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Mitsubishi MOTORS Montero 1984, Service Manual

The Mitsubishi MOTORS Montero 1984 Service Manual is essential for any Montero owner or enthusiast. This comprehensive manual offers detailed instructions and diagrams for maintaining, repairing, and troubleshooting this classic vehicle. Download it for free from manualshive.com to unlock a wealth of valuable knowledge and keep your Montero running smoothly.

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Summary of Contents for Montero 1984

Page 1: ...AN CERTIFICATION THROUGH tsubishi Motors Corporation reserves the right to make changes in Zesign or to make additions to or improvements in its products without mposing any obligations upon itself to install them on its products reviously manufactured Introduction 0 Lubrication and Maintenance 2 3 5 6 Front Suspension RearAxle Brakes Service and Parking Clutch 7 8 Cooling Electrical System 9 11 E...

Page 2: ...on to the key points ILLUSTRATIONS 1 illustration is given in pertinent text for reference Symbol I 2 47 I I G J Page number DEijINITION OF TERMS Standard Dimensions or Values Design dimensions or values or finished dimensions after adjustment of part Service Limit The allowable limitation of wear bends deformation or other damage which restricts the use of parts due to poor performance or insuffi...

Page 3: ...5th digit I 1st digit 2nd digit country Make J A Japan Mitsubishi 6th digit 7th 8th digit digit Series Body 4 High 5 Premium 2 2 door canvas top 3 2 door metal top 11th digit 9th digit Check digit Vehicle type 10th digit Model yea E 1984 year 12th digit Trans mission 4 S speed 49 states 5 S speed California l A T 49 states A T California 13th thru 17th digit Serial number 00001 to 99999 Plant Y Na...

Page 4: ...A4FJ53EOEYS JA4FJ53EOEY7 JA4FJ53EClEY8 Brand Package MONTERO Can also be sold in Federal States Destination I FdderaJ California Federal California Federal California Federal California Federal California Federal Califorrh i T T Engine displacement 2 555 liters 155 9 C I D Model code LO42GN JLF L042GNJLH L042GNULF L042GNULH L042GVNJLF L042GVNJLH L042GVKJLF L042GVKJLH LO42GVNULF L042GVNULH L042GVKU...

Page 5: ...attached to face of left door pillar 72W502 This label indicates the month and year of manufacture Gross Vehicle Weight Rating G V W R front and rear Gross Axle Weight Rating G A W R and Vehicle Identifi cation Number V I N ENGINE MODEL STAMPING The engine model number is stamped at the right front side on the top edge of the cylinder block as shown in the follow ing Engine model Engine displaceme...

Page 6: ...NJLF G54B KM 145 O THQ L042GVNJLH L042GVNULF L042GVNULH 1 M42GVKJLF L042GVKJLH L042GVKULF G54B KM146 L042GVKULH I BODY COLOR CODE Exterior code Body color Two tone B93B91X13 C38C19X13 H74H80X13 A R79R78X13 W44W42X13 X04X21H80 Black Light blue M Black Brown Metal Black Silver Metalk Black Red Black White Veliet black Silver 6 i efi lit id I T sllic etallic ...

Page 7: ...rimental effect on performance and or appearances If an area having many parts similar parts and or parts which are symmetrical right and left is disassembled be sure to arrange the parts so that they do not become mixed during the assembly process 1 Arrange the parts removed in the proper order 2 Determine which parts are to be reused and which are to be replaced 3 If bolts nuts etc are to be rep...

Page 8: ...sed to wash the vehicle be the spray nozzle at a distance of at least 3 from any plastic parts and all opfning par compartment sunroof etc SERVICING THE ELECTRICAL SYSTEM When servicing the electrical system discor cab e terminal from the battery Cautibn Before connecting or disconnecting the I sure to turn off the ignition switch and tl If this is not done there is the possibility 1 parts being d...

Page 9: ...location C 1638 1 2 If any section of a wiring harness contacts the edge of a part or a corner wrap the section of the harness with tape or something similar in order to protect it from damage 3 When using a circuit tester to perform continuity or volt age checks on connector terminals insert the test probe from the harness side If the connector is a sealed connector insert the test probe into the...

Page 10: ...icated by the arrows 6 Connect connectors which have catcl connectors until they snap hesby pressing in the illustration les ELECTRICAL COMPCiNENTS 1 When installing any of the vehicle part pinch or damage any of the wiring han by inserting the be careful no1 sses 10 I Cl6384 Y1634 Cl6382 ...

Page 11: ...he procedure listed in the appropriate instruction manual however be sure to pay careful attention to the following points 1 In order to avoid overloading the wiring take the electrical current load of the optional equipment into consideration and determine the appropriate wire size 2 Where possible route the wiring through the existing harnesses 3 If an ammeter or similar instrument is to be con ...

Page 12: ... Service Manual apply the specified lubricants in the specified locations dur ing assembly and installation BRAKE FLUID Be careful to avoid spilling any brake flui q because if it heres to the vehicle body the paint coat nIi it be discolor DOING SERVICE WORK IN GROUPS C MECHANICS If the service work is to be done by two working together all the mechanics inv safety into consideration while they wo...

Page 13: ...wheels from the lifted end of the disabled vehicle and carrying the lifted end closer to the ground A 20 cm 8 in ground clearance must be maintained between brake drums and ground Front Towing Pickup The vehicle may be towed on its rear wheels for extended distances provided the parking brake is released Make certain the transmission remains in NEUTRAL Safety Precautions The following precautions ...

Page 14: ...e Floor Jack A regular floor jack may be used under the front cross member or rear axle housing Caution 1 A floor jack must never be used on any part of the underbody 2 Do not attempt to raise one entire side of the vehicle by pIacing a jack midway between front and rear wheels This practice may result in permalient damage to the body Emergency Jacking Jack receptacles are located at the front cro...

Page 15: ...rt point shown as Section A A are the same as those of the twin post hoist or sissors jack emergency shown in the illustration OOW554 below Lifting and Jacking Support Locations 1 i f Twinposthoist m Floor jack 0 Frame contact or jack jack supplied with the vehicle on hoist oow554 15 ...

Page 16: ...350 92 5 8 1 400 55 1 1 400 551l 1 400 55 1 1 400 55 1 1 400 55 1 1 400 55 1 a 1 375 54 1 1 375 54 1 1 375 54 1 1 375 54 1 1 375 54 1 1 375 54 1 745 29 3 745 29 3 745 29 3 745 29 3 745 29 3 745 29 3 8 900 35 4 900 35 4 900 35 4 900 35 4 900 35 4 800 35 4 480 18 9 480 18 9 480 18 9 480 18 9 480 18 9 480 18 9 o 440 17 3 440 17 3 440 17 3 440 17 3 440 17 3 440 17 3 210 8 3 2iO 8 3 210 8 3 210 8 3 210...

Page 17: ...56 0 856 0 856 Reverse 3 578 3 578 3 578 2 214 3 578 2 214 High Low 1 ooo 1 ooo 1 ooo 1 ooo 1 ooo 1 ooo 1 944 1 944 1 944 1 944 1 944 1 944 4 625 4 625 4 625 4 222 4 625 4 222 4 875 4 875 4 875 4 625 4 875 4 625 Clutch Type Chassis Tire size Front suspension Type Spring constant Wheel position Rear suspension Type Spring constant At load of 1 OOO 2 500 N 220 551 lbs At load of 4 670 8 870 N 1 030 ...

Page 18: ... 2 10 i R 10 1 2 10 314 1l 1 4 1l 3 4 12 CAPACITY CONVERSION U S GALLONS TO I TERS Gallons 0 1 2 3 4 5 6 7 8 9 Liters 3 7854 7 5708 11 3560 15 1420 18 9270 22 7120 41 640 45 425 49 210 52 996 56 781 60 567 79 494 83 279 87 064 90 850 94 635 98 421 117 35 121 13 124 92 128 70 132 49 136 27 155 20 158 99 162 77 166 56 170 34 174 13 193 06 196 84 200 63 204 41 208 20 211 98 230 91 234 70 238 48 242 2...

Page 19: ...54 5 08 7 62 10 16 12 70 15 24 17 78 20 32 22 86 25 4 50 8 76 2 101 6 127 0 152 4 177 8 203 2 228 6 254 0 279 4 304 8 330 2 355 6 381 0 406 4 431 8 451 2 482 6 508 0 533 4 558 8 584 2 609 6 635 0 660 4 690 6 rMillimeters to inches Fahrenheit Celsius 0 001 0 002 0 003 0 004 0 005 0 006 0 007 0 008 0 009 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 08 0 09 0 1 0 2 0 3 0 4 2 0 7 0 8 0 9 1 2 3 4 5 6 9 10 11 1...

Page 20: ...es 20 xl1 es oic te dl 5 Jic Ii 51 I 1 ers I 1bit 162SX by ree he les I ki s lo ix Pounds to Kilograms When changing pounds to kilograms multiply pounds times 4536 to obtain kilograms Pounds x 4536 Kilograms Kilograms to Pounds When changing kilograms to pounds multiply kilo grams times 2 2046 to obtain pounds Kilograms x 2 2046 Pounds Pounds to Newtons When changing pounds to newtons multiply pou...

Page 21: ...90 190 to 240 Head mark 4 9 to 7 8 13 to 19 27 to 39 47 to 72 77 to 110 130 to 160 180 to 230 160 to 320 340 to 430 420 to 550 3 6 to 5 8 9 4 to 14 20 to 29 35 to 53 57 to 85 90 to 120 130 to 170 190 to 240 250 to 320 310 to 410 7 9 to 12 16 to 19 19 to 30 34 to 45 39 to 54 58 to 73 gt l 4 14 t 22 25 to 33 29 to 40 43 to 54 Internal thread Aluminum Internal thread Cast iron Internal thread Aluminu...

Page 22: ...IGNMENT CONTENTS SPECIFICATIONS 2 MEASUREMENT METHODS 2 GENERAL SPECIFICATIONS 2 MEASUREMENT POINTS 3 TORQUE SPECIFICATIONS 2 FRAME ALIGNMENT 3 BODY DIMENSIONS AND MEASUREMENT METHODS 2 HOW BODY DIMENSIONS ARi INDICATED 2 13 1 ...

Page 23: ... gauge probes are adjustable make the measurement by lengthening one probe by the amount equivalent to the difference in height of the two surfaces 2 If hole diameters are the same and the probes are conical insert the probes into the holes and then make the measurement This method of measurement should be used if the diameters of the holes in the location to be measured are the same 3 If hole dia...

Page 24: ...he point at the hole circumference of the surface from which the measuring instrument is applied is the measurement point FRAME ALIGNMENT COMPONENTS 1 Body mounting bracket 2 Differential mounting bracket 3 Engine mounting bracket 4 Support bracket 9 No 5 crossmember 10 dear shock absorber bracket left 11 Front suspension crossmember 12 No 1 crossmember 1 5 Side frame 13 6 No 4 crossmember 14 7 Re...

Page 25: ...ole ter of steering gear box mounting Center of lower arm rear mounting hole Center of body mounting hole 15w5051 Center of lower arm front mounting hole enter of differential mounting bracket ale enter of upper arm mounting hole enttir of body mounting hole 13 4 ...

Page 26: ... shackle mounting ale Center of shock absorber mounting end L H I enter of rear spring front mounting iole Center of body mounting hole I 15W516 F n r of shock absorber mounting end 15w51 enter of body mounting hole enter of torsion bar anchor arm mount ing hole Center of body mounting hole 13 s ...

Page 27: ...ds and distortion Correct if not within specifications I INSTALLATION 1 Install the front suspension crossmember NOTE It isimportant that the bolts be installed from therear 15W519 3 2 When replacing the floor plug be sure to apply an appro priate amount of semi drying sealant REPAIR When a crack is found in the frame it should be repaired as follows 1 Using a 6 8 mm drill drill a stop hole at a p...

Page 28: ...gle steel stock of the same material and thick nessasframe 8 To prevent stress concentration on the patch make sure that its corners are cut away obliquely 9 The patch should be long enough so that the ends pro perly extend beyond the crack 10 Make sure that edges of the patch are not positioned near spring hangers crossmember ends or other points sub ject to concentrated loads 11 Arc weld the pat...

Page 29: ...SHOOTING 4 COMPONENT SERVICE 5 BGDY PANELING 5 MOUNTING 11 HOOD 14 FUEL FILLER DOOR 16 UNDER GUARD 17 BUMPERS 17 FENDERS 19 GRILLE AND MOULDINGS 21 MUD GUARD 22 WINDOW GLASS 23 FRONT DOORS 27 BACK DOOR 38 FOLDING TOP 43 STRIPE TAPE 49 INSTRUMENT PANEL 52 FLOOR CONSOLE 55 TRIMS 57 HEADLINING AND ASSIST STRAPS 60 SEATS 63 SEAT BELTS 69 23 l ...

Page 30: ...n 5 C 2 Suspension seats Suspension mechanism Coil spring type with shock absorber Up and down movement stroke mm in 80 3 15 Body weight adjustment kg lbs 50 100 110 2 220 5 Seat height adjustment 3 levels TORQUE SPECIFICATIONS Body to frame Under skid plate to frame Under cover to under skid plate Hood releasecable Front door hinges to body Back door hinges to body Spare tire carrier to back door...

Page 31: ...atherstrip and windshield Windshield weatherstrip and body flange Back door window weatherstrip and back door window glass Specified adhesive Quantity 3M Super Weatherstrip Adhesive 8001 or equivalent 3M Super Weatherstrip Adhesive 800 1 or equivalent 3M Super Weatherstrip Adhesive 8001 or equivalent As required As required As required SPECIAL TOOL D see page 2 for instructions 23 3 ...

Page 32: ...d Adjust DOORS Stiff opening and closing Improperly adjusted latch and striker Adjust Adjust Adjust WATER LEAKS Leaking in from bulkhead holes Sealant improperly applied to grommets in bulkhead Apply sealant Deformed or damaged weatherstrip Leaking in from center of door Clogged drainage hole Insufficiently bonded or damaged waterproof Clean hole Replace DUST Entering from floor Cracked or imprope...

Page 33: ...r pillar inner 12 Center pillar outer 13 Side rail upper 14 Fender shield extenison 15 Dash panel upper 16 Cowl top extenison 17 Front pillar inner lower 18 Front pillar outer 19 Drip channel 20 Center pillar inner lower 21 Rear wheel house inner panel 22 Side sill outer 23 Dash panel lower 24 Side sill inner 25 Front floor pan 26 Rear floor pan 27 Rear wheel house outer panel 28 Side panel inner ...

Page 34: ...1 Side panel inner upper 14 Rear roof rail 15 Rear end panel inner upper 16 Fender shield extension 17 Dash panel upper 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 Cowl top extension Front pillar inner lower Front pillar outer Drip channel Rear wheelhouse inner panel Side sill outer Dash panel lower Side sill inner Front floor pan Rear floor pan Rear wheelhouse outer panel Side panel inner low...

Page 35: ...COMPONENT SERVICE BODY PANELING CROSS SECTIONS OF SHELLTO BODY JUNCTIONS I i 23 7 ...

Page 36: ...COMPONENT SERVICE BODY PANELING z Z r ff JI 23 8 ...

Page 37: ...I4 A F 7 0 18W590 B B I D D 4 F 18W589 E E 18W594 ...

Page 38: ...COMPONENT SERVICE BODY PANELING 7 A 0 23 10 ...

Page 39: ...COMPONENT SERVICE MOUNTING COMPONENTS 1 Body mounting rubber A 2 Spacer 3 Body mounting rubber B Nm ft lbs G 28 32 20 23 A 18W658 18W635 18W635 18W635 18W658 23 11 ...

Page 40: ... can also be sold in Federal States 16 Oxygen sensor connector 17 Carburetor control wiring harness 18 Air temperature sensor connector 19 Water temperature sensor connector Under body and rear of body 1 Disconnect the hydraulic clutch hoses from the body 2 Disconnect the brake pipes and BPV blend propor tioning valve 18W618 3 Remove the steering shaft from the steering gear box Refer to GROUP 19 ...

Page 41: ...h the grommets out downward 18W623 12 Disconnect the front harnessand frame harness 13 Remove the frame harness grommet 18W625 14 Remove the filler neck from the body 15 Remove the transmission gearshift lever and transfer gearshift lever Refer to GROUP 21 16 Disconnect the parking brake cable from the parking brake lever 17 Remove the parking brake cable mounting bolts from the floor Refer to GRO...

Page 42: ...h a crane 18W628 HOOD COMPONENTS 1 Hood panel 2 Hood hook 3 Hood lock 4 Hood support rod 5 Rod bushing 6 Hood bumper 7 Hood damper 8 Hood release cable 9 Hood release knob 10 Release cable bracket 11 Hood hinge 12 Hood iear weatherstrip 13 Hood heat protector metal top vehicle Nm ft lbs A 3 540 2 5 2 9 18W811 23 14 ...

Page 43: ...W567 NOTE Apply chassisgrease to the sliding part the rotating part and the spring of the hood lock HOOD HINGE REPLACEMENT To replace the hood hinges use a hood hinge kit and follow these procedures 1 Remove the hood from the hood hinges Caution Protect the front deck with a rag so that the hood protru sions do not damage it 2 Remove the hood hinges Use an 8 mm 32 in drill to break the spot welds ...

Page 44: ...acilitated if adhesive 3M Super Weatherstrip Adhesive 8001 is applied to the surfaces of the brackets in contact with the front deck 6 Install the hood 7 Adjust the hood alignment 18W506 I 7 w 18W506 HOOD REAR WEATHERSTRIP REPLACEMENT 1 Remove the hood rear weatherstrip mounting clips 2 Remove the hood rear weatherstrip 3 Apply a drying sealant to and around the two hood rear weatherstrip mounting...

Page 45: ...rotector Nm ft lbs A 18 25 13 18 8 10 13 7 9 18W654 BUMPERS COMPONENTS 2 3 I 1 Bumper guard 2 Front bumper side 3 Bumper stay assembly 4 Front bumper center 5 Rear bumper center 6 Rear bumper side 7 Rear bumper side support 7 6 18W662 REMOVAL Front Bumper Remove the front bumper from the frame 23 17 ...

Page 46: ...BUMPERS COMPONENT SERVICE BUMPERS Bumper Guard Bumper Guard Remove the bumper guard from the center sf the front Remove the bumper guard from the center sf the front bumper bumper 1 1 Rear Bumper Remove the rear bumper fr6m the frame 23 18 ...

Page 47: ...Waterproof pad 4 Air duct 5 Rubber packing 6 Front fender 7 Splash shield REMOVAL 1 Remove the front combination light mounting screws I 18W632 2 Disconnect the front combination light connector and remove the front combination light 3 Remove the headlight bezel I I I 18W5OG 23 19 ...

Page 48: ... damp er 9 Remove the front fender 18WS 15 I INSTALLATION 1 Apply a nondrying sealant to the flange part of the fen der when installing the splash shield 18W5 15 2 Apply a non drying sealant to the entire top part of fender 18W515 3 Mount the fender temporarily in position make sure that clearance is uniform at all points and th en tighten it securely Bolt i 1 h3w51c I I I 18w515 23 U ...

Page 49: ... outlet garnish l8W577 18W633 REMOVAL Radiator Grille Remove the radiator grille mounting screws and then remove the radiator grille upward Air Outlet Garnish 1 Remove the air outlet garnish mounting screws 1 SWSO2 2 Remove the rear pillar trim Refer to p 23 59 18W502 23 21 ...

Page 50: ...COMPONENT SERVICE u M lfLD NGS 3 Remove the air outlet garnish mounting nut and then remove the air outlet garnish MUD GUARD COMPONENTS 23 22 ...

Page 51: ... rubber seal Back door window weatherstrip Back door window glass 18W636 WINDSHIELD GLASS Removal 1 Remove the wiper arms dome light and sun visors 2 Using a screwdriver push the upper moulding joint to the right or left until the moulding ends appear 3 Insert the screwdriver between the jointed ends of the moulding and pry them out of the weatherstrip Then remove the moulding by hand 1SW558 4 Ins...

Page 52: ...ly soapy water to the entire periphery of the body flange 4 Place the glass in positioA from outside with the cords placed inside the passenger compartment 1 I 18W571 5 With the aid of an assistant to push the glass from out side slowly pull one end of the cord at right angles to the windshield glass and fit the lips of the weatherstrip correctly on the windshield flange NOTE Pull the cords workin...

Page 53: ...emoval 1 Remove the defogger terminal 1SW589 2 Remove the rear wiger arm Refer to GROUP 8 3 Remove the weathersfrip and then remove the window glass Installation Apply recommended adhesive to the weatherstrip Recommended adhesive 3M Super Weatherstrip Adhesive 800 1or equivalent QUARTER WINDOW GLASS Removal 1 With the glass in position push the quarter window assembly outward while raising the lip...

Page 54: ...remove it after removing the weatherstrip Installation 1 After the quarter window rear glass has been installed install the stopper by applying a drying type adhesive 2 Follow the same installation procedure as for the wind shield glass Refer to p 23 24 and p 23 25 I II18165 Quarter window glass F I D18586 23 26 ...

Page 55: ...e 18 Inside handle cover 19 Door upper trim metal top vehicle 20 Waterproof film 21 Door trim 22 Armrest 23 Ventilator window weatherstrip 24 Ventilator window glass 25 Ventia tor sash 26 Center sash protector 27 Window glass runchannel 28 Window glass 29 Door glass pad 30 Glass holder 31 Door lower sash 32 Regulator han dle 33 Escutcheon 34 Clip 35 Window regulator 36 Lock handle 37 Power window ...

Page 56: ... Striker Adjustment t 1 Adjust the vertical and lateral positions of the door striker by moving the striker itself S1864 1 2 Insert shim s as necessary to adjust the longitudinal position of the striker S186p 1 Door GlassAdjustment 1 Remove the door trim and the waterproof film from the door Refer to p 23 30 f 2 Loosen the screws and or bolts which secure the venti lator window and rear lower sash...

Page 57: ...ide handle rod and then turn it right or left to adjust the play Inside Handle Adjustment Move the inside handle to the right or left in order to adjust the play REMOVAL Door Assembly 1 Remove the spring pin from the door check 2 Position a jack beneath the door at the center to support it 3 For vehicles equipped with power windows disconnect the front harness and door harness and then remove the ...

Page 58: ...nsert the tip of a screwdriver between the window regulator and the door trim and remove the clip 188734 4 Remove the regulator handle 5 For vehicles equipped with power windows remove the switch cover 6 Using a screwdirver pry up and detach the door trim clips 18W584 7 Remove the door trim 23 30 I i Clip N 18K107 ...

Page 59: ...ve the outer jweatherstrip toward the rear 3 Remove the inner weatherstrip with a screwdriver 4 Lower the door glassto the accesshole position 5 For vehicles equipped with power windows remove the power window switches 16W774 6 Peel the waterproof film off carefully to avoid damaging it 7 Remove the retaining screws lator window and bolts from the venti 23 31 ...

Page 60: ...entilator window 9 Remove the ventilator window by pulling upward 10 Remove the glass mounting bolts from the glass holder lSW517 _ NOTE When removing the glassmpunting bolts support the glassto prevent it from falling I 1 Gently remove the door g assupward while tilting it 18W517 58 23 32 ...

Page 61: ...t does not fall when bolts are removed 14 Remove the regulator assembly through the accesshole 15 Remove the mounting bolts and remove the lower sash through the accesshole 18873 1 18W522 Power Window Motor vehicles equipped with power windows only Remove the power window motor from the window regu lator Caution Because the force of the regulator spring may cause the regulator arm to jump up when ...

Page 62: ...handle rod is removed the rod sna pmust be replaced with a new one when the handle rod is reinstalled 2 Disconnect the inside handle rod from the latch and then remove it with the inside handle 3 Disconnect the outside lock rod from the lock cylinder lSW566 4 Remove the lock cylinder retainer and the lock cylinder 5 Remove the door latch assembly and rods 52 I 23 34 ...

Page 63: ...k door hinges for cracks damage or abnormal noise 2 Check door hinge attaching bolts for looseness 3 Check mouldings for cracks or damage 4 Check door panel for damage or deformation 5 Check door regulator for wear or damage 6 Check door glass runchannel for wear damage or defor mation 7 Check door inside handle and latch for wear damage or malfunction NOTE For the inspection procedure for the pow...

Page 64: ...ing the window regulator on vehicles equipped with power windows first install the regulator spring and then proceed with the assembly Waterproof Film Apply nondrying adhesive as shown in the illustration and then attach the waterproof film Door Runchannel Apply a drying adhesive to the positions shown in illustration and install the door runchannel I 76 5 77 5 466 5 467 5 3 0 3 1 18 4 18 41 mm in...

Page 65: ...dow strip and then mount it onto the ventilator window weather Door Hinges Apply chassisgrease to the sliding parts of the door hinges Door Regulator Apply chassisgrease to the sliding parts and rotating parts of the door regulator Door Latch Apply chassisgrease to the sliding parts of the door latch 23 37 ...

Page 66: ...d 5 15 Outside handle rod 16 Door pull handle 17 Latch 18 Outside handle 19 Inside handle rod 20 Inside handle cover 21 Spare tire carrier 22 Back door garnish bracket 23 Back door garnish Nm ft lbs A 3040 22 29 B 8 10 5 8 7 0 Metal top vehicle 16W677 ADJUSTMENT 1 Adjust the door fit by adjusting the position Iof the door striker and or increasing or reducing the number of shims Refer to p 23 28 2...

Page 67: ...el the waterproof film off carefully to avoid damaging it 4 Disconnect the following points 18W53 1 1 Defogger connector 2 Rear washer tube joint 3 Rear wiper connector 5 Remove the back door hinge mounting bolts and then remove the back door 18W532 6 Remove the hinge mounting bolts from the body and then remove the hinges 18W532 Door Trim 1 Remove the inside handle cover 18W5321 23 39 ...

Page 68: ...l handle plug and remove thle door pull handle Plug Dooi Handle and Door Latch 1 Remove the door trim and the waterproof film 2 Remove the back door garnish 18W535 3 Disconnect the outside handle rod from the outside handle and then remove the outside handle 18W534 23 40 ...

Page 69: ...e rod from the inside handle 5 Disconnect the outside lock rod and the inside lock rod from the lock cylinder 18W538 6 Remove the lock cylinder retainer and the lock cylinder 7 Remove the door latch assembly together with the rods Door Opening Weatherstrip Remove the door opening weatherstrip with the tool shown in the illustration ...

Page 70: ... hinge attaching bolts for looseness 3 Check door panel for damage or deformation 4 Check door inside handle and latch for wear damage or malfunction INSTALLATION Waterproof Filni Apply nondrying adhesive at the positions shown in the illustration and then attach the waterproof film Ii 8W675 Door Hinges Apply chassisgrease to the sliding parts of the door hinges Door Latch Apply chassisgrease to t...

Page 71: ...me 6 Rear cover 7 Rear cover bracket 8 Side cover 9 Side cover bracket 10 Roof cover retainer 11 Plate ADJUSTMENT Perform roof cover tension adjustment by the following procedures Side Rail Release the tape of the fixing band of the side rail and adjust tension by changing the length of the band W69034 When loosened When tightened 23 43 ...

Page 72: ...ing the side and rear curtains to the plate 3 To make sure that the Jock pin of the plate fits in the lock hole adjust tension by moving the plate up and down REMOVAL Roof Cover Assembly 1 Remove fasteners and fixed portions of the rear and side curtains 2 Pull the roof cover upward from the side rail 69W022 I I WfslO37I w o38 23 44 ...

Page 73: ...it from the side Undo the fixing tapes of roof cover from inside the room 5 First pull the band on the rear side of the roof cover retainer While holding the roof cover retainer up pull the band on the front side of the roof cover retainer 6 Raise the roof cover retainer and remove the fastening band rlxlng tapes I 69WO2 W6907 1 23 45 ...

Page 74: ...al fittings etc to strike the body Roof Cover Front Retainer Remove the roof cover front retainer from the roof Roof Cover Retainer and Roof Cover Bow 1 Remove the roof cover lock attaching screws and remove the roof cover retainer 18W570 2 Remove the roof cover bow 18W570 Roof Cover Frame 1 Detach the roof cover frame from the ce nter pillar i8W540 _ 2 Pull the rear of roof cover frame upward to ...

Page 75: ...NENT SERVICE FOLDING TOP Side Cover Retainer Remove the side cover retainer Side Cover Bracket 1 Remove the side cover 2 Remove the side cover bracket Rear Cover Bracket 1 Remove the rear cover 1 18W54 23 47 ...

Page 76: ...bows for bending 5 Check the roof cover lock pin mounting nuts for loose ness 6 Check the roof cover frame for deformation and damage INSTALLATION Mount the roof cover securely so that it is neither too loose nor too tight Caution Be sure that the roof cover is securely connected to the vehicle body and to the top frame When installing the cover to the front rail be sure to fit it in correctly as ...

Page 77: ...NENT SERVICE STRIPE TAPE COMPONENTS Vehicles with a P line only Metal top vehicles with a P line only II I 10W647 1 2 4 1 Fender tape 2 Front door tape 3 Rear door tape 4 Quarter tape 5 Back door tape 23 49 ...

Page 78: ... INSTALLATION C D of back door Back door opening line Door line 18WO48 NOTE Using a rag soaked in unleaded gasoline wipe any grease from the body surfaces where the tapes are to be attached 16W670 10W647 Door opening line mm in 1 18W646 23 50 ...

Page 79: ... 2 Use the spatula to press on the tape beginning at the center and moving evenly to both the top and bottom in order to remove any trapped air bubbles C18156 Caution If the spatula is slid to the side there will be slack at the end of the tape causing wrinkles and the tape may deviate from the correct application position 3 If the tape is not applied properly it may come off later pull the backin...

Page 80: ...ring wheel Refer to GROUP 19 Remove the center console Refer to p 23 55 Remove the combination meter Refer to GROUP 8 Remove the combination gauge Refer to GROUP 8 Remove the lap heater ducts B and C and the release cable bracket 19W53 1 Remove the heater control assembly Refer to GROUP 24 7 Remove the fuse cover and then the fuse block mounting screws Push the fuse block into the instrument panel...

Page 81: ... box stopper has been removed null the glove box toward you and then disconnect the heater relay from the front wiring harness 12 Remove the instrument panel mounting bolts and nuts and then remove the instrument panel 19W534 Glove Box 1 Remove the glove box stopper 2 Remove side lap heater duct B on the passenger seat side Refer to GROUP 24 3 Remove the glove box frame mounting bolts from the ins...

Page 82: ...securely Make sure that the wiring harnessesare not pinched Adjust the heater control wires Refer to G ROUP 24 When installing the glove box first temporarily tighten the screws and then after checking the top 1e ftand right clearances between the glove box lid and the instrument panel with the lid closed tighten the screwis 19W525 19W522 I 19w525 19w522 23 H ...

Page 83: ... Remove the radio switch knobs and the radio panel Remove the center panel mounting screws Slightly pull off the center panel Disconnect the front harness to center panel harness connector and the antenna lead wire Remove the center console assembly Disconnect the radio and car stereo player from the front harness Remove the center reinforcement and backbone bracket mounting screws Remove the cent...

Page 84: ... Am Q 0 n COMPONENT Sf RVICE FLOOR CONSOLE Floor Console 1 Remove the floor console 1QW52r 2 Remove the tray plate A or the console and plate B from the floor console I 19w528 23 56 ...

Page 85: ...ening trim canvas top vehicle 12 Rear scuff plate 13 Quarter trim 14 Ashtray left side only 15 Rear wheelhouse trim 16 Center pillar lower trim 17 Rail cover REMOVAL Door Opening Trim 1 Remove the rail cover 2 Remove the door opening trim Cowl Side Trim 1 Remove the door opening trims 2 Insert special tool MB990784 under the cowl side trim and remove the clips 19W508 3 Remove the cowl side trim Fr...

Page 86: ...wer trim 19W579 4 Being careful of the double faced tape pull the center pillar upper trim out from the quarter window weather strip 19W579 Quarter Trim 1 Remove the ashtray L H 2 Insert special tool MB990784 under the quarter trim and remove the clips 19W582 3 Remove the quarter trim Wheelhouse Trim 1 Remove the rear seat Refer to P 23 68 2 Undo the hooks and remove the wheelhouse trim NOTE When ...

Page 87: ...m the quarter window weatherstrip 19W578 Rear Opening Trim Remove the rear opening trim Rail Cover Sun Visors 1 Remove the screws and then remove the rail covers 19WS0 2 2 Remove the screws and then remove the sun visors and sun visor holders 19W519 Rear view Mirror 1 Remove the rear view mirror cover S19527 2 Remove the screws and then remove the rear view mirror S19528 23 59 ...

Page 88: ...of rail trim 8 Front roof rail trim 9 Assist grip 19W58l REMOVAL Assist Straps 1 Remove the assist strap caps 19S565 2 Remove the assist strap mounting screws and then remove the assiststraps 198565 Front Rail Trim 1 Remove the front pillar trim Refer to P 23 5 7 2 Remove the rear view mirror Refer to P 23 59 3 Remove the sun visor holders Refer to P 23 59 4 Remove the front rail trim 19WO52 4r 1S...

Page 89: ...of Rail Trim 1 Remove the assiststrap 2 Remove the center pillar upper trim Refer to P 23 58 3 Pull the rear side roof rail trim out from the quarter p _ window weatherstrip 19WO60 Rear Roof Rail Trim 1 Remove the rear opening trim 2 Remove the rear roof rail trim 19WO53 Headlining 1 Remove the roof rail trim 2 Remove the dome light mounting Screws and then remove the dome light 19W553 23 61 ...

Page 90: ... sponge are thorough ly removed as they produce uneven surfacesLwhen the head lining is bonded to the roof panel INSTALLATION 1 Evenly apply adrying sealant to the roof panel 2 When installing the rear headlining connect the dome light connector pass it through the hole in lthe lining and then bond the lining so that the hole matches the dome light mounting hole 19W552 3 Using care to prevent wrin...

Page 91: ...lel link assembly 9 Seat support brakcet 10 Suspension assembly 11 Seatback rear 12 Seat cushion rear 13 Rear seat stopper Nm ft lbs Front seats A 10 14 7 10 B 32 49 23 35 FRONT SEATS Removal 1 Detach the seat from the floor panel and remove the seatassembly 19W536 19W517 2 Detach and separate the seat cushion from the bracket of the seat assembly I 19W536 1 19w517 I 23 63 ...

Page 92: ... and lock securely SUSPENSION SEAT Outline The suspension seat has a special suspension mechanism in the base frame and is installed on the driver s seat side When the vehicle travels on an uneven ground surface or rough road the seat absorbs the body vibration the vehicle takes from the road surface reducing driver fatigue and assuring a more comfortable ride The seat offers the following feature...

Page 93: ...usting mechanism is constructed as shown in the illustration at right When the handle is turned to match the driver s weight the coil spring secured to the upper bracket at one end and mounted through alink at the other is displaced in the direction of the arrow by movement of the nut at the end of the shaft of the handle so the spring tension changes Clockwise rotation of the handle increases the...

Page 94: ...ge 5 Check links for cracks bending or dents 6 Check body weight adjusting handle for bends damage or looseness 7 Check lock lever for bends and damage 8 Check damper rubber for cracks and damage DISASSEMBLY 1 Turn the body weight adjusting handle counterclockwise all the way body weight scale reading should be less than 50 kg 2 Lock the lock lever in the upper level position 19WO18 3 Turn the sus...

Page 95: ...Ol9 t NOTE Before removing the indicator make note of its position for use during reassembly 6 Using a screwdriver remove the link side coil spring 7 Remove the upper bracket side link mounting bolts and nuts Indicator 8 Remove the lower bracket side link mounting snap ring and then remove the shaft 23 67 ...

Page 96: ...entical ones REAR SEAT Removal Fold the seat cushion forward and down remove the mount ing bolts and then remove the rear seat Installation 1 Apply recommended multipurpose grease to the follow ing places 19W510 Recommended grease Multipurpose grease SAE 53lOa NLGI grade 2EP 1 Sliding part of rear seat stopper 2 Contacting part of rear seat stopper striker 2 After the seat has been installed check...

Page 97: ...e stalk Rear seat belt 5 Rear seat belt inner Nm ft lbs A 23 65 17 47 19wo41 19W563 FRONT SEAT BELTS Removal 1 Remove the center pillar trim Refer to p 23 58 2 Remove the shoulder anchor plate 19W5 12 3 Remove the screws of the seat belt guide located at the center of the belt 19WS 13 I I lQW512 23 69 ...

Page 98: ...into the hole in the side sill 19W546 2 Fit the anchor plate anti turning boss securely into the retractor side hole and jointly tighten the retractor and the anchor plate 19W543 3 Install the shoulder anchor plate 4 Install the seat belt guide 5 Install the sashguide coyer 19W540 NOTE After installation check to ensure that the sashguide rotates smoothly 6 Install the seat belt buckle stalk paral...

Page 99: ...in bolts are used for the seat belt moun bolts ting Installation Position the anchor plates at the center of the vehicle so that the belts are parallel to the vehicle center line and then secure the plates with the bolts 19W5 15 19W516 19w515 19W516 1 Parallel to center line of vehicle Wheelhouse 23 71 ...

Page 100: ...ING 4 SERVICE ADJUSTMENT PROCEDURES 6 SERVICE BRAKE PEDAL INSPECTION AND ADJUSTMENT 6 PARKING BRAKE STROKE ADJUSTMENT 7 BRAKE BOOSTER OPERATING TEST 7 BLEND PROPORTIONING VALVE FUNCTION TEST I 8 BLEEDING 8 COMPONENT SERVICE 9 BRAKE PEDAL 9 BRAKE MASTER CYLINDER 11 BRAKE BOOSTER 14 BRAKE LINES 15 FRONT DISC BRAKES 16 REAR DRUM BRAKES 22 PARKING BRAKES i 27 5 l ...

Page 101: ...rear wheels Brake engagement Lever type Cable routing V type SERVICE SPECIFICATIONS Standard values Brake pedal height mm in Stop light switch outer case to pedal arm clearance mm in Brake pedal free play mm in Brake pedal to floorboard clearance mm in Booster push rod to master cylinder piston clearance mm in Disc brake dragging force N lbs Brake shoe outside diameter mm in Parking brake lever st...

Page 102: ...asher Brake booster push rod seal lip Brake booster push rod perimeter Brake booster push rod body perimeter Plug plate and stopper plug Caliper bore Dust boot mounting groove in caliper body Rear brake piston and wheel cylinder Contact surfaces at shoe assemblies and backing plate Rotating portion of shoe adjuster assembly Clevis pm and bushing and ratchet plate DOT 3 Multipurpose grease SAE J310...

Page 103: ... Loose suspensioq parts Retighten Difference in left land right tire inflation pressures 9 Grease or oil on pad or lining surface Drum eccentriciiy or uneven wear Replace Incorrect wheel cylinder iristallation Auto adjuster malfunctioq Correct Correct a 8 Low or deteriorated brake fluid Replenish or change Air in brake systk m Bleed the system Brake booster m alfunction Correct Inadequate contact ...

Page 104: ...pring Lack of lubrication in sliding parts Remedy Correct Adjust Replace Correct Replace Lubricate Defective master cylinder check valve Replace or piston return spring Excessive push rod to master cylinder clearance Worn brake lining Grease or oil on lining surface Parking brake cable sticking Auto adjuster malfunction Excessive parking brake lever stroke Adjust Replace Correct Adjust the parking...

Page 105: ... 14591 Dimension B 0 5 1 0 mm 02 04 in 2 While the engine is stopped depress the brake pedal two or three times After thus eliminating the vacuum in the power brake booster press the pedal down by hand and confirm that the amount of movement before resistance is met the free play is within the standard v alue range Brake pedal free play C 1 15 mm 4 6 in If the free play is less than the standard v...

Page 106: ...tests 1 Run the engine for one or two minutes and then stop it Step on the brake pedal several times with normal pres sure If the pedal depresses fully the first time but gradu ally becomes higher when depressed succeeding times the booster is operating properly If the pedal height remains unchanged each time the booster is defective 2 With the engine stopped step on the brake pedal several times ...

Page 107: ...ke hydraulic system should be bled whenever the brake tube brake hose master cylinder or wheel cylinder has been removed or whenever the brake pedal feels sfiongy when depressed Bleed the brake system in the sequence shown in the illust ration S14594 Recommended brake fluid DOT 3 Caution 1 Use the recommended brake fluid Avoid using a mixture of the recommended brake fluid and other fluid 2 If bra...

Page 108: ...transmission REMOVAL Brake Pedal 1 Remove the return spring and stop light switch 2 Remove the cotter pin that connects the operating rod of the brake booster to the brake pedal 14W525 3 Remove the bolt that attaches the brake pedal to the pedal support member 4 Remove the brake pedal Brake Pedal Support 1 Remove the steering column assembly Refer to GROUP 19 2 Remove the brake pedal 3 Remove the ...

Page 109: ...ting 4 Check brake pedal return spring for damage INSTALLATION I 1 Apply the specified multipurpose grease to the bushing and the spacer Y 14590 Recommended multipurpose grease SAE 53109 NLGI grade 3 2 Apply the specified multipurpose grease to thle clevis pin and washer Y 14187 Recommended multipurpose grease SAE J31Oa NLGI grade 2EP 5 10 Y 14590 Y1418 ...

Page 110: ...eck valve case 15 Tube seat 16 Check valve cap 17 Secondary piston 18 Primary piston 19 Piston stopper ring A 6 C D Nm ft Ibs 1 5 3 0 l 2 40 50 29 36 25 35 18 25 8 12 6 9 REMOVAL 1 Disconnect the harness connector of the fluid level sensor 2 Detach the brake tubes from the master cylinder 14W507 3 Remove the master cylinder from the brake booster 14W507 DISASSEMBLY 1 Remove the reservoir 2 While d...

Page 111: ...on 6 Check the clearance between master cyljnder inner diameter and piston outer diameter asfollows Clearance between Master Cylinder Iruiei Diameter and Piston Outer Diameter 1 Measure of the master cylirider inner diametler at three different positions bottom middle and top by using a cylinder gauge 14E 108 Master cylinder to piston clearance Service limit 0 15 mm 006 in 2 If the clear e between...

Page 112: ... A A B C D O l 0 5mm 004 020 in NOTE If the clearance is not within the standard value range adjust by changing the push rod length by turning the screw of the push rod Caution Insufficient clearance may cause excessive brake drag 2 Make sure that the brake pedal free play is within the standard value range Brake pedal free play lo 15 mm 4 6 in 3 Torque all parts to specifications during assembly ...

Page 113: ...eck valve 2 If the air passesthrough when you blow from the booster side but not when you blow from the engme side the check valve is functioning properly INSTALLATION 1 Check the booster push rod to master cylinder piston clearance Refer to p 5 13 2 Install the check valve being careful that the direction of installation is correct 3 Fasten the vacuum hose securely to prevert air leaks from the c...

Page 114: ...e and leakage INSTALLATION 1 Install the brake hoses being careful not to twist them 2 The brake tubes should be installed away from sharp edges weld beads or moving parts 3 Tighten the connections to the specified torque Flare nuts tightening torque 13 17 Nm 9 12 ft lbs BLEND PROPORTIONING VALVE tB P V 1 Connect the brake tubes in accordance with the arrows marked on the B P V body 14363 1 Cautio...

Page 115: ...y 13 Piston 14 Piston seal 15 Piston boot 16 Boot ring 17 Dust cover 18 Brake disc Nm ft lbs A 7 9 5 J B 70 90 51 65 C 50 60 36 43 148660 BRAKE PAD INSPECTION 1 Check the pads for wear 2 If the pad thickness is less than the service limit replace the pads 9 z I ke pad thickness Service limit 1 mm 04 in F _ 3 BRAKE PAD REPLACEMENT Removal 1 Remove the spigot I S 2 Remove the stopper plugs and remov...

Page 116: ...itable means in such a manner so that the brake hoses are not twisted 4 Remove the pad outer shim pad clips and anti rattle springs from the mounting support Installation 1 Install the anti rattle springs pad clip B inner pad clip and outer pad clip onto the mounting support S14112 2 Install the pads together with the outer shim 3 Bottom the piston into the caliper bore 143607 5 17 ...

Page 117: ...to measure the brake drag S14105 I 5 Remove the brake pads and use the spring scale to meas ure the rotational force The difference between brake drag and rotational force should not exceed the standard value Brakedrag 74N 16 lbs NOTE If the difference exceeds the standard value remove the cali per body and disassemble it Check the piston a nd seal for deterioration corrosion dirt or scoring FRONT...

Page 118: ...plied behind the piston 2 Be sure to keep your fingers away from the front of the piston during removal 3 Remove the piston seal E 14620 Caution Be careful not to damage the caliper bore The piston seal must be replaced with a new one 4 Clean the caliper bore with alcohol or brake fluid 1 E1462C Inspection 1 Check mounting support for cracks 2 Check caliper body for cracks or rust of cylinder port...

Page 119: ... DOT 3 3 Apply the specified brake grease to the piston boot mounting groove in the caliper body Y 14541 Recommended brake grease Repair kit grease orange 4 Install the piston boot and retain it with the boot ring Installation 1 Bleed the air from the caliper 2 Check the brake drag Refer to p 5 18 BRAKE DISC Inspection BRAKE DISC WEAR If the brake disc thickness becomes lessthan the service limit ...

Page 120: ...hickness of brake disc Service limit 18 4 mm 72 in Caution Do not grind the brake disc beyond the service limit 14F612 Removal 1 Remove the front brake assembly and use wire to sup port it 2 Remove the front hub assembly from the knuckle 3 Make mating marks and then disassemble the brake disc from the hub 12F013 Installation 1 Align the mating marks and assemble the brake disc to the hub 2 Check t...

Page 121: ...d down spring 14 Shoe retainer spring 15 Brake drum Nm ft Ibs A J 9 5 J B 18 2 1 13 15 C 50 60 36 43 6 REMOVAL 1 Remove the brake drum NOTE If it is hard to remove the brake drum install two bolts M8 x 1 25 into the threaded holes provided in the drum flange surface 143609 2 Disconnect the parking brake cable from the shoe and lever assembly 3 Remove the shoe return spring shoe retainer spring and...

Page 122: ...m 04 in 2 Use a caliper gauge to measure the inside diameter of the brake drum D14144 Brake drum inside diameter Service limit 256 mm 10 08 in 3 If the brake lining or brake drum wear exceeds the service limit replace the parts WHEEL CYLINDER PISTON CUP REPLACEMENT 1 Remove the wheel cylinder to backing plate retaining bolt 2 Detach the wheel cylinder boot and remove the piston assembly F 14100 3 ...

Page 123: ...tion In order to keep the piston cup from becoming twisted or slanted slide it down the tool slowly and carefully without stopping 8 Use the brake fluid to clean the cylinder wall and the piston Recommended brake fluid DOT 3 9 Apply the brake fluid to the wheel cylinder walls and the piston cup and then install the piston assembly 14Y553 10 Apply a sufficient amount of grease to both ends of the p...

Page 124: ...e adjuster and shoe return spring and install the shoe and lining assembly and the shoe and lever assembly 14W504 Caution Note the differences between right and left brake shoe adjusters and between right and left shoe return springs and install them in the correct position The shoe return spring should first be installed to only the shoe and lever assembly 5 After the shoe hold down pin and shoe ...

Page 125: ...outer diameter of brake shoes to the standard value will also facilitate adjustment of the shoe clearance 14W503 8 Check to ensure that the parking brake cable is loose before installing the brake drum 9 Pull the parking brake lever repeatedly to adjwt the shoe clearance Refer to p 5 29 10 Adjust the parking brake lever stroke Refer to p 5 7 11 Torque all parts to specifications during installatio...

Page 126: ... the cable adjuster from under the vehicle and disconnect the parking brake cable and equalizer 14WSO6 3 Disconnect the parking brake switch connector 4 Remove the parking brake shaft cover mounting bolts The parking brake shaft cover is fasten to the stay together with the ratchet plate Pakking Brake Cable 1 Loosen the parking brake lever 2 Remove the parking brake cable clamps from the leaf spri...

Page 127: ...Using a screwdriver draw out the parking brake cable from the backing plate INSPECTION 1 Check bushing for wear 2 Check parking brake switch for malfunction 3 Chkck parking lever latch for wear 4 Check parking brake cable for damage and rough opera tion INSTALLATION Parking Brake Lever Assembly Apply the specified multipurpose grease to the clevis pin bushing and ratchet plate Recommended multipur...

Page 128: ...omes constant to adjust for proper shoe clearance Adjust the parking brake lever stroke to the standard value with the cable adjuster Parking brake lever stroke 4 6 clicks Release the parking brake lever remove the brake drum and check to ensure that the brake lever adjuster is touch ing the shoe 14W509 Caution If the parking brake cable is pulled too far the adjuster lever will not fit the adjust...

Page 129: ...ERAL SPECIFICATIONS 2 SERVICE SPECIFICATIONS 2 TORQUE SPECIFICATIONS 2 LUBRICANTS 3 TROUBLESHOOTING 3 SERVICE ADJUSTMENT PROCEDURES 4 E CLUTCH PEDAL INSPECTION AND ADJUSTMENT 4 BLEEDING 4 COMPONENT SERVICE 5 CLUTCH ASSEMBLY 5 CLUTCH CONTROL 8 6 l ...

Page 130: ... We 3 432 772 264 10 39 Angular contact self centering type 1 6 06 19 05 75 SERVICE SPECIFICATIONS Standard value Clutch pedal height Clutch pedal free play Clearance between clutch pedal and floorboard when pedal is depressed Service limit Clutch disc Rivet sink 186 191 7 3 7 5 5 10 2 4 35 1 4 or more 0 3 012 mm in TORQUE SPECIFICATIONS Clutch to flywheel Flywheel to crankshaft Release cylinder t...

Page 131: ...ch pedal free play Interference between pedal and floor panel Pilot bearing worn or broken Clutch disc warped Pressure plate disc or throwout bearing damaged Hydraulic system failure Facing stained with oil or grease Weak or broken disc damper springs Improper facing contact or disc runout Pressure plate or flywheel warped Loose engine mounting Release bearing broken worn or poorly lubricated Pilo...

Page 132: ...al several times and check the clutch pedal to floorboard clearance is within the standard value range when the clutch is disengaged Pedal to floorboard clearance C when pedal is de pressed 35 mm 1 4in ormore 4 If the clutch pedal to floorboard clearance is less than the standard value air mixture in hydraulic system or defective clutch assembly is suspected Bleed the hydraulic system or repair th...

Page 133: ...nder 6 Release fork boot 7 Return clip 2 8 Clutch release bearing 9 Release fork 10 Fulcrum 11 Bolt 6 12 Clutch cover assembly 13 Clutch disc NOTE Numbers show order of disassembly For reassembly reverse order of disassembly A B C D Nm ft lbs 43 53 32 39 30 41 22 30 30 41 22 30 15 21 II 15 Clutch cover assembly Release fork Clutch release cylinder 6CLO12 6 5 ...

Page 134: ...r direction will result in damage to clip INSPECTION Clutch Disc Check facing for wear Replace excessively worn facing Wear is measured from facing surface to rivet head 6CLOO3 Clutch disc rivet sink Service limit 0 3 mm 012 in Clutch Cover Assembly Inspect diaphragm spring for excessive wear of fingers and looseness of strap rivets and inspect pressure pla te for scor ing Replace if damage is evi...

Page 135: ...sc spline and main drive gear spline of transmission Release bearing I 5 Using a universal clutch alignment tool or the main drive gear of transmission install clutch disc and clutch cover assembly on to flywheel 6CLOO4 6 When installing clutch disc be sure that surface having manufacturer s stamped mark is on pressure plate side Caution When installing transmission do not shake it or install in s...

Page 136: ...per bolt 8 Lock nut Nm ft lbs A 25 35 18 25 B 8 12 6 9 5 6 Clutch Master Cylinder and Tube 1 Reservoir cap 2 Reservoir 3 Clutch master cylinder 4 Sealer 5 Piston assembly 6 Piston stop ring 7 Piston boot 8 Damper and push rod assembly 9 Clutch tube 10 Clutch hose 11 Gasket 12 Eye bolt Nm ft lbs A 20 25 15 18 B 1317 10 12 C 7 9 5 7 D 8 12 6 9 05w501 6 8 ...

Page 137: ... tube from the master cylinder 5 Remove the master cylinder OSW 502 6 Disconnect the clutch hose from the clutch tube and release cylinder OSW504 7 Remove the clutch tube I OBW504 INSPECTION 1 Check sealer for damage 2 Check master cylinder or clutch hose for fluid leakage 3 Check clutch hose and tube for cracks or clogging 4 Check pedal shaft bushings for wear 5 Check pedal arm for bending and tw...

Page 138: ... specified brake fluid to the inner surpce of the cylinder and to the entire periphery of the piston assembly Y085 17 Recommemded brake fluid DOT 3 INSTALLATION 1 After tightening the clutch tube flare nut and eye bolt check to be sure there is no leakage of the clutch fluid 2 Apply specified multipurpose grease to the pedal shaft and bushings Y085 19 Recommended multipurpose grease SAEJ3 1Oa NLGI...

Page 139: ... clutch release cylinder assembly 3 Remove the boot and push rod and take out piston and spring Inspection 1 Check inside cylinder body for rust or scoring 2 Check piston cup for wear or deformation 3 Check piston for rust or scoring Reassembly and Installation 1 2 3 4 5 6 Insert spring into release cylinder Apply brake fluid to outer surface of piston piston cup and cylinder bore DCL006 Install t...

Page 140: ...ONS LUBRICANT TROUBLESHOOTING SERVICE ADJUSTMENT PROCEDURES COOLANT LEAK CHECK RADIATOR CAP PRESSURE TEST 4 5 5 5 SPECIFIC GRAVITY TEST 5 FAN BELT TENSION ADJUSTMENT 7 COMPONENT SERVICE 8 RADIATOR 8 FAN AND WATER PUMP 10 THERMOSTAT 12 WATER TEMPERATURE GAUGE UNIT 13 AUTOMATIC TRANSMISSION OIL COOLER 14 7 1 ...

Page 141: ...ssion oil cooler Performance kcal h Water cooling forced circulation type Pressurized corrugated fin type 43 600 74 103 11 15 5 or less 0 7 or less Centrifugal type impeller 410 16 1 7 Thermostatic controlled fluid coupling 2 750 150 rpm at pulley speed of 4 000 rpm 65 C 149lF or FrTe1 300 rpm at pulley speed of 4 000 rpm 55 C 13 1 F Wax pellet type with jiggle valve 88 C 190 F 100 C 212 F at valv...

Page 142: ...vehicles with a manual transmission Radiator shroud to radiator vehicles with an automatic transmission Radiator to headlight support Automatic transmission oil cooler Oil cooler tubes to transmission 20 25 14 18 12 15 8 5 l 1 12 14 8 5 10 5 30 39 22 28 3 7 2 5 8 11 6 8 8 11 6 8 20 14 LUBRICANT Engine coolant Total quantity Quantity in reserve tank 8 O 8 45 7 04 0 65 69 57 lit U S qts Imp qts 7 3 ...

Page 143: ...ulty radiator cap Foreign material in coolant Faulty thermostat Faulty radiator cap Restriction of flow in cooling system Loose or slipping drive belt Faulty water pump Faulty temperature gauge or wiring Faulty thermostat Faulty temperature gauge or wiring Repair or replace Tighten clamps or replace Replace gasket or retighten Replace gasket or retighten Replace Replace coolant Replace Replace Cle...

Page 144: ...there is leakage repair or replace the appropriate part RADIATOR CAP PRESSURE TEST 1 Use an adapter to attach the cap to the tester 04D008 2 Increase the pressure until the indicator of the gauge stops moving 3 Check that the pressure level is maintained at or above the service limit for 5 to 6 seconds 4 Replace the radiator cap if the reading does not remain at or above the service limit Opening ...

Page 145: ... 1 067 1 062 1 057 1 052 25 13 20 4 40 1 079 1 074 1 069 1 064 1 058 30 22 25 13 45 1 087 1 082 1 076 1 0 70 1 064 36 32 8 31 23 8 50 Example The safe operating temperature is 15 C 5 F when the measured specific gravity is 1 058 at the coolant tem perature of 20 C 68 F Recommended Antifreeze Antifreeze DIA QUEEN LONG LIFE COOLANT Part No 0103044 XI QUALITY ETHYLENE GLYCOL ANTIFREEZE COOLANT Concen...

Page 146: ...ction 7 l 0 mm 28 39 in 3 Tighten bolt B and then tighten bolt IA Caution An over tensioned belt could cause not only premature wear of belt but also noise and damage to water pump bearing and alternator bearing A loose belt also could cause damage to the belt and failure of the alternator to generate enough power and consequently a rundown battery 7 10 mm I In Q O eJ O Ill _ 100 N 22 Ibs Water pu...

Page 147: ...8 Upper shroud 9 Lower shroud Nm ft lbs A 8 11 68 8 3 7 2 5 REMOVAL 1 Set the warm water flow control lever to the hot position 2 Loosen the radiator drain plug to drain the coolant 3 Disconnect the upper and lower hoses 4 Remove the upper and lower shrouds 04W5 1 5 Remove the radiator mounting bolts 04W522 04W521 6 Remove the radiator 04W522 04W521 7 8 ...

Page 148: ...seal for cracks or damage INSTALLATION 1 Torque all parts to specifications during assembly 2 Fill the radiator and reserve tank with clean coolant 3 Run the engine until the coolant has warmed up enough so that the thermostat valve opens and then stop the engine 4 Remove the radiator cap pour in the coolant until it is up to the filler neck of the radiator and then fill the reserve tank to the up...

Page 149: ...bly For reassembly reverse the order of disassembly INSPECTION Cooling Fan Check following items and replace if defective 1 Check blades for damage or cracks 2 Check around bolt holes in fan hub for cracks and damage Fan Clutch Check following items and replace if defective 1 Check to ensure that fluid in the fan clutch is not leaking at case joint and seals If fluid quantity decreases due to leak...

Page 150: ... Check for worn or hardened rubber Water Pump Check the following items and replace if defective 1 Check for water leakage If water leaks from hole A 2 seal unit is defective Replace as an assembly Check bearing for noise or roughness INSTALLATION Water Pump 1 Install new water pump gasket and install water pump 2 Install fan belt and adjust belt tension Reter to p 7 7 7 11 ...

Page 151: ...ning temperature 88 C 190 F Full opening temperature 100 C 2 12 F Valve lift at full open 8 mm 3 1 in or more 3 INSTALLATION Check to ensure that flange of thermostat is correctly seated in socket of thermostat housing If thermostat is installed in wrong direction bottom of thermostat will touch rib inside inlet manifold making it itipossible to seat flange in posi tion 1 Thermometer 888888 L 7 12...

Page 152: ...sor terminal and ground it as illustrated lCOOO9 3 Observe the decrease in resistance as the temperature increases Indication point Resistance value 70 C 158 F 104n 100 C 212 F 38 ra INSTALLATION Apply sealant to the threaded portion and tighten to the specified torque Water temperature gauge unit tightening torque 30 39 Nm 22 28 ft lbs Heating ICOlO 7 13 ...

Page 153: ...3 Feed hose 4 Feed tube 5 Return tube Nm ft lbs A 04W524 REMOVAL 1 Disconnect the oil cooler hoses from the radiatlor 04W525 NOTE Be careful that the automatic transmission fluid does not spill out of the hoses 2 Detach the oil cooler tubes from where they are secured to the engine 04W525 7 14 ...

Page 154: ...acks damage and deteriora tion 2 Check oil cooler tubes for leakage and deformation INSTALLATION 1 Torque all parts to specifications during assembly NOTE When connecting the oil cooler tubes to the transmission first securely connect the oil cooler tubes to the transmission side flange bolts and then tighten by the sleeve tube nuts 04YO22 2 After installation add 120 cc of transmission fluid and ...

Page 155: ...STEM 77 COMPONENT SERVICE 79 CHARGING SYSTEM 79 STARTING SYSTEM 84 IGNITION SYSTEM 97 IGNITION COIL 101 WIRING HARNESS 102 FUSES 131 IGNITION SWITCH 133 METERS AND GAUGES 134 LIGHTING SYSTEM 144 WINDSHIELD WIPERS AND WASHER 149 REAR WINDOW WIPER AND WASHER 152 HEADLIGHT WASHER 154 HORN 156 CLOCK 158 REAR WINDOW DEFOGGER 159 RADIO AND STEREO 161 POWER WINDOW 166 3 POINT ELR SEAT BELTS WITH TENSION ...

Page 156: ... less 0 2 008 or less 38 7 1 524 32 1 260 37 7 1 484 31 1 220 0 5 2 0 020 079 0 5 2 0 020 079 M2T53083 Reduction drive 1 2 12 Clockwise 9 Distributor Federal California Model No Type Igniter Turning direction Firing order Centrifugal advance distributor angle at distributor rpm Initial Middle Final T3T61971 MD073074 T3T61972 MD073075 Contact pointless type Built in type Clockwise l 3 4 2 Contact p...

Page 157: ...direction as viewed from pulley Voltage regulator A5T2 1077 MD064068 12150 14 4 f 0 5 at 20 C 68 F Minus ground Clockwise Electronic built in type A2T41377 MD074645 12 55 14 4 0 5 at 20 C 68 F Minus ground Clockwise Electronic built in type _ Battery Type Capacity 20HR Ab Voltage V Electrolyte specific gravity 2O C 60 F NXlOO S6 S MF Maintenance free battery 45 12 1 280 NX120 7 MF Maintenance free...

Page 158: ...00 Sub Ignition circuit Power window Headlight headlight circuit washer circuit Cable color Green Green Brown Fusible link size mm2 in 0 5 0008 0 5 OOOS 0 3 0005 Permissible continuous current A 27 27 19 Fusing current A 100 100 65 Fuse capacity A Color 10 Red 15 20 Light blue Yellow Ignition Switch Ignition switch Type Load capacity A AM ACC AMGIG AM ST M R Key reminder switch Load capacity W I i...

Page 159: ... i f 100 2 000 rpm 100 3 000 rpm f 150 4 000 rpm f 200 5 000 rpm f 250 Fuel gauge 5pe Bi metal type built in constant voltage relay Constant voltage relay resistance value Q 68 72 Fuel gauge unit 5Pe 7 V resistance type Standard resistance value fi Float position F point 14 9 19 1 Float position E point 113 5 126 5 Float vertical movement range mm in 222 220 8 81 8 97 Water temperature gauge Type ...

Page 160: ...alue 0 kPa 0 psi 588 kPa 85 psi Inclinometer Type Damping system Indication angle Forward backward Right left Voltage meter Type i 2 Indication ratings range of allowable error IOV 14v Bi metal tyPe Bi metal type 0 136 Gravity type Oil fdled system V 45 max 49 max Bimetal type f 0 5 0 5 8 6 ...

Page 161: ...dicator light 1 4 74 1 4 74 1 4 74 1 4 74 1 4 74 1 4 74 1 4 74 1 4 74 I 4 16W735 Sensor and Switches Parking brake switch Rated load W 5 Voltage drop at 12 V rated load V 0 1 or less Brake fluid lever sensor Rated load W 3 6 Voltage drop at 12 V rated load V 0 1 or less Door switch Rated load W 15 Voltage drop at 12 V rated load V 0 2 or less Belt switch Me Normally closed type Seat Belt Warning T...

Page 162: ...Back up lights License ate lights Sub lights W SAE trade number Dome light Combination meter illumination light Cigarette lighter illumination light Heater panel illumination light Rear window defogger switch illumination light Ashtray illumination light Turn signal flasher unit Type Rated load W 4 Blinking freguencx cycle min 12 8 V 20 C 68 F 60150 27 1156 3 8 194 27 8 1157 3 8 194 27 1156 6 10 3...

Page 163: ...t washer switch Rated load A Voltage drop at 12 V and the rated load V 6 1 7 1 0 2 or less 16 1 18 7 9 4 10 8 0 2 or less V 16 1 18 7 9 4 10 8 0 2 or less 0 17 0 27 0 2 or less 0 5 0 2 or less Hazard warning switch Voltage drop at 12 V and the rated load V 0 2 or less I Light control relay Rated load W 200 Range of voltage used V lo 16 Voltage drop between terminals V 0 2 or less Dimmer control sw...

Page 164: ... Tank capacity lit U S qts Imp qts Intermittent wiper relay Intermittent cycle sec Delay time in combined intermittent wiper and washer operation Load current A Wiper switch Rated load A Intermittent Low speed High speed Lock Voltage drop at 12 V and the rated load V Washer switch Rated load A Voltage drop at 12 V and the rated load V Permanent magnet type 3 brush system Dynamic brake system 35 4 ...

Page 165: ...d A Wiper switch Washer switch Voltage drop at 12 V and the rated load Ferrite magnet type Dynamic braking system 50 5 6 4 or more 2 or less 108 334 13 Direct current ferrite magnet type Centrifugal type 3 5 or less Max 60 Max 20 78 11 4 or more 1 1 1 2 l O or more V 3 5 0 2 or less Headlight washer Headlight washer motor Motor type Pump type Power consumption A Nozzle injection pressure kPa psi T...

Page 166: ...isplay Daily variation seconds day k2 at a power supply of 9 to 16V 20 C 68 F ambient temperature I Cigarette Lighter Rated input W 120 Timing of plug pop up Within 18 seconds Cigarette lighter light bulb capacity W 1 4 x 1 Ashtray light bulb capacity W 1 1 4x 1 Rear Window Defogger Rear window defogger switch Type Seesaw type Rated current A 12 Indicator light W 0 9 Rear window glass with defogge...

Page 167: ... 1 step superheterodyne amplification Ratio detection PLL FM stereo demodulation and noise killer circuits AM kHz 5251 615 FM MHz 88 108 RX 750 SY RY 4 track auto reverse stereo playback Normal C 90 or shorter tape 4 4 76 Manual search tuning Mechanical memory tuning AM kHz 525 1 615 FM MHz 88 108 Speakers Model Rated input power W Output sound pressure level Mounting position dB SG 28A8 SG 3K44 G...

Page 168: ... load current A Lock switch 30 L H switch 11 R H switch i 11 Power window sub switch I Type Automatic reset type Rated load current A 11 Power window relay I I L Maximum contact current A 20 Rated coil current A 0 13 0 19 Voltage drop between terminals V 0 2 or less at 12V andthe ratedload current i _ 3 Point ELR seat belts with tension reliefers Belt switches Seatbelt solenoids Normally opentype ...

Page 169: ... resistance is 23 8 a Scale indication C When resistance is 104 Q Scale indication D Water temperature gauge continuity test Resistance value 52 Approx 55 Water temperature gauge unit operation check When water temperature is 70 C 158 F SI 104 Oil pressure gague indication test When resistance is 120 s2 Scale indication E Oil pressure gauge continuity test Resistance value fi Approx 42 Voltage met...

Page 170: ...tandard value 1 Wiper blade stopping position mm in distance between blade tip and back door window weatherstrip 20 8 TORQUE SPECIFICATIONS Fuel Gauge Unit Nm ft lbs Fuel gauge unit 1 1 0 7 Windshield Wipers and Washer Nm ft lbs Wiper pivot shaft mounting nut Wiper armlocking nut Wiper motor 7 5 IO 16 7 12 3 2 Rear Window Wiper and Washer Nm ft lbs Rearwiper pivot shaftmounting nut Rearwiper armlo...

Page 171: ...ent flows 1 I Go to TEST 6 t0 TEST 5 TEST 3 Short circuit the B terminal and the R terminal of the alternator with a jumper wire and then repeat TEST 2 I oto1v I I 1 to3V I Poor ignition switch ground 1 TEST 4 Remove the connector from the alternator and then check for continuity between the L and R terminals of the alternator I Continuity 35 to 100 52 No continuity Malfunction of the regulator or...

Page 172: ...in the OFF position puIl the connector from the alternator Then measure the voltage at the L terminal If the voltage battery voltage the t diode is short circuitd CAUTION When measuring the voltage of the F terminal for testing be careful not to let the voltmeter probe contact the rear bracket If by chance it does contact it there s no problem if it s immediately pulled away 8 18 ...

Page 173: ...ominal output 90 or more of nominal output Normal function of alternator Alternator is normal 1 TEST 7 I Output current test recheck Check for poor contact of the wiring between the B terminal of the alternator and the positive terminal of the battery After slightly discharging the battery make TEST 6 once again I I Less than 90 of nominal More than 90 of nominal output output Remove the alternato...

Page 174: ...l for checking the alternator at idle speed and at approx 3 000 rpm Is the voltage higher at 3 000 rpm I Higher J I Not higher or no change Malfunction of alternator malfunction of electronic voltage regulator or negative brush is grounded NOTE The voltage of the F terminal may not increase if the battery is discharged TEST3 Regulated voltage test See p 8 76 I Alternator normal I 1 Malfunction of ...

Page 175: ...utch races l Clutch drive spring weakened Motor does not rotate in overrun direction l Spline section does not slide smoothly 0 Bearing worn l Improper soldering of field coil 1 Wiring broken between starter switch and magnetic switch terminal Faulty contact between battery and ground strap Spark plug gap incorrect Loose or defective spark plug cable I Defective ignition coil Primary wiring connec...

Page 176: ...ficient electrolyte 0Defective plate internal short L I Electrical overload l Addition of non standard electrical loads Blown charging circuit fuse a Defective I C regulator v Battery r l connected in reverse polarity Drive belt loose Poor contact starting switch 1 Faulty wiring connectors Q Defective I C regulator I strange sound r l from alte inator emitted by radio Alternator 0 Defective bearin...

Page 177: ...d to engine Set ignition switch to ST Does switch make operating sound 1 Generally starting difficulty aside from inoperative starting motor is often attributable to defective ignition system fuel system battery electrical wiring etc If makeshift corrective steps are taken without locating the cause same trouble will develop again Starting motor turns but engine does not start Does initial explosi...

Page 178: ...A betwe switch B andM teyals I j J I I Point to Note when Checking I 1 To measure a voltage drop across contacts B titd M make connections as shown 1 EL030 If there is a voltage drop of more than 0 3 V per 100 A hard starting could result when engine resistance in creases as in very cold weather In such a case replace switch assembly I lEL030 1 8 24 ...

Page 179: ...park check and timing measurement are carefully For on vehicle troubleshooting of the ignition system the short cut is to determine on the basis of symptoms which is defective the power supply primary low tension circuit or high tension circuit For example when all spar plugs fail to produce sparks the pro bable cause is in power supply or primary circuit If misfiring occurs only at a specific spa...

Page 180: ... Defective wiring between battery and ignition coil TEST 3 With ignition key at ON position measure voltage of terminal of ignition coil 1 Voltage equal to battery voltage Faulty igniter or opened ignition coil TEST 4 Remove ignition coil and install normal ignition coil Make a spark test as in the same manner shown in TEST 1 1 No spark produced I Faulty distributor pickup coil Spark produced I De...

Page 181: ...gniter I Engine stalls or misfires occasionally I I Faulty insulation of hi r I tension cables cap rot and or spark plugs Faulty primary circuit Damaged primary wire or ignition coil or overheated ignition coil IIncorrect spark plug gap 1 Defective governor advance mechamsm advance mechanism Incorrect spark plug heat value IFaulty advance mechanism I I I 8 27 ...

Page 182: ...ing Foreign matter caught onthe magnet _I The speedometer pointer moves Flexible shaft improperly routed Repair the routing of the speed ometer cable or replace the cable Gear malfunction ins de the speedometer NOTE If oil is inside the meter replace the speedometer cable as well Check the transmission fluid quantity and check for clogged breather plug too 0 8 28 ...

Page 183: ...rness and replace m the fuse cover etc Yes Does the tester needle remain with in the area between 2 V and 7 V when the voltage between the Y wire on the fuel gauge side and ground is measured IYes No Constant voltage relay mal function Replace the fuel gauge Constant voltage relay is built into the fuel gauge t Does the fuel gauge needle go above the scale s highest marking Fuel gauge malfunction ...

Page 184: ...ring harness damaged wiring harness burnt cover et Repair the harness and replace the fuse Yes 1 No Itage relay mal Replace the fuel gauge w Constant voltage relay is built into the fuel gauge IYes Does the water temperature gauge Water temperature gauge Replace the water temperature indicator move to approximately malfunct ion gauge the second marking from the No bottom of the scale when a 100 a ...

Page 185: ...ulum defective Remedy Replace inclinometer assembly When vehicle inclines to right or left spherical dial does not perform follow up operation Internal parts such as dial and pendulum defective Oil like fluid flows out from bottom of case Seal of oil case broken Pointer and spherical dial frequently swing during vehicle operation Oil case broken and oil leaking 8 31 ...

Page 186: ...on meter and ground meter Yes When YB wire at back of con No Open circuit in light bulb Replace light bulb nectar of combination meter is grounded does the indicator c c light illuminate Yes Does the indicator light illuminate No when oil pressure switch harness is grounded Yes Open circuit in harness between combinat ion meter and oil pressure switch Repair the harness Oil pressure switch defecti...

Page 187: ...switch harness is No Short circuit in harness Repair the harness between the disconnected damaged harness burnt combinatibn meter connector covering etc and oil pressure gauge unit terminal Yes Does oil pressure switch operate NO properly Oil pressure switch defective Replace the switch Yes I Check oil circulation system I 8 33 ...

Page 188: ...nator harness connector I I is grounded 4 Is light Replace the light bulb b bulb good No Light bulb defective IYes IYes in harness between fuse block and alternator Repair the harness t Is there continuity between alternator I and alternator harness connector I No Alternator malfunction Repair or replace the alternator IYes I IC electronic voltage regulator malfunction Replace the regulator assemb...

Page 189: ...ove fuse No 4 from fuse Check the connection of the alternator terminals Is each terminal correctly connected IYes Check alternator terminal B Is about 12 V indicated No Loose contact terminal c _ No Check continuity of fusible link Is 0 fl indicated No Repair harness and replace c fusible link 1 Yes 8 35 ...

Page 190: ...ss or replace thefuse _ __ Repair the hai ess or correct the connection No _ Yes _ Does the indidator light illuminate when one end of the test bar is iqserted into the 9 3 RG wire from the back of the combination meter connect and the other end of the test bar is grounded IYes I Yes Replace the light No 1 Repair the harness I Replace the door switch I 8 36 ...

Page 191: ...t in harness damaged harness burnt covering etc 1 Is there 12 V between combina No Open circuit in harness RL wire Repair the harness tion meter RL wire and ground between fuse block and combina b tion meter L Yes Is brake warning light bulb No Open circuit in brake warning good light bulb IYes 8 37 ...

Page 192: ...t remain lit after disconnection of brake fluid level sensor connector Yes Brake fiuid level sensor defective Replace the brake fluid sensor Ground side of brake warning light circu it short circuited L Repair the harness IBrake warning light does not light when parking brake lever is pulled I th ignition key in ON posi tion check by pulling parking I Does the indicator light illuminate when parki...

Page 193: ... with parking brake lever T Disconnect connector of brake fluid level sensor and short circuit harness 0 3 YG and 0 3 B wires Does warning light illuminate I Yes Is 12V indicated at harness 0 3 Y wire of sensor connector IYes Damaged0 3 YG wire in ground harness Repairthe harness w c Brakefluid level Replacethebrake fluid level sensor defective sensor A 8 39 ...

Page 194: ...o Open circuit in harness between Repair the harness w key reminder switch and combina c bination meter and ground tion meter IYes When 0 3 YB wire at back of No Open circuit in light bulb connector of combination Repair the light bulb meter is grounded does the e warning light illuminate 4 Yes Is there 12 V between 0 3 YB Repair the harness wire at back of connector of No combinatifon meter and s...

Page 195: ... c c buckle unlocked Does buzzer sound Yes Is there 12 V between 0 3 RB Open circuit in harness between Repair the harness wire at back of seat belt warning No seat belt switch and seat belt timer connector and ground warning timer with buckle unlocked Set ignition key to ON NOTE If the malfunction is in the following circuits in addition to warning buzzer not sounding the warning light will not i...

Page 196: ...r switch door switch Does buzzer sound c Yes in ground of buzzer Repair the harness 1 r Disconnect timer connector No Short circuit of 0 3 YB wire Repair the harness Does warning light go out between combination meter w and timer IYes Seat belt warning timer defective I Replace the seat belt warning a 42 ...

Page 197: ...ms when the passing switch is at ON position 0 X X 0 0 A A Position tail rear side marker and license plate lights All of these lights should illuminate when the lighting switch is at the first stage o o o x o o A Probable cause Light control relay Column switch Dimmer switch segment l l 0 l Passing switch segment 0 0 l a Lighting switch segment l 0 0 0 Body ground points Front pillar inner l 0 Le...

Page 198: ...inate when 0 5 R wire located on back of light control relay connector is grounded No Caution Be sure not to ground 2 R 1 25 R and OS GW wires Light relay defective Replace the light control relay I _ Replace the column switch I zly grounded I l Correct the ground connection 8 44 ...

Page 199: ... in coil of light control relay and poor relay Replace the light control relay e contacts t I IYes Caution Be sure not to ground the other wires Do tail and rear side marker lights illuminate when OS GW wire at back of column switch connector is grounded Yes Do position tail rear side marker and license plate lights illuminate when 0 3 B wire at back of column switch connector is grounded r No Ope...

Page 200: ... or less indicated on voltmeter about 20 V range when t and test probes are connected to 2 R B and 1 25RL wires respectively at back of light control relay connector I Yes Is there 0 5 V or less between test probe and ground when test probe is inserted into 2 B wire from back of column switch connector No I Improperly grounded Correct the ground connection 1 Replace the column switch 1 connector o...

Page 201: ...op light switch and hazard and ground warning switch 1 Yes Is there 12 V between 0 85 WC wire of hazard warning switch No Hazard warning switch defective Replace the hazard warning c switch aa ground 1Yes 1 Is there 12 V between 0 85 WG No Open circuit in harness between Repair the harness wire of column switch and hazard warning switch and a ground column switch Yes Is 12 V indicated between Colu...

Page 202: ...ght switch improperly adjusted or defective Adjust stop light switch position Turn signal and hazard lights Incorrect connector connection I Improper ground connection Correct the iround connection i Light bulb malfunction I Replace the light bulb I i ...

Page 203: ...ing switch OFF is there continuity between GR wires Yes No Hazard warning switch defective c Is there continuity between GR Open circuit in harness between wire of turn signal flasher unit No turn signal flasher unit and connector and GR wire of hazard hazard warning switch warning switch 1Yes 4 Is there continuity between GR No Open circuit in harness between wire of hazard warning switch c hazar...

Page 204: ...lashing is irregular All lights illuminate without flashing I Is each bulb the specified type No _ Replace the light bulb 1Yes Is 12 V indicated as battery terminal voltage No IYes 1 Are lights properly grounded No and bulbs properly mounted 8 50 ...

Page 205: ... No Open circuit in harness between Repair the harness 1 25GB wire and fuse block w fuse block and hazard warning c flasher unit IYes 4 I Is there continuity between Open circuit in harness between 1 25GO wire of hazard warning flasher unit connector and 1 25 No hazard warning flasher unit and I hazard warning switch GO wire of hazard warning switch Yes Repair the harness With the hazard warning s...

Page 206: ...catedbetweeneach wire LO andLB andground whena test probeis inserted from the back of the column switch connector No Yes Isthere 12V between2 Bwire of column switch connector andgroundwhenwiper switch issetto 1 and 2 Repairthe harness and replacethe fusiblelink I Repairthe harness and replacethe fuse I Correct the connector or repair the harness Replacethe iper motor I I _ _ I Correct connector or...

Page 207: ...rly of the washer motor connected connector connector I I J lYes Does the washer function when the YL wire of the washer motor connector is grounded 1 Does the washer function when the YL wire of the column switch connector is grounded Yes Does the washer operate when the washer switch is turned on while the 2B wire of the column switch con nector is grounded No I INo I I Correct the connector or ...

Page 208: ...operate when the washer switch is turned on but washer operates properly Refer to the troubleshoot ing section The wipers do not operate at all when the wiper switch is set to the star mark Replace the wiper control 8 54 ...

Page 209: ...tor No J Does wiper perform inter mittent operation when test probe is inserted from back of intermittent wiper control unit No and grounds 1 0 3 BY wire 2 B wire I I 2 Yes 1 Yes Open circuit in harness between Correct harness intermittent wiper control unit and wiper motor c I I Malfunction in intermittent wiper control unit I I Replace intermittent wiper control unit 1 I Open circuit in harness ...

Page 210: ...r mark Yes Intermittent wiper control unit defective A Replace intermittent wiper control unit Replace column switch I I g zy t Disconnect wiper switch Faulty wiper switch variable connector and operate time resistor adjustment switch Does No resistance between 0 3 Y wire and 2 B wire vary between 0 and 50 ohms _ Yes 1 Yes Faulty intermittent wiper relay c Replace intermittent wiper relay 8 56 ...

Page 211: ... of the rear wiper motor connector A broken wire between fuse No 9 and the wiper motor connector or a poor Con nectar connection Correct the connector or repair the harness Yes Does the wiper motor func tion when a test probe is inserted from the back of the rear wiper and washer switch connector and the BrW wire is grounded Yes Set the igniton key to the A malfunction in the wiper motor brush or ...

Page 212: ...washer function when a test probe is inserted from the back of the rear No c window washer motor and the 0 3 WB wire is grounded Yes Does the washer motor func A broken harness between Correct the connector or repair tion when a test probe is the rear window washer the harness inserted from the back of No motor and the rear wiper the rear window wiper and c and washer switch br a t washer switch c...

Page 213: ...e and ground when the rear washer switch is turned on No A poor connection of the rear wiper and washer switch connector or a malfunction in the rear wiper and washer switch Repair the connector or replace the wiper and washer switch Yes Improperly grounded Correct the ground connection 8 59 ...

Page 214: ... harness and 0 3 Lw wire and ground when a No No replace the fuse test probe is inserted from the P m back of the headlight washer control relay connector Yes IYes Repair the harness between the fuse block and the headlight washer control relay connector A malfunction in the headlight washer motor Replace the headlight washer motor c Does the headlight washer motor operate when the 1 25 L wire of ...

Page 215: ...place the headlight washer control relay Disconnect the main hose from the check valve NOTE Have a receptacle prepared in order to avoid spilling the washer fluid Yes No Are the hoses free from clogging No c twisting leakage etc Yes Correct the hose installation c remove the clogging or replace the hose Inspect the washer motor Y for pump blockage and repair or replace it Does the washer fluid spr...

Page 216: ...ect while the ignition key is in the AU position I Is fuse block No 8 OK Yes No A short circuited wiring m harness damaged wiring harness burnt cover etc Repair the harness and w replace the fuse t Is 12 V indicated between the Does horn sound when it is dis Repair the harness 0 85 B wire of the horn connec No connected and connected to No tor terminal and ground different battery of specified vol...

Page 217: ...und key reminder switch Yes 1 Is there continuity between G wire of key reminder switch No Key reminder switch defective Replace the key reminder switch c w connector and ground 1 Yes I I I I I Yes Does buzzer sound when 0 3 Y wire of buzzer connector is grounded Yes No Open circuit in harness between c key reminder switch and buzzer Repair the harness c No Buzzer defective Replace the buzzer b t ...

Page 218: ...t ch defective Replace door switch wire of driver s door switch connector is disconnected Yes Does buzzer sound when seat No Belt switch or timer defective belt switch connector of driver s seat belt is disconnected Yes Short circuit at ground side of Repair the harness c 8 64 ...

Page 219: ...d rear window defogger switch and ground switch Yes 4 Does continuity exist between A malfunction in the rear Replace the rear window the terminals when the rear No w window defogger switch defogger switch window defogger switch is removed and then operated Yes Check with the rear window defogger switch ON I Is there 12 V between printed No Open circuit between rear Repair the harness heater t ter...

Page 220: ...ss The front door windows cannot be operated by using the main switches The door windows can be operated by using the main switches but cannot be operated by using the sub switches The door windows can be operated even though the lock switch is at ON Malfunctioning main switch Break in harness or poor connection Malfunctioning motor Malfunctioning main switch Malfunctioning sub switch Break in har...

Page 221: ...djusted Adjust the trimmer Yes Does the sensitivity improve when a different antenna and lead m are connected to the radio No The radio itself is malfunc tioning w Yes 1 I The antenna is improperly grounded The antenna lead in is malfunctioning t I 1 t i Repair or replace the radio itself Correct the ground connection or replace the antenna lead m 8 67 ...

Page 222: ...o 1 1 Is the antenna lead in routed too close tb a harness Yes No Correct the ground connection of replace the antenna lead in There is no malfunction Reroute the antenna lead in I c Beeping Horn Irregular cracking Tachometer Popping Stop light switch Sputtering Ignition system Whining Motor Whining Wiper motor Whining Alternator Intermittent clattering Turn signal flasher unit the ground connecti...

Page 223: ...wire or a malfunction in either a w capacitor or in the tape player itself The tape being used was recorded monaurally Correct the connection or re place the malfunctioning parts Use tapes which have been recorded in stereo 1 The auto reverse does not function The program changes when the direction selector button is pressed No t A malfunction in the reverse circuit Repair or replace c Yes A malfu...

Page 224: ...t short or open t circuit in antenna lead in Correct or replace radio I 1 No sound I Repair the harness and replace the fuse Check while the ignition key is in the ACC position I Is radio power supply available No Main body fuse blown Check main body for improper c grounding or loose connector connections before replacing fuse Yes r No d r in loose contact Connect connector Is speaker connector se...

Page 225: ...nna improperly installed Install antenna properly Is everything in order between Antenna lead in defective antenna lead in and body No Replace antenna lead in ground Yes I 7 Is antenna trimmer properly adjusted Yes No Timmer out of adjustment Adjust trimmer Radio proper defective Repair or replace radio I 8 71 ...

Page 226: ...rounded Does tension reliefer system operate when the belt switch is disconnected and the 0 3 YB wire is grounded I Yes Short circuited wiring harness k gyring harness burnt Repair the harness and replace c the fuse No A broken harness between the fuse block and the seat belt solenoid or a poor connection No Repair the harness or correct the connection Replace the seat belt assembly 1 1 A broken h...

Page 227: ...case is cracked or leaking to protect hands from the electrolyte A suitable pair of rubber gloves not the household type should be worn when removing battery by hand 4 Inspect battery carrier for damage caused by loss of acid from battery If acid damage is present it will be necessary to clean area with a solution of clean warm water and baking soda Scrub area with a stiff bristle brush and wipe o...

Page 228: ...oubleshooting easier The F in the circuit in the illustration lEL042 is the F terminal for checking The voltage of this terminal can be checked from outside the alternator through the accesshole provided in the rear bracket The voltage readings of the F terminal indicatk asfollows 1 Ignition switch at OFF Normal if voltage is 0 V If voltage is close to battery voltage the diode is short circuited ...

Page 229: ...ow even though the engine rpm is increased the regulator has not yet reached the operating voltage or current is continuing to flow to the regulator If the latter an overcharge will result CURRENT OUTPUT TEST 1 Place the ignition switch at OFF 2 Disconnect the battery ground cable 3 Disconnect the cable from terminal B of the alternator and connect a 60 A ammeter between the terminal B and cable 4...

Page 230: ...inals and start the engine NOTE Make sure that the starter current does not flow through the ammeter while starting the engine Increase the engine speed to 2 000 to 3 090 rpm and check the ammeter reading If the reading is 5 A or less check the voltmeter reading This reading is the regulated voltage If the ammeter reading is more than 5 A either continue charging until the reading drops below 5 A ...

Page 231: ...adjust ignition timing loosen distributor mounting nut and turn distributor housing 1 EL002 5 After adjustment securely tighten mounting nut SPARK PLUG CABLE TEST 1 Disconnect spark plug cable from spark plug When spark plug cable is pulled out be sure to pull by the cable cap If spark plug is removed by pulling on cable only open circuit might result 2 Hold the spark plug cable about 6 8 mm 24 3 ...

Page 232: ...d because of small discharge gap If the spark plug is good however sparks will occur in discharge gap between electrodes In a defective spark plug no sparks will occur because of leak of insulation puncture Check plug gap with plug gap gauge If it is not within specified limit adjust by bending ground electrode Make sure that the gap of even a new spark plug is checked before spark plug is mounted...

Page 233: ...ck of the engine lEL038 Turn the ignition switch to ON Then when a piece of metal the tip of a screwdriver for instance is inserted into the detection coil of the pick up and then moved away a spark can be generated 6EL069 CHARGING SYSTEM COMPONENTS 1 Through bolt 3 2 Nut 3 Spring washer 4 Pulley 5 Fan 6 Collar 7 Screw 3 8 Seal 2 9 Front bracket 10 Bearing 11 Retainer 12 Rotor 13 Stator 14 Screw 1...

Page 234: ...r leads soldered to main diodes on rectifier 3EL046 Caution 1 When soldering or unsoldering use care to make sure that heat of soldering iron is not transmitted to diodes for a long period Finish soldering or unsoldering in as short a time as possible 2 Use care that no undue force is exerted to leads of diodes 11 When separate the rectifier from brush holder unsolder two plates soldered to rectif...

Page 235: ...ester If there is continuity in both directions diode is shorted Replace rectifier assembly 2 HEATSINK ASSEMBLY TEST Check for continuity between heatsink and stator coil lead connection terminal If there is continuity in both direction diode is shorted and rectifier assembly must be replaced 3 DIODE TRIO TEST Check three diodes for continuity by connecting a circuit tester to both ends of each di...

Page 236: ...replaced without removing stator etc IWith brush holder assembly raised as illustrated unsolder pigtail of brush NOTE If L and B terminals of rectifier assembly are bent damage to rectifier moulding might result Therefore plates B and L should be gently bent at center 4 When installing new brush solder pigtail so that brush will be pressed into holder about 5 mm 2 in l Unsolder this portion Brush ...

Page 237: ...k clear ance A between alternator leg and front case or timing chain case If clearance is more than 0 2 mm 008 in insert spacers O 198 mm 0078 in thick as required If support bolt is tightened without reducing clearance A alternator leg might be broken 4 Install the washer and nut to the support bolt 5 Install drive belt and adjust the drive belt tension 6 Tighten first the brace bolt and then tig...

Page 238: ...E Numbers show order of disassembly For reassembly reverse order of disassembly 9 8 Reduction drive type 1 Screw 2 2 Front bracket 3 Lever 4 Spring 5 Spring retainer 6 Center bracket 7 Packing 8 Magnetic switch 9 Snap ring 10 Stop ring 11 Pinion gear 12 Spring 13 Pinion shaft and overrunning clutch 14 Reduction gear 15 Adjusting washer 16 Washer 17 Retaining ring 18 Cover 19 Screw 2 20 Bolt 21 Fro...

Page 239: ... will move out Caution This test must be performed quickly in less than 10 seconds to prevent coil from bourning 4 Check pinion to stopper clearance pinion gap with a feeler gauge 6EL003 If pinion gap is out of specification adjust by adding or removing washers between magnetic switch and front bracket Pinion gap 052 0 mm 020 079 in 5 Lightly push back the pinion and measure the amount of travel w...

Page 240: ...ace magnetic switch Return Test of Magnetic Switch 1 Disconnect field coil wire from M terminal ocfmagnetic switch 2 Connect a 12 V battery between M terminal and body 6EL006 Caution This test must be performed quickly in less than 10 seconds to prevent coil from burning 3 Pull pinion out and release If pinion quickly returns to its original position everything is in order If it doesn t replace ma...

Page 241: ... Voltage 11 5 Volts Amperage draw 60 Amps Minimum rpm 6 800 rpm DISASSEMBLY DIRECT DRIVE TYPE 1 Disconnect field coil wire from M terminal of magnetic switch 2 Remove two magnetic switch mounting screws and remove magnetic switch 3 Remove two through bolts and two screws 4 Remove rear bracket IMagnetic switch S terminal I B terminal Field coil wire EL07 Magnetic switch I Magnetic switch Mounting s...

Page 242: ...springs back 6 Remove brush holder 7 Remove yoke assembly 8 Remove washer from rear end of armature 9 Remove spring retainer spring and spring seat from front bracket 10 Remove armature assembly and lever from front bracket Retaining sying Brush I 6EL075 6E LO76 Y 6EL077 1 Clutch shift lev clutch 8 88 ...

Page 243: ... Remove washer from front bracket 12 Pressstop ring off snap ring with suitable socket 13 Remove snap ring with snap ring pliers and then remove stop ring and overrunning clutch 6E LO80 Snap ring Snap ring Caliers Armature 6E LO81 8 89 ...

Page 244: ...itch mounting screws and remove the magnetic switch 3 Remove the two through bolts and two screws and then remove the rear bracket 4 Slide the two brushes from brush holder by prying retaining springs back and then remove the brush holder assembly 5 Remove the yoke assembly 6 Remove the armature Field coil wire Magnetic switch 1 I I k l 5EL018 Retaining spring 8 90 ...

Page 245: ...gauge for reassembly 9 Remove the retaining ring and washer from the pinion shaft 10 Remove the center bracket 11 Remove the lever spring retainer and spring 12 Remove the adjusting washer and reduction gear 13 Remove the clutch shift lever and two lever holder 14 Pressthe stop ring off the snap ring with suitable socket Lever holder 5E LO22 ...

Page 246: ...R PARTS 1 Do not immerse parts in cleaning solvent Immersing the yoke and field coil assembly and or armature will damage insulation Wipe these parts with a cloth only 2 Do not immerse drive tinit in cleaning solvent Over running clutch is pre lubricated at the factory and solvent will wash lubrication from clutch 3 The drive tinit may be cleaned with a brush moistened with cleaning solvent and wi...

Page 247: ...brush from brush holder by prying retaining spring back TESTING ARMATURE Testing Armature for Short Circuit 1 Place armature in a growler 2 Hold a thin steel blade parallel and just above while rotating armature slowly in growler A shorted armature will cause blade to vibrate and be attracted to the core Replace shorted armature Testing Armature for Grounding 1 Touch armature coil core and the end...

Page 248: ...and yoke assembly TESTING BRUSH HOLDER 1 Touch each of the insulated brush holders with one test probe while holding other test probe against brush holder plate 2 The lamp should not light during this test since the brush holders are insulated If the lamp lights brush holders on brush holder plate are grounded Replace brush holder assembly if brush holders are grounded SERVICING DRIVE UNIT Overrun...

Page 249: ...burred replace front bracket assembly or rear bracket assembly REASSEMBLY Direct drive tvDe Reassemble starter motor in the reverse order of disassembly with the following exception 1 Using a suitable pulling tool pull overrunning clutch stop ring over snap ring Reduction drive typ 5EL026 Snab ring lEL013 Reduction drive type gear v 5EL027 ...

Page 250: ...ces of starter motor flange and rear plate 2 Install starter motor to engine and tighten two bolts to specified torque 1 Starter motor mounting bolts 1 22 3 1 Nm 16 23 ft lbs 3 Connect battery cable and switch wire to starter motor 4 Connect battery ground cable 8 96 ...

Page 251: ... Distributor shaft 18 Oil seal 19 Packing I 20 Distributor housing 21 O ring 22 Washer 23 Gear 24 Pin T 24 NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 6E LO87 DISASSEMBLY r 1 Lightly clamp distributor in a vise equipped with soft jaws 2 Remove retaining clips and lift off distributor cap and sealring 3 Pull off rotor from rotor shaft 4 Remove two vacuum contr...

Page 252: ...haft tightening screw and two breaker plate retaining screws 9 Remove signal rotor shaft and breaker plate assembly 10 Remove signal rotor shaft from signal rotor 11 Remove two spring ret ers with pliers and th en remove two governor springs 12 Remove two governor weights Spring retainer I Governor I spring 6ELO92 I 8 98 ...

Page 253: ...rts 2 Install shaft into housing 3 Install drive gear into distributor shaft at previously marked location Then install new roll pin 4 Install governor weights on the governor plate 5 Install governor springs and spring retainer 6 Install signal rotor shaft into distributor shaft 7 Install breaker plate to housing Position the breaker plate so that the projection A fits into the groove B 8 Tighten...

Page 254: ...stall two screws 1 1 Connect one end of lead wire to igniter mounting screw and other end to breaker plate 12 Adjust air gap between signal rotor and pick up of igniter 1 6EL09E 13 Connect vacuum control link to breaker plate and tighten two vacuum controller screws 14 Install rotor to rotor shaft 15 Install seal ring and distributor cap to housing and set the retaining clips 8 100 ...

Page 255: ...of distributor installing stud and tighten nuts lELO19 4 Adjust ignition timing IGNITION COIL INSPECTION 1 Using a circuit tester measure resistance An open or short circuited coil should be replaced Model No Primary resistance E 064 1 1 1 3 a at 20 C 68 F Secondary resistance 11 6 15 8 kn at 20 C 68 F External resistor resistance 1 2 1 5 G at 20 C 68 F I terminal d f 1 terminal resistor 3E LOO 2 ...

Page 256: ...e light wiring harness Back door Control wiring harness For California can also be sold in c l A s Front wiring harness Door wiring harness R H Door wiring Back up light and 4WD harness L H Center oanel indicator ligh t wiring harness wiring harness SW763 wiring harness ...

Page 257: ...alve linht IR H 1 I Sub fus I Iink I E S S temperature i I Carburetor sensor C Power relav Oil pressure switch E S S solenoi d or Tn frrY t Wirinn T air conditioner J I harness wi _ _ w rinn harness Ground Water temperature Air temperature Magnet clutch Water temperature gauge unit Throttle position sensor NOTE l For California can also be sold in Federal States l indicates connection for vehicles...

Page 258: ...Engine compartment Rear Battery cable I Main fusible link Wiper motor I 16W755 ain fusible link arter motor Battery cable 1 NOTE For California can also be sold in Federal States ...

Page 259: ...itch harnesstfor metal top Rear wiper and washer switch I I I Column 1 Intermittent wiper relay IF switch Turn signal flasher unit To rear wiring t To ddor wiring harness control unit 16W761 Seat belt brake switch I H switch r wiring heater larness NOTE l For California can also be sold in Federal States indicates connection for vehicles with an air conditioner ...

Page 260: ...COMPONENT SERVICE WIRING HARNESS 1 8 106 ...

Page 261: ...COMPONENT SERVICE WIRING HARNESS n z n i 0 ...

Page 262: ...Frame Rear combination light R H 1 I Rear combination light L H Back door wiring harness 16W696 ...

Page 263: ...Back door Vehicles without a rear wiper and washer Frame wiryg harness Rear washer motor Back door Vehicles with a rear wiper and washer Frame wiring harness Rear wiper motor ...

Page 264: ...COMPONENT SERVICE WIRING HARNESS ...

Page 265: ...nder shield inner right side Fender shield inner left side Front pillar inner left side NOTE l For California can also be sold in Federal States 16W722 Front pillar inner right side I k J I 16K774 0 4 Engine block left side Frame left side Fender shield left side 8 111 ...

Page 266: ...r shield inner left side 16W626 Dash panel upper 1 Light control relay 2 E S S relay 3 Headlight washer relay 4 Turn signal flasher unit 5 Hazard warning flasher unit 6 Power window relay 7 Intermittent wiper relay 8 Carbul etor control unit I For California can also be sold in Federal States 1 9 Seat belt timer 10 Heater relay 8 112 ...

Page 267: ... eft side Right side 16W726 16W72 I Headlight washer motor and relay ieadlight washer motor Headlight washer relay 16W738 NOTES 1 If ACC spare terminal 1 is used it must not be used for more than 5 A 2 If the vehicle is not equipped with the optional equipment corresponding to a spare terminal that spare terminal will be secured to the main line with blue tape 8 l 13 ...

Page 268: ...Air conditioner compressor and low pressure switch Left side Right side I I 1 31Rear Heater A 16W768 11 11 Air conditioner switch 25 16W722 d Air conditioner unit 1101 Power Window For California can also be sold in Federal stat a 114 ...

Page 269: ...inal number indicated in the diagram 2 The numbers indicate the nominal cross sectional area of the wire refer to the table at right If a number is not NO used it indicates that the cross sectional area of the wire is 0 5 mm 3 F indicates that this is flexible wire 0 3 0 85 1 25 2 3 5 Nominal SAE size mni gauge No 0 3 AWG 22 0 5 AWG 20 0 85 AWG 18 1 25 AWG 16 2 0 AWG 14 3 0 AWG 12 5 0 AWG 10 Permi...

Page 270: ...ght IND Indicator light 7 Parentheses contain supplementary information in the example the 1 indicates the number 1 fuse of the fuse block 8 The boxed numbers I indicate to which terminal is connected 9 If neither a ci cuit nor a number is listed it i ndicates that this wire of this terminal is not connected to an qther terminal COMPONENT SERVICE WIRING HARNESS 4 The letters indicate the color of ...

Page 271: ...onnectors illustrated with diagonally cut comers on which one section is marked with an X are small flat terminal connectors The X indicates the position of a guide to prevent the connector from being improperly connected i Classification according to number of poles The number of sections represents the number of poles inside the connector However sections in the illustra tion marked with an X or...

Page 272: ...o prevent them from becoming disconnected thus provid ing increased reliability 5 Classification according to sealed connector Classification of round shape sealed connector pin ter minal water proofed connector which is used for engine wiring harness is the same as above Terminal numbers If a pair of connectors male and female is illustrated as dis connected the corresponding terminal numbers vlr...

Page 273: ...Main fusible link Seat belt solenoid IL H l Rear For California can ah be sold in Federal States1 Air conditmne IIA I 0 Air conditioner wiring harnerr C Hazard Headlight Intermittent warning washer wiper relay flasher relay unit Furs block 16W707 ...

Page 274: ...NO ...

Page 275: ...OL UNIT A CARBURETOR CONTROL UNIT A CARBURETOR CONTROL UNIT A CARBURETOR CONTROL UNIT A CARBURETOR CONTROL UNIT A CARBURETOR CONTROL UNIT A CARBURETOR CONTROL UNIT A CARBURETOR CONTROL UNIT B CARBURETOR CONTROL UNIT B CARBURETOR CONTROL UNIT B CARBURETOR CONTROL UNIT B CARBURETOR CONTROL UNIT B CARBURETOR CONTROL UNIT B CARBURETOR CONTROL UNIT B VACUUM SWITCH CARBURETOR ASSEMBLY CARBURETOR ASSEMBL...

Page 276: ...UIT 1 R FRONT WIRING HARNESS BACK UP LIGHT SWITCH 2 RL FRONT WlRlrjG HARNESS BACK UP LIGHT iWITCH 3 BR FRONT WIRING HARNESS 4WD INDICATOR LIGHT SWITCH 4 YR FRONT WIRING HARNESS 4WD INDICATOR LIGHT SWITCH DOME LIGHT WIRING HARNESS 16W635 NO 1 WIRE 1 CIRCUIT 1 RB FRONT WIRING HARNESS DOME LIGHT B 2 B FRONT WIRING HARNESS DOME LIGHT E 3 RG FRONT WIRING HARNESS DOME LIGHT DR 8 122 ...

Page 277: ...ighter illumination light 16W636 CIRCUIT FRONT WIRING HARNESS ACC FRONT WIRING HARNESS ILL FRONT WIRING HARNESS E FRONT WIRING HARNESS B FRONT WIRING HARNESS ILL CLOCK E CLOCK ACC CLOCK ILL FRONT WIRING HARNESS ILL ASHTRAY ILLUMINATION LIGHT E ASHTRAY ILLUMINATION LIGHT ILL CIGARETTE LIGHTER CIGARETTE LIGHTER ILLUMINATION LIGHT CIGARETTE LIGHTER ILLUMINATION LIGHT CLOCK HEATER CONTROL ILLUMINATION...

Page 278: ...WIRING HARNESS FRONT WIRING HARNESS FRONT WIRING HARNESS FRONT WIRING HARNESS FRONT WIRING HARNESS FRONT WIRING HARNESS REAR COMBINATION LIGHT R H E REAR COMBINATION LIGHT L H REAR COMBINATION LIGHT 1L H TAIL REAR COMBINATION LIGHT L H BACK REAR COMBINATION LIGHT L H E SIDE MARKER LIGHT L H SIDE MARKER LIGHT L H 1 SIDE MARKER LIGHT R H SIDE MARKER LIGHT R H BACK DOOR WIRING HARNESS LI BACK DOOR WI...

Page 279: ... TAIL 18 0 3RL REAR COMBINATION LIGHT L H BACK 19 B REAR COMBINATION LIGHT 1L H E 31 GW SIDE MARKER LIGHT L H 32 0 38 SIDE MARKER LIGHT L H 33 0 3GW SIDE MARKER LIGHT R H 34 0 3B SIDE MARKER LIGHT R H Front wiring harness 0 II 1 Back door wiring harness 4334 33 Side marker light R H Rear combination light L H 16W776 BACK DOOR WIRING HARNESS LIB BACK DOOR WIRING HARNESS E BACK DOOR WIRING HARNESS D...

Page 280: ...NESS Vehicles withouta rear wiper and washer Defogger Frame wiring harness License plate light J 16W705 NO WIRE 1 FGW FRAME WIRING k ARNESS 2 FB FRAME WIRING HARNESS 3 2FB FRAfvc WIRING HARNESS 7 GW LICENSE PLATE LldHP Bi 8 B LICENSE PLATE LIGHT E 1 8 126 ...

Page 281: ...RAME WIRING HARNESS 2FB FRAME WIRING HARNESS FL FRAME WIRING HARNESS FBrW FRAME WIRING HARNESS FBr FRAME WIRING HARNESS GW LICENSE PLATE LIGHT B B LICENSE PLATE LIGHT E 3 3WB FRAME WIRING HARNESS 3 3L REAR WASHER MOTOR Rear wiper motor 4 5 6 i 1 El CIRCUIT LICENSE PLATE LIGHT B LICENSE PLATE LIGHT E DEFOGGER REAR WIPER MOTOR ACC REAR WIPER MOTOR LO REAR WIPER MOTOR AS El 121 REAR WASHER MOTOR 141 ...

Page 282: ...ER WINDOW MAIN SWITCH FRONTWIRING HARNESS POWER WINDOW MAIN SWITCH R H UP FRONT WIRING HARNESS POWER WINDOW MAIN SWITCH R H DOWN POWkR WINDOW MAIN SWITCA POWER WINDOW MOTOR POWER WINDOW MAIN SWITCH POWER WINDOW MOTOR Gght sick Power window motor r 3 5 R 1 Front 2 wiring q Tb 3 y e dow harness 4 1 WbJ 16W752 NO WIRE 1 2FR FRONT WIRING HARNESS 2 2FL FRONT WIRING HARNESS 3 2RB POWER WINDOW MOTOR 4 2F...

Page 283: ... 0 85GB THERM0 SWITCH 0 85L POWER RELAY B 0 85LW POWER RELAY B 0 85B POWER RELAY B 0 85BY POWER RELAY A 0 85LR POWER RELAY A 0 85BW POWER RELAY A 3LR FUSE 1 85L FRONT WIRING HARNESS AIR CONDITIONER SWITCH THERM0 SWITCH El POWER RELAY B POWER RELAY A FRONT WIRING HARNESS ACC FRONT WIRING HARNESS E FRONT WIRING HARNESS FUSE FRONT WIRING HARNESS FRONT WIRING HARNESS 191 Power relay B Fuse 16W751 Fron...

Page 284: ...W 13 0 85BW I 13 pJ Idle up solenoid valve 3 as 12 Diode Front wiring harness 16W750 WIRE CIRCUIT I MAGNETIC CLUTCH III DIODE FRONT WIRING HARNESS DIODE FRONT WIRING HARNESS FRONT WIRING HARNESS CONDENSER FAN MOTOR El GROUND I TJ FRONT WI RING HARNESS 1 1 FRONT WIRING HARNESS IDLE UP SOLENOID VALVE IDLE UP SOLENOID VALVE WATER TEMPERATURE SWITCH E S S SOLENOID VALVE E S S SOLENOID VALVE POWER RELA...

Page 285: ...ing harness at the rear of the left front fender shield Inspection Check for a burnt fusible link with a circuit tester since visual diagnosis may be difficult If a fusible link bums out the cause is a short or some other problem in the circuit Carefully determine the cause and correct it before replacing the fusible link When replacing fusible links be sure to use a fusible link of the specified ...

Page 286: ...nse plate lights Illumination lights Headlight washer relay Position lights Heater relay Seat belt warning timer Turn signal lights Alternator Seat belt switches power window relay lights Fuel and water temperature gauges indicator and waming lights oil pressure gauge voltage meter Rear window defogger Rear heater switch Stop lights Buzzer Seat belt switch L H Door switch L H Windshield wipers and...

Page 287: ...battery 2 Remove the column cover Refer to GROUP 19 3 Remove the band clip of the wiring harness and then disconnect the ignition switch harness connector and the key reminder switch harness connector 4 Remove the ignition switch segment and key reminder switch mounting screws and then pull the switch seg ment out of the key cylinder 16W74 1 16YO62 16YE45 16YO62 1 Steering wheel lock cylinder key ...

Page 288: ...ness connector should be connected to the front wiring harness together with the column switch harness connector at the left side of steering support bracket 16W730 METERS AND GAUGES COMPONENTS 1 Speedometer cable 2 Buzzer 3 Printed circuit board 4 Meter cover 5 Meter case 6 Meter glass 7 Meter hood 8 Speedometer 9 Fuel gauge water temperature gauge 10 Tachometer 11 Window plate 12 Combination met...

Page 289: ...TION When installing the instrument cluster be sure to secure the speedometer cable and connector positively SPEEDOMETER Replacement of the Speedometer Cable 1 Replace the cable assembly if there is a malfunction 2 When connecting the cable to the speedometer insert the cable until the stopper properly fits to the speedometer groove 16F554 3 After installing the speedometer pull the speedometer ca...

Page 290: ... reverse polarity the transistors and diodes will be damaged FUEL GAUGE AND UNIT Inspection FUEL GAUGE INDICATION TEST Disconnect the wiring connector from the fuel gauge unit inside the luggage compartment Connect a resistance be tween the terminals and confirm the gauge indications indication p t Empty Full Resistance value 120 a 17 a FUEL GAUGE CONTINUITY TEST Measure the resistance value betwe...

Page 291: ...ing connector from the water tempera ture gauge unit inside the engine compartment 2 Connect a resistance to the connector and then confirm the gauge indications Indication point Resistance value 1 115 C 239 F 23 8 52 2 70 C 158 F 104a WATER TEMPERATURE GAUGE CONTINUITY TEST Measure the resistance value between the terminals with an ohmmeter Resistance value Approx 55 s2 NOTE If the resistance val...

Page 292: ...rical dial The spherical dial is coupled through the dial support plate to the rolling damper plate The rolling damper plate is swivel bearing coupled to a stationary frame by the center axis so it can incline side to side but is always held in a llevel posi tion by apendulum The pointer is coupled with the pitching damper plate Since the pitching damper plate is swivel bearing coupled to the roll...

Page 293: ...enterline of the spherical dial shows the side to side inclina tion angle FORWARD OR BACKWARD INCLINATION The spherical dial inclines forward or backward with the vehicle but the pointer maintains a level position so the pointer indicates the forward or backward inclination angle COMBINED FORWARD OR BACKWARD AND SIDE TO SIDE INCLINATION The forward or backward inclination angle and the side to sid...

Page 294: ...e spherical dial and pointer indicate alevel position 3 If the spherical dial and pointer do not indicate that the vehicle is level adjust the inclinometer by insefting shims between it tid either the combination gauge bracket or the instrument panel If the pointer indication is very far from horizontal replace the inclinometer OIL PRESSURE GAUGE AND UNIT Removal 1 Remove the combination meter 2 R...

Page 295: ...e may be a broken wire or some other problem in the coil VOLTAGE METER Removal 1 Remove the combination meter 2 Remove the pad 3 Disconnect the voltage meter from the meter wiring harness 4 Remove the voltage meter to meter caseattaching screws Inspection VOLTAGE METER CONTINUITY TEST 1 Connect an ohmmeter to the voltmeter 16W779 2 Contirm that the value indicated on the ohmmeter agrees with the s...

Page 296: ...ate and the buzzer to sound for 4 to 8 seconds If the seat belt switch is set to OFF the seat belts buckled during theseat belt wam ing timer interval only the buzzer is cancelled Seat Belt Switch CONTINUITY TEST 1 Pull back the floor mat and disconnect th e seat belt switch connector from where it is at the attachment to the buckle stalk assembly 2 Use an ohmmeter to check for a short circuit at ...

Page 297: ...e terminal 3 and 0 3 B wire terminal 4 are connected with a jumper wire In this condition fasten the buckle if the buzzer stops sounding the seat belt switch is good 16C953 If the buzzer does not sound when terminal 3 and termi nal 4 are connected with a jumper wire and check con tinuity of the seat belt switch If these is continuity in the seat belt switch replace the buzzer After performing the ...

Page 298: ...n the lens 3 The low beam is intended for use in congestgd areas and on highways when oncoming vehicles are within a dis tance of 153 m 500 ft 4 The high beam is intended primarily for distant illumina tion and for use on the open highway when there are no oncoming vehicles Headlight Front combination light Rear combination light 16W720 16W62 Rear side marker light License plate light Dome light l...

Page 299: ... the driver or substituted weight of approximately 70 kg 150 lbs placed in driver s seat Thoroughly clean headlight lenses Adjust headlights by following the instructions for the headlight tester Removal 1 Remove the radiator grille front combination light and headlight bezel Refer to GROUP 23 2 Disconnect the harness connector from the bulb socket 3 Remove the retaining ring from the mounting rin...

Page 300: ...hanging operation 16W734 Terminal Llghtmg switch Dimmer and L Turn signal Headlight Horn b washer switch switch R R FF ON OFF ON No Wire Used for OFF 300 go DI Dz P L L N I I I NOTE The sizes for wires whose size is not specified in the Wire column above are 0 3 mm for items in parentheses and 0 5 mm2 for all others 8 146 ...

Page 301: ...ty between the terminals Hazard warning flasher unit 8 d Column switch 9 0 Column switch 10 0 Front turn signal light R H 11 0 Rear turn signal light R H TURN SIGNAL AND HAZARD WARNING FLASHER UNIT Turn signal flasher unit To turn signal switch To fusk No 3 1wl558 Hazard warning flasher unit j ToLwarninQ To fuse No 1 8 147 ...

Page 302: ...together I 6W747 DIMMER CONTROL SWITCH Inspection 1 With the connector disconnected measure the continuity between the dimmer control switch terminals with an ohmmeter F16599 2 If the resistance value varies smoothly between 0 and 10 ohms throughout the entire operation range the dimmer control switch is functioning properly F 16599 Front harness ground wire Turn signal flasher unit nnector 2P I F...

Page 303: ...en the wiper motor mounting bolts and then with the motor pulled out slightly disconnect the linkage and the motor C16555 3 Remove both the motor and the linkage Caution Because the installation angle of the crank arm and the motor has been set do not separate them unless it is necessary to do so If they must be separated do so only after marking the mounting positions Installation Install the wip...

Page 304: ... If the wipers do not operate when the wiper switch is set to the star mark 1 Confirm that power is being supplied to terminals 1 and 4 mm in t ii _ ci6 i ll I 0 a 16Y156 I I 16Y186I 2 Confirm that the voltage between terminal 6 and ground j is 0 V 3 Confirm that the voltage between terminal 3 and ground is 0 V If the wipers do not operate when the washer switch is turned ON 1 Confirm that power i...

Page 305: ... Terminal Wiper washer switch Intermittent time adjusting switch No Wire Used for OFF INT LOW HI SHORT L LONG c 1 2 S L 1 YL Washer switch ON 2 LB Wiper switch High speed I I I I I I I I I 3 2B Ground by 60 a 6 0 4 BY Wiper switch Intermittent A u 5 BR Wiper switch OFF P 6 LO Wiper switch Low speed 0 7 0 3Y Intermittent time adjusting switch Remarks The dotted lines indicate that the automatic ret...

Page 306: ... 1 Remove the spare wheel from the back door 2 Remove the wiper arm and remove the pivot shaft lock ing nut 3 Remove the back door trim and remove the waterproof film Refer to GROUP 23 4 Remove the rear wiper motor mounting bolts and remove the rear wiper motor 16W5 16 Installation Adjust the mounting position of the wiper arm so that the stopping position of the wiper blade agrees with the standa...

Page 307: ...the tank 16W5 19 REAR WASHER NOZZLE Inspection and Adjustment Check the washer fluid spray pattern Adjust the nozzle REAR WIPER AND WASHER SWITCH Removal Remove the switch from the instrument cluster and discon nect the con nector Inspection operate the switch and check the continuity between the temiinals Position Wiper Washer I I 70 2 8 I 1 230 g mm in 16W542 16W620 8 153 ...

Page 308: ...elay 2 Headlight washer switch 3 Headlight washer motor 4 Headlight washer tank 5 Bracket 6 Main h e 7 Clamp 8 Check valbe 9 Nozzle clamp 10 Headlight washer nozzle 16W712 HEADLIGHT WASHER TANK Removal Remove the headlight washer tank remove the tank mounting bolts and 8 154 ...

Page 309: ...inuity shown in the chart below replace the relay NOTE Connect the test probe to terminal 3 There should be no continuity in the opposite direction therefore during inspec tion pay attention to the direction of continuity when con necting the test probe HEADLIGHT WASHER NOZZLES Removal 1 Remove the radiator grille and headlight bezels Refer to GROUP 23 2 Remove the nozzle clamp and remove the wash...

Page 310: ...L 1 Remove the radiator grille Refer to GROUP 2 3 2 Disconnect the horn connectors 3 Remove the horn mounting bobs 16W697 INSPECTION 1 Check horn switch contact for burned out or short circuited 2 Check horn switch spring for broken or damaged 3 Check horn switch hamess for damage 4 Check horn adjustment screw for looseness 5 Check the horn for water dirt or other foreign matter lodged 8 156 ...

Page 311: ...en obtained The sound volume is too loud Turn the adjusting screw 20 to 30 in the DOWN direction and then lock it in positon when a satisfactory sound volume has been obtained Horn will not sound Turn the adjusting screw slightly in the UP direction until the horn sounds find a satisfactory sound volume by continuing to turn the screw within a range of 180 and then lock the screw in place If a sat...

Page 312: ...ton 3 Example of time adjustment Before adjustment After adjustment 1O Ol lo 29 lo oo 10 30 10 59 ll oo Caution This clock is a delicate mechanism containing a crystal oscillator transistors etc and should be handled with care Specialized technical skill is needed to repair the inter nal mechanism do not attempt to disassemble it If the clock itself is malfunctioning replace the entire assembly Wh...

Page 313: ...nal and search for the place where there is a sudden change in the voltage to OV 5 This place where the voltage suddenly changes indicates the location of the broken wire 6 If OV is indicated at point A the wire is broken between point A and the positive terminal Find the point where there is a sudden change in the voltage to 12V as described in step 4 above Repair 1 Prepare the following l Conduc...

Page 314: ...e before supplying power 4 For a better finish scrape away excess deposits with a knife after drying is complete one day later Caution After repair clean the glass with a soft dry shop towel or wipe along the printed heater line with a slightly moistened shop towel REAR WINDOW DEFOGGER SWITCH Removal Remove the switch from the instrument cluster and push the connector bar to detach the switch Insp...

Page 315: ...e following cases therefore adjust it as de scribed below 1 When radio is installed 2 If antenna is replaced 3 If radio has low sensitivity 4 If radio is noisy Trimmer Adjustment Make the following preparations for adjustment 1 Turn the ignition key to the ACC position 2 Extend the antenna all the way 3 Tune accurately to a station near 1 400 kHz in order to receive a broadcast in as weak an elect...

Page 316: ...and a strong impulsive fast pop ping noise from the ignition system Before performing any checking or adjustments tirs t confirm the following points l Adjust the antenna trimmer completely l Set the pushbuttons tuning properly L l Extend the antenna all the way Prevention of Ignition Circuit Noise A resistance equipped cable is used for the high tension cable in order to prevent noise however if ...

Page 317: ...motor Water temperature gaugeunit Engine Ground wire 16E710 Connect a 0 5 PF noise suppression capacitor to the B terminal of the flasher unit Flasher iu unit L 0 5pF noise suppression capacitor 16E712 1 Connect a 0 5 JF noise suppression capacitor to the B terminal of the horn 2 For an FM radio connect an LC filter to the horn terminals Horn LC filter 16E713 Clonnect an LC filter between the term...

Page 318: ... NOTE The fuse box for the radio circuits is located on the back of the radio therefore the radio must be removed in order to replace a fuse 1 FRONT SPEAKER _ _ Removal 1 Remove the speaker mounting screws 16W520 2 Remove the speaker from inside of the instrument panel 3 Disconnect the speaker wiring connector REAR SPEAKER Removal 1 Remove the speaker mounting screws 16W545 2 Remove the speaker an...

Page 319: ...g bolts and screws 4 Detach splash shields from fender about a half of rearward 5 Remove the antenna mounting nut 16W709 6 Remove the screw which mounts the antenna bracket to the body from inside the fender 168597 7 Remove the antenna toward the bottom 16S591 8 165 ...

Page 320: ...COMPONENTS SERVICE POWER WINDOW COMPONENTS 1 1 Sub switch 2 Main switch 3 Power window motor 4 Power window regulator assembly 2 5 Power window relay 16W764 16W671 8 166 ...

Page 321: ... Caution tVhen loosening the connecting screws of the regulator and the motor assembly the compressed force of the regulator spring may cause the regulator arm to spring up Inspection Connect the motor terminals directly to the battery and check that the motor operates smoothly Next reverse the polarity and check that the motor operates smoothly in the reverse direction lW145 8 167 ...

Page 322: ...TCH Check for continuity in accordance with the folldlwing con nection table 345 67 16K512 Switch Power window switch manual UP 0 OFF 0 DOWN Lock switch ON LOCK OFF FREE SUB SWITCH Check for continuity in accbrdance with the following con nection table DOWN ISI l0K573 8 168 ...

Page 323: ...s no continuity when the buckle is unlocked and continuity when it is locked the seat belt switch can be assumed to be functioning properly 4 If a microswitch is defective the buckle stalk assembly containing the microswitch should be replaced For re placement Refer to GROUP 23 SOLENOID Inspection 1 Lock the buckle and set the ignition key to ON 2 Pull the seat belt out slightly from the retractor...

Page 324: ...GROUP 25 IONCONTROL SYSTEMS CONTENTS OPERATIONAL DESCRIPTION 2 EXHAUST EMISSION CONTROL SYSTEM 21 COMPONENT SERVICE 20 EVAPORATIVE EMISSION CONTROL SYSTEM 20 ...

Page 325: ...dary air supply system Exhaust gasrecirculation system EGR valve Therm0 valve Heated air intake system Deceleration device Coasting air valve Air switching valve Throttle opener for air conditioner Tamper proof mixture choke High altitude compensation device Fuel control system Federal not available in California Closed P C V valve Single X X X With relief valve Vapor liquid X X X Dual oxidation t...

Page 326: ...ng into the atmosphere This system has a positive crankcase vent valve PCV valve at the rocker arm cover This system supplies fresh air to the crankcase through the air cleaner Inside the crankcase the fresh air is mixed with blow by gases and this mixture passes through the PCV valve into the induction system The PCV valve has a metered orifice through which the mixture of fresh air and blow by g...

Page 327: ...tored in the canister When the engine is running the fuel vapors absorbed in the canister are drawn into the intake manifold through the purge control valve and an orifice And the carburetor bowl vapors flow into the carbu retor through the bowl vent valve Bowl Vent Valve The bowl vent valve which controls the carburetor bowl vapors is opened when the intake manifold vacuum working on the diaphrag...

Page 328: ...is system for sensing the coolant temperature at the intake manifold closes the purge control valve when the coolant temperature is lower than a pre set value in order to reduce CO and HC emissions under engine warm up conditions and opens the purge control valve when the coolant temperature become above the pre set temperature The therm0 valve is deemed to be an acceptable AECD according to the c...

Page 329: ...ve and by a common rocker arm so that the jet valve and intake valve open and close simultaneously On the intake stroke the air fuel mixture flows th rough the intake valve port into the combustion chamber At the same time jet air is forced into the combusion chamber because of the pressure difference produced between the two ends of the jet air passage between the jet air intake olpenings in the ...

Page 330: ...d the engine is allowed to idle for a prolonged period of time Caution 1 Operation of any type including idling should be avoided if engine misfiring occurs Under thii condition the exhaust system will operate at abnormally high temperature which may cause damage to the catalyst or underbody parts of the vehicle 2 Alteration or deterioration of ignition or fuel system or any type of operating cond...

Page 331: ... the purpose of promoting oxidation of exhaust emissions during the engine warm up operatio n and the vehicle deceleration The reed valve is actuated by exhaust vacuum being gene rated from pulsation in the exhaust manifold and extra air is supplied into the exhaust manifold through the secondary air control valve The secondary air control valve is opened by the intake manifold pressure when the s...

Page 332: ...tle valve openings while the EGR flow is suspended at idle and WOT operation The primary valve controls EGR flow for vehicle operation with relatively narrow throttle valve openings while the secondary control valve allows the recirculation of exhaust gas into the intake mixture when the throttle valve is further opened The vacuum applied on the dual EGR control valve is controlled by a therm0 val...

Page 333: ...valve incorporated in the EGR system for sensing the coolant temperature at the intake manifold closes the EGR control valve when the coolant temperature is lower than a pre set value This prevents deterioration of vehicle driveability and startability during initial starting and opens the EGR control valve when the coolant temperature exceeds the pre set temperature Once the engine is stopped and...

Page 334: ... to the diaphragm of the vacuum motor which in turn opens air control valve A so as to let the pre heated intake air flow through the heat cowl and air duct into the air cleaner When the b metal senses a temperature inside air cleaner of above about 45 C 113 F the air bleed valve is fully opened As a result the intake air to the carburetor comes directly through the fresh air duct since the air co...

Page 335: ...VALVE ASV SYSTEM In order to improve fuel economy as well as reduce HC emissions during vehicle deceleration the air switching valve which is activated by carburetor ported vacuum cuts off the fuel flow to the bypass holes and pilot outlet by supplying additional air into the slow passage The activation of the air switching valve is suspended by opening the solenoid valve when the engine speed sen...

Page 336: ...n this throttle opener system When the sensor detects engine speeds at or below the specified value the deceleration spark advance system does not operate and when the engine speed is above the specified value the deceleration spark advance system functions as designed Therefore the engine speed sensor does not cause this throttle opener system violate the regulations of the Clean Air Act hrottle ...

Page 337: ... CO adjustments are required by state or local regulations TAMPER PROOF AUTOMATIC CHOKE All carburetors also have tamper proof choke The choke related parts are factory adjusted Neither removal of the choke cover nor tampering with W A S wax stroke adjusting screw is required in service except during a major carburetor overhaul or when adjustment of choke calibration related parts is required by s...

Page 338: ...so be sold in Federal States In order to meet the requirements at all altitudes all the feedback carburetor vehicles for California are equipped with high altitude compensation system in addition to feedback carburetor system High altitude compensation system consists of a high altitude compensator HAC and passages for additional bleed air HAC The air fuel ratios at high altitude are maintained by...

Page 339: ...upplied to the solenoid The solenoid operates at a fixed frequency By varying the amount of time the solenoid is energized during each cycle defined as duty cycle the air fuel mixture delivered to the engine can be precisely controlled The duty cycle to the solenoid is con trolled by the electronic control unit ECU in response to signals from the exhaust oxygen sensor throttle position sensor and ...

Page 340: ...re of the intake air in the air cleaner and provides this information to the ECU for use in controlling fuel delivery Electronic Control Unit ECU The Electronic Control Unit is mounted in the passenger compartment and consists of a printed circuit board mounted in a protective metal box It receives analog inputs from the sensors and converts them into digital signals These digital signals and vari...

Page 341: ...acudm supplied to the halve from the carburetor ported vacuum to intake manifold vacuum The solenoid valve is controlled by the ECU based on engine speed 5 Throttle Opener Control When the air conditioner switch is ON or the accessory switch such as instrument panel light and power steering switch is ON in families where applicable the engine idle speed is increased by changing the throttle valve ...

Page 342: ...ve which provides addi tional fuel for main metering system The activation of the on off valve is controlled by the length of time current supplied to the solenoid When additional fuel is required such as heavy acceleration heavy engine loads cold start or warm up operation the ECU energizes the solenoid at the pre set duty cycles Fuel Cut Off system When the ignition key is turned off the deceler...

Page 343: ... rubber and vinyl hoses will deteriorate with normal use replace them with new ones when replacing the canister PURGE CONTROL VALVE Inspection 1 Make sure that the cooling water is at temperatures between 80 and 90 C 176 and 194 F 2 Disconnect the purge hose from the air cleaner and blow into the purge hose If the valve is not open its t operation is normal Then start the engine and increase the e...

Page 344: ... and disconnect the hoses from the check valve Installation When installing the fuel check valve observe the following items 1 Securely tighten each hose clamp 2 Replace hoses if they have cracks 3 Securely tighten the valve mounting bolt EXHAUST EMISSION CONTROL SYSTEM CATALYTIC CONVERTER Removal Caution Before removing or inspecting the exhaust system ensure that the exhaust system is cool enoug...

Page 345: ...pection 1 Check the air hoses and air pipes for damage or cracks replace if necessary 2 Check the air pipe connections for leakage 3 Start and run the engine at idle 4 Disconnect the air hose from the reed valve 5 Put your hand lightly on the intake port of reed1 valve If you feel suction the reed valve is good Check to ensure that no exhaust emission is blown back Replace if defective EGR SYSTEM ...

Page 346: ...EGR valve spray it with a solvent so that it can be turned easily HEATED AIR INTAKE SYSTEM Inspection 1 2 3 4 5 Make sure all vacuum hoses and the heat cowl to air cleaner air duct are properly attached and are in good condition With a cold engine and ambient temperature less than 30 C 86 F the air control valve in the snorkel should be in the up or heat on position With the engine warmed up and r...

Page 347: ...the electrical wiring or engine sp eed sensor is defective 4 Increase the engine speed to 1 500 rpm Check to ensure that voltage is present at the solenoid valve connector If there is no voltage the engine speed sensor is defective 5 Increase the engine speed to 2 500 rpm Check to ensure that no voltage is present at the solenoid valve connector If there is voltage the engine speed sensor is defec...

Page 348: ... RETORQUING OF CYLINDER HEAD BOLTS 14 SILENT SHAFT DRIVE CHAIN TENSION ADJUSTMENT PROCEDURE 14 ENGINE OIL LEVEL GAUGE 15 COMPONENT SERVICE 16 ENGINE MOUNTING 16 ENGINE AND TRANSMISSION ASSEMBLY 19 TIMING CHAIN 2 ROCKER ARMS ROCKER ARM SHAFTS CAMSHAFT 26 CYLINDER HEAD 30 m VALVES AND VALVE SPRINGS 32 JET VALVES 37 SILENT SHAFTS AND OIL PUMP 39 PISTONS AND CONNECTING RODS 43 CRANKSHAFT 47 CYLINDER B...

Page 349: ... ED SPECIFICATIONS G54B ENGINE 1 5EN116 9 2 ...

Page 350: ... of links Pitch mm in Crankshaft sprocket Material No of teeth Crankshaft sprocket B Material No of teeth Camshaft sprocket Material No of teeth Silent shaft and oil pump sprocket Material No of teeth Rocker arm Material I D mm in Oil clearance mm in 4 in line vertical Hemispherical Overhead valve type Overhead camshaft type 2 555 155 9 91 1 x98 3 59 x 3 86 8 2 25 BTDC 59 ABDC 64 BBDC 20 ATDC l 3 ...

Page 351: ...eter mm in Stem diameter mm in Clearance stem to guide mm in Margin mm in Identification mark Exhaust valves Material Chain Cast iron cam surface chilled 42 5 1 673 10 5 413 37 1 457 34 1 339 0 05 0 09 002 004 6 _ Aluminum alloy Less than 0 05 002 13 050 13 068 5138 5145 13 250 13 268 5217 5224 13 500 13 518 5315 5422 47 30047 325 1 8622 1 8632 47 60047 625 1 8740 1 8750 40 300 40 325 1 5866 l 587...

Page 352: ...iameter Standard mm in Clearance Piston to cylinder mm in Pistons for service mm in Piston rings No of rings per piston No of compression rings No of oil rings Compression ring type No 1 ring No 2 ring Gil ring type Ring gap mm in No 1 ring No 2 ring Oil ring Ring side clearance mm in No 1 ring No 2 ring Rings for service mm in Special aluminum alloy Autothermic Steel strut used for 4G54 91 1 3 58...

Page 353: ...and taper mm in Maximum allowable oversize Cylinder bore mm in Oil pump Type Driven by Oil pressure at idle kPa psi Relief valve opening pressure kPa psi Oil filter Type Size Diameter x Length mm in Engine oil Capacity including that of oil filter liters U S qts Im p qts Rear wheel drive models 4 wheel drive models Recommended oil API classification Specifications 166 6 535 21 974 21 985 8651 8655...

Page 354: ...No 2 crossmember to frame Frame to plate Transfer support insulator to transfer mounting bracket Transfer support insulator to plate Transfer mounting bracket to transfer Vehicles with an automatic transmission Engine support rear insulator to No 2 crossmember Engine support rear insulator to transmission No 2 crossmember to frame Frame to plate Transfer support insulator to plate Transfer mountin...

Page 355: ...stud Oil relief valve plug Water temperature gauge unit 5 6 4 5 20 39 15 28 15 19 11 14 12 17 9 13 t 74 83 55 61 45 47 33 34 108 127 80 94 30 39 22 28 30 39 22 28 4 5 3 4 128 137 94 101 128 137 94 101 4049 29 36 8 9 6 7 15 21 11 15 10 l 1 5 7 5 8 5 10 11 7 8 8 9 6 7 8 15 21 11 15 6 7 4 5 5 5 59 78 44 57 11 12 8 9 50 58 3743 1 4049 29 36 30 39 22 28 LUBRICANT Specified lubricant Quantity I Engine o...

Page 356: ...ter 45 d D 44 mm 1 73 in MD998165 D Valve seat cutter 65 O D 44 mm 1 73 in Use Tool Number and name dD998148 D Ialve seat cutter pilot tiD998377 falve stem seal installer MD99 8303 u alve spring compressor UD998 184 Piston pin setting tool MD99825 1 Silent shaft bearing puller MD998250 Silent shaft bearing installer Use Use with valve spring seat May also be used for MA904 For rear bearing For rea...

Page 357: ...6 Crankshaft rear oil seal installer MD998308 Jet valve stem seal installer MD998309 Jet valve spring pliers see page 2 for instructions Use i Tool Number and name MD998054 Oil pressure switch wrench t MD998310 Jet valve socket wrench Use 9 10 ...

Page 358: ...rn sprocket Worn and or broken tension adjusting mecha nism Replace Replace Replace Replace thrust bearing Replace Replace Replace piston and pin or connecting rod Recondition cylinder Repair or replace Realign Replace Replace Replace Adjust or replace Replace Replace Replace Camshaft and valve mechanism knocking Excessive camshaft and bearing clearance Replace Improper valve clearance Adjust Worn...

Page 359: ...e Replace valve Narrow valve seat Reface Overheating Repair or replace Excessive engine speed Drive at proper speed Stuck valve guide Repair or replace 2 Shortage of engine oil Add or change oil Clean crankcase change oil and replace oil filter element Use proper oil Repair or replace Repair or replace Improper piston rin g clearance Replace Clean air cleaner and replace filter Clean or replace ca...

Page 360: ...orn or out of round crankshaft journal Clogged oil passage in crankshaft Repair or replace Add or change oil Check oil level on daily basis Adjust or repair Use proper oil Repair or replace Clean Bearing worn or eccentric Replace bearings and check engine oil lubrication system Bearing improperly assembled Non concentric crankshaft or bearing Loose engine mounts Silent shaft bearings damaged Impro...

Page 361: ...T SHAFT DRIVE CHAIN TENSION ADJUST MENT PROCEDURE _ When a loose silent shaft drive chain is suspected 4s the proba ble cause of abnormal noise the tension must be readjusted Tension of silent shaft drive chain can be adjusted without removing timing chain cover as follows 1 Remove cover from access hole provided a chain case under water pump t center of 2 Loosen special bolt B 1 3 Using your fing...

Page 362: ...pper limit after the engine has been standing for several hours When the engine is started the oil level drop some what due to filling of oil passages etc When the oil level is at or below the MIN mark line lower limit on the level gauge add 1 liter 1 U S qt 0 9 Imp qt The oil should never be allowed to remain below the lower limit Caution Do not overfill crankcase This will cause oil aeration and...

Page 363: ... No 2 crossmember 5 Engine support rear i ulator 6 Transfer mounting bracket 7 Transfer support insulator 8 Plate 9 Stopper 10 Pipe Nm fLlbs A 13 20 9 14 B 6 10 4 7 C 3040 22 29 D 18 25 13 18 E 55 75 40 54 F 3042 22 30 G 17 23 12 17 Rear mounting Vehicles with a manual transmission 01 W502 Vetiicles with an automatic transmission 10 6 F 9 16 ...

Page 364: ...ith ajack 2 After the transfer mounting bracket and transfer support insulator have been separated remove the plate from the side frame 09W507 09W508 3 Detach the transfer mounting bracket from the transfer 09W507 09W508 4 Support the transmission with ajack 5 Detach the engine support rear insulator from the engine SO902O OlW5 19 6 For vehicles with an automatic transmission detach the cross sele...

Page 365: ...cket for deformation or corrosion 3 Check plate for deformation or corrosion 4 Check No 2 crossmember for deformation or corrosion INSTALLATION Front Insulator Make sure that the locating boss and Caution hole are in alignment Do not distort rubber portions and never stain ml x por tions with fuel or oil 21 7 f 85 1 mm in OlW5OL 9 18 ...

Page 366: ...se 0 lW 5 14 6 Disconnect the fuel hoses OlW526 7 Disconnect the accelerator cable Refer to GROUP 14 8 For vehicles equipped to meet California regulations can also be sold in Federal States disconnect the air temperature sensor connector throttle position sensor connector and the carburetor control wiring harness connector 9 Disconnect the Starter motor wiring harness 0 1W507 10 Remove the clutch...

Page 367: ...fuel cu t solenoid valve and bowl vent valve connector 14 Disconnect the high tension cable OlW516 15 Disconnect the water temperature gauge connector OlW516 16 Remove the power steering pump Refer to C ROUP 19 17 For vehicles equipped to meet California regulations can also be sold in Federal States disconnect the water temperature sensor OlW516 9 20 ...

Page 368: ...sconnect the speedometer cable Refer to GROUP 2 1 26 Disconnect the back up light switch harness and 4 wheel drive indicator light switch harness Refer to GROUP 2 1 27 Remove the front and rear propeller shafts Refer to GROUP 16 28 Remove the transmission gear shift lever vehicles with a manual transmission or transmission selector lever vehicles with an automatic transmission and transfer shift l...

Page 369: ...to GROUP 7 2 Supply transmission and transfer case fluid Refer to GROUP 21 3 Supply engine oil Refer to p 9 8 4 Adjust the clutch control system Refer to GROUP 6 Adjust the accelerator cable Refer to GROUP 14 Adjust the hood alignment Refer to GROUP 23 5 Torque all parts to specifications during assembly 9 22 ...

Page 370: ...t Special washer Pulley Flange bolt 8x68 8 Flange bolt 8x73 Flange bolt 8x58 2 Timing chain case Chain case gasket R 1 Chain case gasket L Flange bolt 6x18 2 Cover Gasket Oil seal Flange bolt 10x15 2 Special bolt B 1 Special bolt A Spring washer Chain guide B Flange bolt 6x60 Flange bolt 6x45 Chain guide A Flange bolt 6x45 Flange bolt 6x32 Chain guide C Chain B Crankshaft sprocket B Sprocket B 2 S...

Page 371: ...aft install chain and sprocket Place camshaft sprocket on sprocket holder 6 Install crankshaft sprocket B for driving silent shafts on crankshaft 7 Assemble silent shaft sprockets to chain B Make sure that timing marks are in alignment with plated links Use care not to confuse right and left sprockets as they are installed in opposite directions 9 24 Sprocket holder Chain guide right Tensioner sle...

Page 372: ...nt shaft sprockets slightly to position chain slack at point P 14 Adjust position of chain guide B so that when chain is pulled in direction of arrow with finger tips clearance be tween chain guide B and links of chain B will be 1 to 3 5 mm 04 to 14 in and tighten special bolts A and B Tightening torque Special bolt A Special bolt A 8 9 Nm 6 7 ft lbs Special bolt B 15 21 Nm 1 l 15 ft lbs Chain gui...

Page 373: ...seal 2 5 Rocker cover 6 Rocker cover gasket 7 PCV valve 8 Semicircular packing 9 Flange bolt 10 10 Flange bolt 8x25 2 11 Rocker arm and shaft assembly 1 Bearing cap front 2 Wave washer 2 3 Rocker arm A 4 4 Adjusting screw 4 5 Nut 4 6 Adjusting screw 8 7 Nut 8 8 Rocker arm C 4 9 Bearing cap No 2 10 Rocker arm spring 6 11 Bearing cap No 3 12 Bearing cap No 4 13 Bearing cap rear 14 Rocker arm shaft l...

Page 374: ...evident 1 EN01 2 1 Portion A dented or worn 2 Portion B eccentric 3 Portion C inside diameter excessively loose on shaft 2 Check to ensure that oil holes are clear rocker arm with oil holes only Rocker Arm Shaft 1 Check to ensure that rocker arm mounting portion is not worn 2 Check to ensure that oil holes are clear SEN063 Camshaft 1 If the following areas of the camshaft are badly worn or damaged...

Page 375: ...t bearing cap Then insert the bolts to hold shafts in bearing cap 3 Install the waved washer in the direction shown in the illustration 4 Assemble the rocker arm shaft so that the alignment mark at the front end matches the alignment rnark of the front bearing cap 5ENO12 5 Install the rocker arms shafts caps etc as shown in illustration before installation to the cylinder head Insert the bolts to ...

Page 376: ...earing caps assembly to the cylinder head and tighten the bearing cap bolts to specified torque 9 Adjust the valve clearance See Lubrication and Mainte nance Group 0 for detailed procedure 10 Install the semi circular packing to the front of cylinder head and apply sealant to top of semi circular packing Recommended adhesive 3M Super Weather Strip Adhesive 800 1 or equivalent 11 Install the rocker...

Page 377: ...01 11 Washer 10 12 Cylinder head 13 Cylinder head gasket NOTE Numbers show order of disassembly For reassembly reverse order of disassembly Nm ft lbs A Cold engine 89 98 65 72 Hot engine 98 107 73 79 B 15 21 11 15 C 15 19 11 14 5EN086 1 Remove cylinder head bolts in sequence shown in illustra tion 5ENO15 2 Cylinder head bolts can be loosened with ordinary socket wrench or special tool MD99805 1 9 ...

Page 378: ...y sealant to cylinder head gasket 3 Before cylinder head gasket is installed apply sealant to top surface indicated by arrows in illustration of each butt joint between cylinder block and chain case Cylinder Head 1 Install cylinder head assembly 2 Install cylinder head bolts 3 Starting at top center tighten all cylinder head bolts to l 2 of specified torque in the sequence shown in illustra tion 5...

Page 379: ...alve seat 4 9 Lock 8 10 Retainer 4 11 Spring 4 12 Seat 4 13 Exhaust valve 4 14 Valve stem seal 4 15 Exhaust valve guide 4 16 Exhaust valve seat 4 17 Cylinder head 6 NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 5EN017 Disassembled parts such as valves valve springs should be grouped in accordance with their cylinder numbers 9 32 ...

Page 380: ...in 6EN020 5 Valve seat contact should be made at center of valve face 6 Using marking compound check for even contact with valve seat 7 If inadequate contact with valve seat is evident correct valve seat and or reface valve Valve Springs 1 Check free height of each valve spring and replace if necessary 1 EN03 5 2 Using a square test squareness of each valve spring If spring is excessively deformed...

Page 381: ...ion of seal will adversely aff ct lip and eccentricity resulting in oil leakage past valve guides VALVE SEAT RECONDITIONING 1 When correcting check valve guide for wear Replace guide if worn and then correct seat 2 To correct valve seat use special tools lEN036 lEN037 Contact width Exhaust 1 1 2 l 6 mm 047 063 in Intake 0 9 1 3 mm 035 051 in 3 After correction valve and valve seat should be lapped...

Page 382: ... PROCEDURE Replace the valve guide as follows 1 Using special tool press valve guide out toward cylinder head lower surface 1 EN040 2 Machine valve guide hole in cylinder head to outer diameter of oversize valve guide 3 Using special tool install the valve guide Use of valve guide installer makes it possible to press the valve guide to a predetermined height Valve guide should be installed from to...

Page 383: ...a tion color side toward valve spring retainer 1 EN043 Identification color Blue 3 Use valve spring compressor or suitable tool to comp ress spring and install retainer lock 3EN 127 4 After installation of valves make certain that retainer locks are positively installed Caution When spring is compressed with Valve Spring Compressor or suitable tool check to see that the bottom of r ainer does not ...

Page 384: ...valve assembly with special tool Caution When using the jet valve socket wrench make certain that the wrench is not tilted with respect to the center of the jet valve If the tool is tilted the valve stem might be bent by the force exerted on the valve spring retainer resulting in defective jet valve operation 2 Remove the jet valve spring retainer lock with special tool and remove the valve spring...

Page 385: ...inserting the valve use care to prevent damage to the new valve stem seal lips After installation check to ensure that the valve slides smoothly 3 Mount the jet valve spring and jet valve spring retainer Then compress the spring with the special tool and install the retainer lock When compressing the spring with pliers use care not to avoid damaging the valve stem with the bottom of the spring ret...

Page 386: ...Oil pump drive gear 4 Oil pump driven gear 5 Plug 6 Relief spring 7 Relief valve 8 Pin 2 9 Oil pump body 14 Oil pump gasket 15 Flange bolt 16 Silent shaft right 17 Woodruff key 18 Flange bolt 2 19 Thrust plate 20 O ring 21 Silent shaft left 22 Woodruff key 23 Oil filter 16 23 NOTE Numbers show order of disassembly For reassembly reverse order of disassembly Nm ft lbs A 59 78 44 57 B 6 7 4 5 5 5 C ...

Page 387: ...arance is excessive or if case or cover has stepped wear replace case and cover assembly replace gears or both Silent Shafts 1 Check journals for wear damage or seizure 1 fexcessive damage or seizure is evident check bearing also If necessary replace silent shaft bearing or both 2 Check oil hole passage for clogging Clean or repair if necessary SILENT SHAFT BEARING REPLACEMENT PROCE DURE 1 Using s...

Page 388: ... O ring into groove of thrust plate 4 Apply engine oil around O ring 5 Install two guides into threaded holes for mounting thrust plate Guides should be fabricated by cutting off hexagonal heads of bolts 6 mm 24 in in diameter and 50 mm 2 in long 5EN027 6 Install since thrust plate into cylinder block along guides Without use of guides threaded holes will be hard to align turning to align holes mi...

Page 389: ...engine and put approx 10 cc 0 6 cuin of clean engine oil in delivery port SEN029 Install right silent shaft into oil pump driven gear Install driven gear and silent shaft tightening bolt and tighten to specified torque Apply engine oil to journal of right silent shaft Install silent shaft and oil pump asan assemblyto cylinder block Use care to avoid damaging rear bearing as the shaft is installed ...

Page 390: ...l ring 4 8 Piston 4 NOTE Numbers show order of disassembly For reassembly reverse order of disassembly Nm ft lbs A 45 47 33 34 5 6 7 5EN120 REMOVAL Connecting Rod Cap 1 Before connecting rod cap is removed make the cylinder number on the connecting rod and on the cap and big end side surfaces DENOSO 2 Keep bearings in order of corresponding connecting rods according to cylinder numbers for proper ...

Page 391: ...58 6 Apply engine oil to outer surface of piston pin and small end bore of connecting rod 7 Set connecting rod and piston with front mark facing up 8 Insert push rod piston pin and guide as a unit into piston pin hole and connecting rod small end hlole 9 Align the guide so that the two parallel surfaces are positioned as shown in illustration lEN060 10 Press piston pin into piston pin hole applyin...

Page 392: ...er side rail To install side rail first nut one I end of side rail between piston ring groove and spacer hold it down firmly and then press down the portion which is to be inserted into groove with a finger as illustrated lEN063 Caution Do not use piston ring expander when installing side rail 3 Install lower side rail by same procedure as Step 2 4 Using piston ring expander installNo 2 piston rin...

Page 393: ...ngs asthey are installed into the cylinder 3 Make sure that front mark of piston and front mark identification mark of connecting rod are directed to ward front of engine SEN121 5EN067 4 When connecting rod cap is installed make sure that cylinder numbers which were put on rod and cap at disassembly match 5 When installing a new connecting rod make sure that the notches for holding the bearing in ...

Page 394: ...case 16 Gasket 17 Separator 18 Rear oil seal 19 Bolt 10 20 Bearingcap 5 21 Crankshaft bearing 5 22 Crankshaft 23 Crankshaft bearing 5 NOTE Numbers show order of disassembly For reassembly reverse order of disassembly Nm ft lbs A 128 l 37 94 l 01 B 7483 55 61 Vehicles with an automatic transmission 5EN033 INSPECPON Oil Clearance Measurement 1 After main bearing cap has been tightened to specified t...

Page 395: ...the scale printed on gauge envelope lEN067 INSTALLATION Main Bearing 1 Install grooved main bearing upper bearing ton cylinder block side 2 Install grooveless main bearing lower bearing on main bearing cap side 3 Both upper and lower bearings f r center thrust bearing are grooveless Crankshaft 1 Install crankshaft Apply engine oil to journ and pins 2 Caps should be installed with arrow mark direct...

Page 396: ...all 7 bolt and torque to specifications Flywheel 1 Install flywheel and tighten bolts to specified torque Check clutch mounting surface for runout Tightening torque 128 137 Nm 94 101 ft lbs Flywheel runout 0 1 mm 004 in max 2 To install flywheel use 26 mm 1 024 in bolts with 11 marked on the heads Do not use shorter bolts for installing drive plate Oil seal case Oil separator Oil pan mounting surf...

Page 397: ...SHAFT Drive Plate 1 Install adapter plates and drive plate and tighten bolts to specified torque 2 Use bolts 21 5 mm 846 in in length L to install drive plate Ring gear Drive plate Crankshaft bushing Q I Crankshaft 1ENOi 9 50 ...

Page 398: ...nder bore with a cylinder gauge at three levels in directions of A and B 3EN060 Level 1 No 1piston ring position with piston at TDC Level 2 Center of cylinder Level 3 Bottom of cylinder 2 If cylinder bores show more than specified out of round or taper or if cylinder walls are badly scuffed or scored cylinder block should be rebored and honed and new oversize piston and rings fitted 3 Check for da...

Page 399: ...ck switch lamp and wiring 2 If there is current flow when ignition switch is set to ON and if there is no current flow when engine is run ning at idle switch is good If switch is good check lamp and wiring Oil Pressure Gauge Unit 1 Since bimetal type has constructional characteristics which vary its resistance as it repeats ON OFYF states it cannot be checked by measuring its resistance 2 It can b...

Page 400: ...e all cylinders to calculated bore finish dimension Caution To prevent distortion that may result from temperature rise during honing bore cylinders in the following order No 2 No 4 No 1 No 3 5 Hone to final finish dimension piston O D 0 01 to 0 03 mm 0004 to 0012 in 6 Check clearance between piston and cylinder Clearance between piston and cylinder 0 01 0 03 mm 0004 0012 in NOTE When boring cylin...

Page 401: ...SYSTEM CONTENTS SPECIFICATIONS 2 TROUBLESHOOTING 2 GENERAL SPECIFICATIONS 2 TORQUE SPECIFICATIONS COMP ONENT SERVICE 2 3 EXHAUST PIPES AND MUFFLERS 3 11 l ...

Page 402: ...alytic converter Front exhaust pipe to main muffler assembly Front exhaust pipe to suspender Suspender to No 4 crossmember Main muffler assembly to hangers 15 25 11 18 20 30 15 22 8 12 6 9 8 12 6 9 5 10 4 7 Nm ft lbs TROUBLESHOOTING Symptom Exhaust gas leakage Abnormal noise Probable cause Loose connections Broken pipe or muffler Broken separator in muffler Broken hangers or suspender fnterference...

Page 403: ...s and take out the main muffler 05W507 Front Exhaust Pipe 1 Disconnect the front exhaust pipe from the main muffler 2 Disconnect the front exhaust pipe from the suspender OSW512 3 Disconnect the front exhaust pipe from the catalytic converter and remove the front exhaust pipe OSW509 4 For vehicles with an automatic transmission remove the No 2 crossmember protector and the cross select shaft heat ...

Page 404: ...gers and suspender for deterioration and cracks INSTALLATION 1 Loosely install the front exhaust pipe and the main muffler in that order 2 Install the hangers and suspender making sure that they are not strained or twisted 3 Tighten the parts securely and then confirm that there is no interference with any body components ...

Page 405: ...IGNMENT 11 FRONT AXLE TOTAL BACKLASH 12 CHECKING GEAR OIL LEVEL 12 INSPECTION OF DRIVE SHAFT END PLAY 12 WHEEL BEARING PLAY INSPECTION 13 COMPONENT SERVICE 13 UPPER ARM 13 LOWER ARM 17 TORSION BAR 20 STABILIZER BAR 23 SHOCK ABSORBER 24 KNUCKLE 25 AXLE HUB 27 MANUAL FREE WHEELING HUB 3 1 AUTOMATIC FREE WHEELING HUB 34 DRIVE SHAFTS 42 INNER SHAFT 48 DIFFERENTIAL MOUNTING 51 DIFFERENTIAL CARRIER 53 F...

Page 406: ...tic transmission Optional for Federal not available in California Differential gear type Number of teeth Drive gear Manual transmission Optional for Federal not available in California Automatic transmission Optional for Federal not available in California Drive pinion Manual transmission Automatic transmission Optional for Federal not available in California Side gear Independent double wishbone ...

Page 407: ...length mm in Drive shaft end play mm in Automatic free wheeling hub Brake contact surface depth mm in Final ring gear backlash mm in Drive pinion preload With oil seal Ncm in lbs Without oil seal Ncm in lbs Repair limits Front axle total backlash mm in Differential gear backlash mm in Ring gear runout mm in Automatic free wheeling hub Brake wear mm in Return spring deterioration mm in Shift spring...

Page 408: ...erential case to ring gear Bearing cap Drain plug Companion flange Nm ft lbs 8 12 6 9 loo 120 72 87 8 12 6 9 60 90 43 65 120180 87 130 12 18 9 13 15 22 11 16 140160 101 116 54 7 5 39 54 20 30 14 22 95 120 69 87 40 50 29 36 50 60 36 43 50 60 36 43 18 22 13 16 10 14 7 10 50 60 36 43 80 100 58 72 80 100 58 72 80 100 58 72 80 100 58 72 30 42 22 30 80 100 58 72 40 60 29 43 15 22 11 16 16 20 12 14 80 90...

Page 409: ...utomatic free wheeling hub Tool Number and name MB990799 Ball joint remover and installer A 6 MB990800 Ball joint remover and installer B MB990883 Arbor MB990809 Pitman arm puller MB990925 Bearing and oil seal installer set MB99081 1 Differential side bearing cup Use Removal and installation of upper arm ball joint Removal and pressing of the bushing B Removal of knuckle Disconnection of lower bal...

Page 410: ... of drive pinion front bearing inner race Pressing of drive pinion oil seal i Removal of I companion flange Tool Number and name MB990985 Oil seal installer MB990560 A800ST15 Bearing remover MB990802 Bearing installer MB990810 Side bearing puller MB990955 Oil seal installer Use Pressing of knuckle oil seal Removal and pressing of inner shaft bearing Pressing of drive pinion front bearing inner rac...

Page 411: ...Adjust the tire inflation pressure Refer to GROUP 22 rShock absorber malfunctioning Replace Deteriorated bump stopper or rebound stopper Worn or deformed torsion bar support Deformed torsion bar Replace Broken or deteriorated torsion bar Replace Noise Vehicle leans to one side Loose or deformed anchor bolt Worn torsion bar serration Oil leakage from shock absorber k Inadequate lubrication of vario...

Page 412: ...roken Housing damaged Drive gear damaged Slide gear damaged Retainer A damaged Cam damaged Shift spring deteriorated Slide gear C ring out of position Automatic free wheeling hub mounting bolts loose I Return spring deteriorated Slide gear snap ring out of position Foreign substance on tooth surfaces of drive gear and slide gear Foreign substance on tooth surfaces of slide gear and housing gear Ex...

Page 413: ...aged bent Inner shaft and side gear serration play Drive shaft and side gear serration play Drive shaft and drive flange play Drive shaft and drive flange end play Drive flange looseness Drive shaft assembly bent damaged worn Drive shaft assembly and drive flange play Drive shaft assembly and drive flange play Check or replace Adjust or replace Adjust or replace Tighten or replace Replace Adjust o...

Page 414: ...ial and check replace the parts if necessary Insufficient oil Improper drive pinion preload adjustment Damaged gear Replenish Correct or replace Replace Cracked or damaged drive pinion rear bearing Replace Loose side bearing Damaged side gear pinion gear or pinion shaft Replace _ I Insufficient gear backlash Excessive preload Adjust Insufficient oil 1 Replenish Clogged vent plug Clean or replace t...

Page 415: ...gauge 11 S103 Caster 2 55 30 If caster does not meet specifications remove the upper arm from the crossmember and then adjust by turning the upper arm shaft Upper arm shaft reference dimension 72 5 mm 2 85 in Toe in 1 If the toe in does not agree with the standard value use the left and right tie rod turnbuckles to adjust it 1 lS102 2 Make the adjustment by turning the left and right turn buckles ...

Page 416: ...nd it will not be possible to measure the backlash 3 Turn the companion flange clockwise until all play is removed Make mating marks on the dust cover of the companion flange and on the differential carrier Y11503 4 Turn the companion flange counterclockwise until all play is removed and measure the amount of distance through which the mating marks moved 1 lY504 5 If the backlash exceeds the repai...

Page 417: ...per Nm ft Ibs A 100 l 20 72 87 B 8 12 6 9 C 60 90 43 65 REMOVAL 1 Loosen the anchor bolt of the torsion bar all the way Refer to p 2 20 2 Remove the lower part of the shock absorber Refer to p 2 24 12W504 3 Discharge brake fluid and disconnect the brake hose Refer to GROUP 5 12W504 4 Loosen the nut holding the upper ball joint to the knuck le NOTE The nut should only be partially loosened and shou...

Page 418: ... shaft has play replace the upper arm assembly 128635 Measurement of thk Upper A Shaft Star g Torque 1 With the upper arm shaft held in a vice measure the upper arm shaft starting torque with a spring scale 1 28059 Upper arm shaft starting torque 15 Nm 11 ft lbs 2 If the upper arm shaft starting torque exceeds the stan dard value replace the upper arm assembly Measurement of the Upper Ball Joint S...

Page 419: ...al tools illustrated to press the new ball joint into the upper arm Be sure to align the mating mark with the upper arm center 5 Using snap ring pliers fit the snap ring securely into the groove of the joint case Caution Be careful not to distort the snap ring Check to ensure that there is no play between the ball joint groove and snap ring If there is play replace the snap ring with 9new one 12DO...

Page 420: ...on Refer to p 2 l 1 Caution The dimension shown in the illustration determine caster INSTALLATION _ l When installing the upper arm assembly onto the cross membe insert the upper arm shaft mounting ljolts from tht outSide of the crossmember and put adjusting shims between the crossmemberand upper arm shaft 1 lW5 16 2 Tighten the torsibn bar anchor bdlts to the reference dimension Refer to p 2 21 3...

Page 421: ...ed to the ground 12SO38 REMOVAL l Remove the front skid plate and under cover 2 Remove the torsion bar Refer to p 2 20 3 Remove the stabilizer bar Refer to p 2 23 4 Remove the lower portion of the shock absorber Refer to p 2 24 5 Remove the nut which retains the lower ball joint to the knuckle 6 Using the special tool disconnect the lower ball joint from the knuckle 12SO68 7 Remove the front mount...

Page 422: ...o ration Measurement of the Lower Ball Joint End Play 1 Measure the lower ball joint end play with a dial indi cator 128073 Lower ball joint end play Service limit 0 5 mm 02 in 2 If the lower ball joint end play exceeds the service limit replace the lower ball joint Replacement of Lqiver Arm Bushing 1 Using the special tool remove bushing A from the crossmember bracket 2 Remove bushing B from the ...

Page 423: ...oint 12S603 Recommended multipurpose grease SAE J3lOa NLGI grade 2EP 2 Apply the specified semi drying sealant to the grooves in the lower ball joint 12S603 3 Secure the dust cover to the lower ball joint with the ring Multipurpose grease INSTALLATION 1 Temporarily mount the lower arm shaft to the cross member 12S627 NOTE Work will be easier if a solution of neutral detergent is applied to the low...

Page 424: ...ust covers from the anchor arm assembly and anchor arm B respectively 4 Put a mating mark on the torsion bar in alignment with the mark on anchor arm B 12S609 5 Loosen the adjusting nut and pull the torsion bar out of anchor arm B 12WSOS NOTE Remove the anchor arm assembly as necessary to facilitate removal of the torsion bar 6 Detach the stabilizer bar from the lower arm assembly INSPECTION 1 Che...

Page 425: ...8 NOTE When installing a new torsion bar align the serration which has been painted white with the mark on anchor arm B 4 Select the relative position of the torsion bar and anchor arm serrations so that the length shown in the illustration is within the specified dimension when the torsion bar and the anchor arm are assembled with the upper arm rebound stopper in contact with the crossmember Anch...

Page 426: ...e bump stopper bracket to confirm that it agreeswith the specification 12WOOl Clearance between bump stopper and bump stopper bracket 1 71 mm 2 8 in 7 If the clearance does agree with the specification usethe adjusting nut on the anchor bolt to adjust it 8 Torque all parts to specifications during assembly 2 22 ...

Page 427: ...ink for bending or damage 3 Check bushings for cracks deterioration or wear INSTALLATION 1 When mounting the stabilizer link to the No 1 crossmem ber tighten the nut so as to obtain the specified dimen sion 12W5 18 Stabilizer link assembly mounting bolt end reference dimension 16 18 mm 63 71 in 2 When mounting the ends of the stabilizer bar to the lower arms tighten the nut so as to obtain the spe...

Page 428: ...3 J INSPECTION 1 Check shock absorbers for malfunctions oil leakage or _ noise _ INSTALLATION 1 When mounting the shock absorber to the arm post of the side frame tighten until the distance from joint cup A to joint cup B agrees with the reference dimension Shock absorber reference dimension 1 16 3 mm 64 in 2 Torque all parts to specifications during assembly 128088 2 24 ...

Page 429: ...25 4 Using the special tools remove the upper and lower ball joints 11 S 152 12SO68 5 Remove the knuckle from the drive shaft INSPECTION 1 Check needle bearing for wear or damage 2 Check knuckle for cracks or bends 3 Check knuckle spindle for wear or pounding BEARING REPLACEMENT 1 Remove the oil seal and then remove the spacer 2 Remove the needle bearing by tapping the needles uni formly 1 lS610 C...

Page 430: ...uckle contacting surface of the spacer 11S596 Recommended multipurpose grease SAE 531Oa NLGI grade 2EP 6 Install the spacer onto the knuckle with the chamfered side toward the center of vehicle I I 7 Press the neti oil with the special tools until it is flush with the knuckre end fa ce 11S609 8 Apply the spec f ed multipu rpose greaseto the inside and lip of the oil seal Recommended multipurpose g...

Page 431: ...g hubs Vehicles with manual free wheeling hubs REMOVAL 1 Remove the front caliper assembly Do not disconnect the brake hose Caution To prevent the brake hose from being twisted suspend the brake assembly with wire i4s523 2 Remove the free wheeling hub Refer to p 2 32 35 3 Remove the lock washer and then remove the lock nut with a special tool 113695 4 Remove the front hub assembly from the knuckle...

Page 432: ...ub for cracks 3 Check oil sealsfor cracks and damage BEARING REPLACEMENT 1 Wipe grease from the inside of the front hub 2 Remove the inner and outer bearing outer races by tapping them uniformly 11W038 3 Apply the specified multipurpose grease to the outside surface of the new inner and outer bearing outer races Recommended multipurpose grease SAE 53lOa NLGI grade 2EP a I 4 Install the inner and o...

Page 433: ...AE 53 lOa NLGI grade 2EP 3 Press the new oil seal into the front hub with the special tools until it is flush with the front hub end face 12D059 4 Install the front hub assembly as follows 1 Fit the knuckle into the front hub assembly 2 Using a special tool torque the lock nut as follows 1 lS697 Tighten to 130 200 Nm 95145 ft lbs 1 Loosen to Ohm 0 ft lbs 1 Retighten to 25 Nm 18 ft lbs and then loo...

Page 434: ...r re moving shims Refer to p 2 40 6 Apply a semi drying sealant to the free wheeling hub assembly mounting surface of the front hub and then tighten the front hub to the specified torque 1 lS690 Free wheeling hub body tightening torque 50 60 Nm 36 43 ft lbs 7 Measure the drive shaft end play If the measured value does not meet specifications adjust by adding or removing spacers NOTE For end play m...

Page 435: ...m the drive shafts during 2 wheel drive operation and can reconnect them during 4 wheel drive operation When the control handle is set to the LOCK position the follower moves along the oblique groove in the control handle and causes the clutch which is always in mesh with the free wheeling hub body to engage the splines of the inner hub thus coupling the free wheeling hub body with the drive shaft...

Page 436: ... the front hub 1 lS700 DISASSE iBLY 1 Using a screwdriver remove the snap ring and the inner hub from the free wheeling hub body 11 S589 2 Remove the snap ring from the inner hub with snap ring pliers 11 S590 INSPECTION 1 Check free wheeling hub ring inner hub free wheeling hub body and clutch for wear and seizure 2 Check gasket for damage 3 Check compression spring and tension spring for deter ra...

Page 437: ...b mounting surface of the free wheeling hub body assembly and then tighten the assembly to the specified torque 1 lS690 Free wheeling hub body tightening torque 50 60 Nm 36 43 ft lbs 2 Measure the drive shaft end play Refer to p 2 12 3 If the measured value does not agree with the specifi cations adjust by using a spacer NOTE For play measurement and adjustment procedures refer to p 2 48 Install t...

Page 438: ...heel drive and driving is begun rotation of the drive shaft 1 is transmitted from the drive gear 2 to the slide gear 3 to the cam 4 to retainer A 5 to brake A 6 When this happens brake A 6 is pressed against brake B 7 by the function of the cam of retainer A 5 and friction force is generated Because brake B 7 is secured to the knuckle 8 retainer A 5 ceases to rotate see Fig A and therefore the cam...

Page 439: ...RIVE to REAR WHEEL DRIVE and the vehicle is driven in reverse rotation of the gear of the housing 11 is transmitted from the slide gear 3 to cam 4 to retainer A 5 to brake A 6 but retainer A 5 ceases to turn just as when the shift is made from the free state to the locked state The cam 4 therefore turns as far as the cam groove of retainer A 5 and is pushed into the cam groove by the return spring...

Page 440: ...r 4 Using a special tool remove the automatic free wheel ing hub DISASSEMBLY 1 Remove the housing C ring NOTE The ring can bk easily removed by pushing in brake B and using asmall tipped screwdriver or similar tool MD998360 I 4 1 lWO24 2 Remove brake A brake B and the brake spring 11 W023 2 36 ...

Page 441: ...1 57 in Caution Place a protective cloth under the cover attaching surface of the housing before setting on the press table Make sure that the pressing force does not exceed 200 N 44 1 lbs 5 Slowly reduce the pressure of the press until the return spring fully relaxes Caution When reducing the pressure of the press be sure that retainer A is not caught by retainer B 6 Remove the following parts fr...

Page 442: ...amage 4 Check slide gear and housing tooth surfaces for damage 5 Check retainer B and housing contact surfaces for wear and damage Brake Wear 1 Assemble brake A and brake B set the vernier callipers so that the measuring jaws simultaneously touch the two lugs of brake A and then measure the combined brake thickness 11WO 17 Brake A wear Repair limit 9 6 mm 38 in Caution To equalize the combined bra...

Page 443: ...m 1 2 in Caution To measure the dimension B measure the dimension from the outermost extremity of one wire diameter to that of the other wire diameter 2 If the measured value is below the service limit replace the spring REASSEMBLY 1 Apply the specified grease to the mounting surfaces of all components Recommended multipurpose grease SAE 53 lOa NLGI grade 2EP 2 Pack the grooves of brake B and reta...

Page 444: ... of the hub llW048 3 Aligning the key of brake B with the slot in the knuck le spindle and loosely install the automatic free wheeling hub assembly 1 lWO15 4 Confirm that the hub and the automatic free wheeling hub assembly are in close contact when the assembly is forced lightly against the hub If not turn the hub until close contact is obtained _ 5 Using the special tool tighten the automatic fr...

Page 445: ...e shaft Drive shaft end play 0 2 0 5 mm OOS 020 in 7 Measure the starting torque of the front hub assembly and compare it with that measured before installation of the automatic free wheeling hub assembly If the diffe rence exceeds 14 N 3 1 lbs the automatic free wheeling hub is probably not installed correctly remove and reinstall all it 11W049 8 Install the front brake assembly and tighten the b...

Page 446: ...er assembly Do not dis connect the brake hose Refer to p 2 27 2 Remove the free wheeling hub cover or hub cap 3 Remove the snap ring from the drive shaft Refer to p 2 32 4 Remove the knuckle together with the front hub assem bly Refer to p 2 25 5 Remove the drive shaft asfollows FOR LEFT DRIVE SHAFT 1 Pull the drive shaft out of the differential carrier 1 lSSS5 Caution When pulling the drive shaft...

Page 447: ...tion 2 Check ball joint for operating condition and excessive looseness 3 Check splines for wear or damage DISASSEMBLY 1 Remove the boot bands 2 Remove the circlip from the D O J outer race Separate the drive shaft from the D O J outer race 3 Remove the balls from the D O J cage ...

Page 448: ...r race and D O J cage from the drive shaft Remove the circlip from the drive shaft with snap ring pliers 6 Wrap vinyl tape around the spline on the D O J side of the drive shaft so that the D O J and B J boots are not damaged when they are removed 1 lYO97 7 Remove the D O J and B J boots from the drive shaft Caution Do not disassemble the B J 8 Remove the dust cover from the B J i I 11 Y096 llYO41...

Page 449: ...ase Repair kit grease 3 Install the B J boot boot bands new ones and D O J boot onto the drive shaft in that order 1 IS63 1 Caution The B J and D O J boots are different in size and shape so be sure to install them correctly The identification stamp mark on boot band A is 20 11 B J 95 and that on boot band B is 20 20 B J 95 do not confuse these bands during assembly 4 Install the D O J cage onto t...

Page 450: ...ter race a 9 12 Place the D O J boot over the D O J outer race and then use boot band B to secure the boot 13i Place boot band C at the specified distance in order to adjust the amount of air inside the D O J boot and then tighten boot band C 1 lYO99 2 Setting of D O J boot length 79 mm 3 1 in 14 If the B J is to be reused pack 100 to 150 gr 3 5 to 5 3 oz of the specified grease into the B J boot ...

Page 451: ... the free wheeling hub cover 2 Remove the snap ring of the drive shaft and then remove the spacer 11 W037 3 Mount the snap ring onto the drive shaft NOTE Do not install a spacer 4 Move the drive shaft in the axial direction and mea sure the pla y NOTE To measure the play use a dial indicator Refer top 2 12 1 lS691 5 Select a spacer so that the measured value will be within specifications and then ...

Page 452: ...l the top of the shock abosrber is reattached to the crossmember 3 Remove the right drive shaft Refer to p 2 42 llS587 4 Attach the special tools to the shaft flange and pull the inner shaft from the front differential carrier 113587 Caution When pulling the inner shaft out of the front differential carrier be careful that the spline part of the inner shaft does not damage the oil seal 5 If necess...

Page 453: ...mference of dust cover inward with a hammer 2 After a special tool has been mounted as shown tighten the nut until part A contacts the bearing outer race M 8990560 11wnn5 3 Remove the inner shaft from the bearing C 3 3 4 Remove the dust cover from the inner shaft 2 49 ...

Page 454: ...P Caution 1 When installing the inner shaft be careful that the bearing outer race does not damage the lip of the dust seal 3 Using the steel pipe described below force a new dust cover onto the inner shaft mm in Overall length 50 1 7 Outside diameter 75 3 0 Wall thickness 4 62 NOTE After the dust cover has been installed apply the specified grease to the bearing mounting surface of the dust cover...

Page 455: ...ner shaft with a new one Be careful not to damage the lip of the dust seal on the oil seal 3 Install the right drive shaft Refer to p 2 46 4 Torque all parts to specifications during assembly DIFFERENTIAL MOUNTING COMPONENTS 1 Differential mounting bracket 2 Differential mounting rubber A 3 Differential mounting iubber B 4 Spacer 5 Pin 6 Differential mounting rubber C 7 Bracket 8 Differential moun...

Page 456: ...ferential carrier and front suspension crossmember 11 S 107 INSPECTION 1 Check differential mounting bracket for deformation and damage 2 Check bracket for deformation and damage 3 Check differential mounting rubber for cracks and damage INSTALLATION 1 Install the right and left differential mounting brackets and the rear side bracket by tightening the self locking nuts to the specified torque Dif...

Page 457: ...cap 22 Gear carrier 23 Drive pinion rear shim for preload adjustment 24 Drive pinion rear bearing 25 Oil seal 26 Companion flange 27 Washer 28 Self locking nut Nm ft Ibs A 40 60 29 43 B 15 22 1 l 16 C 80 90 58 65 D 55 65 40 47 E 60 70 43 51 F 160 220 116 159 REMOVAL 1 Remove the drain plug to drain the differential gear oil 2 Remove the drive shafts Refer to p 2 42 3 Remove the inner shaft Refer t...

Page 458: ...sure the final ring gear backlash with adial indicator 11Y 167 Final ring gear backlash 0 13 0 18 mm OOS 007 in NOTE Measure at four different points on the circumference of the ring gear Ring Gear Runout Measure the ring gear runout at the shoulder on the reverse side of the gear teeth 11Y 168 Ring gear runout Repair limit 0 05 mm 8 002in Differential Gear Backlash Lock the side gear with a wedge...

Page 459: ...le Refer to p 2 42 1 lY530 Drive Pinion 1 For the drive pinion disassembly procedure refer to GROUP 3 NOTE The names used for the special tools in GROUP 3 differ from those used here and also the following parts should be interpreted as indicated below 1 lWO42 Drive pinion front shim Drive pinion rear shim Drive pinion rear bearing Drive pinion front bearing INSPECTION 1 Check spline coupling for ...

Page 460: ...thin ner than those removed on both the pinion gear and the ring gear sides of the differential case assembly and then fit the differential case assembly into the gear carrier NOTE Select side bearing adjusting spacers with the same thickness for both the drive pinion side and the ring gear side 3 Push the differential case assembly to one side and measure the clearance between the gear carrier an...

Page 461: ...ring gear backlash Refer to GROUP 3 1 9 Select the side bearing adjusting spacers as illustrated and then adjust the final ring gear backlash between the ring gear and the drive pinion 11Y 194 NOTE Be sure to select the side bearing adjusting spacers on the drive pinion side and on the ring gear side so that the total thickness is equal to that obtained from the calcu lation in step 4 When selecti...

Page 462: ...er 1 lSOS8 2 Install the differential mounting Refer to p 2 52 3 Install the propeller shaft Refer to G ROUP 16 4 Torque all parts to specifications during assembly 5 Supply the specified differential gear oil to the differen tial Recommended front axle gear oil Hypoid gear oil API classification GL 4 or GL 5 SAE viscosity No 90 l lOlit 1 16U S qt 0 97Imp qt llW51 2 58 ...

Page 463: ...crossmember INSPECTION 1 Check crossmember for incorrect alignment 2 Check crossmember for cracks bends and dents INSTALLATION 1 Install the front suspension crossmember making sure that the direction of the bolts is correct 15W 5 19 2 Torque all parts to specifications during assembly 532 20 94 zlq mm in 15w521 2 59 ...

Page 464: ...L 3 TROUBLESHOOTING 4 SERVICE ADJUSTMENT PROCEDURES 7 ENGINE IDLE SPEED ADJUSTMENT 7 FAST IDLE ADJUSTMENT FOR VEHICLES EQUIPPED WITH AIR CONDITIONING 7 IDLE SPEED AND MIXTURE ADJUSTMENT 7 ADJUSTMENT OF ACCELERATOR CABLE 9 COMPONENT SERVICE 9 FUEL TANK 9 FUEL LINE 12 FUEL PUMP 14 CARBURETOR FBC 15 CARBURETOR CONVENTIONAL 26 ENGINE CONTROL 30 14 1 ...

Page 465: ... F Additional mechanisms Down dra fii 2 barrel automatic choke 32 35DItiTA 170 M T High Altitude 32 35DIDTA 171 A T High Altitude 32 35DItiTA 186 M T 32 35DIM A 187 A T 32 mm 1 260 in 35 mm 1 378 in 113 8 M T 115 A T 195 65 65 I 45 47 5 KS lOO 13 5 f 0 5 M T 13 5 f 0 5 M T 14 5 f 0 5 A T 14 5 f 0 5 A T Dashpot Dashpot Air switching valve ASV Coasting air valve CAV Jet air coh trol valve JACV Sub E...

Page 466: ... ft lbs Drain plug 15 25 1 l 18 Fuel tank to body 25 30 18 22 Fuel gauge unit 1 0 7 LUBRICANTS Accelerator arm pin and return spring Sliding surfaces of accelerator pedal Sliding surfaces of accelerator arm Specified lubricant Multipurpose grease SAE 53 lOa NLGI grade 3 or equivalent Multipurpose grease SAE 53 1Oa NLGI grade 3 or equivalent Multipurpose grease SAE 53 lOa NLGI grade 3 or equivalent...

Page 467: ...place as required Clean up or replace as required Replace EGR Exhaust Gas Recirculation valve does Repair or replace as required IJet air control valve does not close Repair or replace as required Except Feed back carburetor Deceleration device does not shut off Except Feed back carburetor Repair or replace as required 1 Clogged nipple of EGR valve 1 Cleanup Clogged passage tn EGR valve Clean up E...

Page 468: ...quired Exhaust gas odor Broken exhaust manifold case Exhaust gas leakage due to loose connections Air pipe nut loose Deceleration device inoperative Purge control device inoperative Replace Retighten Retighten Repair or replace as required Replace or replace as required Poor exhaust gas Pressure leakage from purge air solenoid valve Seized plunger seat in purge air solenoid valve Broken or burned ...

Page 469: ...d or kinked vapor hose Clean reposition the hose Loose fuel hose nipple Retighten or replace as required 1 Fuel leakage from fuel tank Deposit due to improper fuel type Clean or replace as required Back fuel from filler Misaligned filler hose Reposition the hose I a c L 1 a 14 6 ...

Page 470: ...ng system on 3 Adjust the engine speed to the specified speed with the throttle opener setting screw idle up adjusting screw 20K627 A C on idle rpm Specified speed 900 to 950 rpm 4 Reconnect cooling fan connector 5 Turn ON OFF air conditioner switch several times to check the throttle opener for operation lever up down IDLE SPEED AND MIXTURE ADJUSTMENT except FEEDBACK CARBURETOR VEHICLES Unschedul...

Page 471: ... only 1 Remove carburetor from engine Carburetor is to be transferred to a bench and held in a suitable fixture for removing the concealment plug 2 Reinstall carburetor on engine without concealment plug 3 Set condition Light electric cooling fan if applicable and all accessoriesare off and transmission in neutral 4 Run the cold engine at fast idle until the cooling water temperature is raised to ...

Page 472: ...r is free 2 Use the tightening bolt to make the adjustment of the ac celerator cable free play so that it is within the standard value 07WS 12 FUEL TANK COMPONENTS 1 Return hose 2 Main hose 3 Pipe assembly 4 Fuel gauge unit 5 Separator tank 6 Vapor hose 7 Connecting hose 8 Breather hose 9 Clamp assembly 10 Fuel filler neck 11 Shutter assembly 12 Fuel tank cap 13 Fuel return pipe 14 Fuel main pipe ...

Page 473: ...3W5 17 4 Disconnect the fuel gauge unit connector 5 Remove the filler hose protector mounting bol ts from the left rear wheelhouse 6 Remove the filler hose protector and disconnect the 2 way valve and vapor hose from behind the protector 7 Disconnect the fuel filler neck connecting hose and breather hose 03W5 14 8 Remove the clamp assembly _ 14 10 03W523 ...

Page 474: ...L FILTER REPLACEMENT 1 Disconnect the fuel hoses and fuel gauge unit connector from the pipe assembly 03W505 NOTE The pipe assembly is mounted to the side of the fuel tank when the fuel hose and the pipe assembly are to be dis connected remove fuel as necessary so as not to spill the fuel 2 Remove the pipe assembly from the tank 3 Remove the in tank fuel filter by pressing the tabs 4 After install...

Page 475: ... assembly Approx 5 mm 20 in FUEL LINE OMPONENTS I Clamp assembly 1 Fuel return hose 2 Fuel main hose 3 Fuel filter 4 Fuel return valve 5 Vapor hose 6 Vapor pipe 7 Purge control valve 8 Purge hose 9 Stay 10 CaniSter 11 Canister holder 03W525 INSPECTION 1 Check fuel hoses and pipes for cracks bends deforma tion deterioration or clogging 2 Check fuel filter for clogging or damage 3 Check 2 way valve ...

Page 476: ...he filler hose protector from the left rear wheelhouse 2 Remove the 2 way valve from the back side of the filler hose protector 03W5 24 INSTALLATION 1 When attaching the fuel hose to the pipe be sure that the hose is attached as shown in the illustration 03Y678 2 After all of the fuel pipes and hoses have been connected start the engine and confirm that there is no fuel leakage from any of the con...

Page 477: ...kets IOutlet valve inlet valve I 5FUOlL INSPECTION 1 Check the arm where it contacts the camshaft eccentric cam for wear on the end rocker 2 Move the rocker arm to check for spring weakening 3 Check the pump body and the cover for cracks or damage INSTALLATION 1 Position the piston of No 1 cylinder at top dead center of the compression stroke 2 Install new gaskets and insulator 3 Install the fuel ...

Page 478: ...control unit as shown in the system diagram in the preced ing figure The flow of input and output signals of the con trol unit fs asshown in the following chart 1 Oxygen sensor 2 Engine speed Ignition pulse 3 Coolant temperature sensor 4 Throt tle position sensor 5 Vacuum switch 6 Intake air temperature sensor 7 Elect al load Head lamps heater air conditioner and power steering 52 B bJet mixture s...

Page 479: ... will result Therefore the following situations will be encountered 1 Engine is hard to start or does not start at all 2 Unstable idle 4 3 Poor driveability If any of above conditions is noted first perform basic engine checks ignition system malfunctions incorrect engine adjustment etc The FBC system can be checked by use of EC1 checker and adapter Inspection procedure as follows INSPECTION PROCE...

Page 480: ...rt Caution When steps 1 through 12 of the select switch A are checked finish each step quickly and switch the ignition switch to OFF after inspettion of each step to save current consumption This is important for protection of the battery 7 If checker shows any departure from specifications check corresponding sensor and related electrical wiring repair or replace 8 After repair or replacement rec...

Page 481: ...enoid valve Enrichmeqt solenoid valve A C cut relay Power supply for sensor Secordary air control solenoid valve Jet mixture solenoid valve Idle up control solenoid valve Ignition pulse Condition 80 C 176 F Ignition iswitch OFF ON Idling Ignition switch OFF ON Ienition switch OFF ON Ignition switch OFF ON A C switch OFF ON O O 6 V B 6 Ienition switch OFF ON 15V 1 A 3 I I Ignition switch Coolant te...

Page 482: ... this range the shim under the needle seat must be changed Shim kit MD606952 has 3 shims 0 3 mm 0118 in 0 4 mm 0157 in 0 5 mm 0196 in Adding or removing a shim will change the float level by three times the thickness of the shim 3 To remove the float slide the pin out and remove the float and the needle 4 Unscrew retainer and remove the needle seat use with pliers When removing the needle seat cla...

Page 483: ...t chamber cover Readjust if necessary REMOVAL 1 Disconnect battery ground cable 2 Drain coolant down to intake manifold level or below 3 Remove air cleaner 4 Place a container under fuel inlet fitting to catch any fuel that may be trapped in fuel line and disconnect the fuel hose from the carburetor inlet connection 5 Disconnect the vacuum hoses from carburetor 6 Disconnectthe throttle cable from ...

Page 484: ...rinder or other instruments 6FU066 3 Remove the throttle return spring and the damper spring 4 Remove the vacuum hose from the depression chamber and the throttle body 5 Remove the accelerator pump rod from the throttle lever 6 Remove the dashpotlidle up actuator rod for a manual transmission or idle up actuator rod for an automatic transmission from the free lever 7 Remove the dashpot idle up act...

Page 485: ...e the depression chamber rod from the secondary throttle lever 12 Remove the depression chamber To remove depression chamber first remove choke breaker cover Then remove depression chamber attach ing screws 13 Remove the float chatiber cover screws BI and I emove the throttle body 14 Remove the screws A and remove the float chamber cover from main body chamber bracket 5FUO3C Sqew B ...

Page 486: ...16 Pull off the pin and remove the float 17 Remove the needle valve retainer and then remove the needle valve assembly with pliers Remove the main jets from the jet blocks When the main jet is to be removed use a screwdriver with proper blade for slot in jet I Anti overfill r L I L deyice LlltxiK and ba 14 23 ...

Page 487: ... sub EGR control valve from the throttle body _ REASSEMBLY Perform reassemble in reverse procedure of disassembly pay attention to the following items 1 Clean the all reassembling parts 2 Check to be sure that no clogging is in the air passages and fuel passages 3 Check for rough operation of throttle and choke linkage If they are binding apply a small amount of lubricant after cleaning them up 4 ...

Page 488: ...battery cable Caution The practice of priming an engine by pouring gasoline into the carburetor air horn for starting after servicing the fuel system should be strictly avoided Cranking the engine and then priming by depressing the accelerator pedal several times should be adequate I 11 Set carburetor idle speed and mixture adjustment REMOVAL Disconnect battery ground cable Drain coolant down to i...

Page 489: ...mber and the throttle body Detach the accelerator pump rod from the throttle lever Detach the dashpot idle up actuator rod from the free lever Remove the dashpot idle up actuator from the float chamber cover Detach the depression chamber rod from the secondary throttle lever 10 Remove the depression chamber To remove depression chamber first remove choke breaker cover Then remove depression chambe...

Page 490: ...verfill device Check weight and ball 14 Do not remove components unless necessary do not disassemble the auto choke system 15 Pull out the float pin and remove the float 16 Remove the needle valve retainer and then remove the needle valve assembly with pliers iol r F n Bowl vent klve FiFLJO4 5FUO4 14 27 ...

Page 491: ...pull out the secondary pilot jet with pliers 19 Remove the accelerator pump and fuel cut off solenoid 20 Remove the snap ring from the sub EGR control valve pill 21 Remove the pm and then remove the link from the valve Then take out the little steel ball and spring from the sub EGR control valve 22 Remove the sub EGR control valve from the throttle body 14 28 Check weight and ball I 5FUO4f Sub EGR...

Page 492: ...the intake manifold surface 3 Carefully place the carburetor on the intake manifold 4 Install carburetor mounting bolts and tighten alternately a little at a time to compress carburetor gasket evenly The nuts must be drawn down tightly to prevent vacuum leakage between the carburetor and intake manifold 5 Connect the throttle cable vacuum hoses and fuel hoses 6 Check carefully for worn or loose va...

Page 493: ...lts 07WS 19 2 Disconnect the accelerator cable from the throttle lever f _ 3 Remove the bolts which hold the accelerator cable guide from the floorboard within the engine compartment 4 Disconnect the accelerator cable from the end of the accelerator arm and then remove the cable from the engine compartment 7W506 14 30 ...

Page 494: ... 2 Check cable outer casing for damage 3 Check cable for roughness in the movement 4 Check accelerator arm for bending 5 Check return spring for deterioration INSTALLATION 1 Apply specified multipurpose grease and drying type sea lant to the specified positions F07005 07W503 Recommended grease Multipurpose grease SAE 53 1Oa NLGI grade 3 or equivalent 2 Eliminate sharp bends from the accelerator ca...

Page 495: ...E 16 GAS LEAK TEST 17 PERFORMANCE TEST 18 COMPONENT SERVICE FRONT HEATER 20 HEATER OPERATION 20 HEATER CONTROL 21 HEATER UNIT 24 BLOWER ASSEMBLY 27 HEATER RELAY 27 VENTILATION DUCTING 28 COMPONENT SERVICE REAR HEATER 32 HEATER OPERATION I 33 REAR HEATER 33 COMPONENT SERVICE AIR CONDITIONING 37 CONTROL PANEL 38 ELECTRIC WIRING DIAGRAM 38 AIR CONDITIONER SWITCH 39 COOLING UNIT 39 RECEIVER 42 CONDENS...

Page 496: ... recirculating hot water type air mix type 4 884 kW h 4 200 kcal h 0 2 A 20A Warm water type 2 326 kW h 2 000 kcal h 4 070 kW h 3 500 kcaljh 6P148 Inclined plate type 6 148 cc 9 03 cu in 6 000 rpm Dry single plate type 12v 4ow 800 m3 h 12v 96W 2 3 50 rpm 850 to 950 rpm when cooler is ON 1 O C 22 F when fin therm0 is OFF 4 5 C 39 F when fin therm0 is ON R12 700 g 1 542 lb SERVICE SPECIFICATIONS Hea...

Page 497: ... and suction service valve mounting bolts Front housing through bolt 15 17 1 l 13 25 26 18 20 2 5 2 6 1 8 2 0 LUBRICANTS Heater assembly Heater control lever Air conditioner Compressor oil Specified lubricant Multipurpose grease SAEJ3lOa NLGI grade 2 DENSOIL 6 SUNJSO 5GS VGlOO or equivalent Quantity As required Total approx 170 30 CC 10 37 1 83 cu in w 3 ...

Page 498: ...dle blower Remove foreign matter motor _ Incorrect balance of blower motor or fan Replace the blower motor or fan Damaged blower Replace Dust enters passenger compart Ventilator duct connection malfunction Connect the duct securely or ment replace the packing Incorrect adjustment of recirculation Adjust the recirculation fresh air fresh air changeover damper changeover cable With the ignition key ...

Page 499: ...1 25 LB and 2 LR wires and the body ground Yes 4 Is there continuity between the No heater fan switch and the fan Harness damaged or connector Correct the connector or improperly connected harness motor harness Is there continuity between resistor terminals Yes No Resistor malfunction c Replace the resistor i Is there continuity between blower motor terminals No Blower motor malfunction Replace th...

Page 500: ...t circuit in harness harness Correct harness and replace fuse Yes Is 12V indicated as voltage across rear heater and front harness connection connector 0 85RB Yes Open circuit in harness between No fuse block 1 Correct harness I Heater fan switch defective I I Replace heater fan switch r 1 1 24 6 ...

Page 501: ...Ofv Broken brush Abnormal compressor L speed or air volume Malfunction of slectric circuit Blown fuse or shorted circuit Air flow cannot be ad justed 1 Malfunction I I of system I Correct motor circuit voltage Loud noise Incorrect vehi cle Dower I H Voltage drop 1sup y voltage 1 1Malfunction 1 y of ground I I I Excessive air flow 24 7 ...

Page 502: ...sure to operate for confirmation Likely to occur when thermal load or engine load is increased Sight glass shows no air bubbles I I utes after I I I I Refrigerant cir cuit clogged I I I Internal pres sure available t Expansion valve and heat sensitive cvlin pansion y l Cracked Confirm deliv Malfunction valve broken ery pipe tern of compressor packmg wear perature high compression seizure I damage ...

Page 503: ... is not ON it has a problem Correction 1 If there is anything wrong slightly turn the adjust screw clockwise for lower temperature setting and vice versa and check by performing the above steps 1 and 2 2 If this does not correct the problem replace Diagnostic procedure 1 When the air conditioner is stationary connect the gauge manifold to the service valve of the compressor If there is a pressure ...

Page 504: ...he battery There should be a clear passage between A and B Blow through the valve to check it Correction If the solenoid valve is malfunctioning replace it with a new one If the refrigerant level is low the compressor oil can also be assumed to be low Remove the compressor from the vehicle check the amount of oil output from the compmssor and then replenish the oil so that there is approximately 9...

Page 505: ...ows air bubbles the refrigerant is leaking Correction Check to discover leaking points Correci or recharge Diagnostic procedure If the temperature difference between the strainer intake and outlet pipes is more than 5 C 9 F there is a malfunction of the strainer in the receiver Correction Replace Diagnostic procedure High pressure increases more than 98 kPa 14 2 psi over saturation pressure which ...

Page 506: ...ion Replace the receiver drier two or three times A new receiver allows operation for at least three hours The drier can be dehydrated by letting hot dry air pass through Diagnostic procedure 1 Low pressure is high although the interior is cool 2 The suction piping is frosted Correction Check and correct Diagnostic procedure 1 Check to see that the superheating temperature of the compressor suctio...

Page 507: ...ehicle performance which might have been caused by installation of the A C equipment Check operation of the magnetic clutch without running the compressor Check for any parts left unmounted or any tools left behind in the vehicle Check the belt deflection 2OY907 Drive belt deflection 17 20 mm 7 8 in at 10 Nm 22 lbs of force Readjust the belt deflection after two or three weeks to eliminate initial...

Page 508: ...high pressure and low pressure 1 sides Attach service can to charge hose Charge refrigerant 196 kPa 28 4 psi of gaseous refrigerant from the service can held in vertical position J H P valve closed i L P valve closed 1 Replace service can with nitrogen cylinder I I I 1 I Charge nitrogen gas 883 Wa 127 8 psi I L P valve H P valve Reducing valve C2055r Gauge manifold L P valve open t c 1 H P valve o...

Page 509: ...acuum pump to the charging hose Carry out the evacuation in the following sequence Repeat three Operate it until the pressure gaugeindicates Continue to operate the vacuum pump for at least 10 minutes more after 101 kPa 29 9 in Hg is indicated IClose the high pressure and low pressure valves of gauge manifold I Fourth time Stop the vacuum pump I 1 Replace the vacuum pump with the service can 4 Dis...

Page 510: ...nt of refrigerant has been charged close the low pressure valve of the gauge mani fold and check the condition while observing the pressure gauge Close the service can valve and remove the gauge manifold Caution The service cans should always be kept below 40 C 104 F Charging from Refrigerant Cylinder 1 Connect the refrigerant cylinder and measuring instru ment asshown C20558 2 Let the specified a...

Page 511: ...AR TEST Test Points 1 All flare joints of connection piping 2 Shaft seal and check valve mountings on compressor and shaft 3 Soldered piping joints of expansion valve and other parts Test Procedure 1 2 3 4 5 6 7 For gas leak test the use of an electronic gas leak detector is recommended Perform the test in a windless area indoor or under similar conditions Refrigerant is heavier than air Leaks wil...

Page 512: ...ll the specified grommets and seal off piping holes with sealant 2 Heat insulation of piping in passenger compartment After the gas leak test heat insulate the cooling unit low pressure pipe joint with a tacking sheet to prevent moisture condensed on the piping 3 Adjustment of engine idle Stationary Performance Test 1 Operating conditions 1 Place the vehicle in the shade with all wiindows and door...

Page 513: ...he outlet grille 2 Measure the air conditioner intake air temperature humidity etc and the items shown in the Table of Measuring Items at a position free from the effects of cool outlet air 3 The point at which the difference between the intake and outlet air temperatures intersects the relative humidity of the intake air should be within the shaded range in the illustration C20562 bulb thermomete...

Page 514: ...ow control lever i 4 7OW520 b I Fresh air Recirculating air 2OW640 I Gii VENT Qi HEAT BI LEVEL VENT b 2OY878 b 2OY878 2OY878 2OY878 2OY878 a a 4 c 20K019 20K017 20K016 20K015 Hot water flow control linked to damper Recirculation fresh air changeover 7 e I mo 2OY878 0 7ow523 INSIDE 2OY878 e e Water valve f rt d Closed Half opened Fully opened 2OW638 2OW638 2OW63 24 20 ...

Page 515: ... Heater control lever 14 Heater control cable 15 Blower motor 16 Fan 17 Blower motor harness 18 Blower case Nm ft lbs A 131 8 9 l 3 REMOVAL 1 Remove the heater control knob and heater fan switch knob 2OW702 2 Remove the center console Refer to GROUP 23 3 Remove the defroster nozzle at the temperature control cable side 4 Remove lap heater duct B and glove box stopper and push the glove box forward...

Page 516: ...driver as shown in the illustration 7 Remove the heater control assembly mounting screws and pull out the assembly slightly 2OW53 1 8 Disconnect the heater f n switch harness connectors 9 Remove the heater control assembly 10 Remove the heater fan switch from the heater control assembly 2OW53 1 INSPECTION Operate the heater fan switch to check for continuity 2OW530 l I o o 0 0 ok44 0 o o INSTALLAT...

Page 517: ...13 Recirculation Fresh Air Changeover System 1 Place the recirculation fresh air changeover lever at the recirculation position 2OY878 2 With the heater side recirculation fresh air changeover damper lever in position C connect the inner cable to the lever and secure the cable casing with clips 2OWS 15 3 Set the control lever to each position to check for correct operation If not correct adjust by...

Page 518: ...he heater unit 2OW519 4 Remove the instrument panel Refer to GROUP 23 The center reinforcement support bracket and radio should be removed together with the instrument panel 5 Remove the center ventilator duct and defroster duct 6 Remove the rear heater duct 7 Remove the heater unit 2OW535 INSPECTION 1 Check heater core for leaks and clogging 2 Check water valve for operation 3 Check all hoses for...

Page 519: ...ntrol arm linkage 2OW527 4 Remove the control arm 5 Remove the heater core by moving it sideways Caution To prevent some substalices invasion between the heater core and case use care not to remove the heater core felt when removing the heater core 6 After the center ventilator open close damper has been placed in the fully closed position turn the arm fully clockwise and then connect it to the li...

Page 520: ... the water valve fully closed and the air intake damper fully closed connect the arm to the link I I 2QW545 9 Connect each heater hose up to the specified length Heater hose overlap length 25 30 mm 1 0 I 2 in 10 When installing the water hoses apply a coating of non drying adhesive to the engine compartment side of the grommet 2OW519 11 Tighten the clamps in the positions shown m the illus tration...

Page 521: ...embly INSTALLATION Tighten the lower mounting bolt of blower assembly which also secures the blower motor ground wire HEATER RELAY REMOVAL 1 Remove the glove box stopper and remove the glove box by pulling it toward you 2 Disconnect the heater relay connector and remove the heater relay INSPECTION 1 Check continuity between terminals 1 and 2 there should be continuity 2 Check continuity between te...

Page 522: ...8 Lap heater garnish 9 Lap heater duct A 10 Lap heater duct C 11 Rear heater duct B 12 Rear heater duct A 13 Center air outlet 14 Defroster duct 15 Lap heater duct B 16 Rear ventilator duct REMOVAL 1 Remove the mounting bolts and remove the front ventila tion by moving it downward 2 Remove the lap heater duct from under the instrument panel Lap heater duct B Lap heater duct C I 2OW503 24 28 ...

Page 523: ...projections for attaching the demister grille 4 Remove the rear heater duct by detaching it from the floor panel 5 6 7 Remove the lap heater garnish by prying up the edges with a screwdriver Remove the rear ventilator garnish Refer to GROUP 23 Remove the rear ventilator duct by moving it upward from inside the passenger compartment 2OW504 24 29 ...

Page 524: ...l 2OW524 10 Disconnect the demister grille and defroster duct and remove the defroster nozzle by moving it downward 11 Remove the defroster duct from the back of the instiu ment pan el 12 Remove the center air outlet and side air outlet from the back of the instrument panel NOTE The center air outlet and side air outlet are secured together with the instrument pad 24 30 2OW5Oi 2ow521 ...

Page 525: ...COMPONENT SERVICE FRONT HEATER VENTILATION DUCTING m 13 Remove the lap heater duct from the back of the instru ment panel Center 20W52E 24 31 ...

Page 526: ...e 5 Water hose C 6 Water hose D 7 Water hose B 8 Water hose A 9 Cover 10 Heater nozzle 11 Clip 12 Heater core 13 Fan and motor assembly 14 Core cover 15 Secret box packing 16 Secret box 17 Rubber 18 Rear heater wiring harness 19 Piping 20 Water valve 21 Joint hose 22 Heater fan switch Ncm in lbs A 130 180 11 16 2OW726 24 32 ...

Page 527: ...h has a single lever which serves the combined purposes of the heater fan switch and warm water flow control lever Operation is only ON OFF switching REAR HEATER REMOVAL 1 Remove coolant 2 Disconnect the connector of rear heater wiring harness and front wiring harness 2OW671 3 Disconnect the water hoses A and B from the piping 2OW579 4 Remove the grommet upward 5 Remove the cover 2OW583 6 Remove t...

Page 528: ...water hoses C and D and remove the water hose assembly 10 After the water hose assembly has been removed dis connect the water hoses A and B from the water hoses 0 and 0 1 2OWO32 INSPECTION 1 Check water hose and joint hose for deterioration damage and leaks 2 Check fan motor for noise and unsmooth rotation 3 Check secret box for foreign substances 4 Check rubber for deterioration and damage 24 34...

Page 529: ...om the water valve 2OW576 3 Remove the fan and motor assembly from the heater core 2OW577 Remove the chps and remove the heater nozzle heater core and core cover in that order INSPECTION 1 Check water valve for faulty operation clogging and leaks 2 Check heater core for clogging damage and leaks 3 Check piping for damage 4 Check heater fan switch for continuity REASSEMBLY Securely install the rubb...

Page 530: ...ove the intake manifold heating water hose at the bottom of the carburetor Slowly fill the radiator with coolant up to the maximum level Check to ensure that coolant comes out from both the intake manifold and water hose and then install the hoses Allow the eingine to warm up until coolant reaches a temperature of 50 C 122 F or above After the engine has warmed up place the hot water flow control ...

Page 531: ...racket 9 Crankshaft pulley 10 V belt 11 Tension pulley 12 Tension pulley bracket 13 Compressor bracket 14 Air duct 15 Duct joint 16 Air conditioning unit 17 Grommet 18 Drain hose 2OW706 Nm ft lbs O D x length mm in A 20 29 14 22 10x30 1 2 B 20 29 14 22 10x 35 1 4 C 40 50 29 36 10 x 50 2 0 D 20 29 14 22 8x80 3 1 Engine compartment 2OW705 Passenger compartment 2OW707 24 37 ...

Page 532: ...switch Power Relay I1 A C switch Termo switch FIN Temp control 7 Speed senser Solenoid valve FICD r I JrnYd Eia 4P Power relay B Power relay A LK l ki LP switih Power relay C 2OW709 When the A C switch is set to ON the magnetic clutch is energized The following components are used to control A C compressor operation by deenergizing the magnetic clutch The thermostat prevents ice build up on the ev...

Page 533: ...itch COOLING UNIT REMOVAL 1 Remove the glove box The glove box should be re moved with the lower frame attached 2OW712 2 Disconnect the glove box switch harness at the round topped terminal 3 Remove the lap heater duct 4 Remove the under tray stay 5 Disconnect the duct joint Loosen the duct joint tightening bolt to free the duct joint Heater unit side blower motor side 6 Disconnect the A C switch ...

Page 534: ...cooling unit attaching nuts 10 Remove the cooling unit top attaching bolts in the passenger compartment 11 Remove the cooling unit DISASSEMBLY 1 Disconnect the harness from the cooling case I 2OW71 t 2 Remove the two power relays Remove the tapping screws 3 Remove the upper and lower cooling caseattaching clips with a screwdriver Caution Use care to prevent the clips from flying off 1 2OW71 24 40 ...

Page 535: ...upper cooling case 2OW7 19 6 Remove the thermostat Remove the heat sensitive cylinder from inside the fins 7 Remove the cooling unit by lifting it from the lower cooling case Caution Hold the lower cooling case tightly when removing the cooling unit 2OW71 E I 2OW72C 8 Remove the pipe assembly ...

Page 536: ... by lifting it upward CONDENSER REMOVAL 1 Remove the center support 2 Disconnect and plug the receiver outlet and intake pipes 3 Remove the condenser mounting bolts 2OW725 4 Remove the condenser from the vehicle COMPRESSOR REMOVAL 1 Loosen the idler pulley and remove the V belt 2 Disconnect the primary cord of the ignition coil 3 Disconnect the magnet clutch harness 4 Disconnect and plug the HP an...

Page 537: ... Clutch rotor assembly 3 Clutch stator 4 Snap ring 5 Shim Nm ft lbs A 15 17 11 13 DISASSEMBLY 1 Hold the center piece and loosen the nut Y20710 2 Remove the center piece 3 Remove the clearance adjusting shim s located on the end of the compressor shaft Socket wrench Y20711 24 43 ...

Page 538: ...otor off of the compressor NOTE It may be necessary to lightly tap the rotor with a plastic hammer 6 Disconnect the ground terminal for the stator coil NOTE Use an impact driver to remove the attaching screw 7 Remove the snap ring which securesthe stator Clutch otor Y2071 isconnect ground terminal Y20714 nap ring pliers 24 44 ...

Page 539: ...be aligned with the pin in the compression housing and center piece to stator clearance must be checked after installation MAGNETIC CLUTCH CLEARANCE INSPECTION 1 Tighten the clutch nut 2 Check the clutch clearance as illustrated Y207 18 Pressure plate to rotor clearance 0 4 0 7 mm 02 03 in NOTE Remove clearance adjusting shims to decrease clutch clear ance Add shims selected from the following tab...

Page 540: ...5 26 18 20 REMOVAL NOTE The magnetic clutch must be removed Refer to p 24 44 1 Remove the oil drain from the front housing 2 Remove the woodruff key 3 Remove the six compressor through bolts asillustrated NOTE Set the compressor on end to prevent any loss of oil during removal of the front housing 1 I Oil drain guide Y20727 housing Y20732 24 46 ...

Page 541: ...emove the seal plate from the front housing with a remover Y2074 1 NOTE Do not damage the inside surface of the front housing when removing and installing the seal plate 7 Carefully drain the oil from the compressor into a container 8 Check the sealing surfaces for cracks scratches or deformation 2OY763 INSPECTION 1 Check the front housing for cracks or scoring on the seal ing surfaces 2 Check the...

Page 542: ...eck that into the notch on the compressor shaft it is fitted 2 Lubricate the seal plate and a new O ring with com pressor oil Push the seal plate and O ring into the front housing 3 Lubricate the new front housing O ring with compressor oil and install it into the compressor housing 4 Install the front housing in position over the locating pins in the compressor I 2oY788 Seal pIat 20Y7as I 2OY791 ...

Page 543: ...OTE New washers should be used on the six through bolts 6 Install the woodruff key 7 Insert a new oil drain guide in front of the seal plate on the front housing Y20727 8 Pour the specified quantity of new compressor oil into the service valves Compressor oil 90 cc 5 5 cu in Suction service valve i 24 49 ...

Page 544: ...INKAGE 10 FUEL FILTER 10 FUEL SYSTEM 10 IGNITION CABLES 11 SPARK PLUGS 11 AIR CLEANER FILTER 11 ENGINE OIL 12 ENGINE OIL FILTER CRANKCASE VENTILATION SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM DRIVE BELTS COOLING SYSTEM BRAKE FLUID BRAKE HOSES BRAKES FRONT AXLE AND REAR AXLE FRONT WHEEL BEARINGS BALL JOINT SEALS STEERING LINKAGE SEALS AND DRIVE SHAFT BOOTS UPPER CONTROL ARM BUSHINGS MANUAL TRANSMI...

Page 545: ...a number for example SAE 1OW 30 which multigrade oil The API classification system defines oil in terms of engine usage For Service SE or For ble should be used These oils chemical additives to provide maximum protection Both the SAE grade tion can be found on the container GEAR LUBRICANTS The SAE grade number also indicates the viscosity of multipurpose gear lubricants The API classification syst...

Page 546: ...MING AND ADJUST AS REQUIRED EVERY 5 YEARS CLEAN CARBURETOR CHOKE MECHANISM AND LINKAGE REPLACE FUEL FILTER EXCEPT FILTER IN FUEL TANK ATI i CHECK FUEL SYSTEM CAP TANK LINE AND CONNECTIONS OR FOR LEAKS EVERY 5 YEARS REPLACE AIR CLEANER FILTER AT REPLACE SPARK PLUGS AT I I REPLACE IGNITION CABLES EVERY 5 YEARS OR REPLACE VACUUM HOSES SECONDARY AIR HOSES AND CRANKCASE VENTILATION HOSES EVERY 5 YEARS ...

Page 547: ...AKE FLUID FRONT DISC BRAKE PADS REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS BRAKE HOSES BALL JOINT AND STEERING LINKAGE SEALS AND DRIVE SHAFT BOOTS UPPER CONTROL ARM BUSHINGS FRONT WHEEL BEARINGS FRONT AXLE AND REAR AXLE MANUAL TRANSMISSION AND TRANSFER CASE AUTOMATIC TRANSMISSION AND TRANSFER CASE REAR AXLE 0CE AS Y 12 MONTHS I I I I I I 3VELAND AT AKS 4 YEARS AR AT AR AND AT ERIORA AT LEASE...

Page 548: ... CHECK AND CLEAN CONTROL SYSTEM AS REQUIRED MORE FREQUENTLY 0 SPARK PLUGS REPLACE 0 0 a 0 0 FRONT DISC BRAKE PADS INSPECT FOR WEAR MORE FREQUENTLY 0 0 REAR DRUM BRAKE LININGS AND REAR INSPECT FOR WEAR OR LEAKS MORE FREQUENTLY 0 0 WHEEL CYLINDERS MANUAL TRANSMISSION AND TRANSFER CASE CHANGE OIL 0 0 0 0 UPPER CONTROL ARM BUSHINGS LUBRICATE GREASE EVERY 12 000 KM 7 500 MILES o 00 0 Sever usage condit...

Page 549: ...r axle limited slip differential Brake and clutch Front wheel bearing Cooling system Transmission linkage parking brake cable mechanism hood lock and hook door latch hatch latch seat adjuster Door hinges Lubricant specification API classification SE or SF Remarks For further details refer to SAE viscosity number Automatic transmission fluid ATF DEXRON or DEXRON II type API classification SAE grade...

Page 550: ...e 23 C 10 F 23 C to 34 C lOoF to 30 F Below 34 C 30 F Viscosity range SAE 90 SAE 85W 90 SAE 8OW 90 SAE 8OW SAE 8OW 90 SAE 75w 53E531 SAE 5W 20 is not recommended for sustained high speed vehicle operation COOLANT Relation Between Antifreeze Concentration and Specific Gravity Coolant temperature C F and specific gravity NOTE The information in the table pertains to the antifreeze used by the manufa...

Page 551: ...alve stem and the bottom end of the adjusting screw 3EM040 Jet valve clearance on hot engine 0 25 mm OlO in 5 Screw in the adjusting screw clockwise until the bottom end of the adjusting screw touches the feeler gauge Since the jet valve spring has a low spring force use special care not to compress the spring Be particularly careful if the adjusting screw is hard to turn 3EM134 6 While holding th...

Page 552: ... Adjustment condition Lights and all accessories off transmission in neutral and parking brake pulled 1 2 3 4 5 Run the cold engine at fast idle until the coolant tem perature is 85 95 C 185 205 F Disconnect the white stripe vacuum hose from the dis tributor and temporarily plug the hoses Run the engine at the specified curb idle speed Curb idle speed First500km 300miles 675 _ 20 rpm After 500 km ...

Page 553: ...uld be replaced regularly because its per formance is reduced by dirt and water collected over an ex tended period of use Replace as required FUEL SYSTEM Check for leaks Cap Tank Lines and Connections Check for damage or leakage in the fuel lines and connec tions and for looseness of the fuel tank cap Inspect the surface of fuel hoses for heat and mechanical damage Hard and brittle rubber cracking...

Page 554: ...ire properly to assure proper engine performance and emission control They should operate satisfactorily in normal vehicle service for the specified maintenance interval or they should be replaced 2 The new plugs should be checked for the proper gap 1EL022 AIR CLEANER FILTER Relpace 1 Remove the wing nut Use pliers only if the wing nut is difficult to remove 2 Unsnap the clips and remove air clean...

Page 555: ... when available and 2 have the proper SAE grade number for the expected temperature range Never use nondetergent or straight mineral oil ENGINE OIL FILTER Replace The quality of replacement filters varies considekably Only high quality filters should be used to assure most efficient service Genuine oil filters require that the filter be capable of withstanding a pressure of 256 psi and are recomme...

Page 556: ...ture passes through the PCV valve into the induction system Inspection and Service Procedure 1 Remove PCV valve from rocker cover If the valve is not clogged a hissing noise will be heard as air passes through the valve and a strong vacuum should be felt when a finger is placed over the valve inlet 2 Disconnect ventilation hose from the PCV valve 3 Blow from the threaded end of PCV valve If you ca...

Page 557: ... atmosphere Disconnect the line at both ends and blow it clean with com pressed air Remove the filler cap from the tiller pipe and check to see if there is any problem with the sealing surface to the filler pipe The over fill limiter 2 way valve installed in the vapor line between the canister intake and fuel tank outlet should be checked for correct operation The purge control valve installed on ...

Page 558: ...he alternator su ternator brace bolt and power steering pu to specified torque Alternator support bolt Alternator brace bolt Power steering oil pump brace bolt COOLING SYSTEM Check and service Coolant Change Caution When removing the radiator cap use care to with hot coolant or steam Place a shop towe and turn the cap counterclockwise a little t escape through the vinyl tube pressure remove the ca...

Page 559: ...ibitor be sure to maintain its concentration at 50 even when temperature is high BRAKE FLUID Check fluid level and inspect for leaks 1 Check to make certain that the brake fluid is between the MAX and A markings on the fluid reservoir Fill as required 72WO25 2 With disc brakes the fluid level can be expected to fall as the brake pads wear A rapid fluid loss indicates a leak in the brake system whi...

Page 560: ...ar Check for fluid contamination and wear Replace complete set of pads if defective 14E525 Caution The pads for the right and left wheels should be replaced at the same time Never split or intermix brake pad sets All four pads must be replaced as a complete set Thickness of lining A Standard value 10 5 mm 41 in Service limit 1 O mm 04 in Rear Drum Brake Linings and Wheel Cylinders Inspect for wear...

Page 561: ...pect for leaks and damage These components are permanently lubricated at the factory and do not require periodic lubrication Damaged sealsand boots should be replaced to prevent leak age or contamination of the grease Inspect the dust cover and boots for proper sealing and check for leakage or damage Replace if defective UPPER CONTROL ARM BUSHINGS Supply grease at the grease nipple until the greas...

Page 562: ...IVERSAL JOINTS CONTENTS SPECIFICATIONS 2 SPECIAL TOOL 3 GENERAL SPECIFICATIONS 2 SERVICE SPECIFICATIONS 2 TROUBLESHOOTING 3 TORQUE SPECIFICATION 2 COMPONENT SERVICE 4 LUBRICANTS 2 PROPELLER SHAFT AND UNIVERSAL JOINTS 4 16 l ...

Page 563: ...g 14 7 3 SERVICE SPEbFICATION mm in Service limits I Propeller shaft runout Dial indicator reading Front Rear Journal end play 0 5 02 0 6 24 0 06 0024 TORQUE SPECIFICATION Nm ft lbs Flange yoke attaching bolts 50 60 36 43 LUBRICANTS Specified lubricant Quantity Universal joint Sleeve yoke surface Multipurpose grease SAE 531Oa NLGI grade 2EP Hypoid gear oil SAE 810 75W 85W conforming to API GL4 As ...

Page 564: ...rsal joint bearings worn damaged or broken Sleeve yoke loose in transmission Universal joint yokes worn or broken Companion flange bolts loose Vibration Universal joints worn damaged or broken Sleeve yoke loose in transmission Propeller shaft bent distorted or damaged Universal joint yokes out of phase Companion flange bolts loose Remedy Replace Torque to specifications Replace Torque to specifica...

Page 565: ...posit ion and set the transfer lever to 2H 2 Make mating marks on the flange yoke and the differen tial companion flange 1ODSOS 3 Detach the propeller shafts from the front and rear dif ferential carrier assemblies 4 Remove the propeller shafts Caution Be careful not to damage the lip of the transmission oil seal or the lip of the transfer oil seal Do not allow foreign matter to enter the trakmiss...

Page 566: ...4 in 4 Check universal joints for smooth operation in all direc tions UNIVERSAL JOINT REPLACEMENT 1 Make mating marks on the yokes of the universal joint that is to be disassembled lOS5 11 2 Remove the snap rings from the yoke with snap ring pliers 1 OS511 3 Remove the journal bearings from the propeller shaft yoke with the special tool Use the collar as illustrated NOTE If the journal bearings ar...

Page 567: ... amounts of grease may result in difficulty in assembling unit and incorrect selection of snap rings 7 Press the journal bearings to ihe yoke with the special tool and base as illustrated Be sure to align the mating marks on the yokes 8 When attaching the universal joint journals to the pro peller shaft be sure that the grease nipples face in the samedirection for the front propeller shaft and tha...

Page 568: ...ay Service limit 0 06 mm 0024 in If the clearance exceeds the service limit the snap rings should be replaced INSTALLATION 1 Apply hypoid gear oil to the sleeve yoke and install the propeller shaft into the transmission Specified hypoid gear oil SAE80 75W 85W conforming to API GL 4 2 Align the mating marks on the flange yoke and the dif ferential companion flange 3 Install bolts and torque to spec...

Page 569: ......

Page 570: ...ECIAL TOOLS 5 TROUBLESHOOTING 7 SERVICE ADJUSTMENT PROCEDURES 10 REAR AXLE TOTAL BACKLASH 10 AXLE SHAFT END PLAY 10 CHECKING GEAR OIL LEVEL 10 CHANGING GEAR OIL 10 LIMITED SLIP DIFFERENTIAL PRELOAD MEASUREMENT 11 COMPONENT SERVICE 12 AXLE ASSEMBLY 12 AXLE SHAFT 13 CONVENTIONAL DIFFERENTIAL 18 LIMITED SLIP DIFFERENTIAL 30 3 l ...

Page 571: ...configuration Side gear Pinion gear Number of teeth Drive gear Manual transmission Optional for Federal not available in California Automatic transmission Optional for Federal not available in California Drive pinion Manual transmission Automatic transmission Optional for Federal not available in California Side gear Pinion gear Semi floating type Semi floating type 40 1 57 40 1 57 34 5 1 36 34 5 ...

Page 572: ...old clutch plates Nm ft lbs Repair limits Rear axle total backlash mm in 5 w Ring gear runout mm in 0 05 002 Difference in total thickness mm in between left and right clutch plates Difference in distances mm in from backs of left and right pressure rings to end of thrust washer Service limits Axle shaft end play mm in 0 05 0 20 002 008 Axle shaft runout mm in 0 1 004 Axle shaft spline play mm in ...

Page 573: ...arrier to rear axle housing 25 30 18 22 LUBRICANTS vSpecified lubricant Quantity Rear axle gear oil Conventional differential Limited slip differential Axle housing grease Hypoid gear oil API classification CL4 or CL5 SAE viscosity No 90 MITSUBISHI genuine gear oil Part No 8149630EX or Mopar Hypoid Gear Lubricant part No 3744994 or 3744995 plus Mopar Hypoid Gear Oil Additive Friction Modifier part...

Page 574: ...nt of the pinion height Removal of the axle shaft bearing and bearing case Tool Number and name MB990799 Bearing inner race installer MB990201 Side bearing special adjusting wrench MB990339 MB990648 Bearing puller Bearing remover MB990802 Bearing installer MB9908 10 MB99081 1 Side bearing Side bearing cup puller Use Pressing of the axle shaft bearing inner race Removal and adjustment of the side b...

Page 575: ... holder see page 2 for instructions L Use Removal of axle shaft Measurement of the limited slip differ i ential preload Tool Number and name MB99003 1 Drive pinion oil seal installer MB990988 Side gear holding tool set Tool A Use Pressing of the drive pinion oil seal Measurement of the clutch plate preload 3 6 ...

Page 576: ...earing Worn ringgear drive pinion Worn sidegearthrust washeror pinion shaft Deformedring gearor differential case Damaged gear Correct or replace Replace Foreignmaterial Insufficient oil Poor gearengagement Improper gearadjustment Improper drive pinion preloadadjustment Damagedgear Foreignmaterial Insufficient oil Improper drive pinion preloadadjustment Damagedgear Crackedor damaged drive pinion r...

Page 577: ... the propeller shaft universal joint the axle shafts the wheel bearings etc Before disassembling any parts take all possibilities into consideration and confirm the source of the noise Abnormal noise when cornering Gear noise Damaged differential gears Damaged pinion pft Nicked and or abnormally worn inner or outer clutch plates Inferior gear oil Replace Abnormally worn or damaged thrust washer In...

Page 578: ...Insufficient differential gear backlash Excessive clutch plate preload Inferior gear oil Insufficient gear oil quantity Retighten or replace Retighten or apply adhesive Clean or replace Adjust Replace Replenish NOTE In the event of seizure disassemble and replace the parts involved and also be sure to check all components for any ir regularities and repair or replace as necessary 1 I Breakdown Inc...

Page 579: ... and adjust it Rear axle total backlash Repair limit Smm 2 in AXLE SHAFT END PLAY 1 Measure the axle shaft end play with a dial indicator 2 Push the axle shaft all the way in and mount the dial indicator and set it to zero 3 Pull the axle shaft all the way out and note the end play indication on the dial indicator 11 S067 4 If the end play exceeds the service limit replace the bearing Axle shaft e...

Page 580: ...ould be raised up Measure the starting torque at the side on which the wheel is raised by using the following procedure 1 Remove the wheel 2 Mount the special tool to the hub bolts with the hub nuts 3 Find the limited slip differential preload by measuring the axle shaft starting torque in the forward direction with a torque wrench 118682 Limited slip differential preload 15 Nm 11 ftlbs or more 4 ...

Page 581: ...etach the rear propeller shaft assembly from the differ ential carrier assembly Refer to GROUP 16 5 Raise the axle housing slightly on ajack 6 Detach the shock absorbers from the U bolt seats Refer to GROUP 17 7 Remove the U bolts and the U bolt seats Refer to GROUP 17 8 Remove the shackles to separate the spring assemblies from the side frame and lower the rear portions of the spring assemblies R...

Page 582: ...es Refer to GROUP 5 2 Remove the brake drum NOTE If it is hard to remove the brake drum screw bolts M8 x 1 25 into the threaded holes provided in the brake drum flange surface 14S609 3 Disconnect the Brake tubes from the rear wheel cylinder 4 Detach the bearing case from the end of the rear axle housing 5 Pull the wheel toward you with the rear axle shaft and rear brake assembly still attached If ...

Page 583: ...ve thelock washer and the washer 4 Reinsert the lock nut on the axle shaft approximately three turns 5 Using the special tobl push the axle shaft out of the bearing case S11536 6 Apply equal pressure to nuts to ensure smooth removal of wheel bearing 7 Using a hammer and drift remove the bearing outer race from the bearing case 8 Remove the oil seal from the bearing case _ MB99 0785 Y A l A 2 11 S5...

Page 584: ...ress the bearing outer race into the bearing case with the special tools 1lSO20 Apply the specified wheel bearing grease to the outside circumference of the new oil seal 11 SO2 1 Recommended multipurpose grease SAE 53 1Oa NLGI grade 2EP Press the new oil seal into the bearing case with the special tools until it is flush with the surface of the bearing cases 11SO2 1 Apply the specified wheel beari...

Page 585: ... Tighten the lock nut to the specified torque using the special tool Rear axle bearing lock nut tightening torque 180 220 Nm 130 159 ft lbs 12 Bend the tabs of the lock washer into the slots of the lock nut NOTE If the slots in the lock nut and the tabs of the lock washer are out of alignment tighten the lock nut until they align INSTALLATION 1 Apply the specified wheel bearing grease to the oil s...

Page 586: ...ily tighten to about 6 Nm 4 3 ft lbs 4 Measure the clearance between the bearing case and rear axle housing with a feeler gauge 1 lS607 5 Select shim s of the thickness which is equal to the sum of the measured clearance plus 0 05 0 20 mm 002 008 in 6 Remove the right axle shaft and install shim s and O ring on the right rear axle housing 7 Apply semi drying sealant to the mating surface of bearin...

Page 587: ...ring 19 20 21 22 23 Drive pinion rear shim for Drive pinion Ring gear Differential case Lock plate pinion height I Nm ft lbs A 190 250 137 181 B 25 30 18 22 Y C 5565 4047 D 80 90 58 65 E 15 22 11 16 REMOVAL 1 Remove the drain plug and drain the differential gear oil 2 Detach the propeller shaft from the differential carrier Refer to GROUP 16 3 Pull the right and left axle shafts out about 70 mm 3 ...

Page 588: ...007 in NOTE Measure at four different points on the circumference of the ring gear Ring Gear Runout Measure the ring gear runout at the shoulder on the back of the gear teeth Ring gear runout Repair limit 0 05 mm 002 in Differential Gear Backlash Lock the side gear with a wedge and measure the differential gear backlash with a dial indicator positioned on the pinion gear Differential gear backlash...

Page 589: ...tion If the ring gear is rotated too much the tooth contact pat tern will become unclear and difficult to check 3 Inspect the tooth contact pattern of the ring gear and drive pinion NOTE Checking the tooth contact pattern is the way to confirm that the adjustments of the pinion height and backlash have been done properly Continue to adjust the pinion height and backlash until the tooth contact pat...

Page 590: ...o the center of the ring gear For backlash adjustment position the ring gear farther from the drive pinion Tooth contact pattern resulting from insufficient pinion height Problem The drive pinion is positioned too close to the center of the ring gear Solution Decrease the thickness of the pinion height adjusting shim and position the drive pinion farther from the center of the ring gear For backla...

Page 591: ...ntial case assembly with hammer handles NOTE Keep the right and left side bearings bearing caps and side bearing adjusting spacersseparate so that they do not become mixed up at the time of reassembly 4 Remove the side bearing inner raceswith the special tools shown in the illustration 5 Make mating marks on the differential case and ring gear 1 lYO71 6 Loosen the ring gear bolts diagonally and re...

Page 592: ...on 1 Use a special tool shown in the illustration to hold the companion flange and then remove the companion flange self locking nut 2 Make mating marks on the drive pinion and companion flange 3 Remove the drive pinion together with the drive pinion spacer and drive pinion front shims 11 W036 4 Remove the drive pinion rear bearing inner race with the special tools shown in the illustration ...

Page 593: ... With the axle shaft secured in a vice measure the free play with adial indicator 11S641 Axle shaft spline play i Service limit 0 6 mm 024 in REASSEMBLY Drive Pinion I 1 Press the drive pinion front and rear bearing outer races into the gear carrier with the special tools shown in the illustration 2 Adjust the drive pinion height 1 Mount the special tools and front and rear drive pinion bearings o...

Page 594: ...oughly When posi tioning the special tool be sure that the cut out sections of the special tool are in the positions shown in the illustration Also confirm that the special tool is in close contact with the side bearing seat When selecting the drive pinion rear shims keep the number of shims to a minimum 4 Install the selected drive pinion rear shim s onto the drive pinion and press the drive pini...

Page 595: ...ified multipurpose grease to the oil seal lip Recommended multipurpose grease S E 53 lOa N LGI grade 2EP 6 Install the drive pinion assembly and companion flange with the mating marks properly aligned and tighten the companion flange self king nut to the specified torque with the special tool MB990850 Refer to p 3 23 NOTE Apply a thin coat of specified multipurpose grease to the surface of the was...

Page 596: ...limit adjust the backlash by installing thicker side gear thrust spacers 4 Measure the differential gear backlash once again and confirm that it meets specifications 4 Align the pinion shaft lock pin hole with the differential case lock pin hole and then drive in the lock pin 1 lYO63 5 Stake the lock pin at two points with a punch 1 lYO61 6 Clean the ring gear attaching bolts and remove the adhe s...

Page 597: ...r backlash Refer to p 3 19 5 Using the special tool MB990201 adjust the back lash to meet specifications by moving the side bearing nut as shown NOTE First loosen the side bearing nut and then tighten it by the same amount 6 Using the special tool MB990201 tighten both right and left side bearing nuts half the distance between centers of two neighboring holes Y 11077 7 Select and install the neces...

Page 598: ...eds the repair limit reinstall the ring gear by changing the phase of the ring gear and differen tial case and then remeasure the runout 12 Torque all parts to specifications during assembly INSTALLATION 1 Before installing the differential carrier assembly apply semi drying sealant to both sides of the gasket and threaded portions of bolts 11 W046 2 Torque all parts to specifications during assem...

Page 599: ...pinion gear 14 Differential pinion shaf t 15 Gasket 16 Lock plate 17 Differential case A 18 Ring gear 19 Drive pinion 20 Drive pinion rear shim for pinion height adjustment 21 Drive pinion rear bearing 22 Drive pinion spacer 23 Bearing cap 24 Gear carrier 25 Drive pinion front shim for preload adjustment 26 Drive pinion front bearing 27 Oil seal 28 Companion flange Nm ft lbs A 190 250 137 181 B 25...

Page 600: ...se for a conventional I differential Refer to the following items INSTALLATION and REMOVAL of DIFFERENTIAL CARRIER ASSEMBLY Refer to pp 3 18 and 3 29 NOTE Use the special oil in the limited slip differential MITSUBISHI genuine gear oil Part No 8149630EX or Mopar Hypoid Gear Lubricant Part No 3744994 or 3744995 Plus Mopar Hypoid Gear Oil Additive Friction Modifier Part No 4057100 or equivalent INSP...

Page 601: ... speeds the frictional force between the clutch plates will cause the speed of the differential side gear to become closer to that of the differential case and thus the limited slip function will control the spinning In addition the purpose of the pressure rings inside the differential case is to transmit the driving force to the pinion gear and the reason for the separation is to provide an incre...

Page 602: ...s together and maintains straight driving During such driving because the road surface gives equal resistance to both the left and right wheels equal resistance is applied to the left and right differential side gears Therefore the differential pinion gear does not revolve and the ring gear the differ ential case the differential pinion shaft the differential pinion gear and the left and right dif...

Page 603: ... at speeds different from that of the differential case Because of the friction produced between the clutch plates in mesh with both the differential side gear and differ ential case one of the pressure rings increases its rotating speed whereas the other reduces its rotating speed The pressure rings press the tapered portion of the differential pinion shaft with which they are in contact and ther...

Page 604: ...ion to limit differen tial operation which would simultaneously decrease the drive force of the outside wheel therefore the limited slip differ ential moderates sudden speed reductions during vehicle cornering and thereby provides greater cornering capability than a conventional differential MAKING EFFECTIVE USE OF A LIMITED SLIP DIF FERENTIAL Effective Use in Combination with the Brakes If a whee...

Page 605: ...ill be exceeded an excessive amount of torque will be applied to the stationary wheel and the vehicle will move forward Also resistance must never be applied to the spin ning wheel In the event that one of the wheels comes in contact with a slippery road surface and begins to spin if the engine con tinues to be operated at high speed for too long the clutch plates might become abnormally worn such...

Page 606: ...ve the ring gear NOTE An anti looseness agent has been used on the bolts If they cannot be loosened heat the area to approximately 150 C 302 F with a propane torch and then loosen them 67 5 Loosen the screws of differential cases A and B evenly a little at a time 1 1S660 6 Separate differential case A from differential case B NOTE Before disassembling the differential cases confirm that the mating...

Page 607: ...ure is used for the spring discs and the spring plates 1 lS670 Clutch plate thickness Service limit 0 1 mm 004 in or Iess NOTE Make the measurement at several different points 2 If the parts are worn beyond the allowable limit replace them with new parts Refer to the section regarding adjustments for infor mation concerning selection of thickness Inspection of Thrust Washer for Wear 1 Measure the ...

Page 608: ...rojections on the inner circumference of the friction disc Nicks or dents will cause abnormalities in the clutch pressure if present repair with an oil stone or replace the parts if necessary 3 The four projections on the outer circumference of the friction disc Nicks and dents will causeabnormalities in the clutch pressure if present repair with an oil stone or replace the parts if necessary 4 Th...

Page 609: ... outer circumference of the pressure rings 7 The spherical surface of the differential pinion gears and the inner diameter of the pressure rings 8 The V shaped groove in the pressure rings and the V shaped part in the pinion shaft 9 The outer diameter of the pinion shaft and the hole in the differential pinion gears 10 The outer circumference groove of the side gears 11 The inner circumference gro...

Page 610: ... Measurement of spring disc and spring plate thickness Measure the thickness using a micrometer with the spring disc and spring plate both extended in the same direction and one placed over the other Arrange them so that the difference between right and left is minimized Right side Lr Left side L Z 3 Measurement of friction disc and friction plate thick ness In the same way as described the above ...

Page 611: ... the right and left sides 2 Make the adjustment as follows so that the dimensional difference of the shaft direction of the differential side gear while it is assembled into the differential case agrees with the standard value 1 Measure depth of contact surfaces of differfential case Measure the depths of the thrust washer contact surfaces of differential case A and B with calipers Assume these to...

Page 612: ...he order of assembly is the reverse of that for disas sembly 5 The directions for assembly is as shown in the illustra tion 1 lS671 6 Be careful not to insert the clutch plates in the incorrect order or to install the springs in the wrong direction NOTE Be sure that mating marks on the differential cases are matched 7 After assembly in order to check the frictional force of the clutch plates use t...

Page 613: ...GROUP l 7 REAR SUSPENSION CONTENTS SPECIFICATIONS 2 TROUBLESHOOTING 3 GENERAL SPECIFICATIONS 2 COMPONENT SERVICE 3 TORQUE SPECIFICATIONS 2 REAR SUSPENSION 3 17 1 ...

Page 614: ...s at load of 5 000 15 000 N 1 102 3 307 lbs Shock absorbers Type Max length mm in Min length mm in Stroke mm in Damping force at 0 3 m set 0 984 ft set Expansion N lbs Compression N lbs Asymmetrical semielliptic leaf springs I 4 1 200 47 2 78 3 1 24 134 56 3 14 4 1 200 47 2 78 3 1 I 35 196 124 694 Hydraulic cylinder double acting type 548 21 6 328 12 9 220 8 7 1 840 406 720 159 TORQUE SPECIFICATIO...

Page 615: ... broken spring Replace Uneven camber Deteriorated or worn bushing Deteriorated or broken spring Replace REAR SUSPENSION COMPONENTS 1 Spring assembly 6 Rubber bushing 2 U bolt 7 Shackle 3 Bumpstopper 8 Rubber bushing 4 Shock absorber 9 Front pin 5 Shackle plate 10 U bolt seat Nm ft lbs AC 45 60 33 43 B 18 25 13 18 C 14 20 10 14 D 85 l 10 61 80 To be tightened with vehicle lowered to the ground 12W5...

Page 616: ...to separate the spring assembly from the side frame 9 Remove the shock absorber from the side frame 12W507 10 Remove the rubber bushings INSPECTION 1 Check shock absorber for damage fluid leaks and noise 2 Check leaf spring for deterioration and damage 3 Check U bolt for bend 4 Check rubber bushings for wear and damage 17 4 ...

Page 617: ...erly and could break INSTALLATION 1 Install the spring assembly on the vehicle Make sure the front end front pin side to center bolt distance is shorter than the rear end to center bolt distance 2 Install the front pin from the outside toward the inside of vehicle 12W5 15 3 Install the shackle from the outside toward the inside of vehicle 12W514 4 Tighten the U bolt nuts evenly so that the ends of...

Page 618: ... WHEEL FREE PLAY f 10 CHECKING STATIONARY STEERING EFFORT 10 CHECKING STEERING WHEEL RETURN TO CENTER 10 CHECKING POWER STEERING BELT TEN SION 11 CHECKING FLUID LEVEL 11 BLEEDING 11 OIL PUMP PRESSURE TEST 12 CHECKING BALL JOINT END PLAY 13 CHECKING STEERING ANGLE i 13 COMPONENT SERVICE 14 STEERING COLUMN AND SHAFT 14 POWER STEERING GEAR BOX a 18 POWER STEERING OIL PUMP 25 STEERING HOSES 31 STEERIN...

Page 619: ...n lbs Oil pump pressure kRa psi Gauge hose valve closed Gauge hose valve opened Tie rod ends ball joint center distance mm in Idler arm turning torque Ncm inlbs Spring scale reading N lbs Repair limits Steering wheel free play mm in Steering gear backlash mm in Service limits Steering shaft runout mm in Steering shaft length mm in Backlash between rack piston ball groove and balls mm in Free lengt...

Page 620: ... bracket stay Oil pump cover Steering hoses Pressure hose Return hose Clamp bolts Breather stays Steering linkage Tie rod ends Tie rod sockets and relay rod Relay rod to pitman arm Relay rod to idler arm Idler arm and bracket Tie rod end studs Idler arm bracket and frame 35 45 26 33 8 l 1 6 8 3 5 2 4 30 35 22 26 8 12 6 9 8 11 6 8 45 55 33 40 30 45 22 33 3 4 2 3 130 150 94 108 55 65 40 47 3 5 4 5 2...

Page 621: ...bushings i Automatic transmission fluid ATF DEXRON or DEXRON II type Multipurpose greaseSAE 531Oa NLGI grade 2 900 cc 54 9 in As required Multipurpose greaseSAE 531Oa NLGI grade 2EP As required Multipurpose greaseSAE J3 lOa NLGI grade 2EP As required Multipurpose greaseSAE 53lOa NLGI grade 2EP As required Multipurpose greaseSAE 53lOa NLGI grade 2EP Multipurpose greaseSAE 53lOa NLGI grade 2EP As re...

Page 622: ...moval and installa tion of the housing lock nut Removal and installa tion of the top cover Installation of the oil seal and the ball bearing Refer to GROUP 3 Tool Number and name MB990228 Preload socket MB990826 D Torx wrench MB990662 Oil pressure gauge MB990854 Snap ring installer Use Measurement of mainshaft starting torque Removal and installation of the tilt bracket Measurement of oil pump pre...

Page 623: ... replace the ball joint if necessary Malfunction of gear box Check and replace the gear box if necessary Malfunction of oil pump Check the oil pump pressure and repair oil pump Refer to p 19 12 Steering wheel pulls to one side Pxcessive steering wheel play Adjust the steering wheel play I Insufficient tire inflation pressure Adjust the tire pressure Refer to GROUP 22 Unevenly worn or deformed tire...

Page 624: ...GROUP 2 Damaged wheelbearing Replace Distorted or looselower arm Retighten or replace Refer to GROUP 2 Bent or damaged linkage Repairor replace Looselinkagejoints 1 Retighten Worn or damaged balljoints Malfunction of front suspension Replace Checkandadjust replacethe partsif necessary Refer to GROUP 2 Incorrect installation or internal damage of gearbox Malfunction of shockabsorber Loosejoint asse...

Page 625: ...ion Replace the gear box Malfunction of return hose Replace the hose Whistling noise Droning noise Malfunction of gear box port section Loose mounting bolt on oil pump or oil pump bracket Replace the gear box Retighten the pump bracket or pump mounting bolt I Poor condition of oil pump body Replace the oil pump Squeaking noise Malfunction of steering stopper contact Check and adjust the steering s...

Page 626: ...ose Damaged or clogged hose Hose connector malfunction Check and repair or replace Replace Leaking reservoir Improperly welded pipe Overflow 1 Replace Bleed the system or adjust the oil level Malfunction of oil pump housing Malfunction of O ring and or oil seal Malfunction of gear box housing including leakage from air hole Malfunction of O ring and or oil seal Replace the oil pump Replace the O r...

Page 627: ...TIONARY STEERING EFFORT 1 Position the vehicle on a level surface with the steering wheel in the straight ahead position 2 Run the engine at 1 000 rpm 3 Measure the turning force with a spring scale by turning the steering wheel clockwise and counterclockwise one and ahalf turns 13WOO6 Stationary steering effort 37 N 8 2 lbs 4 If the stationary steering effort exceeds the standard value check for ...

Page 628: ...he reservoir to the MAX level with the specified automatic transmission fluid 13Y622 13S617 Specified fluid Automatic transmission fluid ATF DEXRON or DEXRON II type BLEEDING Check the stationary steering effort If it is not within the range of the standard value it is possible that there is air in the system Bleed the system 1 Make certain the reservoir is full 2 Jack up the front wheels 3 Discon...

Page 629: ...reaches about 55 C 131 F 4 Run the engine at 1 000 rpm 5 Completely close the shut off valve of the special tool and read the gauge pressure Caution Do not close the shutoff valve of the special tobl for more than 3 seconds If the hydraulic pressure is not within the range of the standard value replace the oil pump Oil pump pressure Valve closed 7 500 8 200 kPa 1 067 1 166 psi Valve opened 980 kPa...

Page 630: ...vice limit 1 5 mm 06 in CHECKING STEERING ANGLE 1 Place the front wheel on a turning radius gauge and meas ure the steering angle Steering angle Inner wheel 33 00 _ J Outer wheel 29 00 2 Adjust the steering angle of each wheel by turning the stop bolt of the knuckle arm Caution Be sure that the toe in is properly adjusted before adjusting the steering angle 13FOO6 19 13 ...

Page 631: ...2 Column bracket 13 Column tube clamp Nm ft lbs A 35 45 26 33 B 30 35 22 26 c 3 5 2 4 D 8 12 6 9 E 8 l 1 68 F 8 11 6 8 REMOVAL 1 Remove the center pad 2 Remove the steering wheel 13W506 3 Remove the instrument cluster 4 Remove the column cover and then remove tlhe column switch assembly 5 Remove the heater duct Refer to GROUP 24 6 Ldosen the dash panel cover 7 Disconnect the joint assembly from th...

Page 632: ... shaft 2 Undo the column tube clamp and then separate the upper column tube from the lower column tube 13W529 3 Unlock the steering lock and remove the steering shaft from the lower column tube 4 Remove the dash panel cover from the lower column tube 5 If it is necessary to remove the steering lock cut agroove on the head of each special bolt with a metal saw and remove the steering lock with ascr...

Page 633: ... Check column bushing for damage 3 Check dash panel cover for damage 4 Check steering shaft bearing for wear 5 Check steering shaft for length damage and deformation Steering shaft runout Service limit 0 5 mm 02 in Steering shaft length Service limit 1 745 29 33 in 6 Check joint assembly for end play 138606 Joint assembly end play Service limit 0 2 mm 008 in REASSEMBLY 1 When mounting the column b...

Page 634: ...ering gear box Caution Install the boot with the bellows toward the steering column Also be sure that the boots are not damaged by the bolts when the joint assembly is installed 2 Install the column assembly to pedal support 3 Tighten the joint assembly bolt 4 Attach the dash panel cover and apply sealant around the bolt holes 133694 Caution Do not loosen the column tube clamp bolts If the clamp b...

Page 635: ...Rack piston 15 Valve housing 16 Needle thrust bearing 17 Mainshaft 18 Ball bearing 19 Oil seal 20 Top cover 21 Valve housing lock nut 22 Dust cover Nm ft lbs 45 55 33 40 30 45 22 33 3 040 2 3 13cL150 94 108 55 65 40 47 3 5 4 5 2 5 3 3 45 55 33 40 180 230 130 166 13W521 REMOVAL 1 Remove the clamp bolt which connects the joint assem bly to the gear box mainshaft 2 Disconnect the pressure hose and re...

Page 636: ... 1 Place the mainshaft and cross shaft in the straight ahead position 2 Remove the breather plug and drain off the steering gear Oil 3 Remove the side cover attaching bolts Y 1367 1 4 Remove the lock nut of the adjusting bolt and screw in the adjusting bolt so that the side cover rises slightly 5 Tap the bottom of the cross shaft with aplastic hammer to remove the cross shaft and the side cover Y ...

Page 637: ...r 13 11896 11 Apply specified automatic transmission fluid to the O ring and attach it to the side cover 12 Install the needle rollers into the side cover 13 Apply specified multipurpose grease to the needle rollers 14 Apply specified multipurpose grease to the sealsurface of the U packing and fit it into the gear box housirig 15 Apply specified automatic transmission fluid to the oil seal lip and...

Page 638: ...n the mainshaft in the center position during mea surement 19 Tighten the adjusting bolt lock nut to the specified torque Lock nut tightening torque 30 45 Nm 22 33 ft lbs Valve Housing and Top Cover 1 Remove the cross shaft assembly Refer to p 19 I 9 2 Remove the valve housing lock nut with the special tool asillustrated 13YO33 3 Remove the valve housing bolts and remove the valve housing and rack...

Page 639: ...seal then press the oil seal and ball bearing inl o the top cover with special tools 8 Install the thinner thrust plate needle thrust bearing and thicker thrust plate into the top cover in the order shown in the illustration C13181 9 Attach the top cover to the valve housing Caution Be careful that the thrust plates and the needle thrust bear ing do not come off the top cover 13S623 Y 13024 MB9909...

Page 640: ...ut rotate the mainshaft to confirm that there is no binding or abnormal noise 12 Measure the mainshaft starting torque with the special tools asillustrated 13Y85 7 13 Tighten the top cover until the mainshaft starting torque is 20 30 Ncm 1 8 2 7 in lbs greater than the measured value NOTE Tighten the top cover gradually while measuring the starting torque 14 Tighten the valve housing lock nut to t...

Page 641: ...r Mainshaft starting torque 25 65 Ncm 2 6 in lbs 16 Install valve housing assembly and cross shaft assembly to the gear box housing 17 Adjust the mainshaft total starting torque and tighten the adjusting bolt lock nut Refer to p 19 21 INSPECTION 1 Install the pitman arm to the gear box with the mating marks aligned 2 Measure the steering geaFbacklash at the pitman arm top end with a dial indicator...

Page 642: ... each seal for oil leakage Caution If the gear box has been disassembled be sure to check the oil pressure Refer to p 19 i2 POWER STEERING OIL PUMP COMPONENTS 1 Drive belt 2 hction plate 3 Suction tutie 4 Pulley assembly 5 Connector 6 0 rino 7 Flow control valve 8 Flow control spring 9 Cam ring 10 Rotor 11 Collar 12 Reservoir bracket 13 Reservoir cap 14 Oil filter 15 Reservoir 16 Pump cover 17 Sna...

Page 643: ...support it with floor stands 3 Disconnect the coil high tension cable and crank the engine over serveral times to drain the fluid from the power steering system 4 Loosen the brace bolts and lock bolt and then remove the drive belt 13W534 5 Disconnect the pressure hose form the oil pump 6 Remove the oil pump and reservoir from th e bracket 13W535 DISASSEMBLY 1 Remove the oil pump cover 19 26 ...

Page 644: ...vanes from the rotor 5 Remove the snap ring of the shaft with snap ring pliers and separate the rotor from the shaft 6 Tap the rotor side of the shaft lightly with a plastic hammer and take out the pulley assembly I I I 7 Remove the suction connector from the oil pump body I 8 Remove the O ring from suction connector ...

Page 645: ...TION 1 Check flow control spring for spring free lengthi 13C210 2 Check flor control valve for clogging 3 Check pulley assembly for wear or damage 4 Check V belt for cracks and deterioration 5 Check groove of rotor and vane for stepped wear 6 Check contact surface of cam ring and vanes for step ped wear 7 Check vanes for damage 8 Check contact surface of pump body and pump cover with rotor for str...

Page 646: ...on to the pump cover side C13214 4 Apply automatic transmission fluid to the O rings Recommended fluid Automatic transmission fluid ATF DEXRON or DEXRON II type 5 Install the O rings to the cam ring 6 Install the snap ring with the special tool as illustrated 7 Install the cam ring to the pump body 13C216 8 Install the cam ring hole shown in the illustration so that it aligns with the dowel protru...

Page 647: ...d to the O ring and install O ring to the suction connector 12 Install the suction connector INSTALLATION 1 Mount the oil pump onto the oil pump bracket 2 Install the drive belt and adjust the deflection Refer to p 19 11 3 Connect the pressure hose and return hose to the oil pump NOTE Install the hoses so that they are not twisted armso that they do not come in contact with any other parts 4 Fill ...

Page 648: ...shing 4 Tie rod end dust cover 5 Tie rod assembly right 6 Relay rod 7 Tie rod assembly left Nm ft lbs A 55 65 40 47 B 45 33 C 40 60 29 43 D 65 80 47 58 13W518 REMOVAL Tie Rods and Relay Rod 1 Loosen the nut on the ball joint and remove the linkage by using the special tool asillustrated 138668 2 Disassemble the tie rod NOTE The outer tie rod end is left threaded and the inner tie rod end is right ...

Page 649: ... damage or deformation 2 Check idler arm for damage or deformation 3 Check idler arm bushings for wear or deterioration 4 Check dust covers and O rings for damage or deteriora tion 5 Check tie rods for damage or deformation 6 Check relay rod for bends or damage INSTALLATION Ball Joint Dust Cover 1 Before installing the dust cover apply the specified multipurpose grease to the cover lip and the int...

Page 650: ...he relay rod Torque to specification and insert cotter pins 3 Adjust toe in Refer to GROUP 2 Idler Arm Assembly 1 Apply a thin coat of the specified multipurpose greaseto the arm support and bushings 13WOO 1 Recommended multipurpose grease SAE J3 1Oa NLGI grade 2EP 2 Insert the bushings into the idler arm 3 Insert the support into the idler arm NOTE The washer should be installed with the knurled ...

Page 651: ...HOOTING 11 SERVICE ADJUSTMENT PROCEDURES 14 DIAGNOSIS CHART GENERAL AUTOMATIC TRANSMISSION 14 COMPONENT SERVICE 28 TRANSMISSION AND TRANSFER CASE 28 AUTOMATIC TRANSMISSION CONTROL 33 TRANSFER 39 MANUAL TRANSMISSION 50 MAINSHAFT 58 AUTOMATIC TRANSMISSION 6 1 OIL PUMP AND REACTION SHAFT SUPPORT 86 FRONT CLUTCH 90 REAR CLUTCH 93 PLANETARY GEAR 96 VALVE BODY 99 21 1 ...

Page 652: ...il pump Gear ratio 1st 2nd 3rd Reverse Speedometer gear ratio Transfer case Type Gear ratio High LOW Drive system Front wheel Rear wheel KM145 Forward till synchromeshed 3 740 2 136 1 360 1 ooo 0 856 3 578 4 625 4 875 Option 2618 Final gear ratio 4 625 2718 Final gear ratio 4 875 Option Constant mesh type 1 000 1 944 Chain drive Direct drive KM146 Full automatic three speed with torque converter 2...

Page 653: ...te clearance Front clutch Rear clutch Input shaft end play Gear train end play Pump clearance Side clearance Tip clearance Body clearance Band adjustments Kickdown Low reverse band Transfer case Rear bearing end play O o 1 O 004 Adjusting with spacer 0 12 0 28 OOS Oll 0 1 0 25 004 lO GO 06 O 002 Adjusting with snap ring o 0 08 O 003 Adjusting with snap ring 28 1 10 42 1 65 2 5 l 3 3 3 4 0 61 1 78 ...

Page 654: ...iving shell thrust plate Driving shell thrust plate to rear carrier Rear carrier to rear annulus support 2 30 09 1 White MD70 1729 2 35 093 None MD701730 2 40 094 Red MD70 173 1 2 45 096 Blue MD701732 2 50 098 Yellow MD701733 0 84 033 Black MD701845 0 93 037 None MD701839 1 02 040 Red MD70 1840 1 11 044 White MD70 184 1 1 20 047 Yellow MD70 1842 1 29 051 Blue MD701843 1 38 054 Green MD70 1844 2 15...

Page 655: ...b Thickness mm in color Snap ring for input gear bearing Thickness mm in color 2 14 084 None 2 21 087 Yellow 2 28 090 White 2 35 093 Blue 2 42 095 Red 2 30 09 1 None 2 35 093 Red 2 40 094 White 2 45 096 Blue 2 50 098 Green Spacer for rear output shaft bearing Thickness mm in color 0 84 033 Black 0 93 037 None 1 02 040 Red 1 11 044 White 1 20 047 Yellow 1 29 05 1 Blue 1 38 054 Green 21 5 ...

Page 656: ...ft bolt Converter drive plate to torque converter bolt Governor body to support bolt Kickdown band adjusting screw lock nut Kickdown lever shaft plug Oil pan bolt Oil pump housing to transmission case bolt Output shaft support bolt Pressure test take off plug Reaction shaft support to oil pump bolt Reverse band adjusting screw lock nut Transmission to engine bolt Valve body screw Valve body to tra...

Page 657: ...transmission Hypoid gear oil SAE80W 75W 85W conforming to API GL 4 2 2 2 3 1 9 Automatic transmission ATF DEXRON or DEXRON II type Hypoid gear oil SAE80W 75W 85W conforming to API GL 4 Multipurpose grease SAE 53 1Oa NLGI grade 3 Multipurpose grease SAE J310a 6 8 7 2 6 0 Transfer case Sliding parts of the selector lever Sliding parts of the selector handle 2 2 2 3 1 9 As required As required Slidin...

Page 658: ...e MD998352 D Dial gauge support I i D see page 2 for instructions D see page 2 for instructions MD998200 Front bearing retainer oil seal installer vlleasurement of the il pressure deasurement of the nput shaft end play MD998029 Main ring gear bearing MD998303 C 3422 B Valve spring compressor I MD998335 3il Rump band MD998353 D Torque driver set Use Usewith MD998020 Common to engine and automatic t...

Page 659: ...ushing Front clutch retainer installer bushing MD998507 D kzr i h retainer bushing Use 4djustment of the ow reverse band Use with MD998502 Tool Number and name MD998357 D Ki wn band adjusting MD998500 D SP 3551 Pump housing bushing remover 0 3 MD998502 D SP 3524 Reaction shaft bushing remover MD998504 D Ei1911 MD998563 C 3763 Throttle pressure adjust too1 Jse Adjustment of the Lickdown band Use wi...

Page 660: ...he front clutch bearing t I Removing oil pump housing Assembly of oil pump Tool Number and name MD998573 D C 3756 Converter alignment tool 69 MD998581 C 41 71 Driver handle MD998584 A 7 Use Alignment of holes 3f the oil pump rotor Removal and installation of pump housing bushing Use with MD998500 or MD998501 Installation of output shaft support D see page 2 for instructions 21 10 ...

Page 661: ...t of gear Ipoppet spring broken Main drive gear and main shaft bearing worn or broken I Clearance of clutch hub and hub sleeve splines excessive I Second gear and bushing worn AUTOMATIC TRANSMISSION Selector lever operates unsmoothly or is hard to operate Counter gear worn arm connected Transmission noise Lubricating oil insufficient or inadequate Gears or bearing worn or broken Inhibitor switch d...

Page 662: ...kets replace worn or defective parts Listen to transmission and converter for source of noise Remove torque and inspect for loose or cracked converter drive plate inspect for contact of the starter drive with the starter ring gear I 1 1 anm siy has buzz 1 _ Remove the transmis 1 No debris present remove valve body 1 I disassemble clean and inspect parts reassemble install check operation and press...

Page 663: ...stop engine immediately remove the transmis sion and converter as an assembly Disassemble clean and inspect all parts Clean valve body install all new seals rings and gaskets replace worn or defective parts I The following leaks may be corrected without removing the transmission manual lever shaft oil seal filler tube 0 ring pressure gauge plug neutral start switch pan gasket oil cooler fittings e...

Page 664: ...uIaAog pa xmp SFqsnq lo pm 3qIeaq 13qs wdmo 11 1oy iou y31nl3 OuluunIIaQ waumn pe 30 mo pueq urnopy3 JuaurJsn pe ak eyug ap oIyl vaIIo3uI MOI 00 paads alp au Ig pw pww Bup as 33qs lndu uayoiq IO UIOM du md ly Allned pa ol Iallg l o uor m nylew aZiyu l IO pueq oNas asram mo aSyea io uoyxmJ1eur Apoq ablEA luawJsn pe 30 Ino pwq asIaAaI mol MOI 00 saInssaId 3ywIp l y y 003 paads alp au 2 Elsnm aTI1sso...

Page 665: ...F Proper fluid level 6 The fluid level should be between the notches above ADD l PINT and below FULL inscribed on the dipstick 904011 Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly Improper filling can also raise the flui...

Page 666: ...ectly indicates the position 3 For adjustment refer to Maintenance and Adjustment Throttle linkage The throttle linkage adjustment is very important to proper transmission operation This adjustment positions a valve which controls shift speed shift quality and art throttle down shift sensitivity If the setting is too short early shifts and slippage between shifts may occur If the setting is too lo...

Page 667: ...nning clutch are applied in the D first gear and that the rear clutch and low reverse band are applied in L first if the transmission slips in D range first gear but does not slip in L first gear the overrunning clutch must be the unit that is slipping Similarly if the transmission slips in any two forward gears the rear clutch is the slipping unit Using the same procedure the rear clutch and fron...

Page 668: ...n Use at EafchPosition of the Selector Lever Selector Lever Position P PARK R REVERSE N NEUTRAL D DRIVE First Second Direct 2 SECOND First Second L LOCK UP First Gear Start Parking Ratio Safety Wag X X 2 21 X 2 45 1 45 1 00 2 45 1 45 2 45 21 18 Clutches Bands Over Front Rear running KM Jn Lo wX X X X X X X X X X X X X X X ...

Page 669: ...r the vehicle Attach 3MPa 300 psi gauge MD998300 and adaptor MD998356 to ports required for test being conducted Test port locations are shown in illustration 904012 904013 Test 1 Selector in L 1 Attach gauges to line and rear servo ports 2 Operate engine at 1 600 rpm for test 3 Move selector lever on transmission all the way forward L position 4 Read pressures on both gauges as throttle lever on ...

Page 670: ... detents rearward from full forward position This is selector D position 4 Read pressures on both gauges as throttle lever on trans mission is moved from full rearward position to full forward position 5 Line pressure should read 372 to 414 kPa 54 to 60 psi with throttle lever rearward and gradually increase as lever is moved forward 6 Kickdown servo release is pressurized only in 3rd gear direct ...

Page 671: ...left side of extension near the mounting flange 2 Operate transmission in third gear to read pressures and compare speeds shown in chart If governor pressures are incorrect at the given vehicle speeds the governor valve and or weights are probably sticking The governor pressure should respond smoothly to changes in km h mph and should return to 0 to 10 kPa 0 to 1 5 psi when vehicle is stopped High...

Page 672: ...eed 2 300 2 800 rpm Stall Speed Above Specification in D If stall speed exceeds specification transmission overmnning clutch or rear clutch slippage is indicated Follow the trans mission oil pressure checks outlined in this section to deter mine the causeof slippage Stall Speed Below Specification Low stall speeds with aproperly tuned engine indicate torque converter problems If stall speeds are b...

Page 673: ...g checks When leakage is determined to originate from the trans mission check fluid level prior to removal of the trans mission and torque converter High fluid level can result in fluid leakage out of the vent located at the top of the front pump housing If the fluid level is high adjust to proper level After performing these operations re check for leakage If a leakage persists carefully check to...

Page 674: ...id to drain then remove the oil pan 3 If necessary adjust the low reverse band 4 Install a new filter on bottom of the valve body and tighten retaining screws to specified torque Tightening torque 3 5 Nm 2 2 3 6 ft lbs 5 Clean the oil pan and reinstall using a new gasket Tighten oil pan bolts to specified torque Tightening torque 15 20 Nm 11 14 ft lbs 6 Pour 3 8 liter 4 0 U S qts 3 4 Imp qts of re...

Page 675: ...ower of throttle lever 3 Lightly push rod A or the transmission throttle lever toward the idle stopper to the right in illustration 904017 and set the rods to the idle position Tighten the bolt securely to connect rods B and C 4 Make sure that when the carburetor throttle valve is wide open the transmission throttle lever moves as shown in illustration 904017 operating angle 47 5 54 and that there...

Page 676: ... position and tighten lock nut to specified torque Tightening torque 40 55 Nm 3 41 ft lbs Low and Reverse Band I Low reverse band adiustina screw _ 1 2 3 4 5 6 Raise vehicle dram ATF from loosened ojl pan and remove the oil pan After lock nut has been removed tighten adjusting screw to specified torque using special tool 904133 Tightening torque 4 9 Nm 3 6 ft lbs Back off adjusting screw 7 turns f...

Page 677: ... approximately 9 8 kPa 1 4 psi Turning adjusting screw counterclockwise increases pressure and clockwise decreasespressure Throttle Pressure Throttle pressures cannot be tested accurately therefore the adjustment should be measured if a malfunction is evident 1 Insert Special Tool Throttle Pressure Adjust Tool MD998563 between the throttle lever cam and kickdown valve 2 By pushing in on tool compr...

Page 678: ...l transmission and transfer assembly 6 Bell housing cover 7 Automatic transmission and transfer assembly Vehicles with a manual transmission 2 b OQw5 6 Vehicles with an automatic transmission C QW526 146001 Nm ft lbs O D x Length mm in A 42 54 31 40 0 7 10x40 4x1 6 Bolt identification B 42 54 31 40 10x65 4x2 6 07 AxB C 22 31 16 23 10x60 4x2 4 D 20 29 15 22 0 10x651 4x2 6 21 28 ...

Page 679: ...r in the following positions Transmission gearshift lever vehicles with a manual transmission only Neutral position Transfer gearshift lever 4H 4 wheel drive high range position After the gearshift lever assembly has been removed cover it with a shop towel to prevent entry of foreign substances into the extension housing 4 Raise the vehicle 5 Remove the transfer case protector 09WS 12 6 Vehicles w...

Page 680: ...almess 11 Vehicles with a manual transmission detach the clutch release cylinder from the transmission 3 1 12 Remove the bell housing cover 13 Detach the starting motor from the transmission NOTE On vehicles with an air conditioner remove the front propeller shaft and then lower the starting motor down ward from under the vehicle to remove it 21 30 ...

Page 681: ...t rear insulator from the No 2 crossmem ber 15 Remove the No 2 crossmember OOW530 16 Support the transmission and transfer assembly with a transmission jack 17 Detach the transfer from the transfer mounting bracket 18 Remove the transmission mounting bolts from the engine 21 31 ...

Page 682: ... the engine by pulling it slowly toward the rear of the vehicle 09WS11 20 When lowering the transmission and transfer assembly tilt the front of the transmission downward and slowly lower forward while using care to make sure that the rear of the transmission does not hit the No 4 crossmember 09W511 09w511 21 32 ...

Page 683: ...screw 11 Inhibitor switch 12 Lever bracket cover 13 Heat protector 14 Control rod B 15 Cross select shaft 16 Protector 17 Control rod A 18 Cross shaft bracket Nm ft lbs A B C D 2 or more 18 24 13 10 13 1 4 or more 13 17 9 7 9 8 9 18 09WOOl REMOVAL 1 Remove the selector handle from the selector lever 09K505 2 Remove the console box Refer to GROUP 23 3 Remove the indicator panel 09W522 4 Disconnect ...

Page 684: ...ibitor switch NOTE Do not remove the inhibitor switch from the l ever bracket assembly unless it is necessary to do so 7 Remove the lever bracket assembly by loosening the attaching screws 09W5 16 81 Disconnect the crossselect shaft from the heat protector 9 Disconnect the cross Select shaft from control rod B 09W5 18 10 Disconnect the cross select shaft from control rod A 21 34 ...

Page 685: ...emove the cover of selector handle 15 Remove the spring pin in order to disassemble the selec tor handle 09W525 INSPECTION 1 Check detent plate for wear 2 Check pin at the end of selector lever for wear 3 Check the pushbutton and the rod adjusting cam for worn contact surface 4 Check control rods for damage cracking or deformation 5 Check each bushing for cracking deterioration or wear 6 Check the...

Page 686: ...SAE J3 1Oa NLGI glade 3 Mount the selector lever and the control aA the lever bracket assembly and then tighten the lock nut to the specified torque Lock nut Jightening torque 18 24 Nm 13 l 7 ft lbs Set the selector lever to the N position and then turn the rod adjusting cam to adjust it so that its bottom surface is flush with the end of the selector lever as shown in the illustration At this tim...

Page 687: ...nhibitor switch temporarily Connect an ohmmeter to the terminals BY BY of the inhibitor switch connector and prepare for continuity check Set the selector lever so that the selector lever pin comes to the position shown in the illustration 09S565 Slide the inhibitor switch from the rear to the front secure it at the point at which continuity begins and then make a mark on the lever bracket assembl...

Page 688: ...e control arm set the selector lever to the IV position move the control rod A to place the transmission in the Neutral position and then tighten the rod to the lever lock nut 09S567 Torque all parts to specifications during assembly After installing each p art make certain that the selector lever moves smoothly and that the lever o n the trans mission side moves properly to each selector position...

Page 689: ...eedle bearing 2 43 Bearing spacer 44 Snap ring 45 Spring retainer 46 Spring 47 Spring retainer 48 Output shaft assemblv 1 HY VOchain 2 Snap ring 3 Clutch hub High and Low 4 Bearing spacer 5 Low speed gear 6 Needle bearing 7 Locking nut 8 Radial ball bearing 9 Sprocket spacer 10 Steel ball 11 Drive sprocket 12 Needle bearing 2 13 Sprocket sleeve 14 Steel bal I 15 Clutch sleeve Nm ft lbs 30 34 22 25...

Page 690: ...emove the four bolts and two nuts securing the transfer caseto the adapter 7 Remove the transfer case assembly from the adapter and remove the change shifter from the control shaft i Automatic Transmission 1 Remove the bolts securing the transfer case and trans mission case 2 Remove the transfer caseassembly from the transmission 3 Remove the four bolts and two nuts securing the transfer caseto th...

Page 691: ...rd the rear 8 Remove the interlock plunger 9 Remove the snap ring from the rear bearing of the rear output shaft 10 Remove the chain cover 11 Remove the oil guide 12 Remove the side cover 13 Remove the counter shaft locking plate and remove the counter shaft 141 Remove the counter gear two thrust washers two needle bearings and the spacer through the side cover opening 144008 Thrust washer i3 9i I...

Page 692: ...n from the transfer case as a unit 17 Remove the REAR WHEEL DRIVE WHEEL DRIVE shift rail 1440 14 18 Remove the H L shift fork and the clutch sleeve 19 Remove the needle bearing from the input gear 20 Remove the snap ring and the input gear assembly 144015 21 Remove the snap ring from the front end of the rear output shaft and remove the H L clutch hub the low speed gear the thrust washer and the n...

Page 693: ...ear end using a universal bearing puller or a press 24 Remove the sprocket spacer and the steel balls 25 Remove the drive sprocket the two needle bearings the sprocket sleeve and the steel ball 26 Remove the REAR WHEEL DRIVE 4 WHEEL DRIVE clutch sleeve the hub and the stop plate and remove the ball bearing using a puller or press 27 Remove the snap ring from the input gear With the bearing support...

Page 694: ...he control shaft before tightening the bolts and nuts Caution If this sequence is reversed the change shifter cannot be installed Transfer case mounting bolts and nuts tightening torque 30 41 Nm 22 30 ft lbs Caution When inserting the transmission control shaft through the oil seal take care not to damage the oil seal lip If the change shifter lock pin hole in the shaft has burrs remove them befor...

Page 695: ...orrect 144022 8 Mount the steel ball for sprocket sleeve positioning on the rear output shaft and mount the sprocket sleeve Refer to p 21 43 9 Mount the two needle bearings on the outer circumference of the sprocket sleeve and then mount the drive sprocket Refer to p 21 43 10 After mounting the steel balls and the sprocket spacer press the ball bearing Refer to p 21 43 by pushing on the inner race...

Page 696: ...2 85 112 2 90 114 Purple Pink Yellow White Blue 16 Insert the needle bearing into the input gear 17 Mount the H L clutch sleeve and shift fork making sure that the direction of the clutch sleeveis correct The direction of installation is the same as for the clutch sleeve for REAR WHEEL DRIVE 4 WHEEL DRIVE 144025 18 Install the REAR WHEEL DRIVE 4 WHEEL DRIVE shift rail Refer to p 21 42 19 Securely ...

Page 697: ...E4WHEEL DRIVE shift fork is shifted to the 4 WHEEL DRIVE side the H L shift rail can not be inserted 29 Mount the two poppet balls and springs and mount the seal plugs Refer to p 21 41 When mounting the poppet springs the smaller end should face toward the ball 30 With the H L shift fork and shift rail spring pin holes aligned drive in the spring pin using a punch When driving in the spring pin po...

Page 698: ...e clearance to 2 mm 079 in or less 144029 33 Insert the speedometer sleeve assembly into the rear cover Align the mating mark on the sleeve with that on the case according to the number of teeth of the speedo meter driven gear 134045 34 Mount the sleeve clamp and tighten the bolt Clamp bolt tightening torque I 10 12 Nm 7 59 ft lbs 35 Install two 4WD indicator light switches along with their steel ...

Page 699: ... neutral return plungers and the springs in the hole on top of the adapter and tighten the plug until it is flush with the adapter surface 2 Install steel ball resistance spring and plug Automatic Transmission Perform reinstallation in reverse procedure of removal Neutral return plunger A Neutral return plunger B Plug Resistance spring Neutral plunger A ball 21 4 ...

Page 700: ...e 2 Synchronizer key 3 3 Synchronizer spring 2 4 Synchronizer hub 30 Stop plate 31 Spacer 32 Split pin 33 Nut 34 Thrust washer 35 Reverse idler gear 36 Needle bearing 37 Bolt w washer 4 36 Reverse idler shaft 39 Bolt w washer 3 40 Baffle plate 41 Rear bearing retainer 42 Nut 6 43 Spring washer 6 44 Front bearing retainer 4 5 Front bearing retainer gasket 46 Spacer 47 Snap ring 48 Ball bearing 49 B...

Page 701: ...shaft and countershaft The nuts can be loosened by double engaging reverse and 2nd gears 13 2027 7 Move the 1 2 shift rail toward the 1st speed side 8 Remove the counter overdrive gear and ball bearing with a suitable puller 132028 Be sure to remove the ball bearing and the overdrive gear as a unit by installing the puller onto the gear 9 Remove distance spacers and counter reverse gear from count...

Page 702: ...needle bearing i 7 Remove the idler gear shaft locking bolts 18 Loosen the reverse idler gear shaft by driving from inside the case 1340 11 19 Remove the rear bearing retainer 134010 20 Remove the front bearing retainer 21 Remove snap rings from main drive gear and jmain drive gear bearing 22 Using special tool remove the main drive gear bearing 23 Remove the mainshaft bearing outer race snap ring...

Page 703: ...e 28 Remove the main drive gear from case 29 Lift the mainshaft assembly from the case 134015 30 Disassemble the mainshaft assembly in the following order 1 Install suitable puller to the 1st speed gear and remove it along with the inner race of the double row bearing 2 Remove the l 2 synchronizer and the 2nd speed gear by moving them toward the rear of the main shaft 3 Remove the snap ring from t...

Page 704: ...ial tool MD998029 10 Drive in the mainshaft bearing using special tool 1300 19 While driving the bearing in make sure that the synchronizer ring is properly positioned between the main drive gear and the 3 4 synchronizer 11 Install the snap ring large to the main drive gear bearing 12 Select and install a main drive gear snap ring of the proper thickness to mi nize clearance between the snap ring ...

Page 705: ...ommended sealant 3M Super Silicone 8662 or equivalent 15 Install the rear blaring retainer 16 Install the reverse idler gear shaft When installing the shaft install the bolts as guides as illustrated 17 Install the needle bearing the reverse idler gear the thrust washer and the nut Install the cotter pin to lock the nut and prevent it from turning and check the reverse idler gear end play 134038 I...

Page 706: ...t at the mainshaft notch and then check the overdrive gear end play 134039 Overdrive gear end play 1 O l 0 25 mm 004 OlO in 20 Install the spacer the counter reverse gear the spacer the counter overdrive gear and the ball bearing onto the countershaft gear from the rear end After tightening the nut stake the nut at the notch at the rear end of the counter shaft gear 21 Insert the 3 4 and l 2 shift...

Page 707: ...M Super Silicone 8662 or equivalent 26 Install the neutral return plungers A and B the springs and resistance spring and ball Tighten each plug till the top is flush with the boss top surface Apply sealant to the plug heads 134044 27 Apply sealant to the outside surface of the speedometer driven gear sleeve install the sleeve into the extension housing and mesh it with the drive gear After install...

Page 708: ...r spring 2 3 Synchronizer key 3 4 3 4 synchronizer hub 11 Synchronizer ring 1 12 Third speed gear p p_ A 13 Needle bearing r 14 Mainshaft NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 145024 DISASSEMBLY 1 Disassemble in the numerical order indicated in the component illustration 145024 2 Before synchronizer assembly is disassembled put an alignment mark on sync...

Page 709: ...ch a way that center tooth T between two missing teeth will touch synchronizer key 110012 T Teeth missing here 3 Use care when installing 3 4 synchronizer hub since only 3 4 synchronizer is directional Smaller diameter side A of center boss is front of 3 4 synchronizer hub 4 Insert three keys into groove of synchronizer hub 5 Install two synchronizer springs to synchronizer When synchronizer sprin...

Page 710: ...ckest snap ring that fits in snap ring groove 4 Make sure that 3rd speed gear turns smoothly 5 Check synchronizer ring for worn and damaged internal threads and teeth 6 With synchronizer assembled to cone of each gear check dimension A 110009 If A is less than 0 5 mm 02 in replace synchronizer ring and or gear 7 After installation of 2nd speed gear 1st 2nd sy nchronizer and 1st speed gear push bea...

Page 711: ...e band link 39 Reverse band 40 Reverse band strut 41 Overrunning clutch roller 10 42 Overrunning clutch roller spring IO 43 Kickdown servo snap ring 44 Kickdown servo guide 45 Kickdown servo guide ring 46 Kickdown servo spring 47 Snap ring 48 Kickdown servo piston rod 49 O ring 50 Kickdown servo piston 51 Seal ring 52 Seal ring 53 Spring retainer snap ring 54 Reverse servo spring retainer 55 Rever...

Page 712: ... single valve body which contains all of the valves except the governor valve Venting of the transmission is accomplished by a passage through the upper part of the oil pump housing The torque converter is attached to the crankshaft through aflexible driving plate Cooling of the ATF automatic transmission fluid heated in the converter is accomplished by circulating the ATF through the water cooled...

Page 713: ...sure for all the hydraulic and lubrication requirements Pressure Regulating Valves The pressure regulating valves consist of a regulator valve which controls line pressure at avalue dependent on throttle opening The switch valve maintains torque converter operating pres sure and transmission lubricating pressure The governor valve transmits regulated pressure to the transmission in conjunction wit...

Page 714: ... The first is that of providing fast release of the kickdown band and smooth front clutch engagement when the driver takes a lift foot ublshift from second to direct The second function of the shuttle valve is to regulate kick band application and timing when making direct to second kickdowns Clutches Band Servos and Accumulator The front and rear clutch pistons and both servo pistons are moved hy...

Page 715: ...ther the P or N positions As a safety precaution when starting in the N position apply the parking or foot brake The automatic transmission will not permit starting the engine by pushing or towing Mountain Driving When driving in the mountains with heavy loads or when pulling a trailer the 2 or L position should be selected on upgrades which require heavy throttle for 0 8 km l 2 mile or more This ...

Page 716: ...HYDRAULIC PRESSURE t tOILFILTER PUMP I PARK I I I OIL FILTER HYDRAULIC PRESSURE LINE PUMP SUCTION TORQUE CONVERTER 0 LUBRICATION TO FRONT CLUTCH LUBRICATION ...

Page 717: ... GOVERNOR VALVE REAR SERVO FRONT CLUTCH FRONT SERVO ACCUMULiTOR HYDRAULIC PRESSURE GOVERNOR LUBRICATION _ THROTTLE 0 TOROUE CONVERTER I 1 OIL FILTER 1 TO u LUBRICATION 1TO FRONT CLUTCH LUBRICATION II ...

Page 718: ...GOVERNOR VALVE REAR SERVO FRONT SERVO r l REAR CLUTCH I I I 11 I IIrl r II I II LINE LUBRICATION LUBRICATION PUMP SUCTION THROTTLE LUBRICATION I TOROUE CONVERTER El 0 ...

Page 719: ...FRONT SERVO d h GOVERNOR VA REAF SERVO ACCUkLATOR HYDRAULIC PRESSURE GOVERNOR PUMP SUCTION THRDTTI F I I I OIL FILTER LUBRICATION TO FRONT u L L SWITCH VALVE II TOROUE CONVERTEF ...

Page 720: ...COMPONENT SERVICE AUTOMATIC TRANSMISSION Drive Part Throttle Kickdown _ 1 I 1 4 f I 904006 2 l 7 0 ...

Page 721: ... f GOVERNOR V FRONT SERVO REAR CLUJCH FRONT CLUTCH I I I 1 OIL FILTER r ACCUMULATdR COOLER TION HYDRAULIC PRESSURE LINE PUMP SUCTION THROTTLE GOVERNOR LUBRICATION 0 TORQUE CONVERTER 3 0 ...

Page 722: ...GOVERNOR VALVE REAR CLUTCH REAR SERVO FRONT SERVO d U lllH IUL IMWI l 1 II IF I I r VALVE 1 ACCUMULATOR r1 I1 I KICKD WN VALVE PUMiSUCTION 0 ...

Page 723: ...RONT CLUTCH FRONT SERVO GOVERNOR VALVE REAR SERVO ACCUMULATOR il 7SHIFTtiAl F LUBRICATION LUBRICATION HYDRAULIC PRESSURE LINE PUMP SUCTION GOVERNOR LUBRICATION 0 i II 1 1 OIL FILTER TOROUE CONVERTER 3 0 ...

Page 724: ...GOVERNOR VALVE REAR RVO REAHCLUICH FRONT CLUTCH FRONT SERVO I III1 r I PUMP SUCTION I 1 OIL FILTER ...

Page 725: ...nt Service Transfer Case for detailed procedure 3 Place transmission assembly on work bench with oil pan upward Use block such as the one shown in illust ration 904132 under rear of case to hold assembly in position 4 Measuring input shaft end play before disassembly will usually indicate when a thrust washer change is required except when major parts are replaced Thrust washer is located between ...

Page 726: ...nicks scores and wear Inspect spring for distortion Inspect rings for freedom in piston grooves and wear or breakage Replace parts as required 10 Using snap ring pliers remove output shaft bearing snap ring and remove bearing from shaft 11 Carefully pry snap ring from weight end of govlernor valve shaft Slide valve and shaft assembly out of governor body 12 Remove snap ring from behind governor bo...

Page 727: ... to withdraw pump and reaction shaft support assembly from the ca e 17 Loos kickdown band adjusting screw remove band strut and slide band out of the case 904090 18 Slide front clutch asseri bly out of the case 19 Grasp input shaft and slide input shaft and rear clutch assembly out of the case Caution Be careful not to lose thrust washer located between rear end of input shaft and forward end of o...

Page 728: ... springs If overrunning clutch cam and or roher spring retainer are found damaged or worn replace 904065 i _ _ _ 24 Compress kickdotin servo spring by using Special Tool then remove snap ring 904095 25 Remove servo guide spring rod and servo piston from the case Be careful not to damage piston rod or guide during rem oval 26 Comrjiess low reverse servo piston spring by iusing Engine Valve Spring C...

Page 729: ...Position output shaft support over pilot studs and tap it firmly into the case with a soft faced hammer 904064 2 Remove pilot studs 3 Install four bolts and tighten to specified torque 4 Install new seal to reverse servo piston Output shaft support qnA064 5 Install cushion spring and piston plug to reverse servo piston and secure with snap ring Reverse servo piston 904067 21 79 ...

Page 730: ...Compress low and reverse servo piston sprin g by using Special Tool and then install snap ring 904099 8 Install new seal rings to kickdown servo piston I 9 Install new ing to kickdown servo piston rod I 10 Install new seal ring to kickdown guide u 904099 Kickdown servo position Sea I ing Kickdown servo piston rod I O ring 90410 Kickdown guide Seal ring 904102 21 80 ...

Page 731: ...rse drum 18 While supporting assembly in the case insert output shaft through rear support Carefully work assembly rearward engaging rear planetary carrier lugs into low reverse drum slots Caution Be very careful not to damage ground surfaces on output shaft during installation 19 Front and rear clutches kickdown band and oil pump assembly are more easily installed with transmission in an upright ...

Page 732: ... install washer on rear clutch retainer 904106 23 Align front clutch disc inner splines and place front clutch in position on rear clutch Make sure front clutch disc splines are fully engaged on rear clutch splines 24 Align rear clutch disc inner splines grasp input shaft and lower the front and rear clutch assemblies into trans mission case 994107 25 Engage rear clutch splines over splines of fro...

Page 733: ...ll bolts and snug down evenly Rotate input and output shafts to see if any binding exists then tighten bolts to specified torque Check shafts again for free rotation Tightening torque Oil pump tightening bolts 17 23 Nm 20 l 7ft lbs 32 Adjust both bands as described in Maintenance and adjustment 33 Position support and governor body assembly on output shaft Align assembly so governor valve shaft ho...

Page 734: ... NOTE This seal can be replaced without removing valve body from transmission by using a small screwdriver to pry seal out of its bore Be careful not to scratch manual lever shaft or the seal bore in transmission I 42 Install gearshift lever and tighten clamp bolt Check lever shaft for binding in the case by moving lever through all detent positions If binding exists loosen valve body bolts and re...

Page 735: ...embly onto input shaft and reaction shaft until it securely fits projection of pump inner rotor To confirm that they are in complete engagement meas ure distance from transmission case bell housing front surface to ends of three drive plate attaching bosses of torque converter Distance should be at least 1 5 mm 6 in when torque converter is pushed all the way into transmission 21 85 ...

Page 736: ...ck to ensure that it turns freely in groove 2 Check thrust washer l inserted between reaction shaft support and front clutch retainer for wear and replace if necessary 3 Check finished surfaces of oil pump housing and reaction shaft support for damage and burr Check bushing for wear and damage 4 Check pump rotor for scratches and pitching Clean pump rotor reinstall to pump housing and measure all ...

Page 737: ...ng head 904048 Drive bushing straight down and out of pump housing bore Be careful not to cock tool in the bore Position new bushing on Special Tool 904048 With pump housing on a smooth clean surface start bushing and installer in bushing bore Install Handle MD998581 in installer Drive bushing into housing until tool bottoms in the pump rotor housing Be careful not to cock tool during installation...

Page 738: ...bushing 3 to 4 additional turns to firmly engage threads in bushing Turn hex nut down against cup to pull bushing from reaction shaft Thoroughly clean reaction shaft to remove chips made by remover thr ads Lightly grip bushing in a vise or with pliers and back tool remover out of bushing Be careful not to damage threads on bushing remover Slide a new bushing on Special Tool and start them in the b...

Page 739: ...mp body and engage pump inner rotor Rotate rotors with tool to center rotors in pump body then with pump body firm against reaction shaft support tighten clamping tool securely 90405 1 Invert pump housing and reaction shaft support assembly with oil pump band intact Install support to pump housing bolts and tighten to specified torque Remove oil pump band pilot studs B and rotor alignment tool Tig...

Page 740: ...er NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 904134 DISASSEMBLY 1 Install Special Tool over piston spring retainer Compress spring and remove snap ring then slowly release tool until spring retainer is free of hub Remove tool retainer and spring 904053 2 Invert clutch retainer assembly and bump it on a wood block to remove piston Remove seals from piston an...

Page 741: ...s will not interfere with sealing of seal rings Inspect clutch retainer inner bore surface for wear from reaction shaft support seal rings Inspect clutch retainer bushing for wear or scores Inspect inside bore of piston for score marks if light remove with crocus cloth Inspect seal grooves for nicks and burrs Inspect seal rings for deterioration wear and hardness Inspect piston spring retainer and...

Page 742: ... carefully seatpiston in bottom of retainer 3 Place spring on piston hub and position spring retainer and snap ring on spring Compress spring with Special Tool and seat snap ring in hub groove Remove com pressor tool 904053 4 Immerse all clutch plates and discs in ATF and install two clutch plates made of steel and clutch discs with facing each alternately in retainer Install p sure plate and snap...

Page 743: ...ch retainer 16 Seal ring NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 904060 Disassembly 1 Carefully pry one end of wave snap ring out of its groove in clutch retainer then remove wave spring and clutch piston spring 904 140 2 Invert clutch retainer assembly and bump it on a wood block to remove piston Remove sealsfrom piston 3 If necessary remove snap ring an...

Page 744: ...essure plate surface for burning scoring or damaged driving lugs Replace if necessary 2 Inspect clutch plate lug grooves in clutch retainer for smooth surfaces plates must travel freely in grooves Inspect piston seal surfaces in clutch retainer for nicks or deep scratches Light scratches will not inte rfere with sealing of seal rings 3 Check to ensure that check ball of piston can move freely 4 In...

Page 745: ... Install inner pressure plate in clutch retainer with raised portion of plate resting on spring Lubricate all clutch plates and discs with ATF install one clutch disc facing material followed by a steel clutch plate until all plates are installed Install outer pressure plate and selective snap ring Measure rear clutch plate clearance by having an assistant press down firmly on outer pressure plate...

Page 746: ...embly 22 Snap ring 23 Annulus gear support 24 Annulus gear 25 Output shaft NOTE Numbers show order of disassembly For reassembly reverse order of disassembly 904060 DISASSEMBLY Measure end play of planetary gear assemblies sun gear and driving shell before removing these parts from output shaft Stand assembly upright with forward end of output shaft on a wood block so that all parts will move forw...

Page 747: ...r worn gear teeth and for broken pinion shaft lock pins Inspect annulus gear and support teeth for damage Replace distorted snap rings REASSEMBLY 1 Place rear annulus gear support in annulus gear and install snap ring 2 Position rear planetary gear assembly in rear annulus gear and place 10 and l 1 thrust washers on front and rear sides of planetary gear assembly 3 Carefully work output shaft thro...

Page 748: ...st washers on front and rear sides of planetary gear as sembly 8 Carefully work front planetary and annulus gear assembly on output shaft meshing planetary pinions with sun gear teeth 9 With all components properly positioned install selective snap ring on front end of output shaft Check end play of planetary gear train End play can be adjusted by the use of various thickness snap rings 21 98 ...

Page 749: ...rottle valve spring 32 Throttle valve 33 Manual valve 34 Screw 6 35 Shuttle valve cover 36 Screw 5 37 Shift valve plug cover 38 Shuttle valve plug 39 Primary spring 40 l 2 shift valve plug 41 2 3 shift valve plug 42 Snap ring 43 Shuttle valve 44 Sleeve 2 45 Secondary spring 46 Screw 2 47 Regulator valve cover 48 Line pressure plug 49 Sleeve 50 Throttle pressure plug 51 Spring 52 Screw 3 53 Shift v...

Page 750: ...y screws to 2 9 to 4 9 Nrn 2 2 to 3 6 ft lbs Using torque set driver etc torque all screws evenly 1 Insert limit valve and spring into limit valve body I 904117 2 Fit spring retainer in groove of limit valve body 904117 3 Put throttle plug in limit valve body 4 Insert 1 2 and 2 3 shift valves and springs i nto hole of valve body 904118 5 Set limit valve body assembly against shift valve spring 6 M...

Page 751: ... pressure plug Regulator valve cover 904119 10 Install sleeve and secondary spring to shuttle valve end and secure with E clip 904038 11 Install shift valve plug cover and tighten five screws Shift valve plug cover 12 Install shuttle valve cover and tighten six screws 13 Install throttle valve throttle valve spring kickdown valve and kickdown detent plug 904120 14 Slide manual valve into its bore ...

Page 752: ...regulator valve screen to valve body plate 904035 1 17 Install transfer plate support and valve body plate to transfer plate with four screws 904035 18 Install the seven check balls in valve body 19 Place transfer plate assembly on valve body and tem porarily tighten 13 screws 904122 20 Torque screws to specified torque in correct sequence working from center screw to outward ones Tightening torqu...

Page 753: ...After top and bottom screws have been tightened tighten side screw 23 Install oil filter and tighten 24 After valve body has been serviced and completely assembled measure throttle and line pressure adjust ments However if pressures were satisfactory prior to disassembly use original settings 904034 904123 Throttle DressltirP adjusting screw Regulator valve spring Switch valve f Wi screw bracket 9...

Page 754: ...ove four bolts an separate governor and support parking gear 2 Take out governor screen from governor body 3 Remove two snap rings 4 Take out governor weight and spring Support Governor Screen 904126 I 904127 Inner weight E clip _ b 90403 1 21 104 ...

Page 755: ...vent dry with compressed air and test for free movement before assembly Check lugs on parking gear for broken edges or other damage REASSEMBLY 1 Assemble governor body and filter to the support and tighten bolts finger tight Make sure oil passage of gover nor body aligns with passage in the support 2 Assemble inner weight and spring to outer weight and secure with snap ring Place weight assembly i...

Page 756: ...with a 9 5 mm 4 in drill Be careful not to drill into transmission case Chip off rivet heads with a small chisel and drive rivets and cam from the case with a blunt punch of proper size 904062 4 Carefully enlarge rivet holes in the case with a 6 7 mm 17 64 in drill Remove all chips and foreign matter from the case and make sure cam area is free of chips and burrs 904062 5 To install position cam a...

Page 757: ...prag and sprag rod springs for distortion and tension 3 Check square lug on sprag for broken edges also lugs on parking gear for damage 4 Check cam on end of sprag rod for nicks burrs and free turning Parking sprag rod I 904032 REASSEMBLY 1 Install reaction plug assembly in adapter and secure with snap ring 2 Position sprag and spring in adapter and insert shaft Make sure square lug on sprag is to...

Page 758: ... 2 CHECKING OF TIRE WEAR 4 GENERAL SPECIFICATIONS 2 CHECKING OF WHEEL RUNOUT 4 SERVICE SPECIFICATIONS 2 CHECKING OF TIRE RUNOUT 4 TORQUE SPECIFICATION 2 COMPONENT SERVICE 5 TROUBLESHOOTING 3 WHEELS AND TIRES 5 SERVICE ADJUSTMENT PROCEDURES 4 22 l ...

Page 759: ...S Service limits Wheel runout mm in Radial runout Tire runout mm in Radial runout Tread depth of tires mm in Repair limit Wheel dynamic balance Ncm inIbs Tire inflation pressures kPa psi For vehicle unladen Front Rear For vehicle laded Front Rear 1 2 05 3 0 12 1 6 06 3 5 3 180 26 180 26 180 26 240 34 TORQUE SPECIFICATION Nm ft lbs Hub nuts for wheels loo 120 72 87 22 2 ...

Page 760: ...ive toe in Unbalanced wheels Loose wheel bearings Loose ball joints Malfunction of shock absorbers Over inflation or under inflation Unbalanced wheels Wheel runout Abnormally worn tires Unbalanced propeller shaft Remedy Adjust the tire pressure Adjust the tire pressure Adjust Adjust Adjust Adjust Inspect for looseness and adjust the preload Inspect and repair as necessary Inspect and repair as nec...

Page 761: ... Service limit Radial 1 2 mm 05 in I 1 lY602 CHECKING OF TIRE RUNOUT Measure the radial Tire runout Service limit Radial 3 0 mm 1 in Simple Method to Reduce Runout 1 Measure runout and make chalk marks on tire sidewall wheel and nearest stud at point of maximum runout before removing the tire from the wheel 2 Remove the tire from the wheel and remount the wheel on the drum or hub in the former pos...

Page 762: ...nstallation NOTE The metal fittings which attach the center caps are different on the front wheels from those on the rear Attaching Center Cap Metal Fittings to Front Wheels Align any of the guides three projections inside the fitting with a bolt position and then mount the fitting on the hub being careful that the cut ends are not opened 73WO27 Attaching Center Cap Metal Fittings to Rear Wheels A...

Page 763: ...15 O 10 3 10 8 74 8 79 19 13 Checking fluid level Checking gear oil level Checking gear oil level Checking power steering belt tension Checking stationary steering effort Checking steering angle Checking steering wheel free play Checking steering wheel return to center Clock Clutch assembly Clutch control Clutch pedal inspection and adjustment Compressor Air conditioning Compressor front housing A...

Page 764: ...1 Inspection of drive shaft end play 2 12 Instrument panel 23 52 I J I Jet valve clearance adjustment O 8 Jetvalves I c 9 37 K Knuckle 2 25 Lighting system Limited slip differential Limited slip differential preload measurement Lower arm Lubricant capacities table and recommended lubricants M Magnetic clutch Mainshaft Manual free wheeling hub Manual transmission Manual transmission and transfer ca...

Page 765: ...on reliefers Timing chain Torsion bar Transfer Transm on and transfer case Trims I jr 5 6 2 24 9 14 9 39 o 11 7 5 2 23 8 84 19 14 1993 1 19 31 23 49 7 12 8 169 9 23 2 20 21 39 21 28 23 57 U Under guard 23 17 Upper arm 2 13 Upper control arm bushings O 18 V Valvebody 21 99 Valve clearance adjustment O 8 Valves and valve springs 9 32 Ventilation ducting 24 28 W Water temperature gauge unit 7 13 Whee...

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