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Mazda 626 MX-6, Workshop Manual

The Workshop Manual for the Mazda 626 MX-6 is an essential resource for all vehicle enthusiasts. With step-by-step instructions and detailed diagrams, this comprehensive manual allows you to effortlessly maintain, repair, and service your vehicle. Download it for free from manualshive.com and enhance your automotive skills today.

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TROUBLESHOOTING  GUIDE 

4A

The Troubleshooting Guide lists the systems most likely to cause a given symptom.  After finding sys­

tems  to  check,  refer to  the  pages  shown  for  detailed  guides for  each  system.

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4A—45

4A—56

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4A—68

4 A -8 3

4A—81

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86U04A-009

The numbers of the list shown the priorities of inspections from the most possible to that with the lowest 

possibility.

These  were  determined  on  the  following  basis:

•  Ease  of  inspection 

•  Most  possible  system 

•  Most  possible  point  in  system

4 A -9

Summary of Contents for 626 MX-6

Page 1: ...Mazda 626 MX 6 1988 Workshop Manu ...

Page 2: ...l including photocopying and recording and the use of any kind of information storage and retrieval system without permission in writing WARRANTY The manufacturer s warranty on Mazda vehicles and engines can be voilded if improper service or repairs are performed by persons ther than those at an Authorized Mazda Dealer Mazda M otor Corportation HIROSHIMA JAPAN APPLICATION This manual is applicable...

Page 3: ...SPECTION AND SCHEDULED MAINTENANCE SERVICES PRE DELIVERY INSPECTION 0 2 PRE DELIVERY INSPECTION TABLE 0 2 SCHEDULED MAINTENANCE SERVICES 0 3 MAINTENANCE TABLE SCHEDULE 1 0 3 MAINTENANCE TABLE SCHEDULE 2 0 7 86U00X 001 ...

Page 4: ...h and steering lock Inhibitor switch ATX only All lights including warning and indicator lights Sound warning system Headlight cleaner if equipped Horn wipers and washers front and rear if equipped Radio and antenna if equipped Cigarette lighter and clock Remote control outside rear view mirrors if equipped Power windows if equipped Heater defroster and air conditioner at various mode selection if...

Page 5: ... NORMAL DRIVING CONDITION Chart symbols I Inspect and if necessary correct clean or replace R Replace or change T Tighten L Lubricate 2 Z H m z z o m H 09 T m w o x m o c i m O O X m a c r m a Remarks After 60 months or 60 000 miles 96 000km continue to follow the described maintenance items and intervals periodically As for marked items in this maintenance chart please pay attention to the follow...

Page 6: ...R 3 4 Drive belts I 1 Cracks or damage Tension 1 6 Fuel filter 1 R 4A 62 4B 78 Fuel lines I 2 1 Fittings connections and compo nents for leaks 4A 43 4B 57 Brake lines hoses and connection I I 1 1 Proper attachment and connections 11 7 Engine timing belt 1 Replace every 60 000 miles 96 000 km 1 10 Enginfe oil Non turbo R R R R R R R R Oil pan capacity 3 9 liters 4 1 US qt 3 4 Imp qt 2 4 Turbo Repla...

Page 7: ...steering vehicle only I I Damage looseness and grease leakage 13 33 4 wheel steering system operation and linkage I I Operation and looseness Fluid leakage or oozing 10 10 10 13 Steering angle of rear wheels 4 wheel steering vehicle only I I Steering wheel angle Inner 5 00 45 Outer 5 00 45 13 50 Solenoid valve oil filter for 4 wheel steering system R R 10 38 Exhaust system heat shield I I Clearanc...

Page 8: ...on to the following points 1 Replacement of the timing belt is required at every 60 000 miles 96 000km Failure to replace the timing belt may result in damage to the engine 2 This maintenance operation is recommended by Mazda However this maintenance is not necessary for emission warranty coverage or manufacturer recall liability 3 This maintenance operation is required for Canada and all states e...

Page 9: ...R 4A 62 4B 78 Fuel lines I 2 I Fitting connections and compo nents for leaks 4A 43 4B 57 Brake lines hoses and connections I I I I Proper attachment and connections 11 7 Engine timing belt 1 Replace every 60 000 miles 96 000km 1 10 Engine oil Non turbo R R R R R R R R R R R R Oil pan capacity 3 9 liters 4 1 US qt 3 4 Imp qt 2 4 Turbo Replace every 3 000 miles 5 000km or 3 months Oil filter Non tur...

Page 10: ...l steering vehicle only I I Damage looseness and grease leakage 13 33 4 wheel steering system operation and linkage I I Operation and looseness Fluid leakage or oozing 10 10 10 13 Steering angle of rear wheels 4 wheel steering vehicle only I I Steering wheel angle Inner 5 00 45 Outer 5 00 45 13 50 Solenoid valve oil filter for 4 wheels steering system R R 10 38 Exhaust system heat shield I I Clear...

Page 11: ...ANCE 1 10 TIMING BELT 1 10 CYLINDER HEAD 1 16 VALVE SEAL 1 22 REMOVAL 1 28 DISASSEMBLY 1 32 AUXILIARY PARTS 1 32 TIMING BELT 1 34 CYLINDER HEAD 1 36 CYLINDER BLOCK 1 3 8 INSPECTION AND REPAIR 1 42 ASSEMBLY 1 56 CYLINDER BLOCK 1 56 CYLINDER HEAD 1 67 TIMING BELT 1 72 AUXILIARY PARTS 1 76 INSTALLATION 1 81 TRANSAXLE ASSEMBLY 1 81 ENGINE INSTALLATION 1 82 86U01X 001 0 ...

Page 12: ...1 OUTLINE OUTLINE STRUCTURAL VIEW 4BG01A 002 1 2 ...

Page 13: ... order 1 3 4 2 86U01X 002 S TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Difficult starting Malfunction of engine related components Burned valve Worn piston piston ring or cylinder Failed cylinder head gasket Replace Replace or repair Replace 1 43 1 50 51 1 16 Malfunction of fuel system Refer to Section 4 Malfunction of electrical system Refer to Section 5 Poor idling Malfunction of e...

Page 14: ...rts Excessive main bearing oil clearance Main bearing seized or heat damaged Excessive crankshaft end play Excessive connecting rod bearing oil clearance Connecting rod bearing seized or heat damaged Replace or repair Replace Replace or repair Replace or repair Replace 1 58 1 58 1 60 1 61 1 61 Piston related parts Worn cylinder Worn piston or piston pin Seized piston Damaged piston ring Bent conne...

Page 15: ...cedures described in Section 5 4 Check the tightness of the terminals to ensure good electrical connections Clean the terminals and coat them with grease 5 Inspect for corroded or frayed battery cables 6 Check the rubber protector on the positive termi nal for proper coverage Air Cleaner Element Visually check the air cleaner element for excessive dirt damage or oil Replace if necessary Caution Do...

Page 16: ... mm 0 24 0 31 in Used 7 9 mm 0 27 0 35 in If necessary loosen the alternator bolts and ad just the belt deflection by turning the adjust bolt Tightening torque A 31 46 Nm 3 2 4 7 m kg 23 34 ft lb 37 52 Nm 3 8 5 3 m kg 27 38 ft lb 2 P S oil pump belt deflection New 8 10 mm 0 31 0 39 in Used 9 11 mm 0 35 0 43 in If necessary loosen the lock bolt and adjust the belt deflection by turning the adjust b...

Page 17: ...rbon deposits 2 Burnt or corroded terminals 3 Worn distributor center contact High Tension Lead Check the following necessary 1 Damaged lead 2 Carbon deposits points Clean or replace if Hydraulic Lash Adjuster HLA Note Tappet noise may occur if the engine is not operated for an extended period of time The noise should stop after the engine has reached normal operating temperature 1 Check for tappe...

Page 18: ...plug the hose Non turbo 6 Check that the ignition timing mark yellow on the crankshaft pulley and the timing mark on the tim ing belt cover are aligned Ignition timing Turbo 9 1 BTDC Non Turbo 6 1 BTDC 7 If necessary adjust the ignition timing by turning the distributor 86U01X 210 Idle Speed 1 Ground the test connector to the vehicle with a jum per wire 2 Connect a tachometer to the engine 3 Check...

Page 19: ...mal operating tem perature 3 Turn it off for about 10 minutes to allow the exhaust manifold to cool 4 Remove all spark plugs 5 Disconnect the primary wire connector from the ignition coil 6 Connect a compression gauge to No 1 spark plug hole 7 Fully depress the accelerator pedal and crank the engine 8 Note the maximum gauge reading 9 Check each cylinder Compression pressure kpa tg cm Standard Mini...

Page 20: ...sequence shown in the figure for the specially marked parts referring to removal note 1 High tension lead and spark plug 2 Engine side cover 3 Drive belt 4 Crankshaft pulley 5 Upper timing belt cover t 1 1 0 taSa _ ___ _ _____ 6 Lower timing belt cover 7 Baffle plate 8 Timing belt tensioner 9 Timing belt tensioner spring 10 Timing belt ...

Page 21: ...he tensioner 86U01X 211 Timing belt Mark the timing belt rotation for proper reinstallation if it is reused Caution Be careful not to allow oil grease or water on the belt 86U01X 024 Inspection and Repair Inspect the following parts Refer to page 1 54 55 1 Timing belt 2 Timing belt tensioner and spring 3 Timing belt idler pulley 4 Timing belt pulley 5 Camshaft pulley 86U01X 025 1 11 ...

Page 22: ...stallation Install in the reverse order of removal referring to installation note Torque Specifications 86U01X 026 Installation note Timing belt 1 Check that the mark on the timing belt pulley is aligned with the mating mark 86U01X 220 1 1 2 ...

Page 23: ...re is no looseness at the water pump pulley and idler pulley side Caution a If the timing belt is being reused it must be reinstalled to rotate in the original direction b Check that there is no oil greas6 or dirt on the timing belt 5 Loosen the tensioner lock bolt 6 Turn the crankshaft twice in the direction of rota tion and align the mating marks 7 Check that the timing marks are correctly align...

Page 24: ...ction is not correct repeat the adjustment from step 5 above Timing belt deflection 7 5 8 5 mm 0 30 0 33 in 98 N 10 kg 22 lb Caution Be sure not to apply tension other than that of the tensioner spring Baffle plate Install the baffle plate as shown in the figure Drive belt Install each drive belt and check the belt deflection Refer to page 1 6 86U01X 028 69G01B 029 N kg 22 lb 69G01B 030 1 14 ...

Page 25: ...ply anti seize compound or molybdenum based lubricant to the spark plug threads 2 Install the spark plugs Tightening torque 15 23 Nm 1 5 2 3 m kg 11 17 ft lb Steps After Installation Perform the necessary engine adjustment Refer to TUNE UP PROCEDURE 1 15 ...

Page 26: ... 5 Upper radiator hose 14 6 Water bypass hose 15 7 Heater hose 16 8 Oil cooler hose turbo 17 9 Brake vacuum hose 18 10 Three way solenoid as sembly EGR solenoid assembly Engine harness connector and ground Vacuum chamber Exhaust manifold insulator EGR pipe Turbocharger oil pipe Exhaust pipe Exhaust manifold and tur bocharger 86U01X 031 19 Intake manifold bracket 20 Intake manifold assembly 21 Dist...

Page 27: ...d fuel leakage Timing belt 1 Before removing the timing belt turn the crankshaft to align the f1 mark of the camshaft pulley with the front housing timing mark 69G01B 035 2 Loosen the timing belt tensioner lock bolt 3 Shift the tensioner outward as far as possible then temporarily tighten it 69G01B 036 4 Remove the timing belt and secure it out of the way to prevent damage during removal and insta...

Page 28: ...nder head bolt Loosen the cylinder head bolts in two or three steps and in the order shown in the figure Disassembly of Cylinder Head Refer to page 1 36 Inspection of Cylinder Head Refer to page 1 42 Assembly of Cylinder Head Refer to page 1 67 86U01X 033 ...

Page 29: ...moval referring to the installation note Note a Position the hose clamp in the original location on the hose b Squeeze the clamp lightly with large pliers to ensure a good fit Torque Specifications 1 6 2 4 m kg 12 17 ft lb 2 2 2 8 m kg 1 6 20 ft lb 626 MX 6 Revised 10 87 86U01X 034 1 1 9 ...

Page 30: ...the cylinder head bolts in two or three steps in the order shown in the figure Tightening torque 80 86 Nm 8 2 8 8 m kg 59 64 ft lb Cylinder head cover 1 Apply silicon sealant to the shaded area shown in the figure 2 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb 86U01X 037 Timing belt 1 Align the f 1 mark of the camshaft pulley with the front housing timing mark 2...

Page 31: ...1 Knock sensor turbo 2 EGR position sensor turbo 3 Water thermo switch 4 Injector 5 Engine ground 6 Oxygen sensor 7 Crank angle sen sor turbo 8 Solenoid valve idle speed control 9 Idle switch 10 Throttle sensor 11 Water thermo sensor 12 Waste gate sole noid valve turbo 13 Heat gauge unit 14 Water thermo switch 86U01X 040 Steps After Installation 1 Fill the radiator with the specified amount and ty...

Page 32: ...referring to removal note 86U01X 042 86U01X 043 1 High tension lead and spark plug 2 Upper timing belt cover 3 Timing belt tensioner spring 4 Timing belt 5 Cylinder head cover 6 Camshaft pulley 7 Front housing 8 Distributor 9 Rear housing 10 Rocker arm and shaft assembly 11 Camshaft cap 12 Camshaft 13 Valve keeper 14 Upper valve spring seat 15 Valve spring 16 Lower valve spring seat 17 Valve seal ...

Page 33: ...m shafts onto the cylinder head 3 Plug the oil drain hole with a rag to prevent the pos sibility of the valve keepers from falling into the oil pan 86U01X 045 4 Turn the crankshaft to position the piston of the valve seal to be replaced at top dead center 5 Remove the valve keepers with the SST 6 Remove the valve spring and spring seats 7 Remove the valve seal from the valve guide with the SST Cau...

Page 34: ...referring to installation note Torque Specifications 19 25 N m 1 9 2 6 m kg 14 19 ft lb 15 23 N m 1 5 2 3 m kg 11 17 ft lb 7 1 0 Nm 70 100 cm kg 61 87 in lb 86U01X 048 Installation note Valve seal 1 Apply engine oil to the inside of the new valve seal 2 Push it on gently with the SST 1 2 4 ...

Page 35: ...irm that the keepers are all fully seated Rocker arm and shaft assembly 1 Remove the rocker arm shafts and camshaft caps 2 Assemble the rocker arms and springs to the shaft Note a The intake side shaft has twice as many oil holes as the exhaust side shaft b The stepped ends are the rear sides of both intake and exhaust shafts 69G01B 059 3 Apply sealant to the shaded areas as shown in the figure 4 ...

Page 36: ...sing 1 Replace the oil seal in the front housing 2 Apply engine oil to the oil seal lip 3 Install the front housing along with a new gasket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Rear housing Install the rear housing along with a new gasket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Camshaft pulley 1 Install the camshaft pulley so that the f 1 mark is aligned with the camshaf...

Page 37: ... in the figure 4 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb Distributor 1 Apply engine oil to the O ring and position it on the distributor 2 Apply engine oil to the blade 3 Install the distributor into the rear housing 4 Loosely tighten the distributor mounting bolt 86U01X 039 Steps After Installation 1 Fill the radiator with the specified amount and type of ...

Page 38: ...se the fuel pressure Refer to Section 4 1 Disconnect the negative battery cable 2 Drain the engine oil and coolant 3 Remove in the sequence shown in the figure for the specially marked parts referring to removal note TURBO 86U01X 056 ...

Page 39: ... EGI harness 15 Engine harness 16 Brake vacuum hose 17 Three way solenoid as sembly 18 EGR solenoid assembly turbo 19 Canister hose 20 Heater hose 21 Transaxle harness 22 Speedometer cable 23 Clutch release cylinder MTX 24 Control cable ATX 25 Drive belt 26 A C compressor and bracket 27 P S oil pump 28 Engine side cover 29 Front wheel 30 Tie rod end 31 Stabilizer control rod 32 Lower arm bushing 3...

Page 40: ...to avoid fuel leakage Turbocharger Remove the turbocharger hoses and pipe them cov er the turbocharger wirth a clean rag 86U01X 058 Clutch release cylinder MTX Remove the clutch release cylinder with the pipe still connected then avoid the cylinder 86U01X 059 P S pump A C compressor Remove the P S pump and A C compressor with the hoses still connected to them secure the pump and compressor as show...

Page 41: ...move the driveshafts Refer to Section 9 Slide the SST into the transaxle 86U01X 060 Transaxle Separate the transaxle from the engine 86U01X 213 V MTX Turbo MTX Non Turbo ATX 49 H027 003 49 G030 455 626 MX 6 Revised 10 87 1 3 1 ...

Page 42: ...ns piston rings connecting rods and valve springs so that they can be reinstalled in the cylinder from which they were removed 3 Clean the parts with steam blow off any remaining water with compressed air Note Care should be taken during the disassembly of any part or system to study its order of assembly Any deformation wear or damage should also be noted AUXILIARY PARTS 1 3 2 86U01X 061 ...

Page 43: ...e 9 Engine hanger 10 Alternator 11 Alternator strap and bracket 12 Engine mount bracket 13 Distributor and high tension lead 14 Spark plug 15 Thermostat and thermostat cover 16 Intake manifold bracket 17 Intake manifold assembly 18 Oil filter 19 Oil cooler turbo 20 Oil pressure switch 21 Knock sensor turbo 86U01X 062 Disassembly note Engine hanger Remove the exhaust manifold then connect the SST t...

Page 44: ...MING BELT 69G01B 072 1 Crankshaft pulley 6 Tinning belt idler pulley 2 Upper timing belt cover 7 Timing belt 3 Lower timing belt cover 8 Camshaft pulley 4 Baffle plate 9 Timing belt pulley 5 Timing belt tensioner and spring 1 3 4 ...

Page 45: ...lt 1 Loosen the tensioner lock bolt and remove the ten sioner spring after 2 Mark the timing belt rotation for proper reinstalla tion if it is reused 3 Remove the timing belt Caution Be careful not to allow oil or grease on the belt Camshaft pulley Remove the pulley lock nut using a screw driver to prevent the camshaft from turning 1 35 69G01B 074 ...

Page 46: ...r head cover 8 Cylinder head 2 Front housing 9 Cylinder head gasket 3 Rear housing 10 Valve keeper 4 Rocker arm and shaft assembly 11 Upper spring seat 5 Camshaft cap 12 Valve spring 6 Camshaft 13 Lower spring seat 7 Cylinder head bolt 14 Valve 15 Valve seal 1 3 6 ...

Page 47: ... shaft assembly 1 Loosen the bolts in two or three steps in the order shown in the figure 2 Remove the rocker arm and shaft assembly togeth er with the bolts Caution a Do not mixup the various parts of the rock er arm and shaft assembly b Do not remove the HLA unless necessary Cylinder head bolt Loosen the cylinder head bolts in two or three steps in the order shown in the figure Valve Remove the ...

Page 48: ...INDER BLOCK I 1 Clutch cover MTX Backing plate ATX 2 Clutch disc MTX Drive plate ATX 3 Flywheel MTX Adaptor ATX 4 End plate 5 Oil pan 6 Oil strainer 7 Stiffener 8 Rear cover 9 Water pump assembly 10 Oil pump assembly 86U01X 070 1 3 8 ...

Page 49: ...e plate ATX Remove the clutch cover and flywheel MTX or drive plate ATX with the SST Oil pan 1 Remove the oil pan mounting bolts 2 Insert a scraper or a suitable tool between the oil pan and the stiffener to separate them Caution Do not bend the oil pan when prying loose 3 Remove the oil pan ...

Page 50: ... 5 Main bearing cap 6 Crankshaft 7 Pilot bearing MTX 8 Main bearing 9 Cylinder block Disassembly note Connecting rod and cap Before removing the connecting rod clean the bear ing connecting rod and crank pin and measure the following 1 Connecting rod side clearance Refer to page 1 61 2 Crank pin oil clearance Refer to page 1 61 86U01X 074 1 4 0 ...

Page 51: ...ove the pilot bearing from the crankshaft with the SST 86U01X 076 Piston and connecting rod 1 Before disassembling the piston and connecting rod check the oscillation torque as shown in the figure If the large end does not drop by its own weight replace the piston or the piston pin 79G01C 050 2 Remove the piston pin with the SST While removing the piston pin check the pressure If it is lower than ...

Page 52: ...linder head distortion in the six directions shown in the figure Distortion 0 15 mm 0 006 in max 3 If the cylinder head distortion exceeds specificati on grind the cylinder head surface If the cylinder head height is not within specifica tion replace it Height 91 95 92 05 mm 3 620 3 624 in Grinding limit 0 20 mm 0 008 in max Note Before grinding the cylinder head first check the following Replace ...

Page 53: ...78 3 Measure the valve length Length IN 115 81 mm 4 5594 in EX 116 21 mm 4 5752 in 4 Measure the valve stem diameter Diameter IN 6 970 6 985 mm 0 2744 0 2750 in EX 6 965 6 980 mm 0 2742 0 2748 in 86U01X 079 5 Measure the valve guide inner diameter Inner diameter IN 7 01 7 03 mm 0 2760 0 2768 in EX 7 01 7 03 mm 0 2760 0 2768 in 86U01X 080 6 Measure the valve stem to guide clearance 1 Method No 1 Su...

Page 54: ...mm 0 0079 in 7 If the clearance exceeds the maximum replace the valve and or valve guide 8 Check that the valve guide protrusion height dimension A in the figure is as specified Replace if necessary Replacement of valve guide Note Although the shapes of the intake and exhaust valve guides are different use the exhaust valve guide on both sides as a replacement Removal 1 Gradually heat the cylinder...

Page 55: ...ed 86U01X 085 Valve Seat 1 Inspect the contact surface of the valve seat and valve face for the following 1 Roughness 2 Damage 2 If necessary resurface the valve seat with a 45 valve seat cutter and or resurface the valve face 3 Apply a thin coat of prussian blue to the valve face 4 Check the valve seating by rotating the valve against the seat 1 If blue does not appear 360 around the valve face r...

Page 56: ...X 088 8 Check the sinking of the valve seat Measure protruding length dimension L of each valve stem Dimension L 50 2 mm 1 976 in 1 If L is as below it can be used as it is 50 2 51 0 mm 1 976 2 008 in 2 If L is as below insert a spacer between the spring seat and cylinder head to adjust 51 0 51 7 mm 2 008 2 035 in 3 If L is more than as below replace the cylin der head 51 7 mm or more Valve Spring...

Page 57: ... cam lobe height at the two points as shown in the figure Height IN 41 29 41 39 mm 1 626 1 630 in EX 41 80 41 90 mm 1 646 1 650 in Minimum IN 41 14 mm 1 620 in EX 41 65 mm 1 640 in 4 Measure wear of the journals in X and Y directions at the two points as shown in the figure Diameter Front and rear 31 940 31 965 mm 1 2575 1 2585 in Center three journals 31 910 31 935 mm 1 2563 1 2573 in Out of roun...

Page 58: ...ance Front and rear 0 035 0 085 mm 0 0014 0 0033 in Center three journals 0 065 0 115 mm 0 0026 0 0045 in Maximum 0 15 mm 0 0059 in 6 If the oil clearance exceeds the maximum re place the cylinder head 6 Measure the camshaft end play If it exceeds the maximum replace the camshaft and or the cylin der head End play 0 08 0 16 mm 0 003 0 006 in Maximum 0 20 mm 0 008 in Rocker Arm and Rocker Arm Shaft...

Page 59: ... damage Replace if necessary Caution Do not remove the HLA unless necessary to prevent damaging the O ring Cylinder Block 1 Check the cylinder block Repair or replace if necessary 1 Leakage damage 2 Cracks 3 Scoring of wall 2 Measure the distortion of the top surface of the cyl inder block in the six directions as shown in the figure Distortion 0 15 mm 0 006 in max 3 If the distortion exceeds the ...

Page 60: ... 519 3 4055 3 4063 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 2 If the difference between the measurement X and Y exceeds the maximum out of round re bore the cylinder to oversize Out of round 0 019 mm 0 0007 in max Caution The boring size should be based on the size of an oversize piston and be the sam...

Page 61: ...m 0 0014 0 0030 in Maximum 0 15 mm 0 0059 in 4 Ifthe clearance exceeds the maximum replace the piston or rebore the cylinders to fit oversize pistons Note If the piston is replaced replace the piston rings also Piston and Piston Ring 1 Measure the piston ring to ring land clearance around the entire circumference using a new pis ton ring Clearance Top and Second 0 03 0 07 mm 0 001 0 003 in Maximum...

Page 62: ...ions at four points Diameter 21 988 21 998 mm 0 8657 0 8661 in 2 Measure the piston pin diameter Diameter 21 974 21 980 mm 0 8651 0 8654 in 3 Determine the piston pin to piston clearance by subtracting the two figures Clearance 0 008 0 024 mm 0 0003 0 0009 in 4 If the clearance exceeds the specification replace the piston and or piston pin Connecting Rod 1 Measure the connecting rod small end bore...

Page 63: ... 937 59 955 mm 2 3597 2 3604 in Minimum 59 89 mm 2 358 in Out of round 0 05 mm 0 0020 in max Crank pin journal Diameter 50 940 50 955 mm 2 0055 2 0061 in Minimum 50 89 mm 2 004 in Out of round 0 05 mm 0 0020 in max 5 If the diameter is less than the minimum grind the journals to match undersize bearings Undersize bearing 0 25 mm 0 010 in 0 50 mm 0 020 in 0 75 mm 0 030 Main journal diameter undersi...

Page 64: ...Main Bearing and Connecting Rod Bearing Check the main bearings and the connecting rod bearings for peeling scoring or other damage 79G01C 077 Timing Belt 1 Replace the timing belt if there is any oil or grease on it 2 Check the timing belt for damage wear peeling cracks or hardening Replace if necessary Caution a Never forcefully twist turn inside out or bend the timing belt b Be careful not to a...

Page 65: ...and avoid scratching it Timing Belt Tensioner Spring Check the free length of the tensioner spring Replace if necessary Free length 61 1 mm 2 406 in 86U01X 116 Timing Belt Pulley and Camshaft Pulley Inspect the pulley teeth for wear deformation or other damage Replace if necessary Caution Do not clean the pulley with cleaning fluids If necessary use a rag to wipe it clean Timing Belt Cover lower a...

Page 66: ...ation 2 Apply new engine oil to all sliding and rotating parts 3 Replace plain bearings if they are peeling burned or otherwise damaged 4 Tighten all bolts and nuts to the specified torques Caution Do not reuse gaskets or oil seals CYLINDER BLOCK I Torque Specifications ...

Page 67: ...serting the piston pin check the pressure force If it is less than specified replace the piston pin or the connecting rod Press force 5 15 kN 500 1 500 kg 1 100 3 300 lb 7 Check the oscillation torque of the connecting rod Refer to page 1 41 86U01X 120 Piston Ring 1 Install the three piece oil rings on the pistons 1 Apply engine oil to the oil ring spacer and rails 2 Install the oil ring spacer so...

Page 68: ...e second ring to the piston first then in stall the top ring Use a piston ring expander Caution The rings must be installed with the R marks facing upward 4 Apply a liberal amount of clean engine oil to the second and top piston rings 86U01X 121 Crankshaft 1 Before installing the crankshaft inspect the main bearing oil clearances as described Note The bearing with thrust shoulders is the cen ter b...

Page 69: ...ue 82 88 Nm 8 4 9 0 m kg 61 65 ft lb Caution Do not rotate the crankshaft when measuring the oil clearances 7 Remove the main bearing caps and measure the plasti gauge at each journal at the widest point for the smallest clearance and at the nar rowest point for the largest clearance Ifthe oil clearance exceeds specification grind the crankshaft and use undersize main bear ings Refer to page 1 53 ...

Page 70: ...0 28 25 mm 1 1102 1 1122 in Note Wider thrust width is available only in under size center main bearing Pilot Bearing MTX 1 Apply engine oil to the outer circumference of the bearing 2 Set a piece of pipe outer diameter 30 34 mm 1 18 1 34 in against the outer race of the bear ing then tap it evenly into the crankshaft 3 Lubricate the bearing with grease Piston and Connecting Rod Assembly 1 Apply a...

Page 71: ...lling the con necting rod cap 2 If the oil clearance exceeds the maximum grind the crankshaft and use undersize bearings Re fer to page 1 54 3 Check the side clearance of each connecting rod without the cap installed Side clearance 0 110 0 262 mm 0 004 0 0103 in Maximum 0 30 mm 0 012 in Ifthe clearance exceeds the maximum replace the connecting rod 4 Apply a liberal amount of engine oil to the cra...

Page 72: ...DER BLOCK CYLINDER BLOCK II Torque Specifications 69G01A 166 Rear Cover 1 Apply engine oil to the rear cover oil seal and oil seal lip 2 Press the oil seal into the rear cover 70 120 cm kg 61 104 in lb 1 6 2 4BG01A 158 ...

Page 73: ...sket that projects out from the rear cover assembly toward the oil pan side Caution Do not scratch the rear cover assembly 86U01X 132 End Plate Install the end plate Tightening torque 19 30 Nm 1 9 3 1 m kg 14 22 ft lb 4BG01A 160 Oil Pump 1 Apply engine oil to a new oil pump oil seal and the oil pump body 2 Press the oil seal into the oil pump body 79G01C 085 1 63 ...

Page 74: ...ump Tightening torque Bolt A 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Bolt B 37 52 Nm 3 8 5 3 m kg 27 38 ft lb 8 Remove any sealant which has been squeezed out Stiffener 1 Remove any dirt or other material from the con tact surface 2 Apply a continuous bead of silicone sealant to the stiffener along the inside of the bolt holes and over lap the ends 3 Install the stiffener Tightening torque 8 11 Nm 80 11...

Page 75: ...b Flywheel MTX Drive Plate ATX 1 Remove any old sealant from the bolts and bolt holes If old sealant can not removed from the bolt replace it 2 Apply sealant to the bolt threads MTX 3 Install and tighten the flywheel with the SST Tightening torque 96 103 Nm 9 8 10 5 m kg 71 76 ft lb ATX 3 Install and tighten the drive plate adapter drive plate and backing plate with the SST Tightening torque 96 10...

Page 76: ...Tightening torque 22 32 Nm 2 2 3 3 m kg 16 24 ft lb 86U01X 141 Water Pump 1 Remove all dirt grease and other material from the water pump mounting surface 2 Place a new O ring in position Caution Do not reuse the original O ring 3 Install the water pump Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb O 86U01X 142 7BU01B 103 1 66 ...

Page 77: ... cm kg 52 69 In lb 19 25 N m 1 9 2 6 m kg 14 19 ft lb 18 26 N m 80 86 N m 8 2 8 8 m kg 59 64 ft lb 19 25 N m 1 9 2 6 m kg 14 19 ft lb 69G01B 152 Valve Seal 1 Apply engine oil to the inside of the new valve seal 2 Install the valve seal onto the valve guide with the SST 1 6 7 ...

Page 78: ...ve stem lightly two or three times with a plastic hammer to confirm that the keepers are all fully seated Cylinder Head 1 Thoroughly remove all dirt oil or other material from the top of the cylinder block 2 Place the new cylinder head gasket in position 86U01X 146 3 Install the cylinder head 4 Apply engine oil to the bolt threads and seat faces 5 Tighten the cylinder head bolts in two or three st...

Page 79: ... arm 2 Apply engine oil to the new HLA 3 Carefully install the HLA into the rocker arm Caution Be careful not to damage the O ring when in stalling the HLA Camshaft Cap Rocker Arm and Shaft Assembly 1 Assemble the rocker arm and shaft assembly as shown in the figure Note a The intake side shaft has twice as many oil holes as the exhaust side shaft b The stepped ends are the rear of the shafts 2 Ap...

Page 80: ... stalled correctly 5 Install the rocker arm and shaft assemblies Tight en the bolts in two or three steps in the order shown in the figure Tightening torque 18 26 Nm 1 8 2 7 m kg 13 20 ft lb Caution Be careful that the rocker arms or spacers do not get caught between the shaft and cam shaft cap 86U01X 154 Front Housing 1 Apply engine oil to the front housing and a new oil seal 2 Press the oil seal...

Page 81: ...nd a new gasket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Cylinder head cover and gasket 1 Clean out used silicon sealantfrom the gasket and gasket groove 2 Apply new silicon sealant to the back of tie gasket 3 Apply silicon sealant to the shaded areas shown in the figure 4 Install the cylinder head cover Tightening torque 6 8 Nm 60 80 cm kg 52 69 in lb 86U01X 158 86U01X 157 Revised 5 91...

Page 82: ...1 ASSEMBLY TIMING BELT TIMING BELT Torque Specifications v 69G01B 160 1 25 1 75 m kg 109 152 in lb 1 72 ...

Page 83: ...t lb 3 Align the f1 mark on the pulley with the align ment mark on the front housing 86U01X 159 Timing Belt Pulley 1 Reverse the direction of the SST ring gear brake 2 Install the crankshaft key 3 Install the timing belt pulley on the crankshaft Tightening torque 157 167 Nm 16 0 17 0 m kg 116 123 ft lb 4 Release the ring gear brake 5 Align the timing belt pulley and the pump body alignment marks M...

Page 84: ... water pump pulley and idler pulley side Caution a If the timing belt is being reused it must be reinstalled to rotate in the original direction b Check that there is no oil grease or dirt on the timing belt 2 Loosen the tensioner lock bolt 3 Turn the crankshaft twice in the direction of rotation 4 Check that the mating marks are correctly aligned If not aligned remove the timing belt and tension ...

Page 85: ...the tensioner spring if necessary Belt deflection 7 5 8 5 mm 0 30 0 33 In 98 N 10 kg 22 lb Baffle Plate Position the baffle plate on the timing belt pulley Timing Belt Cover Install the lower timing belt cover upper timing belt cover and new gaskets Tightening torque 7 10 Nm 70 100 cm kg 61 87 in lb Crankshaft Pulley Install the crankshaft pulley Tightening torque 12 17 Nm 1 25 1 75 m kg 109 152 i...

Page 86: ...lb N m 3 8 5 3 m kg 27 38 ft lb 22 28 N m 2 2 2 9 m kg 16 21 ft lb 31 41 Nm 3 2 4 2 m kg 23 30 ft lb 19 30 N m 1 9 3 1 m kg 14 22 ft lb N m 3 5 4 5 m kg 25 33 ft lb 19 30 N m 1 9 3 1 m kg 14 22 ft lb 37 52 N m 3 8 5 3 m kg 27 38 ft lb 22 27 N m 2 2 2 8 m kg 16 20 19 25 N m 1 9 2 6 m kg 14 19 37 63 N m 3 8 6 4 m kg 27 46 ft 22 29 ft lb 14 25 ft lb N m 3 0 4 0 m kg 20 34 N m m kg 1 76 626 MX 6 Revis...

Page 87: ...ue 29 39 Nm 3 0 4 0 m kg 22 29 ft lb Oil Filter 1 Apply engine oil to the rubber gasket of the new filter 2 Install the oil filter and tighten it by hand only Do not use a wrench Intake Manifold Assembly 1 Place the new gasket in position 2 Install the intake manifold assembly 3 Tighten the nuts in two or three steps Tightening torque 19 30 Nm 1 9 3 1 m kg 14 22 ft lb Intake Manifold Bracket Insta...

Page 88: ...nti seize compound or molybdenum based lubricant to the spark plug threads 2 Install the spark plugs Tightening torque 15 23 Nm 1 5 2 3 m kg 11 17 ft lb Distributor 1 Apply engine oil to the O ring and position it on the distributor 2 Apply engine oil to the blade 3 Install the distributor into the rear housing 4 Loosely tighten the distributor mounting bolt High Tension Lead Install the high tens...

Page 89: ...86U01X 172 86U01X 173 Coolant Inlet Pipe and Bypass Pipe 1 Install the coolant inlet pipe Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb 2 Apply vegetable oil to the O ring 3 Install the coolant bypass pipe Tightening torque 37 63 Nm 3 8 6 4 m kg 27 46 ft lb Non Turbo Engine Hanger Install the front and rear engine hangers Tightening torque 19 30 Nm 1 9 3 1 m kg 14 22 ft lb Turbocharger Brack...

Page 90: ...arger Hose Turbo 1 Install the oil pipe Tightening torque 22 27 Nm 2 2 2 8 m kg 16 20 ft lb B 16 24 Nm 1 6 2 4 m kg 12 17 ft lb 2 Tighten the oil pipe bracket and connect the oil hose and water hoses Tightening torque 19 30 Nm 1 9 3 1 m kg 14 22 ft lb EGR Pipe Install the EGR pipe Tightening torque 34 44 Nm 3 5 4 5 m kg 25 33 ft lb Exhaust Manifold Insulator Install the exhaust manifold insulator ...

Page 91: ... the engine in the sequence shown in the figure referring to installation note 86U01X 179 1 Transaxle 3 Gusset plate 2 Clutch under cover 4 Starter Installation note Clutch under cover Before installation fill the notches with silicon as shown in the figure 86U01X 217 1 81 ...

Page 92: ...TALLATION ENGINE INSTALLATION Install the engine and transaxle assembly Warning Be sure the vehicle is securely supported Torque Specifications_______________________________ TURBO 8 11 N m 86U01X 180 1 8 2 ...

Page 93: ...INSTALLATION 1 NON TURBO 86U01X 218 1 83 ...

Page 94: ... 3 2 4 7 m kg 23 34 ft lb 64 89 N m 6 5 9 1 m kg 47 66 ft lb 2 Tighten the bracket bolt Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Extension Bar MTX Install the extension bar to the transaxle Tightening torque 31 46 N m 3 2 4 7 m kg 23 34 ft lb Change Rod MTX Install the change rod to the transaxle Tightening torque 16 22 Nm 1 6 2 3 m kg 12 17 ft lb 1 84 ...

Page 95: ...ower Arm Install the lower arm ball joint to the knuckle then tight en the lock nut Tightening torque 43 54 Nm 4 4 5 5 m kg 32 40 ft lb Tie Rod End 1 Install the tie rod end to the knuckle Tightening torque 29 44 Nm 3 0 4 5 m kg 22 33 ft lb 2 Install the cotter pin Stabilizer Control Rod Install and adjust the front stabilizer control rods Dimension A 20 1 mm 0 79 in Tightening torque 16 23 Nm 1 6...

Page 96: ... bracket Tightening torque 19 25 Nm 1 9 2 6 m kg 14 19 ft lb 2 Install the A C compressor bracket Tightening torque 37 63 Nm 3 8 6 4 m kg 27 46 ft lb 3 Install the A C compressor 4 Install the A C compressor upper bracket Tightening torque 37 63 Nm 3 8 6 4 m kg 27 46 ft lb 5 Tighten to the lock nut and mounting bolts Tightening torque 37 52 Nm 3 8 5 3 m kg 27 38 ft lb Drive Belt Install the drive ...

Page 97: ...r position Refer to Section 7B Tightening torque A 44 64 Nm 4 5 6 5 m kg 33 47 ft lb 16 23 Nm 1 6 2 3 m kg 12 17 ft lb Speedometer Cable Install the speedometer cable Three Way Solenoid Assembly Install the three way solenoid assembly Tightening torque 8 11 N m 80 110 cm kg 69 95 in lb EGR Solenoid Assembly Turbo Install the EGR solenoid assembly Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb ...

Page 98: ... 3 Connect the ATF hoses ATX 4 Connect the upper and lower radiator hoses Note Position the hose clamp in the original location on the hose Squeeze the clamp lightly with large pliers to en sure a good fit The damper bush on the bracket and the stud on the radiator should be centered as illustrated Altgn the center by moving the radiator and or brackets Heater Hose and Fuel Hose Connect the heater...

Page 99: ...Tightening torque 8 11 N m 80 110 cm kg 69 95 in lb 3 Install the battery tray and battery Tightening torque 5 7 Nm 50 70 cm kg 43 61 in lb Air Cleaner Assembly 1 Install the air cleaner assembly Tightening torque 16 27 Nm 1 6 2 8 m kg 12 20 ft lb 2 Connect the air flow sensor connector air intake pipe and EGR air hose Engine Oil Add the specified amount and type of engine oil Refer to Sec tion D ...

Page 100: ...PECTION 2 4 ENGINE O IL 2 4 OIL PRESSURE 2 4 ENGINE OIL 2 4 REPLACEMENT 2 4 OIL FILTER 2 5 REPLACEMENT 2 5 OIL COOLER 2 5 REMOVAL AND INSTALLATION 2 5 OIL PAN 2 6 REMOVAL 2 6 INSPECTION 2 7 INSTALLATION 2 7 OIL PUMP 2 8 REMOVAL 2 8 DISASSEMBLY 2 9 INSPECTION 2 9 ASSEMBLY 2 10 INSTALLATION 2 10 86U02X 001 ...

Page 101: ...2 OUTLINE OUTLINE LUBRICATION CIRCUIT 86U02X 003 1 Oil pump 2 Pressure regulator valve 3 Main gallery 4 Oil pressure switch 5 Oil cooler only Turbo 6 Oil filter 7 Oil control plug 2 2 ...

Page 102: ...120 Engine oil 5W 30 X 30 5W 20 20W 20 40 10W 30 10W 40 10W 50 20W 40 20W 50 Temperature range anticipated before next oil change C F TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Engine hard starting Improper engine oil Insufficient engine oil Replace Add oil 2 4 2 4 Excessive oil con sumption Oil working up or working down Oil leakage Refer to Section 1 Repair _ Oil pressure drop Insu...

Page 103: ...switch 69G02A 006 2 Screw the SST into the pressure switch installa tion hole 3 Warm up the engine to normal operating tem perature 4 Run the engine at 3 000 rpm and note the gauge reading Standard oil pressure 294 392 kPa 3 0 4 0 kg cm2 43 57 psi 5 If the pressure is not as specified check for the cause and repair if necessary Refer to Troubleshooting Guide ENGINE OIL REPLACEMENT 1 Warm up the en...

Page 104: ...ing surface on the engine 3 Apply a small amount of engine oil to the rubber seal of the new filter 4 Install the oil filter and tighten it by hand only Do not use a wrench 5 Start the engine and inspect around the filter seal for leaks 6 Check the oil level and add oil if necessary Oil filter capacity 0 30 liters 0 32 US qt 0 26 Imp qt OIL COOLER Only Turbo REMOVAL AND INSTALLATION Remove in the ...

Page 105: ...1 1 Exhaust pipe 2 Gusset plate MTX 3 Clutch housing under cover MTX 4 Sub frame RH 5 Oil pan 6 Oil strainer 7 Stiffener Removal note Oil pan 1 Remove the oil pan mounting bolts 2 Insert a scraper or a suitable tool between the oil pan and the stiffener to separate them 3 Remove the oil pan 4 Remove the oil strainer and stiffener from the engine Caution Do not bend the oil pan when prying loose 2 ...

Page 106: ...ide of the bolt holes and over lap the ends 3 Apply a continuous bead of silicon sealant to the oil pan around inside of the bolt holes and over lap the ends Caution Secure the stiffener and oil pan within 30 minutes after applying the sealant 86U02X 015 86U02X 016 4 Install the stiffener then the oil strainer and a new gasket Oil strainer tightening torque 8 12 Nm 80 120 cm kg 69 104 in lb 5 Inst...

Page 107: ...for the specially marked parts referring to removal note 86U02X 017 1 Timing belt Refer to Section 1 2 Oil pan Refer to page 2 6 3 Timing belt pulley lock bolt 86U02X 018 4 Timing belt pulley 5 Oil pump Removal note Timing belt pulley lock bolt Hold the timing belt pulley with the SST and remove the lock bolt 2 8 626 MX 6 Revised 10 87 ...

Page 108: ...il seal 6 Oil pump body 69G02B 013 INSPECTION 1 Check the following and replace any faulty parts 1 Distorted or damaged oil pump body or cover 2 Worn or damaged plunger 3 Weak or broken plunger spring 2 Measure the side clearance Clearance 0 10 mm 0 004 in max 86U02X 020 3 Measure the tooth tip clearance Clearance 0 18 mm 0 007 in max 69G02B 015 2 9 ...

Page 109: ... Install the rotors with the dimples facing the pump cover Oil Pump Cover 1 Apply thread locking compound to the cover mounting screws threads 2 Attach the oil pump cover to the body Tightening torque 6 9 Nm 60 90 cm kg 52 78 in lb 86U02X 023 INSTALLATION Install in the reverse order of removal referring to in stallation note Installation note Oil pump 1 Apply grease to a new O ring and install it...

Page 110: ...EMENT 3 4 RADIATOR CAP 3 5 INSPECTION 3 5 RADIATOR 3 6 REMOVAL AND INSTALLATION 3 6 INSPECTION 3 6 WATER PUMP 3 7 REMOVAL 3 7 INSPECTION 3 8 INSTALLATION 3 8 THERMOSTAT 3 9 REMOVAL 3 9 INSPECTION 3 9 INSTALLATION 3 9 ELECTRIC FAN 3 10 SYSTEM CIRCUIT 3 10 CIRCUIT INSPECTION 3 10 FAN MOTOR 3 11 WATER THERMO SWITCH 3 12 86U03X 001 ...

Page 111: ...3 OUTLINE OUTLINE 1 Water pump 2 Thermostat 3 Radiator 4 Coolant reservoir 5 Oil cooler only Turbo 6 Electric fan 7 No 1 water thermo switch 8 No 2 water thermo switch 86U03X 027 ...

Page 112: ... opening pressure kPa kg cm2 psi 74 103 0 75 1 05 11 15 Turbo MTX 80 Capacity W ATX 160 Non Turbo MTX 80 Electric fan ATX 120 Number of blade 4 MTX 320 12 6 u u ie r diameter or oiaae mm n ATX 340 13 4 86U03X 002 TROUBLESHOOTING GUIDE Problem Possible Cause Remedy Page Overheating Insufficient coolant Coolant leakage Radiator fins clogged Radiator cap malfunction Electric fan malfunction Thermosta...

Page 113: ...iller neck 2 Check that coolant is free from oil 3 Replace the coolant if necessary Coolant Leakage 1 Connect a tester and SST to the radiator inlet port 2 Apply 103 kPa 1 05 kg cm2 15 psi pressure to the system 3 Check that the pressure is held If not check for coolant leakage Warning When removing either the radiator cap or the tester loosen it slowly until the pressure in the radiator is releas...

Page 114: ...6 Run the engine at idle with the radiator cap re moved Let any air bleed from the system and add more coolant 7 Install the radiator cap and inspect all connections for leakage RADIATOR CAP INSPECTION Radiator Cap Valve 1 Remove foreign material such as water residue from between the radiator cap valve and the valve seat 2 Attach the radiator cap to a tester with the SST Apply pressure gradually ...

Page 115: ... the clamp lightly with large pliers to ensure a good fit 86uo3xoio 86U03X 011 5 Upper and lower radiator hose 6 Electrician and radiator assembly 7 Electric fan INSPECTION Check the following points Repair or replace if necessary 1 Cracks damage or water leakage 2 Bent fins Repair with a screwdriver 3 Distorted or bent radiator inlet 1 Coolant reservoir hose 2 ATF hose ATX 3 Water thermo switch c...

Page 116: ...RACKS DAMAGE OR WATER LEAKAGE 2 BENT FINS REPAIR WITH A SCREWDRIVER 3 DISTORTED OR BENT RADIATOR INLET 86U03X 010 O 6UOEX OO8 1 Coolant reservoir hose 5 Racfiator bracket V g ill 2 ATF hose ATX 3 Cooling fan connector liS 4 Upper and tower radiator hose Revised 3 91 1988 626 MX 6 3 7 70 100 cm kg 61 87 in lb CAUTION AFTER COOLING FAN AND OR RADIATOR COWLING INSTALLATION ROTATE THE COOL ING FAN BY ...

Page 117: ...adiator should be centered as illustrated Align the center by moving the radiator and or brackets INSPECTION Check the following points Repair or replace if necessary 1 Cracks damage or water leakage 2 Bent fins Repair with a screwdriver 3 Distorted or bent radiator inlet 3 7 1 1988 626 MX 6 Revised 3 91 ...

Page 118: ...tery cable 2 Turn the crankshaft so that the No 1 cylinder is at TDC of compression 3 Drain the engine coolant 4 Remove in the order shown in the figure 1 Timing belt Refer to Section B 3 Water pump 2 Idler pulley 4 Gasket 3 8 16U0EX 004 O6UOEX OO7 N m m kg ft lb ...

Page 119: ... water and check the following Initial opening temperature 86 5 89 5 C 188 193 F Full open temperature 100 C 212 F Full open lift 8 5 mm 0 34 in min 69G03B 012 INSTALLATION 1 Install the thermostat into the cylinder head with jiggle pin at the top 2 Install a new gasket with the seal print side facing the cylinder head 3 Install the thermostat cover Tightening torque 19 30 Nm 1 9 3 1 m kg 14 22 ft...

Page 120: ...3 ELECTRIC FAN ELECTRIC FAN SYSTEM CIRCUIT 3 10 626 MX 6 Revised 10 87 ...

Page 121: ...nt temp over 108 C 226 F Main Hi Additional Main Additional Main Hi A C switch ON Main Hi Main Main Con denser fan Pressure switch ON Main Hi Additional Main Additional 86U03X 020 FAN MOTOR Removal and Installation 1 Remove in the sequence shown in the figure 2 Install in the reverse order of removal 86U03X 021 1 Cooling fan assembly Refer to page 3 6 3 Fan 2 Cowling 4 Fan motor 626 MX 6 Revised 1...

Page 122: ...fan water thermo switch Note Make sure that the ignition switch is OFF If not the fan will operate when the connector is removed 2 Place the water thermo switch in water 3 Heat the water gradually and check for continui ty of the switch with an ohmmeter Replace if necessary No 1 water thermo switch over 97 C 177 F ON OFF No 2 water thermo switch over 108 C 226 F OFF ON 4 Install the water thermo s...

Page 123: ... REGULATOR CONTROL SYSTEM 4A 54 COMPONENT DESCRIPTIONS 4A 55 TROUBLESHOOTING 4A 56 REPLACEMENT 4A 58 FUEL TANK 4A 63 DECELERATION CONTROL SYSTEM 4A 66 COMPONENT DESCRIPTIONS 4A 67 TROUBLESHOOTING 4A 68 EXHAUST GAS RECIRCULATION EGR SYSTEM 4A 70 COMPONENT DESCRIPTIONS 4A 70 TROUBLESHOOTING 4A 71 EVAPORATIVE EMISSION CONTROL EEC SYSTEM 4A 73 COMPONENT DESCRIPTIONS 4A 73 TROUBLESHOOTING 4A 74 POSITIV...

Page 124: ...lve Fuel pump Intake air thermo sensor 2 m g o 3J 4 o c m Atmospheric pressure sensor Air flow meter Throttle sensor and idle switch Idle switch EGR control valve Water thermo switch Water thermo sensor Oxygen sensor Water thermo Catalytic valve converter Solenoid Orifice Solenoid vajye f g r valve EGR modulator Idle speed valve control E xhaust gas 422 Vacuum 5n mFuel Air sa Other ...

Page 125: ...ector Green 1 p Idle switch Water thermo valve Air flow meter E L control unit Engine control unit EC AT control unit Atmospheric pressure sensor Circuit opening Clutch switch Brake light switch Water thermo switch Water thermo sensor Inhibitor switch Neutral switch 5th gear switch 86U04A 003 4A 3 ...

Page 126: ...lator Injector Delivery pipe Solenoid valve Idle speed control Check connector Green 6 pin for Self Diagnosis checker EGR control_____ valve Solenoid valve EGR Shift indicator light Separator Three way check valve Check and cut valve 86U04A 004 4A 4 ...

Page 127: ...Exhaust System 86U04A 005 4A 5 ...

Page 128: ... C 2 B Black W White L Blue O Orange G Green Br Brown R Red Y Yellow Vacuum delay valve Pressure regulator R Solenoid valve Purge Solenoid valve Pressure regulator Solenoid valve EGR Charcoal canister VACUUM HOSE ROUTING DIAGRAM ...

Page 129: ... tank Output pressure kPa kg cm2 psi 441 588 4 5 6 0 64 85 Feeding capacity cc cu in 10 sec 220 13 4 min Fuel filter Type Low pressure side Nylon element High pressure side Paper element Pressure regulator Type Diaphragm Regulating pressure kPa kg cm2 psi 235 275 2 4 2 8 34 40 Injector Type High ohmic Type of drive Voltage Resistance fi 12 16 Injection amount cc cu in 15 seconds 44 61 2 68 3 72 Id...

Page 130: ...after warming up TROUBLESHOOTING PROCEDURE Note Step 1 under symptom is to quickly determine what system or unit may be at fault by use of the SST Self Diagnosis Checker 49 H018 9A1 1st Check input sensors and output solenoid valves with the SST Refer to page 4A 11 2nd Check other switches with the SST Refer to page 4A 26 3rd Check the following items Poor acceleration hesi tation or lack of power...

Page 131: ...R control valve stuck and open E E C system Vacuum switch valve No 1 purge valve malfunction P C V System System clogged Deceleration System Fuel cut operation malfunction Shift indicator light control system Exhaust system System clogged Page 4A 33 4A 45 4A 56 4A 40 4A 71 4A 74 4A 79 4A 68 4A 83 4A 81 2 2 1 4 3 1 2 3 5 4 2 3 1 5 4 1 3 2 4 6 5 2 3 4 1 E 5 2 1 o a E 6 3 4 1 2 5 7 3 2 1 8 3 4 1 2 9 ...

Page 132: ...y and that the buzzer sounds for three seconds after turn ing the ignition switch ON 6 If 88 does not flash check the main relay Refer to page 4A 87 power supply circuit and check connector wiring 7 If 88 flashes and the buzzer sounds continuously for more than 20 seconds replace the engine con trol unit and perform steps 3 and 4 again 8 Note the code numbers and check for the causes by referring ...

Page 133: ...eck connector 3 Ground the test connector Green 1 pin with a jumper wire Ignition switch ON for six seconds 4 Turn the ignition switch ON but do not start the engine for six seconds 5 Start and warm up the engine then run it at 2 000 rpm for two minutes 6 Verify that no code numbers are displayed 86U04A 016 ...

Page 134: ...s the number of times the buzzer is on 0 4 sec during one cycle ON OFF 1 cycle 1 2 3 Malfunction code cycle break 0 4 0 4 sec sec 4 0 sec Malfunction code 03 86U04A 019 3 First digit of warning code tens position The digit in the tens position of the warning code represents the number of times the buzzer is on 1 2 sec during one cycle It should also be noted that the light goes off for 1 6 sec bet...

Page 135: ...ircuit Maintains constant command of sea level pressure 15 OFF nm Oxygen sensor w i Sensor output con tinues less than 0 55V 120 sec after engine starts 1 500 rpm Cancels EGI feed back operation 17 0N n nil OFF H Feedback system Sensor output not changed 20 sec af ter engine exceeds 1 500 rpm Cancels EGI feed back operation 25 0 T f i i Solenoid valve pres sure regulator Open or short circuit 26 0...

Page 136: ...TROUBLESHOOTING WITH SST 4A If a malfunction code number is shown on the SST check the following chart along with the wiring diagram Code No 01 Ignition pulse PC Possible Cause 86U04A 021 4A 15 ...

Page 137: ...o page 4A 11 YES Are engine control unit terminal voltages OK Check terminal 2B 2C 2E 3 1 Refer to page 4A 91 and 4A 92 Terminal Fully closed Q Fully open fi E2 Vs 20 400 20 1 000 E2 Vc 100 400 E2 Vb 200 400 YES Is there continuity between air flow meter and engine control unit NO NO NO NO Repair or replace connector PC Open circuit in wiring harness from air flow meter to engine control unit Repa...

Page 138: ...re engine control unit 2 1 and 2C terminal voltages OK Refer to page 4A 91 YES YES Water thermo sensor Control unit A YB wire 21 B LgY wire 2C NO Coolant temp Resistance 20 C 4 F 14 5 17 8 kfl 20 C 68 F 2 2 2 7 kfl 40 C 104 F 1 0 1 3 kfl 60 C 140 F 500 640 fl 80 C 176 F 280 350 fl NO NO Repair or replace connector PC Open circuit in wiring harness from water thermo sensor to engine control unit Re...

Page 139: ...ring harness from intake air thermo sensor in air flow meter to engine control unit YES Is resistance of intake air thermo sensor in air flow meter OK Resistance Terminal Resistance E2 THA 20 C 4 F 13 6 18 4 kU 20 C 68 F 2 21 2 69 kfl 60 C 140 F 4 9 3 667 YES Is same Code No present after performing after repair procedure Refer to page 4A 11 YES Are engine control unit 2J and 2C terminal voltages ...

Page 140: ...TROUBLESHOOTING WITH SST 4A Code No 12 Throttle sensor PC Possible cause 86U04A 025 r 4A 19 ...

Page 141: ...ol unit NO 0V NO Other Atmospheric pressure sensor Control unit A LgY wire 2C D Y wire 2H NO NO PC Possible cause Repair or replace connector PC Open or short circuit in wiring harness from LgR wire to engine control unit Engine control unit malfunction If 2A terminal voltage not 4 5 5 5V PC Short circuit in wiring harness from atmospheric pressure sensor Y wire to engine control unit 2H terminal ...

Page 142: ...ING WITH SST 4 A Code No 15 Oxygen sensor PC Possible Cause Note When the Code No 15 and 17 are present at the same time first preform the checking proce dure for the Code No 17 Refer to page 4A 22 86U04A 027 4A 21 ...

Page 143: ... 4A TROUBLESHOOTING WITH SST Code No 17 Feedback system PC Possible Cause 86U04A 028 4A 22 ...

Page 144: ...TROUBLESHOOTING WITH SST 4A Code No 25 Solenoid valve Pressure regulator PC Possible Cause 86U04A 029 Code No 26 Solenoid valve Purge 86U04A 030 4A 23 ...

Page 145: ...4A TROUBLESHOOTING WITH SST Code No 28 Solenoid valve EGR 86U04A 031 Code No 34 Solenoid valve Idle speed control valve ISC 86U04A 032 t 4A 24 ...

Page 146: ...d Gear IN Neutral switch In gear Neutral Clutch pedal released Idle switch Pedal depressed Pedal released Brake light switch Pedal depressed Pedal released A C switch ON OFF Blower motor position 1 position Headlight switch ON OFF Rear defroster switch ON OFF Blower switch ON OFF Blower motor position 3 or 4 position Inhibitor switch and EC AT control unit D 1 2 and R range P and N range Water the...

Page 147: ...connector Green 6 pin and the negative battery terminal 3 Connect a jumper wire between the test connec tor Green 1 pin and a ground 4 Turn the ignition switch ON Check if monitor lamp illuminates when each switch is made to function as described below Caution a If any one of the switches is activated the monitor lamp will stay on b Do not start the engine 86U04A 035 Procedure 4A 26 ...

Page 148: ...SWITCH MONITOR FUNCTION 4A Idle switch 86U04A 037 Brake light switch 86U04A 038 Blower switch 86U04A 039 A C switch 86U04A 040 4A 27 ...

Page 149: ...ITOR FUNCTION Headlight switch 86U04A 041 Rear defroster switch 86U04A 042 Inhibitor switch 86U04A 043 Water thermo switch circuit not included in switch inspection Warning The electrical fan operates when the 4A 28 ...

Page 150: ...ion of the engine plugs leaks in hoses etc 2 Make sure all accessories are OFF 3 Warm up the engine and run it for Three minutes at 2 500 3 000 rpm in neutral 4 Check the initial ignition timing and adjust if necessary Inspection and Adjustment 1 Ground the test connector with a jumper wire 2 Check that the idle speed is within specification Idle speed 750 25 rpm MTX Neutral ATX P range 3 If the i...

Page 151: ...E Because an automatic compensation function for air fuel mixture is built into the engine con trol unit it is not necessary to check and adjust the idle mixture Idle mixture Automatic Control Function Engine Control Unit 86U04A 049 ...

Page 152: ...racteristics COMPONENT DESCRIPTIONS Component Function Remarks Application New model Prevous model Air cleaner Filters air into throttle body O O Air flow meter Detects amount of intake air sends signal to control unit Intake air temp sensor and fuel pump switch are in tegrated O O Throttle sensor Detects throttle valve opening angle sends signal to control unit Installed on throttle body o o Thro...

Page 153: ...e 86U04A 047 1 Air flow meter connector 2 Air cleaner 3 Air duct 4 Resonance chamber No 1 5 Air flow meter 6 Resonance chamber No 2 7 Air hose 8 Connectors 9 Water hoses 10 Vacuum hoses 11 Accelerator cable 12 Throttle body 13 PCV hose 14 Vacuum pipe assembly 15 Dynamic chamber 16 Gasket 17 Wiring harness 18 Delivery pipe assembly 19 Vacuum hoses 20 EGR pipe 21 Intake manifold bracket 22 Intake ma...

Page 154: ... the accelerator pedal to the floor and con firm that the throttle valve is fully opened Adjust by turning bolt B if necessary Throttle Body Note The No 2 throttle valve is preset at the facto ry to begin opening after the No 1 throttle valve has opened approx 25 degrees MTX or 10 degrees ATX 1 Check that the No 1 and No 2 throttle valves move smoothly when the throttle lever is moved from fully c...

Page 155: ... the dynamic chamber for damage 2 Replace if necessary Intake Manifold 1 Visually check the intake manifold for damage 2 Replace if necessary Resonance Chamber 1 Visually check the resonance chamber for damage 2 Replace if necessary 69G04A 064 69G04C 054 ...

Page 156: ...ll them onto the throttle shaft 3 Install the throttle lever onto the throttle shaft Caution When tightening the throttle lever nut hold the throttle valves fully closed to prevent bending the stopper lever 4 Tighten the throttle lever nut Tightening torque 16 23 Nm 1 6 2 3 m kg 12 17 ft lb 5 Check that the inner and outer washer and spacer are assembled correctly as shown 6 Check that No 1 and No...

Page 157: ...4A INTAKE AIR SYSTEM INSTALLATION Install in the reverse order of removal referring to the installation note Torque Specification 4A 36 86U04A 055 ...

Page 158: ...INTAKE AIR SYSTEM 4A Installation Note Water hose spring clamps Face the clamp end as shown in the figure Gasket Use new gaskets at the intake manifold dynamic chamber and throttle body 86U04A 056 ...

Page 159: ...7 To improve idle smoothness the ISC system controls the intake air amount by regulating the bypass air amount that passes through the throttle body This system consists of the BAC valve and the control system The BAC valve consists of the air valve which functions only during cold engine conditions below 50 C 122 F and the ISC valve which works throughout the entire engine speed range 4A 38 ...

Page 160: ...signal to control unit Installed on throttle body o 0 Ignition coil terminal Detects engine speed sends signal to control unit o o Inhibitor switch Detects in gear condition sends signal to EC AT control unit Switch ON in N or P range o o Neutral switch Detects in gear condition sends signal to control unit Switch ON when in gear o o P S pressure switch Detects P S operation sends signal to contro...

Page 161: ...lve P S pres sure switch Solenoid valve Idle speed control Electrical load con trol unit Engine control unit terminal System in spection 1K 1W 2Q 4A 42 4A 94 4A 42 4A 95 4A 9 0 4A 91 4A 92 4A 41 Engine While warming up 4 1 2 3 stalls After warming up 2 1 3 5 4 6 Rough While warming up 5 2 3 4 1 idle After warming up 3 2 4 6 5 7 1 High idle speed after warming up 7 3 2 4 6 5 7 1 Runs rough on decel...

Page 162: ...e 1 Disconnect the ISC valve connector 2 Connect an ohmmeter to the terminals of the ISC valve 3 Check the resistance Resistance normal operating temperature 6 3 9 9 Q 4 If not correct replace the BAC valve 86U04A 064 Removal 1 Remove the screws 2 Remove the BAC valve from the throttle body 69G04C 070 Installation Caution Use a new gasket 1 Remove any dirt or old sealant from the contact surfaces ...

Page 163: ...he fuel pump fuel filters delivery pipe pulsation damper pressure regulator injectors fuel pump switch incorporated in the air flow meter and the circuit opening relay The fuel pump is mounted in the fuel tank to minimize the operating noise of the fuel pump The injec tors are directly supplied with battery voltage through the main relay The connector of the injectors is blue to distinguish the in...

Page 164: ...itch ST position Sends engine cranking signal to control unit o o Inhibitor switch Detects in gear condition sends signal to EC AT control unit Switch ON in N or P range o o Injector Injects fuel into intake port Controlled by signals from control unit High ohmic injector o o Intake air thermo sensor Detects intake air temperature sends signal to control unit Installed in air flow meter o o Main r...

Page 165: ... con trol unit terminal 3C 3E 3B 4A 96 4A 103 4A 102 4A 97 4A 101 4A 101 4A 50 4A 52 4A 49 4A 92 4A 92 Hard start or won t start Cranks OK 5 4 1 3 2 Engine While warming up 4 3 2 1 5 stalls After warming up 1 3 2 4 Rough idle White warming up 4 3 2 1 After warming up 1 2 4 3 Pooracceleration hesitation or lackof pow er 1 3 4 2 Runs rough on deceleration 1 2 Afterburn on deceleration 1 2 Poor fuel ...

Page 166: ...onnecting any fuel line release the fuel pressure from the fuel system to reduce the pos sibility of injury or fire 1 Start the engine 2 Disconnect the circuit opening relay 3 After the engine stalls turn OFF the ignition switch 4 Reconnect the circuit opening relay b Use a rag as protection from fuel spray when dis connecting the hoses Plug the hoses after removal c When inspecting the fuel syste...

Page 167: ...SURE TESTER 49 9200 750A 49 9200 750A 69G04A 099 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 the tester ...

Page 168: ...mp with the adapter Caution Do not reverse the adapter connection 4 Disconnect the vacuum hose from the pressure regulator control solenoid valve Connect the SST vacuum hose with a three way joint 5 Connect the negative battery terminal 6 Connect the SST to the battery 7 Connect the terminals of the test connector Yel low with a jumper wire Turn the ignition switch ON to operate the fuel pump 8 Ch...

Page 169: ...re 86U04A 074 Fuel Pump Pressure 1 Connect the terminals of the test connector Yel low with a jumper wire 2 Turn the ignition switch ON to operate the fuel pump 3 Set the lever on the adapter as shown in the figure 4 Check the fuel pump pressure Fuel pump pressure 441 588 kPa 4 5 6 0 kg cm2 64 85 psi 5 If the fuel pump pressure is not within specifica tion check the following No pressure Fuel pump...

Page 170: ... 8 kg cm2 34 40 psi 7 If not within specification replace the pressure regulator 8 Connect the vacuum hose to pressure regulator FUEL PUMP Operation Test 1 Connect a jumper wire to the check connector Yellow 2 Remove the fuel filler cap 3 Turn the ignition switch ON 4 Listen for operational sound of the fuel pump at the filler inlet 5 Install the fuel filler cap 6 If no sound was heard check the v...

Page 171: ...return hose from fuel return pipe 3 Turn the ignition switch ON for 10 seconds and check the feeding capacity with graduated cylinder Feeding capacity 220 cc 13 4 cu in 10 sec min 4 If not within specification check the fuel filter and fuel line 5 Turn the ignition switch OFF and disconnect the jumper wire 86U04A 082 PULSATION DAMPER 1 Run the engine at idle 2 Place a finger on the screw of the pu...

Page 172: ... the following No operating sound and no speed drop Perform Quick Inspection for Electrical Signal below No speed drop only Injector resistance Injection volume of injector Quick Inspection for Electrical Signal 1 Ground the test connector Green 1 pin with a jumper wire 2 Turn the ignition switch ON 3 Open the throttle valve and check for a click at the injector with a screwdriver or sound scope a...

Page 173: ...irmly to the delivery pipe so that no movement of the injectors is possible Warning Be extremely careful when working with fuel Always work away from sparks or open flames 4 Connect the terminals of the fuel pump test con nector with a jumper wire Turn the ignition switch ON 5 Check that no fuel leaks from the injector nozzles Note After 1 minute a drop of fuel from the injec tor is acceptable 86U...

Page 174: ...86U04A 092 To prevent percolation of the fuel during idle after the engine is restarted vacuum is cut to the pres sure regulator increasing the fuel pressure Specified time Approx 120 sec Operating condition Coolant temperature above 70 C 158 F Intake air temperature above 20 C 68 F 4A 54 ...

Page 175: ...e cranking signal to control unit o o Intake air thermo sensor Detects intake air temperature sends signal to control unit Installed in air flow meter o o Pressure regulator Adjusts fuel pressure supplied to injectors o o Solenoid valve Pres sure regulator control Controls vacuum line to pressure regulator Closes vacuum line when hot o o Throttle sensor Detects throttle valve opening angle sends s...

Page 176: ...shown in the chart Solenoid Valve Pressure Regulator Control Inspection 1 Disconnect the vacuum hose from the solenoid valve and vacuum pipe 2 Blow through the solenoid valve from vacuum hose A 3 Check that air flows from port B 4 Disconnect the solenoid valve connector 5 Connect 12V and a ground to the terminals of the solenoid valve 6 Blow through the solenoid valve from the vacuum hose A 7 Chec...

Page 177: ...hen servicing the fuel system keep sparks cigarettes and open flames away from the fuel Fuel Pump 1 Remove the rear seat and disconnect the fuel pump connector 2 Remove the service hole cover 3 Disconnect the fuel hoses 4 Remove the fuel pump and fuel tank gauge as sembly 5 Replace the fuel pump Caution Secure the fuel pump terminals and fuel hoses securely 6 Install in the reverse order of remova...

Page 178: ... air hose from the throttle body 5 Remove the engine hanger 6 Remove the dynamic chamber mounting bolts and nuts 7 Lift the dynamic chamber 8 Disconnect the fuel return pipe bracket from the intake manifold 9 Disconnect the injector connectors 1 0 Remove the delivery pipe along with the pressure regulator and pulsation damper 86U04A 104 86U04A 105 Engine 86U04A 106 4A 59 ...

Page 179: ...reverse order of removal referring to installation note Tightening torque Delivery pipe Dynamic chamber Engine hanger 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Installation note Injector 1 Use new O rings 2 Apply a small amount of engine oil to the O rings when installing 3 Install the injectors and the injector insulators 86U04A 109 4A 60 ...

Page 180: ...place the delivery pipe 4 Install in the reverse order of removal referring to installation note Tightening torque Pressure regulator 8 11 N m 0 8 1 1 m kg 69 95 in lb Delivery pipe 19 25 N m Engine hanger Dynamic chamber 1 9 2 6 m kg 14 19 ft lb Installation note Insulator Install the insulators between the intake manifold and delivery pipe Injector Refer to page 4A 60 4A 61 ...

Page 181: ...A 59 2 Remove the pulsation damper 3 Install in the reverse order of removal 86U04A 114 86U04A 116 Fuel Filter Low pressure side Refer to page 4A 58 High pressure side The fuel filter must be replaced at the intervals out lined in the maintenance schedule Warning Always work away from sparks or open flames 1 Disconnect the fuel hoses from the fuel filter 2 Remove the fuel filter and the bracket 3 ...

Page 182: ...ry or fire Refer to page 4A 46 b When removing the fuel tank keep sparks cigarettes and open flames away from the fuel tank Remove in the sequence shown in the figure 86U04A 117 Note Drain the fuel from the fuel tank before removing the tank 1 Fuel pump connectors 2 Fuel hoses 3 Evaporative hoses 4 Fuel filler hose 5 Breather hose 6 Fuel tank strap 7 Fuel tank 4A 63 ...

Page 183: ...ect is found repair or replace the tank Warning Before repairing clean the fuel tank thorough ly with steam to sufficiently remove all explo sive gas 86U04A 118 Installation Install in the reverse order of removal referring to the installation note Torque Specifications 4A 64 86U04A 119 ...

Page 184: ...ote 1 Push the hose ends of the main fuel hose fuel re turn hose and evaporation hoses onto the fuel tank fittings at least 25 mm 1 0 in 2 Push the fuel filler hose ends onto the fuel tank pipe and filler pipe at least 35 mm 1 4 in ...

Page 185: ...4A DECELERATION CONTROL SYSTEM DECELERATION CONTROL SYSTEM The fuel cut system is provided as a deceleration control system This system is to improve fuel economy 4A 66 626 MX 6 Revised 10 87 ...

Page 186: ...control unit Detects signals from input sensors and switches cuts fuel injection o o Idle switch Detects when throttle valve fully closed sends signal to control unit Installed on throttle body o o Ignition coil terminal Detects engine speed sends signal to control unit o o Inhibitor switch Detects in gear condition sends signal to EC AT control unit Switch ON in N or P range o o Neutral switch De...

Page 187: ...DECELERATION CONTROL SYSTEM 4A 0 8 0 20 4 Increase the engine speed to 4 000 rpm then sud denly decrease the engine speed 5 Check that the red indicator lamp stays illuminat ed during deceleration ...

Page 188: ...exhaust gas O O EGR modulator valve Controls vacuum acting on EGR control valve O o Engine control unit Detects signals from input sensors and switches controls solenoid valve EGR o o Ignition coil terminal Detects engine speed sends signal to control unit o o Solenoid valve EGR Controls vacuum line to EGR control valve o o Throttle sensor Detects throttle valve opening angle sends signal to contr...

Page 189: ...0 4A 92 4A 71 Checking order 3 2 4 6 5 7 8 1 86U04A 129 System Inspection 1 Start the engine 2 Accelerate the engine and verify that the di aphragm of the EGR control valve does not move while the engine is still cold 3 Warm up the engine to normal operating temper ature and run it at idle Warning Be careful when checking the EGR control valve because the surrounding area is very hot 4 Accelerate ...

Page 190: ...ase the exhaust gas port and confirm that vacuum is released 86U04A 133 EGR Control Valve 1 Manually actuate the valve by pushing on the di aphragm with finger 2 Check that the spring resistance is present and the diaphragm moves freely with no sticking or binding Note Before replacing the EGR control valve check the intake air and control systems 86U04A 134 3 Warm up the engine and run it at idle...

Page 191: ...ut valve Releases excessive pressure or vacuum in fuel tank to atmosphere 0 X Engine control unit Detects signals from input sensors and switches controls solenoid valve Purge control o 0 Ignition coil terminal Detects engine speed sends signal to control unit o o Separator Prevents fuel from flowing into charcoal canister o X Solenoid valve Purge control Controls vacuum line to vacuum switch valv...

Page 192: ...on of the Troubleshooting Guide Refer to pages 4A 8 and 9 Possible cause Vacuum switch valve Solenoid valve Purge control Three way check valve Check and cut valve Separator No 1 purge valve No 2 purge valve Water thermo valve Water thermo sensor Engine control unit terminal System inspection 2P Page 4A 76 4A 77 4A 77 4A 78 4A 78 4A 76 4A 76 4A 77 4A 101 4A 92 4A 75 Checking order 3 2 9 10 11 4 5 ...

Page 193: ... than 150 mmHg 5 9 inHg 6 If not correct check the water thermo valve 7 Reconnect hose A to No 1 purge control valve 86U04A 139 8 Disconnect vacuum hose B from the canister and place a finger over the end of the hose 9 Accelerate the engine rapidly and check that vacu um is felt at above 1 500 rpm 10 Reconnect hose B to the canister 86U04A 141 11 Disconnect vacuum hose C from the canister and plac...

Page 194: ...k that air does not flow 2 Connect a vacuum pump to the purge control valve 3 Apply 110 mmHg 4 33 InHg vacuum and blow through port A again air should flow No 2 Purge Control Valve 1 Disconnect vacuum hose B from the evaporation pipe 2 Blow through the hose and verify that air flows freely Vacuum Switch Valve 1 Remove vacuum switch valve 2 Connect a vacuum pump to the valve 3 Blow through the valv...

Page 195: ... that air comes out of the other port at 46 54 C 115 129 F Three Way Check Valve 1 Remove the check valve 2 Blow through the valve from port A and check that air comes out of port B Next block port B and check that air comes out of port C 3 Block port B 4 Connect a vacuum pump to port A and verify that no vacuum is held Solenoid Valve Purge 1 Remove the solenoid valve 86U04A 149 86U04A 150 valve O...

Page 196: ...ct a pressure gauge to the passage that nor mally is connected to the fuel tank 3 Blow through the valve from port A Verify that the valve opens at 5 39 6 87 kPa 0 055 0 07 kg cm2 0 78 1 00 psi 4 Remove the pressure gauge and connect it to the passage to atmosphere 5 Blow through the valve from port B Verify that the valve opens at 0 98 4 91 kPa 0 01 0 05 kg cm2 0 14 0 71 psi Note The test must be...

Page 197: ...s the PCV valve is further opened and a larger amount of blow by gas is drawn into the dynamic chamber COMPONENT DESCRIPTION Component Function Remarks Application New model Previous model PCV valve Controls blowby gas amount pulled into engine O O PCV VALVE 1 Warm up the engine to the normal operating tem perature and run it at idle 2 Disconnect the PCV valve and the ventilation hose from the cyl...

Page 198: ...haust manifold Only MTX Main silencer 86U04A 158 The catalytic converter is used to reduce CO HC and NOx The converter contains a compound of platinum and rhodium It is a three way catalyst type with a volume of 2 100 cc 128 cu in 4A 80 ...

Page 199: ...silencer 2 Middle pipe 3 Pre silencer 4 Catalytic converter 5 Bracket 6 Front pipe INSPECTION 1 Check the catalytic converter and exhaust pipe for deterioration or restriction 2 Check the insulation covers welded onto the cata lytic converter for damage Note If the insulation cover is touching the catalytic converter housing excessive heat at the floor will occur 4A 81 ...

Page 200: ...rated O O Clutch switch Detects in gear condition sends signal to control unit Switch ON when clutch pedal depressed O O Engine control unit Detects signals from input sensors and switches controls shift indicator light operation o o 5th gear switch Detects 5th gear driving sends signal to control unit MTX only 0 o Ignition coil terminal Detects engine speed sends signal to control unit o o Neutra...

Page 201: ... 86U04A 163 System Inspection 1 Drive the vehicle in 1st gear and less than half throttle 2 Verify that the shift indicator light illuminates dur ing acceleration 86U04A 164 Shift Indicator Light 1 Ground 1S terminal G of the engine control unit 2 Shift the transmission into a forward gear except 5th 3 Turn the ignition switch ON 4 Verify that the shift indicator light illuminates 5 If the shift i...

Page 202: ...rcuit opening relay Inhibitor switch lutch switch Brake light switch Main relay Neutral switch 5th gear switch Idle switch 86U04A 166 The control system consists of the input devices and the control unit The control unit controls the fuel injection amount EGI fuel injection pressure bypass air amount switch monitor function and fail safe function ...

Page 203: ...RAL AND CLUTCH SWITCH o X X o X X X O OXYGEN SENSOR o X X X X X X X WATER THERMO SWITCH RADIATOR o X X X o X X X ATMOSPHERIC PRESSURE SENSOR o X X O X X X X INTAKE AIR THERMO SENSOR o X X o X X O X WATER THERMO SENSOR o X X o O o O X IDLE SWITCH o o X o X X X O THROTTLE SENSOR o o X o O X O O AIR FLOW METER o X X X X o X O IGNITION COIL o O X o O O O O INPUT DEVICES OUTPUT DEVICES FUEL INJECTION A...

Page 204: ...ISC VALVE Large amount of bypass air Large amount of bypass air Small amount of bypass air No bypass ln extreme cold condition SOLENOID VALVE EGR ON EGR cut OFF EGR ON EGR cut OFF EGR ON EGR cut ON EGR cut ON ATX D range OFF NO EGR due to no vacuum to system SOLENOID VALVE PURGE OFF 2nd stage not operated ON 2nd stage operates OFF 2nd stage not operated OFF 1st stage controlled by water thermo val...

Page 205: ...CUIT OPENING RELAY Relay Circuit 1 Remove the circuit opening relay 2 Check the circuit as described Terminal Checking item Correct result Fp Resistance 0 2 3012 Fc Continuity cranking O O B Voltage Ign ON Battely voltage STA Voltage Cranking Approx 9V Ei Continuity oo Circuit Opening Relay 1 Apply 12V and a ground to the terminals below and check the circuit opening relay as described 12V Grounde...

Page 206: ...200 162 was developed to check the control unit terminal voltages This monitor easily inspects the individual terminal voltages through selection of the monitor switch How to Use the Engine Signal Monitor 1 Connect the Engine Signal Monitor 49 9200 162 between the engine control unit and the en gine harness using the adapter 49 9200 163 2 Turn the selector switch and monitor switch to select the t...

Page 207: ...CONTROL SYSTEM 4A Wiring Diagram 86U04A 172 4A 89 ...

Page 208: ...ght il luminates After 3sec Battery voltage light does not illuminate Test connector grounded approx 5V Test connector not grounded Monitor lamp ON below 6 2V Monitor lamp OFF Battery voltage With Self Diagnosis Checker 1E O Idle switch Accelerator pedal released below 0 5V Accelerator pedal depressed above 7 7V 1F o A C relay Battry voltage A C switch ON be low 2 5V A C switch OFF Battery voltage...

Page 209: ... o Air flow meter Vs Approx 1 7V Approx 3 5V Increase engine speed voltage increases 2F 2G o Throttle sensor Accelerator pedal released approx 0 5V depends on 2A terminal voltage Max voltage Throt tle valve fully open approx 4 3V 2H o Atmospheric pres sure sensor At sea level approx 4 0V 21 o Water thermo sensor 0 3 0 6 V Engine coolant temp 20 C 68 F approx 2 5V 2J o Air flow meter In take air th...

Page 210: ...d No 2 Battery voltage 1 Battery voltage 1 Engine Signal Monitor green and red lights flash 3D O Inhibitor switch through EC AT unit N or P range below 2 5V Other ranges battery voltage ATX Neutral and clutch switch In gear condition Clutch pedal depressed battery voltage Clutch pedal released below 0 5V MTX Neutral con stant battery voltage 3E o Injector No 1 and No 3 Battery voltage 1 Battery vo...

Page 211: ...fer to section 7A for replacement of the neutral switch CLUTCH SWITCH Inspection 1 Disconnect the clutch switch connector 2 Connect an ohmmeter to the switch 3 Check continuity of the switch Pedal Continuity Depressed No Released Yes 4 After checking connect the switch connector Note Refer to section 6 for replacement of the clutch switch BRAKE LIGHT SWITCH Inspection 1 Disconnect the brake light ...

Page 212: ... S pressure switch INHIBITOR SWITCH Inspection 1 Disconnect the inhibitor switch connector 2 Connect an ohmmeter to the switch 3 Check continuity of the switch Position Continuity P and N ranges Yes Other ranges No 4 Connect the switch connector after checking Note Refer to Section 7B for replacement of the in hibitor switch 5TH GEAR SWITCH 1 Disconnect the 5th gear switch connector 2 Connect an o...

Page 213: ...below 97 C 207 F LY Below 1 5V Coolant temp above 97 C 207 F E Control unit 11 OV E L ON GY Battery voltage E L OFF F O Headlight switch Battery voltage Headlight switch ON W Below 1 5V Headlight switch OFF G o Blower motor switch Below 1 5V Blower motor switch ON 3rd or 4th position LB Approx 5V Others H o Rear defroster Below 1 5V Rear defroster switch ON BL switch Battery voltage Rear defroster...

Page 214: ... 4 Disconnect the connector from the ir flow meter 5 Using an ohmmeter check resistance between the terminals with the measuring plate fully closed and fully open 6 Connect the connector to the air flow meter after inspecting Terminal Resistance fl Fully closed Fully open E2 Vs 20 400 20 1 000 E2 Vc 100 400 E2 Vb 200 400 E2 THA Intake air thermo sensor 20 C 4 F 13 6 18 4 kQ 20 C 68 F 2 21 2 69 kfi...

Page 215: ... 9 Check that BLUE wire voltage for the recorded RED wire voltage is as specified below Specification RED wire voltage V BLUE wire voltage V RED wire voltage V BLUE wire voltage V 4 50 4 59 0 37 0 54 5 10 5 19 0 42 0 61 4 60 4 69 0 38 0 55 5 20 5 29 0 43 0 62 4 70 4 79 0 39 0 56 5 30 5 39 0 44 0 63 4 80 4 89 0 40 0 57 5 40 5 49 0 44 0 64 4 90 4 99 0 40 0 58 5 50 0 44 0 66 5 00 5 09 0 41 0 60 10 Ho...

Page 216: ...elim inate the control unit malfunction memory Adjustment 1 Remove the air hose from the throttle body 2 Disconnect the throttle sensor connector 3 pin 3 Connect the SST between the throttle sensor and the wiring harness 4 Turn the ignition switch ON 5 Make sure the throttle valve is fully closed 6 Measure RED wire voltage and record it 7 Change the voltmeter connection to the BLUE wire 8 Loosen t...

Page 217: ...cation 12 Hold the throttle valve fully open 86U04A 192 13 Check that BLUE wire voltage is within specifi cation Specification RED wire voltage V BLUE wire voltage V RED wire voltage V BLUE wire voltage V 4 50 4 59 3 58 4 23 5 10 5 19 4 05 4 79 4 60 4 69 3 66 4 32 5 20 5 29 4 13 4 88 4 70 4 79 3 74 4 41 5 30 5 39 4 21 4 98 4 80 4 89 3 82 4 51 5 40 5 49 4 29 5 07 4 90 4 99 3 90 4 60 5 50 4 29 5 17 ...

Page 218: ... valve fully closed position Measure RED wire voltage Record RED wire voltage Measure BLUE wire voltage Verify that BLUE wire voltage is within the specified range Step 2 Throttle valve fully open position Measure BLUE wire voltage Verify that BLUE wire voltage is within the specified range Adjustment If BLUE wire voltage measured in step 1 exceeds the specific range adjust or replace the throttle...

Page 219: ...Place the sensor in water with a thermometer and heat the water gradually 3 Check resistance of the sensor with an ohmmeter Coolant Resistance 20 C 4 F 14 5 17 8 kQ 20 C 68 F 2 2 2 7 kQ 40 C 104 F 1 0 1 3 kQ 60 C 140 F 500 640 Q 80 C 176 F 280 350 Q 4 If not correct replace the water thermo sensor WATER THERMO SWITCH Inspection 1 Remove the switch from the radiator 2 Place the switch in water with...

Page 220: ...n the speed is increased the meter reads between 0 5V 1 0V and when the speed is decreased it reads between 0V 0 4V 6 If the voltmeter dosen t indicate as specified re place the oxygen sensor 86U04A 206 Inspection of Sensitivity 1 Warm up the engine to the normal operating tem perature and run it at idle 2 Connect the SST to the check connector 3 Increase the engine speed to between 2 000 and 3 00...

Page 221: ... PRESSURE SENSOR Inspection 1 Connect a voltmeter to the atmospheric pressure sensor D terminal 2 Turn the ignition switch on and take a voltage reading Voltage 3 5 4 5V at sea level 2 5 3 5V at high altitude 2 000m 6 500 ft 3 Replace the sensor if necessary ...

Page 222: ...LEASE AND SERVICING FUEL SYSTEM 4B 60 MULTI PRESSURE TESTER 4B 61 FUEL PRESSURE 4B 63 FUEL PUMP 4B 64 PULSATION DAMPER 4B 65 INJECTOR 4B 66 TRANSFER PUMP CONTROL SYSTEM 4 WHEEL STEERING 4B 68 PRESSURE REGULATOR CONTROL SYSTEM 4B 69 COMPONENT DESCRIPTIONS 4B 70 TROUBLESHOOTING 4B 71 REPLACEMENT 4B 73 FUEL TANK 4B 79 DECELERATION CONTROL SYSTEM 4B 82 COMPONENT DESCRIPTIONS 4B 83 TROUBLESHOOTING 4B 8...

Page 223: ...Vacuum switch Distributor Sorenoid valve wastegate Air flo Atmospheric pressure sensor Intake air thermo sensor Air valve Throttle sensor and idle switch Idle switch Solenoid valve Idle speed control EGR position sensor EGR control valve Water thermo switch Turbocharger Wastegate theJmn KhOCk thermo sensor sensor Catalytic converter Solenoid valve EGR vent Exhaust gas 3 Vacuum 5 Fuel 3 Air Other w...

Page 224: ...le sensor Test connector Yellow 2 pin Idle switch EGR position sensor Test connector Green 1 pin Circuit opening relay Clutch switch Brake light switch Water thermo switch Water thermo sensor Inhibitor switch Main relays Neutral switch 86U04A 003 4B 3 ...

Page 225: ...or Injector Vacuum chamber with check valve Solenoid valve Idle speed control Check connector Green 6 pin for Self Diagnosis Checker EGR control valve Solenoid valve Pressure regulator Transfer pump 4 wheel steering Separator Three way check valve Check and cut valve 86U04A 004 4B 4 ...

Page 226: ...OUTLINE 4B Exhaust System 86U04A 005 4B 5 ...

Page 227: ...0 o c C T rv CD Z o g o o o Air bypass valve Pressure regulator Vacuum chamber Solenoid valve Purge Vacuum switch valve Solenoid valve Pressure regulator Black Yellow Blue Green Red White Brown Water thermo valve Solenoid valve EGR Charcoal canister ...

Page 228: ...fer pump 190 11 6 min Fuel filter Type Low pressure side Nylon element High pressure side Paper element Pressure regulator Type Diaphragm Regulating pressure kPa kg cm2 psi 235 275 2 4 2 8 34 40 Injector Type High ohmic Type of drive Voltage Resistance 0 11 15 Injection amount cc cu in 15 seconds 73 90 4 45 5 49 Idle speed control valve Solenoid resistance Q 6 3 9 9 Turbocharger Cooling method Eng...

Page 229: ... or unit may be at fault by use of the SST Self Diagnosis Checker 49 H018 9A1 1st Check input sensors and output solenoid valves with the SST Refer to page 4B 11 2nd Check other switches with the SST Refer to page 4B 33 3rd Check the following items Poor acceleration hesita tion or lack of power 7 8 9 10 11 Runs rough on deceleration Afterburn in exhaust system Poor fuel consumption Excessive oil ...

Page 230: ...m rv J l rv r 5 4B 45 Idle Speed Control ISC System Air valve Idle speed control solenoid malfunction fV 0 5 0 3 1 CU O Turbochargine System Oil water passage Turbine and compressor wheels malfunction k 4B 86 Electronic Spark Advance ESA System Knock control system ro CO CO CO CO r 5 C D 1 C O 0 EGR System EGR control valve stuck and open cn ro 4A 73 EEC System Vacuum switch valve No 1 purge valve...

Page 231: ...res of each input and output device are indicated and retrieved from the control unit as malfunc tion code numbers Note The control unit constantly checks for malfunction of the input devices But the control unit checks for malfunction of output devices only in a 3 second period after the ignition switch is turned ON and the test connector is grounded 4B 10 ...

Page 232: ...hat the buzzer sounds for three seconds after turn ing the ignition switch ON 6 If 88 does not flash check the main relay Refer to page 4B 102 power supply circuit and check connector wiring 7 If 88 flashes and the buzzer sounds continuously for more than 20 seconds replace the engine con trol unit and perform steps 3 and 4 again 8 Note the code numbers and check for the causes by referring to the...

Page 233: ...imes the buzzer is on 0 4 sec during one cycle ON OFF 1 cycle 1 2 3 Malfunction code cycle break 0 4 0 4 sec sec 4 0 sec Malfunction code 03 86U04A 019 3 First digit of malfunction code tens position The digit in the tens position of the malfunction code represents the number of times the buzzer is on 1 2 sec during one cycle It should also be noted that the light goes off for 1 6 sec between the ...

Page 234: ...short circuit Maintains constant command 35 C 95 F for EGI 50 C 122 F for ISC control use 10 Intake air thermo sensor air flow meter Open or short circuit Maintains constant 20 C 68 F command 12 Q P P _fUlll_ Uil_ Throttle sensor Open or short circuit Maintains constant command of throttle valve fully open 14 o fnf nil n i Atmospheric pres sure sensor Open or short circuit Maintains constant comma...

Page 235: ...vacuum 29 ON n r OFF inni Solenoid valve r EGR vent 34 jm iL nn Solenoid valve Idle speed control 42 o FFjm Jom Solenoid valve waste gate 86U04B 006 Caution a If there is more than one failure present the lowest number malfunction code is dis played first the remaining codes are displayed sequentially b After repairing a failure turn off the ignition switch and disconnect the negative battery cabl...

Page 236: ...4B TROUBLESHOOTING WITH SST Code No 01 Ignition pulse PC Possible Cause 86U04B 007 ...

Page 237: ...ontinuity between distributor and engine control unit Distributor Control unit A 1T B 1Q YES Is same Code No present after performing after repair procedure Refer to page 4B 11 YES Are control unit 1T and 1Q terminal voltages OK YES PC Engine control unit malfunction 86U04B 008 4B 17 ...

Page 238: ...tor Control unit E 1N F 1P YES YES Repair or replace connector NO Replace distributor NO PC Open circuit in wiring harness from distributor to engine control unit YES Is same Code No present after performing after repair procedure Refer to page 4B 11 YES Are engine control unit 1N OK Refer to page 4B 1 and 1P terminal voltages 35 and 4B 106 NO G1 signal and circuit OK NO PC Short circuit in wiring...

Page 239: ...tor Control unit C 10 D 1P YES YES Repair or replace connector NO Replace distributor NO PC Open circuit in wiring harness from distributor to engine control unit YES Is same Code No present after performing after repair procedure Refer to page 4B 11 YES Are engine control unit 10 OK Refer to page 4B 1 and 1P terminal voltages 35 and 4B 106 No G2 signal and circuit OK NO PC Short circuit in wiring...

Page 240: ...control unit Open circuit in wiring harness between knock control unit and ground only RY wire PC Knock sensor knock control unit or related har ness malfunction only YL wire PC Open circuit in wiring harness between knock control unit and knock sensor Is same Code No present repair procedure Refer tc after performing after page 4B 11 YES Is engine control unit 1R terminal voltage OK Refer to page...

Page 241: ... to page 4B 11 YES Are engine control unit terminal voltages OK Check terminal 2B 2C 2E 3 1 Refer to page 4B 106 and 107 YES Terminal Fully closed Q Fully open fi E2 Vs 20 400 20 1 000 E2 Vc 100 400 E2 Vb 200 400 YES Is there continuity between air flow meter and engine control unit NO NO NO NO Repair or replace connector PC Open circuit in wiring harness from air flow meter to engine control unit...

Page 242: ...e engine control unit 2 1 and 2C terminal voltages OK Refer to page 4B 106 YES YES Repair or replace connector Water thermo sensor Control unit A YB wire 2 1 B LgY wire 2C NO PC Open circuit in wiring harness from water thermo sensor to engine control unit Coolant temp Resistance 20 C 4 F 14 5 17 8 kfl 20 C 68 F 2 2 2 7 kfl 40 C 104 F 1 0 1 3 kfl 60 C 140 F 500 640 fl 80 C 176 F 280 350 fl NO Repl...

Page 243: ... flow meter OK Resistance Terminal Resistance E2 THA 20 C 4 F 13 6 18 4 kfl 20 C 68 F 2 21 2 69 kfl 60 C 140 F 493 667 fl NO YES Is same Code No present after performing after repair procedure Refer to page 4B 11 NO YES Are engine control unit 2J and 2C terminal voltages OK Refer to page 4B 106 Repair or replace connector PC Open circuit in wiring harness from intake air thermo sensor in air flow ...

Page 244: ...4B TROUBLESHOOTING WITH SST Code No 12 Throttle sensor PC Possible cause 86U04B 015 4B 24 ...

Page 245: ...control unit malfunction If 2A terminal voltage not 4 5 5 5V Is voltage at Y wire of atmospheric pressure sensor connector OK Voltage 3 5 4 5V at sea level 2 5 3 5V at high altitude 2 000 m 6 500 ft NO 0V N O O thers PC Short circuit in wiring harness from atmospheric pressure sensor Y wire to engine control unit 2H terminal Replace atmospheric pressure sensor Atmospheric pressure sensor Control u...

Page 246: ...OOTING WITH SST Code No 15 Oxygen sensor PC Possible Cause Note When the Code No 15 and 17 are present at the same time first perform the checking proce dure for the Code No 17 Refer to page 4B 28 86U04B 017 4B 26 ...

Page 247: ...efer to page 4B 94 YES Is same Code No present after performing after repair procedure Refer to page 4B 11 YES Is engine control unit 2F te to page 4B 106 rminal voltage OK Refer NO NO NO Repair or replace connector Replace EGR control valve Replace EGR control valve PC Open circuit in wiring harness from EGR position sensor to engine control unit PC Short circuit in wiring harness from EGR positi...

Page 248: ...4 B TROUBLESHOOTING WITH SST v Code No 17 Feedback system PC Possible Cause 86U04B 019 ...

Page 249: ...alve YES YES Is there continuity between solenoid valve and engine control unit Solenoid valve Control unit B WB wire 2P YES Repair or replace connector NO Replace solenoid valve Is there battery voltage at RB wire of solenoid valve circuit NO PC Open circuit in wiring harness from RB wire to main relay for engine control unit NO PC Open circuit in wiring harness from solenoid valve to engine cont...

Page 250: ...ent side YES Is there continuity between solenoid valve and en gine control unit Solenoid valve Control unit B LW wire 2M Are there poor connections in solenoid valve circuit NO Is there continuity of solenoid valve YES Is there battery voltage of RB wire of solenoid valve connector YES Repair or replace connector NO Replace solenoid valve NO PC Open circuit in wiring harness from RB wire to main ...

Page 251: ...nit B BrY wire 1C Are there poor connections in solenoid valve circuit NO Is there continuity of solenoid valve YES Is there battery voltage of RB wire of solenoid valve connector YES YES NO NO Repair or replace connector Repair solenoid valve PC Open circuit in wiring harness from RB wire to main relay for engine control unit NO PC Open circuit in wiring harness from solenoid valve to engine cont...

Page 252: ...ch Self Diagnosis Checker Monitor lamp Remarks Light ON Light OFF Clutch switch Pedal released Pedal depressed Gear IN Neutral switch In gear Neutral Clutch pedal released Idle switch Pedal depressed Pedal released Brake light switch Pedal depressed Pedal released A C switch ON OFF Blower motor position 1 position Headlight switch ON OFF Rear defroster switch ON OFF Blower switch ON OFF Blower mot...

Page 253: ... pin and the negative battery terminal 3 Connect a jumper wire between the test connec tor Green 1 pin and a ground 4 Turn the ignition switch ON Check if monitor lamp illuminates when each switch is made to function as described below Caution a If any one of the switches is activated the monitor lamp will stay on b Do not start the engine Procedure 49 H 018 9A1 86U04A 035 Test connector Green 1 4...

Page 254: ...4 B SWITCH MONITOR FUNCTION Idle switch 86U04B 026 Brake light switch 86U04B 026 Blower switch 86U04B 027 A C switch 86U04B 028 ...

Page 255: ...ight switch 86U04B 029 Rear defroster switch Inhibitor switch 86U04B 031 Water thermo switch circuit not included in switch inspection Warning The electrical fan operates when the connector is disconnected Use caution 86U04B 032 4B 35 ...

Page 256: ... plugs leaks in hoses etc 2 Make sure all accessories are OFF 3 Warm up the engine and run it for Three minutes at 2 500 3 000 rpm in neutral 4 Check the initial ignition timing and adjust if necessary Inspection and Adjustment 1 Ground the test connector with a jumper wire 2 Check that the idle speed is within specification Idle speed 750 25 rpm MTX Neutral ATX P range 3 If the idle speed is not ...

Page 257: ...utomatic Control Function Engine Control Unit 86U04A 049 IDLE MIXTURE Because an automatic compensation function for air fuel mixture is built into the engine con trol unit it is not necessary to check and adjust the idle mixture 4B 37 ...

Page 258: ...nction Remarks Application New model Previous model Air cleaner Filters air into throttle body O O Air flow meter Detects amount of intake air sends signal to control unit Intake air temp sensor and fuel pump switch are in tegrated O O Throttle sensor Detects throttle valve opening angle sends signal to control unit Installed on throttle body o o Throttle body Controls intake air quantity Integrat...

Page 259: ...ir flow meter connector 2 Air cleaner 3 Air duct 4 Resonance chamber No 1 5 Air flow meter 6 Air hoses 7 Air bypass valve 8 Intercooler 9 Connectors 10 Water hoses 11 Vacuum hoses 12 Accelerator cable 13 Throttle body 14 PCV hose 15 Vacuum pipe assembly 16 Dynamic chamber 86U04B 033 17 Gasket 18 Wiring harness 19 Delivery pipe assembly 20 Vacuum hoses 21 EGR pipe 22 Intake manifold bracket 23 Inta...

Page 260: ...ccelerator pedal to the floor and con firm that the throttle valve is fully opened Adjust by turning bolt B if necessary Throttle Body Note The No 2 throttle valve is preset at the facto ry to begin opening after the No 1 throttle valve has opened approx 25 degrees MTX or 10 degrees ATX 1 Check that the No 1 and No 2 throttle valves move smoothly when the throttle lever is moved from fully closed ...

Page 261: ...E AIR SYSTEM 4B Dynamic Chamber 1 Visually check the dynamic chamber for damage 2 Replace if necessary Intake Manifold 1 Visually check the intake manifold for damage 2 Replace if necessary 4B 41 69G04A 064 ...

Page 262: ...asher and install them onto the throttle shaft 3 Install the throttle lever onto the throttle shaft Caution When tightening the throttle lever nut hold the throttle valves fully closed to prevent bending the stopper lever 69G04C 131 4 Tighten the throttle lever nut Tightening torque 16 23 N m 1 6 2 3 m kg 12 17 ft lb 5 Check that the inner and outer washer and spacer are assembled correctly as sho...

Page 263: ...INTAKE AIR SYSTEM 4B INSTALLATION Install in the reverse order of removal referring to the installation note Torque Specification 86U04A 055 4B 43 ...

Page 264: ...4B INTAKE AIR SYSTEM Installation Note Water hose spring clamps Face the clamp end as shown in the figure Gasket Use new gaskets at the intake manifold dynamic chamber and throttle body 4B 44 ...

Page 265: ... ISC system controls the intake air amount by regulating the bypass air amount that passes through the throttle body This system consists of the BAC valve and the control system The BAC valve consists of the air valve which functions only during cold engine conditions below 50 C 122 F and the ISC valve which works throughout the entire engine speed range 4B 45 ...

Page 266: ...d on throttle body 0 o Inhibitor switch Detects in gear condition sends signal to EC AT control unit Switch ON in N or P range 0 o Ne rotor and pick up Detects crank angle at 30 intervals sends signal to control unit Engine speed signal o X Neutral switch Detects in gear condition sends signal to control unit Switch ON when in gear o o P S pressure switch Detects P S operation sends signal to cont...

Page 267: ... P S pres sure switch Solenoid valve Idle speed control Electrical load con trol unit Engine control unit terminal System in spection 1K 1W 2Q 4B 49 4B 109 4B 49 4B 110 4B 105 4B 106 4B 107 4B 48 Engine While warming up 4 1 2 3 stalls After warming up 2 1 3 5 4 6 Rough While warming up 5 2 3 4 1 idle After warming up 3 2 4 6 5 7 1 High idle speed after warming up 7 3 2 4 6 5 7 1 Runs rough on dece...

Page 268: ...k that the engine speed is lower when the connector is disconnected warm than when it is disconnected when cold ISC valve 5 Connect the ISC valve connector Note Make sure that the test connector is not grounded and that the idle speed is set to specification 6 Again disconnect the ISC valve connector with the engine is at normal operating temperature 7 Check that the engine speed decreases 8 Recon...

Page 269: ...B 037 ISC valve 1 Disconnect the ISC valve connector 2 Connect an ohmmeter to the terminals of the ISC valve 3 Check the resistance Resistance normal operating temperature 6 3 9 9 Q 4 If not correct replace the BAC valve Removal 1 Remove the screws 2 Remove the BAC valve from the throttle body 69G04C 070 Installation Caution Use a new gasket 1 Remove any dirt or old sealant from the contact surfac...

Page 270: ...evious model Air bypass valve Bypasses compressed air from after tur bocharger to before turbocharger during deceleration prevents noise O X Engine control unit Detects signals from input sensors con trols solenoid valve waste gate operation O X Intake air thermo sensor Detects intake air temperature sends signal to control unit Installed in air flow meter o o Intercooler Reduces compressed air te...

Page 271: ...peed driving before stopping 3 If there is a sudden drop in power while driving it is possible that there is a fault related to the tur bocharger Before shutting the engine off immediately reduce speed and drive at the lowest possi ble engine speed 86U04B 041 SERVICE NOTE Attachment of Hoses To prevent the hoses from becoming disconnected due to boost pressure be sure to attach them secure ly with...

Page 272: ...3 Remove the hose connected to actuator and con nect the SST as shown 4 Apply 58 9 kPa 0 6 kg cm2 8 5 psi of com pressed air 5 Check that the rod moves when disconnecting and reconnecting the hose supplying the compressed air Caution Do not apply compressed air over 98 kPa 1 0 kg cm2 14 psi AIR BYPASS VALVE 1 Remove the air bypass valve 2 Connect a vacuum pump to port A of the valve 3 Apply vacuum...

Page 273: ...ly turns smoothly 4 If there is excessive load or noise replace the tur bocharger Inspection of Turbine Wheel Deflection 1 Be sure the engine is cool 2 Remove the air hose 3 Check that the wheel does not touch the compres sor housing 4 If the wheel touches the housing replace the tur bocharger 86U04B 049 Inspection of Oil Passage 1 Be sure the engine is cool 2 Remove the oil return pipe 3 Check th...

Page 274: ...id valve and tur bocharger as an assembly Removal and Installation Precaution 1 When replacing the turbocharger always check the engine oil level and quality as well as the oil pipe leading to the turbocharger and the oil return pipe Replace if necessary 2 Be careful of the following when removing install ing and handling the turbocharger 1 Do not drop the turbocharger 2 Do not use actuator rod to...

Page 275: ...oil pas sage of the turbocharger 4 After replacing the turbocharger perform the fol lowing 1 Disconnect the connector from the igniter 2 Crank the engine for 20 seconds 3 Reconnect the connector 4 Start the engine and run at idle for 30 seconds 5 Stop the engine and disconnect the negative battery cable and depress the brake pedal for at least 5 seconds to cancel the malfuction code 4B 55 ...

Page 276: ...harger and exhaust manifold as an assembly 4 Disassemble the exhaust manifold and tur bocharger 86U04B 058 Installation 1 Assemble the exhaust manifold and turbocharger Tightening torque Exhaust manifold turbocharger 27 39 Nm 2 8 4 0 m kg 20 29 ft lb Turbocharger joint pipe 37 63 Nm 3 8 6 4 m kg 27 46 ft lb Turbocharger turbocharger bracket 31 41 Nm 3 2 4 2 m kg 23 30 ft lb Caution a Replace gaske...

Page 277: ...fuel pump fuel filters delivery pipe pulsation damper pressure regulator injectors fuel pump switch incorporated in the air flow meter and the circuit opening relay The fuel pump is mounted in the fuel tank to minimize the operating noise of the fuel pump The injec tors are directly supplied with battery voltage through the main relay The connector of the injectors is black to distinguish the inje...

Page 278: ...alled on throttle body 0 o Ignition switch ST position Sends engine cranking signal to control unit o o Inhibitor switch Detects in gear condition sends signal to EC AT control unit Switch ON in N or P range o 0 Injector Injects fuel into intake port Controlled by signals from control unit High ohmic injector o 0 Intake air thermo sensor Detects intake air temperature sends signal to control unit ...

Page 279: ...FUEL SYSTEM 4B TROUBLESHOOTING Check the condition of the wiring harness and connectors before checking the sensors or switches 86U04B 063 ...

Page 280: ...nnecting any fuel line release the fuel pressure from the fuel system to reduce the pos sibility of injury or fire 1 Start the engine 2 Disconnect the circuit opening relay 3 After the engine stalls turn OFF the ignition switch 4 Reconnect the circuit opening relay b Use a rag as protection from fuel spray when dis connecting the hoses Plug the hoses after removal c When inspecting the fuel system...

Page 281: ...200 750A 49 9200 750A Fuel filter 49 9200 750A 69G04A 099 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 the tester 4B 61 ...

Page 282: ...h the adapter Caution Do not reverse the adapter connection 4 Disconnect the vacuum hose from the pressure regulator control solenoid valve Connect the SST vacuum hose with a three way joint 5 Connect the negative battery terminal 6 Connect the SST to the battery 7 Connect the terminals of the test connector Yel low with a jumper wire Turn the ignition switch ON to operate the fuel pump 8 Check fo...

Page 283: ...re 86U04A 074 Fuel Pump Pressure 1 Connect the terminals of the test connector Yel low with a jumper wire 2 Turn the ignition switch ON to operate the fuel pump 3 Set the lever on the adapter as shown in the figure 4 Check the fuel pump pressure Fuel pump pressure 441 588 kPa 4 5 6 0 kg cm2 64 85 psi 5 If the fuel pump pressure is not within specifica tion check the following No pressure Fuel pump...

Page 284: ... 4 2 8 kg cm2 34 40 psi 7 If not within specification replace the pressure regulator 8 Connect the vacuum hose to pressure regulator FUEL PUMP Operation Test 1 Connect a jumper wire to the check connector Yellow 2 Remove the fuel filler cap 3 Turn the ignition switch ON 4 Listen for operational sound of the fuel pump at the filler inlet 5 Install the fuel filler cap 6 If no sound was heard check t...

Page 285: ...el return hose from fuel return pipe 3 Turn the ignition switch ON for 10 seconds and check the feeding capacity with graduated cylinder Feeding capacity 220 cc 13 4 cu in 10 sec min 4 If not within specification check the fuel filter and fuel line 5 Turn the ignition switch OFF and disconnect the jumper wire 86U04A 082 PULSATION DAMPER 1 Run the engine at idle 2 Place a finger on the screw of the...

Page 286: ... not correct check the following No operating sound and no speed drop Perform Quick Inspection for Electrical Signal below No speed drop only Injector resistance Injection volume of injector Quick Inspection for Electrical Signal 1 Ground the test connector Green 1 pin with a jumper wire 2 Turn the ignition switch ON 3 Open the throttle valve and check for a click at the injector with a screwdrive...

Page 287: ... firmly to the delivery pipe so that no movement of the injectors is possible Warning Be extremely careful when working with fuel Always work away from sparks or open flames 4 Connect the terminals of the fuel pump test con nector with a jumper wire Turn the ignition switch ON 5 Check that no fuel leaks from the injector nozzles Note After 1 minute a drop of fuel from the injec tor is acceptable 6...

Page 288: ...Terminal wire Voltage A C WG Approx 12V I J B OV 86U04B 075 7 If the voltages are correct replace the transfer pump 8 If not correct disconnect the transfer pump con nector 9 Check the voltage at the terminals below Terminal wire Voltage A C WG Approx 12V I J B OV 8 If the voltages are correct replace the transfer pump 9 If not correct check the voltage at terminals of the fuel pump control unit b...

Page 289: ... 86U04A 092 To prevent percolation of the fuel during idle after the engine is restarted vacuum is cut to the pres sure regulator increasing the fuel pressure Specified time Approx 120 sec Operating condition Coolant temperature above 70 C 158 F Intake air temperature above 20 C 68 F 4B 69 ...

Page 290: ...sends signal to control unit Installed in air flow meter o o Ne rotor and pick up Detects crank angle at 30 intervals sends signal to control unit Engine speed signal o X Pressure regulator Adjusts fuel pressure supplied to injectors o o Solenoid valve Pres sure regulator control Controls vacuum line to pressure regulator Closes vacuum line when hot 0 0 Throttle sensor Detects throttle valve openi...

Page 291: ...erminal System im spection 2K Sympton 4B 72 4B 116 4B 111 4B 112 4B 106 4B 71 Engine stalls or rough after hot starting 2 3 4 5 6 1 86U04B 079 System Inspection 1 Connect the SST to the engine Refer to page 4B 62 2 Start the engine 86U04B 080 86U04A 096 3 Warm up the engine to normal operating temper ature and stop the engine Warning Be careful when disconnecting the water ther mo sensor connector...

Page 292: ...s as shown in the chart Solenoid Valve Pressure Regulator Control Inspection 1 Disconnect the vacuum hose from the solenoid valve and vacuum pipe 2 Blow through the solenoid valve from vacuum hose A 3 Check that air flows from port B 4 Disconnect the solenoid valve connector 5 Connect 12V and a ground to the terminals of the solenoid valve 6 Blow through the solenoid valve from the vacuum hose A 7...

Page 293: ...ng the fuel system keep sparks cigarettes and open flames away from the fuel Fuel Pump 1 Remove the rear seat and disconnect the fuel pump connector 2 Remove the service hole cover 3 Disconnect the fuel hoses 4 Remove the fuel pump and fuel tank gauge as sembly 5 Replace the fuel pump Caution Secure the fuel pump terminals and fuel hoses securely 6 Install in the reverse order of removal 86U04A 10...

Page 294: ...UEL SYSTEM 86U04B 082 Transfer Pump 1 Remove the fuel tank Refer to page 4B 79 2 Disconnect the fuel hoses from the transfer pump 3 Remove the transfer pump 4 Install in the reverse order of removal f 4B 74 ...

Page 295: ...se from the throttle body 4 Remove the engine hanger 5 Remove the dynamic chamber mounting bolts and nuts 6 Lift the dynamic chamber 7 Disconnect the fuel return pipe bracket from the intake manifold 8 Disconnect the injector connectors 9 Remove the delivery pipe along with the pressure regulator and pulsation damper 86U04B 085 86U04B 086 Engine 86U04B 087 4B 75 ...

Page 296: ...he reverse order of removal referring to installation note Tightening torque Delivery pipe Dynamic chamber Engine hanger 19 25 Nm 1 9 2 6 m kg 14 19 ft lb Installation note Injector 1 Use new O rings 2 Apply a small amount of engine oil to the O rings when installing 3 Install the injectors and the injector insulators 86U04A 109 4B 76 ...

Page 297: ... the delivery pipe 4 Install in the reverse order of removal referring to installation note Tightening torque Pressure regulator 8 11 N m 0 8 1 1 m kg 69 95 in lb Delivery pipe 19 25 Nm Engine hanger 1 9 2 6 m kg Dynamic chamber J 14 19 ft lb Installation note Insulator Install the insulators between the intake manifold and delivery pipe Injector Refer to page 4B 76 86U04B 090 Delivery pipe 86U04B...

Page 298: ...ectors Refer to page 4B 75 2 Remove the pulsation damper 3 Install in the reverse order of removal 86U04B 093 Fuel Filter Low pressure side Refer to page 4B 73 High pressure side The fuel filter must be replaced at the intervals out lined in the maintenance schedule Warning Always work away from sparks or open flames 1 Disconnect the fuel hoses from the fuel filter 2 Remove the fuel filter and the...

Page 299: ...fuel tank keep sparks cigarettes and open flames away from the fuel tank Remove in the sequence shown in the figure 86U04B 095 Note Drain the fuel from the fuel tank before removing the tank 1 Fuel pump connectors 5 Evaporative hoses 2 Fuel hoses 6 Fuel filler hose 3 Steering angle transfer shaft 4 wheel 7 Breather hose steering 8 Fuel tank strap Refer to section 10 9 Fuel tank 4 Cross member 4 wh...

Page 300: ...y defect is found repair or replace the tank Warning Before repairing clean the fuel tank thorough ly with steam to sufficiently remove all explo sive gas Installation Install in the reverse order of removal referring to the installation note Torque Specifications 4 B 80 86U04A 119 ...

Page 301: ...on note Hoses 1 Push the hose ends of the main fuel hose fuel re turn hose and evaporation hoses onto the fuel tank fittings at least 25 mm 1 0 in 2 Push the fuel filler hose ends onto the fuel tank pipe and filler pipe at least 35 mm 1 4 in Steering angle transfer shaft 4 wheel steering Refer to section 10 4B 81 ...

Page 302: ...4B DECELERATION CONTROL SYSTEM DECELERATION CONTROL SYSTEM The fuel cut system is provided as a deceleration control system This system is to improve fuel economy 4B 82 626 MX 6 Revised 10 87 ...

Page 303: ...ects signals from input sensors and switches cuts fuel injection o o Idle switch Detects when throttle valve fully closed sends signal to control unit Installed on throttle body o o Inhibitor switch Detects in gear condition sends signal to EC AT control unit Switch ON in N or P range o o Ne rotor and pick up Detects crank angle at 30 intervals sends signal to control unit Engine speed signal o X ...

Page 304: ...ing Guide Refer to page 4B 8 and 9 Possible cause Water thermo sensor I System inspection Page 4B 116 4B 84 Checking order 2 1 86U04B 097 System Inspection Electrical Signal 1 Connect the SST between the wiring harness and control unit 2 Set 3C or 3E position on the SST Note 3C For No 2 and No 4 injectors 3E For No 1 and No 3 injectors 3 Check that the indicator lamps alternately flash at idle 86U...

Page 305: ...DECELERATION CONTROL SYSTEM 4 B 4 Increase the engine speed to 4 000 rpm then sud denly decrease the engine speed 5 Check that the red indicator lamp stays illuminat ed during deceleration 4B 85 ...

Page 306: ...sensor Throttle sensor Water thermo sensor Water thermo switch Inhibitor switch and EC AT control unit Engine control unit Igniter 86U04B 098 This system electronically controls the ignition timing to obtain better engine performance The best ignition timing is determined and set within the engine control unit based on signals from the various sensors and switches 4B 86 ...

Page 307: ...al from control unit and generates high voltage to ignition coil o X Ignition switch ST position Sends engine cranking signal to control unit o o Main relay Supplies electric current to injectors and control unit o o Ne rotor and pick up Detects crank angle at 30 intervals sends signal to control unit Engine speed signal o X Neutral switch Detects in gear condition sends signal to control unit Swi...

Page 308: ...t an ohmmeter to the terminals of the dis tributor connector 3 Check the resistance of the following Terminal Resistance at 20 C 68 F A B 210 260 1 2 C D E F 4 If not correct replace the distributor Knock Control System 1 Connect the SST to the check connector 2 Ground the test connector with a jumper wire 3 Turn the ignition switch ON 86U04B 102 Check connector Green Test connector Green 1 pin 4B...

Page 309: ... it 6 Perform step 4 again and judge the malfunction ing part as follows Monitor lamp flashes Malfunction YES Knock sensor NO Knock control unit 7 Replace the malfunctioning part Knock Sensor Replacement 1 Disconnect the knock sensor connector 2 Lift the vehicle and remove the intake manifold bracket 3 Remove the knock sensor with the SST 4 Install the knock sensor in the reverse order of removal ...

Page 310: ...Water thermo switch Water thermo sensor Air flow meter Distributor Ne signal c 3 O E to cc o LU Engine coolant temperature 86U04B 105 This system introduces exhaust gas into the intake manifold to reduce NOx in the exhaust gas It operates depending on the throttle valve opening driving condition engine coolant temperature above 40 C 104 F and radiator coolant temperature above 17 C 63 F 4B 90 ...

Page 311: ... solenoid valves vent or vacuum side o o Ne rotor and pick up Detects crank angle at 30 intervals sends signal to control unit Engine speed signal o X Solenoid valve EGR Controls vacuum to EGR control valve Vent side controls vent line Vacuum side controls vacu um line o o Throttle sensor Detects throttle valve opening angle sends signal to control unit Installed on throttle body o o Vacuum chambe...

Page 312: ...tion of the Troubleshooting Guide Refer to pages 4B 8 and 9 Possible cause Water thermo sensor EGR control valve EGR po sition sensor Sole noid valve Throttle sensor Vacuum chamb er Water thermo switch Engine control unit terminal System inspec tion Vent Vac 1H 2M 2N Page 4B 116 4B 94 4B 93 4B 93 4B 112 4B 95 4B 116 4B 105 4B 106 and 107 4B 93 Checking order 7 3 4 2 8 6 5 9 10 1 86U04B 107 4B 92 6...

Page 313: ... hose and make sure air flows 3 Disconnect the solenoid valve connector 4 Apply 12V and ground the valve as shown 5 Blow through the vent hose and make sure air does not flow 6 If not correct replace the solenoid valves 86U04B 109 Solenoid valve EGR Vacuum Side 1 Disconnect the vacuum hoses 2 Blow through the vacuum hose and make sure air does not flow 3 Disconnect the solenoid valve connector 4 A...

Page 314: ...t at C terminal check the sensor re sistance then the wiring harness and the engine control unit 2F terminal 8 Disconnect the SST and reconnect the EGR po sition sensor connector Inspection of resistance 1 Disconnect the EGR position sensor connector 2 Check as shown resistance between the terminals as shown Terminals Resistance A B 5 kfl A C 0 7 5 kfl B C 0 7 5 kfl EGR Control Valve 1 Manually ac...

Page 315: ...rect replace the EGR control valve Vacuum Chamber 1 Disconnect the vacuum hoses from the vacuum chamber and remove it 2 Connect the vacuum pump to the vacuum cham ber as shown 3 Apply vacuum and check that no vacuum is held 4 If not correct replace the vacuum chamber 5 Connect the vacuum pump to the vacuum cham ber as shown 6 Apply vacuum and check that vacuum is held 7 If not correct replace the ...

Page 316: ...um switch valve 86U04B 119 This system is the same as that of the non turbo engine Refer to page 4A 73 page for servicing the system except the replacement of the three way check valve and check and cut valve 4 wheel steering Replacement Three way check valve and check and cut valve 1 Remove the fuel tank Refer to page 4B 79 2 Disconnect the evaporative hoses from the three way check valve and che...

Page 317: ...PCV SYSTEM 4B POSITIVE CRANKCASE VENTILATION PCV SYSTEM 86U04B 121 This system is the same as that of the non turbo engine Refer to page 4A 79 page for servicing the system 4B 97 ...

Page 318: ...le pipe 86U04B 122 The catalytic converter is used to reduce CO HC and NOx The converter contains a compound of platinum and rhodium It is a three way catalyst type with a volume of 2 300 cc 140 cu in This system is the same as that of the non turbo engine Refer to page 4A 80 section for servicing the system 4B 98 ...

Page 319: ... light switch Water thermo switch Water thermo sensor Main relay eutral switch Inhibitor switch 86U04B 123 The control system consists of the input devices and the control unit The control unit controls the fuel injection amount EGI fuel injection pressure bypass air amount ignition timing switch monitor func tion and fail safe function 4B 99 J ...

Page 320: ...O X X X X X X X X X WATER THERMO SWITCH RADIATOR O X X X o o X X X O ATMOSPHERIC PRESSURE SENSOR O X X O X X X X X X INTAKE AIR THERMO SENSOR O X X o X X X o o X WATER THERMO SENSOR O o X o O O o O O O IDLE SWITCH O o X o O O X X X O THROTTLE SENSOR O O X o O O X O X O AIR FLOW METER O X X X O O o X O O Ne SIGNAL O O X o O O O O O O G2 SIGNAL X O X X X X X X X O G1 SIGNAL X O X X X X X X X O x INP...

Page 321: ...EGR valve Operate Duty values EGR amount change OFF Duty value 0 Atmospheric pressure to EGR valve Does not operate Depends on engine condition SOLENOID VALVE EGR Vacuum side OFF No vacuum to EGR valve OFF No vacuum to EGR valve SOLENOID VALVE PURGE OFF 2nd stage not operated ON 2nd stage operates OFF 2nd stage not operated OFF 1st stage controlled by water thermo valve SOLENOID VALVE PRESSURE REG...

Page 322: ...he circuit opening relay 2 Check the circuit as described Terminal Checking item Correct result Fp Resistance 0 2 30 0 Fc Continuity cranking oo B Voltage Ign ON Battery voltage STA Voltage Cranking Approx 9V Ei Continuity oo Circuit Opening Relay Apply 12V and a ground to the terminals below and 86U 04A 170 check the circuit opening relay as described ft STA B Ik FP Ei N Fc 12V Grounded Correct r...

Page 323: ...onitor 49 9200 162 was developed to check the control unit terminal voltages This monitor easily inspects the individual terminal voltages through selection of the monitor switch How to Use the Engine Signal Monitor 1 Connect the Engine Signal Monitor 49 9200 162 between the engine control unit and the en gine harness using the adapter 49 9200 163 2 Turn the selector switch and monitor switch to s...

Page 324: ... W G G B WR W LgB W R YL B R W Th m nw iFM l B I9 A irFlowM ete EM 8 16 TeslC onnector E M B 18 W aterT herm oSensor EM 5 3 LgY Y B B 20 A tm ophencP ressureSensor EM t gr r r SB LgY BLg lg B 21 T h ro n teSensor EM J I j I t I B 24 SolenoidValve EM d p jts c i B 25 lestConnector EM B 42 Fuel Tar U m l B B 27 W aterTherm oSw F W R R B l W S B 28 C lutchSw 0 10 B Y isj d ii L gB R G ______ f i i BW...

Page 325: ...nnector grounded For 3 sec after igni tion switch OFF ON below 6 2V Light il luminates After 3 sec Battery voltage light does not illuminate Test connector grounded approx 5V Test connector not grounded Monitor lamp ON below 6 2V Monitor lamp OFF Battery voltage With Self Diagnosis Checker 1E O Idle switch Accelerator pedal released below 0 5V Accelerator pedal depressed above 7 7V 1F o A C relay ...

Page 326: ... at idle After warming up Increase engine speed 0 5 1 0V Deceleration 0 0 4V 2E o Air flow meter Vs Approx 1 7V Approx 4 6V Increase engine speed voltage increases 2F o EGR position sensor 0 25 0 95V 2G o Throttle sensor Accelerator pedal released Approx 0 5V depends on 2A terminal voltage Max voltage Throt tle valve fully opened approx 4 3V 2H o Atmospheric pres sure sensor At sea level approx 4 ...

Page 327: ...n Below 2 5V While cranking bat tery voltage 3C o Injector No 4 and No 2 Battery voltage 1 Battery voltage 1 Engine Signal Monitor green and red lights flash 3D O Inhibitor switch through EC AT unit N or P range below 2 5V Other ranges Battery voltage ATX Neutral and clutch switch In gear condition Clutch pedal depressed Battery voltage Clutch pedal released below 0 5V MTX Neutral con stant Batter...

Page 328: ...fer to section 7A for replacement of the neutral switch CLUTCH SWITCH Inspection 1 Disconnect the clutch switch connector 2 Connect an ohmmeter to the switch 3 Check continuity of the switch Pedal Continuity Depressed No Released Yes 4 After checking connect the switch connector Note Refer to section 6 for replacement of the clutch switch BRAKE LIGHT SWITCH Inspection 1 Disconnect the brake light ...

Page 329: ...ing Yes Not turning No 4 Connect the switch connector after checking Note Refer to section 10 for replacement of the P S pressure switch INHIBITOR SWITCH Inspection 1 Disconnect the inhibitor switch connector 2 Connect an ohmmeter to the switch 3 Check continuity of the switch Position Continuity P and N ranges Yes Other ranges No 4 Connect the switch connector after checking Note Refer to Section...

Page 330: ...mp below 97 C 207 F Below 1 5V Coolant temp above 97 C 207 F E GY Control unit 11 OV E L ON Battery voltage E L OFF F W O Headlight switch Battery voltage Headlight switch ON Below 1 5V Headlight switch OFF G LB o Blower motor switch Below 1 5V Blower motor switch ON 3rd or 4th position Approx 5V Others H BL o Rear defroster switch Below 1 5V Rear defroster switch ON Battery voltage Rear defroster...

Page 331: ...tor from the air flow meter 5 Using an ohmmeter check resistance between the terminals with the measuring plate fully closed and fully open 6 Connect the connector to the air flow meter after inspecting 86U04B 125 Terminal Resistance fi Fully closed Fully open E2 Vs 20 400 20 1 000 m t o 100 400 E2 Vb 200 400 E2 THA Intake air thermo sensor 20 C 4 F 13 6 18 4 kfl 20 C 68 F 2 21 2 69 kfl 60 C 140 F...

Page 332: ... 86U04A 184 9 Check that BLUE wire voltage for the recorded RED wire voltage is as specified below Specification RED wire voltage V BLUE wire voltage V RED wire voltage V BLUE wire voltage V 4 50 4 59 0 37 0 54 5 10 5 19 0 42 0 61 4 60 4 69 0 38 0 55 5 20 5 29 0 43 0 62 4 70 4 79 0 39 0 56 5 30 5 39 0 44 0 63 4 80 4 89 0 40 0 57 5 40 5 49 0 44 0 64 4 90 4 99 0 40 0 58 5 50 0 44 0 66 5 00 5 09 0 41...

Page 333: ...e the control unit malfunction memory Adjustment 1 Remove the air hose from the throttle body 2 Disconnect the throttle sensor connector 3 pin 3 Connect the SST between the throttle sensor and the wiring harness 4 Turn the ignition switch ON 5 Make sure the throttle valve is fully closed 6 Measure RED wire voltage and record it 7 Change the voltmeter connection to the BLUE wire 8 Loosen the thrott...

Page 334: ...cifi cation 12 Hold the throttle valve fully open 86U04A 192 13 Check that BLUE wire voltage is within specifi cation Specification RED wire voltage V BLUE wire voltage V RED wire voltage V BLUE wire voltage V 4 50 4 59 3 58 4 23 5 10 5 19 4 05 4 79 4 60 4 69 3 66 4 32 5 20 5 29 4 13 4 88 4 70 4 79 3 74 4 41 5 30 5 39 4 21 4 98 4 80 4 89 3 82 4 51 5 40 5 49 4 29 5 07 4 90 4 99 3 90 4 60 5 50 4 29 ...

Page 335: ... 0 5 5 Inspection Steps Step 1 Throttle valve fully closed position Measure RED wire voltage Record RED wire voltage Measure BLUE wire voltage _ Verify that BLUE wire voltage is within the specified range Step 2 Throttle valve fully open position Measure BLUE wire voltage Verify that BLUE wire voltage is within the specified range Adjustment If BLUE wire voltage measured in step 1 exceeds the spec...

Page 336: ... with a thermometer and heat the water gradually 3 Check resistance of the sensor with an ohmmeter Coolant Resistance 20 C 4 F 14 5 17 8 kQ 20 C 68 F 2 2 2 7 kfl 40 C 104 F 3 C O T o 60 C 140 F 500 640 fl 80 C 176 F 280 350 fl 4 If not correct replace the water thermo sensor WATER THERMO SWITCH Inspection 1 Remove the switch from the radiator 2 Place the switch in water with a thermometer and heat...

Page 337: ...tween 0 5V 1 OV and when the speed is decreased it reads between OV 0 4V 6 If the voltmeter dosen t indicate as specified re place the oxygen sensor 86U04A 206 Monitor lamp S E LF D IA G N O S IS C H E C K E R MONITOR J r 49 M 0 I8 9AI O O O O O SELECT SW A Inspection of Sensitivity 1 Warm up the engine to the normal operating tem perature and run it at idle 2 Connect the SST to the check connecto...

Page 338: ...nspection 1 Connect a voltmeter to the atmospheric pressure sensor D terminal 2 Turn the ignition switch on and take a voltage reading Voltage 3 5 4 5V at sea level 2 5 3 5V at high altitude 2 000m 6 500 ft 3 Replace the sensor if necessary f 4B 118 ...

Page 339: ... VEHICLE INSPECTION 5 21 REMOVAL 5 22 DISASSEMBLY 5 22 INSPECTION 5 25 ASSEMBLY 5 29 CHECKING OPERATION 5 30 INSTALLATION 5 31 SPARK PLUGS 5 32 REMOVAL AND INSTALLATION 5 32 INSPECTION 5 32 IGNITION COIL 5 33 INSPECTION 5 33 HIGH TENSION LEAD 5 33 INSPECTION 5 33 DISTRIBUTOR 5 34 SPARK TEST 5 34 IGNITION TIMING 5 34 SPARK CONTROL 5 35 REMOVAL 5 36 DISASSEMBLY 5 37 INSPECTION 5 38 ASSEMBLY 5 38 INS...

Page 340: ...STRUCTURAL VIEW Ignition coil Distributor Battery itarter 86U05X 002 Ignition coil Non Turbo Turbo Alternator High tension lead High tension lead Starter inter lock switch Only M T Starter inter lock switch Only M T 5 2 ...

Page 341: ...Brush length mm in Standard 17 5 0 689 Minimum 10 0 0 394 Ignition Timing BTDC 6 1 Vacuum hoses disconnected BTDC 9 1 C Test connector grounded Distributor Type Fully transistorized HEI Electronic spark advance ESA Centrifugal spark advance Crank angle Engine speed degree rpm 2 2 1 200 12 16 2 400 12 16 3 500 16 20 4 500 Engine control unit con trols spark advance Vacuum spark advance Crank angle ...

Page 342: ...or cap or rotor Replace 5 38 Ignition coil malfunction Replace 5 33 Igniter malfunction Replace 5 41 Starter turns but Tip of overrunning clutch pinion worn Replace 5 27 engine does not Weakened overrunning clutch drive spring Replace 5 27 turn Worn overrunning clutch Replace 5 27 Binding on spline Replace 5 27 Worn brushing Replace 5 28 Worn ring gear Replace Section 6 Starter motor Sticking cont...

Page 343: ...ng the terminal 2 Inspect for corroded or frayed battery cables 3 Check the rubber protector on the positive termi nal for proper coverage Electrolyte Level 1 Check whether or not the electrolyte level lies be tween the UPPER LEVEL and the LOWER LEVEL lines 2 If low add distilled water by the UPPER LEVEL Do not overfill Specific Gravity 1 Measure the specific gravity with a hydro meter 2 If the sp...

Page 344: ...r b Do not use high voltage testers such as a megger because they will damage the rec tifier c Remember that battery voltage is always applied to the alternator B terminal d Do not ground the L terminal while the en gine is running e Do not start the engine while the connec tor is disconnected from the L and S ter minals 86U05X 008 F Terminal L Terminal S Terminal ...

Page 345: ...r both Refer to page 5 5 Charge the battery until the indicator becomes blue or replace the battery with a fully charged one 3 Turn the ignition switch ON and check that the alternator warning light illuminates Alternator warning light 4 Start the engine and check that the alternator warning light goes off 86U05X 009 1 Alternator warning light always not illuminate 86U05X 068 2 Alternator warning ...

Page 346: ...5 ALTERNATOR 3 Alternator warning light operates properly but battery discharged 86U05X 070 4 Battery overcharged Less than 14 1V More than 14 7V At 20 C 68 F At 20 C 68 F 86U05X 071 5 8 ...

Page 347: ...tery and check that the red lamp and green lamp illuminate 5 Start the engine and check that both lamps go off 1 Connect an ammeter 65A min between the wire and the B terminal 2 Turn all headlights and accessories on and depress the brake pedal 3 Start the engine and check that output current is 65A or more at 2 500 3 000 rpm of the engine speed 86U05X 010 TEST 2 Caution Do not ground the B termin...

Page 348: ... 86U05X 013 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 engin speed Voltage 14 1 14 7V S terminal 86U05X 072 TEST 5 1 Turn the ignition switch ON 2 Check that L terminal voltage is within specification Voltage 1 5V L terminal 86U 05X 073 5 10 ...

Page 349: ...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 terminal 86U05X 074 ...

Page 350: ... the wire and connector from the al ternator 3 Remove the bolts 4 Remove the V belt 5 Remove the alternator to upper side 86U05X 018 DISASSEMBLY Disassemble in the sequence shown in the figure 86U05X 019 1 Bolt 5 Rear bracket 2 Front bracket and rotor 6 Stator 3 Lock nut 7 Brush holder assembly 4 Pulley 8 Rectifier 5 12 ...

Page 351: ... 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 The stator may become scratched 63U05X 999 2 Separate the rear and front sections Note Be careful not to lose the stopper spring that fits around the circumference of the rear bearing 5BU05X 057 3 Place the rotor in a vise and loosen the pulley nut then dis...

Page 352: ...ng circumference is at the slip ring side 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 Separate the rear bracket and the stator 86U05X 077 9 Use a soldering iron to remove the solder from the rectifier and the stator leads and then remove the 1C regulator Caution Disconnect quickly use the soldering iron n...

Page 353: ...brushes Remove the solder from the pigtail and then re move the brush When soldering the brush solder the pigtail so that the wear limit line of the brush projects 2 3 mm 0 079 0 118 in out from the end of the brush holder 5 15 ...

Page 354: ...an ohmmeter 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 Check for continuity between the stator coil leads using an ohmmeter 2 Replace the stator if there is no continuity 86U05X 081 Ground of the stator coil 1 Check for continuity between the stator coil leads and the core usin...

Page 355: ...he brush spring using a spring pressure gauge 2 Replace the spring if necessary Standard force 3 0 4 2 N 310 430 g 10 9 15 2 oz Minimum 1 7 2 5 N 170 250 g 6 0 8 8 oz Note Read the spring pressure gauge at the brush tip projection of 2 mm 0 079 in Bearing 1 Check for abnormal noise looseness or insufficient lubrication 2 Replace the bearing s if there is any abnormality 86U05X 023 86U05X 090 5 1 7...

Page 356: ...TERNATOR v Rectifier 1 Check for continuity of the diodes using an ohmmeter Negative Black Positive Red Continuity E Pi P2 P3 Yes B No L No Pi P i P3 E No B Yes L Yes 2 Replace the rectifier 86U05X 025 5 18 ...

Page 357: ...tor When assembling the front bracket and rotor tight en the locknut to the specified torque Tightening torque 49 88 Nm 5 9 m kg 36 65 ft lb Brush lifting 1 Before assembly use a finger to hold the brushes into the brush holder then pass a wire 2 mm 40 50 mm 0 08 in 1 6 2 0 in through the hole shown in the figure 2 Secure the brushes in position Note Be sure to remore wire after assembly is com pl...

Page 358: ... 25 5 Nm 1 9 2 6 m kg 13 7 18 8 ft lb V BELT TENSION Adjustment 1 Loosen the alternator mounting bolt and adjusting bar bolt 2 Adjust the alternator to set to the specified deflec tion when pushing the V belt with a force of 98 N 10 kg 22 ft lb Specified deflection New 6 8 mm 0 24 0 31 in Used 7 9 mm 0 27 0 35 in 3 Tighten the bolts and recheck the tension 86U05X 029 Adjusting bar bolt Alternator ...

Page 359: ...tes 3 If the starter does not operate check the voltage between Sterminal and ground using a voltmeter 4 If the voltage is 8V or more the starter is mal function 5 If less than 8V the wiring harness is malfunction Caution If the magnetic switch is hot it may not func tion even though the voltage is standard volt age or more Note The cranking speed is greatly affected by the viscosity of the engine...

Page 360: ...out the starter from lower side of the vehicle Note Remove the lowest starter bolt last DISASSEMBLY 86U05X 083 1 Magnetic switch 2 Plunger and spring 3 Rear housing 4 Brush holder assembly 5 Armature Caution Do not strike the yoke with a hammer drop it or put it in a vise when disassembling the starter 6 Ball 7 Planetary gear 8 Drive housing front cover 9 Lever 10 Drive pinion 11 Overrunning clutc...

Page 361: ...sher 5 Brush holder assembly Note Put an aligning mark on the yoke and rear bracket for reassembly before removing the rear bracket Yoke and Armature Remove the armature and yoke Note Put an aligning mark on the yoke and front bracket for reassembly before removing the front bracket 7BU05X 035 Overrunning Clutch Planetary Gears and Inter nal Gear Remove the following parts 1 Gasket 2 Plate 3 Plane...

Page 362: ...topper 1 Remove the overrunning clutch stopper using a pipe 2 Disassemble the drive pinion internal gear and washer from the gear shaft Brush and Brush Holder Remove the brush from the brush holder using a flat tip screwdriver 5 24 ...

Page 363: ... ture if there is continuity 67U05X 049 3 Runout of commutator 1 Place the armature on V blocks and measure the runout using a dial gauge 2 Ifthe runout is excessive replace the armature Runout 0 05 mm 0 002 in Maximum 0 1 mm 0 004 in 4 Outer diameter of commutator Replace the armature if the outer diameter of the commutator is less than the grind limit 5 Roughness of commutator surface Repair usi...

Page 364: ...or continuity between the terminal and the terminal using a circuit tester Replace the magnetic switch if there is no continuity 67U05X 053 2 Wiring damage terminal body Check for continuity between terminal and body using a circuit tester Replace the magnetic switch if there is no con tinuity 67U05X 054 Ground of magnetic switch Check for continuity between and terminals using a circuit tester Re...

Page 365: ...vent it is packed with grease and sealed 86U05X 035 Internal Gear and Planetary Gears 1 Internal gear Check for wear or damage Replace if necessary 2 Planetary gears Check for wear or damage Replace if necessary 67U05X 057 Yoke Check for damage Replace if necessary 67U05X 058 Bearing Check for abnormal noise looseness binding Replace the bearing if there is any problem Note Use a bearing puller to...

Page 366: ...imit or if the wear is near the limit Wear limit 10 0 mm 0 394 in New brush 17 5 mm 0 689 in 7BU05X 043 3 Brush holder Check that the brush slides smoothly inside the brush holder 4 Brush spring 1 Measure the force of the brush spring using a spring balance 2 Replace the brush spring if the force is below specification Specification 7 N 0 7 kg 1 5 lb Note a The force is measured at the moment the ...

Page 367: ... note Assembly Note Lubricate During assembly lubricate the following points 1 Gear of armature shaft 2 Internal gear and planetary gears 3 Plunger circumference 4 Lever 5 Ball 6 Gear shaft spline 7 Front bracket housing Installation of lever Check the lever faces in the correct direction 7BU05X 047 5 29 ...

Page 368: ...re the pinion gap while the pinion is pulled out Specification 0 5 2 0 mm 0 02 0 08 in 3 Adjust the pinion gap with an adjust washer drive housing front cover magnetic switch if it is not within specification 7BU05X 050 Return test 1 Disconnect the motor wire from the M terminal and then connect the battery power to the M terminal and ground the body 2 Pull out the overrunning clutch with a flat t...

Page 369: ...A 90 max Gear shaft speed rpm 3 000 min 4 If any abnormality is noted check for the cause according to Inspection INSTALLATION Install in the reverse order of removal Note When installing the starter tighten the bolts to the specified torque Tightening torque Bolts 37 52 Nm 3 8 5 3 m kg 27 38 ft lb B terminal 9 8 11 8 N m 1 0 1 2 m kg 87 104 in lb Intake manifold bracket bolt 37 52 Nm 3 8 5 3 m kg...

Page 370: ...gs to the specified torque Tightening torque 15 23 Nm 1 5 2 3 m kg 10 8 16 6 ft lb 86U05X 042 INSPECTION Check 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 upper insulator also 4 Damaged gasket Plug gap 1 0 1 1 mm 0 039 0 043 in 86U05X 043 5 32 ...

Page 371: ...oil Use a ohmmeter to measure the resistance of the secondary coil If it is not within specification replace the coil Secondary coil resistance at 20 C 68 F Turbo 10 3 13 9 kfl Non Turbo 7 1 9 7 kfl 86U05X 045 86U05X 047 Insulation of Case Use a 500V megger tester to measure the insula tion resistance between the primary terminal and the case The standard reading is 10 Mfl or more HIGH TENSION LEA...

Page 372: ...N TIMING 1 Warm up the engine to the normal operating tem perature 2 Turn all electric loads OFF 3 Connect a tachometer and timing light to the engine 4 Connect a jumper wire between the test connec tor and ground 5 Check the idle speed Set to the specified speed if necessary Refer to section 4A or 4B Idle speed 750 25 rpm 6 Check that the timing mark Yellow on the crank shaft pulley and the mark ...

Page 373: ... tim ing are correct 3 Disconnect the vacuum hoses from the vacuum control unit and plug them 86U05X 052 Crank angle Engine speed rpm 4 While gradually increasing the engine speed use a timing light to check the advance on the pulley Excess advance weak governor spring If the governor spring is broken the advance will rise very high Insufficient advance governor weight or cam malfunction 86U05X 05...

Page 374: ...he advance with the tim ing light 86U05X 055 REMOVAL 1 Remove the high tension leads 2 Disconnect the vacuum hoses and wiring Non Turbo 3 Disconnect the coupler Turbo 4 Loosen the distributor lock bolts 5 Remove the distributor Note Do not turn the crankshaft after the distribu tor has been removed 86U05X 056 5 3 6 ...

Page 375: ...stributor rotor 3 Coupling set 4 Distributor set 86U05X 057 Caution Do not disassemble the distributor set Non Turbo Engine 1 Cap 2 Rotor 3 Gasket 4 Cover 5 Signal rotor and pin 6 Pick up coil with igniter 7 Vacuum control unit 8 Breaker 9 Coupling set 10 Governor set 11 Oil seal 12 Bearing 5 37 ...

Page 376: ...oil 2 Measure the resistance Resistance 900 1 200 fl 3 If it is not within specification replace it Pick up Coil Turbo Refer to page 4B 88 Cap and Rotor 1 Check for corrosion damage and cracks 2 Replace if necessary Distributor Shaft O Ring and Oil Seal 1 Check for damage to the distributor shaft O ring and oil seal 5 38 ...

Page 377: ... rotor is aligned as shown in the illustration 86U05X 084 INSTALLATION Note After installing the distributor adjust the ig nition timing Refer to 5 34 1 Apply engine oil to the O ring and driven gear 2 Install the distributor and connect the high tension leads and distributor connector 3 Tighten lock bolt to the specified torque Torque specification 19 25 Nm 1 9 2 6 m kg 14 18 ft lb 626 MX 6 Revis...

Page 378: ...5 DISTRIBUTOR H E I TROUBLESHOOTING Non Turbo 7BU05X 089 ...

Page 379: ...isconnect the ohmmeter leads Connect as follows lead to ground lead to SST 3 Connect an ohmmeter between the SST and ground and set the scale change dial to X1 4 Connect the SST to the battery 5 Turn the ignition switch ON 6 Push up the SW2 switch on the SST while ob serving the ohmmeter 79G05 010 7 The pointer needle on the ohmmeter should jump up the the approx 1 2 scale and then return 8 Replac...

Page 380: ...n an A T vehicle If the clutch pedal is not depressed during starting battery power will not be supplied to the starter and it will not operate INTERLOCK SWITCH Inspection 1 Disconnect the interlock switch connector 2 Connect a circuit tester to the switch 3 Check the continuity Pedal Continuity Depressed Yes Released No 4 Replace the switch if necessary 5 42 ...

Page 381: ...LUTCH PEDAL 6 5 REMOVAL AND INSTALLATION 6 5 INSPECTION 6 5 CLUTCH MASTER CYLINDER 6 6 REMOVAL 6 6 DISASSEMBLY 6 7 INSPECTION 6 8 ASSEMBLY 6 8 INSTALLATION 6 9 CLUTCH RELEASE CYLINDER 6 9 REMOVAL 6 10 DISASSEMBLY 6 10 INSPECTION 6 11 ASSEMBLY 6 11 INSTALLATION 6 12 AIR BLEEDING 6 12 CLUTCH AND FLYWHEEL 6 13 REMOVAL 6 13 INSPECTION 6 14 INSTALLATION 6 17 86U06X 001 ...

Page 382: ...TLINE OUTLINE STRUCTURAL VIEW 1 Clutch pedal 4 Clutch pipe 7 Clutch release bearing 2 Assist spring 5 Clutch release cylinder 8 Clutch cover 3 Clutch master cylinder 6 Clutch release fork 9 Clutch disc 6 2 ...

Page 383: ...epair or replace 6 1 6 Faulty Excessive runout or deformity of clutch disc Replace 6 1 5 disengagement Clutch disc splines rusted or worn Remove rust or replace 6 1 5 Oil on clutch cover facing surface Repair or replace 6 14 Diaphragm spring weakened Replace 6 14 Excessive clutch pedal play Adjust 6 4 5 Insufficient clutch fluid Add fluid 6 4 Leakage of clutch fluid Repair or replace Clutch vibrat...

Page 384: ...specification Pedal height A 216 5 221 5 mm 8 524 8 720 in Adjustment To adjust the pedal height loosen locknut and turn stopper bolt PEDAL FREEPLAY Inspection Depress the pedal lightly by hand and measure the freeplay to ensure that it is within specification Pedal freeplay 5 13 mm 0 20 0 51 in Adjustment 1 Adjust the free play by loosening locknut C and turning push rod D 2 Check that the distan...

Page 385: ...3 Pin 14 Spring seat 15 Bushings 16 Flat washer 17 Pad 18 Clutch pedal 86U06X 007 INSPECTION Check the following and repair or replace any faulty parts 1 Worn or damaged pedal bushing 2 Twisted or bent pedal 3 Worn or damaged pedal pad After installation 1 Adjust the pedal height 2 Check the pedal free play and adjust if necessary 3 Adjust the installation length of the assist spring The installat...

Page 386: ... the ABS relay box 2 Disconnect the clutch pipe with the SST 3 Remove the mounting nuts 4 Remove the clutch master cylinder 86U06X 009 Caution Clutch fluid will damage painted surfaces Be sure to use a container or rags to collect it If fluid does get on a painted surface wipe it off immediately with a rag 6 6 ...

Page 387: ... cup 5 Return spring 6 Tank cap and baffle 7 Reserve tank 8 Bushing 9 Cylinder body Caution When disassembling or assembling the clutch master cylinder do so in a clean space free from dirt and dust 1 Press down on the piston with a phillips screwdriver and remove the snap ring with snap ring pliers 86U06X 012 6 7 ...

Page 388: ...cessary Note that rubber parts should be cleaned with clutch fluid 1 Wear or damage of cylinder wall and or piston 2 Weakness of return spring 3 Wear or damage of piston cup 4 Damaged or bent reserve tank and or reserve tank installation part ASSEMBLY Apply clean clutch fluid to the piston cup and the cyl inder bore before assembly Caution After applying clutch fluid check that no for eign materia...

Page 389: ...ounting nuts Tightening torque 19 26 Nm 1 9 2 6 m kg 14 19 ft lb 3 Tighten the clutch pipe flare nut securely with the SST 4 Install the ABS relay box After installation 1 Perform air bleeding 2 Verify that there is no leakage 3 Perform a road test 86U06X 018 CLUTCH RELEASE CYLINDER 1 Clutch pipe flare nut 2 Installation bolts 3 Release cylinder 86U06X 019 6 9 ...

Page 390: ...ith the SST Note Plug the pipe in order to prevent fluid from leaking 2 Remove the installation bolts 3 Remove the release cylinder 86U06X 021 DISASSEMBLY 1 Boot 2 Push rod 3 Pjston and pis ton cup 4 Return spring 5 Bleeder cap 6 Bleeder screw 7 Steel ball 8 Cylinder body 86U06X 022 6 1 0 ...

Page 391: ...PECTION After cleaning all parts check the following points Replace any parts with new parts if necessary Note that rubber parts should be cleaned with clutch fluid 1 Wear or damage of cylinder wall and piston 2 Weakness of return spring 3 Wear or damage of piston cup 76U06X 029 ASSEMBLY 1 Install the following parts 1 Steel ball 2 Bleeder screw 3 Bleeder cap 2 Install the return spring 3 Install ...

Page 392: ...is done as described below Note a The fluid in the reserve tank must be main tained at the 3 4 level or higher during air bleeding b Use only the specified fluid type Refer to page 6 3 c Be careful not to spill clutch fluid onto a painted surface 1 Remove the bleeder cap and attach a vinyl hose to the bleeder screw 2 Place the other end of the vinyl tube in a glass con tainer of the appropriate ca...

Page 393: ...L 86U06X 029 4 Clutch disc 5 Pilot bearing 6 Flywheel 7 Ring gear 1 Remove the transaxle Refer to Section 7 2 Attach the SST to the engine and remove the clutch cover and clutch disc 1 Clutch release bearing 2 Clutch release fork 3 Clutch cover 6 13 ...

Page 394: ...ove the flywheel 86U06X 032 5 Remove the release bearing 6 Remove the release fork 86U06X 033 86U06X 034 INSPECTION Check the following and repair or replace any faulty parts Clutch Cover 1 Clutch disc for scoring cracks or discoloration Note Minor scratches or discoloration should be re moved with sandpaper 2 Diaphragm spring and cover for damage 6 14 ...

Page 395: ... in min 4 Runout of clutch disc Runout 1 0 mm 0 039 in max 5 Wear or rust on the splines Remove any minor rust Clutch Release Bearing 1 Turn the bearing both directions and check for any binding or abnormal noise 2 Worn or damaged diaphragm spring Caution The clutch release bearing is a sealed bear ing and must not be washed 3 Sliding condition of bearing Install the bearing on the clutch housing ...

Page 396: ...ws 1 Heat the ring gear with a blowtorch then tap around the gear to remove it from the flywheel 2 Heat the new ring gear to 250 300 C 480 570 F then fit it onto the flywheel Caution The bevelled side of the ring gear must face toward the engine side 4BG06X 029 3 Runout of flywheel 1 To measure set a dial indicator on the clutch disc contact surface and turn the flywheel Runout 0 2 mm 0 008 in max...

Page 397: ...ght en the flywheel installation bolts Tightening torque 96 103 Nm 9 8 10 5 m kg 71 75 ft lb Caution If reusing the flywheel bolts clean the threads to remove old sealant and apply new sealant If old sealant cannot be removed replace the bolts 4 Install the pilot bearing in the flywheel using a suit able bar and a hammer Caution a Tap it in until distance A in the figure is 3 8 4 2 mm 0 150 0 165 ...

Page 398: ...valent organic molybdenum grease 6 Install the clutch disc with the SST Note Install the clutch so that it faces in the direc tion shown in the figure 7 Install the SST and tighten the clutch cover di agonally and evenly Tightening torque 18 26 N m 1 8 2 7 m kg 13 0 20 3 ft lb 8 Install the transaxle Refer to Section 7A 86U06X 044 ...

Page 399: ...CTION 7A 25 ASSEMBLY 7A 28 STEP 1 7A 28 STEP 2 7A 30 STEP 3 7A 35 STEP 4 7A 43 INSTALLATION 7A 78 TRANSAXLE CONTROL 7A 84 OUTLINE 7A 3 STRUCTURAL VIEW 7A 3 CROSS SECTIONAL VIEW 7A 5 SPECIFICATIONS 7 A 6 TROUBLESHOOTING GUIDE 7A 7 ON VEHICLE MAINTENANCE 7A 8 TRANSAXLE OIL 7A 8 DRIVESHAFT OIL SEALS 7A 9 REMOVAL 7A 12 DISASSEMBLY 7A 48 STEP 1 7A 48 STEP 2 7A 50 STEP 3 7A 52 STEP 4 7A 55 INSPECTION 7A...

Page 400: ...Non Turbo 86U07A 002 1 Primary shaft gear assembly 2 Secondary shaft gear assembly 3 Differential assembly 4 Clutch housing 5 Primary reverse synchronizer gear 6 Secondary reverse synchronizer gear 7 Reverse idle gear 8 Transaxle case 7A 2 ...

Page 401: ...U07A 003 1 Primary shaft gear assembly 2 Secondary shaft gear assembly 3 Differential assembly 4 Clutch housing 5 Primary reverse synchronizer gear 6 Secondary reverse synchronizer gear 7 Reverse idle gear 8 Transaxle case 9 Interlock plate 7A 3 ...

Page 402: ...7A OUTLINE CROSS SECTIONAL VIEW Non Turbo I 86U07A 004 7A 4 ...

Page 403: ...OUTLINE 7A CROSS SECTIONAL VIEW Turbo 85U07A 005 7A 5 ...

Page 404: ...selective sliding and synchromesh Gear ratio 1st 3 307 3 250 2nd 1 833 1 772 3rd 1 233 1 194 4th 0 914 0 926 5th 0 717 0 711 Reverse 3 166 3 461 Final gear ratio 4 105 Oil A Type ATF DEXRON II Above 0 F API GL 4 or GL 5 SAE 80W 90 or SAE 90 Capacity 3 35 liters 3 6 US qt 3 0 Imp qt 3 65 liters 3 9 US qt 3 3 Imp qt 76G07A 601 7A 6 626 MX 6 Revised 10 87 ...

Page 405: ...earing preload Adjust 7A 36 67 Improperly adjusted change guide plate Adjust 7A 19 Won t stay in gear Bent change control rod Replace 7A 84 Worn change control rod bushing Replace 7A 84 Weak change lever ball spring Replace 7A 84 Improperly installed extension bar Tighten 7A 84 Wear of shift fork Replace 7A 21 48 Wear of clutch hub Replace 7A 26 59 Worn clutch hub sleeve Replace 7A 26 59 Worn gear...

Page 406: ...y 4 Check that the oil level is between the F and L 5 If not add the necessary amount of the specified oil through the gear case hole 61G07X 190 Replacement 1 Park the vehicle on level ground 2 Remove the speedometer driven gear See Inspection section above 3 Remove the drain plug and drain the oil 61G07X 191 4 Replace the drain plug and add the necessary amount of the specified oil through the sp...

Page 407: ... 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 5 Remove the cotter pin then disconnect the tie rod end with the SST 6 Separate the driveshaft by pulling the front hub out ward Do not use too much force at once increase the force gradually Note a Do not to allow the driveshaft ball joint to be be...

Page 408: ...ont hub outward then fit the driveshaft into the transaxle 2 Insert the driveshaft into the transaxle by push ing on the wheel hub assembly Note a Be careful not to damage the oil seal b After installation is finished pull the front hub slowly outward to check that the driveshaft is held securely by the clip Install the lower arm ball joint to the knuckle and tighten the clinch bolt Tightening tor...

Page 409: ...n plug Tightening torque 39 59 Nm 4 0 6 0 m kg 29 43 ft lb 15 Install the wheel Tightening torque 88 118 N m 9 0 12 0 m kg 65 87 ft lb 16 Add the correct quantity of the specified oil Type A T F DEXRON II Above 0 F API GL 4 or GL 5 SAE 80W 90 or SAE 90 Capacity Non Turbo 3 35 liters 3 6 US qt 3 0 Imp qt Turbo 3 65 liters 3 9 US qt 3 3 Imp qt 626 MX 6 Revised 10 87 7A 11 ...

Page 410: ...ber 1 Battery 2 Main fuse block 3 Distributor lead 4 Air flow meter connector 5 Air cleaner assembly 6 Resonance chamber Non Turbo 7 Intercooler hose s Turbo 8 Speedometer cable 9 Ground s 10 Wheel s 11 Splash shield s 12 Clutch release cylinder 13 Tie rod end 14 Nuts stabilizer 15 Lower arm ball joint 16 Driveshaft left 17 Joint shaft 18 Driveshaft right 19 Gusset plate s 7A 12 ...

Page 411: ... cleaner assembly 86U07A 019 Turbo 5 Remove the inter cooler hoses as follows 1 Inter cooler hose to throttle body 2 Air cleaner to turbocharger Non Turbo 5 Remove the resonance chamber 86U07A 020 6 Disconnect the speedometer cable 7 Disconnect the grounds from the transaxle case 86U07A 021 8 Remove the front wheels 9 Remove the splash shields 10 Drain the transaxle oil 86U07A 022 7A 13 ...

Page 412: ...ints 15 Pull the lower arms downward to separate them from the knuckles Note Do not damage the ball joint dust boots 86U07A 024 16 Separate the left driveshaft from the transaxle by prying with a bar inserted between the shaft and the case Note Do not damage the oil seal 86U07A 025 17 Remove the joint shaft bracket 18 Separate the right driveshaft together with the joint shaft in the same manner 8...

Page 413: ... install the SST may cause the differential side gears to become misposi tioned 86U07A 027 20 Remove the gusset plates 21 Remove the under cover 22 Remove the extension bar and the control rod 23 Remove the surge tank bracket 24 Remove the starter 25 Suspend the engine with the SST 7A 15 ...

Page 414: ...unt No 2 28 Disconnect the hanger rubber then remove the crossmember and the left side lower arm as an as sembly 29 Lean the engine toward the transaxle 30 Support the transaxle with a jack 31 Remove the remaining transaxle mounting bolts 32 Remove the transaxle 86U07A 034 7A 16 ...

Page 415: ...h hub assembly 9 Synchronizer ring 10 5th gear 11 Gear sleeve Secondary 5th gear Lock bolt Guide bolt Lock bolt and ball and spring Transaxle case assembly Magnet Reverse idle shaft Reverse idle gear Lock bolt Shift rod 5th and reverse and clip 22 Gate 86U07A 036 23 Pin 24 Crank lever shaft 25 0 ring 26 Crank lever assembly 27 Shift fork and shift rod as sembly 28 Steel ball 29 Spring 30 Primary s...

Page 416: ...interlock sleeve and of the control lever then turn the shift 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 86U07A 039 3 Lift the control end and remove the steel ball and at the same time remove the shift rod from the clutch housing 4 Separate the shift ...

Page 417: ...oot 13 Spring 14 Reverse gate 15 Selector 16 Oil seal 17 Bolts 18 Bleeder cover 19 Bleeder 20 Bolt 21 Speedometer driven gear assembly 22 0 ring 23 Spring pin 24 Driven gear 25 Gear case 26 Oil seal 27 Bearing outer race 76U07A 229 28 Spring pin 29 Reverse lever shaft 30 Reverse lever 31 Drain plug and washer 32 Neutral switch and gasket 33 Bearing outer race 34 Diaphragm spring 35 Adjust shim 36 ...

Page 418: ...er race secondary shaft Remove the bearing outer race by lifting out the fun nel and race together Spring pin Align the groove for removal of the clutch housing pin with the position of the spring pin then tap the pin out using a pin punch Bearing outer race differential Remove the bearing outer race with the SST 7A 20 ...

Page 419: ...leeve 15 Retaining ring 28 Retaining ring 3 Spring pin 16 Clutch hub assembly 29 Clutch hub assembly 3rd 4 Control end 17 Synchronizer spring and 4th gears 5 Shift fork 1st and 2nd 18 Synchronizer key 30 Synchronizer spring gears 19 Clutch hub 31 Synchronizer key 6 Spring pin 20 Clutch hub sleeve reverse 32 Clutch hub 7 Control lever gear 33 Clutch hub sleeve 8 Control rod 21 Synchronizer ring 34 ...

Page 420: ...o 1st gear 3 Remove the secondary 3rd gear and 2nd gear with the SST Caution Hold the shaft with one hand so that it does not fall 86U07A 047 1st gear 1 Remove the retaining ring 2 Remove the clutch hub assembly reverse gear and 1st gear as shown in the figure Caution Hold the shaft with one hand so that it does not fall Bearing inner race secondary shaft end Remove the bearing inner race with the...

Page 421: ...h one hand so that it does not fall Clutch hub assembly 3rd 4th 1 Remove the retaining ring 2 Remove the clutch hub assembly with the SST Caution Hold the shaft with one hand so that it does not fall Bearing inner race primary shaft end Remove the bearing inner race with the SST Caution Hold the shaft with one hand so that it does not fall 7A 23 ...

Page 422: ...nion gears Refer to page 7A 29 1 Knock pin 2 Pinion shaft 3 Pinion gear 4 Thrust washer 5 Side gear 6 Thrust washer 7 Side bearing in ner race 8 Speedometer drive gear 9 Side bearing in ner race 10 Gear case Side bearing inner race side opposite ring gear Remove the race from the gear case with the SST Caution Hold the gear case with one hand so that it does not fall Side bearing inner race ring g...

Page 423: ...Primary shaft gear run out Run out 0 05 mm 0 002 in max Note If the shaft gear is replaced adjust the bear ing preload Refer to page 7A 36 86U07A 056 Secondary Shaft Gear 1 Worn or damaged gear contact surface 2 Worn or damaged splines 3 Worn teeth 4 Clogged oil passage 5 Secondary shaft gear run out Standard run out 0 015 mm 0 0006 in 63U07A 068 6 Oil clearance between secondary gear shaft and ge...

Page 424: ...e clearance is less than specified re place the synchronizer ring or gear Clutch Hub 1 Worn or damaged splines 2 Worn or damaged synchronizer key groove 3 Worn end surface 4 Operation of the hub sleeve when it is installed 63U07A 070 Clutch Hub Sleeve 1 Worn or damaged 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 Li...

Page 425: ...ing transaxle case or differential gear case is replaced adjust the bearing preload of the shaft gears 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 as a unit b If the bearing is replaced adjust the preload 63U07A 075 Speedometer Driven Gear Assembl...

Page 426: ...etaining rings STEP 1 DIFFERENTIAL 86U07A 059 Assembly 1 Install the speedometer drive gear and the new bearing inner race with the SST Note Press to 19 620 N 2 000 kg 4 400 lb 2 Install the new bearing inner race with the SST Note Press to 19 620 N 2 000 kg 4 400 lb 86U07A 061 49 G030 338 86U07A 060 7A 28 ...

Page 427: ...the left and right driveshafts in the differen tial assembly 8 Support the driveshafts on V blocks as shown in the figure 9 Measure the backlash of both pinion gears Backlash 0 0 1 mm 0 0 004 in 86U07A 064 Identification mark Thickness 0 2 0 mm 0 079 in 1 2 1 mm 0 083 in 2 2 2 mm 0 087 in 86U07A 065 10 If the backlash is more than specified adjust by selecting thrust washers from the table and ins...

Page 428: ...stall the synchronizer key spring in the clutch hub with the hook in the groove This holds the three syn chronizer keys in place Note a The sizes of the synchronizer keys are different 86U07A 067 Specification mm in 1st 2nd 19 0 7480 4 25 0 1673 4 25 0 1673 3rd 4th 5th Rev 17 0 6693 4 25 0 1673 4 25 0 1673 86U07A 068 7A 30 ...

Page 429: ...y with the SST Note a Press to 19 620 N 2 000 kg 4 400 lb b Align the synchronizer ring groove and clutch housing hub key when installing 86U07A 070 3 Install the retaining ring 4 Install the synchronizer ring 4nd gear and bear ing inner race with the SST Note Press to 19 620 N 2 000 kg 4 400 lb 86U07A 071 5 Install both shift forks and the interlock sleeve as in the figure 86U07A 072 7A 31 ...

Page 430: ...asure the clearance between the 4th gear and bearing inner race Clearance 0 165 0 365 mm 0 0064 0 0144 in Maximum 0 415 mm 0 0163 in 86U07A 074 8 Install the new bearing inner race with the SST Note Press to 19 620 N 2 000 kg 4 400 lb Note The styles and sizes of synchronizer rings are different as shown in the illustration 86U07A 075 7A 32 86U07A 076 ...

Page 431: ...hub key when installing 2 Press on the clutch hub assembly reverse gear with the SST Note Press to 19 620 N 2 000 kg 4 400 lb 3 Install the retaining ring 86U07A 078 4 Install the synchronizer ring and 2nd gear 5 Install the secondary 3rd gear with the SST Note Press to 19 620 N 2 000 kg 4 400 lb 86U07A 079 6 Install the retaining ring 7 Install the secondary 4th gear and new bearing in ner race 8...

Page 432: ... differential drive gear Clearance 0 05 0 28 mm 0 0020 0 0110 in Maximum 0 33 mm 0 0199 in 86U07A 081 9 Measure the clearance between the 2nd gear and secondary 3rd gear Clearance 0 175 0 455 mm 0 0069 0 0179 in Maximum 0 505 mm 0 0199 in 86U07A 082 ...

Page 433: ...STEP 3 ASSEMBLY 7A 20 29 N m 2 3 m kg 626 MX 6 Revised 10 87 86U07A 083 7A 35 ...

Page 434: ...401 382A 49 G 030 381 49 F401 384 49 F401 385 49 FT01 51 5A V T 49 G019 021 83U07A 099 49 G030 381 Outer race Differential Outer races Secondary shaft assembly 49 G030 382A Transaxle case Outer races Primary shaft assembly Outer race 49 F401 382A Clutch housing 7A 36 626 MX 6 Revised 10 87 83U07A 033 ...

Page 435: ...o the SST selector as shown in the figure Note Turn the selector to eliminate the gap indicat ed by the arrow in the figure 4 Set the differential assembly onto the clutch hous ing then mount the bearing outer race and the selector on the differential Set the assembled selectors for the primary and secondary shaft in the clutch housing Mount the shaft gear assemblies as shown in the figure 86U07A ...

Page 436: ...e selector Note Measure the gap around the entire circumfer ence of the selector 9 Take the maximum reading and determine the shim to be used as follows Primary shaft adjust shim Subtract the diaphragm spring thickness 0 70 mm 0 0276 in from the gap determined in the step 8 Select the closest thinner shim from the table Example 1 22 mm 0 0480 in 0 70 mm 0 0276 in 0 52 mm 0 0204 in Shim 0 50 mm 0 0...

Page 437: ...the selec tor for the differential Note Measure the gap around the entire circumfer ence of the selector 13 Add 0 15 mm 0 0059 in to the measured clear ance and select the combination of shims closest in value to that measurement See the table below for available shim sizes Example 0 32 mm 0 013 in 0 32 mm 0 013 in 0 15 mm 0 0059 in 0 47 mm 0 019 in So the nearest shim on the thick side to 0 47 mm...

Page 438: ...ential adjust shim s and the bear ing outer race with a suitable pipe 86U07A 103 6 Install the adjust shims diaphragm spring funnel and bearing outer races Note Install the diaphragm spring as shown in the figure 7 Install the bearing outer races with a suitable pipe 86U07A 105 86U07A 102 86U07A 104 Transaxle case y Diaphragm spring J lll II S S Bearing outer race 7A 40 ...

Page 439: ...as shown 11 Install the new roll pin 86U07A 107 12 Install the change arm Tightening torque 12 14 Nm 120 140 cm kg 104 122 in lb 13 Install the guide plate Tightening torque A 8 11 Nm 80 115 cm kg 69 100 in lb 22 33 Nm 2 25 3 35 m kg 16 25 ft lb 14 Install reverse lever and reverse lever shaft 15 Install the new roll pin 16 Install the speedometer driven gear assembly 7A 41 ...

Page 440: ...ment and meas ure the preload Preload 1 4 2 0 N m 14 20 cm kg 12 1 17 3 in lb 76G07A 627 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 25 N m 1 0 2 5 cm kg 0 87 2 18 in lb Note Extend the handle fully and hook the pull scale to the end of the handle 8 Remove the SST transaxle case prim...

Page 441: ...STEP 4 Torque Specifications ASSEMBLY 7A 86U07A 110 626 MX 6 Revised 10 87 7A 43 ...

Page 442: ...hat it contacts the steel ball 5 With the edge of the control end against the knife when the control end is pushed in 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 6 Set each clutch hub sleeve to the neutral position and tap the shift rod from above so that the steel ball go...

Page 443: ... same direction 11 Install the reverse idle gear and the reverse idle shaft 12 Connect the magnet to the clutch housing 13 Align the end of the interlock sleeve with the con trol lever indicated by the arrow and at the same time face the reverse idle shaft screw hole in the direction shown in the figure 14 Apply a thin coat of sealant to the contact surfaces of the clutch housing and transmission ...

Page 444: ... bolt 2 17 Install the ball spring and lock bolt 3 Tightening torque 1 18 26 N m 184 264 cm kg 159 228 in lb 2 9 14 N m 90 140 cm kg 78 121 in lb 3 15 21 Nm 150 210 cm kg 129 181 in lb Note Check that gear change operation is smooth 86U07A 115 7A 46 ...

Page 445: ...he primary shaft with the SST 24 Tighten new lock nuts Tightening torque 128 196 N m 13 0 20 0 m kg 94 145 ft lb 25 Stake the lock nuts 26 Clean and coat the both surfaces and install the rear cover Tightening torque 8 11 N m 80 110 cm kg 68 95 in lb 86U07A 120 7A 47 ...

Page 446: ...ar sleeve Ball Interlock plate Interlock pins Reverse switch Bolt s spring s and ball s Transaxle case Magnet Reverse idle shaft Reverse idle gear Base plate unit Crank lever shaft and snap ring 26 Crank lever assembly 27 Roll pin 28 Shift rod 1st 2nd 29 Shift fork 1st 2nd 30 Roll pin 86U07A 121 31 Roll pin 32 Shift rod 3rd 4th 33 Shift fork 3rd 4th 34 Shift rod end 3rd 4th 35 Roll pin 36 Shift ro...

Page 447: ...unch G rw Lock nut 1 After removing the roll pin shift the gears to 5th gear 2 Shift the gears to 1st gear 3 Remove the lock nuts Caution Uncrimp the tab of the locknuts 86U07A 123 Shift Fork 5th Remove the shift fork 5th together with the clutch hub assembly 4 A 626 MX 6 Revised 10 87 7A 49 ...

Page 448: ...ring outer race and funnel secondary shaft gear clutch housing Remove the bearing outer race by lifting the funnel and the race out together Bearing outer race secondary shaft gear trans axle case Remove the bearing outer race with the SST 86U07A 128 Change rod Remove the roll pin with pin punch 86U07A 129 86U07A 127 7A 51 ...

Page 449: ...g inner race 11 Bearing inner race 21 Synchronizer ring 2 4th gear 12 Primary shaft 22 Clutch hub assembly 3 Needle bearing 13 Bearing inner race 1st 2nd 4 Gear sleeve 14 Secondary 4th gear 23 Synchronizer ring 5 Ball 15 Gear sleeve 24 1st gear 6 Synchronizer ring 16 Secondary 3rd gear 25 Needle bearing 7 Clutch hub assembly 17 2nd gear 26 Thrust washer 3rd 4th 18 Needle bearing 27 Bearing inner r...

Page 450: ...r race with the SST Caution Hold the shaft with one hand so that it does not fall Clutch hub assembly 3rd 4th Remove the 3rd gear clutch hub assembly with the SST 86U07A 132 Bearing Remove the bearing inner race with the SST Caution Hold the shaft with one hand so that it does not fall 86U07A 133 ...

Page 451: ...d the shaft with one hand so that it does not fall 1st gear Remove the clutch hub assembly 1st 2nd and 1st gear with the SST Caution Hold the shaft with one hand so that it does not fall Bearing 1 Set the SST to the bearing inner race as shown 2 Remove the bearing inner race with the SST Caution Hold the shaft with one hand so that it does not fall 7A 54 ...

Page 452: ...eplace with new ones 86U07M 38 1 Knock pin 2 Pinion shaft 3 Pinion gear 4 Thrust washer 5 Side gear 61G07X 067 6 Thrust washer 7 Side bearing inner race 8 Speedometer drive gear 9 Side bearing inner race 10 Gear case Disassembly Note Backlash Before disassembly check the backlash of the side gears and pinion gears Refer to page 7A 62 Standard backlash 0 0 1 mm 0 0 004 in 86U07A 139 7A 55 ...

Page 453: ... hole from the ring gear mounting surface side 61G07X 181 Side bearing inner race side opposite ring gear Remove the bearing inner race with the SST Caution Hold the gear case with one hand so that it does not fall 86U07A 140 Side bearing inner race ring gear side Remove the bearing inner race with the SST Note Use pads in the vise 7A 56 49 0839 425C 86U07A 141 ...

Page 454: ... 1 Worn or damaged gear contact surface 2 Worn or damage splines 3 Worn teeth 4 Clogged oil passage 5 Primary shaft gear run out Run out 0 035 mm 0 0014 in max Note If the shaft gear is replaced adjust the bear ing preload Refer to page 7A 67 Outer diameter A 41 80 41 99 mm 1 646 1 653 in B 36 75 37 00 mm 1 447 1 457 in C 36 17 36 20 mm 1 424 1 425 in 86U07A 143 inner diameter gears 3rd 47 00 47 0...

Page 455: ...mm 0 0012 in max Note If the shaft gear is replaced adjust the bear ing preload Refer to Page 7A 67 Outer diameter A 42 80 42 91 mm 1 685 1 689 in B 36 95 37 11 mm 1 455 1 461 in 86U07A 146 Inner diameter gears 1st 48 00 48 02 mm 1 890 1 891 in 2nd 50 00 50 02 mm 1 968 1 969 in 86U07A 147 Bearing 1 Roughness or noise while turning 2 Damaged bearing 3 Worn bearing 63G07C 122 7A 58 ...

Page 456: ...es 2 Worn or damaged synchronizer key groove 3 Worn end surface 4 Operation of the hub sleeve when installed 61G07X 183 Clutch Hub Sleeve 1 Worn or damaged hub splines 2 Worn or damaged sleeve fork groove 3 Clearance between sleeve and shift fork Clearance mm in Standard Maximum 1st 2nd 0 05 0 408 0 002 0 0161 0 458 0 018 3rd 4th 0 1 0 408 0 0039 0 0161 5th Rev 68U07A 148 Reverse Idle Gear 1 Worn ...

Page 457: ...is replaced adjust the bearing preload of the shaft gears and the preload of the differential side bearings Refer to page 7A 67 Speedometer Driven Gear Assembly 1 Worn or damaged teeth 2 Worn or damaged 0 ring Ring Gear Speedometer Drive Gear Worn or damaged teeth Oil Seal Damaged or worn lip 7A 60 626 MX 6 Revised 10 87 ...

Page 458: ...l to all friction surface c Use new roll pins and retaining rings a a 86U07A 151 1 Install the speedometer drive gear 2 Install the side bearing inner race with the SST 49 F401 331 86U07A 152 3 Install the bearing inner race with the SST 86U07A 153 7A 61 ...

Page 459: ... and washers Backlash of Side Gear and Pinion Gear Check and adjust by the following procedure 1 Install the left and right driveshafts in the differen tial assembly 2 Support the driveshafts on V blocks as shown in the figure 3 Measure the backlash of both pinion gears Backlash 0 0 1 mm 0 0 004 in 4 If the backlash is more than the standard adjust by selecting a thrust washer from the table to go...

Page 460: ...tandard dimension 1st 2nd 22 0 0 87 14 2 0 56 3rd 4th 5th Rev 17 0 0 67 12 2 0 48 86U07A 157 Synchronizer ring Note The size of the 1st 2nd and 3rd 4th syn chronizer rings is the same Be careful when installing them The 2nd ring has the larger cut out as shown in the illustration 86U07A 158 7A 63 ...

Page 461: ...he 3rd gear Note Apply transaxle oil to the needle bearing 2 Install the synchronizer ring and clutch hub assem bly with the SST 86U07A 160 331 338 86U07A 161 3 Install the synchronizer ring 4 Install the ball and gear sleeve 5 Install the needle bearing and the 4th gear Note Apply transaxle oil to the needle bearing 6 Install the new bearing inner race with the SST 7 Install the new bearing inner...

Page 462: ...within specifi cation replace any part which is worn or damaged Clearance 0 150 0 262 mm 0 0059 0 0103 in 86U07A 164 Secondary Shaft Gear 1 Install the thrust washer 2 Install the needle bearing and the 1st gear Note Apply transaxle oil to the needle bearing 3 Install the synchronizer ring Refer to page 7A 63 and clutch hub assembly reverse gear 86U07A 165 4 Install the synchronizer ring 5 Install...

Page 463: ...86U07A 167 8 Install the new bearing inner race with the SST 86U07A 168 9 Measure the clearance between the 1st gear and thrust washer Clearance 0 130 0 354 mm 0 0051 0 0139 in 10 Measure the clearance between the 2nd gear and secondary 3rd gear If clearance is not within specification replace any part which is worn or damaged Clearance 0 150 0 262 mm 0 0059 0 0103 in 86U07A 170 7A 66 ...

Page 464: ...100 in lb 2 Install the new oil seal with the SST 76G07A 638 3 Tap the primary and secondary shaft bearing out er races in until they are fully seated with a suit able pipe Note Install the differential bearing outer race and diaphragm springs and adjust shims after ad justing the bearing preload 86U07A 173 626 MX 6 Revised 10 87 7A 67 ...

Page 465: ...ote Roll pin length is 28 mm 1 10 in 4 Install the baffle plate Tightening torque 10 13 N m 100 130 cm kg 87 113 in lb 5 Tap the new oil seal differential with the SST 6 Tap the new oil seal primary shaft with a suitable pipe f 7 Tap the differential bearing outer race in until it is fully seated with a suitable pipe Note Install the primary and secondary shaft bear ing outer races after adjusting...

Page 466: ...ould be checked and adjusted 49 F401 385 49 F401 382A 49 G019 021 49 FT01 51 5A 86U07A 178 49 G027 001 Outer race Differential Outer races Secondary shaft assembly 49 G030 381 Transaxle case Outer races Primary shaft assembly Outer race 49 F401 382A Clutch housing 76G07A 639 626 MX 6 Revised 10 87 7A 69 ...

Page 467: ...tions in the figure 3 Install the transaxle case and set the SST Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft lb 4 To seat the bearings mount the SST on parts A and B of the selector and then turn the selector so the gap is widened Move the bar by hand until the selector can no longer be turned and then turn it in the reverse direction until the gap is eliminated 5 Manually expand the selecto...

Page 468: ...phragm spring which gose between the shim and the race from the measurement of the gap in the SST Secondary shaft Example 1 18 mm 0 046 in 1 18 mm 0 046 in 0 70 mm 0 028 in 0 48 mm 0 0919 in Diaphragm spring So the nearest shim on the thick side to 0 48 mm 0 019 in is 0 50 mm 0 020 in Note Use a maximum of two shims 8 Remove the SST and the transaxle case 9 Mount the differential assembly the prim...

Page 469: ...mm 0 030 in 0 20 mm 0 008 in 0 80 mm 0 032 in 0 25 mm 0 010 in 0 85 mm 0 034 in 0 30 mm 0 012 in 0 90 mm 0 036 in 0 35 mm 0 014 in 0 95 mm 0 038 in 0 40 mm 0 016 in 1 00 mm 0 040 in 0 45 mm 0 018 in 1 05 mm 0 042 in 0 50 mm 0 020 in 1 10 mm 0 044 in 0 55 mm 0 022 in 1 15 mm 0 046 in 0 60 mm 0 024 in 1 20 mm 0 048 in 0 65 mm 0 026 in 15 Add 0 15 mm 0 0059 in to the measured clear ance and select th...

Page 470: ...housing 86U07A 193 6 Install the primary shaft gear assembly and the differential assembly 7 Install the transaxle case and tighten the specified torque Tightening torque 37 52 N m 3 8 5 3 m kg 27 38 ft lb 76G07A 647 8 Connect the SST 9 Check that the preload is within the specified range Primary shaft 0 1 0 25 N m 1 0 2 5 cm kg 0 87 2 17 in lb Differential 1 4 2 0 N m 14 20 cm kg 12 1 17 3 in lb ...

Page 471: ...shift lever Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb 2 Install the differential assembly the secondary shaft gear assembly and the primary shaft gear as sembly 3 Install the base plate unit the crank lever assem bly and the crank lever shaft Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb 4 Install the snap ring 626 MX 6 Revised 10 87 ...

Page 472: ...all the roll pin 8 Install the interlock pin to shift rod 5th Rev 9 Install the shift rod end the shift rod 5th Rev 10 Install the roll pin 11 Install the shift rod end the shift rod and the shift fork 3rd 4th 12 Set the reverse idle gear and the reverse idle shaft in the direction shown 7A 75 ...

Page 473: ...olt Tightening torque 18 26 N m 1 8 2 6 m kg 13 19 ft lb 17 Install the SST 18 Install the balls springs and bolts 19 Install the reverse switch Tightening torque bolts and switch 20 29 Nm 2 0 3 0 m kg 14 22 ft lb 20 Install the interlock pins 21 Install the interlock plate Tightening torque 18 26 N m 1 8 2 6 m kg 13 19 ft lb 86U07A 205 22 Install the ball gear sleeve needle bearing Note Apply the...

Page 474: ...g 94 145 ft lb 29 Shift to the neutral 30 Install the roll pin to the shift fork 5th Rev 86U07A 207 31 Coat both surface with sealant Note Before coating with sealant clean the contact surfaces 32 Install the rear cover Tightening torque 8 11 N m 80 115 cm kg 69 100 in lb 33 Install the neutral switch Tightening torque 20 29 N m 2 0 3 0 m kg 14 22 ft lb 34 Install the drain plug Tightening torque ...

Page 475: ...kg Non Turbo 37 52 N m 3 8 5 3 27 38 ft lb 67 93 6 8 9 5 m kj 4 9 6 9 ft lb 19 26 N m 1 9 2 6 m kg 14 19 ft lb 27 40 ft lb 64 89 N m 6 5 9 1 m kg 42 66 ft lb 8 11 N m 80 110 cm kg 65 95 In lb 36 54 N m 3 7 5 5 m kg 27 40 ft lb 29 44 N m 3 0 4 5 m kg 22 33 ft lb 88 118 N m 9 0 12 0 m kg 65 87 ft lb 117 N m 8 0 1 1 9 m kg 58 86 ft lb 43 54 N m 4 4 5 5 m kg 32 40 ft lb 7A 78 626 MX 6 Revised 10 87 86...

Page 476: ...e in step 1 to the SST 86U07A 210 3 Install the transaxle onto the engine Note Lift the transaxle using the jack pulling the rope Tightening torque 89 117 Nm 9 1 11 9 m kg 66 85 ft lb 4 Install the engine mount No 4 and braket Tightening torque 85 117 Nm 8 7 11 9 m kg 63 86 ft lb 5 Install the engine mount No 2 Tightening torque Non Turbo 37 52 Nm 3 8 5 3 m kg 27 38 ft lb Turbo 67 93 Nm 6 8 9 5 m ...

Page 477: ...ng torque 31 46 N m 3 2 4 7 m kg 23 34 ft lb 10 12 Nm 100 120 m kg 87 104 ft lb 10 Install the surge tank bracket and the gusset plate Tightening torque 19 30 N m 1 9 3 1 m kg 14 22 ft lb D 43 61 N m 4 4 6 2 m kg 32 45 ft lb 11 Install the end plate Tightening torque 8 11 N m 80 110 cm kg 69 95 in lb 12 Install the clutch release cylinder Tightening torque 19 26 N m 1 9 2 6 m kg 14 19 ft lb 13 Ins...

Page 478: ...n pull the front hub outward to confirm that the driveshaft doesn t come out b Do not damage the oil seal 16 Install the left driveshaft as follows 1 Pull the front hub outward and insert the driveshaft into the transaxle 2 Push the joint at the differential side to connect the driveshaft to the differential side gear Note a Do not damage the oil seal b After installation pull the front hub outwar...

Page 479: ... 3 m kg 12 17 ft lb 20 Install the tie rod ends and new cotter pin Tightening torque 29 44 N m 3 0 4 5 m kg 22 33 ft lb 21 Install the splash shields Tightening torque 8 11 N m 80 110 cm kg 69 95 in lb 22 Install the front wheels Tightening torque 88 118 N m 9 0 12 0 m kg 65 87 ft lb 23 Install the grounds to the transaxle case Tightening torque 8 11 N m 80 115 cm kg 69 100 in lb 24 Connect the sp...

Page 480: ...m kg 69 95 in ib 27 Connect the distributor lead 28 Connect the main fuse block Tightening torque 8 11 N m 80 110 cm kg 69 95 in lb 86U07A 227 29 Install the battery carrier and battery 30 Add the correct quantity of the specified transaxle oil Specified oil Type A T F DEXRON II Above 0 F API GL 4 or GL 5 SAE 80W 90 or SAE 90 Capacity Non Turbo 3 35 liters 3 5 US qt 3 0 Imp qt Turbo 3 65 liters 3 ...

Page 481: ...ver knob 2 Assist boot 3 Mounting rubber boot 4 Bolts and nuts 5 Change control rod 6 Bracket installation nuts 7 Nut and washer 8 Extension bar bracket as sembly and gasket 9 Bushing 10 Pipe 11 Change lever 86U07A 230 12 Spring 13 Ball seat upper 14 Bushings 15 Boot 16 Holder 17 Ball seat lower 18 Extension bar Note Apply a coat of grease lithium base NLGI No 2 to the change lever ball the ball s...

Page 482: ...r shift 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 extension bar to the floor and then install it onto the transaxle Tightening torque 31 46 Nm 3 2 4 7 m kg 23 34 ft lb Bracket Installation Tighten the bracket installation nuts to the specified torque Tightening torque 7 10 N m 70 ...

Page 483: ...Apply grease to all joints Spring Make sure that the hooked part of the spring is properly seated in the bracket groove as shown in the figure Bracket Cavity Put grease in the bracket cavity Change Control Rod Install the change control rod so that its relationship with the shift lever is as shown in the figure Tightening torque 16 22 Nm 1 6 2 3 m kg 12 17 ft lb ...

Page 484: ...TROL UNIT 7B 46 ON VEHICLE MAINTENANCE 7B 48 AUTOMATIC TRANSAXLE FLUID ATF 7B 48 SELECTOR LEVER 7B 49 THROTTLE CABLE 7B 50 CONTROL VALVE BODY 7B 53 OIL STRAINER 7B 55 ADJUSTMENT OF 2 4 BRAKE BAND 7B 56 REPLACEMENT OF DRIVESHAFT OIL SEAL 7B 56 OIL COOLER 7B 57 REMOVAL 7B 58 DISASSEMBLY 7B 63 DISASSEMBLY STEP 1 7B 63 DISASSEMBLY STEP 2 7B 69 DISASSEMBLY STEP 3 7B 74 DISASSEMBLY STEP 4 7B 78 INSPECTI...

Page 485: ...rive plates driven plates Forward clutch 4 4 3 3 Coasting clutch 2 2 3 4 clutch 5 5 Reverse clutch 2 2 Low and reverse brake 5 5 4 4 Servo diameter Piston outer dia retainer inner dia mm in 78 36 3 07 1 42 78 40 3 07 1 57 Speedometer gear ratio Driven Drive gear P185 70 R14 20 25 P195 60 HR15 P195 60 R15 87H 21 25 Automatic transmission fluid Type Dexron II or Mill Capacity liters US qt Imp qt 6 8...

Page 486: ...hicle speed sensor 8 4 Mode indicator light 9 5 Cruise control unit 10 Cruise control switch Mode switch Hold switch Water temperature switch Throttle sensor 86U07B 003 11 Idle switch 12 Fluid temperature switch 13 EC AT 14 Pulse genelator 15 Solenoid valves 16 Inhibitor switch 7 B 3 ...

Page 487: ...3 Reverse clutch 4 Reverse and forward drum 5 3 4 clutch 6 2 4 brake band 7 Low and reverse brake 8 Output gear 9 Idle gear 10 Differential 11 Parking pawl 12 Throttle cable 13 Control body 14 Oil pump 15 Inhibitor switch 16 Pulse generator 17 Fluid temperature switch 7B 4 ...

Page 488: ...h 2 5m p h Yes o O O O o A boveapprox 4 0k m h 2 5m p h Yes 0 o o o o OD Yes o O S 1st No o o o 2nd No 0 o o 3rd B elowapprox 4 0k m h 2 5m p h Yes 0 o o o o A boveapprox 4 0k m h 2 5m p h Yes o o o o o L 1st No o O o o 2nd Yes o o o o HOLD D 2nd No o o o 3rd B elowapprox 4 0k m h 2 5m p h Yes o o o o o A boveapprox 4 0k m h 2 5m p h Yes o o o o o S 2nd Yes o o o o 3rd B elowapprox 4 0k m h 2 5m p...

Page 489: ...ulator Torque converter front chamber Converter housing OUTLET 3 4 clutch Torque converter rear chamber Torque converter front chamber Converter housing INLET Torque converter rear chamber 2 3 accumulator 7 B 6 626 MX 6 Revised 10 87 86U07B 006 ...

Page 490: ...converter rear chamber clutch INLET 2 3 accumulator Torque converter front chamber Torque converter rear chamber 3 4 clutch Low and reverse brake Control valve body C oasting clutch Reverse clutch Forward clutch 2 4 brake engagement 2 4 brake release Transaxle case 7B 7 ...

Page 491: ...to forward INLET AND OUTLET Transaxle case INLET AND OUTLET Outlet for lubrication Outlet to forward clutch Inlet to oil p u m p Outlet to reverse clutch Outlet to coasting clutch Outlet to control valve body Inlet for lubrication Inlet to forward clutch Inlet to coasting clutch Inlet to reverse clutch Oil pump 7B 8 ...

Page 492: ...uit Speed sensor and circuit All solenoid valves and circuits EC AT control unit This step checks conditions surrounding the automatic trans mission This step checks the electronic control system All input signals to EC AT control unit All output signals This step checks the power train Friction element slipping Torque converter capacity This step checks operation of the hydraulic control system A...

Page 493: ...olumn can be checked for malfunction by the results of the stall test 5 Components indicated in the Time Lag Test column can be checked for malfunction by the results of the time lag test 6 Components indicated in the Oil Pressure Test column can be checked for malfunction by the results of the oil pressure test 7 Components indicated in the Road Test column can be checked for malfunction by the r...

Page 494: ...rse brake One way clutch 1 One way clutch 2 Parking gear Planetary gear Differential assembly Accelerating Vehicle does not move in D S L or R range o O O O o O O o O o o Vehicle moves in N range O O Excessive creep O o O No creep at all o O o O O o O o Shifting No shift O o o O O o O O o Abnormal shift sequence O o o o O O o O O o O O o Frequent shifting O O o o O o O O o O Excessively high or lo...

Page 495: ...nd buzzer as shown the table below Code Number Code number Location of m alfunction Buzzer 87 EC AT Tester 49 G019 901 88 EC AT Tester 49 G019 901A 06 Speed sensor u ON OFF 11 r ON OFF 12 Throttle sensor Jin iu 55 Pulse generator 2 0sec 2 0sec nmnruii 60 1 2 shift solenoid valve n m rn 61 2 3 shift solenoid valve Jl nrnnru 62 3 4 shift solenoid valve nmmru 63 Lock up solenoid valve 0 4 sec U2 0sec...

Page 496: ...TROUBLESHOOTING 7B Components EC AT Tester Body 49 G019 901 EC AT Adapter Set 49 G019 9A1 Adapter Harness 49 G019 911 EC AT Tester Body EC AT Tester 49 G019 9A2 Adapter Harness EC AT Tester Body ...

Page 497: ...e EC AT Tester 4 Connect the adapter harness 49 G019 911 to the adapter unit 5 Select the code select switch to A position Note B position of code selector switch is used for 87 626 6 Select the select switch to NEW 626 position For 1988 626 EC AT tester 1 Set the plate 49 G019 912 onto the EC AT tester body 49 G019 901 A 2 Connect the adapter harness 49 G019 911 to the EC AT tester body 3 Perform...

Page 498: ... When the EC AT service connector is not ground ed the indicator flashes in a constant frequency while a malfunction is occurring and goes out if the malfunction recovers However the warning code is memorized in the EC AT control unit 79G07C 061 Sensors Solenoid valve Fail safe program Proces AOut sing V puts 3 The EC AT control unit has a built in fail safe func tion for the throttle sensor the p...

Page 499: ...tor Note The service connector is blue colored con nector 5 Turn the ignition switch ON 6 Check that 88 flashes on the digital display and the buzzer sounds for three seconds after turning the Ignition switch ON 7 If 88 does not flash check the service connec tor wiring 8 If 88 flashes and the buzzer sounds continuously for more than 20 seconds check wiring to 2M ter minal of the EC AT control uni...

Page 500: ...1 mph Kick down Stop the vehicle 3 Drive the vehicle at 50 km h 31 mph then de press the accelerator pedal fully to activate kick down Stop the vehicle gradually 79G07C 069 4 Reconnect the EC AT tester to the service con nector 5 Ground the EC AT service connector with a jum per wire 6 Turn the ignition switch ON 7 Check that no code numbers are displayed 79G07C 070 Inspection Procedure No 06 code...

Page 501: ...7B TROUBLESHOOTING No 12 code display Throttle sensor 79G07C 072 No 55 code display Pulse generator 86U07B 024 No 60 61 62 or 64 code display 1 2 shift 2 3 shift or 3 4 shift solenoid valve t 7B 18 ...

Page 502: ...TROUBLESHOOTING 7B 86U07B 025 No 63 code display Lock up solenoid valve 86U07B 026 7B 19 ...

Page 503: ... Fluid ATF Check ATF level and condition Refer to page 7B 48 2 Selector Lever Check selector lever position and adjust if necessary Refer to page 7B 49 86U07B 027 3 Oil Leakage Check for oil leakage 1 Warm up the ATF 2 Apply the parking brake and position wheel chocks securely to prevent the vehicle from roll ing forward 3 Shift the selector lever to R range 4 Check if oil leaks from the following...

Page 504: ...Make sure that the accelerator operates smoothly 5 Idle Speed Check idle speed Refer to Section 4A 6 Tire Inflation Pressure Check tire inflation pressure Refer to Section 12 7 Inhibitor Switch Check the inhibitor switch for operation Refer to page 7B 42 t 7B 21 79G07C 079 86U07B 029 ...

Page 505: ...e connectors 3 Turn the ignition switch and main switch ON 4 Check indication of the respective light or digital display in each condition referring to the indica tion table below 86U07B 031 Indication table of light and digital display Item Indication Condition Possible cause Input Light ON L range L OFF Other ranges ON S range INHIBITOR o OFF Other ranges Inhibitor switch or wiring SW ON D range...

Page 506: ...d sensor signal All the time Vehicle speed sensor speedometer cable or wiring DRUM SPEED Drum speed All the time Pulse generator or wirings Output Light 1 2 SOLENOID ON Control unit 1 2 shift sol VALVE OFF or wiring 2 3 SOLENOID ON Refer to page 7B 24 solenoid valve operation table Control unit 2 3 shift sol VALVE OFF or wiring 3 4 SOLENOID ON Control unit 3 4 shift sol VALVE OFF or wiring LOCK UP...

Page 507: ...P 7 ROAD TEST Solenoid valve operation table RANGE GEAR SOLENOID VALVES 1 2 2 3 3 4 Lock up P Non ON R Reverse ON N Below approx 18 km h 11 mph ON Above approx 18 km h 11 mph ON D S ON ON 2nd ON ON ON 3rd Below approx 40 km h 25 mph Above approx 40 km h 25 mph Lock up OFF ON Lock up ON ON ON OD Lock up OFF ON ON Lock up ON ON ON ON S 1st ON ON 2nd ON ON ON 3rd Below approx 40 km h 25 mph Above app...

Page 508: ...ulic components Preparation Check the following items prior to testing 1 Engine coolant engine oil and ATF levels 2 Warm the engine thoroughly to raise the ATF temperature to operating level 50 80 C 122 176 F 3 Engage the parking brake and use wheel chocks at the front and rear wheels Pull the parking brake Water temperature ATF 79G07C 084 7B 25 ...

Page 509: ...gently depress the accelerator pedal with the right 5 When the engine speed no longer increases quickly read the engine speed and release the ac celerator Caution Steps 4 5 must be done within 5 seconds 6 Move the selector lever to N and let the engine idle for at least one minute Caution The reason for idling for at least one minute is to cool the ATF and to prevent deterioration of the fluid 7B ...

Page 510: ... oil pump control valve and or transmission case Stuck pressure regulator valve In forward ranges Forward clutch slipping One way clutch 1 slipping In D range One way clutch 2 slipping In S Hold and L Hold ranges Coasting clutch slipping In D Hold and S Hold ranges 2 4 brake band slipping In R L and L Hold ranges Low and reverse brake slipping In R range Low and reverse brake slipping Reverse cluc...

Page 511: ...he test for the following shifts in the same manner 1 N D range Hold mode 2 N R range Note Make three measurements for each test and take the average value Specified time lag N D range 0 5 1 0 second N R range 0 5 1 0 second Evaluation Condition Possible Cause N D Economy shifting More than specification Insufficient line pressure Forward clutch slipping One way clutch 1 slipping One way clutch 2 ...

Page 512: ...speed in P range Idle speed Non Turbo 750 5 rpm Turbo 750 25 rpm 2 Shift the selector lever to D range and read the line pressure at idle 3 Depress the brake pedal firmly with the left foot and gradually depress the accelerator pedal with the right foot 4 Read the line pressure as soon as the engine speed becomes constant then release the accelera tor pedal Caution Steps 3 to 4 must be performed w...

Page 513: ...cation of problem Low pressure in every position Worn oil pump Fluid leaking from oil pump control valve body or transaxle case Pressure regulator valve sticking Low pressure in D and S only Fluid leaking from hydraulic circuit of forward clutch Low pressure in R only Fluid leaking from hydraulic circuit of low and reverse brake Higher than specification Throttle valve sticking Throttle modulator ...

Page 514: ...pm 2 Shift the selector lever to D range and read the throttle pressure at idle 3 Depress the brake pedal firmly with the left foot and gradually depress the accelerator pedal with the right foot 4 Read the throttle pressure as soon as the engine speed becomes constant then release the ac celerator pedal Caution Steps 3 to 4 must be performed within 5 seconds Throttle pressure kPa kg cm2 psi When ...

Page 515: ...agram Note a Drum speed rpm of the EC AT Tester represents the shift point b Vehicle speed of the EC AT Tester and speedometer and vehicle speed on a chassis roller may not meet the specified shift pattern because of tire size Therefore check the shift points with the Drum speed c There is no lock up when the coolant temperature is below 72 C 162 F d There is no overdrive when the cruise control i...

Page 516: ...TROUBLESHOOTING 7B 626 MX 6 Revised 10 87 7B 33 ...

Page 517: ...peed km h mph 7 Select D range Hold mode 8 Accelerate the vehicle and check 2 3 up and down shifts no 1st and no OD is obtained and that the 2 3 shift points are as shown in the D range Hold shift diagram 7B 34 626 MX 6 Revised 10 87 79G07C 094 ...

Page 518: ...or slippage Excessive shift shock Stuck accumulators Stuck or no one way check orifice Worn clutches brakes or one way clutch No engine braking effect Worn clutches or brakes 79G07C 095 Noise and vibration Drive the vehicle in OD lock up OD no lock up 3rd Hold and check for abnormal noise or vibration Note Abnormal noise and vibration can also be caused by the torque converter drive shaft or diffe...

Page 519: ...g in S range Economy mode and 3rd gear select the Hold mode and check that 3rd gear is held until the 3 2 down shift point as shown in the S range Hold shift diagram is achieved 4 Accelerate the vehicle with S range Hold mode and check that 2nd gear is held Non Turbo 4 3 8 8 3 8 11 8 i 34 6 8 2 9 5 8 2 4 4 8 1 9 3 8 1 5 2 8 1 0 1 8 0 5 0 8 0 OD 20 40 60 80 100 120 140 160 12 25 37 50 63 74 87 99 V...

Page 520: ...hift patterns for Economy and Power modes are the same b Shift points are the same as those of the D range Power shift diagram 4 While driving in S range Hold mode and 2nd gear shift the selector lever to L range and check that 2nd gear is held until the 2 1 down shift point as shown in the L range Hold shift diagram is achieved 5 Accelerate the vehicle in L range Hold mode and check that 1st gear...

Page 521: ... and check for abnormal noise or vibration Note Abnormal noise and vibration can also be caused by the torque converter drive shaft or differential Therefore checking of cause must be made with extreme care P Range Test 1 Shift into P range on a gentle slope release the brake and check that the vehicle does not roll 2 Shift into P range while driving the vehicle at maximum of 4 km h 2 5 mph on a l...

Page 522: ...3450 3350 4000 89 107 55 66 F Half throttle 1 6 2 2 volt Lock up ON OD 2050 2500 2400 2850 91 109 56 68 o c o o Lock up OFF OD 1950 2350 2250 2700 85 103 53 64 1 1 1 OD D3 1600 1950 1400 1850 70 86 43 53 54 70 33 43 D3 D2 1200 1550 1250 1550 38 48 24 30 34 42 21 26 OD D3 3500 3700 3550 3800 153 163 95 101 OD D2 2050 2250 90 98 56 61 89 97 55 60 Kick down OD Di 950 1100 1000 1150 42 48 26 30 44 50 ...

Page 523: ... 20 44 27 Turbo 32 20 43 27 3 2nd S range Hold mode Non Turbo 20 20 40 25 60 37 80 50 Turbo 39 24 59 37 78 48 4 3rd D range Hold mode Non Turbo 31 19 61 38 92 57 123 76 Turbo 30 19 60 37 90 56 121 75 5 OD D range Economy mode Non Turbo 44 27 88 55 131 81 175 109 Turbo 43 27 86 53 129 80 172 107 6 OD D range Economy mode Lock up Engine speed rpm Non Turbo 1 000 2 000 3 000 4 000 Turbo 76G07B 731 Ev...

Page 524: ... Power Approx 12V Below 1 5 V Below 1 5 V Below 1 5 V Below 1 5 V Economy Below 1 5 V Below 1 5 V Below 1 5 V Below 1 5 V Approx 12V 4 If correct check for continuty between the terminal Inspection of Terminal Voltage 1 Disconnect the mode switch connector 2 Check continuity of the terminals Mode Connector terminal a f d e b Economy O o o O r rower L V J O O Indicates continuity 3 If not correct r...

Page 525: ... hold switch 86U07B 053 INHIBITOR SWITCH Inspection 1 Check that the starter turns with the ignition switch at START position and the selector in the P and N ranges and dose not operate in other po sitions 2 Check that the back up reverse light illuminates when shifted to the R range with the ignition switch in the ON position 3 Check the inhibitor switch if it is not working properly 86U07B 054 I...

Page 526: ...n lb 7 Recheck the continuity of the individual terminals 86U07B 480 WATER TEMPERATURE SWITCH Inspection 1 Remove the water temperature switch 2 Place the switch in water with a thermometer and heat up the water gradually 3 Check the continuity of the terminals If necessary replace the switch Connection guide Water temperature Continuity Below 65 C 149 F Yes Above 72 C 162 F No FLUID TEMPERATURE S...

Page 527: ...inuity of the switch Inspection of Continuity 1 Disconnect the brake light switch connector 2 Check for continuity between the terminals while depressing the brake pedal PULSE GENERATOR Inspection 1 Disconnect the pulse generator connector 2 Check for continuity between the terminals if necessary replace the pulse generator Resistance 200 4000 SPEED SENSOR Inspection of voltage 1 Connect a voltmet...

Page 528: ... IDLE SWITCH AND THROTTLE SENSOR Refer to Section 4A SOLENOID VALVES Inspection of Resistance 1 Disconnect the negative battery cable 2 Disconnect the solenoid valve connector 3 Measure the resistance of the terminals except A terminal if necessary replace the solenoid valve Resistance 13 27Q Note 1 2 solenoid valve F 2 3 solenoid valve C E 3 4 solenoid valve B Lock up solenoid valve D NO LOAD SIG...

Page 529: ... or P range Approx 12V Other ranges 1G Input Water temperature switch Approx 12V Above 72 C 162 F Below 1 5V Below 65 C 149 F 1H 1 1 1J 1K 1L Input Idle switch Below 1 5V At idle Approx 12V Other speeds 1M 1N Input Brake light switch Approx 12V Brake pedal depressed Below 1 5V Brake pedal released 10 Input Throttle sensor Approx 5V Ignition switch ON Below 1 5V Ignition switch OFF 1P Input Approx ...

Page 530: ...age 7B 24 of solenoid valve operation table Below 1 5V 21 2J Output Lock up solenoid valve Approx 12V Lock up Below 1 5V Other 2K Output Hold indicator Below 1 5V Hold mode Approx 12V Other modes 2L Output Mode indicator Approx 12V Hold mode Below 1 5V Power or economy mode 2M Output EC AT Tester malfunction code Approx 12V Normal Below 1 5V If malfunction present Code signal Self diagnosis check ...

Page 531: ...ven gear 14 Oil cooler return pipe 6 Pulse generator 15 Oil cooler outlet pipe 7 Oil filler tube 16 Fluid temperature switch 8 Throttle cable 17 Blind plugs 9 Bearing cover Inspection of Level 1 Apply the parking brake and position wheel chocks to prevent the car from rolling forward Note Place the car on a flat level surface 2 Run the engine so that the automatic transaxle fluid reaches specified...

Page 532: ... J N J be depressed fO Button must be pressed rsi o m SELECTOR LEVER Inspection 1 Check that the selector lever can only be shifted as shown in the figure 2 Make sure there is a click at each range when shift ed from P L range 3 Check that the position of the selector lever and the indicator are exact 4 Check that the button returns smoothly when used to shift the selector 86U07B 067 Adjustment 1 ...

Page 533: ...rd D range in the same manner and check the amount of movement b 10 Verify the stroke difference of a and B is as specified Stroke difference 8 mm 0 315 in max Note If not within specification return to step 1 11 Check the selector lever operation Refer to Inspection section THROTTLE CABLE Inspection 1 Check the inner and outer cable for damage 2 Make sure that the accelerator operates smoothly 86...

Page 534: ... valve body 9 Remove the mounting bolt and throttle cable from the transaxle 10 Remove the O ring 86U07B 074 Installation Install in the reverse order of removal referring to in stallation note Installation note Throttle cable Install the throttle cable and a new O ring into the transaxle case Tightening torque A 8 11 Nm 80 110 cm kg 69 95 in lb 1 19 26 Nm 1 9 2 6 m kg 14 19 ft lb Control valve bo...

Page 535: ...and install the SST 3 Shift into P range and start the engine Warm up the engine to normal operating temperature and adjust the idle speed Idle speed Non Turbo 750 i 5 rpm Turbo 750 25 rpm 4 Adjust locknuts as follows When the locknuts are moved line pressure is in creased or decreased as shown Adjust the lock nuts to the correct position using the following procedure 1 Initially install the lockn...

Page 536: ...ing torque 5 10 Nm 50 100 cm kg 43 87 in lb 7 Fully open the throttle valve then crimp the pin with the protector installed as shown 8 Remove the protector 86U07B 080 CONTROL VALVE BODY Note Remove the control valve body only if troubleshooting indicates a probable failure Removal 1 Remove the throttle cable Refer to 7B 50 2 Disconnect the solenoid connector 86U07B 081 3 Remove the control valve b...

Page 537: ...To place the manual plate in the correct po sition of the manual valve shift into R be fore installation b Verify that the manual plate and manual valve are assembled correctly by using a mirror then tighten the mounting bolts 86U07B 084 ATF level After installation add ATF and with the engine idling check the fluid level and for leaks Refer to page 7B 48 86U07B 085 Throttle cable Adjust the throt...

Page 538: ...emove the oil strainer 6 Remove the O ring from the oil strainer Inspection Check the following and repair or replace any faulty parts 1 Deformed or cracked oil pan 2 Deformed or clogged oil strainer 86U07B 089 Installation 1 Apply ATF to the O ring and install it onto the oil strainer 2 Install the oil strainer Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb 86U07B 090 86U07B 087 7B 55 ...

Page 539: ...m kg 69 95 in ib 4 Add ATF and with the engine idling check the fluid level and for leaks Refer to page 7B 48 ADJUSTMENT OF 2 4 BRAKE BAND 1 Remove the oil pan Refer to page 7B 55 2 Adjust the 2 4 brake band Refer to page 7B 158 REPLACEMENT OF DRIVESHAFT OIL SEAL Replace the oil seal in the same manner as for the manual transaxle Refer to page 7A 9 7B 56 ...

Page 540: ...pection Check the following and repair or replace any faulty parts 1 Cracks damage or oil leakage 2 Bent fins repair with a screwdriver 86U07B 097 Installation Install the oil cooler referring to installation note Installation note Oil cooler Install the oil cooler Tightening torque 8 11 N m 80 110 cm kg 69 95 in lb 86U07B 098 86U07B 096 7B 57 ...

Page 541: ...ket Non Turbo 9 Speedometer cable 10 EC AT connectors 11 Grounds 12 Selector cable 13 Throttle cable 14 Front wheels 15 Splash shields 16 Oil cooler outlet and inlet hoses 17 Tie rod ends 18 Stabilizer bar control links 19 Lower arm ball joints 20 Driveshaft 21 Joint shaft bracket 86U07B 099 22 Joint shaft and driveshaft 23 Exhaust pipe bracket 24 Gusset plates 25 Under cover 26 Torque converter n...

Page 542: ...ooler hoses as follows Turbo 1 Intercooler to throttle body 2 Air cleaner to turbocharger 6 Remove the air cleaner hose and resonance cham ber Non Turbo 7 Remove the resonance chamber bracket Non Turbo 8 Disconnect the speedometer cable 9 Disconnect the EC AT connectors 1 Inhibitor switch 2 Solenoid valve 3 Pulse generator 4 Fluid temperature switch 10 Disconnect the grounds from the transaxle cas...

Page 543: ...d nuts at the left and right low er arm ball joints 20 Pull the lower arms downward to separate them from the knuckles Caution Do not damage the ball joint dust boots 21 Separate the left driveshaft from the transaxle by prying with a bar inserted between the shaft and the case Caution Do not damage the oil seal 22 Remove the joint shaft bracket 23 Separate the right driveshaft together with the j...

Page 544: ...nto the differential side gears Caution Failure to install the SST may allow the differential side gears to become misaligned 25 Remove the exhaust pipe hanger and gusset plates 26 Remove the under cover 27 Remove the torque converter nuts 86U07B 109 7B 61 ...

Page 545: ... mount No 2 33 Remove the crossmember and the left side lower arm as an assembly 34 Lean the engine toward the transaxle by loosen ing the engine support hook bolt 35 Support the transaxle with a jack 36 Remove the transaxle mounting bolts 37 Remove the transaxle 7B 62 ...

Page 546: ...d O ring 11 Control valve body cover and gasket 12 Throttle cable 13 Solenoid connector Valve body side 14 Control valve body 15 Oil pump and gasket 1 Torque converter 2 Oil pump shaft 3 Oil level gauge and oil filler tube 4 Pulse generator fluid temperature switch and inhibitor switch 5 Solenoid connector 6 Wire harnesses 7 Harness clip 7B 63 ...

Page 547: ...ividual transax le components in accordance with the Troubleshooting during disas sembly 5 Use plastic hammers when applying force to separate the light alloy case joints 6 Do not use rags during disassembly 7 Neatly arrange the removed parts in order during disassembly 86U07B 117 1 Remove the torque converter from the converter housing Note Do not allow the ATF to spill when removing the torque c...

Page 548: ...ach the suitable hanger to the oil pump as shown Lift the transaxle and mount it on the SST Warning Avoid leaning the transaxle to one side dur ing disassembly it may turn quickly and cause injury 76U07B 453 626 MX 6 Revised 10 87 7B 65 ...

Page 549: ...ture switch and inhibitor switch 8 Disconnect the solenoid connector 9 Remove the harnesses 10 Remove the harness clip then remove the oil pipes oil hoses and switch box as an assembly Note Remove the ball from the case 7B 66 76G07B 713 626 MX 6 Revised 10 87 ...

Page 550: ...l strainer and O ring 76G07B 715 76G07B 716 13 Remove the control valve body cover and gasket 14 Remove the throttle cable 1 Remove the throttle cable attaching bolt and bracket 2 Remove the cable from the throttle cam of the valve body 76G07B 717 626 MX 6 Revised 10 87 7B 67 ...

Page 551: ...7B DISASSEMBLY 16 Remove the control valve body as an assembly 17 Remove the oil pump as an assembly 7B 68 626 MX 6 Revised 10 87 ...

Page 552: ...se brake 2 Snap ring 9 Retaining plate 3 Clutch assembly 10 Drive and driven plates 4 2 4 brake band 11 Internal gear 5 Small sun gear and one way clutch 12 O ring 6 Anchor strut and shaft 13 3 4 clutch assembly 7 Servo 14 Turbine shaft 8 One way clutch and carrier hub assembly 7B 69 ...

Page 553: ...ISASSEMBLY 2 Pull the reverse and forward drum and remove the clutch assembly 3 Remove the 2 4 brake band Note Use a piece of wire to secure the brake band so that it is not damaged by being stretched 7B 70 ...

Page 554: ...07B 140 5 Pull the anchor shaft while holding the strut then remove the strut 86U07B 141 6 Remove the servo 1 Remove the snap ring with the SST 2 Remove the servo and spring 7 Remove the one way clutch and carrier hub as sembly 1 Remove the snap ring 86U07B 143 7B 71 ...

Page 555: ...together with the carrier hub assembly 8 Remove the low and reverse brake assembly 1 Remove the snap ring 2 Remove the retaining plate and the drive and driven plates 9 Remove the internal gear 1 Remove the snap ring 86U07B 144 86U07B 147 7B 72 ...

Page 556: ...rnal gear from the 3 4 clutch drum Remove the 3 4 clutch assembly 1 Remove the O ring from the turbine shaft at the converter housing side 2 Pull out the turbine shaft to remove the 3 4 clutch assembly 3 Remove the 3 4 clutch assembly ...

Page 557: ...151 7 Bracket 8 Manual shaft and manual plate 9 Actuator support 10 Parking assist lever 11 Parking pawl 1 Transaxle case 2 Output shell 3 Snap ring 4 Spring and retainer assembly 5 Low and reverse brake piston 6 Plug washer spring and detent ball 7B 74 ...

Page 558: ...ng lightly with a plastic hammer Remove the output shell from the output gear Remove the low and reverse brake piston 1 Install the SST 2 Compress the spring and retainer assembly 3 Remove the snap ring with snap ring pliers then remove the spring and retainer assembly 7B 75 ...

Page 559: ...n by applying compressed air through the fluid passage 4 Remove the manual shaft and manual plate 1 Remove the plug washer spring and detent ball 2 Remove the bracket 3 Loosen the nut and pull the manual shaft out 4 Remove the nut washer spacer and manual plate 7B 76 ...

Page 560: ... 7B 5 Remove the actuator support 6 Remove the snap ring then remove the parking assist lever 7 Remove the parking pawl 1 Remove the snap ring 2 Pull the parking shaft then remove the spring and parking pawl 7B 77 ...

Page 561: ...7B 163 1 Differential assembly 2 2 3 accumulator piston assembly 3 Roll pin 4 Bearing housing 5 Idle gear assembly 6 Output gear assembly 7 Bearing cover assembly 8 Bearing outer races 9 Adjust shim 10 Oil seals 11 O rings 12 Converter housing 7B 78 ...

Page 562: ...ssembly 3 Remove the bearing housing 1 Remove the bolt indicated in the figure 2 Remove the roll pin with a pin punch 3 Remove the bearing housing by tapping light ly with a plastic hammer 4 Remove the idle gear assembly and output gear assembly by tapping out from the torque convert er side 7B 79 ...

Page 563: ...ing cover assembly out of the converter housing 6 Remove the bearing outer race 1 Press out the bearing outer races with the SST Note Install the bearing outer race during reassem bly to adjust the preload 7 Check the oil seals for damage replace if necessary 8 Check the O rings for damage replace if necessary 86U07B 170 86U07B 169 7B 80 626 MX 6 Revised 10 87 ...

Page 564: ...place the assembly which includes that bushing 86U07B 171 TORQUE CONVERTER The torque converter is welded together and cannot be disassembled Inspection 1 Check the outer part of the converter for damage or cracks and replace it if necessary 2 Check whether there is any rust on the pilot hub of the converter or on the boss If there is any re move it completely 3 Measure the bushing of the converte...

Page 565: ...Inspection Check the following and replace any faulty parts 1 Sliding surfaces of the oil pump cover and oil pump body for damage or wear 2 Broken or worn seal ring 3 Weakened spring Free length of springs 1 For the cam ring No 8 41 6 mm 1 64 in 2 For the valve No 12 35 0 mm 1 38 in 1 Bearing race 2 Seal rings 3 Oil pump cover 4 Pump flange 5 Guide ring and guide spring 6 Vane 7 Rotor 8 Spring 7B ...

Page 566: ... 0 015 0 050 mm 0 0006 0 0020 in Maximum 0 080 mm 0 003 in 5 Vane Rotor groove Standard 0 010 0 045 mm 0 0004 0 0018 in Maximum 0 065 mm 0 0026 in 5 Wear limit Check each part for wear if not within specification replace the oil pump 1 Oil pump body sleeve outer di ameter Standard 28 00 mm 1 102 in 2 Rotor bushing inner diameter Standard 28 00 mm 1 102 in Maximum 28 05 mm 1 104 in 3 Guide rin g ou...

Page 567: ...he oil pump body and check that the valve moves smoothly 2 Install the plug Tightening torque 24 35 Nm 2 4 3 6 m kg 17 26 ft lb 3 Install the cam ring and pivot roller onto the oil pump body 4 Install the rotor onto the oil pump body 5 Install the vanes into the rotor as shown 7B 84 ...

Page 568: ...am ring 86U07B 182 7 Install the pump flange onto the rotor 86U07B 183 8 Install the spring between the cam ring and oil pump body 86U07B 184 9 Install the seal pins and springs with the pins fac ing toward the oil pump body Note Install the seal pins round end first 10 Install the O rings 86U07B 185 7B 85 ...

Page 569: ... 8 11 Nm 82 112 cm kg 71 97 in ib 86U07B 186 12 Install the oil pump shaft and check for smooth oil pump operation 13 Install the seal rings 86U07B 187 14 Apply petroleum jelly to the bearing race to secure it to the oil pump cover then install it on the oil pump cover Bearing race outer diameter 88 0 mm 3 46 in 86U07B 188 ...

Page 570: ...rive and driven plates 2 Snap ring sembly 21 Dished plate 3 Retaining plate 12 Coasting clutch drum 22 Snap ring 4 Drive and driven plates 13 Coasting piston 23 Return spring stopper 5 Dished plate 14 Outer seal 24 Piston return spring Coasting clutch 15 Inner seal 25 Reverse piston 6 Snap ring 16 Outer seal 26 Seal rings inner and outer 7 Retaining plate 17 Seal rings 27 Reverse and forward drum ...

Page 571: ...mbly 5 Remove the coasting clutch drum from the reverse and forward drum by applying compressed air through the fluid passage 86U07B 191 G019 029 G019 026 G019 024 G019 027 Coasting piston 1 Remove the coasting clutch drum from the coast ing clutch drum by applying compressed air through the fluid passage Reverse piston 1 Install the SST in the reverse and forward drum as shown 2 Compress the pist...

Page 572: ... reverse piston by applying com pressed air through the fluid passage 86U07B 197 Inspection Check the following and repair or replace any faulty parts 1 Drive and driven plates for damage or wear Drive plate thickness Standard 1 6 mm 0 063 in Minimum 1 4 mm 0 055 in 2 Clutch piston for damage or cracks 3 Clutch drum for damage or deformation 4 Seal contact area for damage 5 Check ball for leaking ...

Page 573: ...everse piston 2 Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the reverse clutch drum 86U07B 199 86U07B 200 3 Install the reverse piston by pushing evenly around the circumference being careful not to damage the seal rings 2 Install the piston return spring with the tabs facing away from the reverse piston 3 Install the re...

Page 574: ...e and driven plates Note Installation order Driven Drive Driven Drive 11 Install the retaining plate with the step facing downward 12 Install the snap ring 86U07B 204 13 Check the reverse clutch clearance 1 Measure the clearance between the snap ring and the retaining plate of the reverse clutch 2 If the clearance is not within specification ad just it by selecting a proper retaining plate Reverse...

Page 575: ... the coasting clutch drum the correct po sition in the reverse and forward drum 4 Push evenly around the circumference being careful not to damage the outer seal 2 Install the coasting piston 1 Apply ATF to inner and outer faces of the seals and install them onto the coasting piston 2 Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installati...

Page 576: ...n 5 Compress the spring and retainer assembly 6 Install the snap ring 7 Remove the SST 8 Install the dished plate with the dished side upward 9 Install the drive and driven plates Note Installation order Driven Drive Driven Drive 10 Install the retaining plate 11 Install the snap ring 86U07B 210 86U07B 211 86U07B 212 ...

Page 577: ...ard clutch 1 Install the dished plate with the dished side downward 2 Install the drive and driven plates Note Installation order Non Turbo model Driven Drive Driven Drive Driven Drive Turbo model Driven Drive Driven Drive Driven Drive Driven Drive 3 Install the retaining plate 4 Install the snap ring 86U07B 215 5 Check the forward clutch clearance 1 Measure the clearance between the snap ring and...

Page 578: ...st ing clutch drum and coasting clutch piston are fully submerged 4 Check that no bubbles come from between the piston and drum seal when applying com pressed air through the fluid passages as shown Caution The compressed air must be under 392 kPa 4 0 kg cm2 57 psi and should not applied for over 3 seconds 7 Apply petroleum jelly to the thrust bearings to se cure them then install them on both sid...

Page 579: ...on Check the following and replace any faulty parts 1 Sun gear drum and small sun gear for damage or wear 2 Bushing for damage or wear Specification Sun gear drum 33 425 mm 1 316 in max Small sun gear 24 021 mm 0 946 in max 3 Inner and outer race for damage or wear 4 Damaged or worn clutch hub 5 Damaged or worn gear 6 Damaged or worn thrust bearing 7 Broken or worn snap ring 8 One way clutch opera...

Page 580: ...outer race and replace if necessary 86U07B 225 5 Apply petroleum jelly to the thrust bearing to se cure it then install it to the one way clutch inner race Thrust bearing outer diameter 62 1 mm 2 44 in 86U07B 226 6 Install the one way clutch into the one way clutch outer race Caution Check that the spring cage of the one way clutch faces toward the outer race i 86U07B 227 86U07B 224 7B 97 ...

Page 581: ...228 Assembly 1 Install the small sun gear into the sun gear drum 2 Install the snap ring 3 Apply petroleum jelly to the thrust bearing to se cure it then install it to the one way clutch inner race Thrust bearing outer diameter 62 1 mm 2 44 in 86U07B 230 4 Install the one way clutch inner and outer race to the sun gear drum Note Align the splines of the one way clutch inner race and small sun gear...

Page 582: ...heck that when the small sun gear is held the one way clutch outer race turns smoothly and only clockwise 7 Apply petroleum jelly to the thrust bearing to se cure it then install it to the sun gear drum Thrust bearing outer diameter 72 0 mm 2 83 in 7B 99 ...

Page 583: ... Carrier hub as sembly 5 Inner race Low and reverse hub 86U07B 235 Inspection Check the following and replace any faulty parts 1 Damaged or worn gear and operation 2 Clearance between pinion washer and planetary carrier Clearance 0 2 0 7 mm 0 008 0 028 in 3 Damaged or worn inner race 4 Broken or worn snap ring 5 Damaged or worn bearing race 7B 100 626 MX 6 Revised 10 87 ...

Page 584: ...40 Assembly 1 Assemble the carrier hub assembly to the inner race 2 Install th snap ring 3 Apply petroleum jelly to the bearing races to se cure them then install them to both sides of the one way clutch and carrier hub assembly Bearing race outer diameter Sun gear drum side 72 0 mm 2 83 in 3 4 clutch side 57 0 mm 2 21 in Note Install the tabs of the bearing race into the alignment holes clutch In...

Page 585: ... 3 Retaining plate 4 Drive and driven plates 5 Snap ring 6 Spring and re tainer assembly 7 3 4 clutch piston 8 Outer seal 9 Inner seal 10 3 4 clutch drum 86U07B 242 Disassembly note 3 4 clutch piston 1 Install the SST to the 3 4 clutch as shown 2 Compress the spring and retainer assembly 3 Remove the snap ring 4 Remove the SST then remove the spring and re tainer assembly 86U07B 243 7B 102 ...

Page 586: ...l contact areas for damage 5 Check ball for leaking or sticking 6 Spring and retainer assembly for separation or deformation 7 Broken or worn snap ring 8 Broken or weakened spring Free length of spring 33 2 mm 1 307 in Assembly 1 Install the 3 4 clutch piston 1 Apply ATF to the inner and outer seals and install them onto the 3 4 clutch piston 2 Install the piston by pushing evenly around the circu...

Page 587: ... upward 9 Install the snap ring 86U07B 250 10 Check the 3 4 clutch clearance 1 Measure the clearance between the snap ring and the retaining plate of the 3 4 clutch 2 If the clearance is not within specification ad just it by selecting a proper retaining plate 3 4 clutch clearance 1 3 1 5 mm 0 051 0 059 in Retaining plate sizes mm in 3 8 0 150 4 0 0 157 4 2 0 165 4 4 0 173 4 6 0 181 4 8 0 189 86U0...

Page 588: ...hile applying compressed air Caution The compressed air must be under 392 kPa 4 0 kg cm2 57 psi and not applied for over 3 seconds 12 Apply petroleum jelly to the thrust bearings and se cure them to both sides of the 3 4 clutch drum Thrust bearing outer diameter Carrier hub side 56 1 mm 2 21 in Output shell side 72 1 mm 2 84 in 86U07B 254 49 G019 012 86U07B 253 7B 105 ...

Page 589: ...ring 4 2 3 accumulator spring 5 2 3 accumulator piston 6 Large seal ring 7 Small sea ring 86U07B 255 Inspection Check the following and replace any faulty parts 1 Damaged or worn piston 2 Damaged or worn stopper plug 3 Broken or weakened spring Free length of spring Non Turbo 83 3 mm 3 280 in Turbo 75 4 mm 2 968 in 86U07B 256 7B 106 ...

Page 590: ...ug 86U07B 259 LOW AND REVERSE BRAKE Inspection Check the following and replace any faulty parts 1 Damaged or worn drive and driven plates Drive plate thickness Standard 1 6 mm 0 063 in Minimum 1 4 mm 0 055 in 2 Broken or worn snap ring 3 Deformed or detached spring and retainer as sembly 4 Broken or weakened spring 86U07B 260 Free length of spring 20 5 mm 0 807 in 5 Damaged or worn piston 6 Damage...

Page 591: ...spring Free length of spring Non Turbo 43 25 mm 1 703 in Turbo 42 0 mm 1 654 in 86U07B 262 OTHER INSPECTION Check the following and replace any faulty parts 1 Damaged or worn output shell 2 Damaged or worn internal gear 3 Damaged or worn turbine shaft 4 Damaged or worn oil pump shaft 5 Damaged or worn anchor strut and shaft 86U07B 263 6 Damaged or cracked valve body cover 7 Damaged or cracked oil ...

Page 592: ...oid mixing up similar parts 3 Disassemble the control valve assembly and thoroughly clean it when the clutch and or brake bands are burned and or when the automatic transmission fluid is degenerated Components I 1 1 2 Solenoid valve 2 2 3 Solenoid valve 3 Bolts 4 Front control body 5 Front premain front gasket 6 Premain separator 7 Front premain rear gasket 8 Premain control body 9 Premain main fr...

Page 593: ...l body 3 Main rear front gasket 4 Rear separator 5 Main rear rear gasket 86U07B 266 6 Rear control body 7 3 4 solenoid valve 8 Lock up solenoid valve 9 Bolts Disassembly of Control Valve Body 1 Remove the 3 4 solenoid valve and lock up sole noid valve 2 Remove the O rings and oil strainers 86U07B 267 7B 110 ...

Page 594: ...rainers 86U07B 268 5 Remove the front indicated bolts and pull out the front control body with premain separator as a unit 86U07B 269 6 Remove the front premain gaskets and separator from the front control body 86U07B 270 7 Remove the orifice check valve 0 8 mm 0 071 in and spring from the premain control body 86U07B 271 7B 111 ...

Page 595: ...trol body 10 Remove the orifice check valves f 2 0 mm 0 079 in and springs and the throttle relief ball and spring from the premain control body 86U07B 273 11 Remove the converter relief bail and spring and the orifice check valve 00 8 mm 0 031 in and spring from the main control body 86U07B 274 12 Turn the assembly over and remove the bolts shown in the figure Remove the rear separator as a unit ...

Page 596: ... body 14 Remove the orifice check valves 01 5 mm 0 059 in 01 0 mm 0 039 in 02 0 mm 0 079 in and spring from the rear control body 86U07B 276 15 Remove the orifice check valve Non Turbo 02 5 mm 0 098 in Turbo 02 0 mm 0 079 in and spring and the rubber ball from the main control body 86U07B 277 ...

Page 597: ...ervo control valve 7 Servo control spring 8 Stopper pin 9 Stopper plug 10 Bypass valve 11 Bypass spring 12 Bolt 13 1 2 accumulator plate and gasket 14 1 2 accumulator spring 15 1 2 accumulator piston 16 1 2 accumulator seal rings 17 Bolt 18 N R accumulator plate and gasket 19 N R accumulator piston 20 N R accumulator rear spring 21 N R accumulator seal rings 22 N D accumulator front spring 23 N D ...

Page 598: ...7 Light green N D accumulator front spring Non Turbo 9 8 0 386 52 9 2 083 1 0 0 039 Brown Turbo 9 8 0 386 68 0 2 677 1 1 0 043 Orange Coasting bypass spring 5 8 0 228 37 7 1 484 0 6 0 024 Dark blue 3 2 timing spring 8 2 0 323 28 6 1 126 0 8 0 031 Red 3 2 capacity spring 5 4 0 213 30 6 1 205 0 5 0 020 White Throttle relief ball spring 6 6 0 260 21 6 0 850 0 8 0 031 86U07B 279 Assembly 1 Install the...

Page 599: ...n install the 1 2 accumulator piston and 1 2 accumulator springs 8 Install the 1 2 accumulator gasket and plate then tighten the plate Tightening torque 6 8 Nm 66 80 cm kg 57 69 in lb 9 Install the bypass spring bypass valve stopper plug and stopper pin 10 Install the servo control spring servo control valve stopper plug and stopper pin 11 Install the 2 3 timing valve 2 3 timing spring and retaine...

Page 600: ... 10 1 2 shift valve 11 1 2 shift spring 12 Stopper pin 13 Stopper plug 14 2 3 shift valve 15 2 3 shift spring 16 Stopper pin 17 Stopper plug 18 3 4 shift valve 19 3 4 shift spring 20 Retainer 21 Throttle backup valve 22 Throttle backup spring 23 Stopper pin 24 Stopper plug 25 Throttle modulator valve 26 Throttle modulator spring 27 Throttle cam assembly 28 Throttle plug assembly 29 Throttle spring...

Page 601: ...ow 2 3 3 4 shift spring 7 4 0 291 36 6 1 441 0 8 0 031 Gray Throttle backup spring 9 65 0 380 29 6 1 060 0 55 0 022 Red Throttle modulator spring 6 3 0 248 47 9 1 886 0 8 0 031 Throttle assist spring 5 15 0 203 32 3 1 272 0 55 0 022 Dark green Throttle spring 5 4 0 213 47 2 1 858 0 8 0 031 Pink Converter relief ball spring 6 9 0 272 24 1 0 949 0 9 0 035 Maroon Orifice check valve spring 5 0 0 197 ...

Page 602: ...per pin 5 Install the throttle backup spring throttle back valve and retainer 6 Install the 3 4 shift spring 3 4 shift valve stopper plug and stopper pin 7 Install the 2 3 shift spring 2 3 shift valve stopper plug and stopper pin 8 Install the 1 2 shift spring 1 2 shift valve stopper plug and stopper pin 9 Install the low reducing valve low reducing spring and retainer 10 Install the pressure modi...

Page 603: ...nual valve 2 Stopper pin 3 Stopper plug 4 Pressure regulator backup plug 5 Pressure regulator plug sleeve 6 Pressure regulator plug 7 Pressure regulator spring seat 8 Pressure regulator spring 9 Pressure regulator valve 10 Stopper pin 11 Stopper plug 12 Lock up control valve 13 Lock up control spring 7B 120 ...

Page 604: ...3 26 5 1 043 1 0 0 039 Maroon Lock up control spring 5 0 0 197 35 2 1 386 0 6 0 024 Purple 86U07B 295 Assembly 1 Install the lock up control spring lock up control valve stopper plug and stopper pin 86U07B 296 2 Install the pressure regulator valve pressure regu lator spring pressure regulator spring seat pres sure regulator plug pressure regulator plug sleeve pressure regulator backup plug stoppe...

Page 605: ... letter 1 Install the orifice check valves 01 5 mm 0 059 in 01 0 mm 0 039 in 02 0 mm 0 079 in and springs in the rear control body as shown 2 Install the gaskets on both sides of the rear sepa rator then install it onto the rear control body 86U07B 301 front gasket rear gasket Note The main rear rear gasket and main rear front gasket are not interchangeable 86U07B 302 86U07B 300 7B 122 ...

Page 606: ...ol body as shown 86U07B 303 4 Install the rear control body to the main control body 5 Loosely tighten the bolts Note Match the bolt head letter as shown 86U07B 305 6 Turn the assembly over and install the orifice check valve 00 8 mm 0 031 in and spring and the con verter relief ball and spring in the main control body as shown 86U07B 306 86U07B 304 7B 123 ...

Page 607: ...rol body as shown 86U07B 307 8 Install the gaskets on both sides of the main sepa rator then install it onto the premain control body 86U07B 308 front gasket rear gasket Note The premain main rear gasket and pre main main front gasket are not inter changeable 86U07B 309 9 Set the premain control body onto the main con trol body 86U07B 310 7B 124 ...

Page 608: ...ck valve 00 8 mm 0 071 in and spring in the premain control body as shown 86U07B 312 12 Install the gaskets on both sides of the premain separator then install it onto the front control body 86U07B 313 Note The front prem ain front gasket and front premain rear gasket are not inter changeable 86U07B 314 86U07B 311 7B 125 ...

Page 609: ...sely tighten the bolts Note Match the bolt head letter as shown 15 Install the control valve body mounting bolts as shown for alignment 16 Tighten the mounting bolts 1 Tighten the front control body Tightening torque 6 8 Nm 66 80 cm kg 57 69 in lb 7B 126 ...

Page 610: ...nstall the 3 4 solenoid valve and lock up solenoid valve along with new O rings and oil strainers Tightening torque 6 8 Nm 66 80 cm kg 57 69 in lb 86U07B 320 18 Install the 1 2 solenoid valve and 2 3 solenoid valve along with new O rings and oil strainers Tightening torque 6 8 Nm 66 80 cm kg 57 69 in lb 86U07B 321 7B 127 ...

Page 611: ...ring inner race 8 Speedometer drive gear 9 Ring gear and gear case assembly Disassembly note Checking backlash Before disassembly measure the backlash of the side gears and pinion gears If not within specification re place the differential assembly Backlash Standard 0 025 0 1 mm 0 001 0 004 in Maximum 0 5 mm 0 020 in 1 Roll pin 2 Side gear 3 Side gear thrust washer 4 Pinion shaft 5 Pinion gear 7B ...

Page 612: ...rential b Insert the punch into the spring pin hole from the ring gear side Side bearing inner race 1 Remove the side bearing inner race side oppo site the ring gear from the gear case with the SST 86U07B 325 2 Remove the side bearing inner race ring gear side with a combination of parts from the SST 86U07B 326 Inspection Check the following and replace any faulty parts 1 Damaged or worn gears 2 C...

Page 613: ... side oppo site the ring gear onto the ring gear and case assembly with the SST 2 Press on the other side bearing inner race ring gear side in the same manner Caution Do not reuse the bearings if they were removed Install the pinion gears and thrust washers into the case Install the pinion shaft Install the roll pin and make a crimp so that it will not come out of the gear case 7B 130 ...

Page 614: ...e left and right driveshafts in the differential assembly 2 Support the driveshafts on V blocks 3 Measure the backlash of both pinion gears Backlash Standard 0 025 0 1 mm 0 001 0 004 in Maximum 0 5 mm 0 020 in 8 If the backlash is not within specification place the differential assembly 86U07B 333 OUTPUT GEAR Disassembly Disassemble in the sequence shown in the figure referring to the disassembly ...

Page 615: ...ed or worn output gear 2 Damaged bearing Assembly 1 Press the output gear bearings onto the output gear with the SST IDLE GEAR Disassembly Disassemble in the sequence shown in the figure referring to the disassembly note for the specially marked parts 1 Ilocknut 2 Idle gear bearing 3 Spacer 4 Idle gear 5 Adjust shim 6 Idle gear bearing 7 Idle shaft 8 Bearing outer race 9 Bearing outer race 86U07B ...

Page 616: ...otective plates to prevent damage to the SST 86U07B 338 Bearing outer race Remove the bearing outer race from the idle gear with the SST 86U07B 339 Inspection Check the following and replace any faulty parts 1 Damaged or worn idle gear 2 Damaged or worn bearing Assembly 1 Press the bearing outer races in with the SST 86U07B 341 7B 133 ...

Page 617: ...damage to the SST 86U07B 343 J 4 Check and adjust the idle gear bearing preload 1 Turn the idle gear assembly and SST over and secure the gear in the vice Note Use protective plates to prevent damage to the idle gear 2 Attach the SST and spring scale or torque wrench and measure the preload while tight ening the locknut Tightening torque 128 177 Nm 13 18 m kg 94 130 ft lb Preload 0 03 0 9 Nm 0 3 9...

Page 618: ... 0 0063 in 0 18 mm 0 007 in 0 20 mm 0 008 in Note a The maximum allowable number of shims is 7 b Preload is reduced by increasing the thick ness of the shims or increased by reduc ing the thickness of the shims BEARING COVER ASSEMBLY Disassembly Disassemble in the sequence shown in the figure referring to the disassembly note for the specially marked parts 1 Oil seal 2 Bearing outer race 3 O ring ...

Page 619: ...ng Assembly 1 Press the bearing outer race into the cover 2 Press the oil seal into the cover with the SST 86U07B 349 BEARING HOUSING Disassembly Remove the bearing outer race with a pin punch and hammer Note Install the bearing outer race during reassem bly of transaxle to adjust the preload Inspection Check the following and replace any faulty parts 1 Damaged bearing housing 2 Damaged bearing ou...

Page 620: ...ions 3 Before assembly apply ATF to each O ring seal ring rotating part and friction part 4 If the brake band or drive plates are replaced with new ones first soak them in ATF for at least 2 hours before installing 5 Each seal gasket and O ring must be replaced with a new one 6 Be sure to install all thrust bearings and races in the correct direction and position ASSEMBLY STEP 1 Torque Specificati...

Page 621: ...s the bearing cover in after aligning it with guide bolts as shown Tightening torque 11 14 Nm 110 140 cm kg 95 122 in lb 86U07B 354 2 Install the converter housing onto the transax le hanger 3 Remove the bearing outer race and adjust shims from the bearing housing Refer to page 7B 136 4 Mount the output gear assembly onto the con verter housing 7B 138 86U07B 499 626 MX 6 Revised 10 87 ...

Page 622: ...3 7 Set the bearing housing on the SST selector and install the four SST bolts then tighten them to the specified torque Tightening torque 19 26 N m 1 9 2 6 m kg 13 7 18 8 ft lb 8 Turn the SST selector to increase the clear ance indicated by the arrow with the SST bars until it no longer turns Note This is to seat the bearing 9 Turn the selector in the opposite direction un til the preload is elim...

Page 623: ...07B 361 Note Read the preload when the output gear starts to turn 12 Measure the clearance Select adjust shim s equivalent to the measured clearance Thickness of shim 0 10 mm 0 004 in 0 12 mm 0 005 in 0 14 mm 0 006 in 0 16 mm 0 0063 in 0 18 mm 0 007 in 0 20 mm 0 008 in 0 50 mm 0 020 in Caution a Measure the clearance around the entire cir cumference and select shims equivalent to the maximum clear...

Page 624: ...within specification return to step 2 Preload 0 03 0 9 Nm 0 3 9 0 cm kg 0 26 7 81 in lb Reading on pull scale 0 3 9 N 0 03 0 9 kg 0 066 1 98 lb 17 Remove the bearing housing and output gear assembly 2 Adjust the differential side bearing preload and select the adjust shim s as described below Note To inspect and adjust the preload use the SST shown below 49 G 0 3 0 381 4 9 D 0 1 9 001 49 G 0 1 9 0...

Page 625: ... into the S ST then set them on the differential as sembly Caution Eliminate the gap by turning either A or B of the selector 4 Set the six SST in the positions shown Note Install the bolts in the positions shown in the illustration above 86U07B 369 5 Set the transaxle case on the selectors 6 Tighten the SST bolts to the specified torque Tightening torque 36 52 N m 3 7 5 3 m kg 27 38 ft lb 86U07B ...

Page 626: ... to ob tain the specified preload pull scale reading Preload 0 5 N m 5 cm kg 4 3 in lb Reading on pull scale 5 N 0 5 kg 1 1 lb Note Read the preload when the differential starts to turn 12 Measure the clearance between A and B 13 Add 0 2 mm 0 0079 in to the measured clearance and select the shim s closest in valve to that measurement Thickness of shim 0 10 mm 0 004 in 0 12 mm 0 005 in 0 14 mm 0 00...

Page 627: ...9 N 3 0 4 0 kg 6 6 8 8 lb 19 Remove the transaxle case 3 Install the idle gear and output gear as an assem bly by tapping in with a plastic hammer 4 Install the bearing housing 1 Install the bearing housing on the converter housing Tightening torque 19 26 Nm 1 9 2 6 m kg 14 19 ft lb 2 Align the groove on the idle shaft with the matching mark on the bearing housing 3 Tap the roll pin in with a pin ...

Page 628: ...ASSEMBLY 7B ASSEMBLY STEP 2 Torque Specifications 86UQ7B 379 626 MX 6 Revised 10 87 7B 145 ...

Page 629: ... 1 2 44 72 0 2 83 56 1 2 21 72 1 2 84 Race 88 0 3 46 72 0 2 83 57 0 2 21 72 0 2 83 Note Install with petroleum jelly to prevent the thrust bearing or bearing race from falling out Procedure 1 Install the parking pawl 1 Install the parking pawl and shaft 2 Install the spring and snap ring 3 Move the manual shaft and check that the park ing pawl operates 7B 146 ...

Page 630: ...torque 11 14 Nm 1 1 1 4 m kg 8 0 10 ft lb 4 Install the manual shaft and manual plate 1 Install the manual plate spacer washer and nut 2 Tighten the nut to specified torque Tightening torque 41 55 Nm 4 2 5 6 m kg 30 41 ft lb 3 Install the bracket Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb 7B 147 ...

Page 631: ...uter seals and install them to the low and reverse brake piston 2 Face the outer seal lip toward the inside by gently rolling it down around the circumference for easier installation into the case 3 Install the low and reverse brake piston by pushing evenly around the circumference be ing careful not to damage the outer seal 4 Install the spring and retainer assembly 7B 148 86U07B 389 626 MX 6 Rev...

Page 632: ...n applying compressed air through the fluid passage Refer to page 7B 152 Caution The compressed air must be under 392 kPa 4 0 kg cm2 57 psi and not applied for over 3 seconds Install the output shell to the output gear and in stall the bearing race onto the output shell Bearing race outer diameter 72 0 mm 2 83 in Apply a thin coat of silicon sealant to the contact surfaces of the converter housing...

Page 633: ...mporarily install the SST to hold the turbine shaft 49 G019 0A0 49 0107 680A 86U07B 395 86U07B 396 2 Install the turbine shaft and 3 4 clutch assembly 1 Assemble the turbine shaft and 3 4 clutch as sembly 2 Check that the thrust bearing and bearing race are installed in the correct position 3 Install the turbine shaft and 3 4 clutch assem bly into the transaxle case 86U07B 397 B earing R ace 7B 15...

Page 634: ...ternal gear to the 3 4 clutch drum 2 Install the snap ring Install the carrier hub assembly 1 Check that the thrust bearing and bearing race are installed in the correct position 2 Hold the turbine shaft with one hand to pre vent it from rotating 3 Install the carrier hub assembly into the 3 4 clutch drum by rotating it 7B 151 ...

Page 635: ...ce 1 Measure the clearance between the snap ring and the low and reverse brake retaining plate 2 If the clearance is not within specification ad just it by selecting a proper retaining plate Low and reverse brake clearance 2 1 2 4 mm 0 083 0 094 in Retaining plate sizes mm in 6 8 0 268 7 0 0 276 7 2 0 283 7 4 0 291 7 6 0 299 7 8 0 307 86U07B 404 10 Check the low and reverse brake operation by ap p...

Page 636: ...the snap ring 12 Install the servo to the transaxle case 1 Install the servo spring and servo 2 Compress the servo with the SST 3 Install the snap ring 4 Remove the SST 5 Install the piston stem 13 Install the anchor strut 14 Install the 2 4 brake band in the transaxle case so that it is expanded fully Note Interlock the 2 4 brake band and anchor strut as shown 7B 153 ...

Page 637: ... 410 2 Install the small sun gear and one way clutch by rotating it 16 Install the piston stem in the position while pulling out the 2 4 brake band with a pliers then loosely tighten the piston stem by hand 86U07B 412 17 Install the clutch assembly 1 Check that the thrust bearing is installed in the correct position 86U07B 411 86U07B 413 B earing 7B 154 ...

Page 638: ...bly by rotating it Note Measure the height difference between the re verse and forward drum and transaxle case Non Turbo 0 8 mm 0 032 in Turbo 3 8 mm 0 151 in 17 Install the snap ring into the bottom ring groove of the turbine shaft 7B 155 ...

Page 639: ...7B ASSEMBLY ASSEMBLY STEP 4 Torque Specifications 31 47 N m 8 11 Nm 0 8 1 1 m kg 69 95 in lb 86U07B 417 ...

Page 640: ... clearance A between the transaxle case and oil pump 6 Select a suitable bearing race from the chart below N K V i Clearance A I Select this bearing race mm in 0 91 1 10 0 036 0 043 1 2 0 047 0 71 0 90 0 028 0 035 1 4 0 055 0 51 0 70 0 020 0 027 1 6 0 063 0 31 0 50 0 012 0 019 1 8 0 071 0 11 0 30 0 004 0 011 2 0 0 078 0 0 10 0 0 003 2 2 0 087 7 Remove th qit pump 8 Place the selected bearing race ...

Page 641: ...urns 3 Tighten the locknut to the specified torque Tightening torque 25 39 Nm 2 5 4 0 m kg 18 29 ft lb 3 Install the oil strainer along with a new O ring to the transaxle Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb 4 Install the oil pan along with a new gasket Tightening torque 8 11 Nm 85 110 cm kg 74 95 in lb Note Install the magnets in the positions shown in the illustration 7B 158 ...

Page 642: ... O ring in the transaxle case 7 Install a new O ring on the bracket then feed the throttle cable through the transaxle case and con nect it to the throttle cam 8 Install the throttle cable attaching bolts and bracket Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb 19 26 Nm 1 9 2 6 m kg 14 19 ft lb 9 Install the control valve body cover along with a new gasket Tightening torque 8 11 Nm 85 110 cm...

Page 643: ... ft lb Harness clip 8 11 Nm 80 110 cm kg 69 95 in lb 11 Install the ball spring gasket and a plug Tightening torque 31 47 Nm 3 2 4 8 m kg 23 35 ft lb 13 Install the pulse generator and fluid temperature switch Tightening torque Pulse generator 8 11 Nm 80 110 cm kg 69 95 in lb Fluid temperature switch 29 39 Nm 3 0 4 0 m kg 22 29 in lb 7B 160 86U07B 433 626 MX 6 Revised 10 87 ...

Page 644: ...h the holesj h j I 5 Install the screw then tighten the bolts to the specified torque it i j Tightening torque 86U07B 434 8 11 Nm 80 110 cm kg 69 95 in lb 15 Install the harness with the remaining clip Tightening torque 8 11 Nm 80 110 cm kg 69 95 irvlb 16 Remove the transaxle from the SST r a v V JFSV JPW l 86U07B 435 jf gninsft Igi ivM 3 17 Install the oil level gauge and tube along with a new O ...

Page 645: ...verter in an erect posi tion when filling it with ATF do not allow the fluid to overflow b If the converter does not fit in easily do not try to force it install carefully 22 To ensure that the torque converter is installed ac curately measure distance A between the end of the torque converter and the end of the converter housing A approx 25 mm 0 98 in 23 Install the engine mount No 1 Tightening t...

Page 646: ...INSTALLATION 7B INSTALLATION TORQUE SPECIFICATIONS 626 MX 6 Revised 10 87 86U07B 440 7B 163 ...

Page 647: ...Mount the transaxle to the engine Tightening torque 89 117 Nm 9 1 11 9 m kg 66 86 ft lb Note a Lift the transaxle with the jack while pull ing the rope b Align the torque converter bolts and drive plate holes 4 Install engine mount No 4 and bracket Tightening torque Bolt 36 54 Nm 3 7 5 5 m kg 27 40 ft lb Nut 64 89 Nm 6 5 9 1 m kg 47 66 ft lb 5 Install engine mount No 2 Tightening torque 85 117 Nm ...

Page 648: ...Install the manifold bracket Tightening torque 6 19 30 Nm 1 9 3 1 m kg 14 22 ft lb 6 37 52 Nm 3 8 5 3 m kg 27 38 ft lb 11 Install the torque converter nuts Tightening torque 43 61 Nm 4 4 6 2 m kg 32 45 ft lb m V V y 12 Install the end plate il 08 lio S d j 3 gSft E s fc S biewjuo dwr men s n n o s teteniistiA d emo tea sn ob Miiasvhh m i yftiav it Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb...

Page 649: ... damage the oil seal b After installation pull the front hub outward to verify that the driveshaft does not come 16 Install the left driveshaft as follows 1 Pull the front hub outward to insert the driveshaft into the transaxle 2 Push the joint from the differential side to con nect the driveshaft to the differential side gear Caution a Do not damage the oil seal b After installation pull the fron...

Page 650: ... 23 Install the front wheels Tightening torque 88 118 Nm 9 12 m kg 65 87 ft lb 24 Connect the throttle cable Note Adjust the throttle cable with the oil pressure test Refer to page 7B 52 25 Connect the selector cable Tightening torque Nut 29 39 Nm 3 0 4 0 m kg 22 29 ft lb Bolts 16 22 Nm 1 6 2 3 m kg 12 17 ft lb 26 Connect the ground wires to the transaxle case Tightening torque 8 11 Nm 80 115 cm k...

Page 651: ...leaner assembly then connect the air flow meter connector and inlet hose Tightening torque foU Bolt 31 40 Nm 3 2 4 1 m kg 23 30 in lb Nut 8 11 Nm 80 110 cm kg 69 95 in lb no J c I 33 Connect the distributor lead H 34 Connect the main fuse block M cf 1 0 Tightening torque 8 11 Nm 80 110 cm kg 69 95 in lb 86U 07B 459 35 Install the battery carrier and battery Tightening torque 31 40 Nm 3 2 4 1 m kg ...

Page 652: ...rvo control y valve Blocked Pressure modifier valve Blocked Throttle modulator Throttle back up valve Blocked Low reducing valve Pressure regulator valve 3 2 Icapacity valve Manual valve Oil pump Throttle pressure Throttle modulated pressure Line pressure Torque converter pressure _ Lock up control valve Throtflevalve j Forward clutch w p re s s u re Reverse clutch pressure __ o jj c r o o a o c B...

Page 653: ...ed Throttle modulator valve Low reducing valve Pressure regulator valve 20 3 2 timing valve 3 2 capacity valve Manual valve Apply side Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Torque converter pressure Lock up control valve Throttle valve Forward clutch pressure Reverse clutch pressure 1 2 accumulator accumulator check port Throttle back up valve Blocked ...

Page 654: ...ccumulator accumulator 2 3 Timing valve Coasting bypass valve __ Servo control x Tl 1valve Blocked Pressure J modifier 1 valve x Blocked Throttle modulator valve valve Blocked Low reducing valve Pressure regulator valve 3 2 capacity valve I Throttle pressure j Throttle modulated pressure Line pressure Torque converter pressure Throttle valve Forward clutch pressure Reverse clutch pressure Oil pump...

Page 655: ...sure Lock up icontrol valve N R accumulator 3 accumulator 3 Timing i1 8 jC o a s tin g bypass valve Bypass valve Servo control x valve Blocked Pressure r modifier 1 valve x Blocked IThrottle Low reducing Ivalve Hocked 19 Pressure regulator valve 3 2 timing valve 1 2 0 3 2 Icapacity valve Forward clutch pressure Reverse clutch pressure Oil pump Throttle pressure Throttle modulated pressure Line pre...

Page 656: ...ol valve Blocked j Pressure m o d ifie r j valve x Blocked L _ j Throttle R modulator p i valve Low reducing valve Blocked 19 Pressure regulator valve 20 3 2 timing valve Apply side Throttle pressure H S Throttle modulated pressure M B Line pressure I Operating line pressure I Torque converter pressure Lock up control valve Throttle valve Forward clutch pressure Reverse clutch pressure 1 2 accumul...

Page 657: ... valve Blocked Pressure modifier valve Blocked Throttle modulator valve 1 2 shift valve 19 Pressure regulator valve 3 2 capacity valve Apply side I Throttle pressure I Throttle modulated pressure Line pressure Operating line pressure Torque converter pressure Throttle valve Forward clutch p re s s u re Reverse clutch pressure 1 2 accumulator N R accumulator Throttle back up valve Blocked reducing ...

Page 658: ...rottle pressure Throttle modulated pressure Line pressure Operating line pressure Torque converter pressure _Lock up control valve 3J z o m co 30 O O m J 03 m i O O D 30 O o 7 T 3 ro ui 3 TJ Oil pump X D U c n o o aj o c s i CD ...

Page 659: ...ve Bypass valve Servo control x valve Blocked Pressure modifier valve Blocked Low reducing valve 19 Pressure regulator valve 3 2 capacity valve Manual valve Apply side Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Torque converter pressure Forward clutch p re s s u re Reverse clutch pressure 1 2 accumulator N R accumulator Throttle modulator 2i l i I valve Thr...

Page 660: ...469 Apply side I Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Torque converter pressure Lock up control valve Oil pump 33 z o m O o o 0 1 c u z o 3J c n o o J3 O c s i m ...

Page 661: ... bypass valve Servo control1111 valve Blocked j Pressure modifier valve x Blocked Throttle modulator valve Throttle back up valve Blocked Low reducing valve Pressure 1 regulator n _ _ valve 3 2 timing valve i Oil pump 3 2 capacity valve Forward clutch pressure Reverse clutch pressure i Throttle pressure Throttle modulated pressure I Line pressure Operating linge pressure Torque converter pressure ...

Page 662: ...lve Servo control1 valve Blocket Bypass valve j Pressure S 1 modifier I valve x Blocked IThrottle modulator Ivalve Low reducing valve Pressure regulator 3 2 timing valve Manual valve Throttle pressure Throttle modulated pressure H Line pressure I Operating line pressure J Torque converter pressure 1 2 accumulator Forward clutch pressure Reverse clutch pressure ____ _ Throttle back up af Blocked I ...

Page 663: ...86U07B 472 r j 00 o o o Throttle pressure Throttle modulated pressure 1 Line pressure Operating line pressure L I Torque converter pressure 3J Z o m ro O m 33 X O qj X o a c n o o JO o c H 1 Oil pump ...

Page 664: ...e Servo control x x valve Blocked Pressure modifier valve Blocked W j Throttle fBJ modulator 2m valve 1 2 shift valve Low reducing valve Blocked 19 Pressure regulator valve 1 2 0 3 2 timing valve 3 2 capacity valve Manual valve Apply side I Throttle pressure I Throttle modulated pressure Line pressure Operating line pressure Torque converter pressure Release side Forward clutch pressure Reverse cl...

Page 665: ...e Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Torque converter pressure Lock up control valve I Oil pump 30 z Q m co 30 O O m 30 CD O m u a 30 o X p o 7 T 3 ro ai 3 T3 U X o u c n o o 3 O c 1 C ...

Page 666: ...9 I Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Low reducing pressurre Operating low reducing pressure Torque converter pressure Oil pump u z o m to H O m n X a D c n o o a o c n I CD ...

Page 667: ...6U07B 476 I n J O D I O O Apply side Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Low reducing pressure I Operating low reducibg pressure Torque converter pressure ...

Page 668: ...side Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Low reducing pressure Torque converter pressure 30 Z o m ro Z o o m JO C D m r O D T 3 3D O X O 00 3 T3 X a jj c n o o 3D O c 1 GO j ...

Page 669: ... side I Throttle pressure Throttle modulated pressure Line pressure Operating line pressure Low reducing pressure Torque converter pressure 3J z o m ro O m 33 00 O m T J 73 3J O X o 7 C 3 O 00 3 T3 Oil pump ...

Page 670: ...16 Drum Brake 9 17 REMOVAL 9 17 DISASSEMBLY 9 18 INSPECTION 9 19 ASSEMBLY 9 19 INSTALLATION 9 20 Disc Brake 9 21 REMOVAL 2WS 9 21 REMOVAL 4WS 9 22 DISASSEMBLY 9 23 INSPECTION 9 24 ASSEMBLY 9 25 INSTALLATION 2WS 9 26 INSTALLATION 4WS 9 27 DRIVESHAFT 9 28 ON VEHICLE MAINTENANCE 9 28 REMOVAL 9 29 DISASSEMBLY MTX 9 31 INSPECTION MTX 9 32 ASSEMBLY MTX 9 33 DISASSEMBLY ATX 9 35 INSPECTION ATX 9 36 ASSEM...

Page 671: ...L VIEW Driveshaft MTX 86U09X 080 1 Lock nut 2 Shaft and ball joint as sembly 3 Boot 4 Boot band 5 Ball joint assembly differential side 6 Snap ring 7 Clip 8 Clip 9 Joint shaft assembly 10 Reamer bolt 11 Bracket mounting bolt 9 2 ...

Page 672: ...OUTLINE 9 Driveshaft ATX 86U09X 081 1 Lock nut 2 Shaft and ball joint as sembly 3 Boot 4 Boot band 5 Tripod joint assembly 6 Clip 7 Joint shaft assembly 9 3 ...

Page 673: ...9 OUTLINE Front Axle 86U09X 002 1 Lock nut 4 Driveshaft 2 Disc plate 5 Wheel speed sensor ABS 3 Caliper assembly 9 4 ...

Page 674: ...OUTLINE 9 Rear Axle 86U09X 003 Drum brake Disc brake 1 Lock nut 2 Brake drum 3 Back plate 4 Parking cable 5 Brake pipe 6 Disc plate 7 Dust cover 8 Knuckle spindle 9 Wheel speed sensor ABS 9 5 ...

Page 675: ...er 86U09X 004 Item Turbo Non Turbo Right Left Right Left Length of joint mm in MTX 355 5 14 00 355 5 14 00 360 0 14 17 360 0 14 17 between centers of joints ATX 348 8 13 73 348 8 13 73 355 5 14 00 355 5 14 00 Shaft diameter mm in MTX 26 0 1 02 24 0 0 94 ATX 26 0 1 02 24 0 0 94 86U09X 005 Length of joint Shaft diameter 86U09X 082 9 6 ...

Page 676: ...Refer to Section 11 Unstable handling Bent steering linkage Refer to Section 10 Joint in steering system worn or damaged Refer to Section 10 Incorrect steering pinion preload adjustment Refer to Section 10 Fatigued coil spring Refer to Section 13 Faulty shock absorber s Refer to Section 13 Lower arm bushing worn or damaged Refer to Section 13 Incorrect toe in adjustment front or rear Refer to Sect...

Page 677: ...sembly and suspend it us ing a rope 5 Position a dial indicator against the hub cap then push and pull the disc plate by hand in the axial direction and measure the end play of the wheel bearing If the end play exceeds specification replace the wheel bearing End play 0 2 mm 0 0079 in max 6 Install the caliper assembly Tightening torque 78 98 Nm 8 0 10 0 m kg 58 72 ft lb 7 Install the wheel Tighten...

Page 678: ...he sequence shown in the figure referring to the removal note for the specially marked parts 86U09X 009 1 Hub cap 2 Lock nut 3 Caliper assembly 4 Disc plate 5 Tie rod end 6 Stabilizer 7 Lower arm 8 Wheel speed sensor ABS 9 Knuckle 9 9 ...

Page 679: ...T AXLE Caliper assembly Remove the caliper assembly and suspend it Tie rod end Disconnect the tie rod end with the SST Stabilizer Remove the stabilizer bolt Wheel speed sensor ABS Remove the speed sensor 9 10 ...

Page 680: ... Front wheel hub 3 Retaining ring 4 Front wheel bearing 5 Dust cover 6 Knuckle 86U09X 015 Disassembly Note Front wheel hub Remove the front wheel hub with the SST Note If the bearing inner race remains on the front wheel hub grind a section of the bearing in ner race to approx 0 5 mm 0 0197 in Then remove it with a chisel 626 MX 6 Revised 10 87 9 11 ...

Page 681: ...ring with the SST 86U09X 016 INSPECTION Check as described below replace parts if necessary 1 Check the knuckle for cracks or damage S6U09X 084 2 Check the front wheel hub for seizure cracks or damage 3 Check the dust cover for cracks or damage 86U09X 098 9 12 ...

Page 682: ...If applicable Install a new dust cover with the SST Install a new front wheel bearing with the SST Install the retaining ring Install a new oil seal with the SST Note Apply grease to the oil seal lip Install the front wheel hub with the SST 9 13 ...

Page 683: ...cifications 86U09X 021 1 Install the knuckle to the shock absorber Tightening torque 93 117 Nm 9 5 11 9 m kg 69 86 ft lb 2 Install the lower arm ball joint Tightening torque 43 54 N m 4 4 5 5 m kg 32 40 ft lb 3 Install the driveshaft 9 14 ...

Page 684: ...d end Tightening torque 29 44 Nm 3 0 4 5 m kg 22 33 ft lb 7 Install the lock nut Tightening torque 235 319 Nm 24 0 32 5 m kg 174 235 ft lb 8 Check the end play Refer to page 9 7 End play 0 2 mm 0 0079 in max 9 Stake the lock nut to groove 10 Install the caliper assembly Tightening torque 78 98 Nm 8 0 10 0 m kg 58 72 ft lb 11 Install the wheel Tightening torque 88 118 Nm 9 0 12 0 m kg 65 87 ft lb 6...

Page 685: ...d it us ing a rope 69G09X 012 5 Position a dial indicator against the hub cap then push and pull the disc plate or brake drum by hand in the axial direction and measure the end play of the wheel bearing If the end play exceeds specification replace the wheel bearing End play 0 2 mm 0 0079 in max 6 Install the caliper assembly Disc Tightening torque 45 67 Nm 4 6 6 8 m kg 33 49 ft lb 7 Install the w...

Page 686: ...in the figure referring to the removal note for the specially marked parts 86U09X 030 1 Hub cap 5 Brake pipe 9 Shock absorber 2 Lock nut 6 Back plate 10 Knuckle spindle 3 Brake drum 7 Trailing link 11 Brake shoe assembly 4 Parking brake cable 8 Lateral link 9 17 ...

Page 687: ...ble in the sequence shown in the figure referring to the disassembly note for the specially marked parts 1 Oil seal 2 Retaining ring 3 Rear wheel bearing 4 Brake drum Disassembly Note Bearing Remove the rear wheel bearing with the SST ...

Page 688: ... surface 86U09X 034 Brake Drum Wear or damage to brake drum Note Remove minor rust with sandpaper ASSEMBLY 1 Install a new rear wheel bearing with the SST 2 Install the retaining ring 3 Install a new oil seal with the SST Note Apply grease to the oil seal lip 86U09X 036 61G09X 036 86U09X 035 9 19 ...

Page 689: ...nstallation note Torque specifications Installation Note Brake pipe 1 Connect the brake pipe with the SST Tightening torque 13 22 N m 1 3 2 2 m kg 9 16 ft lb 2 Bleed the air Refer to Section 11 End play Measure the end play Refer to page 9 16 98 177 N m 10 18m kg 73 131 ft lb H 9 2 0 ...

Page 690: ...ake REMOVAL 2WS Remove in the sequence shown in the figure 1 Hub cap 2 Lock nut 3 Caliper assembly 4 Disc plate 5 Wheel speed sensor ABS 6 Dust cover 7 Trailing link 8 Lateral link 9 Shock absorber 10 Knuckle spindle 9 21 ...

Page 691: ...s 86U09X 040 1 Hub cap 2 Lock nut 3 Parking brake cable 4 Caliper assembly 5 Disc plate 6 Dust cover 7 Control link 8 Wheel speed sensor ABS 9 Stabilizer bracket 10 Tie rod end 11 Shock absorber 12 Knuckle spindle Removal Note Tie rod end Remove the tie rod end from the knuckle spindle with the SST 49 0118 850C 86U09X 041 9 22 ...

Page 692: ...sc plate Disassembly Note Note a Do not remove the hub bolts unless necessary b Do not reuse the hub bolts if removed Sensor rotor ABS Remove the sensor rotor with the SST Note a Do not remove the sensor rotor unless necessary b Do not reuse the sensor rotor if removed Rear wheel bearing Remove the rear wheel bearing with the SST Note Do not reuse the rear wheel bearing if removed 86U09X 085 626 M...

Page 693: ...ks or damage INSPECTION 69G09X 028 2 Check the sensor rotor for cracks or damage 69G09X 029 3 Check the knuckle spindle for cracks or damage and the oil seal friction surface for wear or rust 86U09X 043 4 Check the dust cover for damage 5 Check the hub cap for damage 69G09X 031 ...

Page 694: ... hub bolts 86U09X 045 2 Install a new sensor rotor with the SST ABS 86U09X 046 3 Install a new rear wheel bearing with the SST 4 Install the retaining ring 5 Install a new oil seal with the SST Note Apply grease to the oil seal lip 9 25 ...

Page 695: ... 2WS Install in the reverse order of removal Torque Specifications 86U09X 049 98 117 N m 10 18 m kg 73 131 ft lb 86U09X 050 Installation Note End play Measure the end play Refer to page 9 16 End play 0 2 mm 0 0079 in max 9 2 6 ...

Page 696: ...LE 9 INSTALLATION 4WS Install in the reverse order of removal Torque Specifications 86U09X 051 86U09X 052 Installation Note End play Measure the end play Refer to page 9 16 End play 0 2 mm 0 0079 in max 9 2 7 ...

Page 697: ...acks dam age grease leakage or loose boot bands Replace if necessary Spline Looseness Turn the driveshaft by hand and check that the spline and joint are not excessively loose Replace if necessary Twisted or Cracked Check that the driveshaft is not twisted or cracked Replace if necessary 9 28 86U09X 090 ...

Page 698: ...to the removal note for the specially marked parts 6 Hub cap 7 Lock nut 8 Driveshaft 9 Joint shaft 10 Transaxle Removal Note Lock nut Applying the brakes Raise the lock nut tab and loos en it Do not remove it 1 Wheel 2 Tie rod end 3 Stabilizer 4 Lower arm 5 Splash shield 9 29 ...

Page 699: ... the figure insert a pry bar between the driveshaft and the joint shaft and tap on the bar to uncouple them Non turbo y r Front wheel hub If the driveshaft is stuck to the front wheel hub and can t be removed use the SST to push the shaft out Differential Install the SST to hold the side gear after removing the driveshaft 9 30 86U09X 058 626 MX 6 Revised 10 87 ...

Page 700: ... the ball joint at the wheel side Do not wipe the grease off if there is no problem d Do not remove the clip used to secure the outer ring to the ball joint at the differential side if there is no problem If the clip is removed replace it with a new one 1 Boot band 2 Clip 3 Outer ring 4 Snap ring 5 Ball joint 6 Boot band 7 Boot 8 Clip 9 Sensor rotor Refer to Section 11 Clip 1 Make matching marks o...

Page 701: ... matching marks on the inner ring and cage Note Mark with paint do not use a punch 2 Turn the cage approximately 30 then pull it away from the inner ring Boot 1 Wrap the shaft splines with tape 2 Remove the boot INSPECTION Wash the parts Check and replace all damaged parts 1 Twisted bent or damaged shaft 2 Worn or scored splines 3 Worn rusted or damaged outer ring 86U09X 061 ...

Page 702: ...hown in the figure b Fill the inside of the ball joint with the speci fied grease included in the kit c Securely fit the boot to the shaft and the outer race boot grooves 86U09X 062 Balls inner ring and cage 1 Align the matching marks and install the balls 86U09X 094 2 Apply molybdenum disulfide grease to the joint Note Do not use other than specified grease 86U09X 095 9 33 ...

Page 703: ... boot band Note a Use a new band b Fold the band in the direction opposite the forward rotation of the driveshaft 1 Fold the band back by pulling on the end of the band 86U09X 096 2 Bend the locking clip to lock the end of the band 9 34 ...

Page 704: ...09X 064 1 Boot band 6 Boot band 9 Clip 2 Tripod joint assembly 7 Boot 10 Sensor rotor Refer to Sec 3 Boot band 8 Shaft and ball joint as tion 11 4 Boot sembly 5 Boot band Disassembly Note Tripod joint assembly 1 Remove the snap ring using snap ring pliers then remove the tripod joint bearing 2 Disassemble the joint shaft assembly 86U09X 065 9 35 ...

Page 705: ...oint shaft bearing 86U09X 066 86U09X 067 86U09X 068 ASSEMBLY Assemble in the reverse order of disassembly refer ring to assembly note Assembly Note Note a The wheel side and differential side boots are different as shown in the figure b Fill the inside of the ball joint with the speci fied grease included in the kit c Securely fit the boot to the shaft and the outer race boot grooves Tripod joint ...

Page 706: ...rque specifications 86U09X 070 42 62 N m 88 118 N m 9 0 12 0 m kg 6 5 8 7 ft lb 235 319 N m 24 0 32 5 m kg 174 235 ft lb grease 86U09X 071 Installation Note Clip Install a new clip Note a Before installing the shaft check the trans axle oil seal for damage b Apply transaxle oil to the oil seal lip 9 3 7 ...

Page 707: ...ont wheel hub outward and check that the driveshaft does not come out Stabilizer Lock the nut with 20 1 mm 0 79 in of the threads exposed Tightening torque 16 23 Nm 1 6 2 3 m kg 12 17 ft lb Oil Add the specified grade and quantity of transaxle oil Refer to Section 7 9 38 ...

Page 708: ... for the specially marked parts 1 Clip 2 Joint shaft 3 Oil seal 4 Oil seal 5 Bearing 6 Bracket Disassembly Note Bearing Remove the shaft and bearing with the SST and press Caution Hold the shaft and the bearing by hand does not drop Assembly Note Bearing 1 Install the shaft and a new bearing with the SST and press 2 Install new oil seals 3 Install a new clip 9 3 9 ...

Page 709: ...ON 10 30 4 WHEEL STEERING GEAR AND LINKAGE 10 31 STRUCTURAL VIEW 10 31 4WS PERFORMANCE INSPECTION 10 32 ADJUSTMENT OF STEERING ANGLE TRASFER SHAFT 10 35 REMOVAL AND INSTALLATION 10 37 INSPECTION 10 44 MANUAL STEERING 10 48 DISASSEMBLY 10 48 INSPECTION 10 51 ASSEMBLY 10 52 ENGINE SPEED SENSING POWER STEERING 10 58 DISASSEMBLY 10 58 INSPECTION 10 62 ASSEMBLY 10 64 ELECTRONICALLY CONTROLLED POWER STE...

Page 710: ...10 OUTLINE OUTLINE STRUCTURAL VIEW Manual Steering 1 Steering wheel 2 Steering shaft 3 Intermediate shaft 4 Steering gear assembly 86U10X 002 ...

Page 711: ...ring ESPS 86U10X 003 1 Steering wheel 4 Steering gear assembly 7 Oil pump 2 Steering shaft 5 Pressure hose 8 Reserve tank 3 Intermediate shaft 6 Return hose Note Engine speed sensing power steering is abbreviated ESPS 10 3 ...

Page 712: ... Steering angle sensor 12 Check connector 1 Steering wheel 5 Pressure hose 2 Steering shaft 6 Return hose 3 Intermediate shaft 7 Oil pump 4 Steering gear assembly 8 Solenoid valve Note Electronically controlled power steering is abbreviated ECPS ...

Page 713: ...haft 7 Solenoid valves 8 Rear steering gear assembly 9 Steering wheel 10 Steering shaft 11 Relay and timer Note 4 wheel steering is abbreviated 4WS 1 Reserve tank 2 Oil pump 3 Front steering gear assembly 4 Speed sensor 5 Control unit 1 0 5 ...

Page 714: ...10 OUTLINE SPECIFICATIONS 86U10X 006 Note 2 Wheel steering is abbreviated 2WS ...

Page 715: ...hing Refer to Section 13 Malfunctioning shock absorber Refer to Section 13 Improperly adjusted wheel alignment Refer to Secton 13 Steering wheel Incorrect tire pressure Refer to Section 12 vibrates Unevenly worn tires Refer to Section 12 Worn wheel bearing or incorrect adjustment Refer to Section 13 Worn or damaged steering joints Replace 10 21 Improperly adjusted steering pinion preload Adjust 10...

Page 716: ... mounting bolts Worn linkage or tie rod ball joint Worn lower ball joint Worn or damaged steering joint Worn rack and pinion gear Tighten Replace Refer to Section 13 Replace Replace 10 30 10 18 10 21 10 58 75 Steering wheel vibrates Insufficient tire pressure Damaged or unbalanced wheel Improperly adjusted wheel alignment Loose gear box housing mounting bolts Incorrect pinion preload adjustment Wo...

Page 717: ...TROUBLESHOOTING GUIDE 10 4WS Rear Steering Gear 1 0 9 ...

Page 718: ... wear steering shaft joint play steering wheel looseness and column looseness STEERING WHEEL EFFORT Manual Steering 1 Jack up the vehicle Move the steering wheel to put the wheels in the straight ahead position 2 Measure the steering wheel effort by connecting a pull scale to the outer circumference of the steer ing wheel Steering wheel effort 5 25 N 0 5 2 5 kg 1 5 5 lb during one turn of the stee...

Page 719: ... age at hose or connections function of oil pump and gear box and tire pressure Steering wheel effort ESPS Type 25 31N 2 6 3 2 kg 6 7 lb ECPS Type 15 23 N 1 7 2 3 kg 3 5 lb 4WS Type 25 35N 2 5 3 5 kg 6 8 lb during one turn of the steering wheel Note 4WS 1 If not within specification separate the transfer shaft from the front steering gear and check again 2 If still not within specification there i...

Page 720: ...ey 2 Turn the adjust bolt on the idler pulley until the cor rect tension is obtained 3 Tighten locknut and recheck the tension Tightening torque 49 59 N 5 6 m kg 36 43 ft lb Drive belt Deflection New Used Power steering oil pump drive belt 8 10 mm 0 31 0 39 in 9 11 mm 0 35 0 43 in REAR STEERING GEAR OIL Fluid Level 4WS Remove the bleeder valve and check the fluid level with a wire 86U10X 019 Cauti...

Page 721: ...enoid valve ECPS Type 4WS Type Note a Start the engine and check for fluid leakage after turning the steering wheel completely to the left and right to apply fluid pressure Do not however keep the steering wheel in the fully turned position for more than 15 seconds b The points where fluid leakage may occur are indicated by the arrows in the figure 86U10X 020 ...

Page 722: ...10 ON VEHICLE MAINTENANCE Power Steering 4WS 86U1 OX 235 10 14 ...

Page 723: ...l has lowered add fluid and repeat from step 1 4 Start the engine and run it at idle 5 Turn the steering wheel fully in both directions 5 times to bleed air from the system 6 Check that the fluid is not foamy and the fluid lev el has not lowered If a problem is found add fluid as necessary and repeat from step 5 Note If bleeding is not done completely the follow ing problems may appear Foamy fluid...

Page 724: ...replace the oil pump assembly Warning If the valve is left closed for more than 15 sec onds the fluid temperature will increase ex cessively and adversely affect the oil pump Oil pump fluid pressure 2WS 7 355 7 846 kPa 75 80 kg cm2 1 066 15138 psi 4WS Front 8 093 8 829 kPa 82 5 90 0 kg cm2 1 173 1 280 psi Rear 7 112 7 848 kPa 72 5 80 0 kg cm2 1 031 1 138 psi 86U10X 025 5 To measure the fluid press...

Page 725: ... 066 1 138 psi 4WS Front 8 093 8 829 kPa 82 5 90 0 kg cm2 1 173 1 280 psi Rear More than 2 943 kPa 30 kg cm2 427 psi If the fluid pressure is low repair or replace the gear box 6 Remove the gauge set then tighten the high pressure hose to the specified torque Tightening torque 31 36 Nm 3 2 3 7 m kg 23 27 ft lb 7 Bleed the air from the system Refer to page 10 15 626 MX 6 Revised 10 87 10 17 ...

Page 726: ... in the figure referring to the removal note for specially marked parts 3 Install in the reverse order of removal referring to the installation note for specially marked parts 4 Tighten all nuts and bolts to the specified torque referring to the figure 1 Lug nuts 3 Tie rod end 5 Boot 2 Wheel 4 Nut 1 Lug nuts 3 Tie rod end 5 Boot 2 Wheel 4 Nut 10 18 ...

Page 727: ...g the nut from the tie rod end make a mark for reference during installation Boot Secure the tie rod end in a vise Place a chisel against the boot and hold it at the angle shown Remove the boot by tapping with a hammer Caution Be careful not to scar the part where the boot is attached to the tie rod end 86U10X 031 69G10X 039 10 19 ...

Page 728: ...10 TIE ROD END BOOT n Installation Note Boot Put a small amount of grease lithium base NLGI No 2 into the new boot and set it onto the SST Install the boot to the tie rod end with a press 86U10X 032 ...

Page 729: ...N STRUCTURAL VIEW 86U10X 033 1 Ornament 6 Combination switch 11 Steering shaft 2 Lock nut 7 Switch panel 12 Steering shaft assembly 3 Horn cap 8 Lower panel 13 Intermediate shaft 4 Steering wheel 9 Duct 14 Dust boot 5 Column cover 10 Universal joint 10 21 ...

Page 730: ...ve the locknut 4 The steering wheel must be removed with a suita ble puller Caution Be careful not to subject the steering shaft to severe impact in the axial direction when removing or installing the steering wheel 86U10X 035 5 Remove the column cover 6 Disconnect the ignition switch connector 7 Remove the combination switch 86U10X 036 8 Remove the lower panel and switch panel 9 Remove the duct 8...

Page 731: ...cting the universal joint and steering shaft 11 Remove the nuts from the lower bracket of the steering shaft 12 Remove the bolts from the upper bracket of the steering shaft 13 Remove the steering shaft assembly 14 Remove the bolts from the intermediate shaft 10 23 ...

Page 732: ...SSEMBLY 1 Disassemble in the sequence shown in the figure referring to the disassembly note for specially marked parts 2 Assemble in the reverse order of removal referring to the assembly note 86U10X 043 1 Steering lock bolt 2 Steering shaft 10 24 ...

Page 733: ...ssembly Note Steering lock Install the steering lock on the jacket then use new steering lock mounting screws and tighten them until the heads break off Caution Check the operation of the lock while tight ening the steering lock mounting screws INSPECTION Check the following and replace any faulty parts Shaft 1 Wear of column bushing 2 Length of steering column Length 614 616 mm 24 2 24 3 in 3 Dam...

Page 734: ...10 STEERING WHEEL AND COLUMN Intermediate Shaft and Universal Joint Looseness abnormal noise or sticking while rotating Dust Boot Damage or deterioration 86U10X 048 10 26 ...

Page 735: ...on note for specially marked parts Torque specifications 86U10X 049 1 Combination switch Installation Note Combination switch angle sensor Position the angle sensor in the following order 1 Set the wheels in the straight ahead position 2 Align the alignment marks arrows 86U10X 050 626 MX 6 Revised 10 87 10 27 ...

Page 736: ... STEERING GEAR AND LINKAGE STEERING GEAR AND LINKAGE STRUCTURAL VIEW 1 Oil pressure switch connector 2 Pipes 3 Tie rod end 4 Steering shaft universal joint 5 Mud flap 10 28 Manual steering Power steering ...

Page 737: ...nect the negative battery cable 2 Disconnect the pressure switch connector 3 Raise the vehicle on a lift or safely stands and re move the front wheels 4 Disconnect the power steering hose and pipe 5 Disconnect the tie rod ends from the knuckles with the SST 6 Remove the steering shaft universal joint 86U10X 053 7 Remove the mud flap 8 Remove the mounting bolts and the steering gear 86U10X054 10 29...

Page 738: ...10 STEERING GEAR AND LINKAGE INSTALLATION Install in the reverse order of removal Torque Specifications ...

Page 739: ...EAR AND LINKAGE STRUCTURAL VIEW 1 Reserve tank 6 Steering angle transfer shaft 2 Oil pump 7 Solenoid valve 3 Front steering gear assembly 8 Rear steering gear assembly 4 Speed sensor 9 Steering wheel 5 Control unit 10 Steering shaft 11 Relay and timer 10 31 ...

Page 740: ...po sition on the steering wheel and column cover tape Drive the vehicle again and check the marks 3 With the marks between the steering wheel and column cover aligned check that the rear wheels do not turn off center when the engine is started 4 Ifthe rear wheels move adjust the steering an gle transfer shaft Inspection by dial indicator 1 Mark between the steering wheel and column cover as shown ...

Page 741: ...otation of the steering wheel at the point where the rear wheels begin to turn dial indicator begins to move 86U10X 306 6 Turn the steering wheel left and right a few times to equalize the hydraulic pressure Rea lign the marks between the steering wheel and column cover 86U10X 307 7 Reset the dial indicator to 0 and turn the steer ing wheel slowly to the left Using the scale on column cover again ...

Page 742: ...that the center is within specification Specification R 5 mm 0 4 in to L 5 mm 0 4 in 10 If not correct adjust the steering angle trans fer shaft 2 Steering Inspection With the vehicle stopped and the engine running check that the rear wheels turn in the opposite direction when the steering wheel is turned and that there is no abnormal noise 86U10X 310 3 4WS Electric System Inspection Drive the veh...

Page 743: ... of an accident or per sonal injury 1 Raise the vihicle on a lift or safety stands 2 Remove cover B and joint bolt A 3 Slide the shaft out of the joint 86U10X 313 4 Remove the plug from the rear steering gear Sight through the hole and turn the steering angle input shaft to align the notch in the input shaft with the center of hole 5 Remove the set bolt attached to the rear steering gear and insta...

Page 744: ...haft and rear joint removed at step 2 and tighten the bolt to the specified torque Tightening torque 22 30 N m 2 2 3 1 m kg 191 269 in lb 10 Install and tighten a new wire on the joint boot 86U10X 317 11 Install the set bolt in the rear steering gear Tightening torque 20 28 Nm 2 0 2 9 m kg 14 21 ft lb After installing the steering angle transfer shaft check the steering angle transfer shaft alignm...

Page 745: ...all nuts and bolts to the specified torque referring to the page 10 39 Note The power steering fluid will leak out when the return hose or the pressure hose is discon nected Prepare a suitable container for it to drain into Front Steering Gear 8 6U10X 063 1 Pipes 9 Engine mount 2 Bolt 10 Bolts and nut 3 Exhaust pipe 11 Bolt 4 Under cover 12 Bolt and mounting 5 Shaft Refer to next page 13 Bolts and...

Page 746: ... 3 Bolt 4 Bolt 5 Bolt 6 Bolt 7 Steering angle transfer shaft Rear Steering Gear 86U10X 065 1 Connector 6 Cover 11 Bolt 2 Cover 7 Nuts 12 Bolt 3 Universal joint and bolts 8 Nuts 13 Bolt 4 Boot and boot band 9 Pipes 14 Rear steering gear as 5 Bolts 10 Bolt sembly 15 Solenoid valve 10 38 ...

Page 747: ...4 WHEEL STEERING GEAR AND LINKAGE 10 Torque Specifications 7 6 9 5 m kg 55 69 ft lb 8 0 11 9 m kg 58 86 ft lb 86U10X 066 10 39 ...

Page 748: ...the knuckles with the SST 2 Remove the mounting bolts and nuts from the body and crossmember Let the lower members hang down Steering angle transfer shaft Be careful not to bend the joints to extreme angles 86U10X 069 Rear steering gear 1 Disconnect the tie rod ends from the knuckles with the SST 49 86U10X 070 10 40 ...

Page 749: ...ames hang down 86U10X 072 Solenoid valves 1 Remove the oil pipes 2 Remove the bolts 3 Disconnect the solenoid valve connectors 4 Remove the solenoid valve assembly 86U10X 073 Oil filter Replace the oil filter in the sequence shown in the figure 1 Filter cap 5 Rubber 2 O ring 6 Oil filter 3 Spring 7 Magnet 4 Set plate Note Clean up and install the magnet and set plate 86U10X 074 10 41 ...

Page 750: ...e after installation of the rear steering gear Refer to Page 10 35 Note When the replacement of rear steering gear or the oil pan gasket owing to the oil likage add fluid to the specified level Refer to page 10 12 86U10X 077 Steering angle transfer shaft Caution Installation of the steering angle transfer shaft must be done correctly Work carefully referring to the adjustment of steering angle tra...

Page 751: ... 1 7 2 ft lb Caution The shaft should be installed by two or more persons taking care not to bend the joint part 4 Connect the joint of the front steering gear side and then tighten the bolt 5 Connect the joint of the rear steering gear side and then tighen the bolt Caution Check to be sure that the front and rear brack ets do not contact the oil seal 6 Attach a new wire and clamp and as shown in ...

Page 752: ...he following and replace any faulty parts a Clogged bent or pinched pipes b Faulty oil pressure switch c Damaged mounting bracket and mounting rubber d Cracked damaged or deteriorated boots 86U10X 080 Available spare parts 86U10X 081 1 Tie rod end 7 Oil pressure switch 2 Tie rod end boot 8 O ring 3 Nut 9 Mounting bracket 4 Boot 10 Mounting rubber 5 Boot band large 11 Oil pipe 6 Boot band small 12 ...

Page 753: ...wing and replace the shaft assembly if necessary 1 Shaft a Cracked damaged or deteriorated boots b Stuck carrier bearing c Bent d Damaged mounting brackets 2 Universal joint Looseness or damage 3 Rear boot Cracked damaged or deteriorated 1 Shaft 2 Universal joint 3 Rear boot 4 Wire 5 Clip 10 45 ...

Page 754: ...ring ratio sensor c Sticking bearings d Oil leakage Note There is no fluid in a new replacement rear steering gear assembly add fluid to the spe cified level Refer to 10 12 86U10X 085 2 Check and tighten bolts and nuts if necessary 3 Check the following and replace any faulty parts a Cracked damaged or deteriorated rear stee ring gear boots and bands b Cracked or damaged oil pan c Malfunctioning s...

Page 755: ...rts 1 Tie rod end 2 Tie rod end boot 3 Nut 4 Boot 5 Boot band wire 6 Boot band clip 7 Oil pan 8 Oil pan gasket 9 Bolt 10 Oil filler bolt 11 Solenoid valve Refer to 10 41 12 Bolt 13 Oil filter set Refer to 10 41 14 Steering gear assembly 15 Pipe 16 Nut 10 47 ...

Page 756: ... and remove all external grease and dirt 19 Bearing 20 Pinion 21 Bearing 22 Rack 23 Gear housing 24 Mounting rubber and bracket 25 Bushing 1 Tie rod end 2 Nut 3 Clip 4 Boot wire 5 Boot 6 Tie rod 7 Washer 8 Adjust cover locknut 9 Adjust cover 10 Spring 11 Friction block 12 Dish spring 13 Holder 14 Needle roller 15 Roller assembly 16 Boot support 17 Rear cover locknut 18 Rear cover and oil seal 10 4...

Page 757: ...n Insert protective material such as copper plates in the jaws of the vise Tie rod ends Before removing the tie rod ends make a mark for proper installation 86U10X 090 Tie rods Remove the tie rods 1 Uncrimp the washer as shown in the figure 86U10X 091 2 Secure the rack in a vise and remove the tie rod 86U10X 092 10 49 ...

Page 758: ...d pull it out of the gear housing Caution If the pinion is difficult to remove gently tap the gear housing with a plastic hammer while pulling Rack Remove the rack by taking it out in the direction indi cated by the arrow Caution Do not damage the rack bushfng with the edge of the rack gear Bearing lower Heat the housing in water to about 80 C 176 F then tap the end of the housing with a wooden ha...

Page 759: ...king bearing in gear housing 4 Cracked or damaged gear housing 5 Worn rack and housing bushing 6 Tie rod ball joint operation and looseness 7 Bent tie rods or tie rod ends 86U10X 098 8 Cracked worn teeth or damaged rack 9 Runout of rack Runout 0 30 mm 0 012 in max 10 Worn or damaged of roller and friction block 11 Bearing operation 12 Cracked or damaged holder 13 Weak or damaged spring Note If the...

Page 760: ...10 MANUAL STEERING 14 Damaged dish springs 86U10X 101 ASSEMBLY Torque Specifications 86U10X 102 10 52 ...

Page 761: ...ng Caution a Before pressing in put grease lithium base NLGI No 2 in the bearing and bearing bore b Install the bearing in the proper direction c Use the pinion to press the bearing in 86U10X 104 4 Fill or coat the following points with grease lithi um base NLGI No 2 before assembly a Pinion bearing and teeth b Inside gear housing 86U10X 105 c Oil seal lip d Roller surface e Holder f Friction bloc...

Page 762: ...tall the rack in the direction of the arrow 86U10X 108 6 Set the notch of the teeth of the rack at the pinion position then insert the pinion Caution This notch is used for adjustment of the pin ion bearing preload without the pinion en gaged with the rack 7 Install the upper bearing and then screw on the rear cover Caution a Apply sealant to the threads of the rear cover b Do not install the oil ...

Page 763: ... 6 oz Tighten the locknut Tightening torque 49 69 Nm 5 0 7 0 m kg 36 51 ft lb Caution Recheck the pinion torque after tightening the locknut If it is not within 200 350 g 7 12 3 oz loosen the locknut and adjust once again 10 Carefully move the rack so that the pinion is set to the center neutral position of the rack gear 86U10X 113 11 Install the roller assembly needle roller holder dish springs f...

Page 764: ...400 g 35 50 oz Any other position Pull gauge reading less than 1 700 g 60 oz 86U10X 116 14 Mark the positions of the rack grooves of the left tie rod for staking 15 Install the new washer on the left tie rod and in stall the tie rod Tightening torque 78 98 Nm 8 0 10 0 m kg 58 72 ft lb 16 Stake the washer in two places 86U10X 117 Dust Cover TT Oil seal 17 Use a pipe to press in the oil seal until i...

Page 765: ...oot then wrap a new wire around it two times and twist 4 to 4 5 times Install the clip Caution Check that the boot is not twisted or dented 21 Install the tie rod ends aligning them with the marks made before disassembly 86U10X 119 10 57 ...

Page 766: ...ion fittings then thoroughly clean the steering gear and linkage 1 Oil pressure switch 11 Adjust cover 21 Rack 2 Oil pipe 12 Spring 22 Oil seal 3 Tie rod end 13 Pressure pad 23 Spacer 4 Tie rod end locknut 14 Snap ring 24 Oil seal 5 Spring clip 15 Housing cover 25 Lower bearing 6 Boot wire 16 Lower bearing locknut 26 Oil seal 7 Boot 17 Pinion shaft and control 27 Needle bearing 8 Tie rod valve ass...

Page 767: ... in the jaws of the vise 86U10X 122 Tie rod ends Before removing the tie rod ends make a mark for proper installation 86U10X 123 Tie rod 1 Remove the tie rod from rack 2 Remove the roll pin with a pin punch and hammer 86U10X 124 Adjust cover 1 Remove the locknut from the adjust cover 2 Remove the adjust cover with the SST 3 Remove the spring and pressure pad 86U10X 125 10 59 ...

Page 768: ...press and re move the pinion shaft assembly as shown in the figure 86U10X 127 Rack bushing 1 Cut away the staked areas with a drill 2 Remove the rack bushing 86U10X 128 Rack and oil seal at tube side 1 Slide the SST over the rack from the gear hous ing side Note If the rack is removed without using the SST there is the possibility that the rack housing may be damaged by the rack teeth 86U10X 129 1...

Page 769: ...ck 86U10X 130 Spacer and oil seal at housing side 1 Insert the SST from the pinion housing side so that it contacts the spacer 86U10X 131 2 Set the SST against the SST inserted in step 1 3 Secure the gear housing in a vise 4 Drive the spacer and oil seal out of the housing Lower bearing Drive the lower bearing out of the housing with the SST 86U10X 133 86U10X 132 10 61 ...

Page 770: ...tacts the needle bearing 2 Drive the oil seal and needle bearing out with the SST bar INSPECTION Check the following and replace any faulty parts Pinion shaft assembly 1 Pinion shaft teeth wear or damage 2 Control valve damage clogging and wear Rack bushing Wear or damage Bearing Wear damage and operation ...

Page 771: ...tie rod end 1 Tie rod damage 2 Tie rod ball joint damage and operation 3 Tie rod end damage and operation Pressure pad and spring 1 Pressure pad damage 2 Spring damage Rack 1 Rack cracking damage or wear of teeth 2 Seal ring holder wear or damage 3 Rack piston side corrosion 86U10X 141 10 63 ...

Page 772: ...NSING POWER STEERING Gear housing and boots 1 Gear housing cracking or damage 2 Boot cracking or tearing as _ 3 1 3 6 N m 3 2 3 7 m kg 23 27 ft lb 3 5 4 5 m kg 25 33 ft lb ASSEMBLY Torque Specifications 10 64 86U1 OX 251 ...

Page 773: ...nstall the seal ring in the groove of the rack Note Be careful not to cut or otherwise damage the edge of the seal ring 4 Compress the seal ring by hand to fit it to the groove 86U10X 144 Needle bearing 1 Apply grease to the end of the SST 2 Apply ATF to the needle bearing 3 Set the needle bearing on the SST Note When installing the needle bearing to the SST install the embossed side first 86U10X ...

Page 774: ...press and press in the bearing Oil seal 1 Apply grease to the end of the SST 2 Apply ATF to the oil seal 3 Set the oil seal on the SST 86U10X 148 4 Insert the oil seal and the SST into the housing 86U10X 149 5 Set the housing on a press and press in the seal 86U10X 150 10 66 ...

Page 775: ...ENGINE SPEED SENSING POWER STEERING 10 10 67 ...

Page 776: ... lithium base NLGI No 2 to the fric tion surface and teeth of the rack 2 Slide the SST over the rack and slide it in from the tube side 3 Remove the SST Oil seal Rack 1 Apply ATF to the oil seal and slide it on the rack 86U10X 157 2 Set the SST on the rack 3 Turn the SST as far as it will go and push the oil seal into the tube 4 Remove the SST 86U10X 158 49 G 0 3 2 30 5 86U10X 156 M fflM ffll J 10...

Page 777: ...center punch Hermetic inspection 1 Connect the SST to the cylinder housing 2 Connect a vacuum pump to the SST 3 Apply 400 mmHg 15 7 inHg vacuum 4 Verify that vacuum is held for at least 30 sec If not check the seal and assembly Lower bearing 1 Secure the gear housing in a vise so that the low er bearing bore faces upward 2 Apply ATF to the lower bearing then install it in the housing 3 Press the b...

Page 778: ...o damage the edge of the seal ring and control valve Upper bearing Apply ATF to the upper bearing then install it 86U10X 164 Oil seal 1 Apply ATF to the oil seal and fill inside the lip with grease lithium base NLGI No 2 2 Slide the SST over the serrations of the pinion shaft assembly 3 Slide the oil seal over the SST and position it in the housing 86U10X 165 4 Tap the oil seal in with the SST unt...

Page 779: ... of the rack 2 Install the locknut and turn it until the tie rod con tacts the tube 3 Tighten the locknut Tightening torque 39 49 Nm 4 0 5 0 m kg 29 36 ft lb 86U10X 168 Housing cover 1 Apply thread sealant to the housing cover threads 2 Install the housing cover Tightening torque 44 54 Nm 4 5 5 5 m kg 33 40 ft lb 86U10X 169 3 Stake between the rack housing and housing cover at two points with a ce...

Page 780: ... 1 Set the rack in the center position 2 Tighten the adjust cover to 9 8 N m 100 cm kg 7 2 ft lb then loosen it 3 Tighten again to 4 9 0 5 N m 50 5 cm kg 3 6 0 4 ft lb and then return it 45 4 Apply thread sealant to the exposed threads of ad just cover 86U10X 172 5 Install and tighten the locknut Tightening torque 49 59 Nm 5 0 6 0 m kg 36 43 ft lb 86U10X 173 Tie rod 1 Secure the rack in a vise 2 I...

Page 781: ...f the boot two times and then twist it 4 to 4 5 times Bend the twisted part toward the mounting bracket Note Be careful not to break the boot wire 3 Install the spring clip on the small end of the boot Tie rod end Align with the mark made before disassembly and then tighten the nut Oil pipe Secure the mounting bracket in a vise so that the oil pipe connections face upward 86U10X 177 86U10X 178 10 ...

Page 782: ...GINE SPEED SENSING POWER STEERING Oil pressure switch 1 Install the pressure switch O ring in the gear housing 2 Install the oil pressure switch Tightening torque 31 36 Nm 3 2 3 7 m kg 23 27 ft lb 86U10X 179 ...

Page 783: ...airs are necessary replace the gear box assembly b In order to prevent the entrance of dirt all disassembly and assembly should be done in a clean area c Before disassembly plug the openings of all pipe installation fittings then thoroughly clean the steering gear and linkage 86U10X 180 1 Pipe 2 Solenoid valve 3 Tie rod end 4 Tie rod end locknut 5 Spring clip 6 Boot wire 7 Boot 8 Tie rod 9 Adjust ...

Page 784: ...aution Insert protective material such as copper plates in the jaws of the vise 86U10X 181 Tie rod ends Before removing the tie rod ends make a mark for proper installation 86U10X 182 Oil pipe Mark the pressure and return pipes and the valve case for proper installation Remove the pipes Solenoid valve Remove the solenoid valve 86U10X 184 86U10X 183 10 76 ...

Page 785: ... shown in the figure 86U10X 185 2 Remove the tie rod from the rack 63U10X 127 Locknut and adjust cover Loosen the locknut and remove the adjust cover spring and pressure pad 86U10X 186 Outer box Protect the outer box with cloth and remove it with a pipe wrench 86U10X 187 10 77 ...

Page 786: ...ION Check the following and replace any faulty parts 1 Cracked damaged or deteriorated boots 2 Worn pressure pad friction surface 3 Loose or sticking tie rod balljoint 4 Bent or damaged tie rod or tie rod end 5 Worn outer box bushing 6 Cracked or damaged gear housing 7 Steering gear oil leakage 10 78 ...

Page 787: ...TRONICALLY CONTROLLED POWER STEERING 10 ASSEMBLY Torque Specifications 86U1 OX 252 1 Install the outer box in the rack housing Note Coat the seals and O rings with ATF 29 39 N m 626 MX 6 Revised 10 87 10 79 ...

Page 788: ...ICALLY CONTROLLED POWER STEERING 3 Stake between the outer box and the rack hous ing with a center punch 4 Install the oil seal with a suitable pipe 5 Install the pressure pad and spring in the gear housing 10 80 ...

Page 789: ...asure the pinion torque with the SST Pull scale 1 000 1 400 g 35 3 49 4 oz 9 Ifthe pinion torque is not within specification read just the adjust cover 86U10X 198 10 Lock the adjust cover with the locknut Tightening torque 40 50 Nm 4 5 m kg 29 36 ft lb 86U10X 199 11 Set the rack in a vise and install the and washer Tighten the tie rod Tightening torque 60 80 Nm 6 8 m kg 43 58 ft lb Caution Insert ...

Page 790: ...10 ELECTRONICALLY CONTROLLED POWER STEERING 10 82 ...

Page 791: ...oval 4 Tighten all nuts and bolts to the specified torque referring to the figure Note a The power steering fluid will leak out when the return hose or the pressure hose is dis connected Prepare a suitable container for it to drain into b After installation inspect the deflection of the oil pump belt and bleed the air from the system then check for fluid leakage 1 Belt 4 Bracket 2 Nut 5 Oil pump 3...

Page 792: ... 3 Pipes 4 Bracket 5 Oil pump 6 Oil pump pulley Removal Note Oil pump 2WS 4WS 1 Hold the oil pump pulley with the SST and remove the pulley nut 2 Slide the pulley forward Remove the hose pipes and the pump 3 Remove the pulley 86U10X 207 ...

Page 793: ...the problem is located by outputting specific voltage pulsations at terminal wire YB of the check connector Troubleshooting of the ECPS system then is easily performed by comparing the output pattern with those of the Diagnosis Table on pages 10 87 and 88 TROUBLESHOOTING How To Use Self Diagnosis System By using the control unit s self diagnosis function and a voltmeter malfunctions of the system ...

Page 794: ...rom the center and check the output pattern Refer to page 10 87 for other patterns and indi cated failure points Condition C 1 Turn the ignition switch OFF 2 Place the vehicle on a chassis roller tester Block the rear wheels and secure it with chains 3 Start the engine Put the transmission in gear and operate the vehicle to more than 10 km h 6 2 mph 4 Check the output pattern Normal pattern 4 4V O...

Page 795: ...e sensor or wiring har ness Control unit to Angle sensor P S 3 Refer to page 10 90 4 4V 0V Normal operation Wiring harness Fuse box to Control unit or Control unit to Body ground P S 5 Refer to page 10 91 0V 4 4V 0V 10 seconds Power steering sole noid valve or wiring harness Control unit to Solenoid valve P S 1 Refer to page 10 89 B Steering wheel turned 45 left and right from center with engine i...

Page 796: ... Solenoid valve P S 1 Refer to page 10 89 4 4V 0V Wiring harness Con trol unit to Ignition coil P S 2 Refer to page 10 89 Front wheels driv en at more than 10 km h 6 2 mph 4 4V 0V Steering wheel angle sensor or wiring har ness Control unit to Angle sensor P S 3 Refer to page 10 90 4 4V 0V Vehicle speed sensor or wiring harness Control unit to Meter P S 4 Refer to page 10 90 4 4V 0V Normal operatio...

Page 797: ... Terminal Resistance M LB N LG 3 5 7fl NG Check the solenoid valve Refer to page 10 91 NG Replace solenoid valve P S 2 Broken wiring harness Control unit to Coil Terminale of control unit connector with engine running Check voltage between YL and D B terminal of control unit connector with engine running Terminal Voltage L YL D B Approx 12V NG Repair the wiring harness Control unit to Ignition coi...

Page 798: ... Refer to page 15 14 OK Terminal Continuity Angle sensor Control unit G KG Yes GY H GY Yes GW J GW Yes NG Replace angle sensor Check for continuity between each terminals of steer ing angle sensor and control unit harness side con nector NG Repair wiring harness Control unit to angle sensor OK Replace control unit OK Replace control unit 86U10X 217 10 90 626 MX 6 Revised 10 87 ...

Page 799: ...olenoid valve when applying 12V between A and B terminals 2 If no sound is heard check the resistance of the solenoid valve with an ohmmeter Terminals Resistance A B 3 4 6 9 fi 3 Ifthere is no continuity replace the solenoid valve Steering Angle Sensor Inspection Refer to page 15 14 Vehicle Speed Sensor Inspection Refer to page 15 84 86U1QX 220 626 MX 6 Revised 10 87 10 91 ...

Page 800: ...hr ii J r t p f i H l __ ______ T kk SE 5 o o Ltoipas J3I3W o m w itoiieuiqwoQwojj L __ r fc qys rT g r i g J0SU3S pads o i __ 0 V UWP8R I i 0 S D 6 f lW a Jn D e nf s j s s 71 s i S i s i f os 0 j i g O fl Q C 3 fl o S5 5 D o 0 0 _ i 0 D S s fl 0 g 5 P 1 I 0o 0 C D fs D Q CS Note Refer to page 10 31 for component location 86U1 OX 221 10 92 ...

Page 801: ... problem is located and the 4WS warn ing light in the instrument cluster will flash for one minute with a specific pattern Troubleshoot the 4WS system according to the following flow chart 86U1 OX 222 TROUBLESHOOTING Checking Condition Condition A 3 Turn the ignition switch OFF Start the engine after the ignition switch has been OFF for at least 10 seconds and check ifthe 4WS warning light flashes...

Page 802: ...mph 4 Check if the 4WS warning light flashes or il luminates within 60 second 5 If flashing or illumination occur inspect the circuit by referring to the table below Diagnosis Output Pattern Warning light output pattern Malfunction Flow chart No Normal operation control unit or wir ing harness 4WS 0 0 5 sec 2 5 sec Speed sensors or wiring harness 4WS 1 Rear steering gear assembly 4WS 2 Solenoid va...

Page 803: ... Warning light output pattern Malfunction Flow chart No ON OFF Stepper motor or wiring harness 4WS 6 ON OFF Oil leakage or oil level switch 4WS 7 ON OFF Control unit 4WS 8 ON OFF Control unit alter nator or wiring harness 4WS 9 86U1 OX 226 10 95 ...

Page 804: ... 01 7 pin connector Check that 4WS warning light flashes or illuminates No electrical problem NO Reconnect connector Check voltage between terminals and body ground Terminal Voltage G B OV H B ov K BG Approx 12V L BG Approx 12V N B OV OK Replace control unit NG Repair harness Fuse box to Control unit or Control unit to Body ground 10 96 ...

Page 805: ...s and body ground with ignition switch ON Terminal Voltage E R Approx 12V F RY Approx 12V NG Disconnect solenoid valve connector Check for con tinuity between each terminals on valve side Terminals continuity A R B BG Yes C RY D BG Yes A R D BG No B BG C RY No OK Replace control unit OK Repair harness Fuse box to Solenoid valve or Sole noid valve to Control unit NG Replace solenoid valve unit 86U1...

Page 806: ...BG No OK OK NG Repair harness Step per motor to Control unit Replace rear steering gear assembly Check for continuity between terminals of R 01 17 pin harness side connector Terminal Continuity A WB L BG Yes B WL L BG Yes C WR L BG Yes D WY L BG Yes NG Disconnect stepper motor connector Check for con tinuity between terminals of motor side connector Terminals Continuity WB BG Yes WL BG Yes WR BG Y...

Page 807: ...ion switch OFF Check the level of oil in reservoir Fill if necessary i Start engine Check that 4WS warning light flashes or illuminates No flash or illumination Locate and repair oil leakage Flashes or illuminates Check voltage between 0 Y terminal of R 01 17 pin connector and a body ground Terminal Voltage 0 Y 0 V OK Replace control unit NG 10 99 ...

Page 808: ...ss and alternator Turn ignition switch OFF Start engine Check if 4WS warning light flashes or illuminates NO YES Momentary problem If warning light often flashes or illuminates check battery and alter nator Replace control unit if necessary Replace control unit Replace relay and timer 86U10X 231 4WS WARNING LIGHT 1 Turn the ignition switch OFF 2 Turn the ignition switch ON and check that the 4WS w...

Page 809: ...of the control unit connector and a body ground 3 Start the engine Check that periodic voltage is de tected when turning the front wheels slowly 4 If periodic voltage is not detected check the wir ing harness Replace the speed sensor if necessary REAR TO FRONT STEERING RATIO SENSOR Check the resistance between the terminals with an ohmmeter Terminal Resistance GB GO 3 5 6 5 kQ GB GW 3 2 5 9 kfi If...

Page 810: ...12V i 12V j OV If the voltage is not as specified replace the fuse or repair the harness 3 Check voltage between each terminal and a body ground with the engine running Terminal Voltage f 12V h 12V 4 Check that the voltage of f and h terminal is 12V for approximately 7 to 10 seconds after the igni tion switch is turned OFF If not replace the relay and timer 86U1 OX 238 10 102 626 MX 6 Revised 10 8...

Page 811: ...STALLATION 11 28 FRONT DISC BRAKE 11 29 SIMPLE INSPECTION OF DISC PAD WEAR 11 29 REPLACEMENT OF DISC PAD 11 29 REMOVAL 11 31 DISASSEMBLY AND ASSEMBLY 11 32 INSPECTION 11 34 INSTALLATION 11 35 REAR DISC BRAKE 11 36 SIMPLE INSPECTION OF DISC PAD WEAR 11 36 REPLACEMENT OF DISC PAD 11 36 REMOVAL 11 38 DISASSEMBLY AND ASSEMBLY 11 39 INSPECTION 11 43 INSTALLATION 11 44 REAR DRUM BRAKE 11 45 REMOVAL 11 4...

Page 812: ...NE OUTLINE 86U11X 002 1 Brake pedal 4 Parking brake lever 7 Rear drum brake 2 Power brake unit 5 Dual proportioning valve 8 Parking brake cable 3 Brake master cylinder 6 Front disc brake 9 Rear disc brake 1 1 2 ...

Page 813: ... Pipe joint 7 Control unit 4 Master cylinder 8 Wheel speed sensor 9 Sensor rotor 10 Rear disc brake 11 Parking brake lever 12 Parking brake cable 86U11X 003 Anti lock brake system ABS Front disc brake Ventilated disc Rear disc brake Solid disc Rear drum brake Leading trailing 11 3 ...

Page 814: ...mm in 30 2 1 19 Pad dimensions area x thickness mm2 x mm in2 x in 2 900 x 8 4 5 x 0 31 Disc plate dimensions mm in outer diameter x thickness 259 x 10 10 2 x 0 39 Rear drum brake Non Turbo model Type Leading trailing Wheel cylinder inner diameter mm in 17 46 0 69 Lining dimensions mm in width x length x thickness 30 x 219 3 x 4 5 1 18 x 8 63 x 0 18 Drum inner diameter mm in 228 6 9 0 Shoe clearanc...

Page 815: ...12 11 29 36 45 11 29 36 45 11 29 36 45 11 29 36 45 11 45 11 50 11 46 Brakes do not release No brake pedal play Improper adjustment of push rod clearance Clogged master cylinder return port Shoe does not return properly Wheel cylinder does not return properly Improper return due to malfunction of piston seal of disc brake Excessive runout of disc plate Improper return of parking brake cable or impr...

Page 816: ... Check the fluid level in the reservoir It should be be tween the Max and Min lines on the reservoir Ifthe fluid level is extremely low check the brake sys tem for leaks Fluid specification FMVSS 116 DOT 3 or DOT 4 or SAE J1703 BRAKE HYDRAULIC LINE STRUCTURAL VIEW Standard Front 1 1 6 626 MX 6 Revised 10 87 86U11X 007 ...

Page 817: ...LE INSPECTION OF BRAKE LINES Check the following and replace or repair any faulty parts 1 Cracks damage corrosion of brake hose 2 Damage to brake hose threads 3 Scars cracks and swelling of flexible hose 4 Fluid leakage of all lines 86U11X 009 11 7 ...

Page 818: ...rake fluid from the reservoir with a suction pump 2 Fill the reservoir with new specified brake fluid 3 Pump out the old brake fluid by loosening the bleeder screws one by one and pumping the brake pedal Refer to page 11 9 for details 86U11X 011 AIR BLEEDING Air Bleeding Locations After repairs have been made to the points shown air bleed as follows Disassembly point Air bleeding locations Front R...

Page 819: ...e other end in a receptacle 4 Have an assistant depress the brake pedal a few times and then hold it in the depressed position 5 Loosen the bleeder screw drain out he fluid and retighten the bleeder Note a The two people should stay in voice con tact with each other b Be sure the pedal remains depressed until the bleeder is tightened 6 Repeat steps 4 and 5 until no more air is dis charged 7 Tighte...

Page 820: ...t contacts the ped al then turn an additional 1 2 turn Tighten lock nut B Locknut B tightening torque 14 18 Nm 1 4 1 8 m kg 10 13 ft lb Locknut D tightening torque 24 34 Nm 2 4 3 5 m kg 17 25 ft lb 86U11X016 Pedal Play Inspection 1 Depress the pedal a few times to eliminate the vacuum in the system 2 Depress the pedal again by hand with a force of 20 N 2 kg 4 4 lb and check the free play Until the...

Page 821: ...dal pad is as specified when the pedal is depressed with a force of 589 N 60 kg 132 3 lb Pedal to floor clearance 95 mm 3 7 in min If the distance is less than specified check for the following problems 1 Air in brake system 2 Malfunction of automatic adjuster rear drum brakes 3 Worn shoes or pads 86U11X 020 1 Clevis pin 2 Brake pedal 3 Return spring 4 Guide pipe 5 Bushing 6 Brake pad 11 11 ...

Page 822: ...TALLATION 1 Install in the reverse order of removal 2 Tighten all nuts and bolts referring to torque specifications 3 After installation Check and adjust the pedal height and play Refer to page 11 10 Torque specifications 86U11X 022 Installation Note Application of grease Apply grease to the following parts 1 Inner and outer surfaces of bushing 2 Outer surface of guide pipe 3 Contact surface of cl...

Page 823: ...urfaces If it does get on a painted surface wipe it off immediately Standard 1 Fluid level sensor connector 2 Brake pipe 86U11X 024 3 Master cylinder 4 Clutch pipe holder MTX ABS Removal Note Brake pipe Standard 1 Place rags under the master cylinder to prevent brake fluid from dripping on painted surfaces 2 Disconnect the brake pipe from the master cylin der with the SST 86U11X 025 ...

Page 824: ...he specially marked parts Caution a Be careful not to let foreign material into the master cylinder during repairs b Do not scratch the inside of the cylinder or the outer surface of the piston Note The primary piston assembly is not repairable Replace it as an assembly f u n m 20 25 cm kg 17 22 in lb 86U11X 026 1 Fluid level sensor 5 Secondary piston assembly 2 Stopper screw and O ring 6 Reservoi...

Page 825: ...iver and remove or install the snap ring with snap ring pliers Secondary Piston Assembly Remove the secondary piston assembly by gradual ly blowing compressed air into the cylinder Caution Use a rag to catch the secondary piston as sembly when applying compressed air Assembly Note Application of brake fluid Before assembly apply brake fluid to the following parts 1 Cylinder inner surface 2 Piston ...

Page 826: ...the stopper screw 3 Push and release the screwdriver to verify that the position of the stopper screw is correct 86U11X 031 INSPECTION Check the following and replace any faulty parts 1 Piston and cylinder bore for abnormal wear rust and damage 2 Springs for weakness and damage 3 Reservoir for damage and deformation 11 16 ...

Page 827: ...eed air from the system Refer to page 11 8 3 Check each part for fluid leakage 86U11X 033 Installation Note Piston to push rod clearance Before installing the master cylinder check the clear ance between the piston of the master cylinder and the push rod of the power brake unit as follows 1 Place the SST on the top of the master cylinder then turn the adjust bolt until it contacts the bot tom of t...

Page 828: ...um pump 86U11X 035 3 Invert the SST used in step 1 and place it on the power brake unit 86U11X 036 4 Check the clearance between the end of the gauge and the push rod of the power brake unit If it is not 0 mm loosen the push rod locknut and turn the push rod to adjust 86U11X 037 Locknut 11 18 ...

Page 829: ...9 Third step 1 Start the engine 2 Depress the pedal with the usual force 3 Stop the engine with the pedal still depressed 4 Hold the pedal down for about 30 seconds 5 If the pedal height does not change the unit is operating 6 If there is a problem check for damage to the check valve or vacuum hose and check the con nection Repair if necessary and check once again If the nature of the problem is s...

Page 830: ...es 500 mm Hg 19 7 in Hg 4 Observe the vacuum gauge for 15 seconds Ifthe gauge shows 475 500 mm Hg 18 7 19 7 in Hg the unit is operating 86U11X 042 Checking for Hydraulic Pressure 1 With the engine stopped and the vacuum at 0 if the pedal force and fluid pressure are within specifi cation the unit is operating Pedal force Fluid pressure 196 N 20 kg 44 lb 1 177 kPa 12 kg cm2 171 psi min 69G11X 041 2...

Page 831: ... hose from the engine side Check that air flows only toward the engine If the air passes in both directions or not at all re place the check valve along with the hose REMOVAL Remove in the sequence shown in the figure referring to removal note for the specially marked parts 86U11X 045 1 Fluid level sensor connector 5 Vacuum hose and check 8 Power brake unit 2 Brake pipe valve 9 Gasket 3 Master cyl...

Page 832: ...ly marked parts 2 Inspect each part referring to inspection note 3 Assemble in the reverse order of disassembly referring to assembly note for the specially marked parts 1 Dust boot 2 Rear shell assembly 3 Retainer 4 Bearing 5 Dust seal 6 Retainer 7 Air filters 8 Air silencer 9 Diaphragm and plate 10 Power piston assembly 11 Retainer key 12 Valve rod and plunger as sembly 13 Reaction disc 14 Sprin...

Page 833: ...ate the rear shell counterclockwise to unlock Caution The rear shell is spring loaded loosen it carefully Retainer key Depress the plunger rod fully then remove the re tainer key Assembly Note Application of Grease Before assembly coat the parts shown in the figure with silicon grease 1 Entire surface of reaction disc 2 Dust seal lip 3 Push rod 4 Diaphragm to shell contacting surfaces 5 Power pist...

Page 834: ...rks are aligned Caution Fit suitable nuts to two studs of the rear shell and tighten them to mount the wrench INSPECTION 1 Inspect all rubber parts Wipe free of fluid and care fully inspect all rubber parts for cuts nicks and other damage 2 Check the power piston for cracks distortion chip ping and damaged seats 3 Inspect the reaction disc rubber for deterioration 4 Check that the seats of the val...

Page 835: ...orque referring to torque specifications 3 After installation 1 Add fluid and bleed the air Refer to page 11 8 2 Check all parts for fluid leakage 3 Make an on vehicle check of the unit Refer to page 11 19 4 Verify that the vacuum hose does not contact other parts EC AT Torque specifications 86U11X056 2 0 3 0 m kg 14 23 ft lb 1 Vacuum hose and check valve 626 MX 6 Revised 10 87 11 25 ...

Page 836: ...pply grease to the clevis pin contact surface 2 Apply sealant to the gasket contact surface 86U11X 057 Vacuum hose and check valve Install the vacuum hose and check valve noting the installation direction Note Except EC AT The check valve is pressed into the vacuum hose 11 26 ...

Page 837: ...efer to page 11 8 86U11X 061 t CD A A B Master cylinder pressure kPa kg cm2 psi 86U11X 062 3 Depress the brake 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 B Specification Fluid pressure kPa kg cm 2 psi A A B B 2 943 2 943 196 6 867 4 120 196 30 427 30 2 427 28 ...

Page 838: ...r the spe cially marked parts 2 Install in the reverse order of removal 3 After installation 1 Add brake fluid and bleed the air Refer to page 11 8 2 Check the brake lines for fluid leakage Caution Brake fluid will damage painted surfaces If it does get on a painted surface wipe it off immediately 1 Brake pipe 2 Dual proportioning valve 11 28 ...

Page 839: ... REPLACEMENT OF DISC PAD Caution Replace the left and right pads at the same time 1 Loosen the front wheel lug nuts 2 Block the rear wheels firmly 3 Jack up the front of the vehicle and support it with safety stands 4 Remove the wheels 5 Remove the lower mounting bolt 6 Pivot the caliper on the top bolt and support it 7 Remove the pads and shims Warning Asbestos dust is a health hazard Do not blow...

Page 840: ...fied torque Tightening torque 31 41 Nm 3 2 4 2 m kg 23 30 ft lb 86U11X 069 13 Mount the wheels 14 Apply the brakes a few times then turn the wheels and check that the brakes do not drag excessively 15 Lower the vehicle 16 Tighten the wheel lug nuts Tightening torque 88 118 Nm 9 0 12 0 m kg 65 87 ft lb 11 30 86U11X 070 ...

Page 841: ...e sequence shown in the figure Warning Asbestos dust is a health hazard Do not blow away brake dust with compressed air Caution Brake fluid will damage painted surfaces If it does get on a painted surface wipe it off immediately 86U11X 071 1 Flexible hose 4 Guide plate 2 Caliper assembly 5 Mounting support 3 Pad and shim 6 Disc plate Refer to section 9 11 31 ...

Page 842: ...ly note for the specially marked parts 86U11X 072 1 Snap ring 4 Piston seal 7 Bushing 2 Dust seal 5 Guide pin 8 Cap 3 Piston 6 Pin boot 9 Bleeder screw Disassembly Note Piston Place a piece of wood in the caliper then blow com pressed air through the hose connection hole to force out the piston Caution Blow the compressed air a little at a time to prevent the piston from jumping out Piston seal Re...

Page 843: ...Boot for damage or poor sealing 86U11X 075 Assembly Note Application of grease Coat the following parts with the grease supplied in the seal kit 1 Piston seal 2 Dust seal 3 Guide pin 4 Guide pin boot 5 Bushing Piston Coat the piston and the cylinder with brake fluid then insert the piston straight into the cylinder 1X 077 86U11X 078 626 MX 6 Revised 10 87 11 33 ...

Page 844: ...r or cracks 3 Deterioration or heat damage 4 Remaining lining thickness Thickness 2 0 mm 0 08 in min Disc Plate 1 Runout Runout 0 1 mm 0 004 in max Caution a There must be no wheel bearing looseness b Measure at the outer edge of the disc plate surface 2 Wear or damage Thickness Standard 24 mm 0 94 in Minimum 22 mm 0 86 in 11 34 ...

Page 845: ...d torque referring to torque specifications 3 After installation 1 Add brake fluid and bleed air Refer to page 11 8 2 Depress the brake pedal a few times and check that the front brakes do not drag excessively while rotating the wheels Note Refer to page 11 29 for pad installation Torque specifications 86U11X 082 11 35 ...

Page 846: ...stands 4 Remove the wheels 5 Remove the parking brake cable from the cable bracket and the operating lever 6 Remove the upper mounting bolt then pivot the caliper 7 Remove the V springs 8 Remove the pads and shims Warning Asbestos dust is a health hazard Do not blow away brake dust with compressed air 86U11X 086 9 Apply the grease supplied in the pad attachment set to the new shims then attach the...

Page 847: ...end to the operating lever then tighten the locknut Tightening torque 20 28 Nm 2 0 2 9 m kg 14 21 ft lb Caution There must be no clearance between the ca ble end and the operating lever 16 Mount the wheels 17 Apply the brakes a few times then check that the brakes do not drag excessively while turning the wheels 18 Lower the vehicles 19 Tighten the wheel lug nuts Tightening torque 88 118 Nm 9 12 m...

Page 848: ...equence shown in the figure Warning Asbestos dust is a health hazard Do not blow away brake dust with compressed air Caution Brake fluid will damage painted surfaces If it does get or a painted surface wipe it off immediately 86U11X 090 1 Parking brake cable 2 Flexible hose 3 Caliper assembly 4 V spring 5 Pad and shim 6 Guide plate 7 Mounting support 8 Disc plate Refer to section 9 11 38 ...

Page 849: ...assembly note for the specially marked parts 5 9 8 8 N m 60 90 cm kg 52 78 In lb 1 Guide pin 2 Pin boot 3 Bushing 4 Retaining ring 5 Dust seal 6 Piston 7 Piston seal 8 Snap ring 9 Adjuster spindle 10 Stopper 11 0 ring 12 Connecting link 13 Return spring 14 Operating lever 15 Boot 16 Boot clip 17 Needle bearing 18 Cable braket 86U11X 091 Disassembly Note Piston Remove the piston with the SST Note T...

Page 850: ...ction Note 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 Sleeve bolt and sleeve for damage and wear 4 Guide pin for damage and rust 5 Adjuster spindle threads for damage 86U11X 095 86U11X 096 Assembly Note Application of grease Before assembly apply the grease supplied in the seal kit to the parts indicated...

Page 851: ... until the SST bottoms against the caliper 86U11X 098 Adjuster spindle 1 Assemble the adjuster spindle and the stopper 2 Install the adjuster and stopper straight intothe cal iper cylinder with the two stopper pins fit into the caliper 3 Install the snap ring 86U11X 100 11 41 ...

Page 852: ...y 86U11X 101 11 42 Piston 1 Clean the piston 2 Install the dust seal in the piston groove 3 Turn the piston intothe caliper cylinder while rotat ing the SST clockwise Note Turn the piston in fully and align the piston grooves as shown in the illustration 4 Fit the dust seal into the caliper cylinder ...

Page 853: ...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 looseness b Measure at the outer edge of the disc plate surface 2 Wear or damage Thickness Standard 10 mm 0 39 in Minimum 8 mm 0 31 in 11 43 ...

Page 854: ...Adjust the parking brake lever stroke Refer to page 11 54 3 Depress the brake pedal a few times and check that the rear brakes do not drag excessively while rotating the wheel Note Refer to page 11 36 for pad installation Torque specifications 1 Parking brake cable Installation Note Parking brake cable Connect the parking brake cable end onto the oper ating lever then fix it to the bracket by the ...

Page 855: ...igure referring to removal note for the specially marked parts Caution Do not damage the wheel cylinder dust boots when removing the brake shoes 1 Hub cap 2 Locknut 3 Brake drum 4 Parking brake cable 5 Return spring 6 Dust cover 7 Return spring upper 8 Hold pin and spring 9 Brake shoe leading side 10 Return spring lower 11 Anti rattle spring 12 Hold pin and spring 13 Brake shoe trailing side 14 Op...

Page 856: ...cking plate Removal Note Locknut Uncrimp the locknut and remove it Caution Do not reuse the locknut Brake drum It the drum is difficult to remove push the operating lever stopper at backing plate upward to release the operating lever and increase shoe clearance 86U11X 111 11 46 ...

Page 857: ...brake assembly Warning Asbestos dust is a health hazard When clean ing the brake assembly do not use compressed air or a brush Brake pipe Disconnect the brake pipe with the SST Caution Brake fluid will damage painted surfaces If it does get on a painted surface wipe it off im mediately 86U11X 113 11 47 ...

Page 858: ...sembly note for the specially marked parts Caution Do not damage the piston or cylinder Do not let foreign material in the cylinder Note Use new piston cups when installing 1 Dust boot 2 Piston 3 Piston cup 4 Spring 5 Rubber cap 6 Bleeder screw 7 Steel ball 8 Wheel cylinder body Inspection Note Check the following and repair or replace any faulty parts 1 Weak or broken spring 2 Worn rusted or dama...

Page 859: ... any faulty parts 1 Scratches uneven or abnormal wear inside drum Note Repair by sanding if the problem is minor 2 Drum inner diameter Diameter 228 6 mm 9 00 in Maximum 230 1 mm 9 06 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 assembly replace the left and right shoes at the same time as a set 86U11X 118 86U11X...

Page 860: ...N 1 Install in the reverse order of removal 2 Tighten all nuts and bolts to the specified torque referring to torque specifications 3 After installation 1 Add brake fluid and bleed air Refer to page 11 8 2 Adjust the parking brake lever stroke Refer page to 11 54 3 Depress the brake pedal a few times and check that the rear brakes do not drag while rotating the wheel Torque specification ...

Page 861: ...ion 10 18 m kg 72 130 ft lb 3 Locknut Installation Note Brake shoes 1 Apply grease to the following points 1 Shoe and cylinder contact points 2 Shoe anchor points 3 Projections of backing plate 1 Brake shoe 2 Brake 86U11X 122 S jje 11 51 ...

Page 862: ...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 trail ing side and leading side 8 Install the shoe leading side to the operating lever then to the wheel cylinder and anchor plate 9 Fix the shoe with the hold spring and hold pin 10 Install the return s...

Page 863: ...learance 2 Install the brake drum Note The shoe clearance will be automatically ad justed by applying parking brakes Locknut Tighten the new locknut to the specified torque and securely stake it to the spindle groove Tightening torque 98 177 Nm 10 18 m kg 72 130 ft lb Caution Do not use a pointed tool for staking 11 53 ...

Page 864: ...1X 130 Adjustment Before adjustment start the engine and depress the brake pedal several times 2 Stop the engine 3 Remove the adjust nut clip and turn the adjust nut at the front of the parking cable 4 After adjustment check the following points 1 Turn the ignition switch ON pull the parking brake lever one notch and check that the park ing brake warning lamp illuminates 2 Check that the rear brak...

Page 865: ...e 4 Inspect all parts referring to inspection note 5 Install in the reverse order of removal referring to installation note for the specially marked parts 6 After installation Adjust the parking lever stroke Refer to page 11 54 1 8 2 5 m kg 13 18 ft lb 1 Rear console 4 Adjust nut 7 Button 2 Parking brake switch 5 Parking brake lever 8 Spring 3 Clip 6 Cover 11 55 ...

Page 866: ...or wear and damage 2 Spring for weakness and breakage Installation Note Parking switch 1 Install the parking switch sothat itcontactsthe park ing brake lever when the lever is released 2 Turn the ignition switch ON and check that the parking brake warning lamp illuminates with the lever pulled one notch 86U11X 135 11 56 ...

Page 867: ...5 3 Release the parking brake and remove the adjust nut of the parking brake lever Refer to page 11 55 4 Jack up the vehicle and support it with safety stands 5 Remove the parking brake cable in the sequence shown in the figure 1 Front parking cable 3 Parking brake cable left 2 Spring 4 Parking brake cable right 11 57 ...

Page 868: ... the specially marked parts 2 Tighten all nuts and bolts to the specified torque referring to torque specifications 3 After installation 1 Adjust the parking brake lever stroke Refer to page 11 54 2 Depress the brake pedal a few times and check that the rear brakes do not drag while rotating the wheels Torque specifications 11 58 ...

Page 869: ...r disc brake Connect the cable end to the operating lever then tighten the locknut Tightening torque 20 28 Nm 2 0 2 9 m kg 14 21 ft lb Caution There must be no clearance between the ca ble end and the operating lever 1 Parking brake cable rear disc brake 11 59 ...

Page 870: ...TEM ABS ANTI LOCK BRAKE SYSTEM ABS STRUCTURAL VIEW 86U11X 140 1 Hydraulic unit 4 Sensor rotor front 7 Wheel speed sensor rear 2 Relay box 5 Wheel speed sensor front 8 Sensor rotor rear 3 Control unit 6 Check connector 11 60 ...

Page 871: ...86U11X 141 2 z o g o ANTI LOCK BRAKE SYSTEM ABS 1 1 ...

Page 872: ... used When tires of different gripping performance are used When while the vehicle isjacked up or stuck the front wheels only are spun for 20 seconds or more When there is insufficient battery voltage Note Under the above conditions the warning light will not illuminate a second time when the ignition is switched OFF then back ON and there will be no memory entry to the control unit of a problem T...

Page 873: ...is indication Refer to page 11 75 Set system for diagnosis indication mode before reading warning light and voltmeter indications Treat repeated indications as one failure Indicated Erase one mem ory Refer to page 11 75 Illum inates constantly Present failure Read and note diagnosis indi cation Refer to page 11 75 Set system for diagnosis indica tion mode before reading warn ing light and voltmete...

Page 874: ...i Left rear sensor rotor ABS 7 r n Hydraulic unit Harness Control unit connector 11 pin ABS 8 nnnn J _nn Relay box Hydraulic unit Harness ABS 9 J T J T J T J T J L T L _ ABS 10 J _nnn ABS 11 Jinnnnn_ ABS 12 j nnnn ABS 13 JiruiriruL ABS 14 r jmnnn Hydraulic unit Harness Control unit ABS 15 JITUUUUL ABS 16 _r j w l t u u l Control unit ABS 17 jirLruinjL_ ABS 18 j No signal failure condi tions not st...

Page 875: ...k followings Clearance between sensor and rotor standard 0 3 1 1 mm 0 0 1 2 0 0 4 3 in Objects sticking to sensor or rotor Damaged sensor or rotor Sensor installation Tightening torque 1 6 2 3 N m 1 6 2 3 m kg 1 2 1 7 ft lb OK Connect Q 01 11 pin connector Jum p GB to B at Q 07 connector Start engine Check that warning light stays ON Drive vehicle and check that warning light flashes 0 25 sec ON O...

Page 876: ...tor Sensor installation Tightening torque 1 6 2 3 N m 1 6 2 3 m kg 1 2 1 7 ft lb NG Repair harness Control unit Left front sensor OK Measure resistance at harness side NG Disconnect Q 02 Measure resistance at sensor Q 02 Resistance W R 800 1200 fl NG OK NG Repair or replace as necessary Replace left front wheel speed sensor Repair harness Control unit Left front sensor All conditions can be verifi...

Page 877: ... engine Check that warning light stays ON Drive vehicle and check that warn ing light flashes 0 25 sec ON OFF at 15 km h 9 mph NG Repair harness Control unit Rear speed sensor OK Measure resistance at harness side NG Disconnect Q 09 and Q 05 Measure resistance at sensor Q 09 Q 05 Resistance YG YL 800 1200 0 G L NG OK NG Repair or replace as necessary NG Check Q 01 connector or Replace control unit...

Page 878: ...11 ANTI LOCK BRAKE SYSTEM ABS 86U11X 148 86U11X 149 86U11X 150 86U11X 151 11 68 ...

Page 879: ...ec Check that warning light i luminates within 102 sec from engine start Illu minated Illuminates after indicating failure mode M otor operates Disconnect Q 01 11 pin connector Check continuity at harness side Q 01 11 pin Continuity LB 2K Ground No GR 2L Ground No OK OK Not illu minated No problem Illum inates after 90 105 sec Disconnect Q 01 11 pin connector Check continuity at harness side Q 01 ...

Page 880: ...eversing and test leads Check relay box Refer to page 11 76 OK Repair harness Control unit Relay box Hydraulic unit NG Replace relay box NG OK Check continuity at harness side Q 01 17 pin Continuity RY B Ground Yes OK Relay control unit NG Disconnect Q 09 connector Check continuity at motor side NG Q 09 Continuity RY Ground Yes Repair harness Motor Ground OK Check continuity at motor side Q 09 Con...

Page 881: ...O C BG G No OK Q 01 17 pin Resistance BL E Ground Approx 75Q OK Replace control unit NG Check resistance at harness side Check relay box Refer to page 11 76 OK Repair harness Control unit Relay box Hydraulic unit NG Disconnect Q 08 connector Check continuity at relay side Q 08 Continuity BL Ground No NG Replace relay box NG OK Repair harness Control unit Relay box Hydraulic unit 86U11X 155 86U11X ...

Page 882: ...er to page 11 76 OK NG Replace relay box Repair harness Control unit Relay box or Ignition switch Hydraulic unit OK Turn ignition switch ON Check continuity at harness side Q 08 6 pin Q 08 2 pin Continuity BG LR Yes Q 09 Q 08 2 pin Continuity RY RY Yes OK Check continuity at hydraulic unit side Q 09 Continuity RY Ground No Q 09 Resistance RY B approx 0 1 G NG OK Disconnect Q 09 and Q 08 2 pin conn...

Page 883: ... pin connectors Check continuity at hydraulic unit side Q 10 Continuity BR Ground No OK Disconnect Q 06 connector Check continuity at hydraulic side Q 10 Continuity BR Ground No Disconnect Q 06 connector Meas ure resistance at hydraulic unit side Q 06 Q 10 Resistance Br BW L YG BR approx 3 fi YR YW NG NG OK Check Q 06 connector for proper connection OK NG OK NG Replace hydraulic unit Repair harnes...

Page 884: ...17 pin and Q 10 connectors Check that hydraulic unit and har ness resistance does not fluctuate when moving harness Q 01 17 pin Q 10 Resistance Br K BW 0 L R YG J YR M YW Q BR Must be constant NG Repair connector or harness Q 01 17 pin Q 10 OK Replace control unit 86U11X 160 86U11X 161 11 74 ...

Page 885: ...fer to page 11 64 MEMORY CANCEL Note Failures are contained in the control unit mem ory They are not erased when the battery is disconnected Follow the procedure below to erase them 1 Connect the terminal wires GR and GB of the check connector with a jumper wire 2 Turn the ignition switch ON 3 Check that the warning light is illuminated and wait 1 2 seconds 4 Turn the ignition switch OFF 5 Disconn...

Page 886: ...an ohmmeter Replace the relay box if necessary Connecting to BR B Q 08 B Q 09 12V Ground O O BG BL O O O O Indicates continuity 2 Check that the resistance between terminal wire BR and terminal wire LY changes when revers ing the and test leads Replace the relay box if necessary Inspection of Motor Relay 1 Check for continuity of the relay with an ohmmeter Replace the relay box if necessary Connec...

Page 887: ...e not interchange able L or R is indicated on the bracket 2 Install the sensor harness bracket onto the knuckle Tightening torque 16 23 Nm 1 6 2 3 m kg 12 17 ft lb 3 Push the sensor harness through the splash shield and secure it with the clip 4 Install the sensor harness bracket to the body Tightening torque 16 23 Nm 1 6 2 3 m kg 12 17 ft lb Caution Verify that the harness is not twisted and does...

Page 888: ...ge able L or R is indicated on the bracket 86U11X 174 2 Install the sensor harness bracket onto the knuckle Tightening torque 16 23 Nm 1 6 2 3 m kg 12 17 ft lb 3 Feed the sensor harness through the body and in stall the grommet 4 Install the sensor harness bracket to the body Tightening torque 11 26 Nm 1 1 2 6 m kg 8 19 ft lb Caution Verify that the harness is not twisted and does not contact the ...

Page 889: ...r Rotor 1 Loosen the front wheel lug nuts 2 Block the rear wheels 3 Jack up the front of the vehicle and support it with safety stands 4 Remove the wheels 5 Remove in the sequence shown in the figure referring to removal note for the specially marked parts 86U11X 178 1 Hub cap 3 Driveshaft Refer to section 9 2 Locknut 4 Sensor rotor 11 79 ...

Page 890: ...he reverse order of removal referring to installation note for the specially marked parts Torque specifications Installation note Sensor rotor Press the sensor rotor onto the driveshaft with the SST Caution Install the sensor rotor with chamfered edge toward the driveshaft 11 80 ...

Page 891: ...ront wheels 3 Jack up the rear of the vehicle and support it with safety stands 4 Remove the wheels 5 Remove in the sequence shown in the figure referring to removal note for the specially marked parts 86U11X 182 1 Hub cap 3 Caliper assembly and 4 Disc plate 2 Locknut mounting support 5 Sensor rotor 11 81 ...

Page 892: ...rque specifications 11ANTI LOCK BRAKE SYSTEM ABS Installation Sensor rotor Press the sensor rotor onto the hub with the SST 86U11X 185 Locknut 1 Install and tighten the locknut 2 Stake a new locknut securely in the driveshaft groove Caution Do not use a pointed tool for staking 3 Check that the hub rotates freely by hand 86U11X 186 11 82 ...

Page 893: ...y damage the filter in the reservoir b Only the amount of fluid shown can be re moved from the reservoir 3 Fill the reservoir with the specified type and amount of brake fluid Caution a Do not let any foreign material into the reservoir b Do not soak the upper filter with brake flu id Otherwise pouring fluid into may be dif ficult Fluid FMVSS 116 DOT 3 or DOT 4 or SAE J1703a 4 Check the fluid leve...

Page 894: ...essed turn the ignition switch ON 9 With the brake pedal still depressed check that the wheel can be turned intermittently when pressure reduction is operating Pressure ON Rj F L F reduction OFF 1 0 5 V Ignition 0 N sec 360 seC___________________ switch OFF 10 Check operation at the remaining wheels 11 If not operated correctly check the warning light a brake light switch circuit for proper operat...

Page 895: ...6 2 6 4 If the measurement is not within specification re place the hydraulic unit assembly REMOVAL Caution a Brake fluid will damage painted surfaces If it does get on the painted surfaces wipe it off immediately b Do not tip the hydraulic unit to prevent the brake fluid in the reservoir from draining 1 Remove the nuts mounting the fuel filter and ignitor to the bracket and move them toward the e...

Page 896: ...11ANTI LOCK BRAKE SYSTEM ABS 86U11X 196 1 Coupler 4 Brake pipe to rear brakes 2 Brake pipe from master cylinder 5 Mount bushing 3 Brake pipe to front brakes 6 Hydraulic unit 1 1 8 6 ...

Page 897: ...ter cylinder reservoir and hydraulic unit reservoir 2 Tighten all bolts and nuts to the specified torque referring to torque specifications 3 After installation 1 The sealing reservoir cap red is installed on the new hydraulic unit to prevent the brake fluid from leaking while shipping Replace it with an original cap black after replacing the hydraulic unit 2 Check that the hydraulic unit operates...

Page 898: ... 2L WB Alternator output Voltage 2L WB Ground Run engine Approx 14V Q 01 17 pins A WG Brake light switch Voltage A WG Ground Depress brake pedal 12V B RY Motor Continuity B RY Ground Continuity C LO Motor relay Resistance C Lo test lead J Approx 6 0 7 0 Q D GR Check connector Continuity D GR A GR Q 07 Continuity E BL Fail safe relay Resistance E BL G BG Approx 7 0 8 0 Q F LY W arning light Continu...

Page 899: ...AND TIRES OUTLINE 12 2 SPECIFICATIONS 12 2 TROUBLESHOOTING GUIDE 12 2 WHEELS AND TIRES 12 3 INSPECTION AND ADJUSTMENT 12 3 TIRE ROTATION 12 4 WHEEL BALANCE 12 5 WHEEL MOUNTING 12 5 SPECIAL NOTE 12 5 86U12X 001 ...

Page 900: ...ed wheel s or tire s Irregular tire wear Adjust Adjust Repair or replace Replace 1 2 2 12 5 Steering wheel vibration Irregular tire wear Right and left tread depths different Deformed or unbalanced wheel s Deformed tire s Unequal tire pressures Loose lug nuts Replace Replace Replace or adjust Replace Adjust Tighten 1 2 5 1 2 2 1 2 5 Uneven one sided braking Unequal tire pressures Adjust 1 2 2 Stee...

Page 901: ...rmal tire wear patterns shown in the illustra tion can occur Refer to the chart for the probable causes and remedies Probable cause Remedy a Underinflation both sides worn Incorrect camber one side wear Hard cornering Lack of rotation Measure and adjust pressure Repair or replace axle and suspension parts Reduce speed Rotate tires b Overinflation Lack of rotation Measure and adjust pressure Rotate...

Page 902: ...formation and damage to the wheel 5 Loose wheel lug nut s 6 Air leaking from the valve stem 86U12X 008 TIRE ROTATION To prolong tire life and assure uniform wear rotate the tires every 6 000 km 3 750 miles or sooner if ir regular wear develops Caution a Do not include TEMPORARY USE ONLY spare tire in rotation b After rotating the tires adjust each tire to the specified air pressure Refer to page 1...

Page 903: ...ls 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 Nm 9 12 m kg 65 87 ft lb Caution a The wheel to hub contact surfaces must be clean b Never apply oil to the nuts bolts or wheels doing so might cause looseness or seizure of the lug nuts 86U12X 012 SPECIAL NOTE Regarding wheels and ti...

Page 904: ...e never 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 to 250 300 kPa 2 55 3 06 kg cm2 35 55 42 66 psi Check to be sure that the bead is seated correctly onto the rim and that there are no air leaks Then reduce the pressure to the specified level 7 If ...

Page 905: ...OVAL AND INSTALLATION 13 23 REAR SHOCK ABSORBER AND SPRING 13 25 REMOVAL AND INSTALLATION 13 25 DISASSEMBLY AND ASSEMBLY 13 28 LATERAL LINK AND TRAILING L IN K 13 30 REMOVAL AND INSTALLATION 13 30 REAR LOWER ARM AND TRAILING LINK 4 W S 13 32 REMOVAL AND INSTALLATION 13 32 REAR STA B ILIZE R 13 35 REMOVAL AND INSTALLATION 13 35 REAR STABILIZER AND CONTROL LINK 4W S 13 37 REMOVAL AND INSTALLATION 13...

Page 906: ...1 3 OUTLINE OUTLINE STRUCTURAL VIEW Front Suspension 13 2 86U13X 002 ...

Page 907: ...OUTLINE 1 3 Rear Suspension 86U13X 003 13 3 ...

Page 908: ...14 6 372 14 6 365 14 4 350 13 8 358 14 1 340 13 4 Coil number 5 42 5 53 5 46 5 34 5 45 5 28 Rear Suspension Item Specifications Suspension type Strut Rear wheel alignment Toe in mm in 2WS 0 3 0 0 12 4WS 3 3 0 12 0 12 Camber angle 2WS 0 30 45 4WS 0 00 45 Maximum rear steering angle 4WS Inner 5 00 45 Outer 5 00 45 Stabilizer Type Torsion bar Diameter mm in 16 0 63 Shock absorbers Standard suspension...

Page 909: ...o o F2 o 0 o TURBO EC AT o o o 0 o o o M 5 o o o o F2 o o NO N TURBO o o EC AT o Sedan o o o o o M 5 o o F2 TURBO 0 o o o o EC AT o o 0 0 4WS o o M 5 o o o o F2 o o NO N TURBO o o Touring EC AT o sedan o o o o o M 5 o o F2 o o o TURBO EC AT 0 o o o 0 86U13X 005 O Available M 5 Manual transaxle 4WS 4 wheel steering Not available EC AT Electronically controlled automatic transaxle 13 5 ...

Page 910: ...L 0 o R L o R L M 5 R L o o R L F2 o R L NON TURBO o R L EC AT R L Sedan o o R L o R L M 5 o R L F2 TURBO o o R L o R L EC AT o o R L R 4WS L 4WS o R L M 5 R L o o R L F2 o R L NON TURBO o R L Touring EC AT R L sedan o o R L o R L M 5 o R L F2 o o R L TURBO EC AT o R L o o R L 86U13X 006 M 5 Manual transaxle 4WS 4 wheel steering EC AT Electronically controlled automatic transaxle t 13 6 O Availabl...

Page 911: ... steering gear Refer to section 10 Insufficient grease on steering gear Refer to section 10 Malfunction of steering shaft universal joint Refer to section 10 Low tire pressure Refer to section 12 Abnormal tire wear Refer to section 12 Steering wheel pulls Weak coil spring Replace 13 11 28 to one side Lower arm or stabilizer bushing worn or damaged Replace 13 16 34 Damaged knuckle arm Refer to sect...

Page 912: ...16 34 General instability Weak coil springs Shock absorber malfunction Worn or damaged lower arm or stabilizer bushing Improperly adjusted wheel alignment Improperly adjusted pinion preload Loose steering shaft universal joint Incorrect tire pressure Damaged or unbalanced wheel Malfunction of wheel bearing Replace Replace Replace Adjust Refer to section 10 Refer to section 10 Refer to section 12 R...

Page 913: ...the removal note for the specially marked parts 3 Install in the reverse order of removal referring to the installation note for the specially marked parts 4 Tighten all nuts and bolts to the specified torque referring to the figure 1 Lug nut 5 Rubber cap 8 Bolt and nut 2 Wheel and tire 6 Actuator AAS 9 Nut 3 Clip 7 Nuts and bolts Ignition coil 10 Shock absorber assembly 4 Harness and bracket bolt...

Page 914: ...nd nuts 2 Remove the upper mounting shock absorber nuts 86U13X 012 Installation Note Mounting block Install the mounting block to the suspension tower with the white mark facing the front inside direction Tightening torque 46 63 Nm 4 7 6 4 m kg 34 46 ft lb 86U13X 013 Shock absorber clinch bolts and nuts Install the clinch bolts and nuts Tightening torque 93 117 Nm 9 5 11 9 m kg 69 86 ft lb 86U13X ...

Page 915: ...ponents and parts referring to inspection note 3 Assemble in the reverse order of disassembly referring to the assembly note for the specially marked parts 4 Tighten all nuts and bolts to the specified torque referring to the figure 86U13X 015 1 Nut 2 Actuator bracket 3 Mounting block 4 Bearing 5 Spring upper seat 6 Spring seat 7 Dust boot 8 Bound stopper 9 Coil spring 10 Shock absorber 13 11 ...

Page 916: ...e 3 Secure the shock absorber in the SST 4 Compress the coil spring with the SST then re move the upper nut 5 Remove the coil spring 86U13X 018 Inspection Note Check the following and repair or replace any faulty parts 1 Oil leakage or abnormal noise from shock ab sorbers 2 Deterioration or damage of mounting block and bearing 3 Wear or damage of the bound stopper 4 Smooth rotation of control rod ...

Page 917: ...rber 4 Install the compressed coil spring compressed with SST 5 Install the rubber seat spring upper seat bearing and mounting block 6 Remove the SST 7 Secure the mounting block in the vise Caution Use copper or aluminum plates in the jaws of the vice 8 Tighten the piston rod upper nut Tightening torque 64 84 Nm 6 5 8 2 m kg 47 59 ft lb Caution Check that the spring is well seated in the up per se...

Page 918: ...ents and parts referring to inspection note 4 Install in the reverse order of removal referring to the installation note for the specially marked parts 5 Tighten all nuts and bolts to the specified torque referring to the figure 16 23 N m 9 12 m k g 65 8 7 ft lb 1 Lug nut 6 Retainer and bushing 10 Nut 2 Wheel and tire 7 Retainer bushing and 11 Bolt 3 Bolt and nut spacer 12 Front lower arm 4 Nuts 8...

Page 919: ...FRONT LOWER ARM 1 3 Removal Note 1 Remove the stabilizer bar control link 2 Remove the lower arm ball joint 3 Remove the lower arm spindle from the lower arm ...

Page 920: ...the ball joint re place the lower arm assembly Ball joint preload Attach the SST to the ball stud and measure the preload with a pull scale Caution Measure the preload after shaking ball joint the stud 3 or 4 times Lower arm bushing Front Removal 1 Cut away the projecting rubber of the lower arm bushing 2 Set the SST on the lower arm and remove the bushing Installation Apply soapy water to the new...

Page 921: ... the new bushing and then pull it into the low er arm with the SST Ball joint dust boot Removal Remove the dust boot with a chisel Caution Do not damage the ball joint Installation 1 Liberally coat the inside of the new dust boot with grease 2 Install the dust boot onto the ball joint with the SST 86U13X 034 49 G034 2A0 Bushing 86U13X 032 13 17 ...

Page 922: ...m ball joint to the knuckle arm Tightening torque 43 54 Nm 4 4 5 5 m kg 32 40 ft lb Caution Lower the vehicle and check the torque with the vehicle unloaded 86U13X 037 13 18 3 Lower the vehicle from the jack Torque the lower arm spindle nut which was loosely tightened in step 1 Tightening torque Front and rear lower arm spindle nut 93 127 Nm 9 5 12 9 m kg 69 93 ft lb Caution Lower the vehicle and ...

Page 923: ...note 4 Install in the reverse order of removal referring to the installation note for the specially marked parts 5 Tighten all nuts and bolts to the specified torque referring to the page 13 22 1 Nut retainer and bushing 2 Bolt retainer and bushing 3 Bushing retainer and spacer 4 Nut retainer and bushing 5 Bolt retainer and bushing 6 Bushing retainer and spacer 7 Bolt and nut 8 Bolt and nut 9 Bolt...

Page 924: ... 1 Remove the wheel and tire 2 Remove the stabilizer bar control link 86U13X 040 3 Remove the bolts indicated by the arrows 4 Remove the stabilizer bushing and bracket 86U13X 042 5 Remove the stabilizer 86U13X 043 C Front 86U13X 041 13 20 ...

Page 925: ...stallation Note Stabilizer bushing and control link Align the bushing with the installation position line on the stabilizer mount it so that the notch faces the rear of the chassis Caution Mount the brackets of the stabilizer first and loosely tighten them After mounting the con trol links tighten the bracket to the specified torque with the vehicle on the ground and un loaded Tightening torque 36...

Page 926: ...Tightening torque 1 3 FRONT STABILIZER 4WS 13 22 86U13X 047 ...

Page 927: ...nspect all components and parts referring to inspection note 4 Install in the reverse order of removal referring to the installation note for the specially marked parts 5 Tighten all nuts and bolts to the specified torque referring to the figure 1 Nuts 4 Bushing retainer and 6 Bushing and bracket 2 Retainer and bushing spacer 7 Stabilizer 3 Bolt retainer and bushing 5 Bolt 13 23 ...

Page 928: ...nstallation Note Stabilizer bushing Align the bushing with the installation position line on the stabilizer and mount it so that the notch faces the rear of the chassis Caution Mount the brackets of the stabilizer first and loosely tighten them After mounting the con trol links tighten the brackets to the specified torque with the vehicle on the ground and un loaded Tightening torque 36 54 Nm 3 7 ...

Page 929: ... referring to the removal note for the specially marked parts 3 Install in the reverse order of removal referring to the installation note for the specially marked parts 4 Tighten all nuts and bolts to the specified torque referring to the figure ft lb 1 Bolt seat belt 5 Clip 8 Bolt and nut 2 Trim 6 Harness and bracket ABS 9 Nut 3 Lug nut 7 Actuator AAS 10 Shock absorber assembly 4 Wheel and tire ...

Page 930: ...te Seat belt and trim 1 Remove the seat belt 86U13X 053 2 Remove the trim 86U13X 054 ABS harness bracket Remove the ABS harness and bracket 86U13X 055 AAS actuator 1 Disconnect the AAS actuator connector 2 Remove the AAS actuator 86U13X 056 13 26 ...

Page 931: ...linch bolts Shock absorber upper nuts Remove the upper mounting shock absorber nuts Installation Note Shock absorber Tighten the shock absorber mounting bolts and nuts Tightening torque Upper nuts 46 64 Nm 4 7 6 5 m kg 34 47 ft lb Clinch bolts 93 117 Nm 9 5 11 9 m kg 69 86 ft lb 13 27 ...

Page 932: ...Tighten all nuts and bolts to the specified torque referring to the figure 86U13X 060 Caution a Do not remove the nut b Use copper or aluminum plates in the jaws of the vise 2 Set the SST in a vise 3 Secure the shock absorber in the SST 4 Compress the coil spring with the SST then re move the nut 5 Remove the coil spring 13 28 49 G 034 103 49 G 034 102 86U13X 061 1 Nut 2 Seat 3 Mounting block 4 Sp...

Page 933: ...in a vise Secure the shock absorber in the SST Install the bound stopper and dust boot onto the shock absorber Install the compressed coil spring compressed with SST Install the spring seat and mounting block Remove the SST Secure the mounting blocks in the vise Caution Use copper or aluminum plate in the jaws of the vice Tighten the piston rod upper nut Tightening torque 64 84 Nm 6 5 8 2 m kg 47 ...

Page 934: ...ly marked parts 3 Inspect all components and parts referring to inspection note 4 Install in the reverse order of removal referring to the installation note for the specially marked parts 5 Tighten all nuts and bolts to the specified torque referring to the figure 86U13X 065 1 Nut 5 Bolt and nut 2 Bushing and retainer 6 Bolt and nut 3 Retainer bushing and bolt 7 Lateral link 4 Retainer bushing and...

Page 935: ...ateral link or trailing link assembly Installation Note Lateral links Loosely tighten the mounting bolts of each link and lower the vehicle from the safety stands Adjust the toe in and then tighten the bolts with the vehicle un loaded Tightening torque 86 117 N m 8 8 11 9 m kg 64 86 ft lb Trailing link 1 Loosely tighten the mounting bolt and nut 2 Lower the vehicle from the safety stands 3 Tighten...

Page 936: ...ct all components and parts referring to inspection note 4 Install in the reverse order of removal referring to the installation note for the specially marked parts 5 Tighten all nuts and bolts to the specified torque referring to the figure 1 Bolt and nut 2 Cotter pin and nut 3 Retainer 4 Bushing 5 Bolt 6 Bolt and nut 7 Bolt and nut 8 Lower arm 86U13X 070 9 Trailing link retainer and bushing 10 B...

Page 937: ...ball joint replace the lower arm assembly Measurement of ball joint rotation torque Connect the SST to the ball stud 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 18 30 N 1 8 3 1 kg 3 9 6 8 lb Dust boot Removal Use a chisel to remove the dust boot Caution Do not damage the ball joint Installation Apply lithium grease to the inside of ...

Page 938: ... Crossmember side 93 117 N m 9 5 11 9 m kg 69 86 ft lb Knuckle arm side 43 54 N m 4 4 5 5 m kg 32 40 ft lb Caution Lower the vehicle and check the torque with the vehicle unloaded Trailing link Tighten the trailing link to the body and lower arm Tightening torque Body side 63 93 N m 6 4 9 5 m kg 46 69 ft lb Lower arm side 89 103 N m 9 1 10 5 m kg 66 76 ft lb Caution a Lower the vehicle and check t...

Page 939: ...spect all components and parts referring to inspection note 4 Install in the reverse order of removal referring to the installation note for the specially marked parts 5 Tighien all nuts and bolts to the specified torque referring to the figure 1 Nuts 4 Retainer bushing and 6 Bushing and bracket 2 Bushing and retainer spacer 7 Stabilizer 3 Retainer bushing and bolt 5 Bolt 13 35 ...

Page 940: ...izer bushing and bracket 1 Install the bushing on the stabilizer 2 Align the bushing with the stabilizer installation po sition line 3 Install the stabilizer bracket and loosely tighten the bolts 4 Install the stabilizer link to the lower arm 5 Install the retainers rubber bushings and nuts 6 Lower the vehicle then tighten the bracket bolts with the vehicle unloaded Tightening torque 36 54 Nm 3 7 ...

Page 941: ...the figure referring to the removal note for the specially marked parts 3 Inspect all components and parts referring to inspection note 4 Install in the reverse order of removal referring to the installation note for the specially marked parts 1 Rear steering cover and 3 Nut 6 Bolt bolts 4 Control link assembly 7 Bushing and bracket 2 Nut bushing and retainer 5 Bushing and retainer 8 Rear stabiliz...

Page 942: ...l link Inspection Note Check the following and repair or replace any faulty parts 1 Worn or deteriorated rubber bushing 2 Bent deteriorated or damaged stabilizer 3 Damaged control link 4 Damaged control link dust boot 5 Worn or deteriorated bushing Note If it is necessary to replace the ball joint re place the control link assembly 13 38 ...

Page 943: ...am faces the front of the vehicle Caution Mount the brackets of the stabilizer first and loosely tighten them After mounting the con trol links tighten the brackets to the specified torque with the vehicle on the ground and un loaded Tightening torque 43 54 Nm 4 4 5 5 m kg 32 40 ft lb Tighten the link nut so that there is 13 mm 0 51 in of thread A exposed 86U13X089 ...

Page 944: ...stall in the reverse order of removal referring to the installation note for the specially marked parts 5 Tighten all nuts and bolts to the specified torque referring to the page 13 45 86U13X 090 1 Cotter pin and nut 2 Bolt 3 Bolt 4 Cover 5 Oil hose and pipe 6 Bolts 7 Rear steering assembly 8 Nut retainer and bushing 9 Nut retainer and bushing 10 Bolts 11 Stabilizer 12 Nuts and bolts 13 Cotter pin...

Page 945: ...ear steering Refer to Section 10 Lower arm and trailing link 1 Remove the lower arm from the crossmember 2 Remove the trailing link from the lower arm and body Stabilizer and control link Remove the stabilizer bar control link Crossmember Remove the crossmember from the body 13 41 ...

Page 946: ...o Section 11 Caution Do not allow brake fluid to get on painted sur faces If it does wipe it off immediately 86U13X 095 Inspection Note Check the following and repair or replace any faulty parts 1 Crossmember for bending or damage 2 Crossmember mounts for deterioration or wear 86U13X 096 Crossmember bushing Removal 1 Cut away the projecting rubber of the crossmem ber bushing 2 Remove the bushing f...

Page 947: ...5 11 9 m kg 69 86 ft lb 86U13X 100 2 Mount the rear steering to the crossmember and tighten the bolts Refer to Section 10 Tightening torque 31 46 N m 3 2 4 7 m kg 24 34 ft lb 86U13X 101 Lower arm side Body side Jr 86U13X 102 3 Install the lower arm to the crossmember 4 Install the trailing link to the lower arm and body Caution Lower the vehicle then tighten the bolts to the specified torque with ...

Page 948: ... 5 5 m kg 32 40 ft lb Caution Lower the vehicle and check the torque with the vehicle unloaded 6 Install the stabilizer control link Tighten the link nuts so that there is 13 mm 0 51 in of thread A exposed 7 Install the rear steering pipe and hose 8 Air bleed the brake system Refer to Section 11 13 44 ...

Page 949: ...Tightening torque REAR CROSSMEMBER 4WS 1 3 86U13X 107 13 45 ...

Page 950: ...l alignment Refer to Section 10 TOE IN Inspection 1 Raise the front of the vehicle until the wheels clear the ground 2 Turn the wheels by hand mark a line in the center of each tire tread using a scribing block 3 Place the front wheels in the straight ahead posi tion and lower the vehicle 4 Measure the distance between the lines at the front and rear of the wheels Both measurements must be taken a...

Page 951: ... 1 13 45 Left right difference Camber 30 max Caster 40 max 86U13X 112 Adjustment 1 Jack up the front of the vehicle and support it with safety stands 2 Remove the mounting block nuts 3 Push the mounting block downward and turn it to the desired position 4 Retighten the nuts to the specified torque Tightening torque 46 63 Nm 4 7 6 4 m kg 34 46 ft lb 86U13X 113 Mark Difference from standard position...

Page 952: ...on 10 TOE IN Inspection 1 Raise the rear of the vehicle until the wheels clear the ground 2 Turn the wheels by hand mark a line in the center of each tire tread using a scribing block V s 3 Lower the vehicle 4 Measure the distance between the marked lines at the front and rear of the wheels Toe in 0 3 mm 0 0 12 in 2WS 3 3 mm 0 12 0 12 in 4WS Adjustment 2WS 1 Loosen the adjusting rod lock nuts then...

Page 953: ...d turn the left tie rod by the same amount toward the rear b One turn of the tie rod both sides changes the toe in by about 7 8 mm 0 31 in c Adjust the toe in after adjusting the steer 86U 13X 119 ing angle Tighten the tie rod lock nuts to the specified torque Tightening torque 69 98 N m 7 10 m kg 51 72 ft lb CAMBER Preparation 1 Remove the center caps from the wheels 2 Uncrimp the lock nut and re...

Page 954: ... the rear wheels will return to the straight ahead direction and when the engine is later started once again the direction of the rear wheels will change Be sure therefore to check to be sure that the wheels are not touching or close to anyone s hands or feet or any other object when the engine is stopped or started 4 Turn the steering wheel fully left and right and measure the rear turning angle ...

Page 955: ... 41 41 41 14 42 CENTER PILLAR GARNISH SEDAN AND TOURING SEDAN REAR FINISHER MX 6 AND SEDAN REAR FINISHER TOURING SEDAN SAIL GARNISH SIDE PROTECTOR MOLDING 14 14 14 14 1 4 DOOR MIRROR 1 4 DISASSEMBLY 1 4 ASSEMBLY 14 TRUNK LID LOCK REMOTE RELEASE 1 4 REMOVAL AND INSTALLATION 1 4 FUEL FILLER LID REMOTE RELEASE 1 4 REMOVAL AND INSTALLATION 1 4 WINDSHIELD GLASS 14 STRUCTURAL VIEW 1 4 REMOVAL 1 4 INSTAL...

Page 956: ...1 4 HOOD HOOD STRUCTURAL VIEW 1 Hood 2 Hinge 3 Cowl seal rubber 4 Hood stay 5 Hood lock 6 Hood insulator 7 Front seal rubber 8 Windshield washer hose 14 2 ...

Page 957: ...int shown in the figure 86U14X 003 2 Remove hood insulator fasteners then remove the insulator 86U14X 004 3 Remove the front seal rubber fasteners then re move the seal rubber 4 Remove the hood hinge installation bolts then re move the hood 86U14X 006 86U14X 005 14 3 ...

Page 958: ...ood ADJUSTMENT Hood Adjust the hood laterally and vertically by loosening the hood to hinge mounting bolts and repositioning the hood Hood Lock Adjust the hood lock after the hood has been aligned The lock can be moved vertically and horizontally Align it with the striker on the hood after loosening the mounting bolts Tightening torque 7 8 11 N m 0 8 1 1 m kg 5 8 8 0 ft lb 86U14X 010 86U14X 008 86...

Page 959: ... TRUNK LID STRUCTURAL VIEW SEDAN AND MX 6 1 Trunk lid lock 4 Retainer 7 Trunk lid hinge bracket 2 Trunk lid opener protector 5 Trunk lid key cylinder 8 Trunk lid hinge 3 Opening rod 6 Balance spring 9 Trunklid 14 5 ...

Page 960: ...emove the bolts and the trunk lid opener Trunk Lid Key Cylinder Remove the retainer and the trunk lid key cylinder 86U14X 014 Trunk Lid 1 Remove the trunk lid installation bolts then remove the trunk lid 2 Remove the balance spring 3 Remove the rear seat Refer to page 14 99 86U14X 015 86U14X 013 Opening rod 14 6 ...

Page 961: ...RUNK LID 14 4 Remove the fasteners and remove the rear pack age tray 5 Remove the bolts and remove the trunk lid hinge bracket Tightening torque INSTALLATION Install in the reverse order of removal 1 4 7 ...

Page 962: ...to hinge mounting bolts and repositioning it 86U14X 019 2 Align the trunk lid evenly as shown in the figure Trunk Lid Striker 1 Loosen the striker mounting bolts 2 Tighten the bolts after adjusting Tightening torque 7 8 11 Nm 0 8 1 1 m kg 5 8 8 0 ft lb 86U14X 021 86U14X 020 14 8 ...

Page 963: ...R HATCH STRUCTURAL VIEW 86U14X 022 1 Rear hatch 5 Rear finisher 9 Stay damper 2 Upper trim 6 Rear hatch lock 10 Key cylinder 3 Side trim 7 Lock controller 11 Rear hatch screen 4 Lower trim 8 Rear hatch outer handle 14 9 ...

Page 964: ...tor then remove the car go room light 4 Remove the rear hatch screen Caution Remove the screen carefully so that it may be reused 86U14X 024 5 Disconnect the rear defogger and wiper motor con nectors then remove the wire harness through the rear hatch 86U14X 025 86U14X 026 6 Remove the wiper arm 7 Remove the wiper motor 14 10 ...

Page 965: ...REAR HATCH 14 8 Remove the opening rod 9 Remove the rear hatch opener 14 Remove the rear hatch hinge to door mounting bolts 15 Remove the rear hatch 14 11 ...

Page 966: ...ALLATION Install in the reverse order of removal ADJUSTMENT Rear Hatch Hinge Loosen the door hinge mounting nuts and make the adjustment Striker Loosen the striker mounting bolts and make the ad justment 86U14X 033 14 12 ...

Page 967: ...15 Door checker 2 Regulator handle 9 Key cylinder 16 Door 3 Inner handle cover 10 Glass 17 Outer handle 4 Door trim 11 Glass guide 18 Door mirror 5 Door screen 12 Runchannel 19 Beltline molding 6 Weatherstrip 13 Weatherstrip 20 Weatherstrip 7 Regulator power type 14 Glass guide 21 Sail inner garnish 14 13 ...

Page 968: ...andle cover 5 Door trim 6 Door screen 7 Weatherstrip 8 Regulator power type 9 Regulator manual type 10 Glass guide 11 Glass 12 Runchannel 13 Weatherstrip 14 Door 15 Door checker 16 Beltline molding 17 Weatherstrip 18 Door mirror 19 Outer handle 20 Key cylinder 21 Sail inner garnish 14 14 ...

Page 969: ...ndle Manual type 2 Remove the inner handle cover the screws ar rows and the door trim Note For vehicles with power windows disconnect the connectors 3 Remove the door screen Caution Remove the screen carefully so that it may be reused 4 Position the door glass so that the mounting bolts can be removed from the service holes 5 Remove the mounting bolts 14 15 ...

Page 970: ...Remove the door glass upward 8 Remove the mounting bolts and remove the regu lator through the service hole 9 Remove the window motor mounting bolt and re move the motor from the regulator power window Removal of Outer Handle and Key Cylinder 1 Disconnect the rod from the outer handle 14 16 ...

Page 971: ... outer handle Removal of Door Lock Assembly 1 Remove the mounting screws 2 Remove the door lock assembly 69G14X038 INSTALLATION Install in the reverse order of removal noting the fol lowing Power Window Before installing the motor connect the leads to a bat tery and run the regulator down to the position shown 86U14X 043 14 17 ...

Page 972: ...erally 2 Check the rear offset of the door to the body If there is a problem adjust by moving the door lock striker laterally 86U14X 044 Door Hinge 1 If looseness is found when the door is opened tighten the door hinge mounting bolts arrows 2 Align the door and body by loosening and adjust ing the door hinge mounting bolts Note If noise is heard from the checker when the door is opened apply greas...

Page 973: ...r window switch 4 Inner handle cover 5 Door trim 6 Belt line molding 7 Door screen 8 Door lock 9 Outer handle 10 Regulator power type 11 Regulator manual type 12 Glass guide 13 Glass 86U14X 046 14 Weatherstrip 15 Weatherstrip 16 Door checker 17 Door 18 Weatherstrip 19 Sail inner garnish 20 Sail outer garnish 14 19 ...

Page 974: ...move the clip Manual type 3 Remove the regulator handle Manual type 86U14X 047 6 Remove the door screen Caution Remove the screen carefully so that it may be reused 7 Position the door glass so that the mounting bolts can be removed from the service hole 8 Remove the mounting bolts 14 20 ...

Page 975: ...ALLATION Install in the reverse order of removal noting the fol lowing Tightening torque _Jorque Nm m kg ft lb Door lock assembly 4 22 6 18 0 43 0 63 3 10 4 54 Outer handle 8 8 13 0 9 1 3 6 5 9 4 Glass guide 7 8 11 0 8 1 1 5 8 8 0 Regulator Nut 8 8 13 0 9 1 3 6 5 9 4 Bolt 7 8 11 0 8 1 1 5 8 8 0 Door lock striker 18 26 1 8 2 7 13 20 Before installing the motor connect the leads to a bat tery and ru...

Page 976: ...the lock is cor rect when using the key and the door lock knob 86U14X 054 ADJUSTMENT Door Lock Striker 1 Check that the door can be closed easily and whether there is any looseness If there is a prob lem loosen the striker mounting screws and ad just by moving the striker vertically or laterally 2 Check the rear offset of the door to the body If there is a problem adjust by moving the door lock st...

Page 977: ...FRONT BUMPER 14 FRONT BUMPER STRUCTURAL VIEW 86U14X 056 1 Bumper stay 3 Reinforcement 5 Bumper 2 Set plate 4 Energy absorbing foam 6 Front airdam skirt 14 23 ...

Page 978: ...rews 3 Disconnect the side turn signal light connector 4 Remove the front side bumper stay mounting bolts and loosen the rear side bolts INSTALLATION Install the front side bumper stay mounting bolts and torque the rear side bolts Tightening torque 31 46 Nm 3 2 4 7 m kg 23 34 ft lb 86U14X 059 69G14X099 14 24 ...

Page 979: ...REAR BUMPER 14 REAR BUMPER STRUCTURAL VIEW 86U14X 060 1 Flap 4 Set plate 7 Bumper 2 Splash shield 5 Reinforcement 3 Bolts 6 Energy absorbing foam 14 25 ...

Page 980: ...the bumper mounting nuts 86U14X 062 3 Remove the nuts and fasteners shown in the fig ure and remove the reinforcement from the bumper INSTALLATION Install in the reverse order of removal Tightening torque Bumper stay installation nuts 31 46 Nm 3 2 4 7 m kg 23 34 ft lb 86U14X 063 14 26 ...

Page 981: ... in the reverse order of removal referring to installation note for the specially marked parts 86U14X 065 1 Screw 2 Fasteners 3 Radiator grille Removal Note Fasteners Push the tabs of the fasteners 5 with a small screw driver Installation Note Insert the fasteners into the grille then align with the installation holes in the body and press in the grille 86U14X 066 14 27 ...

Page 982: ... to removal note for the specially marked parts 3 Install in the reverse order of removal 1 Screw 2 Screw 3 Turn signal light assembly 4 Screw 5 Radiator grille 6 Bolt 7 Bolts 8 Headlight assembly 9 Screws 10 Light garnish 86U14X 067 11 Fog light bulb 55W 12 Headlight bulb 65 45W 9004 13 Parking light bulb 8W 67 14 Turn signal light bulb 27W 1156 15 Side turn signal light bulb 5W 194 14 28 ...

Page 983: ...4X 068 1 Screw 2 Screw 3 Turn signal light assembly 4 Screw 5 Radiator grille 6 Bolts 7 Fastener 8 Screw 9 Headlight assembly 10 Light garnish 11 Headlight bulb 65 45W 9004 12 Parking light bulb 8W 67 13 Turn signal light bulb 27W 1156 14 29 ...

Page 984: ...Disconnect the turn signal light connector 3 Remove the turn signal light assembly 86U14X 070 Turn signal light sedan and touring sedan 1 Remove the screws shown in the figure 2 Disconnect the turn signal and parking light con nector 3 Remove the turn signal and parking light assembly 86U14X 071 14 30 626 MX 6 Revised 10 87 ...

Page 985: ...ndard pressure 2 Position the vehicle on a flat level surface unload ed condition 86U14X 073 3 Adjust the headlights to meet local regulations To adjust turn the two adjusting screws 86U14X 074 Vertical Lateral Down1 Foglight MX 6 To adjust turn the adjusting screw 86U14X 075 14 31 ...

Page 986: ...Install in the reverse order of removal 86U14X 076 Touring sedan Model 1 End trim 2 Nuts 3 Lens and body 4 Cover 5 Bulb Turn signal light 27W 1156 Brake and tail light 27 8W 1157 Side marker light 5W 168 Sedan and MX 6 Model 1 End trim 2 Nuts 3 Lens and body 4 Cover 5 Bulb Turn signal light 27W 1156 Brake and tail light 27 8W 1157 Side marker light 5W 168 14 32 ...

Page 987: ...lens from the light housing by push ing the rear of the lens with a hammer handle or round bar 3 Heat the light housing and remove the hot melt and any fragments of the lens Note a The hot melt should be reused if possible b If the hot melt can be reused the follow ing step is unnecessary 4 Put Uni sealer 8531 77 739 adhesive in the light housing groove 14 33 ...

Page 988: ...14 REAR COMBINATION LIGHTS 5 Fit the new lens onto the light housing Press the lens firmly so that it will adhere 86U14X 080 6 Immerse the combination light in water to check for leaks 76U14X 038 ...

Page 989: ...ll in the reverse order of removal 86U14X 081 Sedan and MX 6 Touring Sedan Sedan and MX 6 License plate light 1 Screws 2 Lens 3 Bulb 5W x 2 Back up light 4 End trim 5 Bulb 27W 1156 6 Nuts 7 Rear finisher Touring Sedan Cargo room light 1 Lens 2 Switch and bulb assembly 5W License plate light 3 Side trim 4 Lower trim 5 End trim 6 Screws 7 Lens 8 Bulb 5W x 2 9 Rear finisher 626 MX 6 Revised 10 87 1 4...

Page 990: ...HT AND MAP LIGHT REMOVAL AND INSTALLATION 1 Disconnect the negative battery cable 2 Remove in the sequence shown in the figure 3 Install in the reverse order of removal 86U14X 082 Interior Light Map Light 1 Lens 1 Lens 2 Bulb 10W 2 Bulb 8W 14 36 ...

Page 991: ...H MOUNTED STOP LIGHT 14 HIGH MOUNTED STOP LIGHT REMOVAL AND INSTALLATION 1 Disconnect the negative battery cable 2 Remove in the sequence shown in the figure 3 Install in the reverse order of removal 14 37 ...

Page 992: ...molding 2 Windshield lower molding 3 Drip molding 4 Beltline molding 5 Quarter window molding 6 Rear window lower molding 7 Rear window side molding 8 Hood molding 9 Front lower molding 10 Trunk lid molding 14 38 11 Rear window upper molding 12 Center pillar garnish 13 Rear finisher 14 Sail garnish ...

Page 993: ...e reverse order of removal DRIP MOLDING Removal and Installation 1 Insert a screwdriver between the roof rail and drip molding and slightly loosen the end of the molding Note Be careful not to scratch the molding 2 Remove the molding by twisting upward with both hands 3 Install in the reverse order of removal BELTLINE MOLDING Removal and Installation 1 Remove the door mirror 2 Remove the screw fro...

Page 994: ...oval and Installation 1 Remove the rear window lower molding screws then the rear window lower molding 2 Install in the reverse order of removal REAR WINDOW UPPER MOLDING SEDAN TOURING SEDAN AND MX 6 Removal and Installation 1 Remove the rear window side molding Refer to page 14 55 2 Remove the rear window upper molding 3 Install in the reverse order of removal 86U14X 091 HOOD MOLDING SEDAN AND TO...

Page 995: ... 3 Remove the screws and the package side shelf 4 Remove the screws and the rear pillar trim 5 Remove the nuts and the quarter window molding 6 Install in the reverse order of removal QUARTER WINDOW MOLDING SEDAN Removal and Installation 1 Remove the rear header screw 2 Remove the bolt and the rear side seatback 3 Remove the quarter trim 4 Remove the nuts and the quarter window molding 5 Install i...

Page 996: ...der trim 3 Remove the center pillar trim 4 Remove the nuts with a deep socket wrench then remove the garnish 5 Install in the reverse order of removal REAR FINISHER MX 6 AND SEDAN Removal and Installation 1 Remove the nuts and the rear finisher 2 Install in the reverse order of removal REAR FINISHER TOURING SEDAN Removal and Installation 1 Remove the hatchback door side trims 2 Remove the hatchbac...

Page 997: ...L GARNISH SEDAN AND TOURING SEDAN Removal and Installation 1 Remove the sail inner garnish 2 Remove the screws and remove the sail garnish 3 Install in the reverse order of removal 86U14X 102 1 Side protector A molding 2 Side protector B molding 3 Side protector C molding 14 43 ...

Page 998: ...as possible with out damaging the painted surface 4 If the adhesive is difficult to remove soften it with a hot air blower Installation 1 Remove any grease or dirt from the molding adhe sion surface and the body surface 2 Mark the installation position on the body with masking tape 3 Attach double sided adhesive tape to the molding adhesion surface 4 Align the molding on the body and attach it se ...

Page 999: ...for approx 3 minutes 86U14X 103 2 Insert a scraper between the mirror glass and the frame then pry the mirror loose 3 Remove any remaining adhesive 86U14X 104 ASSEMBLY 1 Warm the frame with a lamp 86U14X 106 2 Install the glass in the frame then gently press it in to secure it 86U14X 107 626 MX 6 Revised 10 87 14 45 ...

Page 1000: ...ASE TRUNK LID LOCK REMOTE RELEASE REMOVAL AND INSTALLATION 1 Remove in the sequence shown in the figure 2 Install in the reverse order of removal 1 Screws 4 Cover 7 Release wire 2 Scuff plate 5 Bolts 3 Screws 6 Release lever 14 46 ...

Page 1001: ... 14 FUEL FILLER LID REMOTE RELEASE REMOVAL AND INSTALLATION 1 Remove in the sequence shown in the figure 2 Install in the reverse order of removal 1 Screws 2 Scuff plate 3 Screws 4 Cover 5 Bolts 6 Release lever 7 Release wire 14 47 ...

Page 1002: ...AL VIEW 86U14X 110 1 Rear view mirror 2 Sunvisor 3 Front header trim 4 Front pillar trim 5 Wiper arm 6 Lower molding 7 Front windshield molding 8 Windshield glass 9 Spacer Note Use window tool set 49 0305 870A to remove and install the glass 14 48 ...

Page 1003: ... the sealant 5 Pass the piano wire through the hole 6 Wind each end of the wire around a bar 7 Pull the wire to and fro and saw through the seal ant around the edge of the glass Then remove the glass Caution a Use a long sawing action to spread the work over the whole length of wire to prevent it from breaking b Be careful that the wire does not rub on the body or instrument panel Note If the glas...

Page 1004: ... Carefully clean a 5 cm 1 97 in wide area around the circumference of the glass and the bond on the body 3 Bond a new dam along the circumference of the glass 5 mm 0 20 in from the edge Caution Securely bond the dam and allow it to dry 86U14X 116 4 Apply primer with a brush to the bonding area of the glass and the body and allow it to dry for ap prox 30 minutes Caution Keep the area free of dirt D...

Page 1005: ...tula Lift the glass into place Push it in lightly toward the vehicle to compress the sealant Caution Open the windows to prevent the glass from being pushed out by air pressure if a door is closed Hardening time of repair seal Temperature Surface hardening time Time required until car can be put in service 5 C 41 F Approx 1 5 hrs 12 hrs 20 C 68 F Approx 1 hr 4 hrs 35 C 95 F Approx 10 min 2 hrs 8 U...

Page 1006: ...tion a Apply premer with a brush to the bonding area of the molding and allow if to dry for approx 30 minutes b Use a new window molding 11 Insert the molding ends into the flanges of lower moling Then push it in the along sides 12 After checking for water leakage mount the pillar garnish 13 Attach the front header trim pillar trim sunvisors and rearview mirror 14 52 ...

Page 1007: ...ear package tray 4 Rear window side molding 7 Rear window glass 2 Rear header trim 5 Rear window lower molding 8 Spacer 3 Rear pillar trim 6 Rear window upper 9 Seat belt bolts molding Note Use window tool set 49 0305 870A to remove and install the glass 14 53 ...

Page 1008: ... 6 86U14X 126 1 Seat belt bolts 5 Rear window side molding 8 Rear window lower molding 2 Rear side trim 6 Rear package tray 9 Rear window glass 3 Rear header trim 7 Rear window upper 10 Spacer 4 Rear pillar trim molding 14 54 ...

Page 1009: ...nect the defogger connector 3 Remove the seat belts 4 Remove the screws and the quarter trim MX 6 5 Remove the screws and the center pillar trim 6 Remove the screws and the rear header 7 Remove the nuts and the rear window side molding 8 Remove the fasteners and the rear package tray 14 55 ...

Page 1010: ... around the glass 13 Remove the glass from the body 86U14X 132 Caution a Cut along the border between the glass and the sealant b lf too much heat develops the piano wire may break so cool it occasionally or don t work on one place too long c If the glass is not to be reused a tool like that shown in the figure is faster than piano wire Insert the blade in the sealant pull on the bars and cut the ...

Page 1011: ... to 30 minutes Caution Be sure not to allow dirt water oil or similar materials to come into contact with the coat ed surfaces and do not touch them by hand 5 Install the spacers at the positions shown in the figure Caution Spacer with flaws must be replaced 6 When the primer has dried apply an 11 mm 0 43 in thick bead of repair seal B001 77 739 11 mm 0 43 in from the periphery of the window glass...

Page 1012: ...em perature Surface hardening time Time required until car can be put in service 5 C 41 F Approx 1 5 hrs 12 hrs 20 C 68 F Approx 1 hr 4 hrs 35 C 95 F Approx 10 min 2 hrs 8 Remove any excess or add repair seal where necessary 63U14X 069 9 Check for water leaks If a leak is found wipe the water off well and add repair seal B001 77 739 63U14X 070 10 After checking for water leakage install the mold i...

Page 1013: ...ASS STRUCTURAL VIEW 86U14X 137 1 Rear wiper arm 4 Lower trim 7 Rear hatch glass 2 Upper trim 5 Window upper molding 8 Clips 3 Side trim 6 Window upper molding joint Note Use window tool set 49 0305 870A to remove and install the glass ...

Page 1014: ... one outside the vehicle and then saw the sealant from around the glass 7 Remove the glass from the back door body Caution a Cut along the border between the glass and the sealant b If too much heat develops the piano wire may break so cool it occasionally or don t work on one place too long c If the glass is not to be reused a tool like that shown in the figure is faster than piano wire Insert th...

Page 1015: ...m 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 When the primer has dried apply an 11 mm 0 43 in thick bead of repair seal B001 77 739 11 mm 0 43 in from the periphery of the window glass using a sealant gun Caution Cut the nozzle of the repair seal cartridge as illustrated in the...

Page 1016: ...urface hardening time Time required until car can be put in service 5 C 41 F Approx 1 5 hrs 12 hrs 20 C 68 F Approx 1 hr 4 hrs 35 C 95 F Approx 10 min 2 hrs 9 Remove any excess or add repair seal where necessary 10 Check for water leaks If a leak is found wipe the water off well and add repair seal B001 77 739 11 After checking for water leakage install the mold 12 Install the wiper arm door trim ...

Page 1017: ...d Sedan 86U14X 148 1 Bolt 4 Package side shelf Touring 7 Nuts 2 Rear side seatback sedan 8 Quarter window molding 3 Screw Touring sedan 5 Rear header trim screw 9 Quarter window glass 6 Rear pillar trim 10 Dam Note Use window tool set 49 0305 870A to remove and install the glass ...

Page 1018: ... QUARTER WINDOW GLASS MX 6 1 Seat belt bolts 2 Screw 3 Screw 4 Side trim 5 Screw 6 Rear pillar trim 7 Nut 8 Screw 86U14X 149 9 Drip molding 10 Quarter window molding 11 Quarter window glass 12 Dam 1 4 64 ...

Page 1019: ... bar 9 Pull the wire to and fro and saw through the seal ant around the edge of the glass Then remove the glass Caution a Use a long sawing action to spread the work over the whole length of wire to prevent it from breaking b Be careful that the wire does not rub on the vehicle paint INSTALLATION 1 Use the knife to smoothly cut the sealant on the body side leaving a layer about 1 or 2 mm 0 04 to 0...

Page 1020: ... the surface If primer gets on the hands remove it immediately 86U14X 154 5 After the primer dries apply a bead of repair seal to a height of 10 mm 0 4 in min around the edge of the glass 6 Attach the glass to the body 86U14X 156 7 Remove excess sealant Add sealant where necessary 86U14X 157 R e p a ir seal lO v e r 10m m 1 0 4in Q u a rte r w in d o w g la ss 86U14X 155 14 66 ...

Page 1021: ...QUARTER WINDOW GLASS 14 8 Check for water leaks If a leak is found wipe the water off well and add repair seal B001 77 739 9 Install in the reverse order of removal 86U14X 158 14 67 ...

Page 1022: ...EW MX 6 Sliding sunroof 86U14X 159 1 Rearview mirror and overhead console 2 Sunvisor 3 Center adaptor 4 Assist handle 5 Interior light 6 Front header trim 7 Front pillar trim 8 Rear pillar trim 9 Rear header trim 10 Insulator 11 Headliner ...

Page 1023: ... Touring Sedan Sliding sunroof 1 Rearview mirror and overhead console 2 Sunvisor 3 Center adaptor 4 Assist handle 5 Interior light 6 Front header trim 7 Front pillar trim 8 Rear pillar trim 9 Rear header trim 10 Insulator 11 Headliner ...

Page 1024: ...nsole mounting screws 4 Disconnect the connectors and remove the over head console 5 Remove the sunvisors 6 Remove the center adaptors 7 Remove the interior light lens with a protected small screwdriver 8 Remove the interior light mounting screws and dis connect the connector 9 Remove the interior light 1 4 70 ...

Page 1025: ...ve the caps and screws at the ends of the front header trim 11 Remove the caps and screws at the ends of the rear header trim 86U14X 165 12 Remove the rear side trim 13 Remove the seat belt mounting bolts 86U14X 167 14 71 ...

Page 1026: ...llar trim with a protected stan dard screwdriver 86U14X 168 15 Remove the front pillar trim using a protected stan dard screwdriver 86U14X 169 16 Remove the assist handles 86U14X 170 17 Remove the sliding sunroof seaming welt 86U14X 171 ...

Page 1027: ...Remove the fasteners and remove the headliner INSTALLATION Install in the reverse order of removal noting the fol lowing Note Align the trim and clip positions then install the clips by striking them lightly 86U14X 173 ...

Page 1028: ...console 4 Glove compartment 5 Side cover 6 Side cover 7 Box 8 Ashtray 9 Center panel 10 Heater control assembly 11 Steering wheel ornament 12 Steering wheel 13 Column cover 14 Switch panel 15 Cap 16 Meter hood 17 Duct 18 Duct and under cover 19 Under cover 20 Duct 21 Meter assembly 22 Instrument panel ...

Page 1029: ...INSTRUMENT PANEL 14 INSTALLATION VIEW 67U14X 003 ...

Page 1030: ...rews and remove the shift lever knob ATX 86U14X 175 2 Remove the shift lever knob MTX 86U14X 176 3 Remove the rear console mounting screws 4 Pull the console rearward and remove it 5 Remove the front console mounting screws 86U14X 178 86U14X 179 ...

Page 1031: ...INSTRUMENT PANEL 14 6 Remove the steering wheel ornament 7 Remove the steering wheel mounting nut 8 Remove the screws and the streering wheel cap 9 Remove the steering wheel with a steering wheel puller ...

Page 1032: ...the nut and remove the hood release knob 12 Remove the screws and pull out the meter hood 13 Disconnect the connectors and remove the meter hood 86U14X 185 14 Remove the screws and pull the meter assembly outward 15 Disconnect the speedom eter cable at the speedometer 16 Disconnect the gauge connectors 17 Remove the meter assembly 86U14X 184 86U14X 186 ...

Page 1033: ...emove the switch panel 86U14X 187 22 Remove the center panel 23 Remove the screws and slide out the heater con trol assembly 24 Disconnect the control wires at the DEF M A X COLD and REC positions lever type control Note Disconnect the connectors at the rear of the control Logicon type 86U14X 1E 1 4 79 ...

Page 1034: ...panel side mounting bolts 28 Remove the instrument panel center bracket mounting bolts 29 Remove the steering shaft mounting bolts 30 Disconnect the dash harness connectors 31 Remove the instrument panel 86U14X 191 86U14X 192 86U14X 193 86U14X 194 ...

Page 1035: ...o check that the wire is secured Also check that it moves the full stroke between HOT and COLD 3 Mode control wire a Set MODE control lever to DEF position b Connect the control wire and clamp it with the shutter lever on the heater unit at its closest point Caution Move the mode lever to check that the wire is secured Also check that it moves the full stroke between DEF and VENT REC FRESH air sel...

Page 1036: ...ade 2 Slide panel 3 Weatherstrip 4 Deflector 5 Set plate 6 Drip rail 7 Lower panel 8 Lower panel cover 9 Decoration cover 10 Motor assembly 11 Guide brackets rear 12 Guide bracket front 13 Guide rails 14 Guide 15 Packing 16 Tube assembly 17 Frame assembly 18 Sunroof relay ...

Page 1037: ... way to the rear Fully close the sliding panel Remove the left and right decoration covers Remove the installation nuts for the sliding panel and lower panel Remove the sliding panel by pushing it upward from inside the vehicle 6 Fully close the sun shade ...

Page 1038: ...ly closed 76U14X 048 10 Open the sun shade half way and remove the set plate cap Pull out the sun shade from the notch of the set plate 76U14X 049 11 Use a flat tip screwdriver to pry up the connector at the rear of the deflector link being careful not to scratch it and remove the deflector link 12 Remove the screws and remove the deflector Note Because force is applied to the deflector by the spr...

Page 1039: ...hing to the rear to close fully 14 After removing the screw and the drip rail joint link push the drip rail backward and inward 15 After removing the installation screw of the guide bracket assembly rear remove the right side of the guide front 16 Remove the lower panel 76U14X 052 17 Remove the rear view mirror overhead console and seaming welt 76U14X 054 ...

Page 1040: ...il forward then pull out from the notch of the guide rail INSTALLATION 1 Insert the drip rail Note Paying attention to the direction of the rail push in from the open part to the position where it is not visible 2 Insert the drive cable into the tube Note Apply a liberal coat of grease to the drive ca ble and the sliding part of the guide bracket assembly rear then push the cable all the way forwa...

Page 1041: ...jection of the tilting cam and the slit in the set plate 5 Check that the limit switches LS1 and LS2 of the motor are as shown in the figure at the OFF po sition Note a Be careful of the cam position b Use the handle to position it correctly 6 Install the motor assembly Note There are 2 types of screws long and short Be sure to use the correct ones 7 Connect the wiring of the motor assembly and th...

Page 1042: ...nel and lower panel might interfere with each other when the lower panel is opened check as shown in the figure that the guide roller is completely fitted into the guide rail b Turn the motor while pushing the cable 12 Secure the deflector by tightening the screw and then install the deflector link 13 Turn the motor using the handle and visually check the sliding tilt down and tilt up operations 7...

Page 1043: ...lide panel Cross section A A Adjust so that the height difference between the outer panel and roof panel is 1 5 mm 0 06 in max 76U14X 069 Cross section B B adjustment 1 Loosen installation screws 1 and 2 If the adjustment is only about 2 mm 0 08 in don t loosen screw 1 2 Turn the screws to adjust Turning to the right raises and to the left lowers 3 Tighten installation screws 1 and 2 76U14X 068 B ...

Page 1044: ...to 15 25 kg 33 1 55 7 lb using the torque adjustment nut on the motor To measure use the deep hole in the center of the lower panel After adjustment be sure to lock the nut with the pawl washer Install the ornamental cover Install the front peripheral parts After installation is completed check the operation 1 Is the battery voltage correct 2 Is there any foreign material on the sliding parts of t...

Page 1045: ...SLIDING SUNROOF 14 Caution If the stopper is moved too far forward there might be a malfunction or leaking Do not leave a gap of more than 5 mm 0 2 in be tween the slide panel and roof panel 76U14X 203 ...

Page 1046: ...IELD WIPER WINDSHIELD WIPER STRUCTURAL VIEW 63U14X 132 Note The wiper arms not interchangeable 1 Wiper blade 2 Wiper arm 3 Lower molding 4 Cover 5 Wiper motor 6 Link assembly 7 Washer tank 8 Hose 9 Washer nozzle ...

Page 1047: ...e motor Caution Do not remove the motor arm unless neces sary The motor arm position on the motor shaft decides the automatic stop position lowest position of the wiper arm 6 Disconnect the connector 7 Remove the wiper motor 86U14X 170 8 Remove the wiper link assembly mounting bolts 9 Lift the wiper link assembly out from the left side driver s side service hole 86U14X 171 86U14X 169 ...

Page 1048: ... arms are identified by marks on the arms DL driver s side PL passenger s side ADJUSTMENT Arm Height Set the arm height as shown in the figure 86U14X 173 Adjustment of washer spray Inserting a needle or similar object into the nozzle hole and bend to change the spray direction 86U14X 174 ...

Page 1049: ...REAR WINDOW WIPER 14 REAR WINDOW WIPER STRUCTURAL VIEW TOURING SEDAN 1 Wiper arm and blade 3 Wiper motor 2 Seal cap 4 Washer tank 5 Hose 6 Washer nozzle 86U14X 175 ...

Page 1050: ...Open the rear hatch 4 Remove the rear hatch trim upper side and lower 5 Remove the rear hatch screen Note Remove the screen carefully so that it may be reused 6 Disconnect the rear wiper motor connector 7 Remove the rear wiper motor INSTALLATION Install in the reverse order of removal 86U14X 179 ...

Page 1051: ...REAR WINDOW WIPER 14 86U14X 181 ...

Page 1052: ...X 182 1 Seat side cover 2 Lifter lever 3 Reclining knuckle 4 Lumbar support lever 5 Seat adjuster 6 Front seat cushion 7 Headrest 8 Headrest pole 9 Front seat back 10 Rear seat cushion 11 Rear seat back 12 Seat side 13 Key cylinder 14 98 ...

Page 1053: ... 2 m kg 28 38 ft lb 3 Apply grease to the moving parts 4 Check the seat adjuster lever for wear REAR SEAT Removal 1 Push the locks as shown in the figure to release the cushion then lift the seat cushion out 2 Remove the end bolts and lift the seat back off the hooks 69G14X 236 3 Remove the fastener 4 Remove the seat back Installation Install in the reverse order of removal Note Tightening torque ...

Page 1054: ... Retractors 2 Front seat belts 4 Retractors INSPECTION 1 Check that the belt can be pulled out smoothly and that it retractors lock when belt pulled quickly 2 Inspect the webbing for scars tears and wear and for deformation of the fittings Caution Do not disassemble the buckle or ELR as sembly ...

Page 1055: ... STRUCTURAL VIEW 6 Limit switch Rear 7 Seat belt warning switch 8 Limit switch Front 9 Deflection sensor 1 Automatic shoulder belt control unit 2 Automatic shoulder belt retractor 3 Inner buckle 4 Outer lap belt 5 Automatic shoulder belt motor and rail ...

Page 1056: ...m 0 8 1 2 m kg 5 8 8 7 ft lb R5 38 78 N m 3 9 8 0 m kg 28 58 ft lb Re 7 8 12 N m 0 8 1 2 m kg 5 8 8 7 ft lb R7 7 8 12 N m 0 8 1 2 m kg 5 8 8 7 ft lb Re 7 8 12 N m 0 8 1 2 m kg 5 8 8 7 ft lb Rg 7 8 12 N m 0 8 1 2 m kg 5 8 8 7 ft lb Lap belt S i 38 78 N m 3 9 8 0 m kg 28 58 ft lb S2 38 78 N m 3 9 8 0 m kg 28 58 ft lb Inner buckle Ti 38 78 N m 3 9 8 0 m kg 28 58 ft lb T2 38 78 N m 3 9 8 0 m kg 28 58 ...

Page 1057: ...illar trim and side trim 86U14X 190 86U14X 191 REMOVAL 1 Remove the front pillar trim 86U14X 192 3 Remove the mounting bolts 4 Remove the passive shoulder belt motor and rail INSTALLATION Install in the reverse order of removal 14 103 ...

Page 1058: ...14 UNDERBODY PROJECTED DIMENSIONS UNDERBODY PROJECTED DIMENSIONS f 14 104 86U14X 193 ...

Page 1059: ... Front fender panel mounting nut M6 C Crossmember mounting bolt M12 D Front mounting block E Steering bracket mounting nut M12 F Front fender panel mounting nut M6 G Frame mounting bolt M12 H Front frame lower standard hole 8 t ...

Page 1060: ...ting nut M10 Crossmember mounting bolt M10 4WS K Rear mounting block L Crossmember mounting nut M10 Crossmember mounting bolt M12 4WS M Rear frame lower standard hole 10 j N Rear bumper mounting hole 14 outside 10wer 86U14X 193 UNDERBODY PROJECTED DIMENSIONS 1 4 ...

Page 1061: ...o z w A Frame mounting nut M10 B Crossmember mounting bolt M12 C Frame mounting bolt M12 D Front frame lower standard hole 8 f Protector mounting nut M8 4WS E Front frame c lower standard hole 12 F Crossmember mounting nut M10 Crossmember mounting bolt M12 4WS G Rear frame lower standard hole 100 m m in ...

Page 1062: ...RAM 1 5 52 TROUBLESHOOTING 15 52 INSPECTION 15 53 REAR WINDOW DEFROSTER 15 54 STRUCTURAL VIEW 15 54 CIRCUIT DIAGRAM 15 54 TROUBLESHOOTING 15 55 INSPECTION 15 56 POWER WINDOW 15 57 STRUCTURAL VIEW 15 57 CIRCUIT DIAGRAM 15 58 TROUBLESHOOTING 15 59 INSPECTION 15 62 REMOTE CONTROL MIRROR 1 5 65 STRUCTURAL VIEW 15 65 CIRCUIT DIAGRAM 1 5 65 TROUBLESHOOTING 15 66 INSPECTION 15 66 REAR WINDOW WIPER 15 67 ...

Page 1063: ...rt circuits Caution When checking the control unit never use a bulb over 3 4W Jumper Wire The jumper wire is used for testing by short circuiting switch terminals and to verify the condition of ground connections Caution Do not connect the jumper wire between a power source line and body ground because doing so may cause burning or other damage to harnesses or electronic components etc Voltmeter T...

Page 1064: ...meter 63U15X 005 YELLOW BROWN 47U15X 008 PRECAUTION Wiring Color Code Two color wires are indicated by a 2 letter symbol The first letter indicates the base color of the wire and the second indicates the color of the stripe CODE COLOR B BLACK Br BROWN G GREEN L BLUE Lb LIGHT BLUE Lg LIGHT GREEN 0 ORANGE R RED Y YELLOW W WHITE Bulkhead Type Connector This connector can be separated by pressing the ...

Page 1065: ...rom the wire har ness 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 securely Female Type No 1 Insert a push tool or thin piece of metal from the ter minal side of the connector and then with the lock ing tabs of the terminal pressed down pull the terminal out from the rear side F...

Page 1066: ...terminal is disconnect ed before replacing a main fuse 69G15X 006 3 When replacing a fuse use the supplied fuse puller in the fuse box cover 4BG15X 003 69G15X 007 Thin Insulation Wire To reduce the weight of the wiring harness a thin coating of high resistance insulation material is used Shielded braid wire This wire is used to prevent a malfunction in impor tant circuits that are susceptible to o...

Page 1067: ...erating conditions Relay NO type relay NC type relay Switch NO switch NC switch Not in operation No power supply Flow Stop Flow In operation Power supply vQOPQ Flow C X Stop Fiow c 3 X Stop Other Electrical Symbols Holder Box FUSE FUSIBLE LINK n RESISTOR VARIABLE RESISTOR 1 T CONDENSER LIGHT CIGARETTE LIGHTER HEATER BATTERY MOTOR THERMISTER TRANSISTOR BODY GROUND COIL SOLENOID DIODE SPEAKER 69G15X...

Page 1068: ...LOCATION OF UNIT RELAY AND SWITCH 15 LOCATION OF UNIT RELAY AND SWITCH STRUCTURAL VIEW 15 7 ...

Page 1069: ...Sedan Rear def switch switch Touring sedan Light and turn switch Front wiper and washer switch and cruise control switch AAS switch Front fog light switch Headight cleaner switch Remote control mirror switch Heater control switch Driving mode selector switch Cruise control main switch Hazard switch Rear def switch 1 5 8 86U15X 003 ...

Page 1070: ...UCTURAL VIEW REPLACEMENT Disconnect the negative battery terminal 30 and 60A fuses pull out and push in a new fuse 80A fuse 1 Remove the main fuse box 2 Open the cover 3 Remove the terminal 4 Pull out and push in a new fuse 76U15X 015 1 5 9 ...

Page 1071: ...15 JOINT BOX AND FUSE JO IN T BOX AND FUSE STRUCTURAL VIEW 86U15X 006 ...

Page 1072: ...IGNITION SWITCH 15 IGNITION SWITCH INSPECTION 1 Use an ohmmeter to check continuity of the termi nals of the switch 2 If continuity is not as specified replace the switch O O Indicates continuity ...

Page 1073: ...switch 4 Steering angle sensor 5 Light switch connectors 6 Turn signal switch connector 7 Windshield wiper and washer switch con nector 8 Steering angle sensor connector INSPECTION 1 Check for continuity or the resistance between the terminals in each position with an ohmmeter 2 If the continuity or resistance is not as specified replace the switch 86U15X 008 15 12 ...

Page 1074: ...O o n O O Headlight w r r High beam Passing O o Tail parking O O indicates continuity O O indicates continuity Variable speed intermittent wiper timer control resistance Terminal Position ______ C O I Slow 0 1 kQ Fast 40 60 kQ 86U15X 012 626 MX 6 Revised 10 87 15 13 ...

Page 1075: ... from about 25 kfl to about 50 kfl AL to AR Straight ahead position About 50 kfl 86U15X 014 Note When the steering wheel is turned more than the specified angle in the above test the re sistance value will become as shown in the table below Terminal Steering wheel position Resistance value AO to AR When turned 180 or more to the right from the straight ahead po sition Resistance slowly and gradual...

Page 1076: ...ver switch 2 Switch type Hazard SW A 4 Switch type SSI N Hazard SW Rear def SW 86U15X 016 Type Switch Switch Type Applied model MX 6 Sedan Touring Sedan Two switch type Rear window defroster switch Rocker Hazard switch Rocker Four switch type Rear wiper switch Push Rear washer switch Push Hazard switch Push Rear window defroster switch Push ...

Page 1077: ...switch to ON and check the lights for lighting 3 If the lights do not light replace the lights 4 Check that the switch goes off after 15 min from switch ON 5 Check the voltage between each terminal and a body ground Position Terminal voltage V b d f 9 h OFF 0 12 12 0 12 ON 0 0 12 0 12 ON head light switch ON 0 0 12 2 12 12 OFF head light switch ON 0 12 12 2 12 12 6 If the voltage of d terminal is ...

Page 1078: ...age between each terminal and a body ground Position Terminal voltage V f g h OFF 12 12 0 ON 12 0 0 6 If the voltage of terminal g is 12V with switch off but not OV with switch on replace the defroster switch Ifthe voltage of terminal g is not 12V with switch off trouble is in defroster relay or harness If the voltage of terminal f and h is not cor rect the trouble is in the other parts or harness...

Page 1079: ... O _______ B C CANCEL DIMER POWER E C O N O Water temp gauge Warning and indicator lights Fuel gauge DIGITAL ELECTRONIC DISPLAY METER Fuel gauge Tachometer Speedometer Water temp gauge Tripmeter Twin tripmeter Fuel gauge scale Warning and indicator lights change change ANALOG DISPLAY METER Tachometer 86U15X 024 ...

Page 1080: ...METER 1 5 DISASSEMBLY AND ASSEMBLY 86U15X 025 15 19 ...

Page 1081: ...erminals of 14 pin connector Terminal Voltage 2B Y 12V NG Replace the fuel gauge OK Repair harness Meter to fuel tank unit 86U15X 026 OK NG Remove the meter assembly Connect 1R terminal of 22 pin connector to a battery terminal 1N and 1P terminal of 22 pin connector to a battery terminal and check the voltage at 2D BL terminals of 14 pin connector Terminal Voltage 2D BL 12V NG Replace the water te...

Page 1082: ...METER 1 5 86U15X 028 15 21 ...

Page 1083: ... odometer Replace if necessary 2 Check the speedometer for fluctuation and or ab normal noise Caution a If significant fluctuation occurs or the speedometer does not move at all remove the speedometer cable If normal replace the speedometer assembly b Tire wear and improper inflation will in crease speedometer error Tachometer 1 Connect a test tachometer to the engine and start the engine 2 Check ...

Page 1084: ...d 3 Set the SST to the resistance values shown in the figure 4 Turn the ignition switch ON and check that the needle indicator displays the correct values If the needle displays the correct values the trou ble is in the gauge unit if not the trouble is in the meter or the wiring harness Caution a Continue the above checks for at least two minutes each to correctly judge the con dition b The allowa...

Page 1085: ...nd Standard display Expanded display E f it FUEL F E f f l FUEL F r a v E 2 ga 4 V O ODDODOODOO 86U15X 040 3 Set the SST to the resistance values shown the fol lowing table 4 Turn the ignition switch ON and check that the seg ment displays the correct values in each range If the segment displays the correct values check the gauge unit IF not replace the digital meter as sembly Caution Continue the...

Page 1086: ...e digital meter assembly or repair wiring harness Caution Continue the above checks for at least two minutes each to correctly judge the condition Segment Resistance Q Segment Resistance Q 1 10 less than 17 1 5 33 89 1 9 17 20 1 4 89 120 1 8 20 26 1 3 120 145 1 7 26 28 1 2 145 177 1 6 28 33 1 more than 177 INSPECTION OF METER SENDER Fuel tank unit except 4WS model 1 Disconnect the connector from t...

Page 1087: ... replace the unit Fuel tank unit only 4WS model 1 Remove the fuel tank unit 2 Remove the connector from the fuel tank unit 3 Connect an ohmmeter between d terminal of the connector and fuel tank unit cover 4 Move the unit arm slowly from point F to point E and read the resistance values 5 If not as specified replace the unit 86U15X 045 Water Thermo Sensor 1 Remove the sensor 2 Place the sensor in ...

Page 1088: ...WARNING LIGHT AND SENDER 15 WARNING LIGHT AND SENDER CIRCUIT DIAGRAM 86U15X 047 15 27 ...

Page 1089: ...ARNING LIGHT AND SENDER TROUBLESHOOTING Note Check the Meter 10A fuse in the fuse box before troubleshooting If normal refer to the following troubleshooting chart Brake System Warning Light 86U15X049 15 28 ...

Page 1090: ...WARNING LIGHT AND SENDER 15 Alternator Warning Light 86U15X 050 Stop And Tail Light Malfunction Warning Light 86U15X 052 15 29 ...

Page 1091: ...15 WARNING LIGHT AND SENDER 86U15X 053 Door Ajar Warning Light 86U15X 054 86U15X 055 ...

Page 1092: ...WARNING LIGHT AND SENDER 15 Washer Fluid Low Level Warning Light 86U15X 056 86U15X 057 Engine Oil Pressure Warning Light 86U15X 058 15 31 ___________________________jB S IS S ...

Page 1093: ...1 5 WARNING LIGHT AND SENDER 86U15X 059 Low Fuel Level Warning Light 86U15X 060 86U15X 061 15 32 ...

Page 1094: ...inate when ignition switch on other warning light are all right Check the voltage at BY terminal of the inhibitor switch connector with ignition switch on Terminal Voltage BY 12V NG Repair the harness Fuse box to inhibitor switch OK Check the inhibitor switch Refer to page 7B 42 NG Replace the inhibitor switch OK Check the bulbs of the shift indicator lights NG Replace the bulb OK Turn the ignitio...

Page 1095: ...is not as specified adjust the switch or replace the switch Stop and Tail Light Checker 1 Check for continuity between the terminals of the stop and tail light checker Terminal Continuity Terminal Continuity Terminal Continuity a b O c d X f g X a c O c f O f h O a d X c g x g a o a f o c h o g b 0 a g x d a o g c 0 a h o d b 0 g d X b a o d c o g f o b c o d f 0 g h o b d x d g X h a o b f o d h ...

Page 1096: ...y between C LY terminal and D B terminal of the washer level sensor con nector Terminals Float level Continuity C LY D B Bottom Yes Above bottom No 2 If continuity is not as specified replace the sensor 86U15X 069 Oil Pressure Switch 1 Disconnect the connector from the oil pressure switch 2 Check for continuity between the switch and a body ground with each condition Engine Continuity Running No S...

Page 1097: ...ystem Key reminder alarm Light off reminder alarm Seat belt alarm Automatic shoulder belt alarm only automatic should belt model Turbo charge alarm only turbocharge model Timer System Seat belt timer Key illumination light timer Interior light timer Theft Deterrent Systerrv refer to page 15 139 86U15X 072 15 37 ...

Page 1098: ...1 5 CENTRAL PROCESSING UNIT CPU CIRCUIT DIAGRAM L I 0 15 38 ...

Page 1099: ...Ground Any time OV e Seat belt warning light Ignition switch on Approx 12V f Engine control unit Engine running Approx 12V g Key cylinder illumination light Any time Approx 12V h Automatic shoulder belt control unit Ignition switch ON i Key reminder switch Insert the key into the cylinder Pull out the key from the cylinder Approx 12V OV j Ignition switch ON Ignition switch ON Ignition switch OFF o...

Page 1100: ...1 5 TURN AND HAZARD LIGHT TURN AND HAZARD LIGHT STRUCTURAL VIEW Compination switch Flasher unit Turn and hazard light 8 6 U 1 5 X 0 7 7 15 40 ...

Page 1101: ...TURN AND HAZARD LIGHT 1 5 CIRCUIT DIAGRAM 15 41 ...

Page 1102: ...lace the switch NG Repair harness Fuse box to combination switch Repair harness Terminal Wiring harness A B Flasher unit to ground E BR Flasher unit to combination switch F GY Rasher unit to combination switch H Br Fuse box to Rasher unit NG Check the lights and wiring harness Each bulb to a body ground Replace the lights or repair the wiring harness OK Repair harness Flasher unit to each bulb 8 6...

Page 1103: ...d flasher unit Terminal Continuity Terminal Continuity Terminal Continuity a c X d e X f g X a d X d f X f h X a e o d g X g a X a f o d h X g c X a g X e a X g d X a h X e c X g e X c a o e d X q f X c d o e f X g h X c e o e g X h a o c f o e h X h c o c g o f a X h d o c h o f c X h e o d a X f d X h f o d c X f e X h g o O Indicates continuity X No continuity Note Set the ohmmeter to xIOOOG ra...

Page 1104: ...15 STOP LIGHT STOP LIGHT STRUCTURAL VIEW 8 6 U 1 5 X 0 8 3 1 Stop light 2 Stop light switch 3 Stop and tail light checker 15 44 w 626 MX 6 Revised 10 87 ...

Page 1105: ...STOP LIGHT 15 CIRCUIT DIAGRAM TROUBLESHOOTING Note Check the STOP 15A fuse in the fuse box before troubleshooting 86U15X 085 626 MX 6 Revised 10 87 15 45 ...

Page 1106: ...47 NG Replace the switch Check the voltage between each terminal of the stop and tail light checker connector and a body ground when brake on NG Repair the wiring harness Stop light switch to stop and tail light checker stop and tail light checker to body ground OK Check the stop and tail light checker Refer to page 15 47 OK Check the stop lights OK Repair the wiring harness Stop and tail light ch...

Page 1107: ...a o d c o g f o b c 0 d f o g h o b d X d g X h a o b f o d h o h b 0 b g X f a o h c o b h o f b 0 h d X c a o f c 0 h f o c b o f d X h g X O Indicates continuity X No continuity Note Set the tester to xIOOOQ range 2 If continuity is not as specified replace the checker Stop Light Switch 1 Disconnect the stop light switch connector 2 Check for continuity between terminals of the switch _____ Ter...

Page 1108: ...1 5 HORN HORN STRUCTURAL VIEW 86U15X 089 CIRCUIT DIAGRAM 86U15X 090 15 48 ...

Page 1109: ...hat horn sounds NG Replace the horn or repair the harness Horn to body ground NG OK Repair wiring harness Fuse box to horn relay Check that horn sounds with E GO terminal combi nation switch 6 pin connector grounded NG Repair harness Horn relay to horn switch OK Replace the horn switch or repair wiring harness Horn switch to body ground Replace the horn relay Repair harness Horn relay to horn 86U1...

Page 1110: ...15 HEADLIGHT HEADLIGHT STRUCTURAL VIEW 86U15X 093 CIRCUIT DIAGRAM 86U15X 094 15 50 ...

Page 1111: ...HEADLIGHT 15 TROUBLESHOOTING 86U15X 095 86U15X 097 15 51 ...

Page 1112: ...RB 12V C B OV Brightness of the illum ination lights cannot be controlled Check the panel light controller Refer to page 15 53 f 0K NG Check the voltage between each terminal of the pan el light controller connector and a body ground Replace the controller NG Repair the wiring harness Fuse box to panel light controller Panel light controller to body ground 86U15X 099 15 52 ...

Page 1113: ... 86U15X 100 INSPECTION Panel Light Controller 1 Remove the panel light controller 2 Check the voltage at D GW terminal of the panel light controller Panel light controller Voltage Min 10V Max OV 626 MX 6 Revised 10 87 15 53 ...

Page 1114: ...15 REAR WINDOW DEFROSTER REAR WINDOW DEFROSTER STRUCTURAL VIEW 86U15X 101 CIRCUIT DIAGRAM 15 54 626 MX 6 Revised 10 87 86U15X 102 ...

Page 1115: ...REAR WINDOW DEFROSTER 1 5 TROUBLESHOOTING 86U15X 103 15 55 ...

Page 1116: ...the meter indication is higher than specified the problem exists in the ground side of the filament If the indication is low or zero the problem is in the power side 86U15X 107 Repairing Filament 1 Use paint thinner or ethyl alcohol to clean the damaged part of the filament 2 Attach tape to both sides of the damaged part of the filament 3 Using a small brush or marking pen apply silver paint part ...

Page 1117: ...POWER WINDOW STRUCTURAL VIEW POWER WINDOW 1 5 86U15X 108 15 57 ...

Page 1118: ... d i i i h l i l i ll seV open close open closex openv close openV GL Dr1J RL Dr1 GW Dr1 X 19 It DrIJ r BL R2 GW R RWJR X 21 GW Dr2 M 03 RW Dr2 BL 33 jF It LW Dr1 YW X 20 T BL R LW R YW I LW Dr2 M 0 5 Dr3 YW Df3 r It Dr1J GY Dr1 WR Dr1 BL Dr1 4 X 19 BL R GY R WR I X 23 J Dr3 LW YW Dr4J Dr4 BL Dr4 M 07 POWER WINDOW SW R Dr2 G Dr2l R Dr3 L Dr3 R Dr4 L Dr4j M 06 FL FR RL POWER WINDOW MOTOR R R 15 58 ...

Page 1119: ...POWER WINDOW 15 TROUBLESHOOTING 86U15X 110 86U15X 111 15 59 ...

Page 1120: ...15 POWER WINDOW 86U15X 112 86U15X 113 15 60 ...

Page 1121: ... LW Down YW Rear right side except MX 6 Up GY Down WR Note Use only the main sw itch during the checking operation Check power window switch driver s side Refer to page 15 62 63 OK Check for 12V at terminal to each door power win dow switch connector 5 pin while operating main switch driver s side Door Operation Wire Passenger side Up GW Down RW Rear left side except MX 6 Up LW Down YW Rear right ...

Page 1122: ...U15X 115 INSPECTION Power Window Driver s Side Switch For Sedan and Touring Sedan Check for continuity between terminals of the switch Main switch Terminal Position h i Lock Unlock O O O O Indicates continuity c f i I 0 b e h k n a d X j m O O Indicates continuity 86U15X 116 15 62 ...

Page 1123: ...cates continuity 86U15X 117 O O Indicates continuity Switch on Each Side For Sedan And Touring Sedan Check for continuity between terminals of the switch O O Indicates continuity 86U15X 119 For MX 6 Check for continuity between terminals of the switch errTiinal P o sitio n a b d f h UP 0 O O O OFF O o o O DOWN o O o O O O Indicates continuity 15 63 ...

Page 1124: ...ia 15 64 Power Window Motor 1 Connect 12V to the a terminal and ground the b terminal of the motor connector and check that the motor operates 2 Reverse the above connections and check for re verse operation of the motor ...

Page 1125: ...REMOTE CONTROL MIRROR 1 5 REMOTE CONTROL MIRROR STRUCTURAL VIEW CIRCUIT DIAGRAM 86U15X 123 15 65 ...

Page 1126: ...rY O O O indicate continuity OK Repair the harness Switch to Motor Remote control m irrors do not operate NG Replace RADIO 15A fuse or repair the harness Fuse box to switch switch to body ground NG Replace the switch NG Replace the motor 86U15X 124 bd f h l i ul ul ac g g c a h f d b INSPECTION Remote Control Mirror Switch 1 Remove the negative battery cable 2 Remove the remote control mirror swit...

Page 1127: ...REAR WINDOW WIPER 15 REAR WINDOW WIPER STRUCTURAL VIEW 86U15X 126 1 Wiper arm and blade 3 Wiper motor 5 Hose 2 Seal cap 4 Washer tank and motor 6 Washer nozzle 15 67 ...

Page 1128: ...ADLIGHT CLEANER SW X 06 From Instrument Panel Light Control Section Eb l i t to _ O O O HEADLIGHT CLEANER MOTOR 4 a REAR WIPER V WASHER SW GW 11 Control __ Sedin Eb B F o To Instrument Panel Light D 01 Combination Sw D LO L B t LW LB LR D 05 Rear Washer Motor R 4 50oor D 02 Front Wiper Motor F LT T T T T x LB L D 06 Headlight Cleaner Sw I LY RB LW GW D 03 Rear Wiper Sw I x x GW 5 Door B L BL RB C ...

Page 1129: ...REAR WINDOW WIPER 15 TROUBLESHOOTING 86U15X 128 86U15X 129 K Vi 626 MX 6 Revised 10 87 15 69 ...

Page 1130: ...15 REAR WINDOW WIPER 86U15X 130 86U15X 131 15 70 626 MX 6 Revised 10 87 ...

Page 1131: ... mediately Check that the motor shaft reaches the auto stop position and that there is conductivity through the grounding of the motor body Note Be sure to re install the rubber seal correctly Operation Check of Rear Washer Motor 1 Using a voltmeter measure the voltage between the LG terminal and a body ground with the igni tion switch ON 2 If no voltage check the fuse or repair the harness 3 If t...

Page 1132: ...15 WINDSHIELD WIPER WINDSHIELD WIPER STRUCTURAL VIEW 1 Wiper blade 2 Wiper arm 3 Cowl grille 4 Cover 5 Wiper motor 6 Link assembly 7 Washer tank 8 Nozzle hose 9 Washer nozzle ...

Page 1133: ...Light Control Section Eb I 5 ct L J 1 oSSg pj h o oS 2 HEADLIGHT I CLEANER MOTOR B F 0 REAR WIPER WASHER SW GW Control S e ctio nE b o To Instrument Panel Light D 01 Combination Sw D LO L B r d t LW LB LR D 05 Rear Washer Motor R g l L LG 5 Door D 02 Front Wiper Motor F B LR LW x LB L D 06 Headlight Cleaner Sw LY RB LW GW D 03 Rear Wiper Sw I x x GW 5 Door i i_r i T T T T B L BL RB C 05 Washer Mot...

Page 1134: ...1 5 WINDSHIELD WIPER TROUBLESHOOTING 86U15X 136 15 74 626 MX 6 Revised 10 87 ...

Page 1135: ...WINDSHIELD WIPER 15 86U15X 137 86U15X 138 626 MX 6 Revised 10 87 15 75 ...

Page 1136: ...15 WINDSHIELD WIPER 86U15X 141 86U15X 142 15 76 ...

Page 1137: ...o 86U15X 143 Checking Operation Check the operation by applying 12V between each terminal of the motor connector Terminal Operation speed 12V Ground b a Low c Hiqh 86U15X 144 Washer Motor 1 Check for continuity of the motor with an ohmmeter 2 Connect 12V to the b terminal and the ground to the a terminal and check that the motor operates 86U15X 145 626 MX 6 Revised 10 87 15 77 ...

Page 1138: ...15 CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM STRUCTURAL VIEW 86U15X 146 1 Main switch 4 Stop switch 7 Inhibitor switch ATX 2 Control switch 5 Clutch switch MTX 3 Control unit 6 Actuator ...

Page 1139: ...CRUISE CONTROL SYSTEM 1 5 CIRCUIT DIAGRAM 86U15X 147 15 79 ...

Page 1140: ...en the modified ACC checker is used on these models use a jumper wire and jump across terminal no 6 to 3 indicated on ACC checker connec tor as shown Function of the ACC CHECKER A Check lights Each item is verified by a check light as described below Check light Check items MAIN SW Ignition switch fuse main switch and associated wiring harness terminals and con nectors ACTUATOR VAC VAC coil contin...

Page 1141: ...easing to 2 000 3 000 rpm there is no problem If there is no increase at all or only a slight increase try again after setting the slide switch to the H position If there is still no increase to 2 000 3 000 rpm adjust the free play of the actuator inner cable 76U15X 319 Preparation 1 ACC checker installation Depress the lock hook of the harness connector Remove the connector from the ACC control u...

Page 1142: ... SW LIGHT OFF Check brake switch and associated harness 4 CLUTCH SW CONTINUITY Ignition switch ON Main switch ON Depress clutch pedal o o o o o X O or X CLUTCH BRAKE SW LIGHT OFF Check clutch switch and associated harness 5 SET POSITION OF COMBINA TION SWITCH Ignition switch ON Main switch ON Shift lever to D A T Push to SET position of com bination switch o o o o X o 0 or X COMBINATION INH SW LIG...

Page 1143: ...X O sociated harness Then turn on check switch keep O 4 x X X or in D position O M 1 X Note Engine speed should in A crease to 2 000 3 000 rpm If over 4 000 rpm release the switch immediately 10 SPEED SENSOR OUTPUT O If GENERATOR LIGHT does not flash Keeping idling condition drive ve o O o o X X t trouble may be with speed sensor and hicle slowly X associated harness 76U15X 199 INSPECTION Actuator...

Page 1144: ... condition when check ing above replace the cruise control unit and check system operation Clutch Switch Brake Switch When removing these switches turn each of them so that the corresponding pedal height agrees with the standard value Brake pedal height 214 mm 8 42 in Clutch pedal height 214 mm 8 42 in Speed sensor 1 Remove the combination meter 2 Connect an ohmmeter between ai and a ter minals 3 ...

Page 1145: ...G SUNROOF 15 SLIDING SUNROOF STRUCTURAL VIEW 86U15X 148 1 Slide panel 2 Deflector assembly 3 Motor assembly 4 Guide bracket 5 Driving cable 6 Guide bracket assembly rear 7 Tilt up switch 8 Slide switch 15 85 ...

Page 1146: ...1 5 SLIDING SUNROOF CIRCUIT DIAGRAM 15 86 ...

Page 1147: ...motor Terminal Voltage Y OV YR OV YG 12V NG Repair the harness Relay to motor OK NG Check the sunroof motor and limit switch Refer to Replace the motor and limit switch page 15 88 89 OK Check for 12V at L terminal of the sunroof motor connector NG Repair the harness Relay to motor OK Check the voltage at each terminal of the sunroof switch connector with each roof condition Terminal Roof condition...

Page 1148: ...a c b e f 76U15X 314 Relay 1 Check the continuity between a b and c f 2 Apply power source to the terminal a 3 Connect the negative lead to the terminal b 4 Check the continuity between c e Motor 1 Disconnect the connector of the motor 2 Apply power source to YR and connect Y to the ground 3 Check that motor turns in the direction from the tilt up to the closed to the open position 4 Reverse the c...

Page 1149: ...love box set the sunroof in each position a c e 9 1 1 1 1 T T T T b d f h 2 Use an ohmmeter to check the continuity of the terminals of the switch sw LS1 LS2 Terminal color e d a b c Roof condition L LG YG LW LY Open O r Close o o Tilt up o o o O O Indicates conductive 76U15X 161 15 89 ...

Page 1150: ...orm mechanics If it detects their malfunctions outputs the output pattern to A LW terminal of service connector according to the settled pattern for each mal function Troubleshooting against AAS system can be conducted by knowing the output pattern See page to detect trouble location 86uisx i52 TROUBLESHOOTING How To Use Self Diagnosis System By using the control unit s self diagnosis function and...

Page 1151: ...ering wheel right and left and check the output pattern Condition C 1 Turn the ignition switch ON 2 Change the AAS switch from NORMAL to SPORT or from SPORT to NORMAL and check the out put pattern 86U15X 156 Condition D 1 Operate the vehicle on a chassis roller 2 Check the output pattern at above 15 km h 9 3 mph Caution a Block the rear wheels b ln vehicle equipped with ABS ABS warn ing light may ...

Page 1152: ...AS 3 Refer to page 15 95 0 5 sec 4 4V OV 2 sec Vehicle speed sensor or wiring harness Meter Control unit AAS 1 Refer to page 15 94 B Turn the steering wheel right and left 0 5 sec 4 4V 0V 0 5 sec 2 sec Normal operation 0V Wiring harness Fuse box Control unit Control unit Body ground See page AAS 4 Refer to page 15 95 0 5 sec 4 4V 0V Normal operation 2 sec Change the switch from NORMAL to SPORT or ...

Page 1153: ... 98 4 4V OV Normal operation Operate the vehicle at above 15 km h 9 3 mph on a chassis roller 4 4V OV Speed sensor or Steering wheel angle sensor or wir ing harness Control unit Meter Control unit An gle sensor OV Speed sensor or Wiring harness Control unit Meter Fuse box Control unit Control unit Body ground AAS 8 Refer to page 15 98 AAS 9 Refer to page 15 99 86U15X 158 ...

Page 1154: ...15 AUTO ADJUSTING SUSPENSION Inspection of circuit 86U15X 159 86U15X 160 15 94 ...

Page 1155: ...tion NG Replace TURN 15A fuse or repair the wiring harness Fuse box to Control unit Control unit to Body ground 86U15X 161 AAS 4 Failure of wiring harnesses Fuse box to Control unit Control unit to Body ground Check the voltage between each terminal of control unit connector and a body ground with ignition ON Terminals Voltage G B OV J B ov K BY Approx 12V OK Replace the control unit NG Replace TU...

Page 1156: ...nd a body ground with ignition ON Terminal Voltage A WR Approx 12V B WL Approx 12V C WY Approx 12V NG Terminal Voltage A WR Approx 12V B WL Approx 12V C WY Approx 12V OK Reconnect the front left actuator connector NG Replace front right ac tuator OK Repair the wiring har ness Front right actua tor to Control unit Disconnect the front right actuator connector and check the voltage between each term...

Page 1157: ...the voltage between each terminal of the rear right side actuator connector and a body ground with ignition ON Terminal Voltage A YR Approx 12V B YG Approx 12V C YL Approx 12V NG OK Reconnect the rear left actLjator connector Replace rear right ac tuator Repair wiring harness Rear right actuator to Control unit Disconnect the rear right actuator connector and check the voltage between each termina...

Page 1158: ...nuity between D LY terminal of con trol unit and D LY terminal of AAS switch OK Replace the control unit AAS 8 Failure of speed sensor or steering wheel angles sensor or wiring harness Control unit to Meter Control unit to Angle sensor NG Replace the AAS switch NG Repair wiring harness Disconnect the control unit connector and check the resistance between the terminals with steering wheel in strai...

Page 1159: ... Control unit to Body ground Check the voltage between each terminal of control unit connector and a body ground with ignition ON Terminal Voltage G B OV J B ov K BY Approx 12V NG Replace METER 10A fuse or repair the wiring har ness Fuse box to Control unit Control unit to Body ground OK Go to AAS 1 routine 86U15X 166 15 99 ...

Page 1160: ...d rear damper operates Visual inspection 86U15X 167 3 If the actuator does not operate disconnect the ac tuator connector and check for a few ohms resis tance between the terminals Terminal Resistance Front A WR D BR 2 8 0 B WL D BR C WR D BR Rear A YR D BR B YG D BR C YL D BR Steering Wheel Angle Sensor Inspection See page 15 14 Vehicle Speed Sensor Inspection See page 15 84 86U15X 168 86U15X 169...

Page 1161: ...POWER DOOR LOCK 15 POWER DOOR LOCK STRUCTURAL VIEW CIRCUIT DIAGRAM BATTERY 86U15X 171 15 101 ...

Page 1162: ... voltage at GB terminal of the power door lock relay with each switch condition Terminal Condition Voltage GB Lock 12V Unlock OV OK Check the voltage at R and G terminal of the power door lock relay with each switch condition Terminal Condition Voltage R Lock OV Unlock 12V G Lock 12V Unlock OV NG Replace the switch NG Repair the harness Door lock switch to relay NG Replace the door lock relay OK C...

Page 1163: ...Unlock O O O O indicates continuity 2 If continuity is not as specified replace the switch Power Door Lock Motor 1 Check operation of the door lock actuator when the battery voltage is applied to the terminal Connecting to Door lock motor 12V ground G R LOCK Pull R G UNLOCK Release 2 If not replace the door lock motor 86U15X 174 15 103 ...

Page 1164: ...C SHOULDER BELT AUTOMATIC SHOULDER BELT STRUCTURAL VIEW Limit switch Front Automatic shoulder belt warning switch Limit switch Rear Automatic shoulder belt retractor Automatic shoulder belt motor 86U15X 175 15 104 ...

Page 1165: ...pJ FL 0 06 GR R X 16 0 06 0 0 7 B DM B Dr2 4 X 1 9 x 22 B R B R DOOR CATCH___ SW I T X 18 B LIMIT S W I GR C F R 07 I To Speed y Sensor Section C I LY 0 03 I ri LgB R LB Front Rear B RH 0 03 R PASSIVE SHOULDER BELT MOTOR ASSEMBLY 0 01 Passive Shoulder Belt Control Unit R Y LW L LR GR BY LB LY G c L u c L s c L o cL o c L m ___ I c L i J a G J a E i c cL a Cj3V CjDT Cj3R C j3P C j3N C j3L C j3 j C ...

Page 1166: ...15 AUTOMATIC SHOULDER BELT TROUBLESHOOTING 86U15X 177 r 15 106 ...

Page 1167: ...e the front and center pillar trim and discon nect the automatic seat belt motor connector and disconnect the limit switch connector 76U15X 184 2 Check continuity between the limit switch terminals with each condition using the emergency handle Limit switch Seat belt posit 5 r Front Rear a b c d Released Front O O Released and Locked Locked Rear O O O O Indicates continuity 86U15X 251 Door Catch S...

Page 1168: ...ndicates continuity 86U15X 252 Seat Belt Warning Switch 1 Remove the center pillar trim and disconnect the automatic seat belt motor connector 2 Check continuity between the terminals when the automatic seat belt is at rear the lock position ____ Terminal Set belt position _ _ _ _ _ _ Left LR side B Right LgB side B Locked Belt fastened O o CD O Belt unfastened O O Indicates continuity 15 108 ...

Page 1169: ...1 V U i n n o su A MI L I LI LIc h S n r I f U It SCAN __________TUNE I l o I C If cz 1 fl j 2 5 W X 2 L SW VOL D BAL FAD G BASS P U LL TRE MEMO o l i o 1 4 5 6 8 8 8 S a 0 c L s X s J L s J SCAN TUNE V A a j r F ront le ft Q F ront right fl Rear le ft Q Rear right Fr ont le ft F ront right j Rear le ft 3 Rear righ t s o F ront le ft 3D woofer 0 F ront right Q j Rear le ft Q j Rear right Rear righ...

Page 1170: ...15 AUDIO SYSTEM OUTLINE OF AUDIO SYSTEM 15 110 86U15X 181 ...

Page 1171: ...AUDIO SYSTEM 15 REAR CONECTOR VIEW 86U15X 250 15 111 ...

Page 1172: ...15 AUDIO SYSTEM REAR CONECTOR VIEW AUTO REVERSE CASSETTE DECK To equalizer To tuner 76U15X 208 15 112 ...

Page 1173: ...3 FULL LOGIC AUTO REVERSE CASSETTE DECK only system 6 a Antenna relay Grounded when radio is on b Illumination c 13 2V ACC a Antenna relay Grounded when radio is on 1 NC 2 Output L b Illumination 3 SWD B c 13 2V ACC 4 NC 5 Ground 6 Output R 7 NC 8 NC E Shield ground 86U15X 184 15 113 ...

Page 1174: ...N 4 NOT USED 5 SIGNAL GROUND 5 SIGNAL GROUND 6 OUTPUT R 0 6 OUTPUT R 0 7 INPUT R 0 7 NOT USED 8 BASS TRE CANCEL SIGNAL 8 NOT USED E SHIELD GROUND E SHIELD GROUND 86U15X 251 COMPACT DISC PLAYER To AE system 1 AUX B 2 Input L 3 Ground 4 Inc 5 Input R 6 NC 7 Illumination E Shield ground 0 To ground a 13 2V ACC Back up 15 114 ...

Page 1175: ...R VIEW Amplifier 86U15X 253 From cassette deck 1 NC 2 Input L 3 S W D B 4 NC 5 G round 6 Input R 7 NC 8 NC E Shield ground 7 3 From compact disc 1 AUX B 2 Input L 3 Ground 4 NC 5 Input R 6 NC 7 Illumination E Shield ground 15 115 ...

Page 1176: ... AM FM Deck N sound Turn the graphic equalizer off Do speakers work YES Replace graphic equalizer Check speaker and speaker wire Ohmmeter NG Replace speaker or repair speaker wiring YES Turn the graphic equalizer ON Replace Antenna AM FM No sound k r o t r t in j iJ u H h i k Ohmmeter indicates infinite ohm OK Replace radio deck or Power amplifier Check with known good antenna as specified NG OK O...

Page 1177: ... Fuse OK Faulty wiring Check for open or short circuit YES Main q T lug loose coupler Check antenna p NO YES Main 3 J ii Check antenna 3 Ohmmeter Main Ohmmeter Indicates infinite 1 Sub Indicates shorted Replace ETR NO YES Is cassette working Use known good tape YES YES I Replace antenna or antenna feeder Check sp speaker 1 1 X1Q g range Ohmmeter eaker and harness Tic click NO Replace speaker or re...

Page 1178: ...H J Are screws loose NO NO Noise probably coming in on antenna Check antenna mounting for tightness Is there still noise with antenna plug pulled out j i Tighten Antenna Mounting NG OK Alternator noise Accessory noise Ignition noise Check alternator Check accessories Check ignition system Repair as necessary Repair as necessary Repair as necessary 86U15X 187 15 118 ...

Page 1179: ...lace antenna NG Is radio broadcast or propaga tion cause of poor tone quality NO Replace unit Check antenna and lead in for broken connectors T o body ground AM With engine off tune to a station with a signal that is neither weak nor strong Touch the antenna Other parts of body must not touch the car Volume increases Antenna is defective Volume decreases All right Ohm meter indicates infinite ohm ...

Page 1180: ...ch the antenna Other parts of body must not touch the car Volume increases Antenna is defective Volume decreases All right Ohm meter indicates infinite ohm OK Replace an tenna am plifier NG Replace unit NO DISPLAY OF FREQUENCY PRESET MEMORY IS CANCELED Repair back up circuit Replace unit NO OK Check voltage between back up lead and ground while turning ignition key on and off Is the voltage higher...

Page 1181: ...is defective Change tapes Repair harness Repair speakers NG NO Check with another tape OK NG Check for shorts in speaker harness Ground If ohmmeter indicates infinite ohm when checking value of re sistance between each speaker jack and car body speaker har ness is OK OK Check for object and rattling or c Are speakers O H s lying on speaker amage to speaker s YES Replace unit 86U15X 190 15 121 ...

Page 1182: ...e tape in cassette OK NG Clean head capstan and pinchroller Use Allsop Head cleaner or equivalent Check that 120 minute cassette tape or longer tape is not used NOT USED USED Use 30 60 or 90 minute tapes It is recommended that only 46 60 or 90 minute cassette tapes be used because 120 minute cassette tape is very thin and delicate NG Replace unit OK Tape is defective Change tapes 86U15X 191 15 122...

Page 1183: ...place CD system YES Check CD connector loose connection NO NO Check fuse YES Check back up voltage T L Jrst Volt meter If voltage higher than approx 10 vo up circuit OK jj approx 10 volts back YES c 13 2V ACC YES Replace CD system If voltage higher than approx 10 volts ACC circuit OK NO NO Replace cassette deck Replace AE system 86U15X 192 15 123 ...

Page 1184: ...15 AUDIO SYSTEM POWER ANTENNA STRUCTURAL VIEW 1 Antenna motor 2 Antenna r 15 124 ...

Page 1185: ...ition switch ON 12V GW Ignition switch ACC and radio power switch ON OV LR Any time 12V If not repair the harness 2 Turn the ignition switch on and check the opera tion of the power antenna with each condition Condition Antenna operation GW wire is connected to a body ground Rises GW wire is not connected to a body ground Goes down If the power antenna does not operate replace the power antenna re...

Page 1186: ...15 HEATER HEATER STRUCTURAL VIEW CZD CZZ C D L Jf OFF 1 2 3 4 Heater control switch Lever control switch OFF 1 Logical control switch Heater unit 86U15X 197 15 126 ...

Page 1187: ... IlC Z D C Z Z v jl w OFF 4 I T IA C 0ECO Type B G3 1 3 C3 C3 CD W V J SS CD E Z J e 3 CD CD A C ECON c i __i __i L H I J i I Q I Fresh air 86U15X 198 BI LEVEL model Type A 1 1 A C ne c o Type B e S t S A C EOON CZ CZI D I Jir OFF I 2 3 4 C I M i I Fresh air Warm air 86U15X 199 15 127 ...

Page 1188: ... CD A C EDON _____ j _____1 i z q j Z Z l ZZ Z D i Q i Warm air 86U15X 200 HEAT DEF mode Type A a 1 IL_Jt dg g IZ Z C Z Z Hi 9mm CUD A C jJ p U k 4 F F j 3 4 I j CD CD CD CD CD j W V f j W CD ED CD CD e S c S A C ECON 1 3 c z i c z n _____i B f c C D 1 ii ii ii i c r Jir o T i 2 3 4 i I E I 15 128 86U15X 201 ...

Page 1189: ...n n o n n g V 2 W E S _ A C j PECO I Type B K CffK13 3 4 I W O j Warm air 86U15X 202 RATE OF AIR FLOW MODE AIR VENT OPEN DEF OPEN HEAT OPEN VENT FRESH 100 BI LEVEL 1 2 warm 5Q 50 HEAT WARM 20 80 DEFROSTER HEAT WARM 50 50 DEFROSTER WARM 100 15 129 ...

Page 1190: ... move the full stroke between HOT and COLD 86U15X 203 Mode control wire 1 Set mode control lever to DEF position 2 Connect and clamp the control wire with the shut ter lever on the heater unit at its closest point Caution Move the mode lever to be sure the wire is at tached Also be sure it can move the full stroke between DEF and VENT 86U15X 204 REC FRESH air selector wire 1 Set the selector lever...

Page 1191: ...d control lever REC FRESH air select motor Outline of Components 69G15X 207 Part Name Description Logical control switch One touch push type mode control switch MODE control motor Controls air outlet for each mode Drives VENT HEAT and DEF doors AIR MIX motor Controls air outlet temperature by operating the air mix doors REC FRESH air select motor Controls intake air by driving the rec fresh air se...

Page 1192: ...00 CD c ro o CD ...

Page 1193: ...n these terminals using a voltmeter Terminals Voltage B 0 Approx 12V 86U15X 208 2 Connect a resistance at least 1 kQ between d ter minal and B terminal and check the voltage be tween d terminal and 0 terminal using a voltmeter Terminals Voltage B 0 Less than 1V 15 133 b d f h la c XgJ Note a Remove the logicon switch from the vehicle b Supply 12V as shown in the figure c Check each circuit _______...

Page 1194: ...cking Mode Control Circuit 1 Connect a jumper wire between I terminal and L terminal Connect a resistance at least 1 kfl between D ter minal and L terminal and check the voltage be tween these terminals using a voltmeter Terminals Voltage D L Approx 12V 86U15X 212 d 1 r r v I L I I J _ i r A c 1 1 o o r V oltmete 2 Connect a jumper wire between C terminal and L terminal Connect a resistance at lea...

Page 1195: ...nal Voltage A L Less than 1V 5 Check for continuity between each terminal with following condition using an ohmmeter Condition Terminals Continuity Push the VENT switch J L Yes Push the B L switch G L Yes Push the HEAT switch H L Yes Push the H D switch E L Yes Push the DEF switch F L Yes Checking Air Mix Control Circuit 1 Connect a resistance at least 1 kQ between Q ter minal and T terminal Set t...

Page 1196: ...minal Set temperature control lever to MAX HOT and check that Q terminal voltage is higher than termi nal t voltage 86U15X 219 iL T rH I X_ X 1 Q i i Voltmeter 4 Connect a resistance at least 1 kfl between Q ter minal and terminal t Set temperature control lever to MAX COLD and check that T terminal voltage is higher than Q ter minal voltage 86U15X 220 Checking A C Switch and ECO Switch Circuit 1 ...

Page 1197: ...ge between these terminals Terminals Voltage d g OV d f Approx 12V d h Approx 12V 86U15X 223 4 Turn the A C switch and the ECO switch on Connect a jumper wire between terminal c and L terminal Connect a resistance at least 1 kQ between each terminal and check the voltage between these ter minals Terminals Voltage d g Approx 12V d f OV d h Approx 12V 86U15X 224 b 9 f id L I I 1 k J X X 1 1 86U15X 2...

Page 1198: ...CO switch indicator with ECO switch on 86U15X 226 2 Check that the mode control switch and REC FRESH select switch indicators when the respec tive switches ON 86U15X 227 3 Apply 12V to terminal a and check that the indi cators are dim Checking Illumination Circuit 1 Connect a jumper wire between terminal b and ter minal L 2 Apply 12V to terminal a and check that the indi cators are dim id I I J _ ...

Page 1199: ...M 1 5 THEFT DETERRENT SYSTEM STRUCTURAL VIEW 5 Back door key cylinder switch 6 Back door switch 7 Hood switch 8 Starter cut relay 1 Control unit in the CPU 2 Door switch 3 Lock link switch 4 Door key cylinder switch 15 139 ...

Page 1200: ...tomatic shoulder belt control unit FL Key cylinder SW 4 T T ru n k L o c k link SW i or o Laggage compartmentv light Trunk SW Lock link SW FR Lock link SW Hood SW r 0 KH l l l l l l l l l l l l l T CPU 2d 2m JG key illumination light Interior light Courtesy light Seat belt warning light Security t light Starter cut relay 15A 15A Horn relay 9 Flasher unit I a J Head lj9ht L 9 I relay H ead light Ha...

Page 1201: ...THEFT DETERRENT SYSTEM 15 TROUBLE SHOOTING 86U15X 253 15 141 ...

Page 1202: ... lock knobs OFF OFF Pull hood release lever J l OFF Repair hood switch Pull trunk release lever Jl OFF Repair trunk switch 10 Remove key and exit vehicle OFF OFF Close door A OFF OFF OFF Repair door A switch 11 Turn door A key cylinder to un lock and hold in position _____ OFF OFF Repair door A key cylinder switch 12 Remove key OFF OFF OFF 13 Turn door E trunk key cylinder to unlock and hold in po...

Page 1203: ... OFF Pull hood release lever JT OFF Repair hood switch 10 Pull trunk release lever JT OFF Repair trunk switch 11 Remove key and exit vehicle OFF OFF 12 Close door A OFF OFF OFF Repair door A switch 13 Turn door A key cylinder to un lock and hold in position ______ JT OFF OFF Repair door A key cylinder switch 14 15 Remove key OFF OFF OFF Open door C OFF OFF Repair door C switch 16 Close door C OFF ...

Page 1204: ...er Jl OFF Repair hood switch 10 Remove key and exit vehicle OFF OFF 11 Close door A OFF OFF OFF Repair door A switch 12 Turn door A key cylinder to un lock and hold in position______ OFF OFF Repair door A key cylinder switch 13 Remove key OFF OFF OFF 14 Open door C OFF OFF Repair door C switch 15 16 Close door C OFF OFF OFF Turn door E key cylinder to un lock and hold in position _____ OFF OFF Rep...

Page 1205: ... B Unlocked Yes Locked No Rear right side BrY B Unlocked Yes Locked No Back door Trunk BrR B Unlocked Yes Locked No 2 If not replace the switch Hood Switch 1 Check for continuity of the switch with an ohmmeter Terminal Condition Continuity BrW B Open Yes Close No 2 If not replace the switch Key Cylinder Switch 1 Check for continuity of the switch with an ohmmeter Door Terminal Condition Continuity...

Page 1206: ...MISSION CONTROL SYSTEM 30 7 ENGINE ELECTRICAL SYSTEM 30 8 CLUTCH 30 9 MANUAL TRANSAXLE 30 10 AUTOMATIC TRANSAXLE 30 11 FRONT AND REAR AXLE 30 15 STEERING SYSTEM 30 15 BRAKING SYSTEM 30 16 WHEEL AND TIRE 30 17 SUSPENSION 30 17 BODY ELECTRICAL SYSTEM 30 18 STANDARD BOLT AND NUT TIGHTENING TORQUE 30 19 ...

Page 1207: ...m Maximum difference between cylinders 196 2 0 28 IN Open BTDC 10 Valve timing Close ABDC 49 EX Open BBDC 55 Close ATDC 12 Valve clearance mm in IN 0 Maintenance free EX 0 Maintenance free Cylinder head Height mm in 91 95 92 05 3 620 3 624 Distortion mm in Maximum 0 15 0 006 Grinding limit mm in Maximum 0 20 0 008 Valve and valve guide Valve head diameter mm in IN 32 4 32 6 1 276 1 283 EX 33 9 34 ...

Page 1208: ... 065 0 115 0 0026 0 0045 Maximum 0 15 0 0059 Camshaft runout mm in Maximum 0 03 0 0012 Camshaft end play mm in Standard 0 08 0 16 0 003 0 006 Maximum 0 20 0 008 Rocker arm and rocker arm shaft Rocker arm inner diameter mm in 19 000 19 033 0 748 0 749 Rocker arm shaft diameter mm in 18 959 18 980 0 746 0 747 Rocker arm to shaft clearance mm in Standard 0 020 0 074 0 0008 0 0029 Maximum 0 10 0 004 C...

Page 1209: ...1 2 3051 2 3508 Main journal diameter mm in undersize No 3 59 687 59 705 2 3499 2 3506 0 50 0 020 No 1 2 4 5 59 443 59 461 2 3403 2 3410 undersize No 3 59 437 59 455 2 3400 2 3407 0 75 0 030 No 1 2 4 5 59 193 59 211 2 3304 2 3311 undersize No 3 59 187 59 205 2 3302 2 3309 Main journal taper and out of round mm in Maximum 0 05 0 0020 Standard 50 940 50 955 2 0055 2 0061 Crank pin diameter mm in 0 2...

Page 1210: ...andard 0 03 0 09 0 0012 0 0035 Maximum 0 10 0 004 Oil filter Type Full flow paper element Relief pressure differential kPa kg cm2 psi 78 118 0 8 1 2 11 17 Oil cooler Turbo Type Water cooled 4 stage Oil pressure switch Activation pressure kPa kg cm2 psi 29 0 3 4 3 Engine oil Capacity liters US qt Imp qt Total dry engine 4 6 4 9 4 0 Oil pan 3 9 4 1 3 4 Oil filter 0 3 0 32 0 26 Grade API Service SD S...

Page 1211: ... opening valve pressure kPa kg cm2 psi 74 103 0 75 1 05 11 15 Cooling system pressure kPa kg cm2 psi 103 1 05 15 Electric fan Type Electric Capacity W MTX 80 80 ATX 160 120 Current A MTX 5 6 7 6 5 6 7 6 ATX 10 6 16 6 8 0 11 0 Number of blades 4 Outer diameter mm in MTX 320 12 6 ATX 340 13 4 Switching temperature OFF ON C F 97 207 Coolant Capacity liters US qt Imp qt With heater 7 5 7 9 6 6 Without...

Page 1212: ...s Main pump 220 13 4 min Transfer pump 190 11 6 min Fuel filter Type Low pressure side Nylon element High pressure side Paper element Pressure regulator Type Diaphragm Regulating pressure kPa kg cm2 psi 235 275 2 4 2 8 34 40 Injector Type High ohmic Type of drive Voltage Resistance fi 12 16 11 15 Injection amount cc cu in 15 seconds 44 61 2 68 3 72 73 90 4 45 5 49 Idle speed control valve Solenoid...

Page 1213: ...ion Output V kw 12 1 4 Brush length mm in Standard 17 5 0 689 Minimum 10 0 0 394 Ignition Timing 6 10 BTDC Vacuum hoses disconnected 9 10 BTDC Test connector grounded Distributor Type Fully transistorized HEI Electronic spark advanced ESA Centrifugal spark advance Crank angle Engine speed degree rpm 2 2 1 200 12 16 2 400 12 16 3 500 16 20 4 500 Engine control unit controls spark advance Vacuum spa...

Page 1214: ...20 max Clutch disc Type Single dry plate Set load N kg lb 4 316 440 968 5 494 560 1232 Runout mm in 1 0 0 039 max Wear limit mm in 0 3 0 012 from rivet head Outer diameter mm in 225 8 858 240 9 449 Inner diameter mm in 150 5 906 160 6 299 Flywheel side 3 5 0 14 Pressure plate side 4 1 0 16 3 5 0 14 Clutch cover Type Diaphragm spring Runout mm in 0 05 0 0020 max Grinding limit mm in 0 5 0 020 Maste...

Page 1215: ... 0 012 clearance mm in Third Standard 0 05 0 425 0 002 0 017 0 1 0 212 0 0039 0 0083 Limit 0 5 0 020 0 3 0 012 Fourth Standard 0 002 0 365 0 0001 0 014 0 150 0 262 0 0059 0 0103 Limit 0 5 0 020 0 3 0 012 Bearing preload of primary shaft gear Primary shaft 0 1 0 25 Nm 1 0 2 5 cm kg 0 86 2 18 in lb Secondary shaft 0 2 0 4 Nm 2 0 4 0 cm kg 1 7 3 4 in lb Bearing preload adjust shim mm in 0 25 0 010 0 ...

Page 1216: ...throttle 1 6 2 2 volt D 1 D 2 3 500 4 050 3 550 4 150 38 44 24 27 D2 D3 3 750 4 250 3 850 4 350 75 85 47 53 D 3 O D 3 600 4 250 3 650 4 300 110 130 68 81 Lock up O N 0D 2 500 3 000 2 800 3 000 110 130 68 81 Lock up O FF 0D 2 400 2 850 2 400 2 900 104 124 64 77 O D D 3 1 950 2 450 1 800 2 300 85 107 53 66 77 99 48 61 D 3 D2 1 750 2 300 1 700 2 100 54 70 33 43 51 63 32 39 Kick down O D D 3 3 500 3 7...

Page 1217: ...0 27 31 Half throttle 1 6 2 2 volt L i I_2 3 500 4 050 3 350 4 150 38 44 24 27 D2 D3 850 1 150 1 000 1 350 17 23 11 14 n D D 3 D2 250 400 250 500 7 1 3 4 8 _ i o Fully closed 0 5 volt O D D 3 3 750 4 000 4 350 4 600 165 175 102 109 X S S3 S2 3 600 3 850 4 100 4 400 110 118 68 73 108 116 67 72 L L2 L1 2 150 2 450 2 200 2 500 43 49 27 30 Engine model Item Non Turbo Turbo Torque converter Stall torqu...

Page 1218: ...0 0 276 7 2 0 283 7 4 0 291 7 6 0 299 3 4 clutch Number of drive driven plates 5 5 Drive plate thickness mm in Standard 1 6 0 063 Minimum 1 4 0 055 3 4 clutch clearance mm in 1 3 1 5 0 051 0 059 Retaining plate sizes mm in 3 8 0 150 4 0 0 157 4 2 0 165 4 4 0 173 4 6 0 181 4 8 0 189 Return spring free length mm in 33 2 1 307 Low and reverse brake Number of drive driven plates 4 4 5 5 Drive plate th...

Page 1219: ... 022 Red Throttle modulator spring 6 3 0 248 47 9 1 886 0 8 0 031 Throttle assist spring 5 15 0 203 32 3 1 272 0 55 0 022 Dark green Throttle spring 5 4 0 213 47 2 1 858 0 8 0 031 Pink Converter relief ball spring 6 9 0 272 24 1 0 949 0 9 0 035 Maroon Orifice check valve spring 5 0 0 197 12 5 0 492 0 23 0 009 Pressure regulator spring 11 5 0 453 26 5 1 043 1 0 0 039 Maroon Lock up control spring 5...

Page 1220: ... 1 02 Front axle Front wheel bearing end play mm in 0 2 0 0079 max Rear axle Rear wheel bearing end play mm in 0 2 0 0079 max 10 STEERING SYSTEM _________ Type Item Manual steering Power steering Steering wheel Outer diameter mm in 380 15 0 Turns lock to lock 4 32 2 93 Steering shaft and joints Shaft type Collapsible Joint type Cross joints 2 Tilt stroke mm in 40 1 6 Front steering gear Type Rack ...

Page 1221: ...ing mm in Standard 4 5 0 18 Minimum 1 0 0 04 Inner diameter of drum Standard 228 6 9 00 mm in Maximum 230 1 9 06 Wheel cylinder bore mm in 17 46 0 687 Type Disc solid Thickness of pad mm in Standard 8 0 0 31 Rear disc brake Minimum 1 0 0 04 Thickness of disc plate Standard 10 0 0 40 mm in Minimum 8 0 0 31 Disc plate runout mm in Maximum 0 1 0 04 Wheel cylinder bore mm in 30 2 1 19 Parking brake Ty...

Page 1222: ...em Specification Front suspension Type Strut Front wheel alignment Toe in mm in 3 3 0 12 0 12 Camber angle 0 17 45 Caster angle 1 13 45 King pin angle 12 47 Maximum front steering angle Inner 36 00 2 F2 T C EC AT 34 00 2 Outer 31 00 2 F2 T C EC AT 29 00 2 Stabilizer Type Torsion bar Diameter mm in 20 0 0 79 Shock absorbers Standard Suspension Oil type Auto Adjust Suspension Low pressure cas sealed...

Page 1223: ... 11 9 0 47 12 1 0 48 12 2 0 48 12 4 0 49 12 6 0 50 Coil inner diameter mm in 127 5 5 0 Free length mm in 306 12 0 314 12 4 323 12 7 327 12 9 332 13 1 336 13 2 340 13 4 Coil number 5 58 5 72 5 87 6 03 6 04 6 21 6 36 Refer to pages 13 5 6 for coil spring applications 15 BODY ELECTRICAL SYSTEM Item Front exterior lights Body type Halogen headlight Specification W BULB TRADE NO ______ MX 6______ Sedan...

Page 1224: ...NG TORQUE Diameter mm in Pitch mm in 4T 6T 8T Nm m kg ft lb Nm m kg ft lb Nm m kg ft lb 6 0 236 1 0 039 4 2 6 2 0 43 0 63 3 1 4 6 00 C T I 05 CD 0 7 1 0 5 0 7 2 7 8 11 8 0 8 1 2 5 8 8 8 8 0 315 1 25 0 049 9 8 14 7 1 0 1 5 7 2 10 8 16 23 1 6 2 3 12 17 18 26 1 8 2 7 13 20 10 0 394 1 25 0 049 20 28 2 0 2 9 14 21 31 46 3 2 4 1 23 34 36 54 3 7 5 5 27 40 12 0 472 1 5 0 059 34 50 3 5 5 1 25 37 55 80 C J ...

Page 1225: ...IAL TOOLS GENERAL INFORMATION 40 2 ENGINE 40 3 CLUTCH AND MANUAL TRANSAXLE 40 4 AUTOMATIC TRANSAXLE 40 5 STEERING 40 6 BRAKE 40 7 FRONT AND REAR AXLE 4 0 7 SUSPENSION 40 8 CHECKER AND OTHERS 40 9 86U40X 001 ...

Page 1226: ...have these tools B Selective The tools in this list are not as necessary as tools ranked A but all servise shops should have these tools if possible in order to easily perform operations for efficient repair operations 86U40X 002 Note When ordering tool sets which consist of several tools check the List in the Parts Cata logue or Special Service Tools Booklet 4063 11 85B etc to make sure that some...

Page 1227: ...SPECIAL TOOLS 40 ENGINE ...

Page 1228: ...t A 49 SE01 310 Centering tool clutch disc A i 49 F401 330B Installer set bearing B 49 G030 380B Shim selector set G type transaxle A 49 G027 001 Selector 075 H type transaxle A s 49 G030 455 Holder differential side gear G type transaxle B 49 G017 1AO Remover set bearing A 49 G017 101 Attachment N H type transaxle A ...

Page 1229: ...ulley boss A 49 G027 003 Holder diff side gear H type transaxle A AUTOMATIC TRANSAXLE TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 G019 0A7 Compressor set Return spring 49 G019 0A5A Shim selector set 49 0378 400A Gauge set oil pressure 49 G019 011 Bearing installer TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 G019 013 Bearing remover A w 49 G019 022 Attachment K A 49 FT01 439 Holder idle g...

Page 1230: ...RATION 49 G019 9A1 Adapter set EC AT A 49 S120 785 h n l Boot installer boll joint dust cover A X l F TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 8038 785 Boot installer ball joint dust cover A d i 49 G032 3A0 Repair set power steering ESPS A o a 8 F e r I czzd 49 1232 670A Gauge set power steering A 49 G033 108 Adapter caster camber gauge A 49 0727 575 Puller socket joint 4WS B ...

Page 1231: ... 49 0221 600C Expand tool disc brake B 49 B043 002 Bearing installer A TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 F043 001 Adjust gauge A 49 FA18 602 Wrench disc brake piston B FRONT AND REAR AXLE TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 F026 102 Installer A bearing TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 H026 101A Installer sensor rotor ABS A f P ...

Page 1232: ... seal TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 G034 2A0 Replacer lower arm bush SO0 JZ 49 G034 1A0 Coil spring compressor r y r f rj f J v v 40 SPECIAL TOOLS ____________________________ TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 G028 2A0 Replacer lower arm bush 4WS TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION Attachment t 72 49 G026 102 Replacer bearing 49 V001 795 Installer oil se...

Page 1233: ...il pressure gauge 49 0305 870A Tool set window 49 0839 285 Checker fuel and thermometer 49 9200 020 V ribbed belt tension gauge 49 0242 685A Switch starter 49 9200 162 Monitor engine signal 49 F018 001 Checker lamp 49 9200 443 Adapter harness PRIORITY ILLUSTRATION L J iC 0Q ...

Page 1234: ...rI I t j ff I I 40 SPECIAL TOOLS TOOL NUMBER DESCRIPTION PRIORITY ILLUSTRATION 49 9200 163 Adapter harness A 49 F018 002 Igniter checker A v f I I N f t 4 I t f 4 ...

Page 1235: ...FOR TURBO IGNITION SYSTEM E N G I N E FUEL CONTROL SYSTEM 5 0 2 6 ...

Page 1236: ...50 W IR IN Q D IA G R A M 5 0 2 9 ...

Page 1237: ... UNIT R B b x l W G W G B w b w r R Y W I T H 4 W S DEM 01 D A S H D E M ISSI O N E M W I T H O U T 4W S FE 01 F R O N T F E N G I N E E IW Y W Y W R Y 1 1 1 1 IW R R I B FEM 01 F R O N T F EMI S S I O N EM F EM W R B R R R B R B 3R R W R L B W R G O N O N T U R B O M T DR 01 D A S H D R E A R R THEFT DETERRENT D 0 4 W S A U T O M A T I C S H O U L D E R BELT W B L Y X B B G L W B Y l l f H B R i ...

Page 1238: ...EM 21 GREEN EM 18 BLACK EM 01 YELLOW EM 16 EM 14 YELLOW GREEN F 07 BLACK FEM 01 EM 13 GREEN 4 DOOR 2 DOOR 5 DOOR 12 ________ I_________I_________I_________I_________I_________I_________I_________I_________I_________I_________I_________I_________I_________I_________ 50 31 ...

Page 1239: ...O U WIRING DIAQRAM TURN HAZARD FLASHER L IG H TS STOP LIG H TS BACK UP LIG H TS HORN H IG H MOUNTED STOP LIGHT ...

Page 1240: ...50 61 ...

Page 1241: ...FORMATION G 2 FUNDAMENTAL PROCEDURES G 2 JACK SAFETY STAND POSITIONS G 6 VEHICLE LIFT POSITIONS G 7 TOWING G 8 CHASIS NUMBER LOCATION G 9 ENGINE MODEL NUMBER LOCATION G 9 UNITS G 9 ABBREVIATIONS G 9 CAUTION G 10 626 MX 6 Revised 10 87 ...

Page 1242: ...opardized 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 persons other than an authorized Mazda dealer FUNDAMENTAL PROCEDURES As you read through the procedure you will come across NOTES CAUTIONS and WARNINGS Each one is there for a specific purpose NOTES give...

Page 1243: ...RTS While correcting a problem try also to determine its cause Begin work only after first learning which parts and subassemblies must be removed and disassem bled for replacement or repair DISASSEMBLY If the disassembly procedure is complex requiring many parts to be disassembled all parts should be disassembled in a way that will not affect their per formance or external appearance and be identi...

Page 1244: ...dentify 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 in the appropriate method REASSEMBLY Standard values such as torques and certain adjust ments must be strictly observed in the reassembly of all parts If removed these parts should be replaced with new ones 1 Oil seals 2 Gasket 3 O rings 4 Loc...

Page 1245: ...VEHICLE LIFT 2 SUPPORT TYPE POSITIONS G VEHICLE LIFT 2 SUPPORT TYPE POSITIONS FRONT END Frame Side sills front REAR END Frame Side sills rear 626 MX 6 Revised 10 87 G 7 ...

Page 1246: ...ther conditions prevent tow ing the vehicle with the driving wheels off the ground use wheel dollies Caution Do not tow the vehicle backward with driving wheels on the ground This may damage the transaxle internal parts Do not start or run the engine while vehicle is being towed Only for 4WS vehicle When towing the vehicle with the front wheels raised be sure the rear wheels are in the straight ah...

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