe...

Page 725: ...Adjust the pinion torque to be 0 2 N m 2 cm kg 1 74 in lb by adjusting the pinion plug Check with the SST il install the lock nut with the SST Tightening torque 70 90 N m 7 0 9 0 m kg 50 6 65 1 ft lb...

Page 726: ...Lock nut tightening torque 50 75 N m 6 0 7 6 m kg 43 4 64 2 ft lb 15 Measure the pinion torque Measure the pinion torque with the SST Pinion torque Neutral position f 90 1 0 1 4 Nsm IO 14 cm kg 0 87...

Page 727: ...ck Caution Be sure that the washers face in the proper direction 18 Using a wrench tighten the left and right tie rods to the specified torque Tightening torque 80 100 N m S 10 m kg 58 72 ft lb 19 Ali...

Page 728: ...stall the new boot and then wrap a new wire two times around it and twist it 4 or 4 5 times Caution Be sure that the boot is not twisted or dented 22 install the tie rod ends and align them with the m...

Page 729: ...d end 2 Tie rod end locknut 3 Boot band 4 Boot 5 Boot wires tiayipes 8 Tie rod 9 Washer 10 Damper ring Il Adjust cover locknut 12 Adjust cover 13 Spring 14 Rack support 15 Outer box 16 Oil seal 17 0 r...

Page 730: ...ter box 16 Oil seal 17 0 ring 18 0 ring 19 Seal ring 20 Rack 21 Snap ring 22 Inner guide 23 0 ring 24 Oil seal 25 Dust cover 26 Oil seal 27 Lever 28 Valve case 29 Control valve bolt 30 Control valve 3...

Page 731: ...e jaws of the vise lie rod ends Before removing the tie rod ends make a mark on the threaded parts as a guide for installation Oil pipe 1 Make matching marks on the pressure pipe and the return pipe a...

Page 732: ...wn in the figure Caution Do not damage the tie rod or rack _ 3 Remove the tie rod from the rack Lock nut and adjust cover Loosen the lock nut and remove the adjusting cover the spring and the pressure...

Page 733: ...wer bear ing side Rack Remove the rack by taking it out in the direction indi cated by the arrow Caution If the rack is taken out in the opposite direc tion the inside surface of the rack bushing migh...

Page 734: ...hing inside the gear housing Caution a If replacement is necessary replace the en tire gear housing assembly b lf replacement of the pinion bearing is necessary replace the pinion and bearing as an as...

Page 735: ...Install the inner guide in the following order 2WD 1 Apply A T F to the inner guide 2 Push the oil seal and the inner guide in to the rack housing with the SST as far as they will go Caution Do not d...

Page 736: ...end with a plastic hammer as far as it will go 2 Apply grease to the rack teeth Cover the rack teeth with vinyl to protect the seals and install the rack Caution Do not plug the air hole of the rack w...

Page 737: ...ox to the rack housing by using a punch 7 Install the lower bearing on the pinion shaft fit the lower bearing by tightening the nut and then stake the nut to the pinion shaft Tightening torque 40 50 N...

Page 738: ...kg 28 9 36 2 ft lb 12 Install the adjustment cover to the gear housing and tighten the adjustment cover then loosen the cover by 45O Tightening torque 4 5 5 5 N m 45 55 cm kg 39 1 47 7 in lb Measure t...

Page 739: ...et the rack in a vise and install new damper ring and washer Tighten the tie rod Note a Mount copper plates in a vise b Use the SST for 4WD Tightening torque 60 80 N m 6 0 8 0 m kg 43 58 ft lb 18 Stak...

Page 740: ...he wire 4 or 4 5 times Caution Be sure that the boot is not twisted or dented 20 Install the tie rod ends and align them with the marks made before disassembly 21 Install the oil pipes Tightening torq...

Page 741: ...flection Refer to page 10 8 2 Fill the reserve tank with the specified fluid 31 Bieed air from the system Refer to page 10 10 4j Check for fluid leakage 1 Bolt 6 Oil pressure switch 2 Oil pump belt 7...

Page 742: ...Before assembly apply specified power steering fluid to the vanes rotor and control valve Also apply grease lithium base NLGI No 2 to the lip of the oil seal d Use a new seal kit when assembling 1 Bol...

Page 743: ...MBLY AND ASSEMBLY 11 16 INSPECTION 1 I 18 POWER BRAKE UNIT 11 19 ON VEHICLE INSPECTION II 19 CHECK VALVE 11 20 REMOVAL AND INSTALLATION 11 21 DISASSEMBLY 1 l 22 INSPECTION 1 l 23 ASSEMBLY II 23 FRONT...

Page 744: ...URAL VIEW Front disc rear drum model 1 Brake pedal 4 Parking brake lever 2 Power brake unit 5 Dual proportioning valve 3 Brake master cylinder 6 Front disc brake 7 Rear drum brake 8 Parking brake cabl...

Page 745: ...OUTLINE 11 Front disc brake Ventilated disc Rear disc brake Solid disc Rear drum brake Leading trailing...

Page 746: ...6 x 18 9 37 x 0 71 outer diameter x thickness 14 inch wheel 260 x 18 10 24 x 0 71 TYPO Sold disc mounting support Cylinder bore mm in 30 2 Pad dimensions area x thickness mm2 in x mm in 2 728 x 8 4 23...

Page 747: ...ssures Refer to Saction 12 3rakes do not No brake pedal play Adjust ll 7 etease Improper adjustment of operating rod or push rod Adjust 11 15 Clogged master cylinder return port Cleafl Shoe does not r...

Page 748: ...e to brake hose threads 3 Scars cracks and swelling of flexible hose 4 Fluid leakage of all lines SIMPLE INSPECTION OF DISC PAD Front 1 Loosen the front wheel lug nuts 2 Jack up the front of the vehic...

Page 749: ...ector 2 Loosen locknut B and turn switch A until it does not contact the pedal 3 Loosen locknut D and turn rod C to adjust the height 4 Adjust the pedal free play and tighten locknut D 5 Turn the stop...

Page 750: ...Malfunction of automatic adjuster 3 Worn shoes or pads PARKING BRAKE LEVER STROKE inspection Check whether the stroke of the parking brake lever is within the standard value range when it is pulled by...

Page 751: ...here is a problem check for damage of the check valve or vacuum hose and check for prop er connection Repair if necessary and check once again Third Step 1 Start the engine 2 Depress the pedal with th...

Page 752: ...11 BRAKE HYDRAULIC LINES BRAKE HYDRAULIC LINES STRUCTURAL VIEW Front cr 11 10...

Page 753: ...1 Remove the brake fluid from the reservoir by us ing a suction pump 2 Fill the reservoir with new brake fluid 3 Attach a vinyl tube to the bleeder screw and place the other end of the vinyl tube in...

Page 754: ...d attach a vinyl hose to the bleeder plug 3 Place the other end of the vinyl tube in a container 4 Slowly pump the brake pedal several times 5 While the brake pedal is pressed loosen the bleed er scre...

Page 755: ...if necessary Caution Apply grease to the inner surface of the bushing and to the contact surfaces of the clevis piti and spring 1 Cotter pin 4 Nut lock washer and flat 6 Bushings 2 Clevis pin washer...

Page 756: ...oval 3 After installation add brake fluid and bleed the air then check each part for fluid leakage Caution Brake fluid will damage painted surfaces If it does get on a painted surface clean it im medi...

Page 757: ...master cylinder then turn the adjust bolt until it contacts the bot tom of the push rod hole in the piston 2 Apply 500 mm Hg 19 7 in Hg vacuum to the power brake unit with a vacuum pump 3 Invert the a...

Page 758: ...e the master cylinder flange in a vise when securing b Use a new piston cup and O ring Note that the primary side is replaced as the piston assembly c Do not let foreign material in and do not scratch...

Page 759: ...the secondary piston as sembly when blowing compressed air Stopper Screw 1 When installing the stopper screw use a cross tipped screwdriver to push the primary piston as sembly in all the way 2 Tighte...

Page 760: ...LINDER INSPECTION Check the following points replace parts if necessary 1 Piston and the cylinder bore for abnormal wear rust or damage 2 Springs for weakness or damage 3 Reservoir for damage or defor...

Page 761: ...rve the vacuum gauge for 15 seconds If the gauge shows 475 500 mm Hg 18 7 19 7 in Hg the unit is serviceable Checking for Vacuum Loss at Loaded Condition 1 Start the engine 2 Depress the brake pedal w...

Page 762: ...196 N 20 kg 44 lb 5 390 kPa 55 kg cm 782 psi min CHECKVALVE Inspection 1 Disconnect the vacuum hose with intenal check valve from the engine side 2 Apply suction and pressure to the hose from the engi...

Page 763: ...ter installation 1 Check and adjust the push rod and piston clearance 2 Add fluid and bleed the air 3 Check all parts for fluid leakage 4 Make an on vehicle check of the unit 5 Check that the vacuum h...

Page 764: ...re 1 Dust boot 7 Air filter 13 Reaction disc 2 Rear shell assembly 8 Air silencer 14 Spring 3 Retainer 9 Diaphragm and plate 15 Push rod 4 Bearing 10 Power piston assembly 16 Front shell assembly 5 Du...

Page 765: ...ber parts Wipe free of fluid and care fully inspect all rubber parts for cuts nicks or oth er damage 2 Check the power piston for cracks distortion chip ping or damaged seats 3 Inspect the reaction di...

Page 766: ...valve rod align the groove in the valve plunger with the slot of the power piston and insert the valve retainer key 6 Connect the diaphragm to the power piston and plate Caution Make certain that the...

Page 767: ...t shell Caution Place the front shell assembly in a vise to complete the following operations and to com press the spring 10 Install the push rod 11 Install the return spring 12 Press the rear shell d...

Page 768: ...emoval FRONT DISC BRAKE REPLACEMENT OF DISC PAD Caution Replace the left and right pads at the same time 1 Jack up the front of the vehicle and support it with safety stands 2 Remove the wheels 3 Remo...

Page 769: ...2 mm 0 08 in min Disc Plate 1 Runout Runout limit 0 1 mm 0 004 in Caution a There must be no wheel bearing play b The point of measurement is the outermost diameter of the contact surface of the disc...

Page 770: ...to prevent the piston from jumping out INSPECTION 1 Cylinder and piston for wear or rust 2 Caliper body for damage or cracks 3 Guide pin bushing and dust cover for damage or poor sealing ASSEMBLY 1 C...

Page 771: ...in the sequence shown in the figure Caution Do not damage the wheel cylinder dust boots when removing the brake shoes 1 Hub cap 6 Dust cover 2 Locknut 7 Return spring upper 3 Brake drum 8 Hold pin an...

Page 772: ...7 Gasket 18 Backing plate Locknut Uncrimp the locknut and remove it Caution Do not reuse the locknut Brake Drum If the drum is difficult to remove push the operating lever stopper at backing plate upw...

Page 773: ...assembly Warning Asbestos dust is hazardous to one s health When cleaning the brake assembly do not use compressed air or a brush Brake Pipe Disconnect or connect the brake pipe with the SST Caution B...

Page 774: ...of disassembly Caution Do not damage the piston or cylinder Do not let foreign material in the cylinder 1 Dust boot 4 Spring 7 Steel ball 2 Piston 5 Rubber cap 8 Wheel cylinder body 3 Piston cup 6 Bl...

Page 775: ...7 91 in 3 Peeling cracking or extremely uneven wear of lining 4 Lining wear Thickness 1 0 mm 0 04 in min Caution When replacing the shoe asse mbly replace the left and right shoes at the same time as...

Page 776: ...he reverse order of removal 2 After installation 1 Add brake fluid and bleed air Refer to page 11 l 1 2 Adjust the parking brake lever stroke Refer page to 1l 8 3 Depress the brake pedal a few times a...

Page 777: ...REAR DRUM BRAKE 11 Torque specification Brake Shoe 1 Apply grease to the following points 1 Shoe and cylinder contact points 2 Shoe anchor points 3 Projections of backing plate 11 35...

Page 778: ...e to the operating le ver then to the wheel cylinder and anchor plate 5 Fix the shoe with the hold spring and hold pin 6 Install the anti rattle spring 7 Install the return spring lower to the shoes t...

Page 779: ...a screwdriver to increase the shoe clearance Note The shoe clearance will be automatically ad justed by applying parking brakes Locknut 1 Temporarily tighten a new locknut 2 Adjust the bearing preloa...

Page 780: ...up the rear of the vehicle and support it with safety stands 4 Remove the wheels 5 Remove the parking brake cable and bracket 6 Remove the lower mounting bolt then pivot the cal iper and support it 3...

Page 781: ...m 1 6 2 4 m kg 12 17 ft lb 15 Connect the parking cable and bracket Tightening torque 45 67 N m 4 6 6 8 m kg 33 49 ft lb 16 Mount the wheels 17 Apply the brakes a few times then check that the brakes...

Page 782: ...move in the sequence shown in the figure Warning Asbestos dust is hazardous to one s health Do not blow away brake dust with compressed air Caution Brake fluid will damage painted surfaces If it does...

Page 783: ...eeve pin 8 Piston 2 Boot 9 Piston seal 3 Bushing IO Snap ring 4 Cap 11 Stopper 5 Bleeder screw 12 Adjuster spindle 6 Retaining ring 13 0 ring 7 Dust seal 14 Connecting link 15 Nut 16 Operating lever 1...

Page 784: ...aliper Assembly Check the following and repair or replace any faulty parts 1 Cylinder and piston for wear and rust 2 Caliper body for damage and cracks 3 Mounting support for damage and cracks 4 Sleev...

Page 785: ...ng into the caliper with the SST until the SST bottoms against the caliper Connecting Link Install the connecting link into the operating lever Adjuster Spindle 1 Assemble the adjuster spindle and the...

Page 786: ...ves smoothly Piston 1 Clean the piston 2 Install the dust seal in the piston groove 3 Turn the piston into the caliper cylinder while rotat ing the SST clockwise Note Turn the piston in fully and alig...

Page 787: ...al wear or cracks 3 Deterioration or heat damage 4 Remaining liming thickness Thickness 1 mm 0 04 in min Disc Plate 1 Runout Runout 0 1 mm 0 004 in max Caution a There must be no wheel bearing losenes...

Page 788: ...ation 1 Add brake fluid and bleed air Refer to page 1 l l 1 2 Adjust the parking brake lever stroke Refer to page 11 8 3 Depress the brake pedal a few times and check that the rear brakes do not drag...

Page 789: ...ke pedal until the master cylinder pressure equals A then measure rear brake pres sure A 4 Depress the brake pedal again apply additional pressure until A equals B then measure pressure 0 Fluid pressu...

Page 790: ...oval 3 After installation 1 Add brake fluid and bleed the air Refer to page 1l l 1 2 Check the brake lines for fluid leakage Caution Brake fluid will damage painted surfaces If it does get on a painte...

Page 791: ...shown in the figure 3 Install in the reverse order of removal 4 After installation adjust the stroke See page 11 8 1 Rear console 4 Adjust nut 7 Grip 2 Coupler 5 Bolt 8 Release button 3 Locknut 6 Par...

Page 792: ...LATION 1 Jack up the vehicle and support it with safety stands 2 Remove in the numbered sequence shown in the figure 3 Install in the reverse order of removal 1 Adjusting nut 3 Return spring Equalizer...

Page 793: ...AND TIRES OUTLINE 12 2 SPECIFICATIONS 12 2 TROUBLESHOOTING GUIDE 12 2 WHEELS AND TIRES 12 3 INSPECTION AND ADJUSTMENTS 12 3 TIRE ROTATION 12 4 WHEEL BALANCE 12 5 WHEEL MOUNTING 12 5 SPECIAL NOTE 12 5...

Page 794: ...nced wheel s Adjust 12 5 Deformed wheel s or tire s Repair or replace Irregular tire wear Rf plaCe Steering wheel Irregular tire wear Replace vibration Right and left tread depths different Replace De...

Page 795: ...if wear indicators are exposed Troubleshooting guide Abnormal tire wear patterns shown in the illustra tion can occur Refer to the chart for the probable causes and remedies Probable cause Remedy a U...

Page 796: ...as metal pieces nails and stones in the tire and cracks deformation and damage to the wheel 5 Loose wheel lug nut s 6 Air leaking from the valve stem Front 4WD Front 12 4 __ TIRE ROTATION To prolong t...

Page 797: ...lancer on ATX models Use of this type of balancer may cause clutch damage WHEEL MOUNTING Tighten the lug nuts to the specified torque in a criss cross fashion Tightening torque 88 118 N m 9 12 m kg 65...

Page 798: ...ever use a wire brush or sandpaper 4 Remove any pebbles glass nails etc embedded in the tire tread 5 Be sure the air valve is installed correctly 6 After mounting a tire onto a wheel inflate the tire...

Page 799: ...TALLATION 13 10 INSPECTION 13 12 FRONT STABILIZER 13 13 REMOVAL AND INSTALLATION 13 13 lNSP ECTlON 13 14 REAR SHOCK ABSORBER AND SPRING 13 15 REMOVAL AND INSTALLATION 13 15 DISASSEMBLY AND ASSEMBLY 13...

Page 800: ...13 OUTLINE OUTLINE STRUCTURAL VIEW 2WD 4WD 1 Front shock absorber 2 Lower arm 3 Front stabilizer 4 Rear shock absorber 13 2 5 Crossmember 6 Lateral link 7 Trailing link...

Page 801: ...ndrical double acting TYPO Torsion bar Diameter mm in 27 2 1 07 hem Rear suspension Suspension Model strut type Coil spring Wire diameter mm in 10 2 0 4_ 1 I n mLtrr I spring Spring dimensions Shock a...

Page 802: ...stuck Ball joints stuck or damaged Ball joints insufficiently lubricated foreign material abnor mal wear Improperly adjusted wheel alignment toe in Worn or damaged steering gear bushing Improperly ad...

Page 803: ...r unbalanced wheel Worn or damaged lower arm bushing Improperly adjusted pinion preload Work rack and pinion vVorn or damaged joints Loose steering shaft universal joint rVeakened coil springs Walfunc...

Page 804: ...ty stands 2 Remove in the sequence shown in the figure 3 Install in the reverse order of removal I Brake hose clip 4 Actuator ASA Bolt 5 Bracket ASA 3 Rubber cap ASA 6 Nut 83U13X 00 7 Shock absorber S...

Page 805: ...l 2WD Except ASA Q I Nut and washer 4 Upper spring seat 2 Rubber sheet 5 Spring seat 3 Mounting block 6 Bound stopper 83 13X I1 7 Coil spring 8 Lower spring seat 9 Shock absorber 2WD ASA A 1 1 Nut and...

Page 806: ...inum plates between the part and the jaws of the vise 2 Loosen the piston rod upper nut several turns but do not remove Caution Do not remove the nut 3 Compress the coil spring with the SST and then r...

Page 807: ...ore installation INSPECTION Check the following points repair or replace if necessary 1 Oil leakage or abnormal noise from the shock ab sorbers 2 Loose installation nuts or bolts of the shock ab sorbe...

Page 808: ...cle and support it with safety stands 2 Remove the parts in the numbered sequence shown in the figure 3 Install in the reverse order of removal 1 Bolt bushing and retainer 4 Bolt 2 Nut retainer and bu...

Page 809: ...ove the dust boot Use a chisel to remove the dust boot Installation Apply lithium grease to the inside of the new dust boot and then install it with SST Lower arm bushing Removal 1 Cut away the expose...

Page 810: ...SST to the ball stud and then measure by using a pull scale Rotation torque 1 8 3 1 N m 18 31 cm kg 15 6 26 9 in lb Pull scale reading 1 800 3 100 kg 3 96 6 82 lb INSPECTION Check the following points...

Page 811: ...vehicle and support it with safety stands Remove the under cover Remove in the sequence shown in the figure Install in the reverse order of removal 1 Nut retainer and bushing 2 Bushing retainer and 3...

Page 812: ...he vehicle and tighten the bolts to the speci fied torque with the vehicle unloaded Control Link 1 Install the control link to the stabilizer and temporar ily tighten the bolts 2 Lower the vehicle and...

Page 813: ...ear of the vehicle and support it with safety stands 2 Remove in the sequence shown in the figure 3 Install in the reverse order of removal 2WD 23 m N rn 2 3 3 0 m kg 17 22 ft lb ASA 1WD 1 Clip 2 Flex...

Page 814: ...mounting block faces the inside of the vehicle DISASSEMBLY AND ASSEMBLY 1 Disassemble in the sequence shown in the figure 2 Assemble in the reverse order of removal 2WD including ASA I Rubber sheet 2...

Page 815: ...um plates between the part and the jaws of the vise 2 Loosen the piston rod upper nut several turns but do not remove Caution Do not remove the nut 3 Compress the coil spring with the SST and then rem...

Page 816: ...before installation INSPECTION Check the following points repair or replace if necessary 1 Oil leakage or abnormal noise from the shock ab sorbers 2 Loose installation nuts or bolts of the shock ab s...

Page 817: ...hicle and support it with safety stands 2 Remove the parts in the numbered sequence shown in the figure 3 Install in the reverse order of removal 2WD 1 Nut 4 Retainer bushing and 7 Lateral link 2 Bush...

Page 818: ...lencer hanger 4WD REAR STABILIZER REMOVAL AND INSTALLATION 1 Jack up the rear of the vehicle and support it with safety stands 2 Remove the parts in the numbered sequence shown in the figure 3 Install...

Page 819: ...tighten the bolts to the speci fied torque with the vehicle unloaded Control Link I Install the control link to the stabilizer and temporar ily tighten the bolts 2 Lower the vehicle and tighten the nu...

Page 820: ...t or over a pit 2 Mark the AB and A B positions horizontal wheel center of the left and right wheels and then mark the CC positions vertical center of horizontal 3 Punch marks to represent D equidista...

Page 821: ...ighten the adjusting locknuts and tighten them after adjusting the toe in Inspection 1I Raise the rear of the vehicle until the wheels clear the ground 2 Turn the wheels by hand and mark a line in the...

Page 822: ...counterclockwise Caution Both the left and right rods must be adjusted by the same amount Note One turn of the adjusting rod both sides changes the toe in by about 5 6 mm 0 22 in 3 Tighten the adjusti...

Page 823: ...OVAL 14 27 INSTALLATION 14 27 REAR WINDOW GLASS 14 30 STRUCTURAL VIEW 14 30 REMOVAL 14 31 INSTALLATION I 14 31 QUARTER WINDOW GLASS 3 DOOR HATCHBACK 14 33 REMOVAL AND INSTALLATION 14 33 QUARTER WINDOW...

Page 824: ...taching the hood to the hinge and repositioning the hood 2 Adjust the hood lock after the hood has been aligned The hood lock can be moved up and down and side to side Align it with the striker on the...

Page 825: ...rews and fasteners 3 Open the tabs of the clips with a small screwdrivers then remove the cowl plate 4 Install in the reverse order of removal RADIATOR GRILLE REMOVAL AND INSTALLATION 1 Remove the rad...

Page 826: ...move the installation bolt and then disconnect the trunk lid and fuel lid release wires 2 Disconnect the release wire from the trunk lid lock 3 Ooen the fuel filler lid remove the installation nut and...

Page 827: ...wn in the figure referring to the removal note 3 Install in the reverse order of removal Standarde Type Large Type 1 Front turn signal light 2 Fastener 3 Retainer 4 Bumper reinforcement Removal Note 5...

Page 828: ...STALLATION 1 Remove the parts in the sequence shown in the figure 2 Install in the reverse order of removal Standard Type Large Type 1 Trim 5 Energy absorbing foam 2 Fastener 6 3 Fikainer Bumper face...

Page 829: ...in the figure referring to the removal note 3 Install in the reverse order of removal 1 Combination light 2 Turn and hazard light 3 Headlight Light Headlight Halogen Front turn signal light Front sid...

Page 830: ...GHT AIMING Preparation 1 Adjust the tires to the standard pressure 2 Position the vehicle on a flat level surface unload ed condition Adjustment Adjust the headlights to meet the local regulations To...

Page 831: ...note 3 install in the reveres order of removal Hatchback Sedan 1 Cover Light Turn signal lights Stop and tail lights Side marker lights Back up lights License plate lights For sedan 3 Lens Wattage Bu...

Page 832: ...m the light housing by push ing the rear of the lens with a hammer handle or round bar 3 While heating the light housing remove the hot melt and any remaining fragments of the lens Note The hot melt s...

Page 833: ...REAR COMBINATION LIGHT 14 5 Fit the new lens to the light housing and press the lens firmly so that it will adhere I I 6 Immerse the combination light in water to check for leaks 14 11...

Page 834: ...ry negative cable 2 Remove the parts in the sequence shown in the figure 3 Install in the reveres order of removal Sedan Hatchback 1 Clip 4 Bracket 7 Gasket 2 Cover 5 Lens 8 3 Bulb Sedan Housing 6 Bul...

Page 835: ...battery negative cable 2 Remove the parts in the sequence shown in the figure 3 Install in the reveres order of removals r Hatchback Sedan in rear combination light Refer to page 14 9 I 83V14X 00 1 Tr...

Page 836: ...AL AND INSTALLATION 1 Disconnect the battery negative cable 2 Remove the parts in the sequence shown in the figure 3 Install in the reveres order of removal 1 Lens 3 Bulb 2 Cover 4 Body Interior light...

Page 837: ...e 2 Snap ring 9 Sail inner garnish 16 Weatherstrip 3 Escutcheon 10 Door lock 17 Door checker 4 Regulator handle 11 Key cylinder 18 Door 5 Door trim 12 Outer handle 19 Power window regulator 6 Regulato...

Page 838: ...djust it by moving the door lock striker side to side Door Hinges I Open the door If there is play in the hinges tight en the door hinge installation bolts arrows 2 To adjust the door to body offset l...

Page 839: ...d 6 Remove the regulator installation bolts and then remove the regulator through the service hole 7 Remove the window motor mounting bolts then remove the motor from the regulator power window INSTAL...

Page 840: ...ss 14 Glass channel 2 Snap ring 8 Lift bracket 15 Weatherstrip quarter 3 Escutcheon 9 Quarter window glass window 4 Regulator handle bezel IO Door lock 16 Weatherstrip 5 Door trim 11 Outer handle 17 D...

Page 841: ...r handle 3 Remove the door trim Note For vehicles with power windows disconnect the power window connector 4 Remove the door screen Caution Remove the screen carefully so that it can be reused 5 Remov...

Page 842: ...uter circumference of the weatherstrip when installing the quarter window 2 Before installing the motor connect the leads to a battery and run regulator down to the position shown power window INSTALL...

Page 843: ...ALLATION 1 Remove the parts in the sequence shown in the figure 2 Install in the reverse order of removal 1 Stay damper 2 Back door hinge 3 Back door 1 Adjustment of Striker and Hinge Adjust the strik...

Page 844: ...GLASS FRONT WINDOW GLASS STRUCTURAL VIEW 1 Interior mirror 5 Wiper arm 2 Sun visor 6 Cowl grille 3 Front pillar garnish 7 Front upper molding 4 Front header trim 8 Front side molding 9 Molding joint...

Page 845: ...Use an awl to make a hole in the sealant Pass the end of a piece of the piano wire about 40 cm 15 7 in through the hole and attach bars to both ends 5 Two people should hold the bars one inside and on...

Page 846: ...glass and the remaining bond on the body 3 Bond a dam along the circumference of the glass 5 mm 0 20 in from the edge Caution Securely bond the dam and let it dry 4 Apply primer with a brush to the c...

Page 847: ...glass open until the repair seal hardens to some degree to prevent pressure from being exerted on the front glass if the door is closed quickly Hardening time of repair seal Surface hardening Time req...

Page 848: ...14 BACK DOOR GLASS HATCHBACK BACK DOOR GLASS HATCHBACK STRUCTURAL VIEW 1 Wiper arm 2 Rear upper molding 3 Rear lower molding 4 Rear side molding 5 Weatherstrip 6 Glass 14 26...

Page 849: ...and one outside the vehicle and then saw the seal ant from around the glass 5 Remove the glass from the body Caution a Cut along the border between the glass and the sealant b If too much heat develop...

Page 850: ...dy and it them to naturally dry for 20 to 30 minutes Caution Be sure not to allow dirt water oil etc to come in contact with the coated surfaces and do not touch it with your hand 5 Install the spacer...

Page 851: ...tc Hardening time of repair seal Tem Surface hardening Time required until PCXatUE time vehicle can be put in service 5 41 F Approx 1 5 hrs 12 hrs 20 68OF Approx 1 hr 4 hrs G X 95V Approx 10 min 2 hrs...

Page 852: ...14 REAR WINDOW GLASS REAR WINDOW GLASS STRUCTURAL VIEW 1 Pillar trim 4 Glass 7 Molding joints 2 Package tray trim 5 Upper molding 6 Lower molding 3 Weatherstrip 6 Side molding 14 30...

Page 853: ...s 3 Fit string into the weatherstrip on the interior side of the glass and overlap it about 50 mm 2 0 in at the bottom center 4 Coat the weatherstrip with soapy water so that the weatherstrip will sli...

Page 854: ...ASS 9 Put filler TP 33M or equivalent sealant between the body and glass and the weatherstrip IO Install the filler as shown in the figure Note Mask the body with tape so that excess filler can be eas...

Page 855: ...UARTER WINDOW GLASS 3 DOOR HATCHBACK REMOVAL AND INSTALLATION 1 Remove the parts in the sequence shown in the figure 2 install in the reverse order of removal 1 Screw 3 Hinge cover 5 Glass 2 Lock 4 Sc...

Page 856: ...TER WINDOW GLASS 5 DOOR HATCHBACK REMOVAL AND INSTALLATION 1 Remove the parts in the sequence shown in the figure 2 Install in the reverse order of removal 1 Rear side trim 3 Pillar trim 5 Stud 2 Nut...

Page 857: ...ar bumper molding 2 Front drip molding 6 Back door window molding 3 Rear drip molding F RO N NDOW UPPER MOLDING AND SIDE Removal and Installation 1 Using a molding remover remove the side mold ing fro...

Page 858: ...ding Be careful not to scratch the molding 2 Remove the molding by twisting with both hands beginning at the lower side 3 Install in the reverse order of removal BELTLINE MOLDING Removal and Installat...

Page 859: ...DING Removal and Installation I Remove the trunk lid molding mounting screws 2 Install in the reverse order of removal SIDE PROTECTOR MOLDING SNAP IN AND STICK ON TYPE Note As shown in the figure the...

Page 860: ...ssible with out damaging the surface 3 If the adhesive is hard to remove use a blow dryer to soften it Installation 1 Remove any grease from the body and molding surfaces 2 Use masking tape to mark th...

Page 861: ...essing bout IO cm 0 39 in of the molding into the weatherstrip gradually press in the rest of the molding by moving the tool without removing it from the groove BACK DOOR GLASS WINDOW MOLDING HATCHBAC...

Page 862: ...lation 1 Remove the bumper molding by prying it with a protected screwdriver start removing it at the molding end 2 Snap the molding in starting at one end and pro ceed step by step toward the other e...

Page 863: ...TURAL VIEW 1 Sunroof trim 6 Rail assembly 11 Packing 2 Sliding panel 7 Lower panel 12 Tube assembly 3 Weatherstrip 8 Guide bracket rear 13 Frame assembly 4 Deflector 9 Guide bracket front 14 Regulator...

Page 864: ...ehicle 4 Completely open the lower panel 5 Disconnect the deflector links from the connectors remove the deflector Note Hold the deflector down while disconnecting the deflector links 6 Remove the scr...

Page 865: ...clriv ing cable and insert the cable through the end of the assembly Apply an ample amount of grease on the sliding surfaces of the cam and guide shoe 2 Properly adjust the left and right positions of...

Page 866: ...ower panel fully Note Because the lower panel and roof panel might interfere with each other when the lower panel is opened check that the guide roller is com pletely fitted into the guide rail as sho...

Page 867: ...ide panel Cross section A A Adjust so that the height difference between the out er panel and roof panel is 1 5 mm 0 06 in or less B B cross section Cross section B B adjustment 1 Loosen installation...

Page 868: ...y make the following adjustments 83 14X 027 r 1 11 Instal the synrqof trim 12 After rnstallatlon IS completed check the operation I Set plate and following points 1 Is there any foreign material on th...

Page 869: ...nect the battery negative cable 2 Remove the parts in the sequence shown in the figure 3 Install in the reverse order of removal 1 Wiper blade 5 Cover 2 Wiper arm 6 Wiper motor 3 Seal rubber 7 Link as...

Page 870: ...from the crank arm Do not remove the motor and crank arm unless necessary because the automatic stop angle is fixed 20 l 5 mm 0 79 in f 6 19 in Adjustment of arm height Adjust the arm height as shown...

Page 871: ...NSTALLATION 1 Disconnect the battery negative cable 2 Remove the parts in the sequence shown in the figure 3 install in the reverse order of removal 1 Wiper arm and wiper blade 3 Wiper motor 5 Nozzle...

Page 872: ...R Adjustment of Arm Height Adjust the height as shown in the figure Adjustment of Washer Spray Adjust the washer spray by inserting a needle or simi lar object into the spray hole of the nozzle and be...

Page 873: ...f removal 1 Steering wheel 9 Under cover 2 Column cover IO Lower panel upper and lower Il Duct 3 Combination switch 12 Reinforcement 4 Meter hood 13 Lower louver 5 Meter 14 6 Side wall Bolts 3 15 Bolt...

Page 874: ...the me ter hood 5 Remove the attaching screws 6 Disconnect the speedometer cable and the meter connector 7 Remove the meter assembly I 8 Remove the attaching screws and remove the side wall on both s...

Page 875: ...er cov er on both sides 13 Remove the screws and remove the lower panel 2 14 Remove the screws and remove the lower louver and reinforcement 15 Remove the duct 16 Remove the hood release wire 17 Remov...

Page 876: ...ide cover on both sides and remove the bolts 19 Remove the screws and remove the center bracket attaching bolts after removing the glove box 20 i3zYsve the side bracket attaching nut on both 21 Remove...

Page 877: ...igarette lighter connector and re move the light for illumination 24 Remove the heater control wires 25 Remove the screws and remove the lower cover 26 Remove the instrument panel support bracket at t...

Page 878: ...torque 4 2 6 2 N m 0 43 0 63 m ka 3 1 4 6 ft lb _ _ _ 8 12 8 N m 0 9 I 3 m kg 6 5 9 4 ft lb _ 7 8 10 8 N m 0 8 I I m kg 5 8 8 0 ft lb 8 6 12 8 N m 0 9 l 3 m kg 6 5 9 4 ft lb 8 8 12 8 N m 0 9 l 3 m kg...

Page 879: ...I 1 Cover 4 Front seat back 7 Rear seat cushion 2 Reclining knuckle 5 Front seat cushion 0 Rear seatback 3 Seat adjuster 6 Head restraint INSPECTION a Check that the seat adjuster lever and reclining...

Page 880: ...elt 3 Retractor ELR 4 Rear seat belt INSPECTION 1 Check that the belt can be pulled out smoothly and that it moves smoothly when worn 2 Check the webbing for scars tears or wear and for deformation of...

Page 881: ...console Il Seaming welt 4 Assist grip 12 Interior light 5 Front pillar trim 13 Head liner 6 Front header trim 14 Insulation 7 Center pillar trim 15 Front side trim 8 Side garnish 16 Front scuff plate...

Page 882: ...e tray trim 3 Overhead console 11 Seaming welt 19 Tire house trim 4 Assist grip 12 interior light 20 Trunk room front trim 5 Front pillar trim 13 Head liner 21 Trunk room end trim 6 Front header trim...

Page 883: ...holders and the assist grips 2 Remove the lens of the interior light and remove the screws 3 Disconnect the interior light connector L I 4 Remove the hinge cover and the screws then re move the side...

Page 884: ...trim 9 Remove the weatherstrip fasteners and then re move the rear pillar trim 3 Door 5 Door Hatchback Hatchback Sedan 53 14X 154 10 Remove the fasteners from the head liner 11 Remove the head liner r...

Page 885: ...front part of the head liner INSTALLATION Follow the reverse order of removal REMOVAL VEHICLE WITH SUNROOF 1 Remove the overhead console interior mirror sun visors sunvisor holders and the assist grip...

Page 886: ...ening seaming welts 6 Remove the front pillar trims 7 Remove the head liner front lace 8 e s the rear of the door opening seaming 9 Remove the rear pillar trim 10 Remove the head liner rear lace 11 Re...

Page 887: ...s 4 from the frame as sembly 3 Remove the interior light harness 4 Remove the set bracket attaching bolts 5 Lower the sunroof frame assembly slowly and re move it INSTALLATION Follow the reverse order...

Page 888: ...e antenna feeder from the clips 4 Remove the attaching screws and then pull out the antenna assembly The sunroof drain pipe will come out with it INSTALLATION 1 Install the antenna feeder and the sunr...

Page 889: ...r mounting nut Front suspension mounting block mounting hole Front lower arm attaching nut Ground mounting nut Front fender mounting nut Wiring harness clip mounting hole Condenser mounting nut Front...

Page 890: ...cket mounting nut G Front fender mounting nut H Front lower arm mounting nut I Front frame lower reference hole J Engine member mounting nut K Front frame reference hole L Parking brake cable mounting...

Page 891: ...urface F Steering bracket mounting nut G Front fender mounting nut H Front frame lower reference hole I Engine member mounting nut L l railing linli mounting T racKel reterence nole M Rear suspension...

Page 892: ...r arm reference hole hole E Front suspension mounting block mounting 0 Hook mounting nut surface F Steering bracket mounting nut G Front fender mounting nut H Front lower arm mounting nut I Front fram...

Page 893: ...fender mounting nut C Front frame reference hole D Front lower arm reference hole E Front fender mounting nut F Engine member mounting nut G Front frame lower reference hole H Front frame reference h...

Page 894: ...Rear frame reference hole C Front fender mounting nut J Engine member mounting nut D Front frame lower reference hole K Engine member mounting nut E Front frame reference hole F Front frame reference...

Page 895: ...me reference hole D Front lower arm reference hole E Front fender mounting nut F Engine member mounting nut G Front frame lower reference hole H Front frame reference hole I Parking brake cable mounti...

Page 896: ...38 STOP LIGHT 1 39 STRUCTURAL VIEW 15 39 CIRCUIT DIAGRAM 15 40 TROUBLESHOOTING 15 41 STOP LIGHT CHECKER 15 42 STOP LIGHT SWITCH 15 43 TURN AND HAZARD SIGNAL LIGHT 15 44 STRUCTURAL VIEW 15 44 CIRCUIT D...

Page 897: ...99 CIRCUIT DIAGRAM 15 99 CENTER DIFFERENTIAL LOCK CONTROL SWITCH 15 100 CENTER DIFFERENTIAL LOCK MOTOR 15 101 CENTER DIFFERENTIAL LOCK SENSOR SWITCH 15 104 REAR WINDOW DEFROSTER 15 105 STRUCTURAL VIEW...

Page 898: ...circuits Caution When checking the control unit never use a bulb over 3 4 W Jumper Wire The jumper wire is used for testing by short circuiting switch terminals and to verify the condition of ground c...

Page 899: ...ise dam age the ohmmeter PRECAUTION Wiring Color Code Two color wires are indicated by a 24etter symbol The first letter indicates the base color of the wire and the second indicates the color of the...

Page 900: ...rted from the wire harness side Replacement of Terminal Use the appropriate tools to remove the terminal as shown in the figure When installing a terminal be sure to press it in until it locks securel...

Page 901: ...ied capacity If after a fuse has been replaced it fails again there is probably a short circuit in the circuit and the wir ing should be checked 2 Be sure the battery terminal is disconnected before r...

Page 902: ...itions l Not in operation No power supply In operation Power supply A NO type relay iif2 stop 4iiz ax FIOW I NC type relay Gil dlx stop l S NO switch C CC CIX stop I 3 FIOW h NC switch 1 s FIOW it dlx...

Page 903: ...BOX STRUCTURAL VIEW t box 4WD model Except 4WD model Replacement of Main Fuse Disconnect the battery terminal 30A fuse pull out and push in a new one 80A fuse 1 Remove the main fuse box 2 Open the co...

Page 904: ...ES RELAYS AND CONTROL UNITS 15 SWITCHES RELAYS AND CONTROL UNITS STRUCTURAL VIEW 1 Panel light control switch 3 Engine control unit 2 Intermittent wiper unit 4 Control unit Idle up 5 Circuit open rela...

Page 905: ...L UNITS STRUCTURAL VIEW 1 Door lock relay 6 Timer buzzer unit 2 Flasher unit 3 Entry timer unit 7 Electrical fan relay 4 Stop light checker 6 EGI main relay 5 Oscillator 9 Horn relay IO Cruise control...

Page 906: ...ch 13 Clutch switch MTX 2 Cruise control main switch 8 Ignition key switch 14 O D off switch ATX 3 Hazard switch 9 Horn switch 4 Remote mirror switch 10 Kickdown switch ATX 5 Rear window defroster 11...

Page 907: ...uid level switch 7 Water temperature switch engine side 8 Oil pressure switch 9 Power steering switch 10 Water temperature switch radiator 11 Neutral switch MTX 12 Back lamp switch 13 Neutral switch A...

Page 908: ...itch If the continuity is not as specified replace the switch Terminal S ACC IGl IGz ST Position LOCK OFF ACC o o ON 0 c1 0 START 0 n i 0 m hdicates continuity REPLACE See section 10 CIRCUIT BREAKER I...

Page 909: ...nd washer switch 7 Intermittent wiper unit 2 Wiper unit assembly 5 Turn and hazard switch 8 Cruise control switch 3 Combination switch body 6 Light switch INSPECTION Use an ohmmeter to check the conti...

Page 910: ...Resume Set C a G3 d b Ground Coast Turn Signal and Hazard Switch O O Indicates conductive Light Passing Switch and Horn Switch Passing C 4 Indicates conductive l e terminal is conductive to the plate...

Page 911: ...2V lead to the c terminal and the ground to the a terminal 2 With the switch in the OFF position connect 12V to the c terminal and ground the a terminal Then check for the relay clicking sound when th...

Page 912: ...CLUSTER SWITCH 15 CLUSTER SWITCH STRUCTURAL VIEW 2 Meter hood 3 Cluster switch 15 17...

Page 913: ...es continuity Panel Light Control Switch Connect the 12V probe to the b terminal and the ground to the a terminal Check that the c terminal voltage to the ground changes with the turning angle of the...

Page 914: ...a b c d OFF ON c c 0 Indicator O O Indicates conductive DISASSEMBLY ASSEMBLY 1 Pry off the switch knob 2 Release the lock pins and remove the switch from the rear side 3 Assemble in the reverse order...

Page 915: ...RAL VIEW Type C Type B 1 Speedometer 5 Turn signal hazard warning 8 Warning and indicator lights 2 Odometer flasher light 9 Tachometer 3 Tripmeter 6 Water temp gauge IO Fuel gauge scale change 4 Tripm...

Page 916: ...1 Screws 2 Front lens and window plate 3 Water temp gauge and fuel gauge 4 Speedometer 5 Warning plate 6 Illumination panel 7 Meter case 8 Printed circuit board TYPE B TYPE C 1 Screws 2 Front lens an...

Page 917: ...Short circuit Water temperature gauge Water temperature gauge unit Wiring Remedy Page Replace or repair Replace speedometer Replace speedometer drive gear 15 21 Replace speedometer cable Replace speed...

Page 918: ...er with that of the tachometer replace the tachometer if the error is significant For a digital meter replace the meter unit assembly Digital meter ram display Fuel Gauge 1 Disconnect the connector fr...

Page 919: ...as follows 1 Disconnect the main fuel hose fuel return hose and evaporation hoses from the fuel tank 2 Remove the fixing bolts and fuel tank 3 Remove the fuel tank unit Installation is in the reverse...

Page 920: ...e trouble is in the meter 5 When the meter indicates 18 8 3 0 ohms or less the segments will start flashing Note a Continue the above inspections for at least two minutes each to correctly judge the c...

Page 921: ...15 METER INCL SENDER UNITS METER PRINTED CIRCUIT BOARD INSPECTION 15 26...

Page 922: ...unding with fuel tank gauge unit connector disconnected 1 Fuel gauge I tes FULL 1 Wiring betweenfuse Meter NG 10A Except 4WD Meter 15A 4WD and meteris in terrupted Repair 2 Faulty grounding of meter 0...

Page 923: ...line YW of connector is short circuited to ground Water temp gauge indicated toward 130 or H i OK Note Check the fuse Meter 1OA Except 4WD Meter 15A 4WD in fuse box before trou ble shooting If normal...

Page 924: ...round NO Defective meter grounding OK 1 Defective meter check meter Tachometer does not operate I Turn Ign switch to ON Engine stopped I i Disconnect the cables from IG coil terminal Confirm that tach...

Page 925: ...ing B 1 Check voltage of line WE of warning readout connector with alternator co ectors NG 1 Wiring WE between warning readout and alternator is 1 Replace wiring short circuited to ground 2 Replace al...

Page 926: ...ty when the float is moved up and down The sensor is good if there is continuity when the float is below the MIN mark and if there is no continuity when the float is above the MAX mark If the sensor d...

Page 927: ...T warning light illuminates If it does not illuminate and bulb is not burned out replace switch or stop light checker or repair wiring harness Also refer to page 15 l 1 15 43 Stop Light Checker 1 Chec...

Page 928: ...ck that the BELT warning light illuminates for about 6 seconds 4 If there is no illumination check the fuse warning readout and wiring harness Check bulb control unit and wiring harness and switch rep...

Page 929: ...ck that O D OFF indicator light illuminates when BL wire is con nected to a body ground 2 If there is no illumination check the fuse warning light O D switch and wiring harness Replace or repair as ne...

Page 930: ...LIGHTS REMINDER WARNING 15 LIGHTS REMINDER WARNING STRUCTURAL VIEW I Combination switch 2 Head light 83 15X 04 3 Front combination light 15 35...

Page 931: ...il Pressure Switch El GO2 Stake Fluid Level Switch Fj co3 Parking Brake Switch RI c 04 Oscillator Fl m RY p YYR BW B W OS Washer Fluid Low Level Sensor C 06 Fuel Bank Unfi RI c 07 Wafer Temp sensor Fj...

Page 932: ...Broken RB wire Fuse Oscillator Confirm that beep sound minal is grounded Broken Br wire Meter Oscillator or defective buzzer Broken RY wire Oscillator Door switch or defec tive door switch OK Broken...

Page 933: ...12V to the b terminal and connect e d terminals to the ground 2 Confirm that test light comes on when it is connect ed between the 12V and f terminals Replace oscillator if light does not illuminate C...

Page 934: ...STOP LIGHT 15 STOP LIGHT STRUCTURAL VIEW 1 Stop light checker relay 2 Stop light 3 High mounted stop light 15 39...

Page 935: ...orn L H IFI F 07 Horn R H F F OSSlap Light Switch F 0 GY GR GY GB GR GR 0 WG 09Stop Light Checker PI F 10 High Mounted Stop Light IQ XG 501 CcmbinaNon Switch Fl BL 3 and 5 Door 4 Door WG RB RW 1 20R C...

Page 936: ...stalling condition Remove stop light checker relay from relay box Confirm 12V on a terminal of relay box side connector 4P NG Broken WG wire Switch Relay box 0 OK Confirm that stop lights come on when...

Page 937: ...it 1 OK Check light checker See P15 43 Warning light does not come on when stop light bulb Is burned out I 0 I Remove light checker from relay box Confirm that warning light comes on when 6 terminal o...

Page 938: ...and the ground to the b terminal Connect a test light between the 12V and the c terminal and confirm that the test light comes on 3 Next confirm that the test light goes off when the 12V is removed fr...

Page 939: ...15 TURN AND HAZARD SIGNAL LIGHT TURN AND HAZARD SIGNAL LIGHT STRUCTURAL VIEW 1 Flasher unit 2 Turn and hazard signal light 15 44...

Page 940: ...15 CIRCUIT DIAGRAM F 02 Fla her Unit F F 03 Front Turn F L IF F 04 Front Turn F R Fj w o 00 B GY B GR e B 15 Reverse Light Switch q E 20 Rear Cambi Light R L RI E 21 Rear Combi Light RR R BY BY w RW G...

Page 941: ...Flasher unit Confirm continuity of b terminal to ground Faulty grounding of flasher unit 0 OK Install flasher unit Confirm Defective flasher unit or broken GR wire Combi connector to combination swit...

Page 942: ...rs Broken GB or GW wire Combination switch and rear combination lights Front turn lights or rear combination lights I OK Burnt out bulb or faulty grounding of front turn light and combination light On...

Page 943: ...Apply 12V to the B terminal of the unit and con nect E terminal to the ground 2 Confirm that the two paralleled lamps come on when connected between the L terminal and the ground Caution Do no revers...

Page 944: ...ED ENTRY SYSTEM 15 ILLUMINATED ENTRY SYSTEM STRUCTURAL VIEW 1 Entry timer unit 4 Interior light 2 Door key illumination 5 Courtesy light 3 Door handle 6 Door switch 7 Courtesy light 8 IG key illuminat...

Page 945: ...p w fiQ Ijc Q Q QE 15 Courtesy Light R H DrZ J 06 interior And Spoi Lights In J 07 Luggage Companmenf Light I LR RL vGJ 93And5Dwr 4Dw LR LR LR 18 Luggage Compartment Light Switch RZ J OSDoorSwitchF L...

Page 946: ...room iuse 1OA Short circuit Broken wire 0 OK Remove entry timer unit from relay box Confirm i2V on e terminal of relay box side 6P Broken LR wire Fuse Timer unit connector I OK Confirm continuity of c...

Page 947: ...t Timer unit Only Ign key Illumination and door key illumi nation do not operate I 0 I Remove timer unit from relay box Confirm that light operates when f terminal of relay box side 6P connector is gr...

Page 948: ...ll doors Remove timer unit from relay box NG Confirm NO continuity of a terminal of relay box Short circuit Broken wire of RY wire side 6P connector to ground Defective timer unit Ign key illumination...

Page 949: ...ut 5 seconds after the b terminal is separated from the ground Note Do not connect the electrical source to other terminals Checking the operation of interior light control 1 Connect the 12V to the e...

Page 950: ...HORN 15 HORN STRUCTURAL VIEW 1 Horn switch 2 Horn 3 Horn relay 15 55...

Page 951: ...WI F 0 8 F 08 Stop Light Switch GY GR v 0 GR 9 z 09 Stop Light Checker R F 10 High Mounted Stop Light RZ SG E01 Combination Switch fl BrB WG 63 0 GE W m ZL G B x BL 3 and 5 DwrI 4 Door WG RB RW i 20...

Page 952: ...ken GY wire Fuse Horn relay 0 Confirm that horn connector is grounded Confirm that horn sounds when GB wire of combi nation switch connector BP is grounded 0 NO 4 Confirm 12V on GR wire of above conne...

Page 953: ...ound to the S terminal and then confirm 1 on R terminal Horn Switch 1 Confirm the continuity between the horn conduc tor plate and the serration gear part when the horn switch is pushed ON 2 Confirm t...

Page 954: ...mbination Switch F 0 E 07 H E 08 Headlight R H F GB X X 0 0 WR RW 0 WG RE RW 0 B F Combi Lighf F L F E 10 F Combi Light F R F E l License Light R E 12 R Combi Light R c R W RBIRWGE B w fw B w WI GE w...

Page 955: ...switch 0 Confirm 12V on RB wire wire when High of combination switch connector Defective combination switch 0 OK Disconnect headlight connector Confirm 12 J on RB wire when Low and or on RW wire when...

Page 956: ...REAR WINDOW WIPER 15 REAR WINDOW WIPER STRUCTURAL VIEW 1 Rear wiper motor 2 Rear washer 15 61...

Page 957: ...15 REAR WINDOW WIPER CIRCUIT DIAGRAM 15 62...

Page 958: ...ve connector Check motor see P15 66 0 OK Confirm 12V on BR wire o Broken 3R wire Rear wiper motor Rear wiper nectar 3P switch I 0 OK Disconnect the connector Confirm continuity of B wire of harness si...

Page 959: ...I stops when connector 3P is rear wioer switch Defective rear wiper switch Check rear wiper switch Disconnect 2P connector from rear wiper motor Confirm NO continuity of BR wire of harness side conne...

Page 960: ...to ON Confirm 12V on LG wire of rear washer motor 2P NG Broken LG wire Fuse Rear washer motor connector J 0 Confirm 12V on Lg wire Check rear washer motor See P15 66 1 0 Confirm 12V on Lg wire switch...

Page 961: ...connected to the b terminal of the motor 2 Start the motor again Disconnect the ground from the b terminal and then connect the ground to the motor body im mediately Confirm that the motor shaft reac...

Page 962: ...WINDSHIELD WIPER 15 WINDSHIELD WIPER STRUCTURAL VIEW 1 Wiper motor 2 Washer tank 3 Washer switch 15 67...

Page 963: ...15 WINDSHIELD WIPER CIRCUIT DIAGRAM I 05 Rear wiper And Washer D 06 Rear Washer Motor RI D 07 Headlight Cleaner Switch II DOB Headlight Clewer Motor q Switches UI EW s LR xx LQ BR B RG LY LR B 15 68...

Page 964: ...OK Pull out LB wire pin from wiper motor connector and check that motor operates in high speed NG when LR wire is grounded 0 OK Disconnect 6P connector from combination switch Check that motor operat...

Page 965: ...ntermittent wiper unit in combination switch See P15 15 Intermittent function does not operate Disconnect 6P connector from combination switch and check for 12V on L wire of harness side con NG Broke...

Page 966: ...tor is disconnected Defective intermittent wiperCheck intermittent wip er unit in combination unit See P15 15 1 NG Short circuit Broken LW wire Combination switch Wiper motor 83 1SX 077 IIWiper contin...

Page 967: ...r Broken L wire Fuse Washer motor CD OK Check for 12V on LO wire of washer motor con nector CD OK Check that motor operates when LO wire of combination switch connector is grounded I It NO Check washe...

Page 968: ...ty between the b and d terminals and between the d and e terminals while operating the motor in low speed Terminals Conductivity b d Non conductive mo sl of the time and be canes conductive once per t...

Page 969: ...15 POWER DOOR LOCK POWER DOOR LOCK STRUCiURAL VIEW a c e bd f h 1 Door lock relay 2 Door lock switch 3 Door lock actuator 15 74...

Page 970: ...POWER DOOR LOCK 15 CIRCUIT DIAGRAM 01 Power Door Lock Switch Drl 1 F LR GR GB LX Power Door Lock Motor RR D41 t _ _ 1 I N 0 N 03 Power Door Lock Motor F R...

Page 971: ...door lock relay Check for conductivity between d and h ter conductivity between c and h terminals when NG Defective door lock switch or broken wire Door lock relay Door lock switch Connect 12V to e t...

Page 972: ...or unlocks Door Lock Timer Unit 1 Check the conductivity between the terminals Terminals b onductivty Terminals Conductivily Terminals onduniv y a b X b d x c h X a c 0 b e X d e 0 1 b c I x I c f I 0...

Page 973: ...15 POWER WINDOW POWER WINDOW STRUCTURAL VIEW 1 Power window main switch Driver side 3 Power window switch Rear 2 Front power window motor 4 Rear power window motor 15 78...

Page 974: ...POWER WINDOW 15 CIRCUIT DIAGRAM 323 Revised IO 87...

Page 975: ...to ground Faulty grounding of main switch OK4 Check main switch See P15 831 Only driver aide power wlndow does not operate I Turn ign switch to ON 0 1 Check for 12V on R wiie and G wire of main switc...

Page 976: ...12V on GL Check for 12V on wires to each door switch con nector 6P or 5P while operating the main switch 1 NO Check main switch See P15 83 NG Broken wire Main switch Switch on each door 0 1 OK Check f...

Page 977: ...to ON Turn power switch of the main switch to ON I 0 Check for 12V on EL wire Check power switch of the main switch connector See Pi 5 83 0 OK Check for 12V on BL wire of switch connector 6P or 5P on...

Page 978: ...tes conductive c d e and f terminals for 3HB model are not in use M Indicates conductive Switch on Each Door Check the conductivity between the terminals indicates wire color passenger side O C indica...

Page 979: ...15 REMOTE CONTROL MIRROR REMOTE CONTROL MIRROR STRUCTURAL VIEW 1 Door mirror 2 Remote control mirror switch 15 84...

Page 980: ...REMOTE CONTROL MIRROR 15 CIRCUIT DIAGRAM...

Page 981: ...r switch Check conductivity of the terminals of remote ccn trcl mirror switch and remote control mirror motor REMOTE CONTROL MIRROR CLASS 1 DIRECTION1 6 PIN UP DOWN EFT LEFT REMOTE CONTROL MOTOR Termi...

Page 982: ...ADJUSTABLE SHOCK ABSORBER i 5 ADJUSTABLE SHOCK ABSORBER STRUCTURAL VIEW 1 Adjustable shock absorber 2 Front actuator switch 3 Rear actuator 15 87...

Page 983: ...RCUIT DIAGRAM 01 Adjustable Damper Actuater O 02 Adjustable Damper Actuater 003 Adjustable Damper Actuater O 04 Adjustable Damper Actuater R L Fr RR Fr F L q F R fl RY R RB RB RW 05 Adjustable Damper...

Page 984: ...Defective ground circuit I OK 1 NG Check shock absorber switch See P15 90 Defective shock absorber switch 1 0 Install the switch OK Disconnect all actuator connectors and check as follows In SPORT mod...

Page 985: ...t the tester pointer does not swing when above connection is reversed Note Set the tester to xlOOOD range Note a Do not disassemble the switch as it is diffi cult to assemble b illumination lamp bulb...

Page 986: ...lied to the a terminal and the c terminal is grounded 3 Confirm that in the HARD mode the actuator oper ates when 12V is applied to the 6 terminal and the b terminal is grounded Caution a Observe the...

Page 987: ...15 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM STRUCTURAL VIEW I Main switch 2 Stop light switch 3 Stop switch 4 Control unit 5 inhibitor switch ATX 6 Actuator 7 Clutch switch MTX __ 15 92...

Page 988: ...eplace stop switch Repair as necessary Speed setting Defective control unit Check control unit can not be can Defective clutch switch 15 96 celled Adjust or replace clutch switch Defective stop switch...

Page 989: ...nd associated wiring harness terminals and connectors ACTUATOR VAC VAC coil continuitv in the actuator and associated harness ACTUATOR VENT 2 VENT 2 coil continuity in the actuator and associated harn...

Page 990: ...sts are completed C Slide switch Set the slide switch in the L position before the check switch is used Then engine rpm will increase to approximately 2 000 to 3 000 rpm and will hold steady Note If e...

Page 991: ...n switch ON Check clutch switch and associat l Main switch ON 0 0 0 0 x x or X ed harness l Depress clutch pedal 4 SET POSITION OF COMBINA COMBINATION SW LIGHT OFF TION SWITCH 0 Check SET position of...

Page 992: ...T I 1 C iHTS c iT0 R 2 2 0 X 3 SP I c 1 X X X TROUBLESHOOTING INCORRECT RESPONSE If engine speed does not reach and remain in the 2 000 to 3 000 pm range defect may be in actu dor and associated harne...

Page 993: ...E SWITCH When replacing these switches adjust them so that the corresponding pedal height agrees with the stan dard value Clutch pedal height 229 5 mm 9 02 o02in 4WD 214 5 2 mm 8 45 g2 in Except 4WD B...

Page 994: ......

Page 995: ...y and cigarette lighter 3 Remove the fixing screws 4 Remove the center panel 5 Remove the fixing bolts 6 Remove the center differential lock switch Checking the center differential lock control switch...

Page 996: ...negative battery cable 2 Disconnect the lock motor connector and bleezer hose 3 Remove the lock bolt of the rack 4 Remove the Dad of the motor side 5 Turn rack to the right using standard screw driver...

Page 997: ...ttery cable 2 Disconnect the connector of the center differen tial lock motor 3 Using an ohmmeter check the resistance between the terminals at the motor connector side in FREE and LOCK position Motor...

Page 998: ...e flat edge of the rack locates on the top face 4 Install the lock motor after applying genuine gear oil to the 0 ring 5 Tighten the lock bolts 6 Turn rack to the left using standard screw driver 7 In...

Page 999: ...se that transaxle does not change from FREE to LOCK at once Checking the sensor switch 1 Disconnect the negative battery cable 2 Disconnect the connector of the switch 3 Using an ohmmeter check contin...

Page 1000: ...REAR WINDOW DEFROSTER i 5 REAR WINDOW DEFROSTER STRUCTURAL VIEW 1 Rear window defroster switch 2 Rear window defroster 15 105...

Page 1001: ...15 REAR WINDOW DEFROSTER CIRCUIT DIAGRAM 31 RearWindow Defroster SW I I 02 Rear Window Defroster AZ I 03 Rear Window Delroster Rz l 04 Clock I BY LR 24 Meter Fj 0 15 106...

Page 1002: ...ve defroster switch 0 With the switch ON confirm 12V on BR wire of the defroster heater right side NG Broken wire Defroster switch heater Confirm OV on B wire of left side Faulty grounding of heater I...

Page 1003: ...or zero the malfunction is between the center and positive side Repairing the Filament 1 Use paint thinner or ethyl alcohol to clean the damaged part of the filament 2 Attach tape to both sides of the...

Page 1004: ...R STRUCTURAL VIEW 1 Side defroster outlet 4 Center louver air outlet 2 Side louver air outlet 6 Heater control switch 3 Lower louver 6 Rear heater duct 7 Blower unit 6 Front defroster air outret 9 Hea...

Page 1005: ...15 HEATER JENT 4 to face BI LEVEL 1 To front windoh 2 To side window 3 To floor 4 To face 83U15X l1 15 110...

Page 1006: ...HEATER 15 HEAT E d I 2 A Air flow to outlets 1 To front windocz 2 To side window 3 To floor HEATIDEF Air flow to outlets 1 To front window 2 To side window 3 To floor...

Page 1007: ...15 HEATER XEF t Air flow to outlets 1 To front window 2 To side window 15 112...

Page 1008: ...loop of wire onto lever 3 Pull connecting rod downward to its extreme stop then install connecting rod to fastener 4 Use clip to clamp rod in position 5 Set fan speed at 4 to insure proper air circul...

Page 1009: ...Selec tor Control BLOWER UNIT REMOVAL Blower unit can be removed as per following proce dures without removal of the instrument panel 1 Remove under cover of instrument panel located in passenger sid...

Page 1010: ...Remove resistor provided underneath the blow er unit Note Resistance level max about 4 Q of synthetic resistance degree is normal If fuse is blown replace resistor Do not touch resistor surface as it...

Page 1011: ...AUDIO SYSTEM AUDIO SYSTEM OUTLINE OF AUDIO SYSTEM SYSTEM 1 AM FM MPX ELECTRONIC TUNING RADIO R Front L Front SYSTEM 2 AM FM MPX ELECTRONIC TUNING RADIO AUTO REVERSE CASSETTE DECK R Front L Front 15 1...

Page 1012: ...AUDIO SYSTEM 15 REAR VIEW AND CONNECTORS AM FM MPX ELECTRONIC TUNING RADIO TOFront Speaker To Rear Speaker AUTO REVERSECASSETTEDECK 83 15X 14 15 117...

Page 1013: ...it tester indicatesrating impedance of the speakerwhen checking im pedance between speaker and speaker of the ame channel speaker is OK When circuit tester plugs touch speak er jack clicking sound com...

Page 1014: ...I NO 1 Check harness I Check voltage of power supply Check with another tape Voltmeter 1 Ground 4 Replace fuse and check for short I i OK Check speakers If circuit tester in dicates rating impedance...

Page 1015: ...ra noise should be heard Check antenna Tester indicates infinite Antenna feeder YES ON Engine OFF Ohmmeter Is there still noise when Plug NO pulling out antenna plug YES 4 NO Replace unit OK If noise...

Page 1016: ...GINE NOISE Check grounding Ground completely i OK Check mounting screws Loose OK Check with another tape I NG Tighten the screws OK Tape is defective I NO Is wiring correct Replace tape player unit NO...

Page 1017: ...ith preset button ant set again if the stations be come noisy When FM tuning is correct no extra noise should be heard Tuning 77 Check antenna and lead i for broken connectors Tester indicates infinit...

Page 1018: ...r or OK lother tape L 1 NG Repair harness I OK Check for shorts in speaker harness If circuit tester indicates infinite ohm Ground when checking valve of resistance between each speaker jack and Ohmme...

Page 1019: ...arts of body must not touch the car Volume increases Antenna is defective Volume decreases Antenna OK 1OK 1 Rdace radio unit I NO DISPLAY OF FREQUENCY PRESET MEMORY IS CANCELED IF EQUIPPED Check volta...

Page 1020: ...ide and dirt qiy I Use Ailsop Heac cleaner or equivalent I I I Tighten tape using a pen or pencil 1 Check for tape looseness OK Use 30 60 or SO minute tapes 1 Check that C 120 or longer ta USED Check...

Page 1021: ...15 AUDIO SYSTEM INSTALLATION Radio 2...

Page 1022: ...AUDIO SYSTEM 1 5 Radio and Cassette Deck 3 15 127...

Page 1023: ...ELECTRICAL SYSTEM 30 14 CLUTCH 30 16 MANUAL TRANSAXLE 30 I 6 AUTOMATIC TRANSAXLE 30 16 MANUAL TRANSAXLE 4WD 30 22 PROPELLER SHAFT 30 23 FRONT AND REAR AXLES 30 24 STEERING SYSTEM 30 24 BRAKING SYSTEM...

Page 1024: ...m in 1 390 54 7 1 390 54 7 1 400 55 1 mm in 1 415 55 7 1 415 55 7 1 425 56 1 IA ENGINE 66 EGI Number and arrangement of cylinders Type of combustion chamber Valve system Bore x Stroke OH mm in ompress...

Page 1025: ...Rocker arm shaft diameter mm in Rocker arm to shaftclearance mm in Standard Maximum Cylinder block Height mm in Distortion mm in Grinding mm in Cylinder bore diameter Standard size mm in 0 25 0 010 o...

Page 1026: ...m in Big end width mm in Connecting rod side clearance mm in Standard Maximum 19 974 19 980 0 7864 0 7866 0 013 0 032 0 0005 0 0013 4 905 14 715 500 1 500 l iOO 3 300 132 85 132 95 5 2303 5 2342 0 04...

Page 1027: ...y Timing belt tensioner Timing belt cover Crankshaft pulley Cylinder head cover Oil pressure switch Engine hanger Coolant outlet pipe Thermostat cover n a a xi P rtnr Front Rear 19 30 19 26 R l 1 9 3...

Page 1028: ...I 7 9 1 079 11 O 156 300 Compression pressure Minimum kpa kg cm Psi rPm I 755 7 7 109 300 Maximum difference hP WCAPn 196 2 0 28 Open BTDC 50 Close AEDC 510 Open BBDC 69O Close BTDC 10 Valve clearanc...

Page 1029: ...mm in 0 15 0 006 max Grinding mm in 0 20 0 008 max Cylinder bore diameter Standard size 78 000 78 019 3 0709 3 0717 mm in 0 25 0 010 oversize 78 250 78 269 3 0807 3 0815 0 50 0 020 oversize 78 500 78...

Page 1030: ...mm in 0 25 O OiO 0 50 0 020 Thrust bearing Crankshaft end play mm in Standard 0 080 0 282 0 0031 0 011 Maximum 0 30 0 0116 Standard size 2 500 c w v 1 0984 0 1004 Bearing width mm in 0 25 0 010 oversi...

Page 1031: ...5 Engine hanger Front I 37 52 I 3 8 5 3 I 27 38 Rear 37 52 3 8 5 3 27 38 Alternator Air intake pipe 8 l 1 0 8 l l 69 95 in lb Engine mount 37 52 3 8 5 3 27 36 A C idle pulley 37 52 3 8 5 3 27 38 A C b...

Page 1032: ...rotor and body clearance mm in Standard hA irn Irn IL I Maximum Oil filter TYPO I Relief pressure differential kPa kg cm psi 1 Oil pressure switch Activation pressure kPa kg cm psi 1 Engine oil m my...

Page 1033: ...YSTEM B6 EGI Outer diameter Coolant capacity Antifreeze solution liters US qt Imp qt Protection Above 16 3 F Above 26 15OF Above 40 4O F MTX 5 0 5 3 4 4 ATX 6 0 6 3 5 3 Mixture percentage volume Speci...

Page 1034: ...5 56 62 in lb Thermostat cover Coolant outlet pipe 19 26 1 9 2 6 14 19 water pump 19 26 1 9 2 6 14 19 thermo switch I 6 9 I 0 6 0 9 52 78 in lb j 4A FUEL AND EMISSION CONTROL SYSTEM B6 EGI Item Idle s...

Page 1035: ...3 12 17 4B FUEL AND EMISSION CONTROL SYSTEM B6 DOHC TURBO Engine model 86 DOHC TURBO I Fuel pump TYPO Output pressure Feeding capacity Transfer pump Feeding capacity I Impeller intank kPa kg cm2 psi 4...

Page 1036: ...2 5 3 3 18 1 23 9 5 ENGINE ELECTRICAL SYSTEM I Engine model 86 EGI B6 DOHC TURBO Charging system Type Battery 20 hour rate Voltage Capacity Level of electrolyte Safety gravity at 20 Recharge at 68 F...

Page 1037: ...91 inHg Positive pressure spark advance Crank angle positive pressure I Timing mark location Timing Firing order I 1 c Gsconnected On 1 200 rpm 12 3 500 rpm 12 000 rpm 18 500 rpm O 60 mml lg 2 36 inHg...

Page 1038: ...3 0 0 02 0 12 9 15 0 35 0 59 mm in 82 3 23 min 85 3 3 min mm in 0 2 0 008 mm in 0 5 0 020 I Single dry plat e mm in 1 1 oo 0 039 mm in 0 3 from rive nlm I I I I I Facing thickness mm in Flywheel si Pr...

Page 1039: ...UAL TRANSAXLE IG tvnel Item TIStlSSXlS Shift lever position Gear ratio Fluid capacity Fluid type First Second Third Fourth Fifth Reverse Liters US qt Imp qt 86 DOHC TURBO Floor shift 3 307 1 633 1 233...

Page 1040: ...0 018 0 85 0 034 0 022 Backlash of side gear and pinion gear mm in o o 1 0 004 TIGHTENING TORQUE Gate lock bolt Transaxle case Rear cover Gear shaft lock nut Guide bolt Reverse idle shafi lock bolt N...

Page 1041: ...142 178 R range Idle kpa kg cm2 psi 600 830 l EL SC Stall kpa kg cm psi 1470 1960 15 0 20 0 213 264 Throttle fxessure I kpa Stall kpa kg cm psi 1 540 610 5 5 6 2 5 5 6 2 g cm psi j 63 l 1 8 0 85 1 20...

Page 1042: ...2 I Dtive plate thickness mm in Standard 1 6 0 063 Minimum 1 4 0 055 Reverse clutch clearance mm in 2 1 2 4 0 083 0 094 Clearance beiween pinion washer and planetary carrier mm in 0 2 0 7 0 008 0 028...

Page 1043: ...TECHNICAL DATA I0 Preioad adjusting shims 323 Revised IO 87 30 21...

Page 1044: ...gear teeth OUtW Inner Number of sun gear teeth Pinion gear side idle gear side Number of idle gear teeth Bearing preload N m cm kg in lb Bearing preload adjustment shim mm in End play of ring gear mm...

Page 1045: ...Inter lock sleeve guide bolt N m 37 52 127 206 7 8 l I 25 30 18 6 25 5 12 16 19 26 19 6 29 4 8 8 13 7 19 59 m kg 3 8 5 3 12 9 21 0 8 2 5 1 2 l 6 1 9 2 7 2 0 3 0 0 9 l 4 ft lb 14 5 21 7 6 5 10 1 29 43...

Page 1046: ...0 Hypoid Qear Straight bevel gear 3 909 1 43 11 API Service GL 5 SAE 90 or 8OW 90 0 65 0 69 0 57 TIGHTENING TORQUE Knuckle to shock absorber Knuckle to lower arm ball joint Lower arm to lower ram bal...

Page 1047: ...53 Drive belt Deflectionwith force of 98 N 10 kg 22 lb C G R Constant Gear Ratio V G R Variable Gear Ratio mm in New belt 8 S 0 31 0 35 Used belt S 10 0 35 0 39 TIGHTENING TORQUE I N m I m kg I R lb...

Page 1048: ...30 TECHNICAL DATA 30 26...

Page 1049: ...o caliper 22 29 Flare nut 13 22 1 9 2 6 14 19 1 0 1 6 7 2 12 2 0 3 5 14 25 5 0 6 0 36 43 33 43 1 5 0 7 0 36 51 5 0 7 0 36 51 1 0 l 3 7 2 9 4 2 2 3 0 16 22 m kg ft lb I 4 6 6 0 1 6 2 4 I 12 17 1 3 2 2...

Page 1050: ...51 13 8 I 394 6 15 54 Coil number active 4 62 Cylinder double acting TYPO Torsion bar Diameter mm in Halchback 15 9 0 63 Sedan 17 3 0 68 17 3 0 66 ASA Adjustable Shock Absorber 4WD B6 DOHC Turbo Item...

Page 1051: ...A A Trailing In Ly nllUCnlr fry v Trailinglink to hub spindle ZWD Crossmemberto body Stabilizerto lateral link Stabilizer bracket I 59 74 I 6 0 7 5 43 54 J nl 147 CL I II 1 9 5 l 1 9 69 66 54 69 5 5 6...

Page 1052: ...30 TECHNICAL DATA STANDARD BOLT AND NUT TIGHTENING TORQUE...

Page 1053: ...ION 40 2 ENGINE GROUP 40 3 C W i AND MANUAL TRANSAXLE 40 4 AUTOMATIC TRANSAXLE GROUP 40 6 PROPELLER SHAFT AND DIFFERENTIAL GROUP 40 6 BRAKE AND AXLE GROUP 40 7 STEERING AND SUSPENSION GROUP 40 8 TESTE...

Page 1054: ......

Page 1055: ......

Page 1056: ...ITY Adapter radia tor cm tester A 49 6012 011 66 DOHC HLA hole pro tector CLUTCH MANUAL TRANSAXLE GROUP ILLUSTRATION PRIORITY 49 BOI 7 OAO liB g transaxle 49 8017 1AO B6 EGI Remover set bearing 49 B02...

Page 1057: ...SPECIAL TOOLS 40 49 F401 440 49 GO17 1AO 49 GO1 9 OAO 49 8043 002 49 GO30 370 49 GO30 3808 43 GO30 455 differential side 49 GO30 795 49 SE01 310 49 HO34 201 49 0727 415 49 0839 42 49 B025 OAO 40 5...

Page 1058: ...GO1 9 OA7 49 GO19 011 PROPELLER SHAFT DIFFERENTIAL GROUP 1 TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 I3001 795 66 EGI Installer oil A seal I 40 6 49 GO19 012 Leak checker 49 GO19 013 remover 4...

Page 1059: ...nstaller dust sea 49 0710 520 4WD Puller bearing 49 HO25 003 K r bearing 0 49 0727 570 4WD Gauge body pinion height adjust 49 HO33 101 4WD Bearing remwel 49 MOO5 561 4WD iiangkr differential carrier 4...

Page 1060: ...Wrench flare nut 43 FA16 602 Wrench disc brake piston A 49 1285 071 Puller bearing 43 F043 001 Adjust gauge A STEERING SUSPENSION GROUP PRIORITY ILLUSTRATION PRIORI1 ry ILLUSTRATION TOOL NUMBER DESCR...

Page 1061: ...staller set low er arm bush 49 0180 51OB Attachment steermg worm bearing preload measuring 49 0208 71 OA Air out tool boot 49 0223 6408 Arm coil spring corn pressor 491232 670A Gauge set power steerin...

Page 1062: ...40 SPECIAL TOOLS 49 HO60 740 49 0167 280 49 0259 866A 49 0305 870A 49 0839 285 49 9200 010 Auto cruise 49 9200 0308 49 9200 162 49 9200 750A 40 I 0...

Page 1063: ...SYSTEM INl iiBlTOR n IGNfTION SYSTEM n ENGtNE FUEL CONTROL SYSTEM n 4AT CONPROL SYSTEM _ _ __ __ i METER ii WARNlNG LIGHTS ____ I _ _ _ r FRON7 WIPER WASHER m REAR WIPER WASHER __ _ _ _ l ILLUKVATION...

Page 1064: ...GHTS 50 26 C FRONT WlPER WASHER 50 28 D REAR WtPER WASHER 3 5 Door 50 28 D ILLUMINATION tlGHT CONTROL SYSTEM 50 30 E a 50 FRONT MARKER LIGHTS 50 32 E b H EADLIG HITS 50 32 E b L CENSE LIGHTS 50 32 E b...

Page 1065: ...bed below When reading the wiring diagram following should be noted Section mark System name System ci r t diagram l Connector diagram identifies the exclusive applicable connectors for the circuit Ma...

Page 1066: ...i IG Icptlon w Watt ACC Accessary R Reststance INT h u ErmrtfenI t M 1 Motor I SW Switch 1 Lo Low Mi Midde Square per HI SS mrllimeter R H Right hand Automatrc A T L H Left hand j Cransmisslon Legend...

Page 1067: ......

Page 1068: ...hen A is off OV 3 is on I1 2VI When A is on 12V f3 is off IOVI This can be simply shown in the relay circuit on the right hand side PROCESS makes a simplified representation of cornpllcated functions...

Page 1069: ...a Horn Switch __ _ _ F b Parts Section _ ___ _ _____ _II_ _ j Combination Switch License Light L H R H _ _ __ __ _ _ _ E b Meter Iliumi _ _ __ _ _ _ __ _ C E a Parking Light L H R H _ _ ____ _ __ ___...

Page 1070: ...B la 2a 3a For No 1 Purge Control Valve B l b 2 b 3a Magnet Clutch IA C C For Vacuum Swrtch Valve B l b 2b 3a t S C B lb 2b 3b I Neutral Switch B lb 2b 3b Kick Down __ ES P R C B lb Zb 3b O O Switch...

Page 1071: ...f lgnttlon Switch n ILLUMI LIGHT CONT SYSTEM B I TAIL LIGHTS m LICENSE LIGHTS 1E b LW CIGARE E LIGHTER H l AIR CONDITIONER LB I HEATER CONTROL SYSTEM G f COOLING FAN SYSTEM l IGNUION SYSTEM LG l REAR...

Page 1072: ...m CHARGING SYSTEM m STARTING SYSTEM Note No sed m STARTER INTERLOCK SYSTEM M r m INH h 4AV AlJERNATOR WITH REGULATOR IGNITION SW ITCH...

Page 1073: ...WMNG DIAGRAM 50 A t A 05 InhIbitor SW Starting Motor...

Page 1074: ...RTER WJTERLOCK SYSTEM Note n _ got used A ill 1 A 02 From Meter Section C 1 ALTERNATOR w In 4 REGULATOR A 02 Alternator With Regulator E A 03 Alternator With Reguta Of El A 04 Starter lnterteck SW F e...

Page 1075: ...WIRING DIAGRAM 50 A 2 50 13...

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