Toyota Celica 2000 Repair Manual Download Page 1149

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10-4

IDENT IFICATION INFOflMATION
IDLE AIR CONTflOL (IAGJ

VALVE

IDLE SPEED
IGN!TION (f'REPARAiiON)

IGNITION ISERVICiC SPfCifiCATIONS}

iGNITION COIL
IGNH ION SWITCI I ANU KEY UNLOCK

WARNING SWITCH

IGNITION SYSTEM
IGNITION TIMING
INJECTOR

INPUT SHAFT 1CS6)

INPUT SHAFT (G60t

INSIDE VEHICLl

INSTRUMENT PANEL

INTERIOR LIGHl SYS I FM

KNOCK SENSOH

LUBRICATION (PREPARATION)

U8HICAT!ON (SEHVICE SPEClf'ICATIONS)

MAGNETIC CLUTCH REI AY

MAINTENANCE (PREPARAfiON)
MAINTENANCC (SfnVICfC SPECIFICATIONS)

MANIFOLD GAUGE Sfl

MANUAL TRANSAXLE (C56J

(PREPAFlATION)

MANUAL TRANSAXLE (C56}

(SERVICE SPt.CIHC:AI IONS) .

MANUAL TRANSAXLE {C60)

{PRFPARATION)

MANUAL TRANSAXLf IC60j

{SEfWICE SPECIFICATIONS)

MANUAL TRANSAXLE ASSEMBLY (C56) .
MANUAL TRANSAXLF ASSEMBLY (C60)
MANUAL TRANSAXLE UNIT (C56)

MANUAL -fRANSAXl

UNIT (C60)

MASS AIR FLOW (MAf) MFI

OIL AND  FILTER
OIL  NOZZLE  (27L--Gfl
OIL PUMP
OUTPUT  SHAFT  (CSB)

OUTPUT SHAFT (C60)
OUTSIDE VEHICLE

PARK/NEUl HAL POSI !"ION (f'NP) SWITCH

(U240E)

PAI-HVNEUTRAL POSITION (f'NP) SWITCH

(U341U

PARKING RHAKf
PARKING BRAKE

U:::VEf1

l'ArlfS I AYOU r AN[) SCHFMATIC DRAWING

ALPHABETICAL

INDEX (I

Page

VoL

IN-3 ( 1 )

SF-40(2)

EM-14(2)

PP 1 9 ( \)

SS-23 ( 1 )

IG-5(2)

BE·-13 (2)

IQ--1 (2)

FM-13 (2)

-18 (2)

MX--26 (2)

MX-29 {2)

MA-2 ( 1 )

80-76(2)

BE-27 (2)

SF-66 (2}

PP-15 { 1 )

SS--21 ( 1 )

AG-55 (2)

PP-1 ( 1 \
SS--4 ( 1 )

AC----1 9 (2)

PP-31 ( 1 )

S&---31 ( 1 J

PP-38 (1)

SS--36 ( 1

MX-9 (21

MX-9 (2)

MX-2 (2)
MX-2 (2}

SF-29 t2l

LLJ-1 (2)

LU-14 (2J

LU-5

(2)

MX-34 (2)

MX-37 (2)

MA-1 { 1 )

AX----8 (21

AX-7 {2)

Bn---12 (2l

Em--8

(2l

FC--2 (2)

PARTS LOCATION

(ANTI-LOCK BflAKf SYSTEM WITH ELECTRONIC

BRAKE: f-ORGE DISTRIBUTION (EBO))
(DIAGNOSTICS)

PARTS l OCATION

(AU!OMAliG TRANSAXLE (U240E)}
(DIAGNOSTICS}

PAH I S LO'CAfiON

(AU rOMAl iC -1 f1ANSAXLE (U341E))
(DIAGNOSTICS)

PAH1S LOCAl ION (BODY CUNlHOL SYSTEM)

(OIAGNOSTICSJ

PARTS I OCATION (CRUISE CONTROL SYSTEM)

(DIAGNOSTICS)

PAHl S LOCAriON (ENGINE)

(DIAGNOSTICS)

PARTS LOCATION

!SUPPLEMENTAL RESTRAINf SYSTEM)

(DIAGNOSTICS)

POSHIVE CRANKCASE VENTILATION (PCV)

SYSTEM

POWEH DOOR LOCK CONTROL SYSTEM .

POWER MIRriOH CONTHOL SYSTEM

POWER SOURCE
POWER STEERING fLUID

POWIOA

STEERING GEAR

POWEn STEERING VAN!: PUMf>
POWER WINDOW CONTnOl SYSTEM
PRE--CHECK

!ANTI-LOCK !:lflAKE SYSfFM WITH ELECTRONIC

RAKE FORCE DISTRIBUTION (EBD))

(DIAGNOSTICS) .

PRE-CHECK \AUIOMATIC IRANSAXLE (U240E))

{DIAGNOSTICS}

PRE--CHECK (AUTOMATIC TRANSAXLE (U341E))

(OIAGNOS"IICS) .

PRE--CHECK (Cf1UISE CONTROL SYSTEM)

(DIAGNOSTICS)

Pf1E--01lCK (ENGINf:)

{DIAGNOSTICS}

PRE-CHECK

(SUPPLEMCNTAL RESTnAINT SYSTEM)

(DIAGNOSTICS)

PRFCAUl!ON (FOR ALL OF VEHICLES)

PRESSURE SWITCH
PROBLEM SYMPTOMS TABLE

(ANH-LOCK BRAKE SYSTEM WITH ELECTnONIC
BRAKE FORcrc_ DISTniBUTION (EBD))

(DIAGNOSTICS)

PROBLEM SYMPTOMS "I ABLE

(AUTUMAT!C TRANSAXLE (U240E))
(DIAGNOSTICS)

PROBLEM SYMPTOMS TABLE

{AUTOMATIC TRANSAXLE (U34tl))

(DIAGNOSTICS)

PROBLEM SYMPTOMS TABLE

(BODY CON fROl SYS fEM)
(DIAGNOSTICS) .

PROBLEM SYMPTOMS TABLE

(CRUISE CONTROL SYSTEM}

(DIAGNOSTICS) .

PROBLEM SYMPTOMS TABLE (FNGINE)

{DIAGNOSTICS)

PHOBLEM SYMPTOMS TABLE:

(SUPPLFt.1f-NrAt RESTHAINr SYSTFM)
(DIAGNOSTICS)

PHOPOf-l liONING

VALVL

W VALV[)

Page VoL

Oi--281 ( 1 )

01-169 { 1 )

01-232 ( 1 )

01--491 ( 1 }

01-E l ( l )

01-335 { 1 )

EG-4 {2)

BE---62 (2)

BE--85 (2.i

BE-10 (2)

SH--4 (2)

SR--33 (:l:)

SR-22 (2)

BE-58 {2)

01-276 1 1 )

Dl--157 ( 1 )

01--485 { 1 )

01-3 { 1 )

Dl-326 ( 1 )

IN-1 0 ( 1 )

AC"-51 {2)

Dl-172 ( 1 )

Dl-234 ( 1 )

01 -542 ( 1 )

Dl-494 ( 1 )

Dl-22 ( 1 )

Dl-338 { 1 )

Rfl-47 (2)

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Summary of Contents for Celica 2000

Page 1: ......

Page 2: ...nts and systems in this vehicles Manual Name Pub No U240E Automatic Transaxle Repair Manual Aug 1B99 RM740U U340E U341E AutomaticTransaxle RepairManual Aug 1999 RM735U 2000 CEUCAElectrical Wiring Diagram EW0399U 2000 CEUCANewCar Features NCF169U All information in this manual is based on the latest product information at the time ofpublication However specifications and procedures are subject to c...

Page 3: ...ir and service When performing the operations following the procedures using this manual be sure to use tools spe cified and recommended If using non specified or recommended tools and service method be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer s vehicle before starting the operation If part replacement is necessary must repl...

Page 4: ...CATION 1 1 IGNITION ml STARTING mil CHARGING I III CLUTCH 61 C56 MANUAL TRANSAXLE li J 3 C60 MANUAL TRANSAXLE li J 3 U240E AUTOMATIC TRANSAXLE r tJ U341 E AUTOMATIC TRANSAXLE r tJ SUSPENSION AND AXLE 1 1 BRAKE IEiiJ STEERING lffi SUPPLEMENTAL RESTRAINT SYSTEM 1m BODY ELECTRICAL lml BODY m1 AIR CONDITIONING r l ALPHABETICAL INDEX mJI ...

Page 5: ...ENGINE MECHANICAL CO HC COMPRESSION VALVECLEARANCE IGNITIONTIMING IDLESPEED TIMINGCHAIN CYLINDERHEAD ENGINEUNIT CYLINDERBLOCK EXHAUSTSYSTEM EM 1 EM 3 EM I EM 13 EM 14 EM 15 EM 36 EM 70 EM ssll ll EM 115 ...

Page 6: ...connected f SFJ system wiring connectors fully plugged g Ignition timing check correctly h Transmission in neutral position i Tachometer and CO HC meter calibrated by hand 2 START ENGINE 3 RACE ENGINE AT 2 500 RPM FOR APPROX 180 SE CONDS 4 INSERT CO HC METER TESTING PROBE AT LEAST 40 em 1 3 It INTO TAILPIPE DURING IDLING 5 IMMEDIATELY CHECK COIHC CONCENTRATION AT IDLE AND OR 2 500 RPM Complete the...

Page 7: ...ect and correct the applicable causes if neces sary Causes 1 Faulty ignitior s lnco1rect timing Fouled shorted or improperly gapped plugs Open or crossed high tension cords 2 Incorrect valve clearar ce 3 leaky ir take ar d e haust Vlllves 4 lell y cylir ders 1 Vacuum leaks PCV hoses Intake manifold Throttle body lAC valve Brake booster Iitle 2 Lear mixture causi g mislile 1 Restricted air lifter 2...

Page 8: ...urement must be done in as short a time as pos sible Compression pressure 1ZZ FE 1 500 kPa 15 3 kgf cm2 218 psi 2ZZ GE 1 400 kPa 14 3 kgf cm2 203 psi or more Minimum pressure 1ZZ FE 1 000 kPa 10 2 kgflcm2 145 psi 2ZZ GE 1 000 kPa 10 2 kgflcm2 145 psi Difference between each cylinder 1ZZ FE 100 kPa 1 0 kgf l cm 2 15 psi or less 2ZZ GE 1 10 kPa 1 1 kgflcm 16 psi or less e If the cylinder compression...

Page 9: ...in straight Hne on the timing chain cover surface as shown in the illustration If not turn the crankshaft 1 revolution 360 and align the marks as above 3 INSPECT VALVE CLEARANCE a Check only the valves indicated Using a feeler gauge measure the clearance be tween the valve lifter and camshaft Record the out of specification valve clearance measurements Theywill be used laterto determine the requir...

Page 10: ...haft tim ing sprockets Remove the 2 bolts and chain tensioner d Remove the camshaft and timing sprocket assemblies See page EM 42 HINT i 19 camshaft bearing cap bolts 2 9 camshaft bearing caps No 1 No 3 3 Exhaust camshaft and timing sprocket assembly 4 Intake camshaft and timing sprocket assembly When disconnect the timing chain from the camshaft timing sprocket holding the timing chain e Tie the ...

Page 11: ...ew lifter with a thickness as close as pos sible to the calculated values Litter are available in 35 sizes in increments of 0 020 mm 0 0008 in from 5 060 mm 0 1992 in to 5 740 mm 0 2260 in 5 2ZZ GE ADJUST VALVE CLEARANCE a Remove the adjusting shim 1 Tum the crankshaft so that the cam lobe of cam shaft on the adjusting valve points upward 2 Using SST press down the valve 3 Using SST remove the adj...

Page 12: ...e clearance N Thickness of new shim Intake N T A 0 20 mm 0 008 in Exhaust N T A 0 40 mm 0 016 in Select a new shim with a thickness as close as possible to the calculated values Shim are available in 41 size in incrementsof0 020mm 0 0008 in from 2 000 mm 0 0787 in to 2 800 mm 0 1102 in ...

Page 13: ...2 1 ol _ o i i L L m f o 101 F J _G _ j r l j 1 J J i _ 2 2 1 _f 1 2 1 C i 0C o oo_ _ _ 1 L P _y r L i t 2 r _ _0__ 1 __ 00_ _ _7 __ 1 l i _ r oci0 S _i 2 2 0 7 1 r 4 1 _ o f _ _ i l q 0J _ _ _o 0 E 11 1 I _ L_ _ o 2 I loll L r o L o 2 t C _lfi _ _ e fr t r t S _2 i J New lifter thickness mm ir I I o l1o1oo i 4 oot S n m 1 i5 l i lro _ 7 ic i OO Clm OC I O J 00111 04 U 110 i C i l_ i I I _ 0 9 l l...

Page 14: ... 0 440 mm 0 0173 in Replace the 5 340 mm 0 21 02 in 1ifter with a new No 48 lifter inl l 1 I ep f je j 1 I l 1 I l J 1 _ i _ 0 2 l _ t _ 1 oi i j o l I r r i i c r I m T In Lifter No Thtckness i iftor No 1 jf r Thickness i No 1 h c 1 SS 06 5 060 0 1992 08 5 080 0 2 000 1 5 100 0 2008 16 i 20 20iD zo5 30 5300 0 2087 1 5 5548 02181 32 1 5 3zo o zo84 1 56 i s sso o 2189 34 l5 34o o z oz 1 se is sso i...

Page 15: ...o 20080 2 000000 0 lgg g g l N j NNNNNIN 4 aN u c c 0 8 E c w N p o Q e tho e coco co W ro qo q 0 2e_O 0000 0 C O0N ro NN i iN w N E u E c w 0 u v 0 z 3 c E ro E wo 3 E s 0 E w 0N E roo oq o C 0 7 o Ol E o w E w fig 0 cc5 E j E o _ ow L SO x E w 0 c u u w w E 5 s m 0 s E E 0 0 N 5 a w a ...

Page 16: ...EM 11 ENGINE MECHANICAL VALVf CLEARANCE p ...

Page 17: ...the timing chain and camshaft timing sprocket e Reinstall the camshaft and timing sprocket assemblies See page EM 65 f Checkthatthe point marks of the camshaft timing sprock ets are in straight line on the timing chain cover surface as shown in the illustration g 7 Check that the matchmarks on the timing chain and cam shaft timing sprockets Install the chain tensioner See page EM 25 Recheck the va...

Page 18: ...efer to the TOYOTA hand held tester or OBD I scan tool operator s for further details 3 CONNECT TIMING LIGHT TO ENGINE 4 INSPECT IGNITION TIMING Using a timing light check the ignition timing HINT Ignition timing 1ZZ FE 10 18 8TDC Idle 2ZZ GE 8 12 BTDC idle Transmission In neutral position After engine rpm is kept at 1 000 1 300 rpm for 5 seconds check that it returns to idle speed 5 DISCONNECT TI...

Page 19: ... i Air conditioning switched OFF 2 CONNECT TOYOTA HAND HELD TESTER OR OBDII SCAN TOOL a Connect the TOYOTA hand held tester or 08011 scan tool to the DLC3 b Please refer to the TOYOTA hand held tester or OBD I scan tool operator s manual for further details 3 INSPECT IDLE SPEED a Race the engine at 2 500 rpm for approx 90 seconds b Check the idle speed Idle speed w Cooling fan OFF 1ZZ FE Mrr 700 5...

Page 20: ... TIMING CHAIN COMPONENTS DriveBelt ENGINE MECHANICAL fiMING CHAIN UpperFront Fender ApronSeal f UpperRadiatorSupport Seal RHEngineUnder Cover EM 15 ...

Page 21: ... 1ZZ FE MECHANICAL ENGINE Cham Cover Tunmg TIMINGCHAIN k A gle Sensor Plate I V bration Dumper Cham I Cran n 1 fornuA N fl SpeCII8 _ k f cm h lb I N m p__ blepart t Noi1 reusa H ad Cover 2 Cylinder 8 No i J ...

Page 22: ...ENGINE MECtlANICAL TIMING Cl lAIN 2ZZ GE EM 17 Gasket j No 1 Ventilation Pipe Oii Guide 0 Ring ...

Page 23: ...s and disconnect the PS pump from the engine See page SR 24 HINT Put aside the pump and suspend it to the cowl with a string 7 REMOVE RH ENGINE MOUNTING INSULATOR a Set the jack to the engine HINT Place a wooden block between the jack and engine b 1ZZ FE Remove the 4bolts 2 nuts and RH engine mounting insu lator c 2ZZ GE Remove the 5 bolts 2 nutsand RH engine mounting insu lator 8 1ZZ FE REMOVE CY...

Page 24: ...tila tion hose from the No 1 ventilation pipe Remove the No 1 ventilation pipe and gasket Remove the 9 bolts wire harnessprotector cylinderhead cover and gasket Remove the Q ring from tho cylinder head cover 10 SET NO 1 CYLINDER TO TDC COMPRESSION a Turn the crankshaft pulley and align itsgroovewith timing mark o of the timing chain cover b Checkthat the point marks ofthe camshafttiming sprock ets...

Page 25: ...e the bolt nut and drive belt tensioner 14 REMOVE RH ENGINE MOUNTING BRACKET a 1ZZ FE Remove the 3 bolts and mounting bracket y a b 2ZZ GE Remove the 4 bolts and mounting bracket 15 REMOVE CHAIN TENSIONER Remove the 2 nuts and chain tensioner 16 REMOVE WATER PUMP See page C0 5 17 1ZZ FE REMOVE TIMING CHAIN COVER a Remove the 1 1 bolts and nut b Using a torx wrench socket E8 remove the stud bolt c ...

Page 26: ... If the crankshaft timing sprocket cannot be removed by hand use 2 screwdrivers NOTICE Position shop rags as shown to prevent damage 22 REMOVE CHAIN VIBRATION DAMPER Remove the 2 bolts and damper 23 REMOVE VALVE TIMING CONTROL ASSEMBLY AND CAMSHAFT TIMING SPROCKET Hold the hexagonal head wrench portion of the camshaft with a wrench and remove the bolt valve timing controller assembly and timing sp...

Page 27: ...r more places se lected at random b Wrap the chain around the timing sprocket c Using a vernier calipers measure the timing sprocket di ameter with the chain NOTICE Vernier calipers must contact the chain rollers for measur ing Minimum sprocket diameter w Chain Camshal197 3 mm 3 831 in Crankshaft 51 6 mm 2 031 in If the diameter is less than minimum replace the chain and sprockets 2 INSPECT CHAIN ...

Page 28: ...NER a Check that the plungermoves smoothly when the ratchet pawl is raised with your finger b Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger 4 INSPECT OIL JET See page LU 11 ...

Page 29: ...ng SSTand a hammer tap in a new oil seal until its surface is flushwith the timing chain cover edge SST 09309 3701 0 3 Apply M P grease to the oil seal lip b If timing chain cover is installed to the cylinder block 1 Using a knife cut off the oil seal lip 2 Using a screwdriver pry out the all seal NOTICE Be careful not to damage the crankshaft Tape the screw driver tip 3 Using SST and a hammer tap...

Page 30: ...bly when installing it c Align the knock pin hole in the cam shaft timing sprocket with the knock pin of the cam shaft and exhaust the sprocket to the cam shaft d Temporarily install the timing sprocket bolt e Hold the hexagon wrench head portion of the camshaft with a wrench and tighten the timing sprocket bolt Torque 2 a b 1ZZ FE 45 N m 460 kgf cm 33 ft lbf 2ZZ GE 54 N m 551 kgf cm 40 ft lbf SET...

Page 31: ...hain on the crankshaft timing sprocket with the yellow color llnk aligned with the timing mark on the crankshaft timing sprocket HINT If necessary install the sprocketwith SST SST 09223 2201 0 b 1ZZ FE Install the timing chain on the camshaft timing sprockets with the yellowcolor links aligned with thetiming marks on the camshaft timing sprockets c 2ZZ GE Install the timing chain on the camshaft t...

Page 32: ...cket 5 INSTALL CHAIN TENSIONER SLIPPER a Install the slipper with the bolt Torque lZZ FE 18 5 N m 189 kgf cm 14 ft lbn 2ZZ GE 20 5 N m 209 kgf cm 15 ft lbf b Check that the slipper moves is caught on the cylinder head stopper NOTICE DO not turn the crankshaft 6 INSTALL CRANK ANGLE SENSOR PLATE Install the plate with the F mark facing forward ...

Page 33: ...g chain cover as shown in the illustration HINT Seal packing Part No 08826 00100 or equivalent Install a nozzle that has been cut to a 1 5 mm 0 1 6 0 20 in opening Avoid applying an excessive amount to the surface Parts must be assembled within 3 minutes of ap plication Otherwise the material must be removed and reapplied Immediately remove nozzle from the tube and rein stallcap c Applyseal packin...

Page 34: ... kgf cm 8 ft lbf for others 12 mm head 18 5 N m 189 kgf cm 1 4 ft lbf NOTICE Pay attention not to wrap the chain and slipper over the chain cover seal line After installing the chain cover must install the mounting bracket and water pumpwithin 15 minutes HINT Each bolt length in indicated in the illustration A 45 mm 1 77 in L 7 B 35 mm 1 38 in C 30 mm 1 1 8 in 0 25 mm 0 98 in e Using a torx wench ...

Page 35: ...ration HINT Seal packing Part No 08826 00100 or equivalent Instal a nozzle that hasbeen cut to a 1 5 mm open ing Avoid applying an excessive amount to the surface Parts must be assembled within 3 minutes of ap plication Otherwise the material must be removed and reapplied Immediately remove nozzle from the tube and rein stall cap c Install the 2 gasket to the timing chain cover as shown in the lll...

Page 36: ...unting bolt Seal packing Part No 08826 00080 or equivalent HINT Do not apply sea packing to 2 or 3 threads of the bolt end b Install the mounting bracket with the 3 bolts Torque 47 N m 479 kgf cm 35 ft Jbf 10 2ZZ GE INSTALL RH ENGINE MOUNTING BRACKET Install the mounting bracket with the 4 bolls T orque 49 N m 500 kgf cm 36 ft Jbf 1 1 INSTALL DRIVE BELTTENSIONER a Check the appearance beforeinstal...

Page 37: ...f cm 87 fl lbf 14 INSTALL CHAIN TENSIONER a Check the chain tensioner See page EM 16 b Release the ratchetpawl fully push in the plunger and ap ply the hook to the pin so that the plunger cannot spring out c Insert the D ring with your hand until it reaches to the chamfering position and install nut temporally Then by tightening the nut insert the chain tensionerto the instal lation position HINT ...

Page 38: ...and the plunger springs out 16 CHECK VALVE TIMING a Turn the crankshaftpulley and align its groove with timing mark 0 of the timing chain cover NOTICE Always turn the crankshaft clockwise b Checkthat the point marks of the camshafttiming sprock ets are in straight line on the timing chain cover surlace as shown in the illustration If not turn the crankshaft 1 revolution 360 and align the marks as ...

Page 39: ...9 0 N m 92 kgf cm 80 in lbf e Connect the 2 PCV hoses to the cylinder head cover f Install the ignition coil See page IG 7 18 2ZZ GE INSTALL CYLINDER HEAD COVER a Remove any old packing FIPG material HINT When FIPG on the head cover gasket side cannot be elimi nated completely replace the gasket b Apply seal packing to 2 1ocations as shown in the illustra tion Seal packing Part No 08826 00080 or e...

Page 40: ...LL RH ENGINE MOUNTING INSULATOR a 1 ZZ FE Install the RH engine mounting insulator with the 4 bolts and 2 nuts Torque 52 N m 530 kgf cm 38 ft lbf b 2ZZ GE Install the RH engine mounting insulator with the 5 bolts and 2 nuts Torque 52 N m 530 kgf cm 38 ft lbf 20 INSTALL PS PUMP a Install the PS pump with the 2 through bolts and nuts Torque 36 N m 370 kgf cm 27 ft lbf b Install the PS pump pulley wi...

Page 41: ...EM 36 CYLINDER HEAD COMPONENTS ENGINE MECHANICAL CYLINDERHEAD UpperFrontFenderApronSeal Gasket Fin kQTCfri tt J Specifiedtorque N Norr reusaoJepart ...

Page 42: ...ENGINEMECHANICAL CYLINDERHEAD 1ZZ FE IntakeManifold _t 1 kQ _ B illJ Specifiedtorque N Non reusablepart tJ J It c e f lACValveConnector WireHarness Protector EM 37 ...

Page 43: ...y 1 PCVHose ThrottlePosition IntakeManifold No 2Insulator a I SensorConnector _ _l L AccelecatocContcol _ _ z f r 0 CableBracket IntakeManifold tT Jn3 jl 34 7 _ 2ji5 f l 46 4692 Gasket 1 fJ_ t L lACValveConnector IntakeManifoldInsulator _ j g_ _ll_1 ft lb L Specifiedtorque N Non reusablepart ThrottleBody GeneratorBracket AW3 ...

Page 44: ...EM 39 ENGINEMECHANICAL CYLINDER HEAD 1ZZ FE Gaskett Crankshaft Pos l ion Se sor ...

Page 45: ...EM 40 ENGINEMECHANICAL CYLINDER HEAD 2ZZ GE D ring ...

Page 46: ... GE RockerNo 2 Shaft l RockerNo1 Shaft CylinderHead ENGINE MECHANICAL CYLINDEH HEAD e Shim 119 K L _ eeper lf1fL___ Spc ngReta nec fjj ValveSpring SpringSeat r Oi _controlvalveforvvr 01IFilter Gasket EM 41 ...

Page 47: ...MOVE AIR CLEANER ASSEMBLY 6 DISCONNECT ACCELERATOR CABLE 7 REMOVE DRIVE BELT AND ALTERNATOR See page CH 7 8 REMOVE EXHAUST PIPE See page EM 74 9 1ZZ FE REMOVE EXHAUST MANIFOLD a Remove the 3 bolts and exhaust manifold stay b Remove the 6 bo ts and upper heat insulator c Remove the 5nuts exhaust manifold and gasket d Remove the 3 bolts and lower heat insulator ...

Page 48: ...connector Disconnect the oil control valve for VVT connector Disconnect the 2 ground wires Disconnect the 2 clamps and engine wire protector from the intake manifold 17 2ZZ GE DISCONNECTENGINEWIREFROM CYLINDER HEAD a Disconnect the ECT sensor connector b Disconnect the camshaft position sensor connector c Disconnect the oil control valve for VVT connectors d Disconnect the oil control valve for VV...

Page 49: ...d and gasket Remove the intake manifold insulator REMOVE CAMSHAFT POSITION SENSOR REMOVE ECT SENSOR REMOVE PCV VALVE AND GROMMET REMOVE OIL FILLER CAP REMOVE CAMSHAFTTIMING SPROCKETS See page IG 9 25 1ZZ FE REMOVE CAMSHAFT Uniformlyloosen and removethe 19 bearing cap bolls in sever al passes in the sequence shown and remove the 9 bearing caps intake and exhaust camshafts 26 2ZZ GE REMOVE CAMSHAFT ...

Page 50: ...ove the 10 cylinder head bolts and plate washers NOTICE Head warpage or cracking could result from removing bolts in an incorrect order d Remove the bolt holding the waterbypasspipe to the cyl inder head e Liftthe cylinder from the dowels on the cylinder blockand replace the cylinder head on wooden blocks on a bench HINT If the cylinder bead is difficultto lift off pry between the cylinder head an...

Page 51: ...0i0 c Remove the 3 bolts 2 nuts oil control valve housing and gasket d Remove the oil control valve filter 4 2ZZ GE REMOVE VALVE ROCKER ARM a Remove the 2 bolts rocker No 1 and No 2 shafts b Remove the 8 valve rocker arm HINT Arrange the rocker arms in the correct order 5 REMOVE VALVE LIFTERS HINT Arrange the valve lifters in the correct order 6 REMOVE VALVES a Using SST compress the valve spring ...

Page 52: ...7 ENGINEMECHANICAL CYLINDER HEAD f Using compressed air and magnetic finger remove the spring seat by blowing air HINT Arrange the valves valve springs spring seats and spring re tainers in the correct order ...

Page 53: ... blow carbon and oil from the bolt holes CAUTION Protect your eyes when using high pressure compressed air 2 REMOVE GASKET MATERIAL Using a gasket scraper remove all the gasket material from the cylinder block contact surface NOTICE Be careful not to scratch the cylinder block contact sur face 3 CLEAN COMBUSTION CHAMBERS Using a wire brush remove all the carbon from the combustion chambers NOTICE ...

Page 54: ...gauge measure the surface contacting the cylinder blockand the manifolds for war page Maximum warpage 0 05 mm 0 0020 in If warpage is greaterthan maximum replace thecyllnder head 7 INSPECT FOR CRACKS Using a dye penetrate check the combustion chamber intake ports exhaust ports and cylinder block surface for cracks If cracked replace the cylinder head 8 CLEAN VALVES a Using a gasket scraper chip of...

Page 55: ...0 mm 0 21 437 0 21535 in c Subtract the valve stem diameter measurement from the guide bushing inside diameter measurement Standard oil clearance 1ZZ FE Intake 0 025 0 060 mm 0 0010 0 0024 ln Exhaust 0 030 0 065 mm 0 001 2 0 0026 in 2ZZ GE Intake 0 025 0 058 mm 0 00098 0 00228 in Exhaust 0 030 0 063 mm 0 0011 8 0 00248 in Maximum oil clearance 1ZZ FE Intake 0 08 mm 0 0031 in Exhaust 0 10 mm 0 0039...

Page 56: ...is less than minimum replace the valve e Check the surface of the valve stem tip for wear If the valve stem tip is worn replace the valve 11 INSPECT AND CLEAN VALVE SEATS a Using a 45 carbide cutter resurface the valve seats Remove only enough metal to clean the seats b After resurfacing the valve seat 45 measure the residu ary width of the valve seat 45 Minimum residuary length Intake 3 3 mm 0 13...

Page 57: ...seats as follows 1 If the seating is too high on the valve face use 30 and 45 cutters to correct the seat 2 If the seating is too low on the valve face use 75 and 45 cutters to correct the seat e Hand lap the valve and valve seat with an abrasive com pound f After hand lapping clean the valve and valve seat 12 INSPECT VALVE SPRINGS a Using a steel square measure the deviation of the valve spring M...

Page 58: ...5 1bf at 38 5 mm 1 516 in r Exhaust 208 2 229 8 N 21 2 23 4 kgf 47 6 52 6 1bf at 38 5 mm 1 516 in Maximum working tension 1ZZ FE 244 9 276 1 N 25 5 28 1 kgf 56 2 61 9 lbf at 24 6 mm 0 969 in 2ZZ GE Intake 533 589 N 54 4 60 1 kgf 119 9 132 5 lbf at 27 3 mm 1 075 1n Exhaust 495 5 548 5 N 50 5 55 9 kg 111 3 123 2 1bf at 28 5 mm 1 122 in If the installed tension is not as specified replace the valve s...

Page 59: ...obe height 1 ZZ FE Intake 44 18 mm 1 7394 in Exhaust 43 61 mm 1 7169 ln 2ZZ GE Intake No 1 40 45 mm 1 5925 ln No 2 38 61 mm 1 5201 in Exhaust No 1 39 86 mm 1 5693 No 2 38 71 mm 1 5240 If the cam lobe height ls less than minimum replace the cam shaft 15 INSPECT CAMSHAFT JOURNALS Using a micrometer measure the journal diameter 1ZZ FE No 1 journal diameter 34 449 34 465 mm 1 3563 1 3569 ln Others jou...

Page 60: ...kgf cm 14 ft lbf NOTICE Do not turn the camshaft e Remove the bearing caps f Measure the plastigage at its widest point 1ZZ FE Standard oil clearance 0 035 0 072 mm 0 0014 0 0028 in Maximum oil clearance 0 10 mm 0 0039 1n 2ZZ GE Standard oil clearance No 1 journal 0 035 O o76 mm 0 00138 0 00299 in Other journal 0 035 0 072 mm 0 00138 0 00283 in Maximum oil clearance 0 10 mm 0 039 in If the oil cle...

Page 61: ... the camshafts 18 INSPECT VALVE TIMING CONTROLLER ASSEMBLY a Apply vinyl tape to all the ports except the one indicated by the arrow in the illustration NOTICE Do not apply tape In the range from the tip of the camshaft to 18 mm from that tip b Install the valve timing controller assembly Torque 47 N m 480 kgf cm 35 ft lbf NOTICE Do not push valve timing controller assembly to the cam shaft forcib...

Page 62: ...y turn back and forth andcheckthe movable range and that there is no disturbance Standard Movable smoothly in the range about 30 g Turn the valve timing controller assembly with your hand and lock it at the maximum delay angel position 19 1ZZ FE INSPECT VALVE LIFTERS AND LIFTER BORES a Using a caliper gauge measure the lifter bore diameter of the cylinder head lifter bore diameter 31 000 31 025 mm...

Page 63: ... maximum replace the manifold 21 INSPECT EXHAUST MANIFOLD Using a precision straight edge and feeler gauge measure the surface contacting the cylinder head for warpage Maximum warpage 0 70 mm 0 0276 1n If warpage is greater than maximum replace the manifold 22 INSPECT CYLINDER HEAD BOLTS Standard outside diameter 9 0 9 2 mm 0 354 0 362 in Minimum outside diameter 9 0 mm 0 354 in If the outer diame...

Page 64: ...shing c SST 09201 1055 0995 70010 09951 7100 Using a caliper gauge measure the bushing bore diame ter of the cylinder head d 1 ZZ FE Select the new guide bushing STD or 0 S 0 05 Ifthebushing bore diameterof the cylinder headis greater than 1 0 306 mm 0 4057 in machine the bushing bore to the fol lowing dimension 10 335 10 356 mm 0 4068 0 4077 in If the bushingborediameterof the cylinderhead is gre...

Page 65: ...ol lowing dimension 1 0 538 10 556 mm 0 4149 0 4156 in Ifthe bushing borediameterof the cylinderhead is greater than 10 556 mm 0 4156 in replace the cylinder head g 2ZZ GE Gradually heat the cylinder head to 1 1 0 1 30 OC 230 266 F h Using SST and a hammer tap in a new guide bushing to the specified protrusion height SST 09201 01 055 0995 7001 0 09951 07100 Protrusion height 1ZZ FE 8 7 9 1 mm 0 34...

Page 66: ...efore installing the parts apply fresh engine oil to all slid ing and rotating surfaces Replace oil seals with new ones 1 INSTALL WATER HOSE UNIONS HINT When using a new cylinder head water hose unions must be installed a Mark the standard position away from the edge onto the water hose union b Apply adhesive to the water hose union hole of the cylin der head Adhesive Part No 08833 00070 THREE BON...

Page 67: ...5 in D 69 8 mm 2 630 ln NOTICE Avoid pressing a new water hose union in too far by mea suring the amount of protrusion while pressing 2 a HINT INSTALL VALVES Using SST push in a new oil seal SST 09201 41020 1ZZ FE The intake valve oil seal is light brown and the exhaust valve oil seal is gray 2ZZ GE The intake valve oil seal is black and theexhaust valve oil seal is green NOTICE Pay much attention...

Page 68: ...age the valve stem tip 3 INSTALL VALVE LIFTERS a Instal the valve lifter b Check that the valve lifter rotates smoothly by hand 4 2ZZ GE INSTALL VALVE ROCKER ARM a Set the 8 valve rocker arms b Install the rocker No 1 and No 2 shaft with the 2 bolts HINT 5 a b Torque 7 5 N m 76 kgf cm 66 in lbf Position the slit of the locker shaft in the direction shown in the illustration Align the locker shaft ...

Page 69: ... d Using SST install the oil pressure switch SST 09816 30010 Torque 1 3 N m 130 kgf cm 9 fl lbf e Install the oil control valve for VVTL with the bolt 6 INSTALL CONTROL VALVE for VVT Install the oil control valve for VVT with the bolt 7 INSTALL OIL CONTROL VALVE FILTER Install the oil control valve filter and new gasket with the bolt Torque 29 N m 300 kgf cm 22 fl lbf ...

Page 70: ... progressive steps steps b and d If any cylinder head bolt is broken or deformed replace it a Apply a tght coat if engine oil on the threads and under the heads of the cylinder head bolts b Using a 10 mm bi hexagon wrench install and uniformly tighten the 10 cylinder head bolts and plate washers in several passes in the sequence shown Torque 1ZZ FE 49 N m 500 kgf cm 36 fl lbf 2ZZ GE 35 N m 375 kgf...

Page 71: ...der head with the No 1 cam lobes facing as shown the illustration b Install the bearing caps in their proper locations HINT i ZZ FE No 3 camshaft bearing cap has a numberand front mark 2ZZ GE No 2 No 3 camshaftbearing cap has a number and front mark c Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts d i ZZ FE Install and uniformly tighten the 1 9 bearing...

Page 72: ... SENSOR See page IG 10 10 1ZZ FE INSTALL INTAKE MANIFOLD a Install a new gasket the intake manifold with the 4 bolts and 2 nuts Torque 18 5 N m 189 kgf cm 14 ft lbf b Connect the brake booster vacuum hose c Connect the EVAP hose for ORVR 11 2ZZ GE INSTALL INTAKE MANIFOLD a Install the intake manifold insulator to the cyl lnder block b Install a new gasket the intake manifold with the 4 bolts and 2...

Page 73: ...e for VVTL connector f Connect the camshaft position sensor connector g Connect the ECT sensor connector h Instal the accelerator cable bracket with the 2 bolts 14 INSTALL INJECTORS See page SF 24 15 INSTALL THROTTLE BODY See page SF 39 16 INSTAL PCV HOSES 17 INSTALL SPARK PLUGS See page IG 1 18 INSTALL IGNITION COIL See page IG 7 19 1ZZ FE INSTALL EXHAUST MANIFOLD a Install the ower heat insulato...

Page 74: ...0 kgf cm 37 ft lbf Instal the upper heat insulator with the 5 bolts Torque 20 N m 204 kgf cm 15 ft lbf Install the exhaust manifold stay withe 4 bolts Torque 50 N m 510 kgf cm 37 ft lbf INSTALL EXHAUST PIPE See page EM 10 INSTALL GENERATOR ANO DRIVE BELT See page CH 17 CONNECT ACCELERATOR CABLE INSTALL AIR CLEANER ASSEMBLY INSTALL ECM BOX See page EM 80 INSTALL BATTERY FILL WITH ENGINE COOLANT See...

Page 75: ...ENGINE UNIT COMPONENTS UpperFrontFenderApronSeal EngineHood P J m kgf cm tHbtn Specifiedtorque N UpperRadiator SupportSea n Bat e yClamp ttJ Battery Battery Tray AirCleanerCap 1 s o 51 lil ibt AirFilter LHEngineUnder Cover AirCleanerCase ...

Page 76: ...Radiator Assembly DriveBelt ENGINE MECHANICAL c lbtl Specifiedtorque N 1N m kg _ EM 71 ENGINE UNIT J BCover ...

Page 77: ...72 RHDrive Shaft ENGINE MECHANICAL ENGINE UNIT Stabilizer Bar Bracket lc c Stabilizer Bar Suspension Member I Gasket 43 440 32 i _I _ _ t Gasket Front Exhaust Pipe l f l _ C J _ _ r i I 0 Ring f 4 r 44o 32 ...

Page 78: ... ENGINE UNIT UpperFrontFenderApronSeal 1ZZ FE UpperHeatedInsulator 2ZZ GE RHEngineMountin9f Insulator lA JI _ ClutchReleaseCylinder Q lZZ FE No 2CylinderHeadCover 2ZZ GE No 2 CylinderHead Cover TransmissionControlCable AH 443 ...

Page 79: ...e air cleaner hose from the throttle body 9 REMOVE AIR CLEANER CASE a Remove the air filter b Disconnect the hose from the VSV for Canister Closed VALVE CVC c Disconnect the hose from the intake air control valve d Remove the 2 bolts and disconnect the air cleaner case e Disconnect the 2 hoses from the air cleaner case 10 REMOVE ECM BOX a Remove the 2 bolts and ECM cover b Disconnect the 4 connect...

Page 80: ...Disconnect the actuator connector b Remove the 3 bolts and disconnect the actuator from the body 1 3 REMOVE RADIATOR ASSEMBLY 5ee page CQ 17 14 REMOVE DRIVE BELT AND GENERATOR See page CH 7 15 w AIC DISCONNECT AJC COMPRESSOR a Disconnect the NC compressor connector b Remove the 3 bolts and disconnect the AJC compressor from the engine HINT Suspend the NC compressor securely 16 DISCONNECT TUBE AND ...

Page 81: ...A 20 21 REMOVE EXHAUST PIPE a Disconnect the 2 heated oxygen sensor b c Remove the 4 bolts and springs Disconnect the 2 0 rings and remove the exhaust pipe and 2 gaskets 22 1ZZ FE REMOVE EXHAUST MANIFOLD a Remove the 6 bolts and upper heat insulator b Remove the 3 bolts and exhaust manifold stay c Remove the 5 nuts exhaust manifold and gasket 23 2ZZ GE REMOVE EXHAUST MANIFOLD a Remove the 5 bolts ...

Page 82: ...spend it to the cowl with a string 25 REMOVE STABILIZER BAR BRACKET See page SA 51 26 DISCONNECT PS GEAR Remove the 4 bolts and disconnect the PS gear from the sus pension member HINT Suspend the PS gear securely 27 REMOVE SUSPENSION MEMBER Remove the 9 bolts 3 nuts and suspension member 28 ATTACH ENGINE SLIDING DEVICE TO ENGINE HANGER a Remove the 4 bolts and No 2 cylinder head cover b Disconnect...

Page 83: ...ngine sling device to the engine hangers CAUTION Do not attempt to hang the engine by hooking the chain to any other part 29 REMOVE REAR ENGINE MOUNTING a Remove the through bolt and rear engine mounting insu lator b Remove the 3 bolts and rear engine mounting bracket 30 REMOVE ENGINE AND TRANSAXLE ASSEMBLY a Remove the LH engine mounting through bolt and nut b 1ZZ FE Remove the 4 bolts 2 nutsand ...

Page 84: ...arefully and raise the vehicle HINT Make sure the engine is clear of all wiring hoses and cables e Place the engine and transaxlc assembly onto the stand 31 SEPARATE ENGINE AND TRANSAXLE C56 MIT See page MX 4 C60 MIT See page MX 4 L U240E AfT See page AX 31 U341 E AfT See page AX 31 ...

Page 85: ...gn RH and LH mountings with the body bracket d 1ZZ FE Install the RH engine mounting insulator with the 4 bolts and 2 nuts Torque 52 N m 530 kgf cm 38 ft lbf e 2ZZ GE Install the AH engine mounting insulator with the 5 bolts and 2 nuts Torque 52 N m 530 kgf cm 38 ft lbf f Install the LH engine mounting through bolt and nut Torque 80 N m 816 kgf cm 59 ft lbf 3 REMOVE ENGINE SLING DEVICE 4 INSTALL R...

Page 86: ... a Instal the PS pumpwith the 2 through bolts and nuts See page SR 32 Torque 36 N m 370 kgf cm 27 ft Jbf b Connect the PS oil pressure switch connector 9 1ZZ FE INSTALL EXHAUST MANIFOLD a Install the gasket and exhaust manifold w 1th the 5 nuts Torque 37 N m 377 kgf cm 27 ft lbf b Install the exhaust manifold stay with the 3 bolts Torque 49 N m 500 kgf cm 37ft lbf c Install the upper heat insulato...

Page 87: ...lease cylinder with the 2 bolts Torque 12 N m 120 kgf cm 9 ft lbf b Install the brackets with the 3 bolts Torque Bolt A 1 2 N m 120 kgf cm 9 tt lbl Bolt B 4 9 N m 50 kgf cm 43 in lbf 16 CONNECT TUBE AND HOSE a Connect the brake booster vacuum hose b Connect the 2 heater hoses to the engine side c Connect the fuel tube to the fuel pipe on vehicle side 17 w AJC INSTALL AJC COMPRESSOR a Instal the AJ...

Page 88: ...d Connect the 3 connectors e Install the relay box upper cover 22 INSTALL ECM BOX a Install the ECM box stay with the 2 nuts and bolt Torque Nut 12 N m 120 kgf cm 9 ft lbf Bolt 18 N m 185 kgf cm 13 ft lbf b Jnslal lhe ECM box with the 3 bolts Torque 6 9 N m 70 kgf cm 61 in Jbf c Connect the 2 engine wire to the ECM box d Connect the clamp to the ECM box e Install the ECM to the ECM box I Connect t...

Page 89: ...hose clamp b Connect the air cleaner cap to the air cleaner case with the 3 clamps c Connect the 2 hoses d Connect the VSV for EVAP e Connect the MAF meter connector 25 INSTALL HEADLIGHT AND BUMPER COVER 26 INSTALL BATTERY AND TRAY 27 FILL WITH TRANSAXLE OIL 28 FILL WITH ENGINE OIL 29 FILL WITH ENGINE COOLANT See page C0 2 30 START ENGINE AND CHECK FOR LEADS 31 PERFORM ENGINE ADJUSTMENT 32 CHECK F...

Page 90: ...ECHANICAL CYLINDER BLOCK CYLINDER BLOCK COMPONENTS 1ZZ FE OilPump Gasket _ m kQ GOl ft j f i j j Specifiedtorque N Non reusaO e pa rt WaterBypassPipe EM 85 Oi Guideand OilDipstick KnockSensor i4oo 29 J WaterInlet ...

Page 91: ...EM 86 ENGINE MECHANICAL CYLINDER BLOCK N J fn gf cr j ft ibf 1 Specified torque Non reusablepart WaterBypass Pipe ...

Page 92: ...6 ConnectingRodBushing 1 ConnectingRod 6 ConnectingRodBeanng Qp l EM 17 crankshaftThrustWasher UpperMainBearingi CrankshaftThrustWasher Cranks 1aft Gasket l _oe o in Tbi 1 3i8 2 n j Gasket _0 0 kgf Cm t jbf l Specifiedtorque OilFilterUnion L 306 2 _ ___ Nonreusablepart AOI Io ...

Page 93: ...d 1 j j ConnectingRodBeacing ConnectingRodCap SnapRing l t SnapRmg PistonPin J 4 s00 a a EM 106 1st 30 306 22 2nd Turn 90 OilNozzle OilPanBaHie i 1 t I I Gasket Crankshaft Bearing Cap Assembly seepage EM 106 1st22 225 16 H 2nd44 449 32 j 3rd Turn 45 4rdTurn45 J 18 185 13 OilFilterUnion OiiFilter w OilStramer ____ K j 37 378 I Jf Jt j OilPan Specifiedtorque Gasket A 03 ...

Page 94: ...EM 42 7 1ZZ FE REMOVE OIL DIPSTICK AND GUIDE a Remove the bolt and oil dipstick and guide b Remove the 0 ring from the dipstick_ 8 REMOVE WATER BYPASS PIPE Remove the 2 nuts bolts and water bypass pipe 9 REMOVE THERMOSTAT See page C0 9 10 REMOVE KNOCK SENSOR 11 REMOVE ENGINE COOLANT DRAIN UNION 12 REMOVE OIL PUMP See page LU 9 13 a b 2ZZ GE REMOVE VENTILATION CASE Remove the 3 nuts ventilation cas...

Page 95: ... blade of SST between the bearing cap sub as sembly and oil pan and cut off applied sealer and remove the oil pan SST 09032 00100 NOTICE Be careful not to the damage the oil pan contact sur face of the bearing cap sub assembly Be careful not to damage the oil pan flange 17 1ZZ FE REMOVE OIL STRAINER Remove the 2 nuts bolt oil strainer and gasket 18 2ZZ GE REMOVE OIL STRAINER AND OIL PAN BAFFLE a R...

Page 96: ...kness 19 788 1 9 840 mm 0 7791 0 7811 in 20 REMOVE CONNECTING ROD CAPS AND CHECK OIL CLEARANCE a Checkthe matchmarkson the connecting rod andcapare aligned to ensure correct reassembly b Remove the 2 connecting rod cap bolts c Using the 2 removed connecting rod cap bolts remove the connecting rod cap and lower bearing by wiggling the connecting rod cap right and left HINT Keep the lower bearing in...

Page 97: ...d Turn extra 90 NOTICE Do not turn the crankshaft h Remove the 2 bolts connecting rod cap and lower bear ing See procedure b and c above i Measure the Plastigage at its widest point Standard oil clearance 1ZZ FE 0 028 0 060 mm 0 0011 0 0024 in 2ZZ GE 0 028 0 052 mm 0 0011 0 0020 ln Maximum oil clearance 0 08 mm 0 0031 ln lf the oil clearance is greater than maximum replace the bear ings If necessa...

Page 98: ...remove the Plast1gage 21 REMOVE PISTON AND CONNECTING ROD ASSEMBliES mm in_ mm n_ a Using a ridge reamer remove aU the carbon from the top of the cylinder b Push the piston connecfmg rod assembly and upper bearing through the top of the cylinder block HINT Keep the bearings connecting rod and cap together Arrange the piston and connecting rod assemblies in the correct order 22 REMOVE BEARING CAP S...

Page 99: ...ch main journal and bearing h Check each main journal and bearing for pitting and scratches If the journal or bearing is damaged replace the bearings It necessary replace the crankshaft i Place the crankshaft on the cylinder block j Lay a strip of Plastigage across each journal k Install the bearing cap sub assembly See page EM 106 NOTICE Do not turn the crankshaft I Remove the bearing cap sub ass...

Page 100: ...inted on the cylinder block and crank shaft then selecting the bearing with the same number as the total There are 4 sizes of standard bearings marked 1 2 3 and 4 accordingly Cylinderblock A Crankshaft B Totalnumber 3 5 6 8 9 11 Usebearing T 2 3 c 4 c 1i EXAMPLE Cylinder block 4 A Crankshaftn3 B Totalnumber7 Usebearing 3 o 2ZZ GE If using standard bearing replace it with one having the same number...

Page 101: ... 1 996 1 999 0 0786 0 0787 3 1 999 2 002 0 0787 0 0788 4 2 002 2 005 0 0788 0 0789 1 989 1 992 0 0783 0 0784 2 1 992 1 995 0 0784 0 0785 3 1 995 1 998 0 0785 0 0787 4 1 998 2 001 0 0781 0 0788 5 2 001 2 004 0 0788 0 0789 p Completely remove the Plast1gage 23 CHECK CRANKSHAFT THRUST CLEARANCE mm ln_ Using a dial indicator measure the thrustclearancewhile prying the crankshaft back and forth with a ...

Page 102: ...d oil ring by hand HINT Arrange the piston rings in the correct order only 27 DISCONNECT CONNECTING ROD FROM PISTON a Using a small screwdriver pry out the 2 snap rings b 1ZZ FE Gradually heat the piston to 80 90 C 176 194 F c 1ZZ FE HINT Using a plastic faced hammer and brass bar lightly tap out the piston pin and remove the connecting rod The piston and pin are a matched set Arrange the pistons ...

Page 103: ...he cylinder liner sticks out beyond the cylinder block so always wash the cylinder block at a temperature of 45Q C 133oF or less 3 INSPECT TOP SURFACE OF CYLINDER BLOCK FOR FLATNESS Using a precision straight edge and feeler gauge measure the surface contacting the cylinder head gasket for warpage Maximum warpage 0 05 mm 0 0020 in Ifwarpage is greaterthan maximum replace the cylinder block 4 INSPE...

Page 104: ...r 1ZZ FE 79 013 mm 3 1107 in 2ZZ GE 82 013 mm 3 2289 in If the diameter is greater than maximum replace the cylinder block 6 REMOVE CYLINDER RIDGE If the wear is less than 0 2 mm 0 008 in using a ridge reamer grind the top of the cylinder 7 INSPECT 12 POINTED HEAD BEARINGCAP SUB AS SEMBLY BOLTS Using vernier calipers measure the tension portion diameter of the bolt Standard diameter 7 3 7 5 mm 0 2...

Page 105: ...on diameterat right angles to the piston pin center line 1 2 0 mm 0 048 in from the piston bottom Piston diameter 1 ZZ FE 78 925 78 935 mm 3 1073 3 1077 in 2ZZ GE 81 975 81 993 mm 3 2274 3 2281 ln c Measure the cylinder bore diameter in the thrust direc tions See procedure in step 5 d Subtract the piston diameter measurementfrom the cylin der bore diameter measurement Standard oil clearance 1ZZ FE...

Page 106: ...andard end gap No 1 0 25 0 35 mm 0 0098 0 0138 1n No 2 0 35 0 50 mm 0 0138 0 0197 in Oil Side rail 0 15 0 40 mm 0 0059 0 0157 in Maximum end gap No 1 1 05 mm 0 0413 ln No 2 1 20 mm 0 0472 ln Oil Side rail 1 05 mm 0 0413 1n If the end gapis greaterthan maximum replace the piston ring Ifthe end gap is greaterthan maximum even with a new piston ring replace the cylinder block 12 INSPECT PISTON PIN FI...

Page 107: ... the piston bushing Bushing inside diameter 20 013 20 025 mm 0 7879 0 7884 in c Using a micrometer measure the piston pin diameter Piston pin diameter 1ZZ FE 20 004 20 013 mm 0 7876 0 7879 1n 2ZZ GE 20 004 20 016 mm 0 7876 0 7880 in d Subtract the piston pin diameter measurement from the bushing inside diameter measurement Standard oil clearance 1ZZ FE 0 005 0 011 mm 0 0002 0 0004 in 2ZZ GE Piston...

Page 108: ...0 0012 in If the circle runout is greater than maximum replace the crank shaft 17 INSPECT MAIN JOURNALS AND CRANK PINS a Using a micrometer measure the diameter of each main journal and crank pin Main journal diameter 47 988 48 000 mm 1 8893 1 8898 ln Crank pin diameter 1ZZ FE 43 992 44 000 mm 1 7320 1 7323 in 2ZZ GE 44 992 45 000 mm 1 7713 1 7717 in If the diameter is not as specified check the o...

Page 109: ... pin hole grinder hone the bushing to obtain the standard specified clearance See page EM 98 be tween the bushing and piston pin e Check the piston pin fit at normal room temperature Coat the piston pin with engine oil and push it intothe connect ing rod with your thumb 2 REPLACE CRANKSHAFT REAR OIL SEAL If rear oil seal is installed to cylinder block a Using a knife cut off the oil seal lip b Usi...

Page 110: ...ICAL CYLINDERBLOCK c Apply MP grease to a new oil seal lip EM 105 d Using SST and a hammer tap in the oil seal until its sur face is flush with the rear oil seal retainer edge SST 09223 15030 09950 70010 09951 7100 ...

Page 111: ...er install a new snap ring at one end of the piston pin hole HINT Be sure that end gap of the snap ring is not aligned with the pin hole cutout portion of the piston b 1 ZZ FE Gradually heat the piston to 80 90qC 176 1 94QF c Coat the piston pin with engine oiL d Align the front marks on the piston and connecting rod and push in the piston with your thumb e Using a small screwdriver install a new ...

Page 112: ...NOTICE Do not align the ring ends 3 INSTALL CONNECTING ROD BEARINGS a Align the bearing claw with the groove of the connecting rod or connecting cap b Install the bearings in the connecting rod and connecting rod cap 4 INSTALL MAIN BEARINGS HINT Upper bearings have an oil groove and oil holes Lower bear ings do not a Align the bearingclawwith the clawgrooveof the cylinder block and push in the 5 u...

Page 113: ...nts to remove all the loose material Using a non reusable solvent clean both sealing surfaces b Apply seal packing to the bearing cap sub assembly as shown in the illustration HINT Seal packing Part No 08826 00080 or equivalent Install a nozzle that has been cut to a 1 2 mm 0 004 0 08 in opening Avoid applying an excessive amount to the surface Parts must be assembled within 3 minutes of ap plicat...

Page 114: ... assembly bolt d Markthe frontof the bearing cap sub assembly boltswith paint e Retighten the bearing cap sub assembly bolts by 45 and 45 in the numerical order shown f Check that the painted mark is now at a 90 angle to the front 9 INSTALL HEXAGON HEAD BEARING CAP SUB AS SEMBLY BOLTS a Install and uniformly tighten the 10 bearing cap sub as sembly bolts in several passes Torque 1ZZ FE 18 5 N m 18...

Page 115: ... rod cap bolts are tightened in 2 progres sive steps steps b and d If any of the connecting rod cap bolts is broken or de formed replace lt a Apply a light coat of engine oil on the threads and under the heads of the connecting rod cap bolts b Install and alternately tighten the 2 connecting rod cap bolts in several passes Torque 1ZZ FE 20 N m 204 kgf cm 15 fl lbf 2ZZ GE 30 N m 306 kgf cm 22 H lbf...

Page 116: ...he 2 nuts and bolt 18 a Torque 9 0 N m 92 kgf cm 80 in fbf INSTALL OIL PAN Remove any old packing FIPG material and be careful nottodrop any oil on thecontact surface of the main bear ing cap and oil pan Using a razor blade and gasket scraper remove all theold packing FIPG material fromthegasket sur faces and sealing grooves Thoroughly clean all components to remove all the loose material Using a ...

Page 117: ...s Uniformly tighten the bolts and nuts in several passes Torque 9 0 N m 92 kgf cm 80 in lbf 19 INSTALL OIL FILTER UNION Torque 30 N m 306 kgf cm 21 ft lbf 20 INSTALL OIL FILTER See page LU 3 21 INSTALL OIL PUMP See page LU 13 22 INSTALL ENGINE COOLANT DRAIN UNION a Apply adhesive to 2 or 3 threads Adhesive Part No OB83 Hl0080 THREE BOND 1344 LOCTITE 242 or equivalent b Install the drain union HINT...

Page 118: ...ck guide b Apply soapy water on the 0 ring c Connect the dipstick guide end to the main bearing cap d Install the dipstick guide wlth the bolt Torque 11 N m 113 kgf cm 8 ft lbf 28 INSTALL CYLINDER HEAD See page EM 65 29 INSTALL ENGINE WIRE 30 INSTALL TIMING SPROCKETS AND TIMING CHAIN See page EM 25 31 REMOVE ENGINE STAND 32 M T INSTALL FLYWHEEL HINT The flywheel bolts are tightened in 2 progressiv...

Page 119: ...he front spacer drive plate and rear plate on the crankshaft b Apply adhesive to 2 or 3 threads of the mounting bolt end Adhesive Part No 08833 00070 THREE BONO or equivalent c Install and uniformly tighten the 8 mounting bolts in sev era passes in the sequence shown Torque 88 N m 897 kgf cm 65 ft lbf ...

Page 120: ...n Sensor Bankt Sensor Gasket I J 11 kQfCrTi ft I Specifiedtorque Non reusablepart I 1ZZ FE Tailpipe 2ZZ GE Tailpipe I 0 Riog 0 ring tp I Heated Oxygen Sensor HINT Before installing oxygensensor twist s lrlsorwirecountorclockwise 3 and 112 turns Aller instalt ng oxygensensor check that1 _ sensor wire is not twisted I it is twistOO I l emove ox ger _ ens a _d_ s _tal_t_it __ _ I ...

Page 121: ... MEMO ...

Page 122: ...N CONTROL EMISSIONCONTROLSYSTEM PARTSLAYOUTANDSCHEMATIC DRAWING POSITIVECRANKCASEVENTILATION PCV EC 1 EC 2 SYSTEM EC 4 EVAPORATIVEEMISSION EVAP CONTROL SYSTEM EC 5 THREE WAYCATALYTICCONVERTER TWC SYSTEM EC 11 ...

Page 123: ......

Page 124: ...HC being released from the fuel tank 2 The function of each system is shown in these table System Abbreviation Funct1on 1 Positive crankcase Venttlation PGV Reduces HC 2 Evaporative Emission Control EVAP Reduces evaporated HC 3 Thre waY Catalytic Converter lWC Reduces HC CO and NOx 4 Sequential Mul iport Fuel injection SFI Injects a precisely timOO optimum amount of fuellor reduced exhaust em1ssio...

Page 125: ...EC 2 EMISSION CONTROL PARTS LAYOUTAND SCHEMATIC Df1AWING PARTS LAYOUT AND SCHEMATIC DRAWING LOCATION EVAPServicePart VSVforPressureSwitching Valve I Air n etLine PurgeLine ...

Page 126: ...dValve CCV EMISSION CONTROl PARTS LAYOUT AND SCHEMATIC DRAWING AirDrainHose PurgeLine VaporPressureSensor Ventline EVAPLine Charcoal Canister I Air Line FuelTank EVAPServise Port FuelTank Cap HeatedOxygenSensor Bank1Sensor1 EC 3 HeatedOxygenSensor Bank1Sensor2 TWC ...

Page 127: ...E 3 INSPECT PCV VALVE OPERATION a Blow air into the cylinder head side and check that air passes through easily CAUTION Do not suck air through the valve Petroleum substances inside the valve are harmful b Blow air into the intake manifold side and check that air passes through with difficulty If operation is not as specified replace the PCV valve 4 REMOVE CLEAN HOSE FROM PCV VALVE 5 REINSTALL PCV...

Page 128: ...ION CONTROL EVAPORATIVE EMISSION EVAP CONTROLSYSTEM l EVAPORATIVE EMISSION EVAP CONTROL SYSTEM COMPONENTS 1 m kgf cm iG l N Non reusab epart VSVConnectorfor PressureSwitchingValve HeatedInsulator EC 5 B 8749 ...

Page 129: ...EM LINE a Warm up the engine and stop the engine Allowtheenginetowarm up to normal operating tempera ture b Install a vacuum gauge EVAP control system test equip ment vacuum gauge to the EVAP service port on the purge line c TOYOTA hand held tester Forced driving of the VSV for the EVAP i Connect a TOYOTA hand held tester to the DLC3 2 Start the engine 3 Push the TOYOTA hand held tester main switc...

Page 130: ...lude forced driving of the VSV for the EVAP 1 Stop the engine 1 1 2 Disconnect the positive and negative leads from the battery and from the VSV terminals for the EVAP 3 Connect the VSV connector for the EVAP h Disconnect the vacuum gauge from the EVAP service port on the purge line i Connect a pressure gauge to the EVAP service port on the purge line U Check the pressure HINT 1 Close off the air ...

Page 131: ...nk can be held for 1 minute d Check the connected portions of each hose and pipe e Check the installed parts on the fuel tank If there is no abnormality replace the fuel tank and filler pipe f Reconnect the EVAP line hose to the charcoal canister 7 INSPECT FUEL CUTOFF VALVE AND FILL CHECK VALVE a Disconnect the purge line hose and EVAP line hose from the charcoal canister b Plug the cap to the air...

Page 132: ... Disconnect the purge line hose EVAP line hose and air inlet line hose from the charcoal canister c Disconnect the vent line hose from charcoal canister 1 Push the connector deep inside 2 Pinch portion A 3 Pull out the connector d Remove the 3 nuts and charcoal canister assembly 10 INSPECT CHARCOAL CANISTER a Visually check the charcoal canister for cracks or darn age b Inspect the charcoal canist...

Page 133: ...decrease when the air inlet port is closed and check that the vacuum decreases when the air inlet port is released 5 While holding the airinlet portclosed applyvacuum 3 43 kPa 25 7 mmHg 1 01 in Hg to the EVAP port and check that air flows into the purge port lf a problem is found replace the charcoal canister 6 Remove the cap from the vent port 11 INSPECT VSV FOR EVAP See page SF 57 12 INSPECT VSV...

Page 134: ... of the heat insulator is damaged or dented to the extent that it contacts the three way catalytic converter repair or replace it 2 CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE 3 CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS CRACKS OR DAMAGE 4 CHECK HEAT INSULATOR FOR DAMAGE 5 CHECK FOR ADEQUATE CLEARANCE BETWEEN EXHAUST SYSTEM AND HEAT INSULATOR ON THE BODY ...

Page 135: ... MEMO ...

Page 136: ...OPENINGRELAY VSVFORINTAKEAIR CONTROLVALVE VSVFOREVAPORATIVE EMISSION EVAP VSVFORCANISTERCLOSED VALVE CCV VSVFORPRESSURESWITCHING VALVE ENGINECOOLANT TEMPERATURE ECT SENSOR VAPORPRESSURESENSOR KNOCKSENSOR HEATEDOXYGENSENSOR ENGINECONTROLMODULE ECM FUELCUTRPM SF 1 SF 6 SF 15 SF 18 SF 26 SF 29 SF 33 SF O SF 46 SF 52 SF 53m SF 54 SF 56 SF 58 SF 130 SF 62 SF 134 SF 66 SF 69 SF 71 SF 73 ...

Page 137: ......

Page 138: ...reful to protect the electrical system from water b Precautions when handling oxygen sensor 1 Do not allow oxygen sensor to drop or hit against an object 2 Do not allow the sensor to come into contact with water If vehicle is Equipped with Mobile Radio System HAM CB etc If the vehicle is equipped with a mobile communication system refer to the precaution in the IN section 5 AIR INDUCTION SYSTEM a ...

Page 139: ...g connectors g Parts should be replaced as an assembly h Care should be taken when pulling out and inserting wir ing connectors 1 Release the lock and pull out the connector pulling on the connectors 2 Fully insert the connector and check that it is locked f Use SST for inspection or test of the injector or its wiring connector 7 a SST 09842 30080 FUEL SYSTEM When disconnecting the high fuel press...

Page 140: ...never use engine gear or brake oil m c Install the injector to the delivery pipe and cylinder head as shown in the Illustration Before in installing the injec tor must apply spindle oil or gasoline on the place where a delivery pipe ora cylinder head touches on 0 ring ofthe injector d Observe these precautions when disconnecting the fuel delivery pipe The structure of the metallic connector is sho...

Page 141: ...type 1 Remove the fuel pipe clamp 2 Check if there is any dirt like mud on the pipe and around the connector before disconnecting them and clean the dirt away 3 Be sure to disconnect with hands 4 When the connector and the pipe are stuck pinch the retainer between the hands push and pull the connector to free to disconnect and pull It out Do not use any tool at this time 5 Inspect if there is any ...

Page 142: ...cautions when handling nylon tube 1 Pay attention not to turn the connected part of the nylon tube and the quick connectorwith force when connecting them 2 Pay attention not to kink the nylon tube 3 Do not remove the nylon tube 4 Must not close the piping with the nylon tube by bending it Check that there are no fuel leaks after doing mainte nance anywhere on the fuel system 1 Connect the TOYOTA h...

Page 143: ...ery to terminal 4 of the con necter and the negative lead to terminal 5 f Check that there is pressure in the fuel inlet pipe from the fuel line HINT If there is fuel pressure you will hearthe sound if fuel following If there is no pressure check these parts Fusible link Fuses EFI Main relay Fuel pump ECM and Wilting connector g Turn the ignition switch to LOCK h Disconnect the TOYOTA hand held te...

Page 144: ...er observing the precau tions As there is retainedpressure in the fuel pipe line pre vent If from splashing inside the engine comport ment f Install SST pressure gauge as shown in the Hlustration by using SST and fuel tube connector SST 09268 41047 95336 08070 09268 45014 09268 41200 09268 41220 09268 41250 g Wipe off any splattered gasoline h Reconnect the negative terminal cable to the battery ...

Page 145: ... that the fuel pressure remains as specified for 5 minutes after the engine has stopped Fuel pressure 147 kPa 1 5 kgf cm2 21 psi or more If pressure is not as specified check the fuel pump pressure regulator and or injectors p After checking fuel pressure disconnect the negative terminal cable from the battery and carefully remove the SST and fuel tube connector to prevent gasoline from splashing ...

Page 146: ... the battery to terminal 4 of the connector and the negative terminal 5 Check that the pump operates NOTICE Thesetests must be done quickly within 10 seconds to prevent the coil burning out Keep fuel pump as far away from the battery as pos _ sible Always do the switching at the battery side f operation is not as specified replace the fuel pump or lead wire 8 RECONNECT FUEL PUMP SENDER GAUGE CON N...

Page 147: ... JointClip Outlet E o 35 Jii Em ss onTube e FuellankVentTub _ SetPlate e FuelpumpAssembly Gasket 0 0 Ring Cap FuelPressureRegulator 0 Ring FuelPumpFilter FuelFilterSeal o FuelPumpHar y rfff c v z c J 1 lJ FueiPu S Fuelp mp pacer ump RubberCushion No 2FuelSuctionSupport lkglcm Y Non reus3 blePart Specifiedt orque ll076W ...

Page 148: ...t clip from the No 1 fuel suction plate c Disconnect the fuel tube from the fuel pump assembly d Disconnect the emission tube from the fuel pump assem bly e Attach thetapein orderto protect theportportion from the dust f Protect the disconnected fuel tube from damage and for eign material by covering it with a plastic bag 5 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK a Remove the 8 bolts and fuel tan...

Page 149: ...crewdriver remove the No 1 fuel suction support NOTICE Do not damage the fuel suction support and fuel suction plate c Disconnect the fuel pump harness from the No 1 fuel suc tion support and fuel pump 3 REMOVE VAPOR PRESSURE SENSOR Pull off thejoint clip and remove thevaporpressure sensor from No 1 fuel suction support 4 REMOVE FUEL PRESSURE REGULATOR Pull out the fuel pressure regulator and Q ri...

Page 150: ...the fuel filter 3 INSTALL NO 1 FUEL SUCTION SUPPORT a Connect the fuel pump harness to the No 1 fuel suction support and fuel pump b Install the No 1 fuel suction support to the fuel filter c Connect the fuel sender gauge connector and earth plate 4 INSTALL NO 2 FUEL SUCTION SUPPORT a Install the rubber cushion b Install the No 2 fuel suction support to the No 1 fuel sue tion support 5 INSTALL VAP...

Page 151: ... vent tube set platefrom the fuel tank Torque 4 0 N m 40 kgf cm 35 ln lbf 2 CONNECT FUEL TUBE a Clean up around the fuel tube b Connect the fuel tube and emission tube to the fuel pump assembly c Connect the tube joint clip to the fuel suction plate 3 CONNECT FUEL PUMP AND SENDER GAUGE CON NECTOR AND VAPOR PRESSURE SENSOR CON NECTOR HINT Start the engine check for fuel leakage 4 INSTALL FLOOR SERV...

Page 152: ...SURE REGULATOR COMPONENTS FloorServiceHoleCover FuelPump Sender GaugeConnector TubeJointClip Fuel Tube Outlet EmissionTube RearSeatCushion No 1FuelSuctionSupport I SF 15 v FuelPressureRegulator FuelPumpAssembly 0 Ring FuelFilterwith FuelPump ...

Page 153: ...OR REMOVAL 1 REMOVE FUEL PUMP ASSEMBLY FROM FUEL TANK 5ee page SF 11 2 REMOVE NO 1 FUEL SUCTION SUPPORT See page SF 12 3 REMOVE FUEL PRESSURE REGULATOR a Pull out the pressure regulator b Remove the 0 ring from the pressure regulator ...

Page 154: ...ll the Q ring to the pressure regulator HINT SF 17 Apply a light coat of gasoline to a new 0 ring and instal it to the pressure regulator b Connect the pressure regulator from the fuel filter_ 2 INSTALL NO 1 FUEL SUCTION SUPPORT See page SF 13 3 INSTALL FUEL PUMP ASSEMBLY TO FUEL TANK See page SF 14 ...

Page 155: ...ation with your finger If no sound or unusual sound is heard check the wiring connec tor injector signal from the ECM d Disconnect the PCV hose from cylinder head cover 3 INSPECT INJECTOR RESISTANCE a Disconnect the injector connector b Using an ohmmeter measure the resistance between the terminals Resistance 13 4 1 4 2 n at 20 C 68 F If the resistance is not as specified replace the injector c Re...

Page 156: ...PONENTS 1ZZ FE 1 g 19_3 1 SFI INJEC10R G _ I FuelDeliveryPipeandFuel TubeAssembly 0 Ring Spacer c x Injector Grommet FuelPipeClamp Retainer c k g c i t lbfJ Specifiedtorque Y Non reusablepart PCVHose SF 19 ...

Page 157: ...SF 20 2ZZ GE Injector N m kgf cm ___ No n reusablepart y Specifiedtorque ft lbl INJECTOR SFl No 2 CylinderHeadCover ...

Page 158: ...tions As there is retained pressure in the fuel pipe line prew vent it from splashing inside the engine compartM ment 4 REMOVE DELIVERY PIPE AND INJECTORS NOTICE Be careful not to drop the Injectors when removing the delivery pipe a Disconnect the 4 injector connectors from injector b Remove the 3 bolts and delivery pipe together with tho 4 injectors and fuel pipe c Remove the 2 spacers from the c...

Page 159: ...be connector quick type after observing the precautions c Install the grommet and Q ring to the injector d Connect SST union and hose to the injector and hold the injector to prevent gasoline from splashing out SST 09268 41047 e Put the injector into a graduated cylinder HINT Install a suitable vinyl tube onto the injectorto prevent gasoline from splashing out f Connect the TOYOTA hand held tester...

Page 160: ...t as specified replace the injector 2 a b c d INSPECT LEAKAGE In the condition above disconnect the test probes of SST wire from the battery and check the fuel leakage from the injector SST 09842 30080 Fuel drop 1 drop or less per 12 minutes Turn the ignition switch to LOCK Disconnect the negative terminal cable from the bat tery Remove the SST and fuel tube connector SST 09268 41 047 CAUTION Perf...

Page 161: ...onnector outward f Place the 2 spacers in position on the cylinder head g Apply a light coat of spindle oil or gasoline on the place where a cylinder head touches an 0 ring of the injector h Place the delivery pipe and fuel pipe together with the 4 injectors in position on the cylinder head i Temporarily install the 2 bolts holding the delivery pipe to the cylinder head U Temporarily install the b...

Page 162: ... cm 21 ft lbf n Tighten theboltholding thefuel pipe to the cylinder head Torque 9 N m 92 kgf cm 7 ft lbf 2 CONNECT FUEL TUBE a Connect the fuel tube fuel tube connector to the fuel pipe CAUTION Perform connecting operations of the connector quick type after observing the precautions b Instal the fuel pipe clamp 3 INSTAll NO 2 CYLINDER HEAD COVER ...

Page 163: ...SF 26 FUEL TANK AND LINE PRECAUTION SFl FU LTANKANDLINE Always use new gaskets when replacing the fuel tank or component parts Apply the proper torque to all parts tightened ...

Page 164: ...Vent TubeSetPlate SFI FUEL TANKAND UNF _J_I _Lo _atiopofFuelTankCushion FuelPumpAssembly Gasket No 2FrontFloor HeatInsulator 1 y 1 FrontExhaustPipe y IN m kgf Cm fi lbll Specifiedtorque NOn reusablepart 6 4 sq SF 27 TailPipe ...

Page 165: ...l connee tions for deformation b Check the fuel tank for deformation cracks fuel leakage or tank band looseness c Check the filter neck for damage or fuel leakage d Hose and tube connections are as shown in the illustra L l9 tion If a problem is found repair or replace the part as necessary 2 7 mm 0 08 0 28 in 0 3mm 0 0 12 in fUOO tl ...

Page 166: ... SF MASS AIR FLOW MAF METER MASS AIR FLOW MAF METER COMPONENTS SF 29 Mass Air FlowMeter MassAirFlowMeterConnector O Ring 1 y I I I Y Non reusablepart ...

Page 167: ...SF 30 SFI MASSAIR FLOW MAr METER REMOVAL REMOVE AIR FLOW METER Remove the 2 screws air flow meter and 0 ring ...

Page 168: ...49 0 67k t 60 C 140 F If the resistance is not as specified replace the MAF meter 2 INSPECT MAF METER OPERATION a Connect the MAF meter connector b Turn the ignition switch to ON c Using a voltmeter connect the positive tester probe to terminal VG and negative tester probe to terminal E2G d Blow air into the MAF meter and check that the voltage fluctuates If operation is not as specified replace t...

Page 169: ...SF 32 INSTALLATION INSTALL AIR FLOW METER SFI MASSAIR FLOW MAFl METER Install the air flow meter and a new 0 ring with 2 screws ...

Page 170: ... with alr flow meter b Disconnect the throttle position sensor connector c Using an ohmmeter measure the resistance between each terminal Clearance between lever andstopscrew Omm O in Throttle valvefullyopen Between terminals Resistance VTA E2 0 2 5 7k n VTA E2 2 0 10 2kfl VC E2 2 5 5 9 k l d Reconnect the throttle position sensor connector e Reinstall the air cleaner assembly with air flow meter ...

Page 171: ...SF 34 COMPONENTS 1ZZ FE No 2WaterBy passPipe cs Y Non reusablepart SFI VSV lorEVAP llOT 16 ...

Page 172: ...y 22Z GE THROTTLE BODY SFI N 2CylinderHea o dCover thAirFlow AirCleane e erHose Meterand lr ft ibi l Specifiedtorque N m kgf cm _______j N n Ieusablepart AirFidWMeter Connector SF 35 ll0771 I ...

Page 173: ... cap c Loosen the air cleaner hose clamp bolt d Disconnect the mass air flow meter connector e Disconnect the 3 air cleaner cap clips f Disconnect the air cleaner hose from the throttle body and remove the aircleaner captogetherwith the air clean er hose 5 REMOVE THROTTLE BODY a Disconnect the throttle position sensor connector b Disconnect the lAC valve connector c Disconnect the PCV hose from th...

Page 174: ... r 7 y 09 Remove the 2 b It SF 37 take manifold o s 2 nuts and throttle b Remove the throttl ody from the in SF THROTTLE BODY e body gasket ...

Page 175: ...en the throttle stop screw and throttle lever when the closed throttle position 2 INSPECT THROTTLE POSITION SENSOR Using an ohmmeter measure the resistancebetween each ter minal Claaraoce between lever andstopscrew Eletween terminals Resistance Omm Oin VTA E2 0 2 5 7 k Throttle valve fully open VfA F2 2 0 10 2 kO VC E2 2 5 5 9 kn ...

Page 176: ...e 2 bolts and 2 nuts Torque 1ZZ FE 21 N m 210 kgf cm 1 5 ft lbf 2ZZ GE 22 N m 220 kgf cm 1 6 ft lbf d Connect the 2 water bypass hoses to the throttle body e f g h 2 3 4 1ZZ FE Install the No 2 water by pass pipe with the 2 bolts Connect the lAC valve connector Connect the throttle position sensor connector Connect the PCV hose to throttle body INSTALL AIR CLEANER HOSE AND CAP WITH MAF METER INSTA...

Page 177: ...rature Idle speed set correctly Transmission in neutral AJC switch OFF Y y v b Using SST connect terminals TC and CG of the DLC3 SST 09843 1 8020 c After engine speed are kept at 900 1 300 rpm for 5 se conds check hat they return to idle speed If the rpm operation is not asspecified checkthe lAC valve wir ing and ECM d Remove the SST from the DLC3 SST 09843 1 8020 ...

Page 178: ... I N m kgf cm ft lb a Non reusablep y i l Specifiedtorque SFI lAC VALVE lOU_ AiR CONfROL SF 41 ...

Page 179: ...VE No 2CylinderHeadCover VSVforEVAP AirCleanerCapwithAirFlow MeterandAirCleanerHose E ThrottleBody Y N m kgf cm tiJbf Specifiedtorque Non reusablepart Gasket AirFlowMeter Connector PCVHose waterBy passHose b Throttle 1 SensorConnector ...

Page 180: ...y B0 121 SF IDLEAIR CONTROL lAG VALVE REMOVAL 1 REMOVE THROTTLE BODY See page SF 36 2 REMOVE lAC VALVE Remove the 4 screws lAC va ve and gasket SF 43 ...

Page 181: ...nnect the ECT sensorconnector from the ECT sen sor d Turn the ignition switch ON e Check that the lAC valve moves HINT Repeat connecting and disconnecting of lAC valve connector several times and check the operation of the valve II operation is not as specified replace the lAC valve f Turn the ignition switch OFF g Connect the ECT sensor connector to the ECT sensor h Disconnect the lAC valve conne...

Page 182: ... INSTALLATION SF IDlEA n CONTROL lAC VALVE Installation is in reverse order of removal See page SF 43 HINT Install the lAC valve with a new gasket SF 45 ...

Page 183: ... Remove the No 2 cylinder head cover b 2ZZ GE Disconnect the 2 PCV hoses c Disconnect the oil control valve connector d Using an ohmmeter measure the resistance between the terminals Resistance 6 9 7 9 n at 2o c 68 F If the resistance is not as specified replace the valve e Reconnect the oil control valve connector f Reinstall the V bank cover ...

Page 184: ...COMPONENTS 1ZZ FE l7_0 7 62lrl lbtn SFl MSHAFTTIMING CA a Ring OilControlValve SF 47 OILCONIHOL VALVE No 2CylinderHeadCover Specifiedtorque N m kgf _ _ _ f_t ...

Page 185: ...No 1 Ven1 SF CONTROLVALVE CAMSHAl I TIMING OIL H ad Cover No 2Cylinder e FenderApronSeal UpperFront I lbf B acket Generator 7 0 71 621n RadiatorSuppa Upper rt Seal PCVHose vr c ft ij J Specifiedtorque ft lbf I N m kgf cm rt Non reusablepa fi T 2 ...

Page 186: ...tilation pipe 5 1ZZ FE REMOVE CAMSHAFTTIMING OIL CONTROL VALVE a Disconnect the oil control valve connector b Remove the bolt and oil control valve T orque 7 5 N m 80 kgf cm 66 ln lbf c Remove the D ring from the oil control valve HINT At the time of installation please refer to the following items Use a new D ring 6 2ZZ GE REMOVE 2 CAMSHAFT TIMING OIL CONTROL VALVES a Disconnect the oil control v...

Page 187: ...TION Connect the positive lead from the battery to terminal 1 and negative lead to terminal 2 and check the movement of the valve Battery positive voltilge is applied Valve moves in direction j Battery positive voltage IS cutoil Valve moves in direction If operation is not as specified replace the valve ...

Page 188: ... INSTALLATION SFI CAMSHAFT liMING OJLCONTROL VALVE Installation is in the reverse order of removal See page SF 49 SF 51 ...

Page 189: ...inals 1 and 2 ontinuity Ohmmeter If there is no continuity replace the relay b Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay 3 a b INSPECT EFI MAIN RELAY OPERATION Apply battery voltage across terminals 1 and 2 Using an ohmmeter check that there is continuity be tween terminals 3 and 5 If there is no continuity replace the relay 4 REINSTALL EF...

Page 190: ...re is continuity be tween terminals 1 and 2 Jf there is no continuity replace the relay b Check that there is no continuity between terminals 3 and 5 If there is continuity replace the relay 3 INSPECT CIRCUIT OPENING RELAY OPERATION a Apply battery voltage across terminals 1 and 2 b Using an ohmmeter check that there is continuity be tween terminals 3 and 5 If there is no continuity replace the re...

Page 191: ...SF 54 SFI VSV FOR INTAKE AIR CONTROL VAlVE VSV FOR INTAKE AIR CONTROL VALVE COMPONENTS y AirCleanerCap UpperRadiator SupportSeal AirCleaner VSVforEVAP AirCleanerCase ...

Page 192: ...sistance 37 44 Q at 20 C 68 F If there is no continuity replace the VSV b Inspect the VSV for ground Using an ohmmeter check that there is no continuity be tween each terminal and the body It there is continuity replace the VSV c Inspect the VSV operation 1 Check that air flows from ports E to G 2 Apply battery positive voltage across the terminals 3 Check that air flows from ports E to F If opera...

Page 193: ...SF 56 SFI VSV FOrl EVAPOHATIVE EMISSION EVAP VSV FOR EVAPORATIVE EMISSION EVAP COMPONENTS I VSV lor EVAP y 8 9181 ...

Page 194: ...3 Q at 20 C 68 F It there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body If there is continuity replace the VSV 4 INSPECT VSV OPERATION a Check that air flows with difficulty from port E to port F b Apply battery voltage across the terminals c Check that air flows from port E to port F If operation is...

Page 195: ...SF 58 SFI VSV FOR CANISTER CLOSEDVALVE CCVl VSV FOR CANISTER CLOSED VALVE CCV COMPONENTS AirCleanerHose y ...

Page 196: ...Resistance At 20 C 68 F 24 30 0 If there is no continuity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body II there is no continuity replace the VSV 4 INSPECT VSV OPERATION a Check that air flows from ports A to B b Apply battery positive voltage across the terminals c Check that air does not flow from ports A to B If o...

Page 197: ...SF 0 SFl VSV FOR PRESSURE SWITCHING VALVE VSV FOR PRESSURE SWITCHING VALVE COMPONENTS CharcoalCanisterAssembly Gasket 62_ 630 i im kQf Cm YtX Specifiedtorque y Non reusablepart TailPipe ...

Page 198: ... 68 F 37 44 1 At 120 C 248 F 51 62Ll If there IS no continUity replace the VSV 3 INSPECT VSV FOR GROUND Using an ohmmeter check that there is no continuity between each terminal and the body If there is no continuity replace the VSV 4 INSPECT VSV OPERATION a Check that air does not flow from ports E to F b Apply battery positive voltage across the terminals c Check that air flows from ports E to F...

Page 199: ...GINE COOLANTTEMPERATURE ECTlSENSOrt ENGINE COOLANT TEMPERATURE ECT SENSOR COMPONENTS No 2CylinderHeadCover N ITi k crll 1 1 Specifiedtorque y Non reusablepart 2ZZ GE t f1 620 J w f _ No 2CylinderHeadCover _j lW9 BJ ...

Page 200: ...LINDER HEAD COVER 3 REMOVE ECT SENSOR 4 INSPECT ECT SENSOR RESISTANCE SF 63 Using an ohmmeter measure the resistance between terminals 1 E2 and 2 THW Resistance Refer to the graph If the resistance is not as specified replace the ECT sensor 5 REINSTALL ECT SENSOR Install a new gasket to the ECT sensor 6 REINSTALL N0 2 CYLINDER HEAD COVER 7 FILL RADIATOR WITH ENGINE COOLANT ...

Page 201: ...SF 64 SFI VAPOR PRESSURE SENSOR VAPOR PRESSURE SENSOR COMPONENTS y RearSeatCushion FloorServiceHoleCover r VaporPressureSensor oW JointClip ...

Page 202: ...ng a voltmeter measure the voltage between connec tor terminals 1 and 3 of the wiring harness side Voltage 4 5 5 5 v d Turn the ignition switch to LOCK e Reconnect the vapor pressure sensor connector 2 INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR a Turn the ignition switch ON b Remove the fuel tank cap c Connect a voltmeter to terminals 2 and 3 and measure the output voltage Voltage 3 0 3 6 V d R...

Page 203: ...NSOR COMPONENTS 1ZZ GE Radtator AeseJVotr IntakeManifold lF No 2WaterBy pass Pipe SF KNOCK SENS R r Clip o 71 62 in lbl No 2Cylinder UpperFrontFender HeadCover ApronSeal UpperRadiator SupportSeal __ VSVforEVAP Gasket ...

Page 204: ...iator SupportSeal Cushion 29 295 2 CenterBracket 46 480 3 j I r on f AcceleratorCable i J Bracket Cushion Gasket mi gf cm ft lbf J Spec1fledtorque y Non reusablepart AirCleaner AirCleaner Case IntakeManifold No 2Cylinder HeadCover VSVforEVAP SF 67 AirFla wMeter Connector lll 9180 ...

Page 205: ...g SST remove the knock sensor SST 09816 30010 5 INSPECT KNOCK SENSOR Using an ohmmeter check that there is continuity between the terminal and body If there is continuity replace the sensor 6 REINSTALL KNOCK SENSOR a Using SST install the knock sensor b 7 SST 09816 30010 Connect the knock sensor connector REINSTALL INTAKE MANIFOLD See page EM 65 8 REINSTALL RADIATOR RESERVOIR See page C0 23 9 REIN...

Page 206: ...HEATED OXY SFI COMPONENTS GEN SENSOR y HeatedOx Bank1 S ygenSensor ensor1 XYGEN SENSOR SF 69 ...

Page 207: ...fied replace the sensor Torque 44 N m 450 kgf cm 31 lt lbl c Reconnect the oxygen sensor connector 2 INSPECT HEATER RESISTANCE OF HEATED OXY GEN SENSOR Bank1 Sensor2 a Remove the passenger s seat b Take out the floor carpet c Disconnect the oxygen sensor connector d Using anohmmeter measure the resistance between the terminals B and HT Resistance 11 16 n at 20 C 68 F If the resistance is not as sp...

Page 208: ... SFI ENGINE CONTROL MODULE ECM ENGINE CONTROL MODULE ECM COMPONENTS y if SF 71 ...

Page 209: ...Sf 72 INSPECTION 1 REMOVE ECM 2 INSPECT ECM See page Dl 20 3 REINSTALL ECM SFI ENGINECONTROLMODULE iECMl ...

Page 210: ...ease refer to the TOYOTA hand held tester or 080 II scan tool operator s manual for further details 3 INSPECT FUEL CUT OFF RPM a Increase the engine speed to at least 3 500 rpm b Use a sound scope to check for injectoroperating noise c Check thatwhen the throttle lever is released injector op eration noise stops momentary and then resumes HINT Measure with the AJC OFF Fuel return rpm 1 400 rpm 4 D...

Page 211: ... MEMO ...

Page 212: ...COOLING COOLANT WATERPUMP THERMOSTAT RADIATOR ELECTRICCOOLINGFAN COOLINGFANRELAY CG 1 C0 4 CG 8 C0 12 C0 24 C0 31 ...

Page 213: ... ...

Page 214: ... the FULL line 2 CHECK ENGINE COOlANT QUAliTY a Remove the reservoir cap CAUTION C0 1 Toavoid the dangerof being burned do not remove the reservoirthe capwhile the engine and radla tor are still hot as fluid and steam can be blown out under pressure b There should not be any excessive deposits of rust or scale around the reservoircap or reservoir filler hole and the coolant should be free from oil...

Page 215: ... 7 N m 130 kgf cm1 9 ft lbf for engine FILL ENGINE COOLANT Remove the upper front fender apron seat and upper ra diator support seaL Remove the 2 bolts Disconnect the 3 clamps and 2 hoses then place hoses on air cleaner case d Lift the engine coolant reservoir and hook it on a hood latch to fix e Remove the bleeder plug f Supply coolant of approx 3 7 liters into the reserve tank until the level re...

Page 216: ...oolant g Start the engine with the reservo lf cap and the bleeder I plug removed and warm it up until the cooling fan blows first and then stops HINT At this time the A C switch should be OFF h Additionally supply 500 cc coolant with the engine idling i Install the bleeder plug and reseiVoir cap HINT Close the reservoir cap by marking approx 2 5 rotations until clicks is heard j Repeat 5 sec engin...

Page 217: ...C0 4 WATER PUMP COMPONENTS COOLING UpperFrontFend erApronSea C I r nJ Qi n ft I IL Specifiedtorque N Non reusablepar1 i WATER PUMP UpperRadiatorSupportSeat ...

Page 218: ...an up the engine coolant from the water chamber room 5 2ZZ GE REMOVE WATER PUMP a Using SST remove the 4 water pump pulley set bolts SST 0996G 10010 09962 01000 09963 00600 b Remove the water pump pulley c Remove the 6 bolts water pump and 0 ring d Clean up the engine coolant from the water chamber room NOTICE Do not remove the RH engine mounting bracket and gener ator when the water pump alone is...

Page 219: ...N INSPECT WA TER PUMP a Visually check the drain hole for coolant leakage lf leakage is found replace the water pump b Turn the pulley and check that the water pump bearing moves smoothly and quietly If necessary replace the water pump ...

Page 220: ...5 mm 1 38 ln 2 2ZZ GE INSTALL WATER PUMP a Place a new 0 ring on the timing chain cover b Install the water pump with the 6 bolts Torque 9 0 N m 92 kgf cm 80 in lbf HINT Each bolt length is indicated in the illustration A 30 mm 1 18 in B 35 mm 1 38 in c Install the water pump pulley d Using SST tighten the 4 waterpump pulley set bolts SST 0996 10010 09962 D1000 09963 0600 Torque 15 N m 153 kgf cm ...

Page 221: ...co s THERMOSTAT COMPONENTS COOLING UpperFrontFenderApronSea I N I I I I Driv Belt _ _ _r_n J f crl ft lbf Specifiedtorque UpperRadiator SupportSeal Gen rator THERMOSTAT ...

Page 222: ... efficiency Do not remove the thermostat even if the engine tends to overheat 1 DRAIN ENGINE COOLANT 2 REMOVE DRIVE BELT AND GENERATOR See page CH 7 3 REMOVE WATER INLET AND THERMOSTAT a Remove the 2 nuts and disconnect the water inlet from the cylinder block b Remove the thermostat c Remove the gasket from the thermostat ...

Page 223: ...heck the valve opening temperature Valve opening temperature 80 0 84 0 C 176 183 F I the valve opening temperature is not as specified replace the thermostat c Check the valve lift Valve IIH 10 mm 0 39 1n or more at 90 C 194 F If the valve lift is not as specified replace the thermostat d Check that the valve is fully closed when the thermostat is at low temperatures below 40QC 104QF If not closed...

Page 224: ...ith the jiggle valve upward HINT C0 11 Thejiggle valve maybe set within 1 0 of either side of the pre scribed position_ 2 INSTALL WATER INLET Install the water inlet with the 2 nuts Torque 10 N m 100 kgf cm 7 11 lbf 3 INSTALL GENERATOR AND DRIVE BELT See page CH 17 4 FILL WITH ENGINE COOLANT 5 START ENGINE AND CHECK FOR COOLANT LEAKS ...

Page 225: ...OR Using water or a steam cleaner remove any mud or dirt from the radiator core NOTICE If using a high pressure type cleaner be careful not to deform the fins of the radiator core i e Main tain a distance between the cleaner nozzle and radiator core ...

Page 226: ...0 abovethe hor izontal a Using a radiator cap tester slowly pump the tester and check that air is coming from the vacuum valve Pump speed 1 push 3 seconds or more NOTICE Push the pump at a constant speed If air is not coming from the vacuum valva replace the reservoir cap b Pump the tester and measure the relief valve opening N M m pressure c Pump speed 1 push within 1 seconds NOTICE This pump spe...

Page 227: ... radiator cap tes ter b Warm up the engine c Pump it to 1 1 8 kPa 1 2 kgf cm2 1 7 1 psi and check that the pressure does not drop If the pressure drops check the hoses radiator or water pump for leaks If no external leaks are found checkthe heater core cylinder block and head 4 REINSTALL RESERVOIR CAP ...

Page 228: ...erApronSeal CoolantReservoir Engme CruiseControl Actuator UpperRadiator Support Radiator N LowerRadiator SupportBushing BumperCover UpperRadiatorSupportSeal VSVforEVAP CenterBrace 1 1 MAFSensor rk Coooectoc AirCleanerCap AirFilter i _ AirCleanerCase ...

Page 229: ...C0 16 COOUNG nADIATOR ElectricCc oH 1CFan N DENSOMade Tank 0 Ring PlateWasher T J 0 Ring Tank CoolerPipe I I PlateWasher I DrainPlug 0 Ring Core OilCooler Non reusablepart 1 03772 y ...

Page 230: ...ng fan connector c Disconnect the upper radiator hose d Disconnect the lower radiator hose e Disconnect the 2 NT oil cooler hoses f Remove the 3 bolts and disconnect the hood lock g Remove the 2 bolts and center brace h Remove the 2 bolts 2 nuts and 2 condenser upper sup ports i w Cruise control system Remove the bolt and disconnect the cruise control ac cuator j Remove the 2 bolts and radiator up...

Page 231: ... shown in the diagram is 0 2 0 3 mm 0 008 0 012 in NOTICE If this adjustment Is not done the claw may be damaged 3 DENSO Made UNCAULK LOCK PLATES Using SST to release the caulking squeeze the handle until stopped by the stopper bolts SST 09230 01010 4 DENSO Made REMOVE TANKS AND 0 RINGS Lightly tap the bracket of the radiator or radiator inlet or outlet with a soft laced hammer and remove the tank...

Page 232: ...Jock plate groove are deformed reas sembty of the tank wlll be impossible Therefore firstcorrect any deformationwith pliers orsimi lar object Water leakage will result if the bottom of the lockplate groove is damaged NOTICE The radiator can only be recaulked 2 times After the 2nd time the radiator core must be replaced ...

Page 233: ...RINGS AND TANKS a After checking that there are no foreign objects in the lock plate groove install the new 0 ring without twisting it HINT When cleaning the lock plate groove lightly rub it with sand pa per without scratching it b Install the tank without damaging the 0 ring c Tap the lock prate with a soft faced hammer so thatthere is no gap between it and the tank 3 DENSO Made c Dimension S a S...

Page 234: ...reas protruding around the pipes brackets or tank rids The points shown in the illustration and oil cooler near here NT cannot bestakedwithSST Usewrapvinyltape around the tip of a pairorsimHarobject and becareful not to damage the core plates b Check the lock plate height H after completing the caulking Plate height 7 40 7 80 mm 0 2913 0 3071 in lf not within the specified height adjust the stoppe...

Page 235: ...iator captester apply pressuretothe radiator Test pressure 177 kPa 1 8 kgffcm2 26 psi Submerge the radiator in water f Inspect for leaks HINT On radiators with resin tanks there is a clearance between the tank and lock plate where a minute amount of air will remain giving the appearance of an air leak when the radiator is sub merged in water therefore beforedoing thewaterleaktest first swish the r...

Page 236: ...ports with the 2 bolts and nuts g Install the center brace with the 2 bolts h Install the hood lock with the 3 bolts i Connect the 2 AJT oil cooler hoses j Connect the lower radiator hose k Connect the upper radiator hose Connect the No 1 electric cooling fan connector m Connect the No 2electric cooling fan connector 3 INSTALL ENGINE COOLANT RESERVOIR a Install the engine coolant reservoir with th...

Page 237: ...ot check the engine main relay cooling fan relay cooling fan fuses and check for short circuit between the cooling fan relay and ECT sensor e Reconnect the ECT sensor connector 2 CHECK COOLING FAN OPERATION WITH HIGH TEM PERATURE Above 93 C 199 F a Start the engine and raise coolant temperature to above 93 C 199 F b Check that the cooling fan rotates lf not replace the ECT sensor 3 INSPECT COOLING...

Page 238: ...ENTS N CruiseControl Actuator UpperRadiator Support ElectricCooling Fan ELECTRICCOOLING FAN COOLING Upper EngineCoolantReservoir C0 25 A onSeal FrontFender pr UpperRadiatorSupportSeal AirCleanerCase ll l87U7 ...

Page 239: ...co zs COOLING ELECTRIC COOLING FAN w AJC FanShroud No 1 FanMotor Fan No 1 FanMotor wlo AJC N ...

Page 240: ...er assembly b Remove the engine coolant reservoir c Remove the 3 bolts and disconnect the hood lock d Remove the 2 bolts and center brace e Remove the 2 bolts 2 nuts and 2 condenser upper supports f w Cruise control system Remove the bolt and disconnect the cruise control actuator g Remove the 2 bolts and radiator upper support 5 REMOVE COOLING FAN a Disconnect the 2 cooling fan connectors b Remov...

Page 241: ...C 28 N COOUNG ELECTRICCOOLINGFAN DISASSEMBLY 1 REMOVE FAN S Remove the nut and fan 2 REMOVE FAN MOTOR S a Disconnect the wire and connector holder from the fan shroud b Remove the 3 screws and fan motor ...

Page 242: ...1 INSTALL FAN MOTOR S a Install the fan motor with the 3 screws Torque 2 55 N m 26 kgf cm 23 in lbl C0 29 b Install the wire and connector holder to the fan shroud 2 INSTALL FAN S Install the fan with the nut Torque 6 18 N m 63 kgf cm 55 in lbl ...

Page 243: ...pport with the 2 bolts b w Cruise control system Instal the cruise control actuatorwith the 3 bolts c Instal the 2 condenser upper supports wlth the 2 bolts and nuts d Install the center brace with the 2 bolts e Install the hood lockwith the 3 bolts f Install the engine coolant reservoir g Install the air cleaner assembly 3 INSTALL FRONT BUMPER See page 80 4 4 FILL WITH ENGINE COOLANT 5 INSTALL CO...

Page 244: ... relay d Inspect the No 1 cooling fan relay operation 1 Apply battery positive voltage across terminals 1 and 2 2 Using an ohmmeter check that there is continuity between terminals 3 and 5 If there is no continuity replace the relay e Reinstall the No 3 cooling tan relay f Reinstall the relay box cover w AIC INSPECT NO 2 COOLING FAN RELAY Remove the relay box cover Remove the No 2 cooling fan rela...

Page 245: ...einstall the relay box cover 3 a b wl AIC INSPECT NO 3 COOLING FAN RELAY Remove the relay box cover Remove the No 3 cooling fan relay Marking FAN No 3 c Inspect the No 3 cooling fan relay continuity 1 Using an ohmmeter check that there is continuity between terminals 1 and 2 If there is no continuity replace the relay 2 Check that there is no continuity between terminals 3 and 5 If there is contin...

Page 246: ...LUBRICATION OILANDFILTER OILPUMP OILNOZZLE 2ZZ GE LU 1 LU 5 LU 14 I ...

Page 247: ...I ...

Page 248: ...5 minutes after the en gine stop oil level should be between the L and F marks on the dipstick If low check for leakage and add oil up to the F mark NOTICE Do not fill with engine oil above the F mark 3 REMOVE OIL PRESSURE SWITCH AND INSTALL OIL I PRESSURE GAUGE a Using SST remove the oil pressure switch SST 0981 6 30010 b Install the oil pressure gauge 4 WARM UP ENGINE Allow the engine to warm up...

Page 249: ...ly adhesiveto 2 or3 threadsoftheoil pressure switch Adhesive Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent c Using SST install the oil pressure switch SST 09816 30010 Torque 1 3 N m 130 kgf cm 9 ft lbf 7 START ENGINE AND CHECK FOR LEAKS ...

Page 250: ...line thinners or solvents In order to preserve the environment used oil and used oil filter must be disposed of only at designated disposal sites REMOVE CENTER ENGIEN UNDER COVER DRAIN ENGINE OIL Remove the oil filter cap Remove the oil drain plug and drain the oil into a contain I er REPLACE OIL FILTER Using SST remove the oil filter SST 09221Hl6501 Check and clean the oil filter installation sur...

Page 251: ... 3 5 1iters 3 7 US qts 3 1 1mp qts Dry fill 4 1 liters 4 3 US qts 3 6 Imp qts 2ZZ GE wf Oil filter change 4 4 1iters 4 8 US qts 4 0 Imp qts wlo Oil filterchange 4 2 1iters 4 6 USqts 3 8 1mp qts Dry fill 5 2 liters 5 5 US qts 4 6 1mp ats c Install the oil filter cap 5 START ENGINE AND CHECK FOR OIL LEAKS 6 INSTALL CENTER ENGINE UNDER COVER 7 RECHECK ENGINE OIL LEVEL ...

Page 252: ...NENTS DriveBelt LUBRICATION OIL PUMP UpperFrontFenderApronSeal I jJ ___ fJi y L PSOilPressure _ SwitchConnector t c t PSPump i UpperRadiatorSupport Seal GeneratorWire Generator 52 530 38 I RHEngineUnderCover N LU 5 I ...

Page 253: ...LU 8 L BRlCATION O L PUMP 1ZZ FE RH EngineMountingBracket ainTensionor 1PPer J _ I TimingChain ChamV1brat1on Damper SensorPlate CrankshaftTi Specifiedtorque mlngSprocket i PCV Hose ...

Page 254: ...Seale Crankshaft if Pulley p LUBRICATION OIL PUMP DChainVibration amplec Oil u _ I If B c iv J if Cca I Lc 92 80io Tbi nkAngleSensorPlat CrankshaftTimingS _ l e procket r kgf cn i ft Jbt 1 on reusablepart Specilred torque LU 7 l l ...

Page 255: ... LU 8 Plug _ Spring e ReliefValve LUBRICATION OILPUMP I I DriveRotor DrivenRotor OilPumpBd 1 Y Cover x3 1 x5 2 ...

Page 256: ...LUBRICATION OIL PUMP REMOVAL 1 DRAIN ENGINE OIL LU 9 2 REMOVE TIMING CHAIN AND CRANKSHAFT TIMING SPROCKET See pages EM 18 3 REMOVE OIL PUMP Remove the 5 bolts oil pump and gasket m ...

Page 257: ...OVE RELIEF VALVE Remove the plug spring and relief valve 2 REMOVE DRIVE AND DRIVEN ROTORS a 1ZZ FE OIL PUMP Remove the 3 screws pump body cover drive and driven rotors b 2ZZ GE Remove the 5 screws pump body cover drive and driven rotors ...

Page 258: ...Maximum side clearance 0 16 mm 0 0062 in If the side clearance is greater than maximum replace the ro tors as a seL lf necessary replace the oil pump assembly 4 INSPECT ROTOR TIP CLEARANCE Using a feelergauge measure theclearance between the drive and driven rotor tips Standard tip clearance 0 060 0 180 mm 0 0024 0 0071 in Maximum tip clearance 0 35 mm 0 0138 in If thetip clearance is greaterthan ...

Page 259: ...mp body cover side b 1 ZZ FE Install the pump body cover with the 3 screws Torque 10 5 N m 107 kgl cm 8 fl lbf c 2ZZ GE Install the pump body cover with the 5 screws Torque 10 5 N m 107 kgf cm 8 ft lbf 2 INSTALL RELIEF VALVE Insert the relief valve and spring into the pump body hole and instal the plug Torque 1 ZZ FE 37 N m 375 kgf cm 27 ft lbf 2ZZ GE 49 N m 500 kg em 36 ft lbf ...

Page 260: ...eteethoftheoil pump drive rotorwith the large teeth of the crankshaft and sllde the oH pump c Install the oil pump with the 5 bolts Torque 9 0 N m 92 kgf cm SO in lbf 2 INSTALL CRANKSHAFT TIMING SPROCKET AND TIMING CHAIN See pages EM 25 3 FILL ENGINE WITH OIL 4 START ENGINE AND CHECK FOR LEAKS 5 RECHECK ENGINE OIL LEVEL ...

Page 261: ...OZZLE 2ZZ GE OIL NOZZLE 2ZZ GE COMPONENTS No 1CompressionRmg _Q ConnectmgRodBush1ng No2CompressionRm r OilRing 1 N SideRail ConnectmgRod 011Amg Expander 1 P1ston SnapRmg f ConnectmgRodBeanng SnapRmg ConnectmgRodCap PistonPin ...

Page 262: ...LUBRICATION OIL NOZZLE 2U GE REMOVAL 1 REMOVE CRANKSHAFT See page EM El9 2 REMOVE OIL NOZZLE WITH RELIEF VALVE LU 15 Using a 5 mm hexagonwrench remove the bolt and oil nozzle ...

Page 263: ...LU 16 lUBRICATION OIL NOZZLE 2ZZ GE INSPECTION INSPECT RELIEF VALVE OIL NOZZLE Push the valve with a wooden stick to check if it is stuck If stuck replace the relief valve ...

Page 264: ...CAT ON OIL NOZZLE 2ZZ GE INSTALLATION 1 INSTALL OIL NOZZLE WITH RELIEF VALVE Using a 5 mm hexagon wrench instal the oil nozzle witll the bolt Torque 9 0 N m 92 kg em 80 in lbf 2 INSTALL CRANKSHAFT See page EM 106 ...

Page 265: ... MEMO ...

Page 266: ... IGNITION IGNITIONSYSTEM IGNITIONCOIL CAMSHAFTPOSITIONSENSOR CRANKSHAFTPOSITIONSENSOR JG 1 IG 5 IG 8 IG 11 ...

Page 267: ......

Page 268: ...t the spark occurs 1 Remove the ignition coils with igniter See page IG 6 2 Using a 1 6 mm 0 63 in plug wrench remove the spark plugs 3 fnstaJI the spark plugs to each ignition coils with ig niter and connect the ignition coil connectors 4 Disconnect the 4 injector connectors 5 Ground the spark plugs 6 Check if spark occurs while engine is being cranked NOTICE To prevent gasoline from being inject...

Page 269: ...tionsensor SENSOR See step 3 Cold Hot BAD Resistance 835 1 400 l1 1 060 1 645 l IOK CHECK RESISTANCE OFCRANKSHAFT POSITION Replacethecrankshaftpositionsensor SENSOR See step 4 sm Cold Hot Resistance 1 630 2 740 2 065 3 225 ll IOK CHECK IGT SIGNAL FROM ECU CheckwiringbetweenECUandignition See page 01 114 BAD coil withigniter andthentryanotherECU IOK TRY ANOTHER IGNITION COIL WITH IGNITER I 7 Using ...

Page 270: ...line before using the spark plug cleaner d Check the spark plug for thread damage and insulator damage If abnormal replace the spark plug Recommended spark plug 1ZZ FE DENSOmade NGK made SK16fl11 IFR5A11 2ZZ GE e f g DENSOmade SK20RI1 NGKmade IFR6A1 1 Adjust electrode gap Carefully bend the outer electrode to obtain the correct electrode gap Electrode gap 1 1 mm 0 043 ln Using a 16 mm 0 63 in plug...

Page 271: ...a Disconnect the camshaft position sensor connector b Using an ohmmeter measure the resistance between ter minals Resistance 835 1 400 1 Hot 1 060 1 645 o If the resistance is not as specified replace the camshaft posi tion sensor c Connect the camshaft position sensor connector ...

Page 272: ...N COIL COMPONENTS 2ZZ GE lGNll ON IGNITION COIL 1ZZ FE No 2CylinderHeade l ver il No 2CylinderHeadCover il 9 0 92 791n lbff it X4 t 4 IgnitionCoil withlgni oc i 1 ft c1 b 1o Specifiedtorque N m kg em N I IG 5 ...

Page 273: ...OVER 2 REMOVE IGNITION COILS WITH IGNITER FROM SPARK PLUGS a Remove the 2 bolts and disconnect the wire harness pro tector b Disconnect the 4 ignition coil connectors c Remove the 4 bolts and pull out the 4 ignition coils with igniter Torque 9 0 N m 92 kgf cm 79 in lbf ...

Page 274: ...IG 7 IGNmON IGNITION COIL INSTALLATION Installation is in the reverse order of removal See page IG 6 ...

Page 275: ...IG ll IGNITION CAMSHAFTPOSITIONSENSOR CAMSHAFT POSITION SENSOR COMPONENTS 2ZZ GE No 2 CylinderHeadCover m _ik i Cr ft l Specifiedtorque N Iii I 1ZZ FE No 2CylinderHeadCover ll00759 ...

Page 276: ...E CAMSHAFT POSITION SENSOR a Disconnect the connector b Remove the bolt and camshaft position sensor Torque 8 8 N m 90 kgf cm 78 in lbf 3 2ZZ GE REMOVE CAMSHAFT POSITION SENSOR a Disconnect the connector b Remove the 2 bolts and camshaft position sensor Torque 8 8 N m 90 kgf cm 78 in lbf IG 9 ...

Page 277: ...IG 10 IGNITION CAMSHAFT POSITION SENSOR INSTALLATION Installation Is in the reverse order of removal See page IG 9 ...

Page 278: ...NTS 1ZZ FE No 2 CylinderHeadCover w I a 11 e f __ J jf UpperRadiatorSupportSeal IntakeManifold a 90 in lbf r Crankshaft PositionSensor N m kgf crll tHbf J Specified torque N t Jon ret i s a 5 le part Gasket VSVforEVAP j MAFSensor Connector Cieanec Cap AicFilte r AirCleaner Case ...

Page 279: ... GE Upper ron Fender Apron Sea Oil Dipstick and Oil Guide I Engine Wire N j N ffi kQf rTl _ii l l_l Specified torque Non reusable part IGNITION CRANKSHAFT POSITION SENSOR VSV for EVAP Air Filter Air Cleaner Case ...

Page 280: ...AL 1 REMOVE INTAKE MANIFOLD See page EM 42 2 REMOVE ENGINE UNDER COVER RH 3 REMOVE CRANKSHAFT POSITION SENSOR a Disconnect the crankshaft position sensor connector b Remove the 2 bolt and crankshaft position sensor Torque 8 8 N m 90 kgf cm 78 1n lbn ...

Page 281: ...mpera ture ofthesensor Itself Cold isfrom 10 C 14 F to50 C 122 F and Hot is from 5o c 122 F to 100 c 212 F INSPECTCRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter measure the resistance between termi nals Resistance Cold 1 630 2 740 Q Hot 2 065 3 225 Q Itthe resistanceis not as specified replacethe crankshaftposi tion sensor ...

Page 282: ...IG 15 IGNITION CRANKSHAFT POSITION SENSOR INSTALLATION Installation is in the reverse order of removal See page IG 13 ...

Page 283: ...MEMO ...

Page 284: ...STARTING STARTINGSYSTEM STARTER STARTERRELAY ST 1 ST 2 ST 17 ...

Page 285: ......

Page 286: ...STARTING SYSTEM ON VEHICLE INSPECTION NOTICE ST ARTING STARTING SYSTEM Before changing the starter check these items again Connector connection Accessory installation e g theft deterrent system ST 1 ...

Page 287: ...m ST 2 STARTER COMPONENTS I UpperRadiatorSupport Seal RHEngineUnderCover STARTING STAHfEn AirFlowMeterConnector AirCleaner __ AirCleanerCase _ LHEngineUnderCover ...

Page 288: ...rminalNul 0 R WaveWasher rl Termma l lnsulalm F L I r contactPlat EndCover Q TerminalBolt Gaske 6 CC Piunger jf TerminalBolt l _ ___ F l_ TerminalCKitPart 40 1 v ContactPlate 0 L 1 1 DustProtector Termlnallnstllator zy Termmallnsulator _____ WaveWasher 1 0 Rmg 1ermmalNul Packing r Termmal30K1l Part 11 170 12 I N m k_ t lbt Specifiedtorque NCJ feusablepart ...

Page 289: ...PPER RADIATOR SUPPORT SEAL 2 REMOVE AIR CLEANER ASSEMBLY See page EM 74 3 REMOVE RH AND LH ENGINE UNDER COVER 4 REMOVE STARTER a Disconnect the starter connector b Remove the nut and disconnect the starter wire c Remove the 2 bolls and starter ...

Page 290: ...c switch terminal b Remove the 2 through bolts c Remove the 2 screws and end coverfrom the field frame d Remove the 0 ring from the field frame e f g Using a screwdriver hold the spring tank back and dis connect the brush from the brush holder Disconnect the 4 brushes and remove the brush holder Pull out the field frame from the magnetic switch assem bly Remove the 0 ring ...

Page 291: ...netic switch assembly 1 Starter housing 2 Idler gear 3 Bearing 4 Clutch assembly 5 Return spring 3 REMOVE STEEL BALL Using a magnetic finger remove the steel ball from the clutch shaft hole 4 a b REMOVE ARMATUREFROM MAGNETIC SWITCH AS SEMBLY 1ZZ FE Remove the armature from the magnetic switch assem bly 2ZZ GE Using a press remove the armature from the magnetic switch assembly ...

Page 292: ...ct with sandpaper No 400 or a lathe 4 INSPECT COMMUTATOR CIRCLE RUNOUT a Place the commutator on V blocks b Using a dial gauge measure the circle runout Maximum circle runout 0 05 mm 0 0020 in I the circle runoutisgreaterthan maximum correct iton a lathe 5 INSPECT COMMUTATOR DIAMETER Using vernier calipers rneasure the commutator diameter Standard diameter 30 mm 1 18 in Minimum diameter 29 mm 1 14...

Page 293: ...PECT BRUSH LENGTH Using vernier calipers measure the brush length Standard length 15 5 mm 0 610 in Minimum length 10 0 mm 0 394 in If the length is less than minimum replace the brush holder and field frame 10 INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring sepa rates from the brush 14 kW type Standard spring Installed load 17 6 23 5 N 1 60 2 40 kgf 4 0 5 3 ibl M...

Page 294: ...ar for wear or Ohmmeter Terminal C Ohmmeter Continuity fll 0 S h Bod 1f T erminal 50 wttc y damage 13 INSPECT CLUTCH Rotate the clutch pinion gear clockwise and check that it turns freely Try to rotate the clutch pinion gear counter clockwise and check that it locks If necessary replace the clutch assembly 14 DO MAGNETIC SWITCH PULL IN COIL OPEN CIRCUIT TEST Using an ohmmeter check that there is c...

Page 295: ...g a press press in a new rear bearing 3 REMOVE MAGNETIC SWITCH END COVER a Remove the 3 bolts end cover gasket and plunger b Inspect the contact plate for wear Using vernier calipers measure the contact plate lor depth of wear Maximum wear 0 9 mm 0 035 ln lf the depth of wear is greater than the maximum replace the contact plate c Remove the terminal kit parts 1 Using SST loosen the terminal nuts ...

Page 296: ...erminal bolt Install a 0 rlng Install a packing and terminal insulator outside Install the packing to the terminal insulator and install them Match the protrusion of the insulator with the indentation of the housing 6 Install a wave washer 7 Install a terminal nut e Temporarily install new terminal C kit parts 1 Install a terminal insulator inside 2 Install a contact plate 3 Install a terminal bol...

Page 297: ... 2 x 3 14 n kpa kgflcm2 x 98 1 kpa psi x 6 9 If the contact plate isnot pressed down with the specified pres sure the contact plate may tilt due to coil deformation or the tightening of the nut 2 Using SST tighten the nuts to the specified torque SST 09810 38140 Torque 17 N m 173 kgf cm 1 2 11 lbf NOTICE If the nut Is over tightened it may cause cracks on the In side of the insulator h Clean conta...

Page 298: ...e ring is positioned in the narrowest part b Apply grease to the armature bearings c 1ZZ FE Install the armature to the magnetic switch assembly d 2ZZ GE Using a press install the armature to the magnetic switch assembly 2 INSERT STEEL BALL INTO CLUTCH SHAFT HOLE a Apply grease to the steel ball b Insert the steel ball into the clutch shaft hole INSTALL STARTER HOUSING CLUTCH ASSEMBLY AND GEARS Ap...

Page 299: ...STALL BRUSH HOLDER a Place the brush holder on the field frame b Using a screwdriver hold the brush spring back and con nect the brush into the brush holder Connect the 4 brushes NOTICE Check that the positive lead wires are not grounded 6 INSTALL END COVER a Install a new G ring to the groove of the field frame b Install the end coverto the field frame with the 2 screws Torque 3 8 N m 39 kgf cm 3...

Page 300: ...y connected as above with the clutch pinion gear out disconnect the negative lead from terminal C Ifthe clutch pinion gear returns inward 3 INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative lead from the switch body Check that the clutch pinion gear returns inward If the clutch pinion gear does not return 4 DO NO LOAD PERFORMANCE TEST a Connect the battery and ammeterto the starteras shown...

Page 301: ...r HINT Each bolt length is indicated in the illustration Bolt length A 64 mm 2 72 in 8 54 mm 2 13 in b Connect the starter wire and install the nuL c Connect the starter connector 2 INSTALL RH AND LH ENGINE UNDER COVER 3 INSTALL AIR CLEANER ASSEMBLY 4 INSTALL UPPER RADIATOR SUPPORT SEAL ...

Page 302: ...en terminals 1 and 2_ If there is no continuity replace the relay b Check that there is no continuity betweenterminals 3 and 5 If there is continuity replace the relay 3 INSPECT STARTER RELAY OPERATION a Apply battery positive voltage across terminals i and 2 b Using an ohmmeter check that there is continuity be tween terminals 3 and 5 II there is continuity replace the relay 4 REINSTALL STARTER R...

Page 303: ... MEMO ...

Page 304: ...CHARGING CHARGINGSYSTEM GENERATOR CH 1 CH 5 ...

Page 305: ......

Page 306: ...t the battery cables are connected to the correct terminals Disconnect the battery cables when the battery is given a quick charge Do not pertorm tests with a high voltage insulation resistance tester Never disconnect the battery while the engine is running CH 1 ...

Page 307: ...s less than specification charge the bat tery 3 CHECK BATTERY VOLTAGE a After having driven the vehicle and in the case that 20 minutes have not passed after having stopped the en gine turn the ignition switch ON and turn on the electrical system headlight blower motor rear defogger etc for 60 seconds to remove the surface charge b Turnthe ignition switch OFF and turnoffthe electrical sys tems c M...

Page 308: ...pulley to liili make sure the drive belt will not slip off the pulley If necessary replace the belt tensloner HINT 6 After installing a belt check that il fits properly in the ribbed grooves Check with your hand to confirm that the belt has not slipped out of the groove on the bottom of the pulley After installing a new belts run the engine for about 5 min utes and check the belt tension existing ...

Page 309: ...e to 2 000 rpm check the reading on the ammeter and voltmeter Standard amperage 1OA or less Standard voltage 13 2 14 8 V If the voltmeter reading is more than standard voltage replace the voltage regulator If the voltmeter reading is less than the standard voltage check the voltage regulator and generator as follows With terminal F grounded start the engine and check the voltmeter reading of termi...

Page 310: ...GENERATOR COMPONENTS CHARGING UpperFrontFender ApronSeal f CH 5 GENERATOR 2ZZ GE 7 0 71 62in lbf No 2 CylinderHeadCover 7 0 71 62 in lbf Generator No 2CylinderHeadCover 712B ...

Page 311: ...111 1 t25 1H RetHoldec e Retainer RearBearing L l Bearing over BearingCover SbPiate Rectiflec T G r i BrushHolderCover EndFrame RubberInsulator j BrushHolder_ WireClip 4 VoltageRegulator y kgt _tt IJ Specifiedtorque Non rDUsatifepart I TerminalInsulator RearEndCover ...

Page 312: ... and replace the drive belt tensioner little by little and fix it qu letly 2 REMOVE GENERATOR a Disconnect the wireclamp from thewire clip on the recfili er end frame b Remove the rubbercap and nut and disconnect the gen erator wire c Disconnect the generator connector d 2ZZ GE Remove the 2 bolts and generator bracket e Remove the 2 bolts and generator m ...

Page 313: ...rush holder and voltage regulator c Remove the seal plate from the rectifier end frame 3 REMOVE RECTIFIER HOlDER a Remove the 4 screws and rectifier holder b Remove the 4 rubber insulators 4 REMOVE PUllEY a Hold SST A with a torque wrench and tighten SST B clockwise to the specified torque SST 0982G 6301 0 Torque 39 N m 400 kgf cm 29 lt lbl b Check that SST A is secured to the rotor shaft c Mount ...

Page 314: ...t loosen the pulley nut more than one half of a turn f Remove the generator from SST C g Turn SST 8 and remove SST A and B h Remove the pulley nut and pulley 5 REMOVE RECTIFIER END FRAME a Remove the 4 nuts andwire clip b Using SST remove the rectifier end frame SST 09286 46011 c Remove the generator washer from the rotor 6 REMOVE ROTOR FROM DRIVE END FRAME ...

Page 315: ...r 3 INSPECT SLIP RINGS a Check that the slip rings are not rough or scored lf rough or scored replace the rotor b Using a vernier caliper measure the slip ring diameter Standard diameter 14 2 14 4 mm 0 559 0 567 in Minimum diameter 12 8 mm 0 504 in If the diameter is less than minimum replace the rotor 4 INSPECT STATOR DRIVE END FRAME FOR OPEN CIRCUIT Using an ohmmeter check that there is continui...

Page 316: ... step a c Check that one shows continuity and the other shows no continuity If continuity is not as specified replace the rectifier holder Ohmmeter 8 INSPECT NEGATIVE RECTIFIER HOLDER CA 1 NegativeH a Using an ohmmeter connect one tester probe to each T erminal negative terminal and the otherto each rectifier termi O IilJ nal 0 b Reverse the polarity of the tester probes and repeat step a c Check ...

Page 317: ... 00530 09950 7001 0 09951 Q7100 Install the bearing retainer with the 4 screws Torque 3 0 N m 31 kgf cm 27 ln lbf 11 INSPECT REAR BEARING Check that the bearing is not rough or worn 12 IF NECESSARY REPLACE REAR BEARING a Using SST remove the bearing cover outside and bear ing SST 09820 D0021 NOTICE Be careful not to damage the fan b Remove the bearing cover inside c Place the bearing cover inside ...

Page 318: ...lj SST 4 tk vtr N00578 CHARGING GENERATOR d Using SST and a press press in a new bearing SST 0982CHJ0030 e Using SST push in the bearing cover outside SST 09285 76010 CH 13 ...

Page 319: ...Using a 29 mm socket wrench and press slowly press in the rectifier end frame c Install the wire clip and 4 nuts Torque Nut A 4 5 N m 46 kgf cm 40 ln lbf Nut B 5 4 N m 55 kgf cm 48 ln lbf 3 INSTALL PULLEY a Install the pulley to the rotor shaft by tightening the pulley nut by hand b Hold SST A with a torque wrench and tighten SST B clockwise to the specified torque SST 0982 63010 Torque 39 N m 400...

Page 320: ...wn in the illustration Torque 111 N m 1 125 kgf cm 81 ft lbf g Remove the generator from SST C h Turn SST B and remove SST A and B 4 INSTALL RECTIFIER HOLDER a Install the 4 rubber insulators on the lead wires NOTICE Be careful of the rubber insulators installation direction b Install the rectifier holder while pushing it with the 4 screws Torque 2 9 N m 30 kgf cm 26 1n lbf ...

Page 321: ... careful of the holder Installation direction c Install the 5 screws Torque 2 0 N m 20 kgf cm 18 in lbl d Place the brush holder cover on the brush holder 6 INSTALL REAR END COVER a Install the end cover and plate terminal with the bolt and 3 nuts b 7 Torque Nul 4 4 N m 45 kgf cm 39 in lbf Bolt 3 9 N m 39 kgf cm 35 in lbl Install the terminal insulator with the nut Torque 4 1 N m 42 kgf cm 36 in l...

Page 322: ...1ZZ FE 54 N m 550 kgf cm 40 ft Jbf 2ZZ GE 58 N m 590 kgf cm 43 ft lbf b 2ZZ GE Install the generator bracket with the 2 bolts Torque 29 N m 295 kgf cm 21ft lbf c Connect the generator connector CH 17 d Connect the generatorwire and install the nut and rubber cap e Connect the generator wire and install the rubber cap and nut 2 INSTALL DRIVE BELT ...

Page 323: ... MEMO ...

Page 324: ...CLUTCH TROUBLESHOOTING CLUTCH PEDAL CLUTCH MASTER CYLINDER CLUTCHRELEASE CYLINDER CLUTCH UNIT CL 1 CL 2 CL 4 CL 9 CL 14 E ...

Page 325: ......

Page 326: ...elease cylindercup Damaged Ct 9 1 Release bearing Worn dlfly ordamagod CL 14 Clutch noisy 2 Clutch d1sctorsion rubber Damaged CL 1 4 1 Clutch pedal Free play out ofad1ustment CL 2 2 Clutch disc Oily CL 14 3 Clutch disc Worn out CL 4 Clutch slips 4 Diaphragm spring Damaged CL 14 5 Pressure plate Oistortfon Cl 14 6 Flywheel Distortion 1 Clutch pedal Free playout of adJustment CL 2 2 Clutch line Air ...

Page 327: ...pedal top 5 0 15 0 mm 0 197 0 591 in 4 IF NECESSARY ADJUST PEDAL FREE PLAY AND PUSH ROD PLAY a Loosen the lock nut and turn the push rod until the free play and push rod play are correct b Tighten the lock nut c After adjusting the pedalfree play check the pedal height 5 CHECK CLUTCH RELEASE POINT a Pull the parking brake lever and install wheel stopper b Start and idle the engine c Without depres...

Page 328: ...e clutch ped al is released b Checkthat the engine startswhen the clutch pedal is ful y depressed If necessary replace the clutch start switch 7 INSPECT CLUTCH START SWITCH CONTINUITY Check the continuity between terminals when the switch is ON and OFF Sw1tch position Condition ON pushed Continuity OFF free No continw y E ...

Page 329: ... COMPONENTS ClipInletUnion I Grommet ReservoirHose CLUTCH MASTEn CYLINDER Boot SlottedSpringPin 12 120 9 MasterCylinder y N m kgf cm fHbf J Specifiedtorque Non reusablepart Lithiumsoapbaseglycolgrease SnapRing PushRod Clevis Cllip I Pin ...

Page 330: ... the clip b Disconnect the reservoir hose from the inlet union c Use a container to catch the fluid 3 DISCONNECT CLUTCH LINE a Using SST disconnect the clutch line SST 09023 00100 b Use a container to catch the fluid 4 REMOVE CLIP AND PIN Using needle nose pliers remove the dip and pin CL 5 5 REMOVE 2 MOUNTING NUTS AND PULL OUT MAS a TEA CYLINDER ...

Page 331: ...ring pin b Remove the inlet union c Remove the grommet 2 REMOVE CLEVIS Loosen the lock nut to remove the clevis and remove the lock nut 3 REMOVE BOOT FROM CYLINDER 4 a b 5 REMOVE PUSH ROD While pushing the push rod using snap ring pliers re move the snap ring Pull out the push rod and washer REMOVE PISTON WITH SPRING FROM CYLINDER ...

Page 332: ...PRING INTO CYLINDER 3 INSTALL PUSH ROD a Install the washer to the push rod b Push the push rod into tho piston using snap ring pliers install the snap ring 4 INSTALL BOOT TO CYLINDER 5 TEMPORARILY INSTALL LOCK NUT AND CLEVIS 6 a b c INSTALL INLET UNION Install a new grommet Instal the inlet union Usinga pin punch 3 mm and hammer drive in the slotted spring pin ...

Page 333: ...onnect the clutch line SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf 4 CONNECT RESERVOIR HOSE a Connect the reservoir hose to the inlet union NOTICE Facing the yellow mark upwards b Using pliers connect the clip 5 INSTALL BRAKE BOOSTER See page BR 16 6 FILL BRAKE RESERVOIR WITH BRAKE FLUID AND BLEED CLUTCH SYSTEM See page BR 4 7 ADJUST CLUTCH PEDAL See page CL 2 8 CHECK FOR LEAKS ...

Page 334: ... 4 85 74 in bf ReleaseCylinder ClutchLineBracket ClutchUne _155 11 J ClutchLineClamp l r J rTI kgf cm ft lbf I Specifiedtorque Piston Push Rod CL 9 Boot L Y __ __ Li_ th_ iu_ m _s _ o_ a_ p_ ba _s _ e_ g_ ly_ c_ ol_ g_ ce _ a_ se _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ C C 0 I ...

Page 335: ...rely supported b Remove the LH and RH engine under covers c Using SST disconnect the clutch line SST 09023 001 00 d Use a container to catch the fluid e Lower the vehicle 2 a b c REMOVE RELEASE CYLINDER Remove the air cleaner case assembly with the air hose Remove the clutch line clamp set bolt Remove the 2 bolts clutch line bracket and release cylin der ...

Page 336: ... bootfrom the push rod 2 REMOVE PISTON AND SPRING CL 11 Using compressed air remove the piston with the spring from the cylinder NOTICE 3 Blowing off the air may cause the piston s jump out When removing the piston hold it with your hand us lng a waste cloth Takecare not to splash brake fluid when air blowing REMOVE BLEEDER PLUG ...

Page 337: ... BLEEDER PLUG Torque 8 4 N m 85 kgf cm 74 in lbf 2 COAT PISTON WITH LITHIUM SOAP BASE GLYCOL GREASE AS SHOWN 3 INSTALL PISTON AND SPRING INTO CYLINDER 4 INSTALL BOOT AND PUSH ROD a Install the push rod to the boot b Install the boot with the push rod to the cylinder ...

Page 338: ...ue 4 9 N m 50 kgf cm 43 in lbf c Install the air cleaner case assembly with the air hose 2 CONNECT CLUTCH LINE AND BLEED CLUTCH SYS TEM a Raise the vehicle CAUTION Make sure that the vehicle is securely supported b Using SST connect the clutch line SST 09023 01 00 Torque 15 N m 155 kgf cm 11 fl lbl y 007703 c Fill the brake reservoir tank with brake fluid and bleed clutch system d Check for the le...

Page 339: ...CL 14 CLUTCH UNIT COMPONENTS 49 500 36 Flywheel I N m kgf cm lt lbf Specifiedtorque Non reusablepart Clutchsplinegrease t Releasehubgrease CLUTCH CLUTCH UNIT Boot ...

Page 340: ...overwith the one on the flywheel b Looseneach set boltoneturn ata time until spring tension is released c Removetheset bolts and pull off the clutch cover with the clutch disc NOTICE Do not drop the clutch disc 3 REMOVE RELEASE BEARING AND FORK FROM TRANSAXLE Remove the release bearing with the fork together and then separate them 4 REMOVE RELEASE FORK SUPPORT AND BOOT ...

Page 341: ...OUT Using a dial indicator check the flywheel runout Maximum runout 0 1 mm 0 004 in If necessary replace the flywheel Torque 49 N m 500 kgf cm 36 fl lbf 4 INSPECT DIAPHRAGM SPRING FOR WEAR Usingverniercalipers measure thediaphragmspring for depth and width of wear Maximum A Depth 0 5 mm 0 020 ln B Width 6 0 mm 0 236 1n If necessary replace the clutch cover 5 INSPECT RELEASE BEARING Turn the bearin...

Page 342: ...GM SPRING TIP ALIGNMENT Using a dial indicator with roller instrument check the dia phragm spring lip alignment Maximum non alignment 0 5 mm 0 020 in lf alignment is not as specified using SST adjust the dia phragm spring tip alignment SST 09333 0001 3 3 INSTALL BOOT AND RELEASE FORK SUPPORT TO TRANSAXLE Torque 37 N m 375 kgf cm 27 ft lbf 4 APPLY RELEASE HUB GREASE Apply release hub grease to the ...

Page 343: ... MEMO ...

Page 344: ...AXLE C56 TROUBLESHOOTING MANUAL TRANSAXLE UNIT MANUAL TRANSAXLE ASSEMBLY INPUTSHAFT _ _ OUTPUTSHAFT SHIFTANDSELECT LEVERSHAFT DIFFERENTIALCASE SHIFTLEVER AND CONTROLCABLE MX 1 MX 2 MX 9 MX 26 MX 34 MX 44 MX 45 MX 52 ...

Page 345: ......

Page 346: ...l low MX 4 2 Oil Wrong MX 4 Noise 3 Gear Womordamaged MX 9 4 Bearing Worn or damaged MX 9 1 Oil Level too high MX 4 2 Gasket Damaged MK 4 Oil leakage 3 011 seal Worn or damaged MX 4 4 0 Ring Worn or damaged MX 4 1 Control cable faulty MX 52 2 Synchronizer ring Wom or damaged MX 4 MX 29 Hard to shift or Hill not shift MX 38 3 Sh1ffmg key spring Damaged MX 4 MX 29 MX 38 1 lock irtg ball spring Damag...

Page 347: ...MCover ili _ n Down 6 9 70 61 ln lbl Connector No 2CylinderHeadCover L _ 5 i H f 0 ir l l_JJ Batlery ECMBox n 1 9 i J ID _ r II 11 i r 12 120 9l ECMOutletDuct BatteryCarrier WireHarness 18 185 13 l Control I Back UplightSwitchConnector IJ i S LJ StarterConnectorSpeedSensorConnector l Starter Wire f __ 28j i Starter EngineLeftMountingBracket Transaxle fl07N5 ...

Page 348: ...MANUAL TRANSAXL C56 MANUALTR NSAXU UNIT RH FrontDriveShaft I RH Engine UnderCover f _ gi CrTI fNbijl Specifiedtorque N Non reusable part LH Engine Under Cover CotterPin 1 49 500 360 v 6 MX 3 0 1 7 ...

Page 349: ...ove the 2 bolts and ECM cover Torque 6 9 N m 70 kgf cm 61 in lbf b Disconnect the ECM connectors from the ECM c Remove the ECM outlet duct d Remove the air cleaner case assembly with the air hose e Remove the 3 bolts and ECM box Torque 6 9 N m 70 kgf cm 61 in tbf f Disconnect the wire harness and remove the 2 nuts bolt and battery carrier Torque Bolt 1 8 N m 185 kgf cm 1 3 ft lbf Nut 1 2 N m 120 k...

Page 350: ...wire c Remove the 2 bolts and starter Torque 37 N m 378 kgf cm 28 fl lbf 11 REMOVE CONTROL CABLE BRACKET a Disconnect the wlre harness from the clamp b Removethe 2 bolts clamp and control cable bracket from the transaxle Torque 25 N m 250 kgf cm 18 ft lbf 12 REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING BOLTS Torque 64 N m 650 kgf cm 47 ft lbf 13 ATTACH ENGINE SLING DEVICE TO ENGINE HANG ER a Disconnect ...

Page 351: ... CENTER LH AND RH ENGINE UNDER COV ERS 16 DRAIN TRANSAXLE OIL Oil grade API GL 4 or GL 5 Viscosity SAE 75W 90 Capacity 1 9 1iters 2 0 US qts 1 7 1mp qts Torque 39 N m 400 kgf cm 29 11 lbl 19 REMOVE LH AND RH FRONT DRIVE SHAFTS See page SA 18 20 REMOVE FRONT EXHAUST PIPE a Disconnect the 2 heated oxygen sensors Torque 44 N m 450 kgf cm 33 ft lbf HINT At the time of installation please refer to the ...

Page 352: ...2 22 REMOVE ENGINE REAR MOUNTING INSULATOR AND BRACKET a Remove the bolt and engine rear mounting insulator Torque 87 N m 890 kgl cm 64 11 lbl b Remove the 3 bolts and engine rear mounting bracket Torque 64 N m 650 kgf cm 47 ft lbf 23 JACK UP TRANSAXLE SLIGHTLY Using a transmission jack support the transaxle 24 REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING BOLTS Torque Bolt A 47 N m 480 kgl cm 35 11 lbl ...

Page 353: ...ON MANUALTRANSAXLE C56 MANUALTRANSAXLE UNIT Installation is in the reverse order of removal See page MX 4 HINT After installation check and inspect items as follows Front wheel alignment See page SA 4 Do the road test ...

Page 354: ... Ring 0 ControlCableBracket Ve_hicleSpeed Sensor DnvenGear 8 MX 9 TransaxleCase d TransaxleCaseReceiver 1i ii ki _J Magnet OilSeal______j fA InputShaftFrontBearing OutputShaftCover OutputShaftFrontBearing BearingLockPlate Q t J m kgf c c f l_ Specifiedtorque y Non reusablepart L lJ DifferentialCaseAssembly II ...

Page 355: ...1 Reve eldlecGeac OJ 0 r Ball ReverseIdlerGearShaft Gasket j OutputShaftAssembly InputShaft Assembly 127 280 20 No2GearSh1ft ForkShaft 29 300 22 No 3SynchronizerRing ti kQI_cm tt ibtj Specifiedtorque Non reusablepart Precoatedpart No 3HubSleeve No 3GearShiftForkShaft i IT60 12 No 3GearShiftFork 5thDrivenGear ShiftingKeySpring Ring 216Po l ...

Page 356: ...oo 2 j 171m Q G k OilReceivecp p e aset SlottedSprmgPm ReverseRestrict Pin Gasket StraightScrewPlug 1 3 130 9 I MX 11 ShiftandSelectleverShaftAssembly OilReceiverPipe l 17 175 13 i __ Gasket f lj FillerPluq 3 9 T 400 29fi Y Non reusablepart Precoatedpart ApplyMPgrease TransmissionCase Cover DOTI H ...

Page 357: ...ONTROL CABLE BRACKET Remove the 2 bolts and control cable bracket Torque 25 N m 250 kgf cm 18 ft fbf 5 REMOVE CONTROL SHAFT ASSEMBLY Remove the 2 nuts wave washer and control shaft assembly Torque 12 N m 120 kgf cm 9 ft lbl 6 REMOVE SELECTING BELLCRANK ASSEMBLY a Remove the 2 bolts and selecting bellcrank assembly Torque 25 N m 250 kgf cm 18 fl lbl NOTICE At the time of reassembly please refer to ...

Page 358: ... reassembly please refer to the following Items Install the dust boot into a groove In the control shift lever Be sure to install the dust boot in the correct direc tion as shown in the illustration B REMOVE TRANSMISSION CASE COVER a Remove the 9 bolts Torque 18 N m 185 kgt cm 13 ft lbf b Using a brass bar and hammer carefully tap the projec tion of the transmission case cover to remove the trans ...

Page 359: ...owing item Set the claws of the shift interlock plate Into the shift head part of the gear shift fork shaft securely 11 REMOVE LOCK NUT a Engage the gear double meshing b Using a chisel and hammer loosen the staked part of the nut c Remove the lock nut Torque 118 N m 1 200 kgf cm 87 ft lbf d Disengage the gear double meshing 12 REMOVE NO 3 HUB SLEEVE AND NO 3 GEAR SHIFT FORK a Remove the bolt from...

Page 360: ...20010 NOTICE Besure to install the No 3 hub sleeveassembly in the correct direction as shown in the Illustration Align the No 3 synchronizer ring slots with the No 3 shifting keys 13 INSPECT 5TH GEAR THRUST CLEARANCE Using a dial indicator measure the thrust clearance Standard clearance 0 10 0 57 mm 0 0039 0 0224 ln Maximum clearance 0 57 mm 0 0224 in 14 INSPECT 5TH GEAR RADIAL CLEARANCE Using a d...

Page 361: ... 1004 G 2 61 0 1028 b Using a screwdriver remove the shifting key spring from the No 3 clutch hub c Install a bolt and washer to the tip of the input shaft and using SST remove the No 3 clutch hub SST 0995D 30011 HINT Select a bolt whose outer diameter is smaller than the screw hole of the input shaft so that it can be turned easily d Removethe No 3 synchronizer ring 5th gear needle roll er bearin...

Page 362: ... Hl0080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 29 N m 300 kgf cm 22 ft lbf 20 REMOVE SNAP RING FROM NO 2 SHIFT FORK SHAFT Using 2 screwdrivers and a hammer tap out the snap ring 21 REMOVE STRAIGHT SCREW PLUG SEAT SPRING AND BALL a Using a hexagon wrench remove the 3 straight screw plugs Sealant Part No 0883 Hl0080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 25 N m 250 kgf cm 18 ft l...

Page 363: ...er pipes from thetransmission case Torque 17 N m 175 kgf cm 13 11 lbf NOTICE At the time of reassembly please refer to the following Items Prevent the oil receiver pipes from being deformed Install the oil receiver pipes while placing it against the transmission case as shown in the Illustration 25 REMOVE REVERSE IDLER GEAR THRUSTWASHER AND SHAFT 26 REMOVE REVERSE SHIFT ARM BRACKET Remove the 2 bo...

Page 364: ...t fork shaft b Remove the 3 bo ts from the No 1 gear shift head No 1 and No 2 gear shift forks Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 16 N m 160 kgf cm 12 ft lbf c Pull up the No 3 gear shift fork shaft remove the No 2 gear shift fork shaft NOTICE At the time of reassembly please refer to the following item To avoid the interference ofthe 2 balls lift up the N...

Page 365: ...NSAXLE CASE 29 REMOVE DIFFERENTIAL CASE ASSEMBLY NOTICE At the time of reassembly please refer to the following item Before reassembly inspect the differential tapered roller bearing preload See page MX 49 30 REMOVE MAGNET FROM TRANSAXLE CASE 31 DISASSEMBLE NO 3 CLUTCH HUB ASSEMBLY a Using a screwdriver remove the shifting key spring NOTICE At the time of reassembly please refer to the following i...

Page 366: ... feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 5 mm 0 020 in If the clearance is lessthan the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound is completely washed off after rubbing 2 INSPECT GEAR SHIFT FORK AND HUB SLEEVE CLEARANCE Using...

Page 367: ... new input shaft front bearing SST 09950 600 1 0 09951 00400 09950 7001 0 09951 7150 Drive in depth 0 0 3 mm 0 0 012 in NOTICE Be sure to install a new bearing in the correct direction as shown in the Illustration 5 a b IF NECESSARY REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER Remove the bolt and bearing lock plate Using SST pull out the output shaftfront bearing SST 09308 00010 c Rem...

Page 368: ...with the bolt Torque 11 N m 115 kgf cm 8 ft lbf 7 IF NECESSARY REPLACE REVERSE RESTRICT PIN jl l _ _ _ a Using a hexagonwrench remove the straight screw plug f l 1 b Using a pin punch and hammer drive out the slotted __ J spring pin j Hq 0 11 1 c __ fiE_ 7850 c d e f Replace the reverse restrict pin Using a pin punch and hammer drive in the slotted spring pin Apply sealant to the screw plug thread...

Page 369: ...in a new bushing SST 09950 6001 0 09951 00180 09950 70010 09951 Q7100 Drive In depth 0 80 1 30 mm 0 0315 0 0512 in IF NECESSARY REPLACE TRANSMISSION CASE OIL SEAL Using a screwdriver and hammer drive out the oil seal Using a socketwrench 17 mm and plastic hammer drive in a new oil seal Drive in depth 10 0 0 3 mm 0 394 0 012 in Coat the lip of the oil seal with MP grease ...

Page 370: ...remove all old FIPG material from the gasket surfaces Thoroughly clean all components to remove all loose material Clean both sealing surfaces with a non residue solvent Apply FIPG in an approx 1 mm 0 04 in wide bead along the sealing surface HINT Parts must be assembled within 1 0 minutes of application Otherwise the FIPG material must be removed and reapplied Coat all of the sliding and rotating...

Page 371: ...NPUT SHAFT COMPONENTS NeedleRollerBearing MANUALTAANSAXLE C56 No 2SynchronizerRing For3rdGear 3rdGear N No 2HubSleeve No 2ClutchHub No 2Synchronizer Ring For4thGear INPUT SHAFT InputShaft RearRadialBallBearing ...

Page 372: ...made O Q15 0 058 mm 0 0006 0 0023 in NSK made 0 015 0 056 mm 0 0006 0 0022 in Maximum clearance KOYO made 0 058 mm 0 0023 ln NSK made 0 056 mm 0 0022 in lf the clearance exceeds the maximum replace the gear needle roller bearing or shaft 3 REMOVE SNAP RING Using 2 screwdrivers and a hammer tap out the snap ring HINT Take care not to damage the journal surface of the input shaft 4 REMOVE REAR RADIA...

Page 373: ...ASSEMBLY 3RD GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NEEDLE ROLLER BEARING a Using SST and a press remove the No 2 hub sleeve as sembly 3rd gear and No 2 synchronizer ring for the 3rd gear SST 09950 00020 HINT Support the inputshaft by hand so that it will not be dropped off b Remove the needle roller bearings 7 DISASSEMBLE NO 2 HUB SLEEVE ASSEMBLY a Remove the No 2 hub sleeve from the No 2 c...

Page 374: ...f after rubbing c Check again the braking effect of the synchronizer ring d Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 3rd gear 0 65 mm 0 0256 in 4th gear 0 75 mm 0 0295 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure...

Page 375: ...t journal surface Minimum outer diameter Part A 24 885 mm 0 9797 in Part 8 28 985 mm 1 1411 in Part C 30 985 mm 1 2199 in c Jooo6 Part D 24 985 mm 0 9837 in L If the outerdiameter is less than the minimum replace the input shaft CMIXI 3 c Using a dial indicator check the shaft runout Maximum runout 0 03 mm 0 0012 in If the runout exceeds the maximum replace the input shaft ...

Page 376: ...ration 2 INSTALL NEEDLE ROLLER BEARING 3RD GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NO 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT a Apply gear oil to the needle roller bearings and install it b Install the 3rd gearand No 2synchronizer ring forthe3rd gear NOTICE Distinguish the No 2 synchronizer ring forthe 3rd gear by the teeth on the synchronizer ring c Instal the No 2 hub sleeve assembly so that t...

Page 377: ...ROLLER BEARING NO 2 SYNCHRONIZER RING FOR 4TH GEAR 4TH GEAR AND REAR RADIAL BALL BEARING a Install the spacer b Apply gear oil to the needle roller bearings and instal it c Place the No 2 synchronizer ring for the 4th gear on the No 2 hub sleeve assembly and align the No 2 synchro nizer ring slots with the No 2 shifting keys L N _ _ _ _ _ _ _ _ oo m J d Install the 4th gear NOTICE Distinguish the ...

Page 378: ... radial ball bearing less than 0 1 mm 0 0039 in Mark Thickness mm m_ Mark Thickness mm in A 2 29 0 0902 n 2 47 0 097 B 2 35 0 0925 F 2 53 0 0996 C 2 41 0 0949 F 2 59 0 1020 b Using a screwdriver and hammer tap in the snap ring HINT Take care not to damage the journal surface of the input shaft_ 7 INSPECT 4TH GEAR THRUST CLEARANCE See page MX 27 ...

Page 379: ...ring NeedleRo 1stGear No Q I stWasher lsiGearThru Ne adl R olllle Bearing SnapRing Ball L 1SynchronizerRing ReverseGear OutputShaft IR No 1ClulchHub SnapRing No Y 4 4 2ndGeac I i 3rdDnvenGeH I OutputGearSpacer I 4thDrivenGear d alBallBeanng RearRaI 2SynchronizerRing 007721 ...

Page 380: ...dial clearance between the gear and shaft Standard clearance KOYO made O o15 0 058 mm 0 0006 0 0023 in NSK made 0 015 0 056 mm 0 0006 0 0022 in Maximum clearance KOYO made 0 058 mm 0 0023 in NSK made 0 056 mm 0 0022 in If the clearance exceeds the maximum replace the gear needle roller bearing or shaft 3 REMOVE REAR RADIAL BALL BEARING 4TH DRIV EN GEAR AND OUTPUT GEAR SPACER FROM OUT PUT SHAFT a U...

Page 381: ...crewdrivers and a hammer tap outthe snap ring HINT Take care notto damage thejournal surlace of the output shaft 6 REMOVE REVERSE GEAR ASSEMBLY 1ST GEAR NO 1 SYNCHRONIZER RING NEEDLE ROLLER BEARING 1ST GEAR THRUST WASHER AND BALL a Using a press remove the reverse gear assembly 1st gear and No 1 synchronizer ring HINT Support the output shaft assembly by hand so that it wl l not be dropped ott b R...

Page 382: ...0 NOTICE When replacing the front bearing inner race replace the output shaft front bearing along with it HINT Support the output shaft by hand so that it will not be dropped off 9 DISASSEMBLE REVERSE GEAR ASSEMBLY a Remove the reverse gear from the No 1 clutch hub b Remove the 3 No 1 shifting keys and No 1 shifting key springs from the No 1 clutch hub ...

Page 383: ...ler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 75 mm 0 0295 in f the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound is completely washed off after rubbing 2 INSPECT 2ND GEAR SYNCHRONIZER RING a Check for wear or d...

Page 384: ...k or hub sleeve 4 INSPECT OUTPUT SHAFT a Check the output shaft for wear or damage l lBBJ b Using a micrometer measure the outer diameter of the output shaft journal surface Minimum outer diameter Part A 32 985 mm 1 2986 in Part B 37 985 mm 1 4955 ln Part C 31 985 mm 1 2592 in MTOO If the outer diameter is less than the minimum replace the out put shaft c Using a dial indicator check the shaft run...

Page 385: ...at will make the thrust clearance of the front bearing inner race less than 0 1 mm 0 0039 in Mark Thickness mm in Mark Thfckness mm in 7 1 85 0 0728 3 2 05 0 0807 8 1 90 0 0748 4 2 10 0 0827 1 95 0 0768 5 2 15 0 0846 2 2 00 0 0187 6 2 20 0 0866 b Usmg a screwdriVer and hammer tap 1n the snap nng HINT Takecare notto damage the journal surface of the output shaft 3 ASSEMBLE REVERSE GEAR ASSEMBLY a I...

Page 386: ...izer ring by the teeth on the synchronizer ring e Place the reverse gear assembly and align the No 1 syn chronizer ring slots with the No 1 shifting keys f Using a press install the reverse gear assembly NOTICE Be sure to install the reverse gear assembly in the correct direction as shown in the illustration When installing make sure that the ball is placed in a groove of the 1st gear thrust washe...

Page 387: ... Place the No 2 synchronizer rings on the 2nd gear NOTICE Properly fit the synchronizer middle ring claws into the holes in the 2nd gear Distinguish the No 2 synchronizer ring by the teeth on the synchronizer ring d Place the 2nd gear with the No 2 synchronizer rings and allgn the No 2 synchronizer ring slots with the No 1 shift ing keys NOTICE Fit the synchronizer inner ring claws Into the slots ...

Page 388: ...RING a Install the output gear spacer b Using SST and a press install the 4th driven gear and rear radial ball bearing SST 09608 00071 NOTICE Be sure to install the 4th driven gear and rear radial ball bearing in the correct direction as shown in the illustra tlon HINT Set SST to the bearing inner race securely ...

Page 389: ...TS y SnapRing CompressionSpring ShiftandSelectLever Shaft I SelectInnerLever ShiftInterlock Plate No 2ShiftInner Lever No 2SelectSpring Seat I A4 _ CompressionSp ing t E Ring No 1SelectSpringSeat __ SlottedSpringPin e 1 SlottedSp ingPin No 1ShiftInnerLever SlottedSpringPin ApplyMPgrease 07696 ...

Page 390: ...AXlE C56 DIFFERENTIAL CASE COMPONENTS OilSeal Pinion l ii lliW DIFFERENTIAL CASE Ring Gear PinionThrustWasher L kg m tt l Specifiedtorque Non reusablepart ApplyMPgrease MX 45 Straight Pin DifferentialCase Oil Seal ...

Page 391: ...g gear side REMOVE TAPERED ROLLER BEARING FROM DIF FERENTIAL CASE Using SST remove the tapered roller bearing SST 0995G 40011 0995 60010 09951 00350 HINT Set the claw of SST to the bearing inner race at the position where the differential case is indented 4 INSPECT SIDE GEAR BACKLASH Using a dial indicator measure the backlash of one side gear white holding one pinion toward the differentia case S...

Page 392: ... new oil seal SST 09226 1001 0 Drive in depth 9 9 0 3 mm 0 390 0 012 in d Coat the lip of the oil seal with MP grease e Place the shim into the differential case f Using SST and a press install the tapered roller bearing outer race SST 09950 60020 09951 0071 0 09950 70010 09951 7150 NOTICE When replacing the tapered roller bearing outer race re place the tapered roller bearing along with it 7 Tran...

Page 393: ...sing SST and a press install the tapered ro er bearing outer race SST 09950 60020 09951 00680 09950 7001 0 09951 07150 NOTICE When replacing the tapered roller bearing outer race re place the tapered roller bearing along with it e f Using SST and a hammer drive in a new oil seal SST 0971Q 28021 09710 08041 Drive in depth 1 9 0 3 mm 0 075 0 012 in Coat the lip of the ol seal with MP grease ...

Page 394: ... indicator check the side gear backlash Measure the side gear backlash while holding one pinion toward the differential case Standard backlash 0 05 0 20 mm 0 0020 0 0079 in If the backlash is not within the specification install a thrust washer of different thickness e Using a pin punch and hammer drive in the straight pin c Kooo7 through the differential case and hole in the pinion shaft f Using ...

Page 395: ...differential case b Heat the ring gear in boiling water 007315 c Carefully take the ring gear out of the water d After the moisture on the ring gear has completely evapo rated quickly install the ring gear to the differential case HINT Align the matchmarks on the differential case and contact the ring gear e Temporarily install the 8 set bolts CAUTION The rlng gear set bolts should not be tightene...

Page 396: ...n case side outer race of the tapered roller bearing with SST See page MX 46 Select an appropriate shim HINT The preload wilt change by about 0 3 0 4 N m 3 4 kgf cm 2 6 3 5 in lbf corresponding to a change of 0 05 mm 0 0020 in in shim thickness M K lhickness mm in Mmk fhlckrl Ss mm rn M 2 10 O ml27 Ll 2 60 0 1024 BB 2 15 0 0846 MM 2 65 0 1043 cc 2 20 0 0866 NN 2 70 0 1063 DO 2 25 0 0886 pp 2 75 0 ...

Page 397: ... MANUAL TRANSAXLE lC56l SHIFTLEVERAND CONTROLCABLE SHIFT LEVER AND CONTROL CABLE COMPONENTS PassengerAirbagAssembly FrontPillarGarnish InstrumentPanel LH EndFinishPanel CowlSideTrim DoorScuffPlate ConsoleBox ...

Page 398: ...p MANUALTRANSAXLE C56 SHIFT lEVERAND CONTROL CABLE HeaterHose AJCUnit Non reusablepart LiquidTube SuctionTube BlowerUnit InstrumentPanel No 2Brace MX 53 ...

Page 399: ...anerCaseAssembly withAirHose I L ECMOutletDuct ShiftCableRetainer Clip u n Clip I l Gmmmet J j I Bracket I i l I 1 I l l iig 50 43 n fbf 1 eke il i __L___ I 9 Clip t r Clip I Clip__________ SelectControlCable Washer ShiftLeverAssembly Washer ShiftControlCable 0774 ...

Page 400: ...ESHOOTING MANUALTRANSAXLEUNIT MANUALTRANSAXLEASSEMBLY INPUTSHAFT OUTPUTSHAFT SHIFTANDSELECTLEVERSHAFT DIFFERENTIALCASE REVERSESHIFTWARNING BUZZERSYSTEM SHIFTLEVERANDCONTROLCABLE MX 1 MX 2 MX 9 MX 29 MX 37 MX 47 MX 48 MX 55 MX 57 ...

Page 401: ......

Page 402: ...X 9 011 Level toohigh MX 4 Oil leakage 2 Gasket Damaged MX 9 3 Oil se l Worn or damaged MX 9 4 0 fling Worn ordamaged MX 9 1 Controlcable Faulty MX 57 2 Synchronizm ring Worn or damaged MX 24 MX 32 Hard to shift or will not shift MX 41 J_ Shifting key spring Damaged MX 24 MX 32 MX 41 1 lod ing ball spring Damaged MX 24 Jumps out ol gear 2 Gear shill fork Worn MX 24 3 Gear Worn or damaged MX 24 4 B...

Page 403: ...d __ iO snn lbfl 1 13 130 9 i ECMCover rtHold Down 6 9 70 61 m 1bi J No 2 CylinderHeadCover 4 9 50 43ill l J l 11 Clamp EGMGonnectm 8 J H j BatteryCarrier ECMOutletOuct WireHarness 18 185 ControlCableBracket WireHarness Back UplightSwitchConnector S G SpeedSensorConnector tarter onnector Starter Wire f 37 37a D _ j Starter ...

Page 404: ...ket I Compresstonr 1 1 _1 _ Spnn g i lij _ SnapRing 1 o __ P1peSupport i4 3 i 3 440 32 l r FrontExhaustPipe _ f f CotterP1n Compression _ 1 Sprrng 3 440 1 49 501 i 3 6 1 v ifJ 7 f J I 64 65h j EngmeRear _ r v Mounllnglnsulator i 1 1 Eng1neRear 87 890 64 J PSGearAssembly Moun lngBracket _ _ RHEngineUnderCover N m k lt lbQ_ Specifiedtorque Non reusablepart LHEngineUnderCover MX 3 i 717 ...

Page 405: ...ve the 2 bo ts and ECM cover Torque 6 9 N m 70 kgf cm 61 in lbf b Disconnect the ECM connectors from the ECM c Remove the ECM outlet duct d Remove the aircleanercase assembly with the air hose e Remove the 3 bolts and ECM box Torque 6 9 N m 70 kgf cm 61 in lbf f Disconnect the wire harness and remove the 2 nuts bolt and battery carrier Torque Bolt 18 N m 185 kgf cm 13 ft lbf Nut 12 N m 120 kgf cm ...

Page 406: ...arter wire Remove tho 2 bolts and starter Torque 37 N m 378 kgf cm 28 tt lbf 11 REMOVE CONTROL CABLE BRACKET a Disconnect the wire harness from the clamp b Remove the 2 bolts clamp and control cable bracket from the transaxle 12 Torque 25 N m 250 kgf cm 18 tt lbf REMOVE 2 TRANSAXLE UPPER SIDE MOUNTING II BOLTS Torque 64 N m 650 kgf cm 47 ft tbf 13 ATTACH ENGINE SLING DEVICE TO ENGINE HANG ER a Dis...

Page 407: ...VECENTER LH AND RH ENGINE UNDER COV ERS 18 DRAIN TRANSAXLE OIL 011 grade API GL 4 or GL 5 Viscosity SAE 75W 90 Capacity 2 3 liters 2 4 US qts 2 0 Imp qts Torque 39 N m 400 kgf cm 29 ft lbl 19 REMOVE LH AND RH FRONT DRIVE SHAFTS See page SA 18 20 REMOVE FRONT EXHAUST PIPE a Disconnect the 2 heated oxygen sensors Torque 44 N m 450 kgf cm 33 ft lbl HINT At the time of installation please refer to the...

Page 408: ... 22 REMOVE ENGINE REAR MOUNTING INSULATOR AND BRACKET a Remove the bolt and engine rear mounting insulator Torque 87 N m 890 kgf cm 64 11 lbf b Remove the 3 bolts and engine rear mounting bracket Torque 64 N m 650 kgf cm 47 ft lbf 23 JACK UP TRANSAXLE SLIGHTLY Using a transmission jack support he transaxle 24 25 REMOVE 4 TRANSAXLE LOWER SIDE MOUNTING Iii BOLTS Torque Bolt A 47 N m 480 kgf cm 35 ft...

Page 409: ...ON MANUALTRANSAXLE COOl MANUALTMNSAXLE UNIT Installation Is in the reverse order of removal See page MX 4 HINT After installation check and Inspect items as follows Front wheel alignment See page SA 4 Do the road test ...

Page 410: ... Clip 0tr Q Ring 0 VehicleSpeedSensor A DrivenGear 8 ControlCableBracket 25 250 18 MX 9 TransaxleCaseReceiver l Magnet OilSeal______ Jfa lnputShaftFrontBearing OutputShaftCover OutputShaftFrontBearing BearingLockPlate tJ __ gf cm tt Specifiedtorque y Non reusablepart 11 115 8 DifferentialCaseAssembly ...

Page 411: ... I Snap Ring Js 300 22 Gasket No 2GearShiftForkShaft o 1 No 1Gear hiltFork No 1GearShiftForkShaft _ __4 _ No 1GearShiftHead c _ r SnapRing L16 160 12 I No GearShiftFork 1 J l 1s 160 121 1 SnapRing InputShaft___ Assembly No 3 s o Ring ff NeedleRoller Bearing 6thGear InputShaftRear l f l l RadialBallBearing P Ct f B e aringRetainer SnapRing 11 til 5thGea Sl Spacer NeedleRollerBearing ShiftingKeySpri...

Page 412: ...rewPlug 113 1 OilReceiverPipe I r L__1__ 0__ _ 20_ 200 14 J ControlShaftCover T Gasket Back UpLightSwitch 1 1 o ao iJ I diJl lrGS 1in e i s tl Gasket Compression CompressionSpring Spnng j r 8___La mbly_ _ _ _ _ _ _ _ J 29 300 _j SelectSpringSeat ShiftandSelectLevE JrShaftAssembly TransmissionCase TransmissionCase Cover ...

Page 413: ... CONTROL CABLE BRACKET Remove the 2 bolts and control cable bracket Torque 25 N m 250 kgf cm 18 ll lbl 5 REMOVE CONTROL SHAFT ASSEMBLY Remove the 2 nuts wave washer and control shaft assembly Torque 1 2 N m 120 kgf cm 9 11 lbl 6 REMOVE SELECTING BELLCRANK ASSEMBLY a Remove the 2 bolts and selecting bellcrank assembly Torque 25 N m 250 kgl cm 18 11 lbl NOTICE At the time of reassembly please refer ...

Page 414: ...fer to the following items Install the dust boot into a groove in the control shift lever Be sure to install the dust boot in the correct dirac tion as shown Jn the illustration 8 REMOVE PLUG LOCK BALL ASSEMBLY AND CON TROL SHAFT COVER ASSEMBLY a Using a hexagon wrench remove the plug and gasket Torque 39 N m 400 kgf cm 29 fl lbf b Remove the lock ball assembly Sealant Part No 08833 00080 THREE BO...

Page 415: ...ork shaft securely b Remove the select spring seal and compression spring from the shift and select lever shaft assembly 11 REMOVE TRANSMISSION CASE COVER a Remove the 9 bolts Torque 18 N m 185 kgf cm 13 lt lbl b Carefully tap the projection of the transmission case cov er with a brass bar and hammer and remove it HINT At the time of reassembly please refer to the following item Apply FIPG to the ...

Page 416: ...a snap ring from the table below that will make the thrust clearance of the output shaft rear radial bat bearing less than 60Z6 ___ SST N OG J B 0 1 mm 0 0039 in Mark R c 0 E F G Th ckness mm ifl_ 2 31 0 0909 2 37 0 0933 2 43 0 0957 2 49 0 0980 2 55 0 1004 2 61 0 1028 Mark Thickness mm m H 2 67 0 1051 J 2 73 0 1075 K 2 79 0 1098 l 2 85 0 1122 M 2 91 0 1146 b Using SST remove the rear radial ball b...

Page 417: ...learance of the No 3 clutch hub less than 0 1 mm 0 0039 in Mark Thickness mm in M uk ThickMss mm in A 1 70 0 0669 G 2 00 0 0787 8 1 75 0 0689 H 2 05 0 0807 c 1 80 0 0709 J 2 10 0 0827 D 1 85 0 0728 K 2 15 0 0846 E 1 90 0N48 L 2 20 0 0866 F 1 95 0 0768 M 2 25 0 0886 b Using SST remove the rear radial ball bearing and 6th gear HINT SST 09950 4001 1 09951 04010 09952 0401 0 09953 04030 09954 04 0 1 0...

Page 418: ...bolt No 3 gear shift fork and No 3 hub sleeve Sealant Part No 08833 00080 THREE BOND 1344 LOCTITE 242 or equivalent Torque 1 6 N m 160 kgf cm 1 2 11 lbf 18 INSPECT 5TH GEAR THRUST CLEARANCE Using a dial indicator measure the thrust clearance Standard clearance 0 1 0 0 62 mm 0 0039 0 0244 1n Maximum clearance 0 62 mm 0 0244 ln 19 INSPECT 5TH GEAR RADIAL CLEARANCE Using a dial indicator measure the ...

Page 419: ...emove the No 3 clutch hub assembly HINT SST 09950 300 1 1 0995 1 03010 09953 03010 0995Q 50012 09954 Q5030 At the time of reassembly please refer to the following items Before driving in the No 3 clutch hub assembly and input shaft rear radial ball bearing place the suitable sized wooden block on the rearside of the input shaft as shown in the Illustration When driving them in fix the input shaft ...

Page 420: ...nd 2 spacers 21 REMOVE 5TH DRIVEN GEAR Using SST remove the 5th driven gear SST 09950 30011 09951 03010 09953 03010 09954 03010 09955 03021 HINT At the time of reassembly please refer to the following item Using SST and a hammer drive in the 5th driven gear SST 09612 22011 22 REMOVE REAR BEARING RETAINER Remove the 5 bolts and rear bearing retainer Sealant Part No 08833 0080 THREE BOND 1344 LOCTIT...

Page 421: ... 242 or equivalent Torque 25 N m 250 kgf cm 18 ft lbt b Using a magnetic linger remove the 3 seals springs and balls 27 REMOVE STRAIGHT SCREW PLUG Using a hexagon wrench remove the 2 straight screw plugs 28 a b HINT Sealant Part No 0883 Hl0080 THREE BOND 1344 LOCTITE 242 or equivalent Torque Plug A 1 3 N m 130 kgf cm 9 ft lbt Plug B 39 N m 400 kgf cm 29 ft lbl REMOVE TRANSMISSION CASE Remove the 1...

Page 422: ...s and reverse shift arm bracket Torque 1 7 N m 175 kgf cm 13 fHbf NOTICE At the time of reassembly please refer to the following items Set the pin on the top of the reverse shift arm into a groove on the reverse idler gear Fit the claw of the reverse shift arm bracket with the notch of the input shaft front bearing 31 REMOVE REVERSE IDLER GEAR THRUST WASHER AND SHAFT NOTICE At the time of reassemb...

Page 423: ...sembly please refer to the following item Make sure that the 3 gear shift heads are positioned as shown in the illustration 34 REMOVE NO 2 GEAR SHIFT FORK SHAFT Remove the No 2 gear shift forkshaft from the No 2 gear shift fork No 1 gear shift head No 1 gear shift fork reverse shift fork and transaxle case 35 REMOVE NO 1 GEAR SHIFT FORK SHAFT Remove the No 1 gear shift forkshaft from the No 1 gear...

Page 424: ...ND OUTPUT SHAFTS TOGETHER FROM TRANSAXLE CASE 41 REMOVE DIFFERENTIAL CASE ASSEMBLY NOTICE At the time of reassembly please refer to the following item Before reassembly inspect the differential tapered roller bearing preload See page MX 52 42 REMOVE MAGNET FROM TRANSAXLE CASE 43 DISASSEMBLE NO 3 CLUTCH HUB ASSEMBLY a Using a screwdriver remove the 2 shifting key springs NOTICE At the time of reass...

Page 425: ... feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 75 mm 0 0295 in If the clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound Is completely washed off after rubbing 2 INSPECT GEAR SHIFT FORK AND HUB SLEEVE CLEARANCE Us...

Page 426: ...input shaft front bearing SST 09950 6001 0 09951 00400 09950 7001 0 09951 7150 DriVe In depth 0 0 3 mm 0 0 012 ln NOTICE Be sure to install a new bearing in the correct direction as shown in the illustration 5 a b IF NECESSARY REPLACE OUTPUT SHAFT FRONT BEARING AND OUTPUT SHAFT COVER Remove the bolt and bearing lock plate Using SST pull out the output shaft front bearing SST 09308 0001 0 c Remove ...

Page 427: ... Install thetransaxle casereceiverto the transaxle case with the bolt Torque 11 N m 115 kgf cm 8 tt lbf 7 IF NECESSARY REPLACE TRANSMISSION CASE BUSHING a Using a socketwrench 12 mm extension bar and plastic hammer drive out the bushing NOTICE When driving out the bushing be careful not to damage the transmission case by the socket wrench b Using SST and a hammer drive in a new bushing SST 09950 6...

Page 428: ...27 MANUALTRANSAXLE C60 MANUAL TRANSAXLEASSEMBLY b c Using a socketwrench 17 mm and plastic hammer drive in a new oil seaL Drive in depth 10 0 0 3 mm 0 394 0 012 in Coat the lip of the oilseat with MP grease ...

Page 429: ...move all old FIPG material from the gasket surfaces Thoroughly clean all components to remove all loose material Clean both sealing surfaces with a non residue solvent Apply FIPG in an approx 1 mm 0 04 in wide bead along the sealing surface Parts must be assembled within 1 0 minutes of application Otherwise the FIPG material must be removed and reapplied HINT Coat all of the sliding and rotating s...

Page 430: ...INPUT SHAFT COMPONENTS MANUAL TRANSAXLE C60 INPUT SHAFT NeedleRollerBearing 4th GearSnapRing MX 29 ...

Page 431: ... 0 01 5 0 058 mm 0 0006 0 0023 in NSK made O G15 0 056 mm 0 0006 0 0022 in Maximum clearance KOYO made 0 058 mm 0 0023 in NSK made 0 056 mm 0 0022 in If the clearance exceeds the maximum replace the gear needle roller bearing or shaft 3 REMOVE SNAP RING Using 2 screwdrivers and a hammer tap out the snap ring HINT Take care not to damage the journal surface of the input shaft 4 REMOVE CENTER RADIAL...

Page 432: ...ASSEMBLY 3RD GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NEEDLE ROLLER BEARING a Using SST and a press remove the No 2 hub sleeve as sembly 3rd gear and No 2 synchronizer ring for the 3rd gear SST 09950 00020 HINT w Support the input shaftby hand sothat it will not be dropped off b Remove the needle roller bearings 7 DISASSEMBLE NO 2 HUB SLEEVE ASSEMBLY a Remove the No 2 hub sleeve from the No 2 ...

Page 433: ... off after rubbing c Check again the braking effect of the synchronizer ring d Using a feeler gauge measure the clearance between the synchronizer ring back and gear spline end Minimum clearance 3rd gear 0 65 mm 0 0256 in 4th gear 0 75 mm 0 0295 ln Ifthe clearance is less thanthe minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensur...

Page 434: ...journal surtace Minimum outer diameter Part A 21 991 mm 0 8658 ln Part B 24 885 mm 0 9797 in Part C 28 985 mm 1 1411 in Part D 30 985 mm 1 2199 in Part E 24 985 mm 0 9837 in Ifthe outerdiameteris less than the minimum replace the input shaft c Using a dial indicator check the shaft runout Maximum runout 0 03 mm 0 0012 ln 1f the runout exceeds the maximum replace the input shaft ...

Page 435: ...2 INSTALL NEEDLE ROLLER BEARING 3RO GEAR NO 2 SYNCHRONIZER RING FOR 3RD GEAR AND NO 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT a Apply gear oil to the needle roller bearings and install it b Install the 3rd gear and No 2 synchronizer ring forthe 3rd gear NOTICE Distinguish the No 2 synchronizerring forthe 3rd gear by the teeth on the synchronizer ring c Install the No 2 hub sleeve assembly so that the N...

Page 436: ...EEDLE ROLLER BEARING NO 2 SYNCHRONIZER RING FOR 4TH GEAR 4TH GEAR AND CENTER RADIAL BALL BEARING a Instal the spacer b Apply gear oil to the needle roller bearings and install it c Place the No 2 synchronizer ring for the 4th gear on the No 2 hub sleeve assembly and align the No 2 synchro nizer ring slots with the No 2 shifting keys LN _ _ _ _ _ _ _ _ _ s d Install the 4th gear iJi T c JJ __ 000 N...

Page 437: ...terradialball bearing less than 0 1 mm 0 0039 in Mark Thfckness mm in Mark Thickness mm in A 2 29 0 0902 D 2 47 0 0972 8 2 35 0 0925 E 2 53 0 0996 c 2 41 0 0949 F 2 59 0 1020 b Using a screwdriver and hammer tap in the snap ring HINT Take care not to damage the journal surface of the input shaft 7 INSPECT 4TH GEAR THRUST CLEARANCE See page MX 30 ...

Page 438: ...SAXLE C60 OUTPUT SHAFT OUTPUT SHAFT COMPONENTS 1stGearThrustWa sh ec 2ndGear 3rdDrivenGear OutputGearSpacer 4thDrivenGear I __ OutputShaft No 1ClutchHub j SnapRing No 2SynchronizerRing CenterRadialBallBearing MX 37 ...

Page 439: ... radial clearance between the gear and shaft Standard clearance KOYO made O Q15 0 058 mm 0 0006 0 0023 ln NSK made O Q15 0 056 mm 0 0006 0 0022 in Maximum clearance KOYO made 0 058 mm 0 0023 ln NSK made 0 055 mm 0 0022 in If the clearance exceeds the maximum replace the gear needle ro er bearing or shaft 3 REMOVE CENTER RADIAL BALL BEARING 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT a...

Page 440: ...ewdrivers and a hammer tap out the snap ring HINT Take care not to damage the journal surfaceof the output shaft 6 REMOVE REVERSE GEAR ASSEMBLY 1 ST GEAR NO 1 SYNCHRONIZER RING NEEDLE ROLLER BEARING 1ST GEAR THRUST WASHER AND BALL a Using a press remove the reverse gear assembly 1 st gear and No 1 synchronizer ring HINT Support the output shaft assembly by hand so that it will not be dropped off b...

Page 441: ...earing inner race SST 0995 0020 NOTICE When replacing the front bearing inner race replace the output shaft front bearing along with it HINT Support the output shaft by hand so that it will not be dropped off 9 DISASSEMBLE REVERSE GEAR ASSEMBLY a Remove the reverse gear from the No 1 clutch hub b Remove the 3 No 1 shifting keys and No 1 shifting key springs from the No 1 clutch hub ...

Page 442: ...e the clearance between the synchronizer ring back and gear spline end Minimum clearance 0 75 mm 0 0295 in lfthe clearance is less than the minimum replace the synchro nizer ring and apply a small amount of the fine lapping com pound on gear cone NOTICE Ensure the fine lapping compound is completely washed L off after rubbing p 2 INSPECT 2ND GEAR SYNCHRONIZER RING a Check for wear or damage b Chec...

Page 443: ... or hub sleeve 4 INSPECT OUTPUT SHAFT a Check the output shaft for wear or damage b Using a micrometer measure the outer diameter of the output shaft journal surface Minimum outer diameter Part A 32 985 mm 1 2986 ln Part B 37 985 mm 1 4955 in Part C 31 985 mm 1 2592 ln If the outer diameter is less than the minimum replace the out put shaft c Using a dial indicator check the shaft runout Maximum r...

Page 444: ... that wH make the thrust clearance of the front bearing inner race less than 0 1 mm 0 0039 in Mark Th1cknoss mm l11 MM Thfclc ness mm in 7 1 85 0 0728 3 2 05 0 0807 8 1 1 90 0 0748 1 95 0 07il8 2 00 0 0787 4 2 10 0 0827 5 2 15 0 0846 6 2 20 0 0866 b Usmg a screwdnver and hammer tap m the snap nng HINT Take care not to damage thejournal surface of the output shaft 3 ASSEMBLE REVERSE GEAR ASSEMBLY a...

Page 445: ...ynchronizer ring by the teeth on the synchronizer ring e Place the reverse gearassembly and align the No 1 syn chronizer ring slots with the No 1 shifting keys f Using a press install the reverse gear assembly NOTICE Be sure to install the reverse gear assembly In the correct direction as shown in the Illustration When Installing make sure that the ball Is placed in a groove of the 1st gear thrust...

Page 446: ...ynchronizer rings on the 2nd gear NOTICE Properly fit the synchronizer middle ring claws into the holes in the 2nd gear Distinguish the No 2 synchronizer ring by the teeth on the synchronizer ring d Place the 2nd gear with the No 2 synchronizer rings and align the No 2 synchronizer ring slotswith the No i shift ing keys NOTICE Fit the synchronizer inner ring claws into the slots in the No 1 clutch...

Page 447: ...ING a Install the output gear spacer b Using SST and a press install the 4th driven gear and center radial ball bearing SST 09608 00071 NOTICE Be sure to install the 4th driven gear and center radial ball bearing in the correct direction as shown in the illustra tion HINT Set SST to the bearing inner race securely ...

Page 448: ...fAND SELECT LEVER SHAFf SHIFT AND SELECT LEVER SHAFT COMPONENTS p ShiftandSelectLeverShaft No 2SelectSpringSeat I r o r Compress10nSpnng SlottedSpringPin E Aing No 2ShiftInnerLever ApplyMPgrease SlottedSpringPin No 1 ShiftInnerLever ...

Page 449: ...ANSAXLE C60l DIFFERENTIAL CASE COMPONENTS Pinion ii DIFFERENTIALCASE L 7 79o s7l RingGear 0 PinionThrustWasher Q Lcm lt_ QJ Specifiedtorque Non reusablepart P ApplyMPgrease StraightPin DifferentialCase OilSeal 007366 ...

Page 450: ...aring inner race securely b Remove the vehicle speed sensor drive gear 3 Ring gear side REMOVE TAPERED ROLLER BEARING FROM DIF Jrt l SST FERENTIAL CASE OOD6l Using SST remove the tapered roller bearing HINT SST 09950 40011 09951 04010 09952 0401 0 09953 04020 09954 0401 o 09955 04061 09957 0401 0 09958 0401 1 09950 6001 0 09951 00350 Set the claw of SST to the bearing inner race at the position wh...

Page 451: ...ND TAPERED ROLLER BEARING OUTER RACE a Using SST pull out the tapered roller bearing outer race and shim b SST 09612 6501 4 Using SST and a hammer drive out the oil seal SST 09226 10010 c Using SST and a hammer drive in a new oil seal SST 09226 1 0010 Drive in depth 9 9 0 3 mm 0 390 t 0 012 in d Coat the lip of the oil seal with MP grease e Place the shim into the differential case I Using SST and...

Page 452: ...spacer SST 09612 65014 c Place the spacer into the differential case d Using SST and a press install the tapered roller bearing outer race SST 09950 60020 09951 00680 09950 7001 0 0995Hl7150 NOTICE When replacing the tapered roller bearing outer race re place the tapered roller bearing along with it e Using SST and a hammer drive in a new oil seal SST 09710 28021 09710 08041 Drive in depth 1 9 0 3...

Page 453: ...a dial indicator check the side gear backlash Measure the side gear backlash while holding one pinion toward the differential case Standard backlash 0 05 0 20 mm 0 0020 0 0079 ln If the backlash is not within the specification install a thrust washer ofdifferent thickness e Using a pin punch and hammer drive in the straight pin through the differential case and hole in the pinion shaft I Using a c...

Page 454: ...rential case b Heat the ring gear in boiling water c Carefu y take the ring gear out of the wateL d After the moisture on the ring gear has completely evapo rated quickly instal the ring gear to the differential case HINT Align the matct1rnarks on the differential case and contact the v D lms ring gear Ll e Temporarily install the 8 set bolts CAUTION The ring gear set bolts should not be tightened...

Page 455: ...on case side outer race of the tapered roller bearing with SST See page MX 49 Select an appropriate shim HINT The preload will change by about 0 3 0 4 N m 3 4 kgf cm 2 6 3 5 in lbf corresponding to a change of 0 05 mm 0 0020 in in shim thickness MatI Thickness mm in Mark Thickness rnm in M 2 10 0 0827 LL 2 60 0 1024 88 2 15 0 0846 MM 2 B5 0 1043 cc 2 20 0 0866 NN 2 70 0 1063 DO 2 25 0 0886 pp 2 75...

Page 456: ...MANUALTRANSAXLE C60 REVERSE SHIFT WARNING BUZZER SYSTEM REVERSE SHIFT WARNING BUZZER SYSTEM LOCATION CombinationMeter ReverseShiftWarningBuzzer Back UpLightSwitch y MX 55 ...

Page 457: ...MX 56 MANUAL TRANSAXLE C60 REVERSE SHIFTWARNING BUZZER SYSTEM INSPECTION 1 INSPECT REVERSE SHIFT WARNING BUZZER SYSTEM See page BE 46 2 INSPECT BACK UP LIGHT SWITCH CONTINUITY See page BE 30 ...

Page 458: ...ABLE COMPONENTS PassengerAirbagAssembly FrontPillarGarnish InstrumentPanel CowlSideTrim MX 57 FrontDoorOpeningTrim LHEndFinishPanel Cowl SideTrim DoorScuffPlate LowerFinish Panel RHEndFinishPanel ConsoleBox HeaterControland AccessoryAssembly J m kgf c fHbtD Specifiedtorque UP ...

Page 459: ...MX 58 Non reusable part MANUALTRANSAXLE C60 SHIFT LEVERAND CONTROLCABLE 0 Ring LiquidTube Suction Tube No 1 Brace Blower Unit Instrument Panel Reinforcement No 2 Brace 113009 ...

Page 460: ...Assembly AirHose II r ECMConnector ECMOutletDuct 4 9 50 43 in lbf ShiftCableRetainer Clip 12 12o 9U Grommet Bracket _ 5_0 0J fr n Clip ShiftControlCable I J J Clip 1 i Bcacket L y r Ciip SelectControlCable Washer ShiftLeverAssembly fTITI k9f cm ft lbf I SpecilieUtorque N J ...

Page 461: ... MEMO ...

Page 462: ...DSENSOR SPEEDSENSOR AX 1 AX 3 AX 4 ATFTEMPERATURESENSOR AX 6 PARK NEUTRALPOSITION PNP SWITCH AX 8 VALVEBODYASSEMBLY AX 10 DIFFERENTIALOILSEAL AX 14 SHIFTLOCKSYSTEM AX 15 FLOORSHIFTASSEMBLY AUTOMATICTAANSAXLEUNIT TORQUECONVERTERCLUTCH ANDDRIVEPLATE AX 17 AX 30 AX 36 ...

Page 463: ......

Page 464: ...AUTOMATICTAANSAXLE U240E AUTOf MT G TRANSAXLC SYSTEM AUTOMATIC TRANSAXLE SYSTEM PRECAUTION AX 1 If the vehicle is equipped with a mobile communication system refer to the precautions in the INsection ...

Page 465: ...ke 82 DirectClutch C2 No 1One wayClutch F1 U 0 On e w ay Clutch F2 U 0 Forv ardClutch Ctl hittl p _ t_i n 8 p i _ c r c _ _ f_ _ _ c CB _ 82 83_ e _ac_ n st_ _ L_ P Parking i r c I 1 C 1 1st 2nd CJ I c D i f f C l ___ t u D L 2 L f C 1 c l J j L c _j s ___ _ _ u ____ __ J_ __l____ _2__j ...

Page 466: ...m the vehicle speed sensor Remove the D ring from the vehicle speed sensor_ INSTAll VEHIClE SPEED SENSOR ASSEMBlY Coat a new 0 ring with ATF and install it to the vehicle speed sensor Install the speedometer driven gear to the vehicle speed sensor with clip Install the vehicle speed sensor assembly with the bolt Torque 5 5 N m 56 kgf cm 49 in lbf CONNECT VEHIClE SPEED SENSOR CONNECTOR INSTAlL ECM ...

Page 467: ...OR Coat a new 0 ring with ATF and instal II to the input tur bine speed sensor Install the input turbine speed sensor with the bolt Torque 11 N m 115 kgf cm 8 ft lbf CONNECT INPUT TURBINE SPEED SENSOR CON NECTOR DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR REMOVE COUNTER GEAR SPEED SENSOR Remove the bolt and counter gear speed sensor Remove the 0 ring from the counter gear speed sensor INSTALL C...

Page 468: ...TRANSAXLE U240El SPEED SENSOR 12 INSTALL ECM BRACKET Torque Bolt 18 N m 185 kgf cm 13 11 lbl Nut 12 N m 120 kgf cm 9 11 lbl 13 INSTALL ECM AND ECM CASE Torque 6 9 N m 70 kgf cm 61 in ibl 14 INSTALL BATTERY AX 5 ...

Page 469: ...remove the oil pan assem bly_ Discard the gasket 5 REMOVE OIL STRAINER a Remove the 3 bolts and oil strainer b Remove the 0 ring 6 7 DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC TORS REMOVE ATF TEMPERATURE SENSOR Remove the bolt and lock plate and remove the ATF tempera ture sensor B SEPARATE WIRE HARNESS FROM 2 CLAMPS 9 CLAMP WIRE HARNESS TO 2 CLAMPS 10 INSTALL ATF TEMPERATURE SENSOR Install the ATF ...

Page 470: ...strainer with the 3 bolts Torque 1 1 N m 110 kgf cm 8 ft lbf 13 INSTALL OIL PAN Instal the oil pan and a new gasket with the 18 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 14 INSTALL DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 15 CONNECT SOLENOID CONNECTOR 16 FILL ATF AND CHECK ATF LEVEL See page Dl 157 17 INSTALL LH ENGINE UNDER COVER AX 7 ...

Page 471: ...ITCH Remove the nut Remove the nut washer and control shift lever Using a screwdriver pry off the lock plate Remove the nut and lock plate Remove the 2 bolts and pull out the park neutral position switch INSTALL AND ADJUST PARK NEUTRAL POSITION SWITCH Install the park neutral position switch with the 2 bolts Torque 5 4 N m 55 kgf cm 48 in Jbf Install a new lock plate and nut Torque 6 9 N m 70 kgf ...

Page 472: ...Torque 12 N m 120 kgf cm 9 ft lbf AX 9 5 CONNECT PARK NEUTRAL POSITION SWITCH CON NECTOR 6 CHECK PARK NEUTRAL POSITION OPERATION Check that the engine can be started with the shift lever only in the N or P position but not in other position If the engine can not be stated not as started above carry out the adjustment procedure Sec page 01 157 7 INSTALL AIR CLEANER ASSEMBLY 8 TEST DRIVE VEHICLE ...

Page 473: ...AN Remove the magnets and use them to collect any steel chips Look carefully at the chips and particles in the pan and on the magnet to anticipate what type ofwearyou wilt find in the trans axle Steel magnctic bearing gear and plate wear Brass non magnetic bushing wear 5 REMOVE OIL STRAINER a Remove the 3 bolts and oil strainer b Remove the 0 ring 6 DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC TORS 7 ...

Page 474: ...RING 11 REMOVE 3 APPLY GASKETS 12 REMOVE SHIFT SOLENOID VALVE Remove the 5 bolts and 5 shift solenoid valves 13 INSTALL SHIFT SOLENOID VALVE Install the 5 shift solenoid valves with the 5 bolts Torque Bolt A 6 6 N m 67 kgf cm 58 in lbf Bolt B 11 N m 110 kgf cm 8 11 lbf Bolt length Bolt A 12 mm 0 47 in Bolt B 45 mm 1 77 in 14 INSTALL APPLY GASKET a Coat 3 new apply gaskets with ATF b Install the ga...

Page 475: ... Boll C 45 mm 1 77 in L _ oo m s c Check that the manual valve lever contacts the center of the roller at the tip of the detent spring d Tighten lhe 1 7 bolls Torque 11 N m 110 kgf cm 8 ft lbf 17 CLAMP WIRE HARNESS TO 2 CLAMPS 18 INSTALL ATF TEMPERATURE SENSOR Install the ATF temperature sensor with the lock plate and bolt Torque 6 6 N m 67 kgf cm 58 in lbf 19 CONNECT5 SHIFT SOLENOIDVALVE CONNECTO...

Page 476: ... AX 13 Install the 3 magnets in the oil pan as shown in the illustration 22 INSTALL OIL PAN Install the oil pan and a new gasket with the 18 bolts Torque 7 8 N m 80 kgf cm 69 ln lbf 23 INSTALL DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 24 FILL ATF AND CHECK ATF LEVEL See page Dl 157 25 INSTALL LH ENGINE UNDER COVER ...

Page 477: ...08 10010 INSTALL LH SIDE OIL SEAL Using SST and a hammer drive in a new oil seaL SST 09350 3201 4 09351 321 50 09950 7001 0 09951 7150 Oil sealdrive in depth 2 7 0 5 mm 0 106 0 020 in Coat the oil seal lip with MP grease INSTALL RH SIDE OIL SEAL Using SST and a hammer drive in a new oil seal SST 09223 0001o Oil seal drive in depth 0 0 5 mm 0 0 020 in Coat the oil seal lip with MP grease INSTALL LH...

Page 478: ...AUTOMATIC TRANSAXLE U240E SHIFT LOCK SYSTEM SHIFT LOCK SYSTEM COMPONENTS StopLightSwitch N ShiftlockControlUnitAssembly AX 15 ...

Page 479: ...YSTEM 005910 Ignition switchON DePressingbrakepedal INSPECTION INSPECT SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter measure the voltage at each terminal HINT Do not disconnect the shift lock control unit assembly cor ec tor MeasuringCondition Voltage V 1 0 1 4 1 0 1 4 ...

Page 480: ...FT ASSEMBLY COMPONENTS Reinforcement InstrumentPanel FrontDoorOpeningTr lm FLOOR SHIFTASSEMBLY LHEndFinishPanel CowlS 1deTrim DoorScuffPlate P B kgi Cr n f btT l Specifiedtorque ConsoleBox AX 17 FrontDoor OpeningTrim Heater Cor1sole arld ...

Page 481: ...LE U240E FLOOR SHIFT ASSEMBLY InstrumentPanel HeaterHoses Clamp SuctionTube Clamp Blc we Unit q Reinforcement No 1Brace P Non reusablepart No 2Brace KeyInterlockCable P N n kgf cm ft lbf I Specifiedtorque FloorShiftAssembly ...

Page 482: ...age Shape Size Sha _ p _ e _ Size Shape Size 0 8 f t 6 L 0 3 lo 3 i R 11 1 in Lo 2 1 0 63 t lF 0 59 i 8 0 87 lf 1 I o s 0 24 L 16 0 63 0 5 22 0 2055 L 16 0 63 1 11 o 6 I 0 24 I_ U L 18 i OJ1 i 0 5 22 0 2055 L 16 0 63 1 l 1 tl 0 5 0 20 L 18 0 71 ICD 0c 5 0 20 L 16 0 63 I lf 1 I 0 5 0 5 0 4 GDi 1 rf 1 11 1 __j_ i ____ _ 11 0 8 0 32 i PL_ L_ __ __ __ __ _L __ __ _L 0 6 0 24 I ...

Page 483: ...ver ShiftLockRelease Butlon Spring 1 LowerPosition Indicatorhousing ShiftLockUnit ShaftControl BulbCap 6 Bulb Precoatedpart Collar IndicatorLampWire Sub assembly ShiftLeverKnob Sleeve ShiftLeverKnob M ShiftLeverKnob JW ButtonGuide 010 MainSwitch I ShiftLeverPlate K ManualDetent Spring ShiftLever Sub assembly 0 l20 ...

Page 484: ...rod of the floor shift as sembly b Pull out the cable while pressing the clip of the key inter lock cable c d 4 a b c With the key in ACC remove the cable cap claw from the key interlock and pull it Disconnect the 2 key interlock cable clamps REMOVE FLOOR SHIFTASSEMBLY Disconnect the 2 connectors Disconnect the 2 wire harness clamps from the floor shift assembly Remove the 4 bolts from the floor s...

Page 485: ...TIC TAANSAXLE U240E FLOOR SHIFTASSEM8LY d e f Remove the cable end from the rod of the floor shift as sembly Pull out the cable while pressing the clip of the transaxle control cable Remove the floor shift assembly ...

Page 486: ...rness b Remove the 0 D main switch c Remove the No 2 slide cover d Remove the shift lever stop pin shift lever knob button shift lever knob button guide and compression spring_ 3 a b C 4 a b c d e REMOVE UPPER POSITION INDICATOR HOUSING Remove the upper position indicator housing Remove the control position mdicator plate_ Remove the 4 slidecoversfrom the lower position indica tor housing REMOVE L...

Page 487: ...ENT SPRING 7 REMOVE SHIFT LEVER SUB ASSEMBLY Using a screwdriver and hammer drive off the shaft contra while disengaging the c aw of the shaft control and remove the shift lever sub assembly_ 8 REMOVE DETENT ROO a Set a 1 4 mm deep socket wrench b Using a punch and hammer remove the grooved pfn c Remove the detent rod and spring d Remove the shift lever knob sleeve from the detent rod 9 REMOVE COL...

Page 488: ...o the detent rod pin hole A 8 0 t 0 2 mm 0 315 0 008 in e Check the detent rod operation 3 INSTALL SHIFT LEVER SUB ASSEMBLY a Apply MP grease on the spring b Install the shift lever sub assembly and shaft control to shift lever plate HINT Checkthat the claw of the shaft control is fit onto the shift lever plate 4 INSTALL MANUAL DETENT SPRING AND SCREW a Apply MP grease to the parts indicated by th...

Page 489: ...hown in the illustration Install the control position indicator plate Install the upper position indicator housing 8 INSTALL SHIFT LEVER KNOB SUB ASSEMBLY a Apply MP grease on the compression spring b Install the compression spring shift lever knob button guide shift lever knob button and shift lever stop pin c Install the No 2 slide cover d Install the 0 0 main switch e Install the shift lever kn...

Page 490: ...he 2 connector 2 INSTALL KEY INTERLOCK CABLE a Pass the key interlock cable end through the hole in the floorshift assembly HINT Make sure that the claws shown by the arrow in the illustration are locked b With the shift lever in N position set the hole of the cable end to the floor shift assembly to assemble them c At the time of reassembly HINT With the key in ACC push a claw into lock key At th...

Page 491: ...tion make sure that the shift ing fever moves smoothly can be moderately operated and the position indicator displays correctly Positions which can be operated without pressing the shift lever knob button R N 7 D 7 M 7 D l 2 0 7 N Positions which can be operated only while pressing the shift lever knob button 0 0 2 L N R 7 P Positions which can be operated only while pressing the shift lever knob ...

Page 492: ...can not be locked Readjust the key interlock cable 7 READJUSTMENT OF KEY INTERLOCK CABLE HINT Assembly shall be undertaker in the same way as step 2 a Using a screwdriver unlock the clawofthe lockkey ofthe automatic adjustment part b Remove the key interlock cable end from the rod of the floor shift assembly c Pull out the cable while pressing the clip of the key inter lock cable e With the key in...

Page 493: ...UNIT COMPONENTS N No 2CylinderHead Cover AirCleanerAssembly 4 9 in L t RadiatorReservoir ForLine PressurePlug SuspensionMe m b LHEngineUnderCover N m kgl C m h lbfj Specifiedtorque Non reusablepart f 60 a16 59 r _ EngmeLeftMountmg Bracket EngmeRearMountmg Insulator SnapRing41J ...

Page 494: ... m 185 kgf cm 13 fl lbf AX 31 8 DISCONNECT CONTROL CABLE FROM CLAMP 9 DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR 10 DISCONNECT COUNTER GEAR SPEED SENSOR CONNECTOR 11 REMOVE VEHICLE SPEED SENSOR CONNECTOR 12 REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE Torque 64 N m 650 kgf cm 47 ft lbf 13 DISCONNECT SOLENOID CONNECTOR AND PARK NEUTRAL POSITION SWITCH CONNECTOR Disconnect the so...

Page 495: ...d starter Torque 37 N m 378 kgf cm 28 11 lbf 17 REMOVE LH RH CENTER ENGINE UNDER COVERS 18 DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque 54 N m 550 kgf cm 40 11 lbf 19 REMOVE LH AND RH DRIVE SHAFTS See page SA 20 20 DISCONNECT LH AND RH STABILIZER BAR LINKS FROM SHOCK ABSORBER Torque 44 N m 450 kgf cm 32 11 lbf 21 REMOVE 4 BOLTS AND DISCONNECT PS GEAR AS SEMBLY HINT Support the PS gear assembly se...

Page 496: ...ENGINE REAR MOUNTING INSULATOR Remove the bolt and engine rear mounting insulator Torque 87 N m 890 kgf cm 64 ft lbt 24 ATTACH ENGINE SLING DEVICE TO ENGINE HANG ERS a Disconnect the 2 PCV hoses b Install the No 1 and No 2 engine hangers in the correct direction Parts No No 1 engine hanger 12281 88600 No 2 engine hanger 12282 88600 Bolt 91512 61020 Torque 38 N m 387 kgf cm 28 fl lbf c Attach the e...

Page 497: ...RTER CLUTCH MOUNT ING BOLT Turn the crankshaft to gain access and remove the 6 bolts hold ing the crankshaft pulley set bolt with a wrench Torque 41 N m 418 kgf cm 30 ft lbf HINT At the time of insta ation please refer to the following item First install black colored bolt and then 5 other bolts 29 REMOVE TRANSAXLE ASSEMBLY a Remove the 4 bolts Torque A bolt 46 N m 470 kgl cm 34 ft lbf B bolt 23 N...

Page 498: ...face and the front surface of the trans axle housing Correct distance More than 13 3 mm 0 524 in 2 TRANSAXLE INSTALLATION Installation is In the reverse order of removal See page AX 31 HINT After installation adjust the shift control cable and park neutral position switch See page 01 157 Fill ATF and check the fluid level See page 01 157 Perform the test drive of the vehicle Adjust the hood See pa...

Page 499: ...the converter and retest the clutch Replace the converter if the clutch still fai s the test 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR a Set up a dial indicator and measure the drive plate runout b Check the damage of the ring gear Maximum runout 0 20 mm 0 0079 in If the runout is not within the specification or ring gear is dam aged replace the drive plate Torque 88 N m 897 kgf cm 65 1l ...

Page 500: ...AUTOMATIC TRANSAXLE U240E TORQUE CONVERTERCLUTCHAND DRIVE PlATE HINT AX 37 Mark the position of the converter clutch to ensure the installa lion is correctly performed ...

Page 501: ... MEMO ...

Page 502: ...DSENSOR AX 3 INPUTTURBINSPEEDSENSOR AX 4 ATFTEMPERATURESENSOR AX 5 PARKINEUTRALPOSITION PNP SWITCH AX 7 VALVEBODYASSEMBLY AX 9 DIFFERENTIALOILSEAL SHIFTLOCKSYSTEM FLOORSHIFTASSEMBLY AUTOMATICTRANSAXLEUNIT TORQUECONVERTERCLUTCH ANDDRIVEPLATE AX 13 AX 14 AX 16 AX 30 AX 36 ...

Page 503: ......

Page 504: ...AUTOMATICTRANSAXLE U341E AUTOMATIC THANSAXLE SYSTEM AUTOMATIC TRANSAXLE SYSTEM PRECAUTION AX 1 If the vehicle is equipped with a mobile communication system refer to the precautions in the IN section ...

Page 505: ...AX 2 AUTOMATIC TAANSAXLE U341E AUTOMATIC TRANSAXLE SYSTEM OPERATION y 1st Brake 83 No 2 Clutch F2 Direct Clutch C2 No 1 Clutch F1 0 D 2nd Brake 82 Brake 81 ...

Page 506: ...edometer driven gear from the vehicle speed sensor Remove the ring from the vehicle speed sensor INSTALL VEHICLE SPEED SENSOR ASSEMBLY Coat a new 0 ring with ATF and install it to the vehicle speed sensor Install the speedometer driven gear to the vehicle speed sensor with clip Install the vehicle speed sensor assembly with the bolt Torque 5 5 N m 56 kgf cm 49 in lbf CONNECT VEHICLE SPEED SENSOR C...

Page 507: ...n speed sensor c Remove the 0 ring from the input turbin speed sensor 5 INSTALL INPUT TURBIN SPEED SENSOR a Coata new0 ring withATFand install ittothe inputturbin speed sensor b Install the input turbin speed sensor with the bolt Torque 5 4 N m 55 kgf cm 48 in lbf c Connect the connector 6 INSTALL ECM BRACKET Torque Bolt 1 8 N m 185 kgf cm 13 ft lbf Nut 12 N m 120 kgf cm 9 ft lbf 7 INSTALL ECM AND...

Page 508: ...iscard the gasket 5 a b 6 7 a b 8 a b 9 REMOVE OIL STRAINER Remove the 3 bolts and oil strainer Remove the 0 ring DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC TORS REMOVE ATF TEMPERATURE SENSOR Remove the bolt and lock plate and remove theATF tem lil perature sensor Remove the 0 ring from the ATF temperature sensor INSTALL ATF TEMPERATURE SENSOR Coat a new ring with ATF and it to the direct clutch spe...

Page 509: ...rainer with the 3 bolts Torque 11 N m 110 kgf cm 8 fl lbf 11 INSTAll OIL PAN Install the oil pan and a new gasket with the 19 bolts Torque 7 8 N m 80 kgf cm 69 in lbf 12 INSTAll DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 13 CONNECT SOLENOID CONNECTOR 14 Fill ATF AND CHECK ATF LEVEL See page Dl 220 15 INSTALL LH ENGINE UNDER COVER ...

Page 510: ...nut Remove the nut washer and control shift lever Using a screwdriver pry off the lock plate Remove the nut and lock plate e Remove the 2 bolts and pull out the park neutral position switch 4 INSTALL AND ADJUST PARK NEUTRAL POSITION SWITCH a Install the park neutral position switch with the 2 bolts Torque 5 4 N m 55 kgf cm 48 in Jbf b Install a new lock plate and nut Torque 6 9 N m 70 kgf cm 61 in...

Page 511: ... shaft Torque 1 2 N m 120 kgf cm 9 ft lbl 5 CONNECT PARK NEUTRAL POSITION SWITCH CON NECTOR 6 CHECK PARK NEUTRAL POSITION OPERATION Checkthat the engine can be startedwith the shift lever only in the N or P position but not in other position If the engine can not be stated not as started above carry out the adjustment procedure See page Dl 220 7 INSTALL AIR CLEANER ASSEMBLY 8 TEST DRIVE VEHICLE ...

Page 512: ... PARTICLES IN OIL PAN Remove the magnets and use them to collect any steel chips Look carefully at the chips and particles in the pan and on the magnet to anticipate whattype ofwear you will find in the trans axle Steel magnetic bearing gear and plate wear Brass non magnetic bushing wear 5 REMOVE OIL STRAINER a Remove the 3 bolts and oil strainer b Remove the Q ring 6 DISCONNECT 5 SHIFT SOLENOID V...

Page 513: ...HECK BALL BODY AND SPRING 10 REMOVE 2 APPLY GASKETS 11 REMOVE SHIFT SOLENOID VALVE Remove the 5 bolts and 5 shift solenoid valves 12 INSTALL SHIFT SOLENOID VALVE Install the 5 shift solenoid valves with the 5 bolts Torque Bolt A 6 6 N m 67 kgl cm 58 in ibf Bolt B 11 N m 110 kgf cm 8 ft lbf Bolt length Bolt A 1 4 mm 0 55 in Bolt B 55 mm 2 17 in 13 INSTALL APPLY GASKET a Coat 2 new apply gaskets wit...

Page 514: ...c Temporarily install the detent spring and cover with the 3 bolts Bolt length Bolt B 45 mm 1 77 1n Bolt C 32 mm 1 26 in Bolt E 14 mm 0 55 in d Check that the manual valve lever contacts the center ot the roller at the tip of the detent spring e Tighten the 1 5 bolts Torque 11 N m 110 kgf cm 8 ft lbf 16 INSTALL ATF TEMPERATURE SENSOR Instal the ATF temperature sensor with the lock plate and bolt T...

Page 515: ...IN OIL PAN Install the 2 magnets in the oil pan as shown in the illustration 20 INSTALL OIL PAN Install the oil pan and a new gasket with the 1 9 bolts Torque 7 8 N m 80 kgf cm 69 1n lbf 21 INSTALL DRAIN PLUG Install a new gasket and drain plug Torque 49 N m 500 kgf cm 36 ft lbf 22 FILL ATF AND CHECK ATF LEVEL See page Dl 220 23 INSTALL LH ENGINE UNDER COVER ...

Page 516: ...IL SEAL Using SST drive out both the side oil seals SST 09308 10010 4 INSTALL LH AND RH SIDE OIL SEAL a Using SST and a hammer drive in a new oil seal p y I SST 1 51 SST 09223 0010 Oil seal drive in depth LH side 2 7 0 5 mm 0 106 0 020 in RH side 0 0 5 mm 0 0 020 in b Coat the oil seal lip with MP grease 103 86 5 INSTALL LH AND RH DRIVE SHAFTS See page SA 32 6 FILL ATF AND CHECK ATF LEVEL See page...

Page 517: ...AX 14 AUTOMATIC TRANSAXLE IU341El SHIFT LOCK SYSTEM COMPONENTS N SHIFTLOCKSYSTEM Shift LockControl Unit Assembly Oil Ht9 ...

Page 518: ...T SHIFT LOCK CONTROL UNIT ASSEMBLY Using a voltmeter measure the voltage at each terminaL HINT Do not disconnect the shift lock control unit assembly connee tor Terminal MeasuringCondition Voltage V 5 1 IG E lgmtion switch ON 10 14 3 1 STP E Depressing brake pedal 10 14 ...

Page 519: ...T ASSEMBLY COMPONENTS No InstrumentPanel FrontDoorOpeningTrim PassengerAirbagAssembly 2 Brace _20 204 1SD LH EndFinishPanel DoorScuffPlate FrontPillarGarnish FrontDoor OpeningTrim DoorScuff Plate Healer Console and n k9f Cr1l i iblf i Specifiedtorque ConsoleBox __j ...

Page 520: ...AUTOMATICTRANSAXLE U341E FlOOR SHIFTASSEMBLY HeaterHoses Clamp Non reusablepart KeyInterlockCable I P f m kgf cm ft lbf Specifiedtorque No 1Brace FloorShiftAssembly AX 17 ilooog ...

Page 521: ...indicated on the previous page Shape C 8 0 32 L 16 I I 0 63 0 6 0 24 L 16 0 63 li I 0 5 22 1 o 2oss I IL 16 0 63 0 5 0 20 L 16 0 63 0 8 0 32 Shape Size _ l f a _ pe _ _____ __ 0 oo 8 0 32 L 1S 0 59 0 6 0 24 L 18 0 71 i I I I P L_ l_ _ _ _ _ _L _ _ J m in Size 0 6 0 24 L 22 0 87 0 5 22 0 2055 L 16 0 63 0 5 0 20 L 16 0 63 0 4 0 16 L 16 0 63 H1 65S ...

Page 522: ...ing i Shift Lever Knob Sleeve Detent Rod Spnng ISh1ft lock Release Bul on Spring Manual Detent Spring Shift lever Knob Button G Shift Lever Knob f Jh Button Guide ltPJ Compression Spring I Shift Lever Stop Pin J7 0 0 Main Swit kl Lower Position Indicator housing Indicator Lamp Wire Sub assembly v Shift Lock Unit Shift lever Plate Collar ...

Page 523: ...d of the floor shift as sembly b Pull out the cable while pressing the clip of the key inter lock cable c With the key in ACC remove the cable cap claw from the key interlock and pull it d Disconnect the 2 key interlock cable clamps 4 REMOVE FLOOR SHIFT ASSEMBLY a Disconnect the 2 connectors b Disconnect the 2 wire harness clamps from the floor shift assembly c Remove the 4 bolts from the floor sh...

Page 524: ...NSAXLE U341E FLQOH SHIFTASSEMBLY AX 21 d Remove the cable end from the rod of the floor shift as sembly e Pull out the cable while pressing the clip of the transaxle control cable f Remove the floor shift assembly ...

Page 525: ...ly unnatural load to OlD main switch wire harness b Remove the OlD main switch c Remove the No 2 slide cover d Remove the shift lever stop pin shift lever knob button shift lever knob button guide and compression spring 3 REMOVE UPPER POSITION INDICATOR HOUSING a Remove the upper position indicator housing b Remove the control position indicator plate c Remove the 3 slide covers from the tower pos...

Page 526: ... a screwdriver and hammer drive off the shaft control while disengaging the claw of the shaft control and remove the shift lever sub assembly 8 REMOVE DETENT ROD a Set a 1 4 mm deep socket wrench b Using a punch and hammer remove the grooved pin c Remove the detent rod and spring d Remove the shift lever knob sleeve from the detent rod 9 REMOVE COLLARS Using a screwdriver and hammer remove the 4 c...

Page 527: ... install the grooved pin to the detent rod pin hole A 8 0 0 2 mm 0 315 0 008 in e Check the detent rod operation 3 INSTAll SHIFT LEVER SUB ASSEMBLY a Apply MP grease on the spring b Install the shift lever sub assembly and shaft control to shift lever plate HINT Check that the claw of the shaftcontrai ls fit onto the shift lever plate 4 a b INSTAll MANUAL DETENT SPRING AND SCREW Apply MP grease to...

Page 528: ...assembly INSTALL UPPER POSITION INDICATOR HOUSING Install the 3 slide covers to the lower position indicator housing as shown in the illustration Install the control position indicator plate Install the upper position indicator housing INSTALL SHIFT LEVER KNOB SUB ASSEMBLY Apply MP grease on the compression spring Install the compression spring shift lever knob button guide shift lever knob button...

Page 529: ...341E FLOOR SHifTASSEMBLY NOTICE Make sure not to catch OlD main switch wire harness 9 INSTALL OlD MAIN SWITCH TERMINAL a Connect the 2 0 D main switch terminals to the connec tor b Connect the connector to the shift lever plate ...

Page 530: ...nnector 2 INSTALL KEY INTERLOCK CABLE a Pass the key interlock cable end through the hole in the floor shift assembly HINT Make sure that the claws shown by the arrow in the illustration are locked b With the shift lever in N position set the hole of the cable end to the floor shift assembly to assemble them c At the time of reassembly HINT With the key in ACC push a claw into lock key At this tim...

Page 531: ...osition make sure that the shift ing lever moves smoothly can be moderately operated and the position indicator displays correctly e 6 a Positions which can be operated without pressing the shift lever knob button R 7 N 7 D 0 L 7 2 7 0 N Positions which can be operated only while pressing the shift lever knob button D 2 1 L N 1 R P Positions which can be operated only while pressing the shift leve...

Page 532: ...djust the key interlock cable 7 READJUSTMENT OF KEY INTERLOCK CABLE HINT Assembly shall be undertaker in the same way as step 2 a Using a screwdriver unlock the claw of the lock key of the automaticadjustment part b Remove the key interlock cable end from the rod of the floorshift assembly c Pull out the cable white pressing the clip of the key inter lock cable d Remove the cable clamp from the ot...

Page 533: ...C TRANSAXLE UNIT COMPONENTS ControlCalble RHEngineUnderCover AUTOMATIC TRANSAXLE UNIT EngineLeftMounting Bracket EngineRearMounting _ J Insulator 7J 90 641J LHEngmeUnderCover I N m__ kQ CrTI J_t_ bl i Specifiedtorque N Non reusablepart 005926 ...

Page 534: ...OUND CABLES Torque 1 8 N m 185 kgf cm 13 ft lbf AX 31 8 DISCONNECT CONTROL CABLE FROM CLAMP 9 DISCONNECT INPUT TURBINE SPEED SENSOR CONNECTOR 10 REMOVE VEHICLE SPEED SENSOR CONNECTOR 11 REMOVE 2 UPPER SIDE TRANSAXLE MOUNTING BOLTS FROM TRANSAXLE Torque 64 N m 650 kgf cm 47 ft lbf 12 DISCONNECT SOLENOID CONNECTOR AND PARK NEUTRAL POSITION SWITCH CONNECTOR Disconnect the solenoid connector and park ...

Page 535: ... 2 bolts and starter Torque 37 N m 378 kgf cm 28 11 lbl 16 REMOVE LH RH CENTER ENGINE UNDER COVERS 17 DRAIN ATF FROM FRONT DIFFERENTIAL CASE Torque 54 N m 550 kgf cm 40 11 lbf 18 REMOVE LH AND RH DRIVE SHAFTS See page SA 20 19 DISCONNECT LH AND RH STABILIZER BAR LINKS FROM SHOCK ABSORBER Torque 44 N m 450 kgf cm 32 ft lbf 20 REMOVE 4 BOLTS AND DISCONNECT PS GEAR AS SEMBLY HINT Support the PS gear ...

Page 536: ... MOUNTING INSULATOR Remove the bolt and engine rear mounting insulator Torque 87 N m 890 kgf cm 64 ft lbf 23 ATTACH ENGINE SLING DEVICE TO ENGINE HANG ERS a Disconnect the 2 PCV hoses b Install the No 1 and No 2 engine hangers in the correct direction Parts No No 1 engine hanger 12281 22021 No 2 engine hanger 12281 15040 or 12281 15050 Bolt 91512 81016 Torque 38 N m 387 kgf cm 28 ft lbf c Attach t...

Page 537: ... MOUNT ING BOLT a Remove the hole plug b Turn the crankshaftto gain access and remove the 6 bolts holding the crankshaft pulley set bolt with a wrench Torque 41 N m 420 kgf cm 25 ft Jbf HINT At the time of installation please refer to the following item First install black colored bolt and then 5 other bolts 28 REMOVE TRANSAXLE ASSEMBLY a Remove the 4 bolts Torque A bolt 46 N m 470 kgf cm 34 fl lb...

Page 538: ...e and the front surface of the trans axle housing Correct distance More than 13 3 mm 0 524 in 2 TRANSAXLE INSTALLATION Installation is in the reverse order of removal See page AX 31 HINT After installation adjust the shift control cable and park neutral position switch See page 01 220 Fill ATF and check the fluid level See page 01 220 Perform the test drive otthe vehicle Adjust the hood See page 8...

Page 539: ...nverter and retest the clutch Replace the converterclutch if the clutch still fails the test 2 MEASURE DRIVE PLATE RUNOUT AND INSPECT RING GEAR a Set up a dial indicator and measure the drive plate runout b Check the damage of the ring gear Maximum runout 0 20 mm 0 0079 ln If the runout is not within the specification or ring gear is dam aged replace the drive plate Torque 78 N m 800 kgf cm 58 ft ...

Page 540: ... AX 37 AliTOMATIC TRAHSAXlE U341 E TORQUE CONVERTER CLUTG lAND OR vt PLAlE HINT Mark the position of the converter clutch to ensure the installa tion is correctly per1ormed ...

Page 541: ......

Page 542: ...BOLT FRONTDRIVESHAFT FRONTSHOCKABSORBER FRONTLOWERSUSPENSIONARM FRONTLOWERBALLJOINT FRONTSTABILIZERBAR REARAXLECARRIER REARWHEELHUBOOLT REARSHOCKABSORBER REARUPPERSUSPENSIONARM REARLOWERSUSPENSIONARM REARSTABILIZERBAR SA 1 SA 2 SA 4 SA 8 SA 11 SA 17 SA 18 SA 33 SA 41 SA 46 SA 50 SA 54 SA 60 SA 61 SA 68 SA 71 SA 75 ...

Page 543: ......

Page 544: ...nt or broken SR 33 6 Suspensioo parts Wom Voh1cte Overloaded 2 Spring Weak SA 33 Bottoming SA 61 3 Shock absorber Wom SA 36 SA 64 T re Worn or lmprop lrly inflated SA 2 2 Slabiliwr bar Bent or broken SA 50 Sways pitchos SA 75 3 Shock absorber Worn SA 36 SA 64 Tiro Worn or improperly inflated SA 2 2 Wheel Out of balance SA 2 3 Shock absorber Worn SA 36 Front wheel shmuny 4 Wheel illigmnent Incorrec...

Page 545: ...95160R15 88H 210 2 1 29 210 2 1 29 P195160R1587H 2ZZ GE engine models Tire size Front R M kPa kgl cm2 psi kPa kgf cm2 psi 205i55R15 87V P205 55F 15 87V 220 2 2 32 220 2 2 32 205 50R16B7V b Using a dial indicator check the tire runou Tire runout 1 0 mm 0 039 in or less 2 ROTATING TIRES HINT See the illustration for where to rotate each tire when you in clude the spare tire in the rotation and when ...

Page 546: ...enter of the axle hub Maximum 0 05 mm 0 0020 in If the backlash exceeds the maximum replace the bearing b Using a dial indicator check the deviation at the surtace of the axle hub outside the hub boiL Maximum 0 07 mm 0 0028 in M J If the deviation exceeds the maximum replace the axle hub 5 CHECK FRONT SUSPENSION FOR LOOSENESS 6 CHECK STEERING LINKAGE FOR LOOSENESS 7 CHECK BALL JOINT FOR LOOSENESS ...

Page 547: ...ear side ower suspension arm suspension member side set boiL NOTICE Before inspecting the wheel alignment adjust the vehicle height to the specified value If the vehicle height is not the specified value try to adjust it by pushing down on or lifting the body INSTALL CAMBER CASTER KINGPIN GAUGE OR POSITION VEHICLE ON WHEEL ALIGNMENT TES TEA Follow the specific instructions of the equipment manufac...

Page 548: ...5 45 0 15 or less 29 45 D 48 0 75 45 0 75 or tess 2 02 45 2 03 0 75 45 0 15 or less 13 12 45 13 20 0 75 45 0 75 or less If the caster and steenng ax1s mcllnat1on are not w1thm the spe cified values after the camber has been correctly adjusted re check the suspension parts for damaged and or worn out parts 4 ADJUST CAMBER NOTICE After the camber has been adjusted inspect the toe in a Remove the fro...

Page 549: ...specified value using the follow ing table estimate how much additional camber adjustment will be required and select the camber adjusting bolt SetBolt Bolt 90105 15001 Adjusting 0 Valuo 1 2 15 30 i l 45 1 oo 1 15 1 30 Adjusting Bolt 90105 15004 1Dot e 1 2 r 90105 15005 2Dots i e 1 2 j f 90105 15006 3Dots e 1 2 fOll95 i Do the steps mentioned above again Between step b and c replace 1 or 2 selecte...

Page 550: ... 74 N m 750 kgf cm 54 ft lbf f Place the boots on the seats and install the clips HINT Make sure that the boots are not twisted 7 INSPECT WHEEL ANGLE Turn the steering wheel fully and measure the turning angle Wheel turning angle 195 60R15 P195 60R15 tire Inside wheel 38 41 0 2 38 68 t 2 Outside wheel Ae erence 33 20 33 33 205 55R15 P205 55R15 ttre lns1de wheel 38 46 2 38 77 t 2 Outside wheel Refe...

Page 551: ...f l 0 18 12 0 3 0 2 total C 0 3 mm 0 1 2 0 08in If the toe in is not within the specified value see step 5 to ad just 5 ADJUST CAMBER AND TOE IN a Measure the distance from the LH lower suspension arm bracketset bolt to the RH axle carrier rear side set bolt as shown in the illustration b Employ the same manner to the RH LH Length difference 6 mm or less If it exceeds the specified value adjust it...

Page 552: ...e Camber 1 11 1 18 Toe in total IN 3mm 0 12 in Formula A B C Camber RH 1 11 0 26 0 45 Camber LH 1 11 1 56 0 45 Toe In total IN3 IN7 OUT 4 Toe in each side OUT 2 c Asshown in the example chart read the distance from the marked point to the origin of the chart and adjust the up perand or lower arm adjusting earns accordingly Amount to turn adjusting cams by graduation Upper arm cam AH Inward 3 2 Low...

Page 553: ...SA 10 Camber Toe in Outward p SUSPENSIONANDAXLE REAR WHEELALIGNMENT J I 01 I 1 1 l l 1 1 s1 1 I r l I i I I I Upperarmcamgraduation Inward I Outward No 01 Lowerarmcamgraduation Inward ...

Page 554: ... FRONT AXLE HUB COMPONENTS DriveShaft I BrakeCaliper p SnapRing CotterPin L 03 l _ _ N 3k m Specifiedtorque N Non feusablepart FrontShockAbsorber SteeringKnuckle LowerBallJo1nt Drsc LockNut 2 200 159 J OustCover SA 11 AxleHub o ooo2s ...

Page 555: ... bearing d Using a dial indicator check the deviation at the surface of the axle hub outside the hub bolt Maximum 0 07 mm 0 0028 in If the deviation exceeds the maximum replace the axle hub e Install the disc 2 bolts and brake caliper Torque 107 N m 1 090 kgf cm 79 ft lbf 3 REMOVE DRIVE SHAFT LOCK NUT a Using SST and a hammer unstake the staked part of the lock nut SST 09930 D0010 b While applying...

Page 556: ...n arenot aligned tighten the nut further up to 60 b Using SST disconnect the tie rod end from the steering knuckle SST 09610 20012 7 DISCONNECT LOWER SUSPENSION ARM FROM LOWER BALL JOINT Remove the 2 nuts and bolt Torque 142 N m 1 450 kgf cm 105 ft lbt B REMOVE STEERING KNUCKLE WITH AXLE HUB a Remove the 2 bolts and nuts on the lower side of the shock absorber HINT At the time of installation coat...

Page 557: ...20 b Using SST and a press remove the inner race outside from the axle hub SST 09555 55010 09950 6001 0 09951 00380 09950 70010 09951 7150 3 REMOVE DUST COVER Using a torx socket T30 remove the 3 bolts and dust cover 4 REMOVE BEARING FROM STEERING KNUCKLE a Using snap ring pliers remove the snap ring b Place the inner race on the outside of the bearing c Using SST and a press remove the bearing SS...

Page 558: ...Place the dust cover and using a torx socket T30 install the 3 bolts Torque 8 3 N m 85 kgf cm 74 in lbl 3 INSTALL FRONT AXLE HUB Using SST and a press install the axle hub SST 09608 32010 0995 60010 09951 D0550 0995 70010 09951 D7150 4 INSTALL LOWER BALL JOINT a Install the lower ball joint and tighten the nut Torque 103 N m 1 050 kgf cm 76 ft lbf b Install a new cotter pin If the holes for the co...

Page 559: ...ATION SUSPENSION ANDAXLE FRONTAXLE HUB Installation is In the reverse order of removal See page SA 12 HINT After installation check the ABS speed sensor signal See page Dl 276 and front wheel alignment See page SA 4 ...

Page 560: ... a screwdriver or an equivalent remove the hub boiL SST 09628 10011 4 INSTALL HUB BOLT a Install a washer and nut to a new hub bolt as shown in the illustration b Using a screwdriver or an equivalent to hold install the hub bolt by torquing the nut c Remove the 3 nuts and washer 5 INSTALL DISC AND BRAKE CALIPER Install the disc brake caliper and 2 bolts Torque 107 N m 1 090 kgf cm 79 ft lbf 6 INST...

Page 561: ...SA 18 SUSPENSIONAND AXLE FRONTDRIVESHAFT FRONT DRIVE SHAFT COMPONENTS 1ZZ FE engine MIT and 2ZZ GE engine N kgf c ft lb J Specified torque N Non reusable part _cc ow ...

Page 562: ... SHAFT SnapRing Clamp Boot SA 19 CenterBearing f 1 I f0 0 StraightPin l Outboard JointShaft InboardJointShaft Clamp InboardJointShaft i DustCover N I N m kgf cm ft lbf J Specifiedtorque Non reusablepart ___ j snapRing 1 S CenterBearingCaseI DustCover ...

Page 563: ...peed sensor rotor serrations on the drive shaft REMOVE FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 ft lbf REMOVE ENGINE UNDER COVER DRAIN GEAR OIL MIT OR ATF AfT 4 REMOVE DRIVE SHAFT LOCK NUT a Using SST and a hammer unstake the staked part of the lock nut SST 0993 0001 0 b While applying the brakes remove the nut Torque 216 N m 2 200 kgf cm 159 ft lbf 5 DISCONNECT TIE ROD END FROM STEERING KNUCKLE...

Page 564: ... and dust cover 9 LH drive shaft REMOVE DRIVE SHAFT a Using SST remove the drive shaft SST 09520 01010 09520 2401 0 09520 32040 NOTICE Be careful not to damage the oil seal and dust cover HINT At the time of installation please refer to the following items Apply gear oil to the inboard joint shaft and differential case sliding surfaces Before installing the drive shaft set the snap ring with its o...

Page 565: ...boots for damage b Remove the inboard and outboard joint boot clamps 1 Using a screwdriver disclamp the 2 inboard joint boot clamps 2 Using a side cutter cut the 2 outboard joint boot clamps and remove them c MIT Remove the dynamic damper clamp Using a screwdriver disclamp the dynamic damper clamp d Remove the inboard joint shaft 1 Slide the inboard joint boot toward the outboard joint r j 2 Place...

Page 566: ...s and inboard joint clamps NOTICE Do not disassemble the outboard joint 2 1ZZ FE engine AfT DISASSEMBLE DRIVE SHAFT a Check the drive shaft 1 Check to see that there is no remarkable play in the outboard joint 2 Check to see that the inboard joint slides smoothly in the thrust direction 3 Check to see that there is no remarkable play in the radial direction of the 1nboard joint 4 Check the boots f...

Page 567: ...ot punch the marks 3 Using a brass bar and hammer remove the tripod from the outboard joint shaft NOTICE Do not tap the roller e Remove the inboard and outboard joint boots and in board joint clamps NOTICE Do not disassemble the out board joint 3 DISASSEMBLE INBOARD JOINT SHAFT a LH Remove the dust cover Using SST and a press remove the dust cover SST 0995G 00020 b LH shaft of 1ZZ FE engine Mrf an...

Page 568: ...r remove the outside snap ring 2 Using a press remove the center bearing case 3 Using a pin punch and hammer remove the straight pin from the center bearing case 4 SST 5 Using SST and a press remove the dust cover 09950 00020 Using a snap ringexpander remove the inside snap ring 6 Using a press remove the center bearing ...

Page 569: ...er bearing case 2 Using SST and a press install a newcenter bearing into the bearing case SST 0995 60010 09951 00650 09950 7001 0 09951 07150 3 Using a screwdriver install a new outside snap ring 4 SST 5 Using SST and a press instal the center bearing with the bearing case assembly to the inboard joint shaft 09710 30021 09710 03141 Using a snap ring expander install a new inside snap ring 6 Using ...

Page 570: ...e2 newclamps on a newinboard jointbootand install them to the outboard joint shaft b Install the tripod 1 Place the beveled side of the tripod axial spline to ward the outboard joint 2 Align the matchmarks placed before removal 3 Using a brass bar and t1ammer lap in the tripod to the outboard joint shaft NOTICE Do not tap the roller 4 Using a snap ring expander install a new snap ring c Install th...

Page 571: ...521 24010 Tighten the SSTso that the large clamp is pinched NOTICE Do not overtighten the SST 7 Using SST adjust the clearance of the large clamp SST 09240 00020 Clearance 0 8 mm 0 031 in or less 8 Employ the same manner to the outboard joint small boot clamp 3 1ZZ FE engine Mff and 2ZZ GE engine REASSEMBLE DRIVE SHAFT a Temporarily install dynamic damper MIT new outboard and inboard joint boots a...

Page 572: ...race HINT 4 Using a snap ring expander install a new snap ring 5 6 7 Align the matchmarks on the cage and inner race Install the cage to the inner race Install the 6 balls Apply grease onto the balls to keep them from falling c Install the boot to outboard joint Before assembling the boot pack the outboard joint and boot with grease in the boot kit 4 Grease capacity Color Black 115 135 g 4 1 4 8 o...

Page 573: ...etched or con tracted when the drive shaft is at standard length Drive shaft standard length RH 845 5 t 5 0 mm 33 287 0 197 in LH 563 7 5 0 mm 22 193 0 197 in 3 Bend the band and lock the Inboard JOint boot clamps with a screwdriver 4 5 SST 6 NOTICE Secure the 2 outboard joint boot clamps onto the boot Place SST onto the outboardjoint large boot clamp 09521 24010 Tighten the SST so thatthe large c...

Page 574: ...HAFT f08679 f MIT 4 Assemble the dynamic damper clamp 1 Set the dynamic damperdistance as described be low Distance 155 0 2 0 mm 6 102 0 079 1n 2 Bend the band and lockthe dynamicdamperclamp with a screwdriver CHECK DRIVE SHAFT See page SA 22 ...

Page 575: ...TION SUSPENSION AND AXLE FRONTDRIVE SHAFT Installation is in the reverse order removal See page SA 20 HINT After installation check the ABS speed sensor signal See page 01 276 and front wheel alignment See page SA 4 ...

Page 576: ...ENTS 9 400 29 r Fl I o cap 1 _ _ 4 75 _ 4 q 1 I 1 I 1 I SuspensionSupport OustSeal SpringSeat UpperInsulator StabilizerBarLink FlexibleHose I I I I I r N 0 _ k9 il Specifiedtorque N Non reusablepart ShockAbsorber withCoilSpring li it SpringBumper LowerInsulator SA 33 ...

Page 577: ...BAR LINK Remove the nut and disconnect the stabilizer bar link from the shockabsorber Torque 44 N m 449 kgf cm 32 ft lbf HINT I the balljointturns togetherwith the nut use a hexagon 5 mm wrench to hold the stud 5 REMOVE SHOCK ABSORBER WITH COIL SPRING a Loosen the 2 nuts on the lower side of shock absorber Torque 153 N m 1 560 kgf cm 113 ft lbf HINT Do not remove the 2 bolts b Remove the 3 nuts on...

Page 578: ... vise b Using SST compress the coH spring SST 09727 30021 09727 00010 09727 0002 1 09727 00031 NOTICE Do not use an impact wrench It will damage the SST c Remove the cap from the suspension support d Using SST to hold the spring seat remove the nut SST 09729 22031 e Remove the suspension support dust seal spring seat upper insulator coil spring spring bumper and lowerinsu lator ...

Page 579: ...SA 36 SUSPENSION AND AXLE FnONTSHOCK ABSORBER ...

Page 580: ...LY EXTEND SHOCKABSORBER ROD 2 DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill make a hole in the cylinder asshown in the illustra tion to discharge the gas inside CAUTION When drilling chips may fly out work carefully The gas is colorless odorless and non poisonous ...

Page 581: ...It will damage the SST b Install the coil spring to the shock absorber HINT Fit the lower end of the coil spring into the gap of the spring low er seat c Install the upper insulator as shown in the illustration d e f Install the spring seat to the shock absorber with the D mark facing to the outside ofthe vehicle Install the dust seal and suspension support Using SST to hold the suspension support...

Page 582: ...Q Q T il SUSPENSION AND AXLE fHONf SHOCK A8SORBER h Apply MP grease mto the suspension support i Install the cap _ SA 39 ...

Page 583: ...SA 40 INSTALLATION SUSPENSIONAND AXLE FRONT SHOCKABSORBER Installation is in the reverse order of removal See page SA 34 HINT After installation check the front wheel alignment See page SA 4 ...

Page 584: ...SUSPENSION ANDAXLE FRONT LOWERSUSPENSIONARM FRONT LOWER SUSPENSION ARM COMPONENTS Engine Rear Mount N Non reusable part PSGear Assembly SA 41 ...

Page 585: ...er suspension arm Torque 137 N m 11397 kgf cm 101 ft fbf HINT At the time of installation after stabilizing the suspension torque the bolts 3 AfT LH side REMOVE LOWER SUSPENSION ARM a Remove the engine under covers b Disconnect the RH and LH tie rod ends 1 Remove the cotter pin and nut Torque 49 N m 500 kgf cm 36 ft lbf HINT At the time of installation lf the holes for a new cotterp m are not alig...

Page 586: ...loy the same manner described above to the other side_ e Loosen the lower suspension arm set bolts Torque 137 N m 1 397 kgf cm 101 ft lbf HINT At the time of installation after stabilizing the suspension torque the bolts f Remove the engine hood See page B0 9 g Attach the engine sling device to the engine hangers 1 Disconnect the 2 PCV hoses 2 Install the No 1 and No 2 eng 1ne hangers In the corre...

Page 587: ...i Remove the bolt A and 3 nuts and disconnect the engine rear mount Torque 52 N m 530 kgf cm 38 11 lbl 0 Remove the 2 bolts B and disconnect the engine front mount Torque 52 N m 530 kgf cm 38 11 lbl k Using a transmission jack support the suspension mem ber I Remove the 6 bolts C and D and lower the suspension member Torque Bolt C 157 N m 1 600 kgf cm 116 11 lbl Bolt D 39 N m 400 kgf cm 29 11 lbl ...

Page 588: ...INSTALLATION SUSPENSIONANDAXLE FRONf LOWER SUSPENSION ARM Installation is In the reverse order of removal See page SA 42 HINT After installation check the front wheel alignment See page SA 4 SA 45 ...

Page 589: ...SA 46 SUSPENSION ANDAXLE FRONT LOWER BALL JOINT COMPONENTS CotterPin J Brake Caliper FRONTLOWER BALL JOINT Disc 01 LockNut j 216 2 2000WD ...

Page 590: ...ENSION AND AXLE FRONT l_OWtR BALLJOINI REMOVAL 1 REMOVE STEERING KNUCKLE WITH AXLE HUB 5ee page SA 12 2 REMOVE LOWER BALL JOINT a Remove the cotter pin and nut b Using SST remove the lower ball joint SST 09628 62011 ...

Page 591: ...s shown in the illustration flip the balljoint studback and forth 5 times before installing the nut Using a torque wrench turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn L _ _ _ _ _ _ _ _ _ _ _ __c co 8 Turning torque 1 0 4 9 N m 10 50 kgf cm 8 7 43 in lbf ...

Page 592: ...ighten the nut Torque 103 N m 1 050 kgf cm 76 ft lbl b Install a new cotter pin SA 49 If the holes for the cotter pin are not aligned tighten the nut fur ther up to 60 Q 2 INSTALL STEERING KNUCKLE WITH AXLE HUB See page SA 16 3 CHECK ABS SPEED SENSOR SIGNAL See page Dl 276 4 CHECK FRONT WHEEL ALIGNMENT See page SA 4 ...

Page 593: ...50 SUSPENSION AND AXLE FRONT STABILIZER BAR COMPONENTS FRONTSTABIUZEA BAR EngineHood StabilizerBarLink 449 32 EngineRearMount J_ Specifiedtorque H Ji rr il 4 Bracket t Bushing PSGearAssembly StabilizerBar ...

Page 594: ... to the other c 22 side N FG8f 58 2 REMOVE FRONTSUSPENSION MEMBERWITH LOW ER SUSPENSION ARM See page SA 42 3 REMOVE STABILIZER BAR a Remove the 2 bolls bracket and bushing Torque 1 9 N m 194 kgf cm 14 11 lbf HINT At the time of installation please refer to the following items Install the bushing so that the cutout will face to the rear Install the bushing to the outside of the paint line on the st...

Page 595: ...OR ROTA TION CONDITION a As shown in the illustration flip the ba ljointstud back and forth 5 times before installing the nut b Using a torque wrench turn the nul continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn Turning torque 0 05 1 0 N m 0 5 10 kgf cm 0 4 8 7 ln lbf ...

Page 596: ...SUSPENSIONAND AXLE FRONT STABILIZER BAR INSTALLATION i Installation is in the reverse order of removal See page SA 51 HINT After installation check the front wheel alignment See page SA 4 SA 53 ...

Page 597: ...XLE CARRIER COMPONENTS UpperSuspensionArm I L 755 wlABS ABSSpeed_ Sensor Connector liil J C _l _ lbLJ Specifiedtorque N Non reusable part CarnBolt HEAR AXLE CARA ER AxleHubAssembly Drum 1 b r v Disc I w ABS ABSSpeedSensor V __ AxleHub ...

Page 598: ...Maximum 0 05 mm 0 0020 in If the backlash exceeds the maximum replace the axle hub b Using a dial indicator check the deviation at the surface of the axle hub outside the hub boll Maximum 0 07 mm 0 0028 in If the deviation exceeds the maximum replace the axle hub 5 wl ABS DISCONNECT ABS SPEED SENSOR CONNECTOR 6 REMOVE REAR AXLE HUB a Remove the 4 bolts and axle hub assembly Torque 56 N m 571 kgf c...

Page 599: ...orque ttle bolt 9 REMOVE REAR AXLE CARRIER a Remove the front side bolt and nut of the lower suspen sian arm Torque 74 N m 755 kgf cm 55 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut b Place matchmarks on both the cam plate and lower sus pension arm c Remove the nut earn plate and cam bolt Torque 74 N m 755 kgf cm 55 ft lbl HINT At the time of installation...

Page 600: ... axle hub assembly if it is dropped or a strong shock is given to it c Using SST and 2 bolts Diameter 12 mm Pitch 1 5 mm remove the ABS speed sensor SST 09520 00031 09520 00040 09521 0020 09950 00020 NOTICE Do not allow any foreign matter sticking to the sensor rotor Pull out the ABS speed sensor straightly not to dam age the sensor rotor If damage has occurred to the sensor rotor replace the axle...

Page 601: ...sticking to thesensorrotor b Place the ABS speed sensor on the axle hub so that the connector is set at the bottom under the on vehicle condi tion c Using SST and a press install a new ASS speed sensor to the axle hub SST 09214 76011 NOTICE Do not tap the speed sensor with a hammer directly Check that there should be no foreign matter on the speed sensor detection portion Press in the ABS speed se...

Page 602: ...SPENSION AND AXLE REAR AXLE CARnlER Installation is In the reverse order of removal See page SA 55 HINT SA 59 After installation check the ASS speed sensor signal See page Dl 276 and rear wheel alignment See page SA 8 ...

Page 603: ...4 REMOVE HUB BOLT Using SST and a brass bar remove the hub bolt SST 09628 10011 5 INSTALL HUB BOLT a Install a washer and nut to a new hub bolt as shown in the illustration b Using a brass bar to hold instal the hub bolt by torquing the nut 6 w Drum brake INSTALL BRAKE DRUM 7 w Disc brake INSTALL DISC AND BRAKE CALIPER Install the disc and brake caliper and 2 bolts Torque 47 N m 475 kgf cm J4 ft l...

Page 604: ...earDeckTrimCover LuggageCompartmentMat I 0 Ring Sprmg d i 4 3 440 32 _j ShockAbsorberwith CoilSpring N m kQfC m fHbl Specifiedtorque N Non reusabi p art DeckTrimSidePanel J _ _ _ LJ Cushion SptingBmcket UpperInsulator 1 __ Suspension Support l SpringBumper CoilSpting ShockAbsorber ...

Page 605: ...0 kgf cm 76 11 1bl 2 REMOVE PACKAGE TRAY TRIM 3 REMOVE LUGGAGE COMPARTMENT MAT 4 REMOVE REAR DECK TRIM COVER 5 REMOVE DECK TRIM SIDE PANEL 6 REMOVE REAR LOWER SUSPENSION ARM See page SA 72 7 REMOVE REAR SHOCK ABSORBER Remove the 3 nuts and rear shock absorber Torque 80 N m 816 kgf cm 59 ft lbf ...

Page 606: ...il spring SA 63 SST 09727 30021 09727 0001 0 09727 00021 09727 0031 NOTICE Do not use an impact wrench It will damage the SST b c Using a 6 mm hexagon wrench to hold the piston rod re move the nut Remove the washer cushion spring bracket upperinsu later suspension support spring bumper and coil spring ...

Page 607: ...ER f Compress and extend the shock absorber rod and check that there is no abnormal resistanceor unusual sound during opera tion 8 If there is any abnormality replace the shock absorber witt a _ new one NOTICE LC J When disposing of the shock absorber see DISPOSAL on page SA 1l5 ...

Page 608: ...TEND SHOCK ABSORBER ROD 2 DRILL HOLE TO DISCHARGE GAS FROM CYLINDER Using a drill make a holein the cylinder as shown in theillustra tion to discharge the gas inside CAUTION When drilling chips may fly out work carefully The gas is colorless odorless and non poisonous ...

Page 609: ...e coil spring into the gap of the spring low er seat 2 INSTALL SPRING BUMPER AND SUSPENSION SUP PORT 3 INSTALL SPRING BRACKET a Set the upper insulator to the spring bracket b Position the spring bracketwith upper insulator as shown in the illustration c Install the cushion and washer d Temporarily tighten the center nuL e Remove the SST SST 09727 30021 09727 0001 0 09727 00021 09727 00031 f Reche...

Page 610: ... INSTALLATION SUSPENSIONANDAXLE REARSHOCK ABSORBER Installation is in the reverse order of removal See page SA 62 HINT After installation check the rear wheel alignment See page SA 8 SA 67 ...

Page 611: ...LE REAR UPPER SUSPENSION ARM REAR UPPER SUSPENSION ARM COMPONENTS HeatInsulator 1 1 I CamBolt CamPlate 17 J lUppe SuspensionA m r I J GJr 1 L J 5s ss SuspensionMember N n kg I_ _Cm 11 fbt J Specifiedtorque N Non reusablepart ...

Page 612: ...4 bolts and heat insulator 3 REMOVE UPPER SUSPENSION ARM a Place matchmarks on both the cam plate and suspension member b Remove the nut cam plate and cam bolt Torque 74 N m 755 kgf cm 55 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut c Remove the bolt nut and upper suspension arm Torque 74 N m 755 kgf cm 55 ft lbt NOTICE Do not turn the nut HINT At the tim...

Page 613: ...SA 70 INSTALLATION SUSPENSION AND AXLE REAli UPPER SUSPFNSIONARM Installation is in the reverse order of removal See page SA 69 HINT After installation check the rear wheel alignment See page SA 8 ...

Page 614: ...S Gasket i t j ___ Lng cc1 c r _ c i v L o 0 _ 7 5 4 55 48in lbf Tailpipe t _ ParkingBrakeCa LowerSuspensionArm ll l lb J 1 426 1 03 ASSSpeedSe J H ness 19 194 14 SA 71 Stoppec SuspenS on Acm cacke i n C _ _ _ _ t I i 3 l ni kgf cm D illJ Sp ifiedtorque Notl feusablepart N Cam Bolt ...

Page 615: ...ARKING BRAKE CABLE CLAMP Remove the 2 bolts and disconnect the parking brake cable clamps Torque 5 4 N m 55 kgf cm 48 in lbf 5 LOOSEN 3 BOLTS ON FRONT SIDE OF LOWER SUS PENSION ARM Torque 65 N m 663 kgf cm 48 lt lbf HINT Do not remove the bolts At the time of installation after stabilizing the suspension torque the bolts 6 DISCONNECT REAR AXLE CARRIER FROM LOWER SUSPENSION ARM a Remove the front s...

Page 616: ...gf cm 103 ft lbf NOTICE Do not turn the nut HINT At the time of installation after stabilizing the suspension torque the bolt 8 REMOVE LOWER SUSPENSION ARM a Remove the bolt and nut on the rear side oflowersuspen sion arm Torque 74 N m 755 kgf cm 55 ft lbf HINT At the time of installation after stabilizing the suspension torque the nut b Remove the front side 3 bolts and lower suspension arm 9 REM...

Page 617: ...SA 74 INSTALLATION SUSPENSIONAND AXLE REAR LOWER SUSPENSIONARM Installation is in the reverse order of removal See page SA 72 HINT After installation check the rear wheel alignment See page SA 8 ...

Page 618: ...R REAR STABILIZER BAR COMPONENTS SA 75 Bushing c JJ Bracket 44 449 B __j I StabilizerBarLink I H__ iii r 43 r i2l J fl r O Aing IL Spnng Tailpipe N m kQ ft lbf _ Specifiedtorque N Nort reusablepart If __ i B us h ng 1 Bracket t 44 449 32 ...

Page 619: ...he 2 nuts and stabilizer bar link Torque 44 N m 449 kgt cm 32 ft lbf HINT If the balljointturns togetherwiththe nul use a hexagon 5 mm wrench to hold the stud b Employ the same manner described above to the other side 4 REMOVE STABILIZER BAA BRACKETS AND BUSH INGS a Remove the 2 bolts bracket and bushing Torque 18 N m 184 kgf cm 13 ft lbf HINT At the time of installation instal the bushing to the ...

Page 620: ...A TION CONDITION a As shown in the illustration flipthe ball joint stud backand forth 5 times before installing the nut b Using a torque wrench turn the nut continuously at a rate of 2 4 seconds per 1 turn and take the torque reading on the 5th turn Turning torque 0 05 1 0 N m 0 5 10 kg em 0 4 8 7 in lbf ...

Page 621: ...SA 78 SUSPENSIONAND AXLE REAR STABlUZEA BAR INSTALLATION Installation Is in the reverse order of removal See page SA 76 ...

Page 622: ...RAKELEVER BR 8 BRAKEMASTERCYLINDER BR 9 BRAKEBOOSTERASSEMBLY BH 13 FRONTBRAKEPAD BR 17 FRONTBRAKECALIPER_ BR 20 REARDRUMBRAKE BR 8 REARBRAKEPAD BR 33 REARBRAKECALIPER BR 36 PARKINGBRAKE BR 42 PROPORTIONINGVALVE PVALVE BR 47 ABSACTUATOR BR 413 FRONTSPEEDSENSOR 8R G5 REARSPEEDSENSOR BR 58 ...

Page 623: ......

Page 624: ...e performance ofthe brake system and result in a driving hazard Replace the parts with parts of the same part number or equivalent It is very important to keep parts and the area clean when repairing the brake system If the vehicle is equipped wlth a mobile communication system refer to the precaution in the IN section ...

Page 625: ...h rod Out of adju tment BA 16 1 Brake pedal lreeplay Minimum BR 2 Pa l ing txake lever travel Out of adjustment BR B 3 Parking brake wire Slicking 4 Rear brake shoe clearance Outof adjustment BR 32 BR 46 5 Padorlining Cracked or distorlod BA 17 BR 33 BR 28 BR 42 6 Piston Stuck BA 20 Brake drag BR 36 BR 28 7 Piston Froz en BR 20 BR 36 BR 28 8 And or tension or return spring Faulty BR 28 BA 42 9 Boo...

Page 626: ... BR 17 BR 33 BR 28 BR 42 8 Drsc Scored R 24 81 l 39 9 Boosterpush rod Out of adjustment Bfl 16 lO Vacuum leaks for boostersystem BR 13 Pad orlining Crackedordistorlod BR 17 BR 33 BR 28 BR 42 2 lnstal atiml bolt loose BH 20 BR 36 3 Disc Scmed BR 24 BR 39 Pad support plate tloose BR 17 5 Sliding pin Worn BR 20 6 Padorlining Dirty BR 17 Noise from brakes BR 33 BA 28 BR 42 7_ Pad or lining Glazed BR 1...

Page 627: ...mes empty bleed the air from the master cylinder a Disconnect the brake lines from the master cylinder SST 09023 001 00 b Slowly depress the brake pedal and hold it c d 4 a b c d e Block off the outlet plug with your linger and release the brake pedal Repeat b and c 3 or 4 times BLEED BRAKE LINE Connect the vinyl tube to the caliper Depress the brake pedal several times then loosen the bleeder plu...

Page 628: ... BRAKE BRAKE FLUID 5 CHECK FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid if necessary Fluid SAE J1703 or FMVSS No 116 DOT3 BR 5 ...

Page 629: ...0 0 59 in turn the stop light switch to lock the nut in the position where the stop light goes off Push the brake pedal in5 1 5 mm 0 20 0 59 in check that stop light lights up After adjusting the pedal height check the pedal lreeplay 3 CHECK PEDAL FREEPLAY a Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster b Push in the pedal until the beg...

Page 630: ...S AfT PedalBracket Clev1s BRAKE BRAKE P DAL p StopLightSwitch __ BrakePedal PedalPad BrakePedal i N ndkgl cm fl iblfi Specifiedtorque N c n reUSabTetari N Lithiumsoapbaseglycolgrease PedalPad i BA 7 CushionPlate ...

Page 631: ... adjust the parking brake Lock Nut Adjusting Nut A093H 2 IF NECESSARY ADJUST PARKING BRAKE HINT Before adjusting the parking brake make sure that the rear brake shoe clearance has been adjusted For shoe clearance adjustment see step 1 on page BR 45 or see step 2 on page BR 32 a Remove the console box b Loosen the lock nut and turn the adjusting nut unti the le ver travel is correct c Tighten the l...

Page 632: ...Brake Rooster Battery cJ Cap Q ___ strainer J Level W rning I Switch Connector _1 5_ _1 0 I MiT I J Reservoir L____ A r Reservo1r rommet V ReservoirStopper I I c I Grommet Cylioder Body N O j_ k Q J c c cc m c ttco lb QJ Specified torque Non reusable part N Lithium soap base glycol greC so BR 9 f 0 520 ...

Page 633: ...ST disconnect the 5 brake lines from the master cylinder and 3 way union SST 09023 00100 Torque 15 N m 155 kgf cm 11 ft lbf b w ABS Using SST disconnect the 2 brake lines from the master cylinder SST 09023 001 00 Torque 15 N m 155 kgf cm 11 H lbf 6 REMOVE MASTER CYLINDER a b c d Remove the 2 mounding nuts Torque 1 3 N m 130 kgf cm 9 H lbf w o ABS Pull out the check valve bracket 3 way and master c...

Page 634: ...a Pull out the reservoir stopper HINT BR 11 Atthetimeof installation make suretoinsertthe reservoirstop per through holes of the reservoir and the master cylinder groove b Remove the rese Voir and 2 grommets c Remove the cap and strainer from the reservoir ...

Page 635: ...rse order of removal See page BR 10 HINT Before installation adjust length of brake booster push rod See page BR 16 Y After installation fill thebrake reservoir with brake fluid bleed the brake system See page BR 4 and check for leaks Check and adjustbrake pedal See page BR 6 ...

Page 636: ...f the pedal goes down slightly operation is normal 2 AIR TIGHTNESS CHECK a Start the engine and stop it after 1 or 2 minutes Depress the brake pedal several limes slowly If the pedal goes down farthest the 1st time but gradually rises after the 2nd or 3rd time the booster is air tight b Depress the brake pedal white the engine is running and stop the engine with the pedal depressed If there is no ...

Page 637: ...OMPONENTS Hold downClamp BatteryTray ECM f w f __ _w ECMBracket N li Q cm lt lbt l Non Specifiedtorque N reusablepart BRAKE _ STERASSFM BLY BRAKE BOO AABSActuator ssemb y Clamp FrontLH BrakeLine LowerNo1p ane ...

Page 638: ...REMOVE ABS ACTUATOR ASSEMBLY See page BR 53 REMOVE FRONT LH BRAKE LINE Using SST and spanner disconnect the brake line from the flexible hose of front LH brake_ SST 09751 36011 Pull out the brake line with the grommet from the body REMOVE BRAKE BOOSTER Remove the lower No 1 panel and finish panel Remove the return spring clip and clevis pin c Remove the clevis and 4 nuts d Pull out the brake boost...

Page 639: ...accessory tooL b Place the accessory tool to the brake booster c Measure the clearance between the brake booster push rod and accessory tool Clearance 0 mm 0 in HINT Adjust the clearance in following cases If there is a clearance between the accessory tool and the shell of the booster floating accessory tool the clear ance is small 1f the chalk does not stick on the tip of the push rod the clearan...

Page 640: ... Shim b 1 ZZ FE engine Anti squeal Shim BRAKE H ONT BRAKE PAD Anti squeal Shim Pad Support Plate Inner Anti squeal Shim Outer Pad 1 1 Inner Anti squeal Shim Anti squeal Shim Pad Support Plate U F m kg c nl ti bi Specified torque N Disc brake grease BR 17 ...

Page 641: ...ain provided that they have sufficient rebound no deformation cracks or wear and have had all rust dirt andforeign particles cleaned off 6 CHECK DISC THICKNESS AND RUNOUT sea page BA 24 7 INSTALL PAD SUPPORT PLATES Install the 2 pad support plates NOTICE Do not assemble the upper and lower pad support plates In reverse 8 INSTALL NEW PADS NOTICE When replacing worn pads the anti squeal shims and we...

Page 642: ...from the reservoir b Press in the piston with a hammer handle or similar imple ment HINT If the piston is difficult to push in loosen the bleeder plug and push in the piston while letting some brake fluid escape c Install the caliper d Hold the sliding pin and torque the installation bolts Torque 34 N m 350 kgf cm 25 ft lbf 10 INSTALL FRONT WHEEL Torque 103 N m 1 050 kgf cm 76 fl lbf 11 DEPRESS BR...

Page 643: ...dingPin f f41 BleederPlug _ a3 8s 74 Cl_br j fr 1 A kcY Anti squealShim lr y g f InnerPad Du tBoot InnerAnl squealSh1m t ToquePlate t i0 InnerAnti squealShim IY 34 35Q 25 OutetPad i0 1 _ Anti squealShim BrakeCaliper i_ i v f N m kg crTI ft fb f Specifiedtorque Non rcusabiH part Lithiumsoapbaseglycolgrease Discbrakeqrease N PadSupportPlate ...

Page 644: ... Weac 1ii _ WI k Indicator Plate fit __ Innee An squeal Sh m fJ aft 1 rtlli mPad Toq Plate V Inner Anti squealShirn E3rake Caliper I i r __ __ k 0 i P8d Support Plate 34 350 ZS i r 9 j I i Ci JiiP ton P ton Seal Y tJ Bool I 01 kQIern fHbf J SpeCified torque Non reusablepart Lithium soap base glycol grease D1sc brake grease Set Ring Anti squeal Shim BR 21 ...

Page 645: ...ct the flexible hose from the caliper Torque 30 N m 310 kgf cm 22 ft lbf HINT At the time of installation install the flexible hose lock securely in the lock hole in the caliper b Use a container to catch the brake fluid as it drains out 3 REMOVE CALIPER a Hold the sliding pin and remove the 2 installation bolts Torque 34 N m 350 kg em 25 ft lbf b Remove the caliper from the torque plate 4 REMOVE ...

Page 646: ...ront of the piston when using compressed air 3 REMOVE PISTON SEAL Using a screwdriver remove the piston sea from the cylinder 4 REMOVE SLIDING PINS AND DUST BOOTS a Remove the 2 sliding pins from the torque plate b 1 ZZ FE engine Remove the 2 dust boots c 2ZZ GE engine HINT Using a screwdriver and hammer tap out the 2 dust boots AI the time of reassembly use a 1 9 mm socket wrench and tap in 2 new...

Page 647: ...the if it is badly scored or worn unevenly 3 MEASURE DISC RUNOUT Using a dial indicator measurethe disc runout 10 mm 0 39 in away from the outer edge of the disc Maximum disc runout 0 05 mm 0 0020 In Ifthe disc s runout is maximumvalueorgreater checkthe bear ing play in the axial direction and check the axle hub runout See page SA 12 1f the bearing play and axle hub runout are not abnormal adjust ...

Page 648: ... lf the minimum runout recorded in b and c is less than 0 05 mm 0 0020 in instal the disc in that position e If the minimum runout recorded in b and c is greater than 0 05 mm 0 0020 in replace the disc and repeat step 3 f Install the torque plate and torque the mounting bolts Torque 107 N m 1 090 kgf cm 79 ft lbf ...

Page 649: ...BA 26 BRAKE FRONT BRAKI CALIPER REASSEMBLY Reassembly Is in the reverse order of disassembly See page BR 23 NOTICE Apply lithium soap base glycol grease to the parts Indicated by arrows See page BA 20 ...

Page 650: ...3f1AKE CAliPlH INSTALLATION Installation is in the reverse order of removal See page BR 22 HINT BA 27 After installation fill the brake reservoir with brake fluid and bleed brake system See page BR 4 Check for leaks ...

Page 651: ...I r Return Spnng i Automatic Parking Brake Lever 1 MT i 1 Adjuster l I AnchorSpring Shoe Hold Down Spring f Adjusting LeverSprrng N m kgt C rTl ft ft i Specified torque Non reusablepart High temperature grease N Lithium soap base glycol grease Cap C Washer i f l h Brake Drum ...

Page 652: ... backing plate c Using another screwdriver reduce the brake shoe adjust er by turning the adjusting wheeL 4 REMOVE FRONT SHOE a Using SST disconnect the adjuster spdng from the rear shoe SST 09703 3001 0 b Using needle nose pliers remove the anchor spring c d e f g 5 a Using SST remove the cap shoe hold down spring and pin from the front shoe SST 0971 8 00010 Remove the adjuster and adjuster sprin...

Page 653: ...from the rear shoe REMOVE WHEEL CYLINDER Using SST disconnect the brake line Use container to catch the brake fluid SST 09751 3601 1 Torque 15 N m 155 kgf cm 1 1 ft lbf Remove the 2 bolts and the wheel cylinder Torque 10 N m 100 kgf cm 7 11 lbf DISASSEMBLE WHEEL CYLINDER Remove the 2 boots from the wheel cylinder Remove the 2 pistons from the wheel cylinder Remove the spring from the wheel cylinde...

Page 654: ...f a brake shoes needs replacing the brake shoes must be re L _ _ _ _ _ _ _ _ _ _ _ _ __ c CJ placed as a set IW15M 3 MEASURE BRAKE DRUM INSIDE DIAMETER Using abrakedrum gauge orequivalent measure the inside di ameter of the drum Standard inside diameter 200 0 mm 7 874 in Maximum inside diameter 201 0 mm 7 913 in II the drum is scored orworn the brake drum may be lathed to the maximum inside diamet...

Page 655: ...ake b Adjust tt1e adjuster length to the as short as possible c Install the brake drum d Pull the parking brake lever all the way up until a clicking sound can no longer be heard 2 CHECK CLEARANCE BETWEENBRAKESHOES AND DRUM a Remove the brake drum b Measure tho brake drum inside diameter and diameter of the brake shoes Check that the difference between the diameters is the correct shoe clearance S...

Page 656: ...REAR BRAKE PAD COMPONENTS Anti squeal Shim Anti rattle Spring N Disc brake grease BRAKE REAR BRAKE PAD Outer Pad BR 33 ...

Page 657: ...OVE PADS AND ANT QUEAL SHIMS a Remove the 2 pads b Remove the anti squeal shim from each pad 5 CHECK DISC THICKNESS AND RUNOUT see page BR 39 6 INSTALL NEW PADS NOTICE When replacing worn pads the anti squeal shims must be replaced together with the pads a Apply disc brake grease to inside of anti squeal shims See page BR 33 b Install the anti squeal shim on each pad c Draw out a small amount of b...

Page 658: ...D GUIDE PINS 2 ANTI RATTLE SPRINGS AND CLIP a Install the 2 anti rattle springs on the each pad b While pressing the anti rattle spring and install the pad guide pin c Install the clip to the pad guide pin 8 INSTALL REAR WHEEL Torque 103 N m 1 050 kgf cm 76 fl lbf 9 DEPRESS BRAKE PEDAL SEVERAL TIMES 10 CHECK THAT FLUID LEVEL IS AT MAX LINE ...

Page 659: ...tBoot BleederPlug lJi 3 85 74 InnerPad Anti rattle f Spring 1 lip rr Wfflil Brakecaliper 1 yo PistonSeal 1 f _ r T ii Crn t Spec1fiedtorque Non reusablepart Lithiumsoapbaseglycolgrease N 0 D1scbrakegrease i I Boot Piston Disc OuterPadAnti squealShim Anti rattle Spring SetRing PadGuidePin ...

Page 660: ...le hose from the caliper Torque 30 N m 310 kgf cm 22 ft lbf HINT At the time of installation insert the flexible hose lock securely in the lock hole in the caliper b Use a container to catch the brake fluid as it drains out 3 a b 4 REMOVE CALIPER Remove the 2 installation bolts and caliper Torque 47 N m 475 kgf cm 34 fl lbl Remove the caliper from the torque plate REMOVE 2 PADS WITH ANTI SQUEAL SH...

Page 661: ...MOVE PISTON a Put a piece of cloth or an equivalent between the piston and caliper b Use compressed air to remove the piston from the cylin der CAUTION Do not place your fingers in front of the piston when using compressed air 3 REMOVE PISTON SEAL FROM CYLINDER Using a screwdriver remove the piston sea 4 REMOVE 2 SLIDING BUSHINGS AND 3 DUST BOOTS ...

Page 662: ... outside edge Maximum disc runout 0 15 mm 0 0059 in If thedisc s runoutisatthe maximumvalueorgreater checkthe bearing play is in the axial direction and check the axle hub run out See page SA 55 Jf the bearing play and axle hub runout are not abnormal adjust the disc runoutor grind iton a On car brake lathe 4 IF NECESSARY ADJUST DISC RUNOUT a Remove the hub nuts and the disc Reinstall tho disc in ...

Page 663: ...R 40 BRAKE REMl BRAKf CALIP R REASSEMBLY Reassembly is in the reverse order of disassembly See page BR 38 NOTICE Apply lithium soap base glycol grease to the parts indicated by the arrows See page BR 36 ...

Page 664: ...AKE CAUfJER INSTALLATION Installation Is in the reverse order of removal See page BR 37 HINT BR 41 Arter installation fi the brake reservoir with brake fluid and bleed the brake system See page BR 4 Check for leaks_ ...

Page 665: ... ffC _ FrontShoe BRAKE PARKING Bf1AKf Parking BrakeShoeLever l RearShoe ShoeStrut ___L_ Adjuster e r I TensionSpring Disc I ShoeHold downSpring I BrakeCaliperAssembly m kQfC ft bfr Specifiedtorque N Hightemperaturegrease r Plug F0 37 ...

Page 666: ... brake securely Ensure that the hose is not stretched 3 REMOVE DISC Release the parking brake lever and remove the disc HINT lfthedisccannot be removed easily turn theshoe adjuster until the wheel turns freely 4 REMOVE SHOE RETURN SPRINGS AND TENSION SPRING Using needle nose pliers remove the 2 shoe return springs and tension spring 5 REMOVE SHOE STRUT 6 a b REMOVE FRONT SHOE AND ADJUSTER Using SS...

Page 667: ...e hold down spring and pin from the rear shoe SST 09718 00010 b Disconnect the rear shoe from the parking brake shoe le ver and remove rear shoe 6 REMOVE PARKING BRAKE SHOE LEVER Using needle nose pliers disconnect the parking brake cable from the parking brake shoe lever ...

Page 668: ...DE DIAMETER Using a brake drum gauge orequivalent measure the inside di ameter of the disc Standard inside diameter 173 0 mm 6 811 in Maximum inside diameter 174 0 mm 6 850 in Replace the disc ifthe inside diameter is atthe maximum value or more Replace the disc or grind lt with a lathe if the disc is scored or is worn unevenly 4 INSPECT PARKING BRAKE LINING AND DISC FOR PROPER CONTACT Apply chalk...

Page 669: ...rn the adjuster and expand the shoes until the disc locks d e 2 a b c Return the adjuster 8 notches Install the hole plug SETTLING PARKING BRAKE SHOES AND DISC Drivethe vehicle at about 50 km h 31 mph on a safe lev el and dry road With the parking brake release button pushed in pull on the lever wilh 98 N 10 kgf 19 8 1bf of force Drive the vehicle for about 400 meters 0 25 mile in this condition d...

Page 670: ...flutd pressure 2 94 kPa 30 kgt cm 427 psi l 2 94 Wa 30 kgf cm2 427 1 7 85 kPa 80 kgf cm2 1 1 38 psi 4 75 kf a 48 5 kof cm2 689 pg1 2ZZ GE eng1ne Master cylinder fluid presSUf Hear brake caliper fiwd pmssure I 96 kPi 20 kgflcm2 284 psi 1 16 kPa 20 kgflcm 284 pSi 7 85 kPa 80 kgl cm2 1 138 psi 5 61 kPa 57 2 kgf cm2 81 l ps1 When tnspectmg the flUid pressure mspect the left font and nght rear together...

Page 671: ...20 seconds e Turn the motor relay OFF and release the brake pedal 3 INSPECT RIGHT FRONT WHEEL OPERATION NOTICE Never turn ON the solenoid which ls not described below a With the brake pedal depressed perform the following operations b Turn the SFRH and SFRR solenoid ON simultaneously and check that the pedal cannot be depressed NOTICE Do not keep solenoid ON for more than 10 seconds contin uously ...

Page 672: ...he actuator operation again 7 INSPECT BATTERY POSITIVE VOLTAGE Battery positive voltage 1 0 14 v B DISCONNECT CONNECTORS Disconnect the 2 connectors from the actuator 9 CONNECT ACTUATOR CHECKER SST a Connect the actuator checker SST to the actuator side wire harness via the sub wire harness SST as shown SST 09990 001 50 09990 00250 09990 00300 09990 00360 b Connect the red cable of the checker to ...

Page 673: ...press the brake pedal and hold it until step g is com pleted e Push and hold in the G switch for a few seconds and check that the brake pedal does not go down NOTICE Do not keep the G switch pushed down for more than 1 0 seconds f Release the G switch and check that the pedal goes down g Push the A switch and check that the pedal returns h Release the brake pedal i OJ k 1 1 a b Push and hold in th...

Page 674: ...es it possible to in spect wherever the selector switch position indicates 12 PUSH MOTOR SWITCH a Push and hold in the A switch for a few seconds b Stop the engine 13 DISCONNECT ACTUATOR CHECKER SST FROM ACTUATOR a Disconnect the actuator checker SST and 3 sub wire harness SST from the actuator SST 09990 00150 09990 00250 09990 00300 0999 0360 b Connect the actuator connectors c Clear the DTC See ...

Page 675: ... LevelWarnmg tjl _ I _ _ Sw1tchConnector _ 5 155 111 I i3 13 I v ifj1 i9 195 _ _4l_l L1s i55 ii _ 1 19 195 14 l FcontLH __ Brakelme ECMBcacket 15fi5s ___ ABSActuator Holdec f 1 Holdec _ h i 19 195 14 l 1l J V C ___ C _J ABSActuator Assembly Clamp Cush on 6 Pi 4 55 48 in l h f J v rr l ActuatorBracket t m kgt Crn ft lbf Specifiedtorque J N Non reusablepart ...

Page 676: ...que 1 9 N m 195 kgf cm 14 ft lbf DISCONNECT 2 CONNECTORS 5 DISCONNECT BRAKE LINES Using SST disconnect the 6 brake lines SST D9023 D0100 Torque 15 N m 155 kgf cm 11 ft lbf 6 REMOVE ABS ACTUATOR a Disconnect the hose clampfrom the actuator bracket un der side b Remove the bolt nut and ABS actuator assembly c d Torque 19 N m 195 kgf cm 1 4 fl lbf Remove the 2 nuts and ABS actuator from the actuator ...

Page 677: ...STALLATION BRAKE ABSACTUATOR Installation is in the reverse order of removal See page BR 53 HINT After installation fiJI the brake reservoir with brake fluid and bleed brake system See page BR 4 Check for leaks ...

Page 678: ...FRONT SPEED SENSOR COMPONENTS BRAKE FRONT SPE ED SENSOR Resin Clip I I if BA 55 FrontSpeedSensor ...

Page 679: ... 2 clamp bolts holding the sensor harness from the body and shock absorber Torque 8 0 N m 82 kgf cm 71 in lbf b Remove the speed sensor installation bolt from the steer ing knuckle Torque 8 0 N m 82 kgf cm 71 in lbf NOTICE Atthe time ofinstallation please refertothefollowing item Thereare no foreign objects on the sensoror the part of the knuckle to which the sensor is to be installed The sensor I...

Page 680: ...INSTALLATION BRAKE FRONT SPECD SENSOR Installation is in the reverse order of removal See page BR 56 AFTER INSTALLATION CHECK SPEED SENSOR SIGNAL See page 01 276 BR 57 ...

Page 681: ...BA 56 REAR SPEED SENSOR COMPONENTS BRAKE REAR SPEED SENSOR RearSpeedSensor ...

Page 682: ...axle hub in a soft jaw vise NOTICE Replace the axle hub assembly If it is dropped or a strong shock is given to it c Using SST and 2 bolts Diameter 12 mm Pitch 1 5 mm remove the speed sensor SST 09520 00031 09520 00040 0952HJ0020 09950 00020 NOTICE Ifa damage is Inflicted tothesensor rotor replace the axle hub assembly Do not scratch the contacting surfaceof axle hub and speed sensor 5 IF NECESSAR...

Page 683: ...E NSOR c d Remove the 2 clamp bolts holding the sensor harness from the lower arm and body Torque Lower arm side 19 N m 195 kgf cm 14 ft lbt Body side 8 0 N m 82 kgf cm 71 in lbt Replace the sensor wire harness with the grommet ...

Page 684: ...d position under the on vehicle condition c Using SST and a press instal a newspeedsensor to the axle hub SST 09214 7601 1 NOTICE 2 3 4 5 Do not tap the speed sensor with a hammer directly Check that there should be no foreign objects on the speed sensor detection portion Press in the speed sensor straight and slowly INSTALL SPEED SENSOR WITH REAR AXLE See page SA 59 CONNECT SPEED SENSOR CONNECTOR...

Page 685: ... MEMO ...

Page 686: ...STEERING STEERINGSYSTEM SR 1 TROUBLESHOOTING SR 2 DRIVE BELT SR 3 POWERSTEERING FLUID SR 4 STEERING WHEEL SR B TILTSTEERINGCOLUMN SR 9 POWERSTEERING VANE PUMP SR 22 POWERSTEERINGGEAR SR 33 ...

Page 687: ......

Page 688: ... equipped with an SRS Supplemental Restraint System such as the driver air bag and front passenger airbag Failure to carry out serviceoperation In the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious accident Before servicing including removal or Installation of parts inspection or teplacew ment be sure to read the precautionary notices in ...

Page 689: ...rect SA 4 Hard steering 5 Steering systemjoints Worn 6 Suspension arm ballJOints Worn SA 48 7 Steering eolumn Binding 8 Powersteeringvane pump SR 22 9 Powersteeringgear SR 33 Tires Improperly inflated SA 2 Poor return 2 Front wheel alignment lrlCorrecl SA 3 Steering column Binding 4 Power steering gear SR 33 Steering systemjoints Won l 2 Suspension arm balljoints Wom SA 48 Excessive play 3 Interme...

Page 690: ...ect has been found replace the drive belt HINT Crackson the ribside ofa beltareconsidered acceptable If the missing chunks from the ribs are found on the drive belt it should be replaced After installing a drive belt check that itfits properly in the ribbed grooves Checkwith your hand to confirm that the drive belt has not slipped out of the groove on the bottom of the pulley ...

Page 691: ...n the engine at idle for a few minutes_ 6 TURN STEERING WHEEL a With the engine idling turn the steering wheel to left or right full lock position and keep it there for 2 3 seconds then turn the steering wheel to the opposite full lock posi tion and keep it there for 2 3 seconds b Repeat a several times 7 STOP ENGINE 8 CHECK FOR FOAMING OR EMULSIFICATION If the system has to be bled twice specific...

Page 692: ...the fluid is cold check that it is within the COLO LEVEL range c Start the engine and run it at idle d Turn the steering wheel from lockto lockseveral times to boost fluid temperature Fluid temperature BO C 176 F e Check for foaming or emulsification lf there is foaming or emulsification bleed power steering sys tem See page SR 4 f With the engine idling measure the fluid level in the oil reservoi...

Page 693: ...hment PSVanePump N f 098 1 Oil rr reservoir E 2 Clos Q t It PSVane Pump SST Zt 98 c Bleed the power steering system See page SR 4 d Start the engine and run it at idle e Turn the steering wheel from lockto lockseveral times to boost fluid temperature Fluid temperature 80 c 176 F f With the engine idling close the valve of the SST and ob serve tho reading on the SST Minimum fluid pressure 7 355 kPa...

Page 694: ... 5 kgf cm2 71 psi or less NOTICE Do not turn the steering wheel i With the engine idling and valve fully opened turn the steering wheel to full lock Minimum fluid pressure 7 355 kPa 75 kgf cm2 1 067 psi NOTICE Do not maintain lock position for more than 10 se conds Do not let the fluid temperature become too high U Disconnect he SST SST 09640 1 0010 0964 1 01 0 1 0 09641 01 030 09641 Q1060 k Conne...

Page 695: ...mm 1 18 1n 2 CHECK STEERING EFFORT a Center the steering wheel b Remove the steering whee pad Sec page SR 11 c Start the engine and run it at idle d Measure the steering effort in both directions Steering effort Reference 6 5 N m 65 kgf cm 58 in lbl HINT Take the tire type pressure and contact surface into consider al on before making your diagnosis e Install the steering wheel set nut T orque 34 ...

Page 696: ...r Finish Panel WiperandWasherSwitch p p P 1t _ _ 34 350 25 _ w Transmission shiftswitch Transmission Shill SwitchAssembly SteeringWheel __ TorxScrew j 8 90 iaio lbO _ Light Control Switch and Headlight o DimmerSwitch SpiralCable ColumnLowerCover No 2IntermediateShaftAssembly ColumnHoleCoverSilencerSheet SteeringColumnAssembly LowerNo 1 Instrument Finish Panel ...

Page 697: ...ar i i I Snap Ring TiltLeverLockBo lt i ColumnTube BracketSpfcer No 1 Support I Adjusting Nut Collar J S J TittLever r sooYaQa SR17 No 1 SupportRe nlocce Stopper r No 1Support i J Y Collar _ _ No 2Ti tleverLockBolt TiltSteering Support _ 1 5 4 55 4 in tbf __j SnapRing 15 15 Main ShaftBushing rrl _fkQ_t Cm __ii J LI Specifiedtorque Non reusablepart Molybdenumdisulfide lithiumbasegrease N MainShaftA...

Page 698: ...ng upward Never disassemble the wheel pad NOTICE When removing the wheel pad take care not to pull the air bag wire harness 2 REMOVE STEERING WHEEL a Disconnect the connector b Remove the steering wheel set nuL C Place matchmarks on the steering wheel and main shaft assembly d Using SST remove the steering wheel SST 0995 50012 09951 05010 09952 05010 09953 05020 09954 05020 3 REMOVE LOWER NO 1 INS...

Page 699: ...sher switch e Remove the spiral cable NOTICE Do not disassemble the spiral cable or apply oil to it a wr REMOVE KEY INTERLOCK CABLE With thekey in ACC push the clawand pull out thekey interlock cable 9 REMOVE COLUMN HOLE COVER SILENCER SHEET 10 DISCONNECT NO 2 INTERMEDIATE SHAFT AS SEMBLY a Place matchmarks on the No 2 intermediate shaft as sembly and intermediate extension b Loosen the bolt A and...

Page 700: ...e the secondary locking device of the connec tor c Release the locking lug of the terminal 1 horn switch ter minal and pull the terminal out of the rear d Remove the speed control main switch assembly 15 w Transmission shift switch and speed control main switch REMOVE TRANSMISSION SHIFT SWITCH AS SEMBLY AND SPEED CONTROL MAIN SWITCH AS SEMBLY FROM STEERING WHEEL a Remove the 2 screws from the tran...

Page 701: ...othe 2 bolts c Using a screw extractor remove the 2 bolts column up per bracket and column upper clamp 2 REMOVE TILT STEERING SUPPORT Remove the bolt and lit steering support 3 REMOVE BRACKET SPACER AND 2 NO 1 SUPPORT COLLARS a Using an extensionbar anda hammer tapout the bracket spacer b Using a screwdriver remove the 2 No 1 support collars 4 REMOVE TILT LEVER AND BREAK AWAY BRACKET a Remove the ...

Page 702: ...ed one d Remove the No 2 support collar from the break away bracket 5 REMOVE MAIN SHAFT BUSHING Using a screwdriver and hammer tapout the main shaft bush ing 6 REMOVE MAIN SHAFT ASSEMBLY a Using a snap ring expander remove the snap ring on the upper side b Remove the main shaft assembly c Using a snap ring expander remove the snap ring on the ower side ...

Page 703: ... IGNITION SWITCH See page BE 14 4 IF NECESSARY REPLACE IGNITION SWITCH a Remove the 2 screws and ignition switch from the column upper bracket b Install a new ignition switch with the 2 screws 5 INSPECT KEY UNLOCK WARNING SWITCH See page BE 14 6 IF NECESSARY REPLACE KEY UNLOCK WARNING SWITCH a Slide the key unlockwarning switch out of the column up per bracket b Slide a new key unlock warning swit...

Page 704: ...molybdenum disulfide lithium base grease b Using SST and a hammer tap in the main shaft bushing SST 09608 04031 4 INSTALL BREAK AWAY BRACKET AND TILT LEVER a Install the No 2 support collar to the break away bracket b Install the break away bracket tilt lever lock boll stopper and tilt lever HINT Align the holes in the column tube with the projections of the tilt leverlock bolt and stopper c Insta...

Page 705: ...PORT COLLARS AND BRACK ET SPACER a Install 2 new No 1 support collars HINT Install the white supportcollar to the RH side blacksupportcol lar to the LH side b Using an extension bar and a hammer drive in the brack et spacer 6 INSTALL TILT STEERING SUPPORT Install the tilt steering support with the bolt Torque 1 5 N m 155 kgf cm 11 ft lbf NOTICE Make sure that the tilt steering support is Installed...

Page 706: ...r Install the 2 screws w Transmission shift switch and speed control main switch INSTALLTRANSMISSION SHIFTSWITCH ASSEMBLY AND SPEED CONTROL MAINSWITCH ASSEMBLYTO STEERING WHEEL Install the transmission shift switch assembly and speed control main switch assembly Push the terminal 1 horn switch terminal into the con nectar Engage the secondary locking device of the connector Install the 2 screws to...

Page 707: ...headlight dimmer switch until the claw is latched c Employ the same manner described above to the wiper and washer switch d Connect the alrbag connector to the spiral cable e Connectthe 3 connectors to the spiral cable light control switch and headlight dimmer switch and wiper and wash er switch 10 INSTALL COLUMN UPPER AND LOWER COVERS Install the column upper and lower covers with the 3 screws 11...

Page 708: ...INSTALL STEERING WHEEL PAD NOTICE Never use airbag parts from another vehicle When replacing parts replace with new ones Make sure the wheel pad Is Installed with the speci fied torque If the wheel pad has been dropped or there are cracks dents or otherdefects in the case or connec tor replace the wheel pad with a new one When installing the wheel pad take carethat the wir ings do notinterferewith...

Page 709: ...TEERING VANE PUMP POWER STEERING VANE PUMP COMPONENTS N PressureFeedTube SuctionHose DriveBelt CenterEngineUnderCover _ _k_gf_ c_m _ _ _l 0 Specifiedtorque ForusewithSST OilPressureSwitchConnector J PS PumpAssembly FC IlBfif ...

Page 710: ...ne p _ pPulley QilPressureS 2113_1_ _ _ w 1 tch SuctionPortU 0100 1 VanePum VanePum Pulleywi t h SidePlate fJ Specifiedtorque 1 Po part N wersteeringfluid 0 Ring F ront Housing I 1 I I I I I I I I I I I I I I I I I I I RearHousin vanePump R a n Q ng 11 21 t 0 Ring I X 10 VanePlate CamRing ...

Page 711: ...DISCONNECT SUCTION HOSE Remove the clip and disconnectthe suction hose NOTICE Take care not to spill fluid on the drive belt 4 DISCONNECT PRESSURE FEED TUBE a Using SST disconnect the pressure feed tube SST 09631 22020 b Remove the boll and disconnect the pressure feed tube damp 5 DISCONNECTOIL PRESSURE SWITCH CONNECTOR 6 REMOVE PS VANE PUMP ASSEMBLY Remove the 2 pump assembly set bolts nuts and P...

Page 712: ...port union flow control valve and spring b Remove the Q ring from the pressure port union 4 REMOVE OIL PRESSURE SWITCH NOTICE Be careful not to drop the oil pressure switch If the oil pressure switch is dropped or strongly damaged re place it with a new one 5 REMOVE REAR HOUSING a Remove the bolt and rear bracket b Remove the 4 bolts and rear housing c Remove the 0 ring from the rear housing 6 REM...

Page 713: ...arance 0 07 mm 0 0028 in If it is more than the maximum replace the front housing and vane pump shaft 2 a INSPECT VANE PUMP ROTOR AND VANE PLATES Using a micrometer measure the height thickness and length of the 1 0 vane plates Minimum height 7 6 mm 0 299 ln Minimum thickness 1 405 mm 0 0553 in Minimum length 11 993 mm 0 4722 in b Using a feeler gauge measure the clearance between the vane pump ro...

Page 714: ... 0 47256 44345 32110 11 999 12 001 0 47240 0 47248 2 44345 32120 1 L997 1 1 999 0_47232 0 47240 3 44 345 32130 1 1 995 1 1 997 0 47224 0 47232 4 44345 32140 11 993 11 995 0_47216 0 47224 INSPECT FLOW CONTROL VALVE Coat the flow control valve with power steering fluid and check that it falls smoothly into the valve hole of the front housing by its own weight b Check the flow control valve for leaka...

Page 715: ... I I Vernier Calipers HGS702 STEERING POWER STEERING VANEPUMP 4 INSPECT SPRING Using vernier calipers measure the free length of the spring Minimum free length 35 8 mm 1 409 in f it is not within the specification replace the spring ...

Page 716: ... SR 29 a Us mg a screwdriver with vinyl tape wound around its tip remove the oil sea NOTICE Be careful not to damage the bushingof the front housing b Coat a new oil seal lip with power steering fluid c Using SST press in the oil seal SST 0995G 60010 09951 0280 0995 70010 09951 7100 NOTICE Make sure that the oil seal is installed facing In the correct direction ...

Page 717: ...m ringwith thedentof thesideplate and instal the cam ring with the inscribed mark facing outward 5 INSTALL VANE PUMP ROTOR a Install the vane pump rotor with the inscribed mark facing RoundEnd outward b Install a new snap ring to the vane pump shaft 6 INSTALL 10 VANE PLATES Install the 1 0 vane plates with the round end facing outward 7 INSTALL REAR HOUSING a Coat a new 0 ring with power steering ...

Page 718: ...t a new 0 ring with power steering fluid and install it to the pressure port union d Install the pressure port union Torque 69 N m 700 kgf cm 51 H lbf 10 INSTALL SUCTION PORT UNION a Coat a new Q ring with power steering fluid and install it to the suction port union b Install the suction port union with the bolt Torque 12 N m 120 kgf cm 9 ft fbi 11 MEASURE PS VANE PUMP ROTATING TORQUE See page Sf...

Page 719: ...lamp with the bolt Torque 7 8 N m 80 kgf cm 69 ln lbl b Using SST connectthe pressure feed tube SST 09631 22020 Torque 37 N m 375 kgf cm 27 ft lbl HINT Use a torque wrench with a fulcrum length of 345 mm 11 81 in This torque value is effective in case that SST is parallel to a torque wrench 4 CONNECT SUCTION HOSE Connect the suction hose with the clip 5 INSTALL DRIVE BELT Loosen the drive belt ten...

Page 720: ...STEERING POWERSTEER NG GEAn POWER STEERING GEAR COMPONENTS RHEngineUnderCover l ffi 9l_ _ m ft lbt I Specifiedtorque Non reusablepart ForusewithSST N CenterEngineUnderCover SR 33 ...

Page 721: ... RackEnd f83 650 61 L 63o 46 lock Nut _ 4 750 54 Chp 9 _ TeflonRing 0 Ring N fn kgfC Ibf Specifiedtorque Non reusablepart Molybdenumdisulfidelithiumbasegrease Powersteeringfluid ForusewithSST Rack End 163 650 ii I l 2 630 46 i SteeringRack ClawWasher J I I I I I RackHousing TieRodEnd f0987 ...

Page 722: ...7_4_ 51 54 __ TurnPressureTube TeflonRing l N ffi kgf _ ii lbf j Specifiedtorque NOn reusablepart Precoatedpart Bearing Molybdenumdisulfidelithiumbasegrease J Powersteeringfluid ForusewithSST I 0 0 RinQ OilSeal BearingGuT eNut L 49 o 30 Bearing RackGUideSpringCap Con alSpnn she RackHousing ...

Page 723: ...3 REMOVE STEERING WHEEL See page SR 11 4 REMOVE RH CENTER AND LH ENGINE UNDER COV ERS 5 DISCONNECT RH AND LH TIE ROD ENDS See page SA 12 6 DISCONNECT NO 2 INTERMEDIATE SHAFT AS SEMBLY See page SR 11 7 DISCONNECT PRESSURE FEED A N D RETURN TUBES Using SST disconnect the pressure feed and return tubes SST 09631 22020 8 DISCONNECT TUBE CLAMP Remove the bolt and disconnect the tube clamp 9 DISCONNECT ...

Page 724: ...SION ARM See page SA 42 13 DISCONNECT STABILIZER BAR a b Remove the nut and disconnect the stabilizer bar Employ the same manner described above to the other side 14 DISCONNECT ENGINE REAR MOUNT INSULATOR AND FRONT SUSPENSION MEMBER Remove the bolt bolt A and 3 nuts and disconnect the engine rear mount insulator and front suspension member 15 DISCONNECT ENGINE FRONT MOUNT INSULATOR AND FRONT SUSPE...

Page 725: ...ntermediate extension and control valve shaft c Remove the bolt and intermediate extension 19 REMOVE ENGINE REAR MOUNT INSULATOR AND ENGINE REAR MOUNT BRACKET a Remove the throughboltand engine rear mount insulator b Remove the 3 bolts and engine rear mount bracket ...

Page 726: ...rks on the tie rod end and rack end b Loosen the lock nut and remove the tfe rod end and lock nut c Employ the same manner described above to the other side 4 REMOVE RH AND LH CLIPS WIRES AND RACK BOOTS a Using needle nose pliers loosen the wire b Remove the clip wire and rack boot NOTICE Be careful not to damage the boot HINT Mark the RH and LH rack boots c Employ the same manner described above ...

Page 727: ...AS SEMBLY 7 REMOVE RACK HOUSING CAP a Remove the rack housing cap b Remove the 0 ring from the rack housing cap 8 REMOVE CONTROL VALVE ASSEMBLY Pull out the control valve assembly NOTICE Be careful not to damage the oil seal lip 9 REMOVE CYLINDER END STOPPER a Using snap ring pliers remove the snap ring b Pull out the cylinder end stopper 10 REMOVE STEERING RACK AND OIL SEAL Using SST press out th...

Page 728: ... GEAR INSPECTION NOTICE When using a vise do not overtighten it INSPECT STEERING RACK SR 41 a Using a dial indicator check the rack for runout teeth wear and damage Maximum runout 0 1 mm 0 004 in b Checkthe back surface for wear and damage ...

Page 729: ...IF NECESSARY REPLACE OIL SEAL a Using a screwdriver with vinyl tape wound around its tip remove the oil seal NOTICE Be careful not to damage the rack housing cap b Coat a new oil seal lip with power steering fluid c Using SST press in the oil seal SST 09950 60010 09951 1021 0 09951 00340 09952 0601 0 09950 70010 09951 07100 NOTICE Make sure that the oil seal is installed facing in the correct dire...

Page 730: ... a Using a punch and a hammer tap out the bearing b Coat a new bearing with molybdenum disulfide lithium base grease c Using a brass bar and a hammer tap in the bearing 5 IF NECESSARY REPLACE 2 UNION SEATS a Using a screw extractor remove the union seat from the rack housing b Using a hammer and anextension bar lightly tap in a new union scat NOTICE Before installing the union seat remove the dust...

Page 731: ...o overexpand the teflon ring d Coat the teflon ring with power steering fluid e Install the teflon ring to the steering rack and settle it down with your fingers 7 IF NECESSARY REPLACE 4 TEFLON RINGS a Using a screwdriver remove the 4 teflon rings from the control valve assembly NOTICE Be careful not to damage the grooves for the teflon rings b Expand 4 new teflon rings with your fingers NOTICE Be...

Page 732: ...45 STEERING POWER STEERING GEAR e Carefully slide the tapered end of SST over the teflon rings until they fit to the control valve assembly SST 09631 20081 NOTICE Be careful not to damage the teflon rings ...

Page 733: ...he oil seal to SST and press them into the rack housing SST 0995o 6001 0 0995HJ0240 0995HJ0400 09952 0601 0 0995D 7001 0 09951 07360 NOTICE Make sure that the oil seal is installed facing In the correct direction Take care that the oil seal does not get reversed as you Install it 3 INSTALL STEERING RACK a Install SST to the rack SST 09631 20051 HINT It necessary scrape the burrs off the rack teeth...

Page 734: ...ng pliers install a new snap ring to the rack housing 6 AIR TIGHTNESS TEST a Install SST to the rack housing SST 09631 12071 b Apply 53 kPa 400 mmHg 15 75 1n Hg of vacuum for about 30 seconds c Check that there is no change in the vacuum If there is a change in the vacuum check the installation of the oil seals 7 INSTALL CONTROL VALVE ASSEMBLY NOTICE Be careful not to damage the teflon rings and o...

Page 735: ...que 25 N m 250 kgf cm 18 ft lbf Return the rack guide spring cap 12 Using SST turn the control valve shaft right and left 1 or 2 times SST 096HHJ0010 Loosen the rack guide spring cap until the rack guide spring is not functioning Using SST and torque wrench lighten the rack guide spring cap until the preload is within the specification SST 09616 00010 Preload turning 0 9 1 3 N m 9 1 3 kgf cm 8 0 1...

Page 736: ...orque wrench with a fulcrum length of 380 mm 14 96 in c Using a brass bar and a hammer stake he washer NOTICE Avoid any impact on the steering rack d Employ the same manner described above to the other side 12 INSTALL RH AND LH RACK BOOTS WIRES AND CLIPS a Ensure that the steering rack hole is not clogged with grease HINT If the hole is dogged the pressure inside the boot will change after it is a...

Page 737: ...ie rod end onto the rack end until the matchmarks are aligned b After adjusting toe in torque the nut See page SA 4 Torque 74 N m 750 kgl cm 54 ft lbf c Employ the same manner described above to tho other side 14 INSTALL 2 TURN PRESSURE TUBES Using SST install the 2 turn pressure tubes SST 09633 00020 Torque 20 N m 200 kgf cm 14 ft lbf HINT Use a torque wrench with a fulcrum length of 300 mm 1 1 8...

Page 738: ...ASSEMBLY Install the front suspension memberwith lowersuspension arm and PS gear assembly wlth tho 6 bolts bolt C 0 and E Torque Bolt C 157 N m 1 600 kgf cm 116 ft lbf Bolt D 157 N m 1 600 kgf cm 116 ft lbl Bolt E 39 N m 400 kgf cm 29 ft lbf 4 CONNECT ENGINE FRONT MOUNT INSULATOR AND FRONT SUSPENSION MEMBER Connect the engine front mount insulator and front suspension member with the 2 bolts bolt ...

Page 739: ...UBES Using SST connect the pressure feed and return tubes SST 09631 22020 Torque 37 N m 375 kgf cm 27 ft Jbf HINT Use a torque wrench with a fulcrum length of 345 mm 13 58 in This torque value is effective in case that SST is parallel to a torque wrench 13 CONNECT NO 2 INTERMEDIATE SHAFT ASSEMBLY See page SR 19 14 CONNECT RH AND LH TIE ROD ENDS See page SA 16 15 INSTALL RH CENTER AND LH ENGINE UND...

Page 740: ... STEERING GEAR 20 CHECK STEERING WHEEL CENTER POINT 21 TORQUE STEERING WHEEL SET NUT Torque 34 N m 350 kgf cm 25 lt lbf SR 53 22 INSTALL STEERING WHEEL PAD See page SR 19 23 CHECK FRONT WHEEL ALIGNMENT See page SA 4 ...

Page 741: ... MEMO ...

Page 742: ... RS 1 STEERINGWHEELPADAND SPIRALCABLE RS 12 FRONTPASSENGER AIRBAGASSEMBLY RS 26 SIDEAIRBAGASSEMBLY RS 39 AIRBAGSENSORASSEMBLY RS 52 FRONTAIRBAGSENSOR R 57 SIDEAIRBAGSENSORASSEMBLY RS 62 DOORSlOEAIRBAGSENSOR R 67 WIREHARNESSANDCONNECTOR RS 72 ...

Page 743: ......

Page 744: ...ag assembly side alrbag assembly airbag sensor assembly front airbag sen sor side alrbag sensor assembly and door side airbag sensor should be inspected See page RS 14 RS 28 R 42 RS 54 RS 59 RS 64 and RS 69 Before repairs remove the alrbag sensor If shocks are likely to be applied to the sensor during repairs Never use SRSpartsfrom another vehicle When replacing parts replace them with new parts N...

Page 745: ...red in the front passen ger airbag assembly and cannot be disassembled The inflater contains a squib Igniter charge gas generator etc and in flates the bag when instructed by the airbag sensor assembly 4 SIDE AIRBAG ASSEMBLY The inflater and bag of the SRS side airbag are stored in the side airbag assembly and cannot be disassembled The inflater contains a squib igniter charge gas generator etc an...

Page 746: ...ly cannot be disas sembled 8 FRONT AIRBAG SENSOR The front airbag sensor is mounted inside each of the side members Thesensor unit is a mechanicaltype When the sen sor detects deceleration force above a predetermined limit contact is made in the sensor sending a signal to the airbag sensor assembly The front airbag sensor cannot be disas sembled 9 SIDE AIRBAG SENSOR ASSEMBLY The side airbag sensor...

Page 747: ... Airbag Sensa j SpiralCable FrontPassengerAirbag Assembly Squib Assembly jjl f5 SteeringWheel Pad Squib FrontAirbagSensor LH DoorSideAirbag Sensor LH SeatBelt Pretensioner LH SideAirbag Assembly LH Squib SideAirbagSensor Assembly LH UC No Item Application J Terminal Twin lock Mechanism Connectors 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 Airbag Activation Prevention Mechanism Connector ...

Page 748: ...n Lock Mechanism Each connector has a two piece component con sisting of a housing and a spacer This design en ables the terminal to be lockedsecurelybytwolock ing devices the retainer and the lance to prevent terminals from coming out 2 Airbag Activation Prevention Mechanism Each connectorcontains a shortspring plate When the connector is disconnected the short spring plate automatically connects...

Page 749: ...the previous page HINT 3 Electrical Connection Check Mechanism This mechanism electricallychecksthatconnectors are connectedcorrectly and completely The electri cal connection check mechanism is designed so that the disconnection detection pin connects with the diagnosis terminals when the connector hous ing lock is locked completeConnection Terminalfor HOIJ1 The illustration shows connectors 1 2 ...

Page 750: ...e sensors 2 squibs in the driver airbag and front pas senger airbag ignite and generate gas The gas discharg ing into the driver airbag and front passenger airbag rap idly increases the pressure inside the bags breaking open the steering wheel pad and instrument panel Bag inflation then ends and the bags deflate as the gas is discharged through discharge holes at the bag s rearor side 12 DISCONNEC...

Page 751: ...without rubbing b As they arefitted in theouterslides rearward Press it un til the outer returns to its original position again If fitting stops half way connectors will separate c Be sure to insert until they are locked After fitting in pull them slightlytocheckthatthey are locked When locked make sure that the outerreturns to its original position and sound at the time of fitting in can be heard...

Page 752: ... SYSTEM SRSA HBAG Slider 14 DISCONNECTION OF SIDE AIRBAG CONNECTOR a Place a finger on the slider b Slide the slider to release lock c Disconnect the connector Disconnection is completed 15 CONNECTION OF SIDE AIRBAG CONNECTOR li ...

Page 753: ... locked When locked makesure thatthe outerreturns to its original position and sound at the time of fitting in can be heard HINT As the slider slides do not touch it Be careful not to deform the release board If the release board is deformed replace it with a new one 16 DISCONNECTION OF CONNECTORS FOR STEERING WHEEL PAD with AIRBAG A N D FRONT PAS SENGER AIRBAG ASSEMBLY a Place a finger on the sli...

Page 754: ...me direction as shown in the illustra tion fit in them without rubbing b Be sure to insert untH they are locked After fitting in pull them slightly tocheckthatthey are locked When locked make sure thatthe outer returnsto its original position and sound at the time of fitting in can be heard HINT As the slider slides do not touch it Be careful not to deform the release board If the release board is...

Page 755: ...LEMENTAL RESTRAINT SYSTEM STEEnJNG WHEEl PADAND SPIRAl CABLE STEERING WHEEL PAD AND SPIRAL CABLE COMPONENTS I Column L wer Cover b Column Upper Cover Spiral Cable Steering Wheel Pad Torx screw L s a 90 78in lbf j ...

Page 756: ...PPLEMENTAL RESTRAINT SYSTEM STEERING WHEEL PADAND SPIRAL CABLE For step 1 to 4 referto page SR 11 1 REMOVE STEERING WHEEL PAD 2 REMOVE STEERING WHEEL 3 REMOVE UPPER AND LOWER COLUMN COVERS 4 REMOVE SPIRAL CABLE RS 13 ...

Page 757: ...check which includes the following items with the steering wheel pad with airbag removed from the ve hicle Check cuts minute cracks or marked discoloration on the steering wheel pad top surface and in the grooved portion Check cuts and cracks in wire harness and chip ping in connectors Check the deformation of the horn button contact plate of the steering wheel CAUTION For removal and installation...

Page 758: ...ct plate of the steering wheel Check the damage on the spiral cable connector and wire harness CAUTION UP 2 For removal and installation of the steering wheel pad see page SR 11 and SR 19 and be sure to follow the correct procedure HINT If the horn buttoncontactplate of the steering wheel isde formed never repair it Always replace the steering wheel assembly with a new one There should be no inter...

Page 759: ...re it will not create a nuisance to nearby residents When deploying the alrbag always use the specified SST SRS Alrbag Deployment Tool Perform the op eration in a place away from electrical noise SST 09082 00700 When deploying an alrbag perform the operation at least 10 m 33 ft away from the steering wheel pad The steering wheel pad is very hot when the alrbag is deployed so leave it alone for at ...

Page 760: ...itch and check that the LEO of the SST activation switch lights up CAUTION Ifthe LED lights up when the activation switch is not being pressed SST malfunction is probable so definitely do not use the SST 3 Disconnect the SST from the battery b lnslall lhe SST CAUTION Check that there is no looseness in the steering wheel and steering wheel pad 1 While turning the steering wheel right left remove t...

Page 761: ...30 minutes af ter deployment Use gloves and safetyglasseswhen handling a steer ing wheel pad with the deployed alrbag Always wash your hands with waterafter completing the operation Do not apply water etc to a steering wheel pad with the deployed airbag When scrapping a vehicle deploy the airbag and scrap the vehicle with the steering wheel pad still installed When moving a vehicle for scrapping w...

Page 762: ...purpose wire harness tie down the steer ing wheel pad to the disc wheel Wire harness Stripped wire harness section 1 25 mm2 or more 0 0019 in2 or more CAUTION If a wire harness which is too thin or some other thing is usedto tie down the steering wheel pad it may be snapped by the shock when the alrbag is deployed This Is highly dangerous Always use a wire harness for vehicle use which is at least...

Page 763: ... disc wheel through the hub nut holes Position the steering wheel pad con nector so that it hangs downward through a hub hole in the disc wheel CAUTION Make sure that thewire harness is tight It Is verydan gerous when looseness in the wire harness results In the steering wheel pad coming free due to the shock from the alrbag deploying Always tie down the steering wheel pad with the pad side facing...

Page 764: ...eelpad tied down on the disc wheeL Cover the steering wheel pad with a cardboard box or tires Covering method using a cardboard box Cover the steering wheel pad with the cardboard box and weight the cardboard box down in 4 places with at least 190 N 20 kg 44 b Sizeof cardboard box Must exceed the following dimensions _ w _ e _ ig _ h _ t X 460 mm 18 11 in Y 650 mm 25 59 in NOTICE When dimension Y ...

Page 765: ... m 33 ft area around the disc wheel which the steering wheel pad is tied to 3 Press the SST activation switch and deploy the air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up l Dispose of the steering wheel pad with airbag CAUTION The steering wheel pad is very hot when the alrbag Is deployed so leave it alone for at least 30 minutes af ter deploymen...

Page 766: ......

Page 767: ......

Page 768: ... moving a vehicle for scrapping which has a steering wheel pad with the deployed airbag use gloves and safety glasses Use gloves and safety glasses when handling a steer Ing wheel pad with deployed airbag Always wash your hands with water after completing the operation Do not apply water etc to a steering wheel pad with deployed alrbag i Remove the steering wheel pad from the steering wheel See pa...

Page 769: ...ad Ifthe spiralcablehas been foundtobefaulty introubleshooting Spiral cable Ifthesteefingwheelpad hasbeenfoondto00faultyduringchecldngitems Steering wheel pad Seepage RS 14 Ifthesteeringwheel has beenfound tobe faultyduringchecking items Steering whool Seepage RS 14 Ifthe spiralcahla has beenfoundto befaulty dJring checking items Spiralcable Seepage A 14 Ifthe steering wheel pad has been dropped S...

Page 770: ...AINTSYSTEM STEEHINGWHEELPADAND SPIRALCABLE INSTALLATION HINT For step 1 to 4 refer to page SR 19 1 INSTALL SPIRAL CABLE 2 INSTALL UPPER AND LOWER COLUMN COVERS 3 INSTALL STEERING WHEEL 4 INSTALL STEERING WHEEL PAD R5 25 ...

Page 771: ... FRONTPASSENGER AIRBAGASSEMBLY FRONT PASSENGER AIRBAG ASSEMBLY COMPONENTS FrontPassengerAirbagAssembly 0 o F I F J t _ _ff J F 0 r p r i f l r L _ L roo l A c _ t_ 0 205 f5 _ I _ II I LowerFinishPane N m kg crr ii f6fjJ Specifiedtorque ...

Page 772: ...rews 2 bolts and lower finish paneL b Remove the connector cover from the lower finish panel NOTICE When handling the airbag connector take care not to dam age the airbag wire harness c Disconnect the airbag connector 2 REMOVE FRONT PASSENGER AIRBAG ASSEMBLY Remove the bolt and 2 nuts CAUTION Do not store the front passenger airbag assembly with the airbag deployment side facing downward Never dis...

Page 773: ...MENTAL RESTRAINT SYSTEM a Do a diagnostic system check See page Dl 326 b Do a visual check which includes the following items with the front passenger airbag assembly removed from tho vehicle Check cuts minute cracks or marked discoloration on the front passenger airbag assembly Checkcuts andcracksin wire harness and for chip ping in connectors Check the deformation or cracks on the instrument pan...

Page 774: ...enger airbag assembly removed from the vehicle Check the deformation or cracks on the instrument panel and instrument panel reinforcement Check the damage on the connector and wire har ness CAUTION P _ i l9 o For removal and installation of the front passenger airbag assembly see page SR 11 and SR 19 and be sure to fol low the correct procedure HINT If tho instrument panel or instrument panel rein...

Page 775: ...hen deploying the airbag always use the specified SST SRS Alrbag Deployment Tool Perform the op eration in a placeaway from electrical noise SST 09082 0700 When deploying an airbag perlorm the operation at least 10 m 33 ft away from the front passenger air bag assembly The front passenger airbag assembly Is very hot when the alrbag is deployed so leave It alone for at least 30 minutes after deploy...

Page 776: ...all the SST 1 Connect the connectors of the 2 SST to the front SST NOTICE passenger airbag assembly connector 09082 Q0700 09082 Q0760 To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock 2 Movethe SSTto atleast 1 0 m 33 ft awayfrom the front of the vehicle 3 Close all the doors and windows of the vehicle NOTICE Take care not to damage the SST wire ha...

Page 777: ...er airbag assembly with the deployed alrbag use gloves and safety glasses HINT The airbag deploys simultaneously as the LED of the SST ac Hvation switch lights up 2 DEPLOYMENT WHEN DISPOSING OF FRONT PAS SENGER AIRBAG ASSEMBLY ONLY NOTICE When disposing ofthefront passengerairbagassem bly only never use the customer s vehicle to deploy the airbag Be sureto follow the procedure given belowwhen de p...

Page 778: ... wire harness it may snap This is highly dangerM ous Always use a wire harness which is at least 1 25 mm2 0 0019 in2 HINT To calculate the square of the stripped wire harness section Square 3 14 X Diameter divided by 4 1 Install the 2 nuts on the front passenger airbag as sembly 2 Wind the wire harness around the bolts and pass the wire harness though the installation holes 3 Position the front pa...

Page 779: ... the airbag use a redundant tire c Check functioning of the SST See step 1 a on page R 16 d SST 09082 00700 Place the tires 1 Placeatleast 2 tires under the tiretowhich the front passenger airbag assembly is tied 2 Place at least 2 tires overthe tire to which the front passenger airbag assembly is tied The top tire should have the whee installed 3 Tie the tires together with 2 wire harness CAUTION...

Page 780: ... air bag HINT The airbag deploys simultaneously as the LED of the SST ac tivation switch lights up g Dispose of the front passenger airbag assembly CAUTION The front passenger airbag assembly is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment Use gloves and safety glasses when handling a front passenger airbag assemblywith the deployed airbag Always ...

Page 781: ...andling a front passengerairbag assemblywith thedeployed alrbag Always wash your handswith water after completing the operation Do not apply water etc to a front passenger airbag assembly with the deployed alrbag 1 Remove the front passenger airbag assembly from the instrument panel See page R 27 2 Place the front passenger airbag assembly in a vi nyl bag tie the end tightly and dispose of it in t...

Page 782: ...ngerairbag assembly shooting If thefrontpassenger airbag assembly has boon found to 00 faulty dunng Front passenger airbag assembly checking items SeepageAS 28 Hthe instrument panelhas boon foundto bo faultyduringchocking items Instrument panBI Soo page R 28 Iftheinstrumentpanel reinforwmenthas been foundto be faultyduring Instrument panel reinforcement cheddng IIams See page R 28 IIthe frontpasse...

Page 783: ...ake care that the wiring does not Interfere with other parts and is not pinched between other parts Make sure that no foreign objects are trapped be tween the alrbag bag and within the module NOTICE If the front passenger airbag assembly has been dropped or there are cracks dents or other defects in the case or connector replace the front passenger airbag assembly with a new one c Install the airb...

Page 784: ... SIDE AIRBAG ASSEMBLY COMPONENTS F _ I I I AS 39 1 J I I 17 SideAirbagAssembly lnnerFrontSeat CushionShield Non reusablepart HogRing m kgf cm f_t lbf 1 Specifiedtorque I SeatTrackCover d FrontSeat CushionShie d RecliningAdjuster Re easeHandle 1 119 5 ...

Page 785: ... the side airbag connector NOTICE When handling the airbag connector takecare not to dam age the airbag wire harness c Remove the front seat 2 REMOVE RECliNING ADJUSTER RELEASEHANDLE 3 REMOVE RECliNING ADJUSTER KNOB 4 REMOVE FRONT SEAT CUSHION SHIELD 5 REMOVE INNER FRONT SEAT CUSHION SHIELD Remove the screw and inner front seat cushion shield 6 REMOVE SEAT CUSHION ASSEMBLY a Remove the wire harnes...

Page 786: ...BAG ASSEMBI Y 1111976 REMOVE SEATBACK ASSEMBLY Remove the hog rings of the seatback frame as shown in the illustration b Remove the 4 bolts and seatback assembly CAUTION Do notstore the seatbackassemblywith theairbag deploy ment side facing downward ...

Page 787: ...ved from the vehicle Check cuts and cracks of the side airbag assembly Check cuts and cracks in wire harness and chip ping in connectors CAUTION For removal and installation ofthe seatbackassembly see page RS 40 and RS 50 Be sure to follow the correct pro cedure 3 Vehicleinvolved in a collision and atrbag is deployed INSPECT SUPPLEMENTAL RESTRAINT SYSTEM a Do a diagnostic system check See page 01 ...

Page 788: ...by residents When deploying the airbag always use the specified SST SRS Airbag Deployment Tool perform the op eration in a place away from electrical noise SST 09082 00700 When deploying an airbag perform the operation at least 10 m 33 ft away from the airbag assembly The side alrbag assembly is very hot when the airbag is deployed so leave it alone tor at least 30 minutes after deployment Use glo...

Page 789: ... damage the SST wire harness 4 Connect the SST red clip to the battery positive terminal and the black clip to the battery negative terminal d Deploy the airbag i Check that no one is inside the vehicle or within 1 0 m 33 ft area around the vehicle 2 Press the SSTactivation switch and deploy the air bag CAUTION The side airbag assembly is very hot when the airbag is deployed so leave it alone for ...

Page 790: ...Open the fastener of the seatback cover c Remove the side alrbag assembly from the seatback as sembly CAUTION When storing the side airbag assembly keepthe uppersur face of the airbag deployment side facing upward d Using a service purpose wire harness tie down the side airbag assembly to the tire Wire harness Stripped wire harness section 1 25 mm2 or more 0 0019 ln2 or more CAUTION If a wire harn...

Page 791: ...ze Must exceed the following dimensions Width 185 mm 7 28 in Inner diameter 360 mm 14 17 ln CAUTION Make sure the wire harness is tight It is very danger ous when a loose wire harness results In the side air bag assembly coming free due to the shock from the airbag deploying Always tie down the side airbag assembly with the airbag deployment side facing inside NOTICE The tire will be marked by the...

Page 792: ... connector SST 09082 0700 09082 00750 NOTICE To avoid damaging the SST connector and wire harness do not lock the secondary lock of the twin lock Also se cure some slack for the SST wire harness inside the tire h Deploy the airbag 1 Connect the SST red clip to the battery positive terminal and the black clip to the battery negative terminal 2 Checkthat no one is within 1 o m 33 ft areaaround the t...

Page 793: ...of the side airbag assembly CAUTION The side airbag assembly is very hot when the airbag is deployed so leave it alone for at least 30 minutes after deployment Use gloves and safety glasses when handling a side airbag assembly with the deployed airbag Do notapplywateretc to a sideairbag assembly with the deployed alrbag Always wash your hands with water after completing the operation 1 Remove the ...

Page 794: ...sideairbagassamb1y has cuts during checking items See page RS 42 SlOE AIRBAGASSEMBLY Seatbar assembly Seiltbilck assembly Sealback assembly If tileside airbagassemblyhas been foundtobefaultyduring checking terns Seatback assemb1y See page RS 42 If the snatback assembly has been dropped Seatback assembly CAUTION As 49 Replacing pan For removal and installation of the seatback assembly see page RS 4...

Page 795: ...ASSEMBLY Install the seatback assemblyto the seat adjusterwith the 4 bolts T orque 43 N m 440 kgf cm 32 fl lbf b Install 5 new hog rings HINT When installing the hog rings take care to prevent wrinkles as little as possible 2 a INSTALL SEAT CUSHION ASSEMBLY Install the seat cushion assembly wlth the 4 bolts Torque 21 N m 210 kgf cm 1 5 fl lbf b Install the wire harness to the seat cushion assembly...

Page 796: ... harness a Connect the side airbag connector U Me J _ b Slide the front seat to the most front position NOTICE Make sure that seat adjuster locks c Without holding the seat track handle mount the seat to the vehicle HINT If holding the seat track handle the adjusted rearmost position slip off d Tighten the bolts on the front side temporarily fror 1 the bolt on the inner side tighten them completel...

Page 797: ...MBLY COMPONENTS AirbagSensorAssembly 1 20 2os 15 AIRBAGSENSORASSEMBLY 2 o os ii J f J EndFinishPanelRH EndFinishPanelLH FinishPanel j gj l i Cf zJ I LowerNo 1 Panel rN m kg_f cmc__ l_l _f j Specifiedtorque p LowerFinishPanel ConsoleBoxHoleCover ConsoleBox ...

Page 798: ...1 REMOVE LOWER FINISH PANEL 2 REMOVE LOWER NO 1 PANEL 3 REMOVE FINISH PANEL 4 REMOVE UPPER CONSOLE COVER 5 REMOVE CONSOLE BOX HOLE COVER 6 REMOVE CONSOLE BOX 7 REMOVE END FINISH PANEL LH 8 REMOVE END FINISH PANEL RH 9 REMOVE AIRBAG SENSOR ASSEMBLY a Disconnect the alrbag sensor connectors NOTICE Disconnect the connectors with the airbag sensor assem bly installed b Using a torx wrench remove the 3...

Page 799: ...E NOT INVOLVED IN COLLISION Do a diagnostic system check See page Dl 326 2 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check See page Dl 326 3 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the alrbag sensor assembly See page Dl 326 ...

Page 800: ...airbag sensor assembly Ifthe SRS has been deployed in a collision If theairbag sensor assembly has been found to be faulty in troubleshooting If the alrbag sensor assembly has been dropped CAUTION RS 55 For removal and installation of the alrbag sensor assembly see page AS 53 and RS 56 Be sure to follow the correct procedure ...

Page 801: ...ag sensor connectors NOTICE Connection of the connector is done after the sensor assembly has been Installed Make sure the sensor assembly is installed with the specified torque Ifthesensorassembly has been dropped orthereare cracks dents or other defects in the case bracket or connector replace the sensor assembly with a new one When Installing the senor assembly take care that the SRS wiring doe...

Page 802: ...ESTRAINT SYSTEM FRONT AJRBAG SENSOR FRONT AIRBAG SENSOR COMPONENTS Air Cleaner Hose Air Cleaner Cap Air Filter Air Cleaner Case Upper Front Fender Apron Seal c lN m kgf cm ft lblf_ Specified torque p it RS 57 H11S07 ...

Page 803: ... repair a sensor In order to reuse it 1 LH REMOVE FRONT AIRBAG SENSOR a Remove the air cleaner hose b Remove the air cleaner cap c Remove the air filter d Remove the 2 bolts and air cleaner case e Disconnect the connector NOTICE Disconnect the connector with sensor assembly installed f Remove the 2 bolts and front airbag sensor LH 2 RH REMOVE FRONT AIRBAG SENSOR a Remove the 5 clips and upper fron...

Page 804: ... 326 b If the front fender of the car or its periphery is damaged do a visual check for damage to the front airbag sensor which includes the following items even if the airbag was not deployed Check the bracket deformation Check the paint peeling off the bracket Check the cracks dents or chips in the case Check the cracks dents chipping and scratches in the connector Check the peeling off of the l...

Page 805: ...ion Replace both the left and right airbag sensors 1f the front airbag sensor has been found to be faulty in troubleshooting If the front airbag sensor has been found to be faulty during checking items See page RS 59 If the front airbag sensor has been dropped CAUTION For removal and installation of the front airbag sensor see page RS 58 and RS 61 Be sureto follow the correct procedure ...

Page 806: ...ar replace the removed sensor with a new one The front sensor is equipped with an electrical con necllon check mechanism Besure to lock this mech anism securely when connecting the connector If the connector is not securely locked a malfunction code will be detected by the diagnostic system HINT lnstaH the front airbag sensor with the arrow on the sensor fac ing toward the front of the vehicle 2 I...

Page 807: ...NSORASSEMBLY SIDE AIRBAG SENSOR ASSEMBLY COMPONENTS SideAirbagSensorAssembly I t J f DeckTrimSideCover J i h JiJ l l b 14 i ServiceHoleCover QuarterTnmPanel PackageTrayTrimPanel DeckTrimRearCover RearSeatCushionAssembly LuggageCompartmentTray tt 191 ...

Page 808: ...static electricity HINT For step 1 to 9 refer to page BQ 88 1 REMOVE PACKAGE TRAY TRIM PANEL 2 REMOVE REAR SEATBACK ASSEMBLY LH AND RH 3 REMOVE REAR SEAT CUSHION ASSEMBLY 4 REMOVE DECK TRIM REAR COVER 5 REMOVE DECK TRIM SIDE COVER 6 REMOVE DECK TRIM SIDE PANEL 7 REMOVE LUGGAGE COMPARTMENT TRAY 8 REMOVE REAR SEATBACK HINGE 9 REMOVE QUARTER TRIM PANEL 10 REMOVE SIDE AIRBAG SENSOR ASSEMBLY a Remove t...

Page 809: ...OT INVOLVED IN COLLISION Do a diagnostic system check See page 01 326 2 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED Do a diagnostic system check See page 01 326 3 VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED Replace the side airbag sensor assembly See page Dl 326 ...

Page 810: ...r assembly If the side airbag assembly has been deployed in a collision If the side airbag sensor assembly has been found to be faulty in troubleshooting If the side airbag sensor assembly has been dropped CAUTION Rs iS For removal and Installation of the side alrbag sensorassembly see page Rs 63 and RS 66 Be sure to follow the correct procedure ...

Page 811: ...ly is installed with the specified torque Ifthesensorassembly has been dropped orthereare cracks dents or other defects in the case bracket or connector replace the sensor assembly with a new one When installing the sensor assembly take care that the SRS wiring does not interfere with other parts and is not pinched between other parts After installation shake the sensor assembly to check that ther...

Page 812: ...STRAINT SYSTEM DOOH SIDE A RBAG SENSOR DOOR SIDE AIRBAG SENSOR COMPONENTS N rfl kQFC _ _ _ tt lbf Specifiedtorque p R 7 FrontDoorLowerFrame BracketGarnish No 2Door InsideHandleBezel OuterMirror SwitchAssembly f 9i iJ ...

Page 813: ...e the sensor involved in a collision when the SRS has deployed Never repair a sensor in order to reuse it HINT For step 1 to 4 refer to page 80 1 1 1 REMOVE NO 2 DOOR INSIDE HANDLE BEZEL 2 REMOVE OUTER MIRROR SWITCH ASSEMBLY 3 REMOVE FROMT DOOR LOWER FRAME BRACKET GARNISH 4 REMOVE DOOR TRIM 5 REMOVE DOOR SIDE AIRBAG SENSOR a Disconnect the door side airbag sensor connector NOTICE Disconnect the co...

Page 814: ...See page 01 326 b If the front door or its periphery is damaged do a visual check for damage to the door side airbag sensor which includes the following items even if the airbag was not deployed Check the bracket deformation Check the paint peeling off the bracket Check the cracks dents or chips in the case Check the cracks dents chipping and scratches in the connector Check the peeling off of the...

Page 815: ... been deployed in a collision If the door side airbag sensor has been found to be faulty in troubleshooting lf the door side airbag sensor has been found to be faulty during checking items See page R5 59 If the door side airbag sensor has been dropped CAUTION For removal and installation of the door side alrbag sensor see page Rs 68 and AS 71 Be sure to follow the correct procedure ...

Page 816: ...s dents or other defects in the case brackets or con nectar replace the removed sensor with new one The door side airbag sensor is equipped with an elec trical connection check mechanism Be sure to lock this mechanism securely when connecting the con nector lf the connector is not securely locked a mal function code will be detected by the diagnostic sys tem Install the door side airbag sensor wit...

Page 817: ...TOR WIRE HARNESS AND CONNECTOR LOCATION p SteeringWheelPad withAirbag SpiralCable DoorSideAirbag Sensor LH L 1 SideAirbagSensor Assembly LH SeatBelt Pretensioner LH SideAirbagAssembly RH SideAirbagSensor Assembly RH SeatBeltPretensioner RH SideAirbagAssembly LH ...

Page 818: ...the connectors in the system are a standard yellow color 1 VEHICLES NOT INVOLVED IN COLLISION Do a diagnostic system check See page Dl 326 2 VEHICLES INVOLVED IN COLLISION a Do a diagnostic system check See page 01 326 b Check breaks in aU wires of the SRS wire harness and exposed conductors c Check to see if the SRS wire harness connectors are cracked or chipped ...

Page 819: ...rness or connector If any partofthe SRS wire harness or any connector has been found to be faulty in troubleshoot ing CAUTION If any partofthe SRSwireharnessorany connector hasbeen found tobe faultyduringchecking items See page R 73 If the wire harness used In the SRS is damaged replace the whole wire harness assembly ...

Page 820: ...STEM BE 25 INTERIORLIGHTSYSTEM BE 27 BACK UPLIGHTSYSTEM BE 30 STOPLIGHTSYSTEM BE 32 WIPERANDWASHERSYSTEM BE 34 COMBINATIONMETER BE 39 ELECTRICTENSIONREDUCERSYSTEM BE 52 DEFOGGERSYSTEM BE 54 POWERWINDOWCONTROLSYSTEM BE 58 POWERDOORLOCKCONTROLSYSTEM BE 62 WIRELESSDOORLOCKCONTROL SYSTEM BE 67 SLIDINGROOFSYSTEM BE 82 POWERMIRRORCONTROLSYSTEM BE 85 AUDIOSYSTEM BE 88 ANTENNA BE 119 CLOCK BE 122 HORNSYST...

Page 821: ......

Page 822: ...t System such as the driver airbag and front passenger airbag failure tocarry out service operation in the correct sequence could cause the SRS to un expectedly deploy during servicing possibly leading to a serious accident Before servicing including re moval or installation of parts inspection or replacement be sure to read the precautionary notices in the RS section 3 AUDIO SYSTEM If the negativ...

Page 823: ...ireHarness HEAD fuse Onty one side light does not light 2 Headlight Gulb 3 Wire Harness Lo Bearn does not tight light Control Switch Headlight Dinuner Swrlch Lo Beam does not lrght All 2 Body Control System 3 Wire Harness HEAD LO LH Fuse HEAD LO RH Fuse Lo Beam does not l ght ONE SIDE 3 Headlight Bulb 4 WireHarness Headlight Dimmer Switch Hi Beam does not light ALL 2 Body Control System 3 Wire Har...

Page 824: ...r L Terminal CH 10 in OFF 3 Parking Brake Switch BE 46 Body Control System Dl 535 5 Wirc Hamoss FOG LIGHTSYSTEM Symptom Suspect Area See page FOG Fuse BE 10 Fronttoglightdoes notlightwith light control switch at HEAD Front FogLight Relay BE 23 Headlight is normal 3 Front Fog LightSwitch BE 3 Wrre Harness Frontfoglightdoes notlightwith lightcontrol swijch at HEAD 1 Headlight and Taillight System BE...

Page 825: ...lumlllationdc03snotlade out immediately when the 1gmtion 2 RADIO NO 2 Fuse BE 0 SWitch is turned to ACC or ON wrthin 15 seconds after all the 3 GAUGr fuse BE 10 doors are closed 4 Body Control System Dl 535 5 WireHarness The illumination docs notfade out immediatelywhen all thedoors 1 Door Unlock Detection S itcll BE 63 2 Body Control System Dl 535 are locked within 15 seconds alter they areclosed...

Page 826: ... Fuse 2 Meter Circuit not operate 3 Wire Hamess L Vehicle Speed Sensor Speedometerdoes not operate Meter Circu t 3 Wire Harness Igniter ECM Tachometer does not operate 3 MeterCirculi 4 Wire Harness 1 Fuel Receiver Gauge 2 FuelSerx erGauge Fuel gauge does not oper Jteor abnormal operfllion_ 3 Meter Crrcu11 4 Wrre Harness 1 Engine Coolant Temperatura Rac ivarGauge Engine coolant temperalure gauge do...

Page 827: ...t does notlightup 3 MeterCircuit BE 42 4 Wire Harness LED 2 DOME Fuse BE 10 3 Door Courtesy SwitCh BE 28 DoOJ ope11 w uning light does no light 11p 4 LuggageRoom L gh Switch BE 28 5 Body Control System Ol 535 6 Meter C rCUlt tlE 42 7 W re Harness Indicator L ghts COMBINATION METER Symptom Suspect Area See page LED SRSincicator light does not light up 2 Airbag Sensm Assembly 01 324 3 Wire Harness L...

Page 828: ...es not light up_ 1 BE 7 u L TRO 8 ES OOTtNG Bulb Tum Signal and HazardWamingSyslem BE 2 Meter C1rcuit BE 42 Wire Harness Bulb Headlight and Taillrghl System BE 2 Meter Circuit BE 42 WiU J Harness LED CruiseControl ECU Dl 483 Meter Circurt BE 42 Wira Harna ss Suspect Area See page HTR Fuse liP JIB BE 10 OEF Fuse liP Jf8 BE 10 Defogger Relay liP JIB BE 55 DefoggerSwitch BE 55 Wire Harness Defoggor W...

Page 829: ...35 BE 63 BE 28 BE 63 0 535 BE 63 Troubleshooting of the wireless door lock control system is based on the premise that the door lock control system power slide door control system and theft deterrent system are operating normally Ac cordingly before troubleshooting the wireless door lock control system first make certain that the door lockcontrolsystem power slide door control system and theftdete...

Page 830: ...icbuttoo is Wireless Door Lock Receiver BE 73 pressed 5 WireHarness SLIDING ROOF SYSTEM Symptom Suspect Area See page 1 GAUGE Fuse liPJIB BE 10 2 POWER Fuse 1 P J 8 BE 10 Slkiingrootsystemdoes not operate 3 Slidir1g RoofCor1 rol Assembly RE 84 Sliding RoofSw1tch BL B4 5 Wne Harness 1 Sliding RoofControl Assembiy BE B4 Slidingrootsystemoperatesabnormally 2 SlidingRoofSwitch BE 4 3 Wire Harness 1 Sl...

Page 831: ...BE 10 POWER SOURCE LOCATION BODY ELECTRICAl POWER SOURCE CenterJunctionBlock Engine Room Junction Block Relay Block l p ...

Page 832: ...8 ST 19 EFI NO 2 20 EFI NO 1 21 HORN 22 HAZ 23 AM2 24 EFI 25 DCC 26 ALT S 27 SPARE 3 I rP I 120A 30 A 40 A 30 A 10 A 20A 30 A 50 A 25 A 1 0 A 1 0 A 1 0 A 1 5 A 30 A 40 A 1 5 A 7 5A S A 7 5 A 1 0 A 1 5 A 7 5A 1 5 A 25 A 7 5 A 7 5 A BE 11 POWER SOURCE RELAYS A FAN NO 2 Relay B FAN NO 1 Relay C CircuitOpeningRelay D HornRelay E FAN NO 3 Relay F MagneticClutchRelay G IG2 Relay H EFI Relay I HeadlightC...

Page 833: ...IPER 14 TURN 15 16 HTR 17 FRR W 18 TAIL 19 MULTI FUSE 20 MULTI FUSE 21 MULTI FUSE 22 MULTI FUSE 23 0EF RELAYS A B IGlRelay C DefoggerRelay 15A 15A 25A 20A 20A 10A 15A 7 5A 7 5A 15A 25A 15A 10A 7 5A D TaillightControlRelay 10A 20A 10A 5A ABS IG WARNING FANRLY C CECU IG 7 5A DOME MPX 8 ECU 8 5A BODYECU IG BK UPLP TENSROC DEFRLY 7 5A ECUACC PANEL2 PANEL1 30A 1 1 ...

Page 834: ...BODYELECTRICAL IGNITION SWITCHAND KEY UNLOCK WARNING BE 13 SWITCH IGNITION SWITCH AND KEY UNLOCK WARNING SWITCH LOCATION IgnitionSwitch KeyUnlockWarningSwitch p ...

Page 835: ...tinuity Continuity Co111inuity Continuity If continuity is not as specified replace the switch 2 INSPECT KEY UNLOCK WARNING SWITCH CONTI NUlTY Switch fX Sition Testerconnoction Specified conditio11 OFF Key removed No continuity ON Key set 1 2 Cominuity If continuity is not as specified replace the switch 3 INSPECT KEY UNLOCK WARNING BUZZER Check that the buzzer sound when driver s door is opened a...

Page 836: ...HEADLIGHTAND TAILLIGHTSYSTEM HEADLIGHT AND TAILLIGHT SYSTEM LOCATION EngineRoomJunctionBlock HEADLH LWRFuse HEADRH LWRFuse HEADLH UPRFuse HEADRH UPAFuse HeadlightControlRelay BE 15 IgnitionSwitch Headlights Taillights p ...

Page 837: ...BE 16 COMPONENTS CombinationSwitch LightControlSwitch HeadlightDimmerSwitch BODY ELECTAICAL HEADLIGHTAND TAILLIGHTSYSTEM CombinationSwitch WiperandWasherSwitch SpiralCable ...

Page 838: ... is not as specified replace the switch 3 INSPECT HEADLIGHT CONTROL RELAY CONTINU ITY Condition Testerconnection Specified condition Cans anl 1 3 Continuity Apply 8 between 2 5 ConlinUoty terminals 1 and 2_ If contlnutty ts not as spec1fled replace the relay 4 INSPECT TAILLIGHT CONTROL RELAY CONTINUITY Condition Testerconnection Spocilied cond1Hon Constant 1 2 Continuity Apply 8 between 3 5 Contin...

Page 839: ...hts auto ON Verify that the lights will go out when light control switch position is OFF or the area surrounding the sensor gets bright 8 wl Automatic light control system INSPECT SENSOR CIRCUIT a Disconnectthe connector fromthe sensor and inspect the connector on thewire harness side as shown in the chart Cond11i0n Specifiedcondition Continuity Ignition switch LOCK or ACC No voltage Ignition swit...

Page 840: ...or and inspect wire harness side connector from the back side HINT Ignition switch ON Light control switch OFF Vehicle s surroundings are bright Condition Speciliedcoodilion Continuity Ignition switch LOCK or ACC No voltage Ignition switch ON 9 5 V or more Taillight and tleadt hl are ON If c1rcu1t ts as spec1hed try replacmg the sensorwith a newone If the circuit is not as specified inspect the ci...

Page 841: ...eat and puts the vehicle in a state ready for driving with a full tank Bounce the vehicle several times Tire inflation pressure is the specified value b Prepare the thick white colored paper c Stand the paper perpendicularly and ensure the distance from it to the head lights is 3 m 9 84 ft d Ensure that the center line of vehicle and the paper are at a 90 degree angle as shown in the illustralion ...

Page 842: ...ector of the other light to avoid heat affection from the light becausethe other lens of the head light assembly is made of synthetic resin When connecting the connector again take care not to make the aiming out of adjustment When covering the headlight finish it within 3 min utes i Turn the headlights ON U Check that the head lights light up the paper as shown in the illustration HINT As shown i...

Page 843: ...BE 22 FOG LIGHT BODVELECTRICAL SYSTEM LOCATION FogLights FOG LIGHTSYSTEM EngineRoom JunctionBlock 113 88 ...

Page 844: ...ion les arconnection Sp ifiEXIcondition OFF No continuity ON 10 1 1 Continuity If continuity is not as specified replace the switch 2 INSPECT FRONT FOG LIGHT RELAY CONTINUITY Condition Testerconnecbon Sp cifled condition Constant 1 2 Continuity Apply B between 3 5 Continuity terminals 1 arxl 2 If continuity is not as specified replace the relay ...

Page 845: ...BE 24 _ _ _ _j BODY ELECTRICAL FOG UGHTSYSTEM ADJUSTMENT ADJUST FOG LIGHT AIM A bolt Vertical Direction ...

Page 846: ...CAL TURN SIGNALAND HAZARD WARNING SYS I EM TURN SIGNAL AND HAZARD WARNING SYSTEM LOCATION TurnSignalLights TurnSignalFlasher a EngineRoomJunctionBlock HAZFuse HazardWarningSwitch CenterJunctionBlock TURNFuse BE 25 ...

Page 847: ...OF 5 7 Continuity ON 5 6 1 2 4 Continuity l urnination circuit 8 9 Continuity If cont1nu1ty rs not as spectf1ed replace the swttch 3 INSPECT TURN SIGNAL FLASHER OPERATION a Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 3 b Connectthe 2 turn signal light bulbs parallel to each other to terminals 1 and 3 check that the bulbs flash HINT Theturn signal ligh...

Page 848: ... BODYELECTRICAL INTERIOR LIGHT SYSTEM LOCATION BE 27 INTERIOR LIGHT SYSTEM I13WJ ...

Page 849: ...sts between termi nals If continuity is not as specified replace the light assembly or bulb 3 INSPECT REAR ROOM LIGHT CONTINUITY a Disconnect the connector from the room light b Turntheroom light switch ON checkthatcontinuity exists between terminal 1 and 2 If continuity is not as specified replace the light assembly or bulb 4 INSPECT DOOR COURTESY SWITCH CONTINUITY 11 281 a Check that continuity ...

Page 850: ...ODY ELECTRICAL INTERIOR LIGHT SYSTEM 5 INSPECT LICENCE PLATE LIGHT CONTINUITY Using an ohmmeter checkthat continuity exists between termi nals If continuity is not as specified replace the light assembly or bulb ...

Page 851: ...BE 30 BODY ELECTRICAL BACK UP LIGHT SYSTEM BACK UP LIGHT SYSTEM LOCATION p Back UpLights lllS90 ...

Page 852: ...6 INSPECTION 1 1 INSPECT BACK UP LIGHT SWITCH CONTINUITY Switch position Tester connection Specilied condition Free _ No continuity Push 1 2 Continuity If continuity is not as specified replace the switch 2 INSPECT PARK NEUTRAL POSITION SWITCH CON TINUITY See page Dl 202 Dl 261 ...

Page 853: ...BE 32 BODY ELECTRICAL STOP LIGHT SYSTEM LOCATION StopLightSwitch p STOP LIGHT SYSTfM SlopLights 113501 ...

Page 854: ...tion Testerconnocl10n Specifiedcondition Switch pin pushed n No conliiiUIIY Pedal released Switch pintree 1 2 Continuity Pedal depressed If continuity is not as specified replace the switch wl cruise control system SW ICh posi1ion fester connection Specifie condition Switch pin pushed in No conlinu ty Pedal released Switch pin free 1 2 Contmuity Pedal OOpressed If continuity is not as specified re...

Page 855: ...BE 34 BODY ELECTRICAL WIPER AND WASHER SYSTEM LOCATION WasherTank WasherMotor p WIPERAND WASHER SYSTEM CombinationSwitch WiperandWasherSwitch CenterJunctionBlock WIPFuse WSHFuse RearWiperMotor 1 3591 ...

Page 856: ...to tNT position b Turn the intermittent time control switch to FAST position c Connect the positive lead from the battery to terminal 1 6 and the negative lead to termina 2 d Connect the positive lead from the voltmeter to termi nal 7 and the negative lead to terminal 2 check that the meter needle indicates battery voltage e After connecting terminal 16 to terminal 17 connect to terminal 2 to term...

Page 857: ...le WasherSwitchON __ OFF I l rthan1 sec l ppro 3sees Battery voltage I I OVolt I If operation is not as specified replace the wiper and washer switch 4 INSPECT REAR WIPER AND WASHER SWITCH CON TINUITY Switchposition TesterconnectiorJ Specilied conditiOn Washer 1 2 12 Continuity OFF No continuity INT 2 13 Con invity ON 2 10 Continuity Washer 2 2 10 1 2 Conti lUtty If conhnwty ts not as spectfted re...

Page 858: ... the stop position by disconnect ing positive lead from terminal S b Connect terminals 1 and 5 c Connect the positive lead from the battery to terminal 2 and negative lead to terminal 4 check that the motor stops running atthe stopposition afterthe motoroperates again If operation is not as specified replace the motor 8 INSPECT REAR WIPER MOTOR AND RELAY OPERA TION a Connect the positive lead from...

Page 859: ... be performed quickly within 20 seconds to prevent thecoil fromburning out If operation is not as specified replace the motor 11 w Rear wiper INSPECT FRONT WASHER MOTOR OPERATION Connect the positive lead from the battery to terminal 2 and the negative lead to terminal 1 check that the motor oper ates NOTICE These tests must be performed quickly within 20 seconds to prevent thecoil from burning ou...

Page 860: ...evelWarningSwitch CombinationMeter MeterCircuit LightControl Rheostat IgnitionSwitch ClockAssembly PassengerSeatBeltWarningLight CenterJuncllOnBlock BodyECU MULTI ECU 8 Fuse BE 39 OccupantDetectionSensor I I SeatBeltBuckleSwitch MULTI WARNING Fuse SRS IGFuse ParkingBrakeSwitch TAllFuse ...

Page 861: ...BE 40 BODYELECTRICAL COMBINATION METER DoorCourtesySwitches FuelSenderGauge I I IIJW ...

Page 862: ...BE 41 BODY ELECTRICAL COMBINATION METER Connector A Connector 8 Iii Sx Q _ c N I l l 735 ...

Page 863: ...BE 42 CIRCUIT N BODY ELECTRICAL COMBINATION METER ECU BLJUer 82 Al3 r s a _Miti FLJsllavel J A14 _____ __ CflUISE 810 815 814 A21 AS A17 AOO 811 A20 817 80 AS A19 A16 ...

Page 864: ...17 Lightcontrolrheostat 18 Evaporatortemp sensor 19 Ground 20 Speedsensor Slterminal 21 Back uplightswitch 22 WARNINGFuse 1 Generator 2 Clock Passengerseatbeltwarning 3 BodyECU 4 TAILFuse 5 NCECU 6 ECM Tachosignal 7 ECM a ABSECU Parkingbrakeswitchsignal 9 Turnsignalswitch Rightside 10 NCcontrolpanel NCswitchindicator 11 ABSECU 12 Automaticlightcontrolsensor 13 0 0 offswitch 14 Frontdefoggerswitch ...

Page 865: ...BE 44 BODY ELECTRICAL COMBINATION METER COMPONENTS MeterCase CharacterPlate CircuitPlate MeterPlate MeterGlass N 11 129 ...

Page 866: ...TION METER Ill DISASSEMBLY COMBINATION METER COVER a Remove the 8 screws b Remove the combination meter cover c Remove the meter circuit plate d Remove the 6 clips and the meter glass e Remove the 4 clips and the meter plate BE 45 ...

Page 867: ...nals with fixing pointerto the stopper Tester connection Resistance fl A B 250 C D 250 If reststance value ts not as spectfted replace the meter 3 INSPECT VEHICLE SPEED SENSOR OPERATION a Connect the positive lead from battery to terminal 1 and negative lead to terminal 2 b Connect the positive lead from testertoterminal 3 and negative lead to terminal 2 c Rotate shaft d Check that there isvoltage...

Page 868: ...CE Measure the resistance between terminals with fixing pointer to the stopper Testerconnection Resistance l A B 250 C D 250 If resistance value IS not as spectfled replace the meter 6 INSPECT FUEL RECEIVER GAUGE OPERATION a Disconnect the connector from the sendergauge assem bly b Turn the ignition switch ON check that the receivergauge needle indicates EMPTY c Connect terminals 2 and 3 of the wi...

Page 869: ...rox 110 0 If resistance value is not as specified replace the sender gauge If resistance value is as specified replace the combination me ter 8 INSPECT ENGINE COOLANT TEMPERATURE RE CEIVER GAUGE OPERATION a Disconnect the connector from the sender gauge b Turn the ignition switch ON check thatthe receivergauge needle indicates COOL c Ground terminal of the wire harness side connector through a 3 4...

Page 870: ...nnect the connector from the warning switch and ground terminal of the wire harness side connector b Turn the ignition switch ON check that the warning light lights up If thewarning light does notlight up testthe bulb or inspectwire harness 11 INSPECT LOW OIL PRESSURE SWITCH CONTINUITY a Check that continuity exists between terminal and ground with the engine stopped b Check that no continuity exi...

Page 871: ...he connector from the parking brake switch b Ground terminal of the wire harness side connector c Start the engine check that the warning light lights up If the warning light does not light up test the bulb or inspect wire harness 15 INSPECT PARKING BRAKE SWITCH CONTINUITY a Check that continuity exists between terminal and switch body with the switch ON switch pin released b Check that no continu...

Page 872: ...NTROL RHEOSTAT OPERATION Gradually turn the rheostat knob from the bright side to dark side and check that the resistance decreases from 1 0 k Q to 0 Q between terminal 2 and 1 Rheostat knob turned to clock wise Ifoperation is not asspecified replace the rheostat light control ...

Page 873: ...BE 52 BODY ELECTRICAL ELECTRIC TENSION REDUCER SYSTEM ELECTRIC TENSION REDUCER SYSTEM LOCATION p BuckleSwitch TensionReducerSolenoid inRetractorAssembly 1 3594 ...

Page 874: ...ead from the battery d Pull the belt upward and check that the belt is retracted more quickly when released than in b HINT Do not tilt the retractor If the operation is not as specified replace the front seat outer belt assembly 2 INSPECT BUCKLE SWITCH CONTINUITY a Check that continuity exists between terminals of the switch side connector with the switch ON belt fastened b Check that no continuit...

Page 875: ...BE 54 DEFOGGE BODY ELECTRICAL R SYSTEM LOCATION IgnitionSwitch p DEFOGGER SYSTEM CenterJunctionBlock MULTI DEFRL F DefoggerRe ayY use DEFM Fuse DefoggerWire ...

Page 876: ...r 12 for 18 minutes then the f 4 2 indicator light and test bulb lights go out If operation is not as specified replace the switch 2 WireHarness Side INSPECT DEFOGGER SWITCH CIRCUIT Connector disconnected JU Ul 1 2 3 4 5 7 8 9 10 Tester connection 3 Ground 5 Ground 5 Ground 111291 Constant Disconnect the connector from the switch and inspect the con nector on wire harness side as shown in the char...

Page 877: ... other parts 4 INSPECT DEFOGGER RELAY CONTINUITY Condition Taster C Jnnection Specifiedcond ion Constant 2 Continuity Apply B betwaen 3 5 Continuity terminals 1 and 2 If contmu1ty 1s not as spec1f1ed replace the relay 5 INSPECT DEFOGGER WIRE NOTICE Whencleaning the glass usea soft drycloth andwipethe glass in thedirectionofthewire Takecare notto damage the wires Do not use detergents or glass clea...

Page 878: ... the defogger positive terminal e Place the voltmeter negative lead with the foil strip against the heat wire at the positive terminal end and slide it toward the negative terminal end f The pointwherethevoltmeterdeflects fromzerotosever al V is the place where the heat wire is broken HINT If the heat wire is not broken the voltmeter indicates 0 V at the positive end of the heatwire but graduallyi...

Page 879: ...BODY ELECTRICAL POWER WINDOW CONTflOL SYSTEM POWER WINDOW CONTROL SYSTEM LOCATION PowerWindowMasterSwitch WindowLockSwitch IgnitionSwitch CenterJunctionBlock BodyECU PWRNo 1Fuse PWRNo 2Fuse PowerWindowMotor p ...

Page 880: ...on UP 1 11 OFF 1 10 DOWN 1 0 1 1 Specilied cond lion Continurty Continuity Continuity Continwty Continuity Continu rty Continuity Specified condition Continu ty Continuity If conttnUIIy ts not as spectfted replace the swttch 2 INSPECT POWER MAIN RELAY CONTINUITY Condition Te ster connection Specified condition Constant 1 2 Continuity Apply B between 3 5 Continuity terminals 1 and 2 If contmwty ts ...

Page 881: ...ERATION a Disconnect the connector from the window motor b Connect the positive lead from the ammeter to termi nal 1 ofthe wire harness sideconnectorand the negative lead to negative terminal of the battery c Connect the positive lead from the battery to terminal 2 of the wire harness side connector and raise the win dow to the fully closed position d Continue to applyvoltage checkthat the current...

Page 882: ...ve lead from the battery to terminal 2 of the wire harness side connector and raise the win 2 e o dow to the fully closed position i I L__ j d Continue to applyvoltage checkthat the current changes from approximately 14 A to less than 1 A within4 to 90 se conds e Disconnect the leads from terminals f Approximately 90 seconds later connect the positive lead from the battery to terminal i and the ne...

Page 883: ...SYSTEM POWER DOOR LOCK CONTROL SYSTEM LOCATION p PowerWindowMasterSwitch DoorLockManualSwitch CenterJunctionBlock lgmt OnSwitCh BodyECU DOORFuse DoorLockAssembly DoorlockMotor DoorUnlockDetectionSwitch DoorCourtesySwitches BackDoor LockMotor llJ592 ...

Page 884: ...uity UNLOCK 3 6 Continuit 111689 UNLOCK If conttnUtly ts not as spectfted replace the swttch i ohJ LOCK i UNLOCK 111690 3 Passenger s door INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY Switchposrtion Tester r onnection Specihed cond t on LOCK 2 4 Continuity OFF No continu ty UNLOCK _ Continuity lf continuity is not as specified replace the switch 4 Driver s door INSPECT DOOR UNLOCK DETECTION ...

Page 885: ...onnect the positive lead from the battery to terminal 1 and the negative lead to terminal 2 and check that the door lock link moves to UNLOCK position b Reverse the polarity and check that the door lock link moves to LOCKposition If operation is not as specified replace the door lock assembly 7 Passenger s door INSPECT DOOR LOCK MOTOR OPERATION a Connect the positive lead from the battery to termi...

Page 886: ...T PASSENGER s DOOR PTC THERMISTOR OPERATION a Connect the negative lead from the battery to terminal 6 b Connect the positive lead from the ammeter to termi nal 5 and the negative lead to battery negative ter minal and check that the current changes from approxi mately 3 2 A to less than 0 5 A within 20 to 70 seconds c Disconnect the leads from terminals d Approximately 60 seconds later connect th...

Page 887: ...minal 6 b Attach a current measuring probe to either the positive lead or the negative lead and check that the cur rent changes from approximately 3 2 A to less than 0 5 A within 20 to 70 seconds c Disconnect the leads from terminals d Approximately 60 seconds later reverse the polarity and check that the door lock moves to the LOCK position If operation is not as specified replace the door lock a...

Page 888: ... LOCK CONTROLSYSTEM WIRELESS DOOR LOCK CONTROL SYSTEM LOCATION p Door Lock Assembly Door Lock Motor Door Unlock Detection Switch Wireless Door Lock Control Receiver t Door Courtesy Switches pf 6 U 0 PANIC BE 7 Back Door Lock Motor ...

Page 889: ...re locked BaSlCfunction check Underthe standard operation when repeating the operation of UNLOCK and LOCK switch 3 times or more alternately check the UNLOCK LOCK operation from 3rd time onward Following procedures are standard operation 1 Keep about 1 M away to the right direction from the outside handle of a driver s seat 2 Face the transmitter toward the vehicle and press one of transmitter swi...

Page 890: ...l y lfoperatingdoorcontrolreceiverintheorderof1through2 themodeturnstodiagnosticmode 1 Insertthekeyplateintheignitionkeycylinderandpullout theninsertitaga1nandturnignitionswitch OFF tON OFFoncewithin5secondsafterpullingout 2 Aftercompletingtheprocedurewithin30seconds turntheignitionswitchOFF J ON OFF9times HINT Inthecasethateitherof 1 and 2 conditionsisnotsatisfied transfertonormalmode Reference W...

Page 891: ...response Checktaillightlightupwhenpressingoneachswitchof transmitter 1 ReceivednormalwaveofLOCKswitch ON OFF 1 0 2sec 1 1 I I 0 5 sec 2 ReceivednormalwaveofUNLOCKswitch ON OFF ill IUL J I I I I I 0 2 sec 0 5 sec 0 2 sec 3 ReceivednormalwaveofPANICswitch ON OFF 1 1 J 10 5sec l0 5sec Transmitterfaultyorwirelessdoorlockre ceiverfaulty Reference Useanother normal transmitterand checkwiththediagnosticm...

Page 892: ...nthesametypevehicle checkthatalltaillightschirps inthesameway BE 71 1 Reference Checkthewavereachingrangewithanother No transmitter normal Whentherangeisnormal transmitterdefectionisdetected therangeis notnormal wirelessdoorlockreceiverdefection isdefected y0ffi1 ssdoorcon tr _ checkd Checkthaicontinuityexistsbetweenthereceiver terminal3 PRG andbodyECUterminal89 PRG Checkthatcontinuityexistsbetwee...

Page 893: ...constantly 10to 14 Vvoltageatthe connector terminal S B of wireless doorcontrol receiver Yes No Body ground check Wireharnessfaulty Check that continuity exists between the connector Body ground open and contact error terminal 1 GND of the wireless door control receiver and body ground Yes Wireless door control receiver faulty ...

Page 894: ...and battery to the bottom termi nal then apply 3 V voltage to the transmitter d In the location where is approx i M away from driver s outside handle in the right direction and check the trans 5 mitter operation when pressing transmission switch on the surface of the transmitter body Standard Remote control of vehicle door lock can be operated HINT The minimum operation distance differs according ...

Page 895: ...oaded is shown on the tester until the energy is completely consumed Accordinglywhen inspecting the energy amount left in the battery it is necessary to measure the voltage when the battery is loaded 1 2 k Q a Remove the screw and coverusing a driver b Remove the battery lithium battery from the transmitter c Connect the lead to the terminal of the transmitter and install the battery d Connect the...

Page 896: ... was pressed Make sure to read the voltage before of it High voltage might be shown 1 to 2 times afterleaving the battery judge should be made with the voltage shown at the 3rd time or later g Disconnect the lead h Set the battery lithium battery in the transmitter i Install the cover so that the 0 ring is not distorted or slipped off j Using a screwdriver tighten the screw 3 INSPECT WIRELESS DOOR...

Page 897: ...e harness side connector to the receiver and inspect the wire harness side connector from the back side as shown below Condition Specified condition 10 14 v Ignitionswitch position OFF Key removed About 6 7 V Transmitter ON If ctrcwt 1s as speclfted replace the recetver lf the circuit is not as specified inspect the circuit connected to other parts ...

Page 898: ...e cover with a finger as shown in the illustration so that there becomes clearance then pry out the cover from that clearance b Remove the transmitter J c Remove the battery lithium battery NOTICE Do not push the terminals with a finger If prying up the battery lithium battery forcibly to re move the terminals are deformed d Install a battery lithium battery as shown in the illustra tion NOTICE Fa...

Page 899: ...codes exceeds 4 codes previously regis tered codes are correspondingly erased in order starting from the first registered code The rewrite mode is used to erase all previously regis tered codes and register only new recognition codes The prohibition mode is used to erase all registered codes and cancels the wireless door lock function Use this mode when the transmitter is lost The confirmation mod...

Page 900: ...door is UNLOCKED Insertthekeyintotheignition keycylinder thenpullitout Aerformthistwice within5 seconds Open and close the door manual operation 2 times 1stlime 2nd lime I I Within OPEN J I I I 40 sacs CLOSE Insert the key into the ignition key cylinder then pull it out Again open and erose the door manual operation 2 times 1st _ tme 2nd _l_me OPEN I i J I I I Within CLOSE 40 secs Close the all do...

Page 901: ...ically perlorms Doorcontrol relay automatically performs the LOCK UNLOCK operation once the LOCK UNLOCK operation 1 to 4 times ortwiceat 1 sec interval to inform the at 2 sec interval to inform the operator of operatorthat eitherthe add mode or the number of the registered codes rewrite mode has been selected HINT ILOCK UNLOCK occurs oncef When the number of the registered code is 0 the operation ...

Page 902: ...OCK UNLOCK occursonce I 3sees Registration of recognition code is completed I I LOCK UNLOCKoccurstwice I i Registration of recognition code has not been completed I Recognition code received first time and second time did not match When select1nQ add mode a registered recognition code was received I IfLOCK UNLOCKoperationcannotbe performedat all the modereturnstothe normal mode then start with Sta...

Page 903: ...yf r10sec ormorefromthestartingpointofthereversemotion 2 Thisshiftsittothemanualoperatiioninwhichthejamprotectionsystemisprohibited withtheignitionON 3 Inthemanualoperation closetheslidingroofcompletelyandstopthemotion 4 ThefullydosedpositionwillbedetectedbyECU Initialization Doesltbecomenormal N_ G __ _ IL __ __ __ __ M __ oc _ h _ a _ n _ lc _ al _ fa _ l _ lu _ re __ __ __ __ I End ...

Page 904: ...LOCATION BODYELECTRICAL SliDING ROOF SYSTEM Sliding Roof Assembly Sliding Roof ECU Sliding Roof Switch Sliding Roof Motor CenterJunction Block S Roof Fuse BE 33 1 1593 ...

Page 905: ...and inspect the con nector on the wire harness side as shown in the chart Condition Speafiedcondition Constant Continuity Ignitionswitch LOCK orACC No voltage Ignitionswitch ON Batterypositive vollage Constant Battery positive voltage Constant Continuity Constant No contintHty Ignitionswitch LOCK or ACC No voltage lgn ion switch ON Battery positive voltage Sliding roof control switch CLOSE DOWN No...

Page 906: ...BODY ElECTRICAL POWER MIRROR CONTROL SYSTEM POWER MIRROR CONTROL SYSTEM LOCATION p M1rrorAssembly MirrorMotor PowerMirrorSwitch BE 85 ...

Page 907: ...RIGHTSIDE MIRROR SWITCH CONTINUITY Switchposition Testerconnection Specifiedcondition OFF Nocontinuity 3 8 UP 6 7 Continuity DOWN 3 7 6 8 Continuity LEFT 2 8 6 7 Continuity RIGHT 2 7 6 8 Continu1ty If cont nwty 1s not as specJfted replace the sw1tch If continuity is as specified inspect the switch circuit 3 INSPECT MIRROR MOTOR OPERATION a Connect the positive lead from the battery to terminal 3 a...

Page 908: ...M I 101813 W 014 c Connect the positive lead from the battery to terminal 3 and the negative lead to terminal 5 and check that the mirror turns to the downward d Reverse the polarity andcheckthatthemirrorturns to the upward If operation is not as specified replace the mirror assembly ...

Page 909: ...reo broadcasts cannot be received even through AM comes in very clearly Not only does FM stereo have the smallest service area but it also picks up static and other types of interference noise easily 3 RECEPTION PROBLEMS Besides the problem of static there are also the problems called fading rnultipath and fade out These problems are caused not by electrical noise but by the nature of the radio wa...

Page 910: ...son FM signals often seem to gradually disappear or fade away as the vehicle goes behind a building or other obstructions This is called fade out 4 NOISE PROBLEMS a Questionnaire for noise It isveryimportant for noise troubleshooting to havegood understanding of the claims from the customers so that make the best use of following quenstionnaire and diag nose the problem accurately Strongpossibilit...

Page 911: ...smitting through the core wire of the coaxial cable Any noise wave other than radio wave is mixed into this core wire that naturallycauses noise in the radioand poor sound quality In order to prevent these noises from mixing into the radio thecore wire inside the coaxial cable is covered with a mesh wire called shield wire This shield wireshelters the noise and transmits it to the ground thus prev...

Page 912: ...sing a pencil or similar object push in the guide Using acleaning pen orcotton applicator soaked in clean er clean the head surface pinch rollers and capstans CD Player Disc Cleaning MAINTENANCE If the disc gets dirty clean the disc by wiping the surface from the center to outside in the radial directions with a soft cloth NOTICE Do not use a conventional record cleaner oranti static pre servative...

Page 913: ...ve been able to add or replace freely 3 Because of the above 2 each manufacture has become able to concentrate on developing products in their strongest field This has enabled many types ofproducts provided inexpensive ly 4 Conventionally a new product developed by a manufacture could not be used due to a tack of compatibility with other manufactures products Because of this new standard users can...

Page 914: ...maller codes are displayed in order displayed codenumbers are switched by operating TUNE UP or DOWN switch In LAN check mode by pressing 5 of PRESET switch for more than 2 sees diagnosis memory of each equipment can be deleted when deletion is completed the mode returns to LAN check mode Preset 1 switch TUNE UP and DOWN switch Preset 6 switch TUNE I COII llG t lKlOE _ CD switch 11 699 Code No phys...

Page 915: ... 21 DTC No 1 Thisis the numberallotted to the diagnosis code ttmt occurred NO DTC No 1 In LAN check mode when pressing 2 of PRESET switch the mode turns to the diagnosis memory mode CCODE is displayed Theresults ofselfdiagnosis performed overtuner and connected equipment are memorized and displayed 2 HINT Perform the operation shown in the following iftustration then read the result of the inspect...

Page 916: ...e numberallotted to the diagnosiscode that occurred 21 Periodic communication number of when occurring in the diagnosis memory code 1 This is the numberallotted to the diagnosis code that occurred d1 DTC No 1 This is the number allotted to the diagnosis code that occurred 360 Physical address Equipment that is communicating code 1 After error is fixed start upthe diagnosis mode 2 Continue pressing...

Page 917: ...cassette deck Cassettecannotbeejected fromHead Unit Communicationwiththe equipmentthatis communicatinghasfailed successively Errorinperiodic communication Resultofdiagnosisisnot Countermeasure Systen Oiagno and inspectedparts Che memory 0 X Radioreceivercheck u Radioreceivercheck Wireharnessand connectercheck I _ I c j u _ Wire harnessand I X _ connector I i 1 FF Oiagnosisnoresponseissuedfromstart...

Page 918: ...sound including noise is produced No1sc present but AM FM not opercl ng_ Any speaker does not work_ Any AM or I M docs not worl Few preset turn ng bands Reception poor_ Sound quaiFty poor Preset memory disappears Tape Player Cassette tape cannot be mserted Cassette tape inserted but no power Power comiflg in but tape player not operating_ Anyspeaker does not work Soundquality poor Tapejammed malfu...

Page 919: ...OK NG __Ispo p _H_ _ B termin l t P eramplifier Yes No Bwire harnessfaulty _ __ _ _ __J CheckifGND wirehamessside ofpoweramplif ii ie r l c I G N D ft au l fy _ _ _ _ _ _ _ _ _ _ _ __j groundednormally ING __j OK Ispowersupplied_t_ o AC C t e rm l in a l o f ra d io a ss e m b ly2 f P _o w e r a m _p pi W if i_e r o _ r_ _A _ CC _ w _ r h rnessfaulty l No Yes c Poweramplifieror B wireharnessfaulty...

Page 920: ...harnessside ofpoweramplifier D_ t_____________ groundednormally OK No IspowersuppliedtoACCterminalofradioreceiver Yes r C h e c k lf G N D w i c ch a n e s s s ldce Tp amplitli le ulty groundednormally NG Doescontinuityexistinspeakerwireharness No Speakerwireharnessfaulty emporarilL nstallanotherspeaker FunctionsOK No Speakerfaulty Yes c c J Hissnoisefromspeake ___ _ _________l r N o il Roewchhe a...

Page 921: ...peratingnormally Yes Radioassemblyfaulty I N r h l ss_n_O c seprodu c e d b y n o n f u n c tio n i g p e ak e J y 1 R a d lo a s s e m b l y fa u l5 ty No Yes Rechecksystemafterrepair Doescontinuity ist _p eharness 1 No 1 Speake wi7e h f Y Yes T e m p o ril y ln_ _il _ _ _ _th_e_ s p e a ke F u n c tl o n s O K JJ Y e s p e a k e i u l IY __ No Poweramplifierfaulty Rechecksystemafterrepair ...

Page 922: ...a l ly _____ _ _ _ _ j j l ioassemc b l y fa u l ly _ _ _ _ _ _ _ _ _ __j No Yes T ityr anothe speakeLFunctio_n_ s_O_K_ _ _____it y e7s i _ peakerfaulty f Hissnoisefromspeaker Powe a m p Jif ie a ul ly Yes No Rechecksystemafterrepair Radioassemblyfaulty Rechecksystemaft _ _ ...

Page 923: ...ee page BE 8 I h tac oftheplugJaCkoftherad10OK H J lN o lQ i T a ke a m e a s u e fo r c o n ta c t D _o_e_s_t h e_c_oL s getb te by gth e o u te l antenna suchaspillarantenna No Yes Isthecon ta c tL of l h e a nt 1 inalontheglass f I N T keameas reforcont surfaceandthedefoggerterminal J No Yes ts_l_ h_ e c o tinuityot ih e n te n n a c o r dJo K K2 J j eP 8Cetheantennacord l Y No Checkthegroundin...

Page 924: ...sertedintapeplayer No Yes I Radioassemblyfaulty ____ J heckitRADfu eisOK OK J 1 Replacefuse NG Ispowersuppliedto Bterminalofpoweramplifier No B wireharnessfaulty 1Yes _ jcheckifGND wireharnessside ofpow e aam mpp lilfuie c J r G N D I a u lly lgroundedno ally NG OK Ll_ s p_o_w_e_c_s_u p p_ lie d t o_ _B _ te_c_ m_in_a_l_o_f_ca_d _i_ o_a_ _ e_m _b o l y_ ___ _ __ _ _ No L weram e_ d_a_u_lt y Yes Ch...

Page 925: ...T BE INSEATE _ _ _ _ _ _ _ _ _ _ _ J j IReplacefuse_ Poweramplifierfaulty J OK 0 assemblyfaulty pow upp t B i rminal radioassembly ____j N o B w ire h a m e s s f a oi IY 1 No eramplifierfaulty __________J IspowersuppliedtoACCterminalofradioassembly Yes ioassemblyfa_t_ l_ ty _ _ ...

Page 926: ... No H is s n o is e o m s p e a k e c J r Ni o JPoweramp fi rfault Yes j Rechecksystemafterre air Radioassemblyfaulty Rechecksystemafterrepair Ii ape Player ANY SPEAKER DOES NOTWORK fT poranly10staHanothe p ea _k_e J l 1 S p e aE ke f a u lty Ct1onOK _____ Yes _j yo Radioassemblyorpow8ramplifierfaUltY ...

Page 927: ...assettetapefaulty L lR _a_ d_io _ a_ ss_e_m_b_ly _ fa_u_lf_Y _ ____ c c TAPE JAMMEDMALFUNCTION WITHT APE SPEED OR AUTO REVERSE Istherealoreignobjectinsidetapeplayer __ __ _ _ _ Y e s 1 R _e_m_o ve f or eTQ Object No Operatesnormallyaftercleaningtheheads No Radioassemblytf ulty Yes Headdirty ...

Page 928: ... cd tko B3iterminail r d assemblylaulty I No Yes 1 o r wireharne s No r ____j side ofCDplayergrounded NG normally OK 1 i CDplayerfaulty __ leek if A A D Iu s e is O K Jj NNiiG l R e p la c e lOK rc ____j__ _ ___ Ispowersuppliedto 8terminalofpoweramplifier Yes No Bwireharnessfaulty CheckifGND wireharne side ofradio s biy groundednormally J NG lOK Qiadioass lyfaulty I ...

Page 929: ...ifferentCD i erted No I Isradiooperatingnormally Yes No OS econtinuityexistinspeakerwireharness r _____j_ves I mpe a llylnst ll speake nctionsOK I I CD faully Yes Istemperatureinsidecabinhot Yes Hassuddentemperaturechan 9ti occurredi T si ecabin ____ _ _j Yes No CO playerfaulty I Protectivecircuitin j operation _ _j IFormationof condensation _ jduetotemp changes l j f l S jp e k e r 0__r _ _ h _ r...

Page 930: ... m t c ha n g e o c c u d s ld e ca b in _ _Yes No CD playerfaulty faulty mationofcondensati dueto J _ tarTT changes SOUNDQUALITYPOOR VOLUME FAINT FunctionOK ifdifferent CDinserted No j CDfau y Yes No Yes toplayertautly _ _ ___ Isspeakerproperty installed Yes Temporarilyinstallanotherspeaker Functions OK J 1 l t a tlc p ro p e d y No t _ c No Radio a em t yo CD_ _ IayerorrO er E i e r fa u lty ...

Page 931: ...erwireharness Speakerwireharnessfaulty _ _j No tYes Temporarilyinstallanotherspeaker Speakerfaulty Yes FunctionOK j No _ ___________ _ __ Poweramplifierfaulty Rechecksystemafterrepair 22 CO Player Isautosearchbuttonofradio operatingnormally CheckifRADfuseisOK CDWILLNOT BE EJECTED Yes 2 Y ji __ _ OK J R Piacefuse NG Radioassembly i faulty _j 1 QSpowersuppliedto B tefmTn al f radioreceiver No Powera...

Page 932: ...spowersupp iedto 8terminalofpoweramplifier Yes ACCwireharnessfaulty Replacefuse J L _ C h e c k lf G N D w l re ha r n es s s ld e o f p _ _ _ _ _ _ m _ p l l fl_ e _ _ _ _ 1 N G f Y_ _ _ __ __ groundednormally _ OK Ispowersuppliedto 8 terminalofradioassembly rcc cc c Poweramplifierorwireharnessfaulty Yes No CheckitGND w l re h ar n e s s _ _ s l d e o f r _ a dJ I o _ _ a s s e _ m b l _ y rN N G...

Page 933: ...de ofpoweramplifi e 1NG i groundednormally c_ OK IspowersuppliedtoACCterminalofradioassembly j Yes No GNDfaulty yoweramplifierfaulty Lspowersuppliedto B terminalofradioassembly f i o ol weramplifier lty _____ _ No CheckifGND wireharnessside ofradioassembly S G N D fa u II Y i groundednormally 1 NG f0K 1 Istherecontinuityinspeakerwireharness r v cs No Temporarilyinstallanotherspeaker FunctionsOK No...

Page 934: ... _ rmaii _ _ _ C D p l ay e cJt a ut ty J N c o c c Yes Ishissnoiseproduced bynon functioningspeaker J f i R Ra d i o a s se m b ly f a i ull y Y es Recheck system after repair No O onlinuity exisfi p e harness _ _ No JYes Temporarily instal another speaker Function OK No j Yes Poweramplifier faulty Recheck system after repair ...

Page 935: ...c rdfromtheradio Yes No Doesthenmseoccurevenafterpullingoutt 1 antennatermmalontheglasssurface ___j p Yeo Isn tthereanyadhesive Butylrubber 1 stuckonthebasesoftheantenna terminal defoggerterminalandbusbar Yeo Failureofglassinstallation Mustplanethebutylrubber __fl t rte 1 Doesthenoiseoccurevenafterpullingout Interferingnoisefromthedefoggerline thedefoggerterminal Yes andchokecoil No Checktheground...

Page 936: ...henhorn buttonis pressed lhen Horn noise released Whirring gratingsoundisheardwhenpushed Yes continuously L No _ urmuringsound stopswhenenginestops I No iacknoiseo c i di ation with blinki g l her No __ Ccursduringwindowwasheroperation I Yes I lgn lion noise J Turnsignalnoise Yes I Washernoise Yes No _ _ _ rs c m t c h in gcn oo c iseoccurswhileengineis runnin c gc 7 iE n g i n e c o o la n t t e ...

Page 937: ...BE 116 BODY ELECTRICAL AUDIOSYSTEM LOCATION Tweeter PowerAmplifier Center Junction Block Radio Assembly CIG Fuse RAO Fuse Front Speakers Rear Speakers p 113595 ...

Page 938: ...iver assembly and in spec the connector on the wire harness side Condition SpecHied condition Constant Battery positive vol1age Lightcontra switchTAIL or HEAD Banery posihve vo age RadiopoWefswitch ON Battery posilive voltage Audio sounding 1 Vor below Audio sounding 5 7 V Audio sounding 5 7 v Constant Continuity Ignition switchACC Battery positive voltage Constant Continuity Audio sounding Audios...

Page 939: ...m the radio receiver assembly and inspect the connector on the wire harness side ConnectorHA Connector B Cond1t on Specified condition Audio sounding 5 7 V Audio soonding 5 7 V Ignition switch ACC Ba1te1y positive voltage Constant Baltery positive voltage Audio sounding 5 7 V Audfo sounding 5 V Constant Contmuity l1ght controlswitch TAIL or HEAD Battery positive voltage Audio sounding 5 7 V Audio ...

Page 940: ...ANTENNA LOCATION p BE 119 BODYELECTRICAL ANTENNA AntennaAssembly L AudioAssembly ...

Page 941: ...nd moving the tester stick along the glass printed antenna check if continuity exists HINT Matching module is built in the bus bar of the glass printed an tenna main terminal side of CEUCA and no continuity exists between the terminal and the antenna Therefore for the conti nuity checking of the glass printed antenna on the main anten na side of CELICA place one probe of the tester on the position...

Page 942: ...8 BE 121 BODYELECTRICAL ANTENNA 8E0151 d Using a nne tip brush apply a small amount of the agent to the wire e After a few minutes remove the masking tape ...

Page 943: ...S NOTOPERATE 1 CLOCK WILL NOTOPERATE ClockAssembly a Turn ignition switch ON I 4 b Check that the battery positive voltage is 1 0 1 6 V ACC ECU ACC Fuse If voltage is not as specified replace the battery 5 c Check that the RAD and ECU ACC fuses are not blown 8 I RAD Fuse If the fuse is blown replace the fuse and check for short d Troubleshoot the clock as follows PBEW Combination HINT Meter Inspec...

Page 944: ...mbly 4 ACC ECU ACC Fuse 5 8 RAD Fuse PBEW 2 Combination Meter ILL 3 TAIL Fuse E Ground a Turn ignition switch ON b Check that the battery positive voltage is 1 0 16 V 1f voltage is not as specified replace the battery c Inspect the error of the clock Allowable error per day 1 5 seconds If the error exceeds the allowable error replace the clock d Check that the clock adjusting button is sticking in...

Page 945: ...oltage between terminal B and Bellow OV _I locate causeand repair or recharge battery I body ground Yes tstherebattery positive voHage between termmal ACC and Bellow 10V _ I locate causeand repair orrechargo battery I bodyground Yes Adjust or replace clock ...

Page 946: ...HORN SYSTEM LOCATION BODY ELECTRICAL HORN SYSTEM _ __ Horn BE 125 EngineRoom JunctionBlock HORNFuse HORNRelay p t i 1 C IS i 7 __ J 1 1 I se S c J _f co _ _ 1 k HornSwitch ...

Page 947: ...e connector and body ground g Check that continuity exists between terminal 6 of the connector and body ground when the horn contact plate is pressed against the steering spoke assembly If continuity is not as specified repair or replace the steering wheel or wire harness as necessary h Install the horn pad in place and using a torx socket wrench torque the 2 bolts Torque 7 1 N m 72 kgf cm 62 in l...

Page 948: ...3 INSPECT HORN RELAY CONTINUITY J 1 2 Condition Teslerconnection Specifiedcondition i s l Constant _ Contmvrty Y0 l Apply 8 between 3 5 Cont nu1ty J T terminals 1 and2 If continuity s not as specified replace the relay T uOL _ 3 N 0 200 ...

Page 949: ... MEMO ...

Page 950: ...ER ROOFDRIPSIDEMOULDING ROOFSIDEMOULDING SIDEMUDGUARD WINDSHIELD QUARTERWINDOWGLASS BACKDOORGLASS SLIDINGROOF INSTRUMENTPANEL ROOFHEADLINING FRONTSEAT REARSEAT SEATBELT SEATBELTPRETENSIONER B0 1 80 3 B0 4 B0 5 BO i B0 9 80 10 BG 22 B0 27 80 28 80 33 80 38 80 42 80 46 80 47 80 55 BO l4 BO l9 80 76 80 86 B0 92 80 101 80 106 80 109 ...

Page 951: ......

Page 952: ...lation methods of typical clips used in body parts are shown in the table below HINT If the clip is damaged during the operation always replace it with a new clip A L_ _ _ r L 1 Shape Example J___ I i Removal lnstallation t Clip Remover t Screwdriver L i ...

Page 953: ...B0 2 Shape Example BODY CUP Removal Installation Removal t 4F c c Installation Removal Installation VOCHJ12 ...

Page 954: ...rbag side airbag and seat belt pretensioner Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possibly leading to a serious acci dent Before servicing including removal or installation of parts inspection or replacement be sure to read the precautionary notices in the RS section ...

Page 955: ...Seal 9 UpperRadiator SupportSeal JU9 RadiatorGrille 1 BODY I I I I I P tk91 c t ibf _ Specifiedtorque Non reusablepart FRONT BUMPf R I FrontBumper ExtensionRetainer 20 200 14 j FrontBumper EnergyAbsorber FrontBumperCover SideMarker LowerFrontBumperCover ...

Page 956: ...e CompartmentTray 80 5 RH Deck Trim Side Panel LH Deck Trim Side Pane No 1 Luggage _ _ Compartment c Tiook 7Hook p No 1 Luggage Compartment e_ _ Trim Hook 0 0 Rear Bumper Cover 0 11 nl it lbf I Specified torque Non reusable part Deck Trim Side Panel ...

Page 957: ...B0 6 HEADLIGHT COMPONENTS UpperRadiatorSupportSeal Headlight p BODY HEAOUGI IT UpperFrontFenderApronSeal Headlight FrontBumperCover ...

Page 958: ...HEADLIGHT a Remove the 3 bolts b Disconnectthe connectors then remove the headlight as shown in the illustration c Employ the same manner described above to the other side HINT At the lime of installation please refer to the following item If the shown partof the headlight is damaged the headlight can be reinstalled to the body by installing a bracket to it ...

Page 959: ...B0 8 BODY HEADLIGHT INSTALLATION Installation Is in the reverse order of removal 5ee page 80 6 ...

Page 960: ...djust the hood by loosening the hood side hinge bolts b Tighten the loosened bolts again Torque 1 3 N m 130 kgt cm 9 fl lbf 2 ADJUST FRONT EDGE OF HOOD IN VERTICAL DIRECTION Adjust the hood by turning the cushions 3 ADJUST HOOD LOCK a Remove the upper front fender apron seal b Remove the upper radiator support seal c Remove the radiator reservoir d Adjust the hood lock by loosening the bolts e Tig...

Page 961: ...B0 10 FRONT DOOR COMPONENTS Front oOOf Belt Moulding BODY FRONl OOOf 1 ...

Page 962: ... tor handle with the snap ring in the position within 15Q as shown in the illustration 2 REMOVE LOWER FRAME BRACKET GARNISH Using a screwdriver remove the tower frame bracket garnish HINT Tape the screwdriver tip before use 3 REMOVE NO 2 DOOR INSIDE HANDLE BEZEL Using a screwdriver remove the No 2doorinside handle bezel HINT Tape the screwdnver tip before use 4 REMOVE REMOTE CONTROL MIRROR SWITCH ...

Page 963: ...VE DOOR SIDE AIRBAG SENSOR NOTICE If the wiring connector of the SRS is disconnected with the ignition switch in ON or ACC position DTCs will be recorded Never use SRS parts removed from another vehicle When replacing parts replace them with new ones Never reuse the sensor involved in a collision where the SRS has deployed Never repair a sensor in order to reuse it Disconnect the connector then re...

Page 964: ...WEETER SPEAKER 9 REMOVESERVICE HOLE COVER NOTICE Do not tear the cover HINT At the time of reassembly please refer to the following item Bring out the 2 cables and wire harness through the slits of service hole cover 10 REMOVE FRONT DOOR WEATHERSTRIP a Using a clip remover remove the 4 clips HINT Tape the screwdriver tip before use b Using a clip remover remove the front door weatherstrip HINT T a...

Page 965: ...careful not to drop the door glass HINT At the time of reassembly please refer to the following item Insert a shop rag inside the panel to prevent the glass from being scratched 14 REMOVE WINDOW REGULATOR a Remove the bolt of lower plate Torque 4 9 N m 50 kgf cm 43 in lbl b Unlock the snap by pulling the tower plate c Remove the snap and lower plate from the stud bolt of lower bracket d Remove the...

Page 966: ...e the drilled rivets and the associated metallic dust from the inside of the door panel CAUTION Do not touch the cut rivets and rivet cutter as they will be not NOTICE HINT Do not jiggle the rivet cutter while cutting Otherwise you may enlarge the rivet hole or damage the rivet cutter Do not drill the door inner hole HINT At the time of reassembly please refer to the following item Using an air ri...

Page 967: ...R NO 2 WEATHERSTRIP a Using a clip remover remove the clip b Remove the front door No 2 weatherstrip 20 REMOVE DOOR LOCK a Disconnect the 2 links from the outside handle and key cylinder b w o Power door lock Remove the nut and 3 screws Torque Nut 5 4 N m 55 kgf cm 48 in lbf Screw 4 9 N m 50 kgf cm 43 in lbf c w Power door lock Disconnect the connector and remove the bolt nut and 3 screws Torque N...

Page 968: ...reassembly please refer to the following item Apply MP grease to the sliding and rotating parts of the door lock 21 REMOVE OUTSIDE HANDLE a Remove the 2 bolts and outside handle with key cylinder Torque 5 4 N m 55 kgf cm 48 in lbl b Remove the bolt and key cylinder from the outside han dle Torque 5 4 N m 55 kgf cm 48 in lbl ...

Page 969: ...ct with the roof drip moulding 3 When the door glass is fully closed check that the outside edge of the door glass is in contact with the weatherstrip at the front pillar and roof side and that the edge of the glass cannot be seen 4 Check thatthedoorglass is not loose when it is halt open 5 When thedoorglass isrising up checkthatthe door glass and roof side weatherstrip are parallel and that the d...

Page 970: ...ons Adjust the door by loosening the door side hinge bolts Torque 25 N m 260 kgf cm 19 tt lbf c Adjust front door Jock striker 2 a 1 Check that the door fit and door lock linkages are adjusted correctly 2 Adjust the striker position by slightly loosening the striker mounting screws and hitting the striker with a hammer 3 Tighten the striker mounting screws again Torque 23 N m 230 kgf cm 17 ft lbf ...

Page 971: ...tion inside outside Shim thickness 1 0 mm 0 039 in 2 0 mm 0 079 in 3 Tighten the nuts Torque 8 3 N m 85 kgf cm 69 1n lbf Adjusttheglass to the properposition forward rearward Loosen the 3 nuts of the carrier plate for adjustment Adjust the glass to the proper position vertical y With the glass fully closed Adjust the door window upper stops Torque 1 1 N m 115 kgf cm 8 fl lbf ...

Page 972: ...BODY FRONTDOOR REASSEMBLY Reassembly is in the reverse order of disassembly See page 80 11 B0 21 ...

Page 973: ...B0 22 BACK DOOR COMPONENTS LowerStopper J O Qii StopPerCushion BackDoorWeatherstnp BODY BACK DOOR RearWiperArm I iri l BackDoorStay w Rearspoiler RearSpoiler DoorPullHandle RearDeckTrimCover ...

Page 974: ...e of reassembly please refer to the following items Operate the wiper motor once and turn the wiper switch OFF Install the rear wiper arm and tighten the nut by hand Adjust the installation position fo the wiper arm at a point in defogger pattern lighten the nut Torque 5 4 N m 55 kgf cm 48 in lbf 5 REMOVE REAR WIPER MOTOR a Disconnect the connector b Unfasten the 3 bolts and remove the rear wiper ...

Page 975: ...E BACK DOOR HANDLE wl Power door lock Disconnect the connector Remove the 2 nuts and outside back door handle Torque 5 4 N m 55 kgf cm 48 in lbf Remove the control Hnk from the outside back door han dle REMOVE OUTSIDE BACK DOOR GARNISH Remove the nut Remove the outside back door garnish by compressing clip from the inside to disengage them 11 REMOVE liCENSE PlATE liGHTS a Disconnect the connectors...

Page 976: ...bolts and nuts to adjust Torque 1 9 N m 196 kgf cm 14 ft lbf 3 ADJUST DOOR LOCK STRIKER a Checkthatthe door fit and door linkagesareadjusted cor rectly b Remove the luggage compartment mat c Remove the 2 hooks and rear deck trim cover d Loosen the striker mounting screws Torque 11 N m 115 kgf cm 8 ft lbf e Using a plastic hammer tap the striker to adjust I Reinstall the rear deck trim cover and 2 ...

Page 977: ...B0 26 BODY BACK DOOH REASSEMBLY Reassembly Is In the reverse order of disassembly See page B0 23 ...

Page 978: ... replaced drill a 2 0 3 0 mm 0 079 0 118 in hole in the bottom of the back door stay as shown In the illustration to completely release the high pressure gas before disposing of it When drilling chips may fly out so work carefully The gas is colorless odorless and non toxic When working handle the back door stay carefully Never score or scratch theexposed part of the piston rod and never allow pai...

Page 979: ...FRONT WIPERAND WASI IER FRONT WIPER AND WASHER COMPONENTS WiperArm WasherNozzle CowlTopVentilator Lower HoodtoCowlTopSeal WiperArmHeadCap I WiperMotor WiperLink Assembly P ffim f crn ii l_ Specifiedtorque I H1251D ...

Page 980: ...nnect the washer hoses HINT Tape the screwdriver tip before use c Removethe 2 washernozzles from the cowl top ventilator louver 4 REMOVE WIPER MOTOR AND LINK ASSEMBLY a Disconnect the connector b Remove the 4 bolts and wiper motor and link assembly 5 REMOVE WIPER MOTOR a Using a screwdriver disconnect the wiper ink from the motor HINT Tape the screwdriver tip before use b c d Remove the nut Place ...

Page 981: ...e range indicated by the hatched line A 241 9 mm 9 524 in B 219 6 mm 8 646 in C 381 2 mm 15 008 in D 102 8 mm 4 047 in E 467 9 mm 18 421 ln F 265 6 mm 10 457 in G 236 3 mm 9 303 in H 475 0 mm 18 701 ln 1 39 mm 15 524 in J 439 6 mm 17 307 in K 237 3 mm 9 343 1n L 225 2 mm 8 866 in M 69 8 mm 2 748 in N 94 4 mm 3 717 in 0 258 2 mm 10 165 in P 517 5 mm 20 374 in 0 234 2 mm 9 220 in R 228 3 mm 8 988 ln...

Page 982: ...nm 0 028 0 030 in BODY FRONT WIPER AND WASHER ADJUSTMENT ADJUST FRONT WASHER NOZZLE B0 31 Using a tool like the one shown in the illustration change the direction of the nozzle hole to adjust the point where washer fluid hits the windshield ...

Page 983: ...OP VENTILATOR LOUVER a Instal the 2 washer nozzle to the cowl top ventilator lou ver b Connect the washer hose then install the cowl top venti lator louver with the 4 screws and 6 cHps HINT Check that the 2 clips on the back side of the cowl top venUiator louver are surety fixed to the body 4 INSTALL HOOD TO COWL TOP SEAL 5 INSTALL WIPER ARMS a Operate the wipers once and turn the wiper switch OFF...

Page 984: ...BODY REAR WIPER AND WASHER COMPONENTS RearWiperArm I REAR WIPER AND WASHER w Rearspoiler RearSpoiler li B0 33 _ 6 K1 5h ...

Page 985: ...e the screwdriver tip before use 4 REMOVE REAR WIPER ARM 5 REMOVE REAR WIPER MOTOR a Disconnect the connector b Unfasten the 3 bolts and remove the rear wiper motor c Remove the packing 6 REMOVE REAR WASHER NOZZLE a Remove the 2 nuts b Disconnecttheconnectorand washer hose then remove the center stop light in order A B as shown in the illustra tion c Remove the screw and rear washer nozzle from th...

Page 986: ...INSPECTION INSPECT WASHER NOZZLE 80 35 While operating the washer check if the upper point where the washer fluid hits the backdoorglass and surgearea are within range indicated by the hatched line A 205 mm 8 07 in B 105 mm 4 13 in ...

Page 987: ...s shown in the illustration c Connect the connector and washer hose then install the center stop light with the 2 nuts INSTALL REAR WIPER MOTOR Install the packing Install the rear wiper motor and fasten the 3 bolts Torque 5 4 N m 55 kgf cm 48 1n lbf Connect the connector INSTALL BACK DOOR TRIM BOARD INSTALL DOOR PULL HANDLE INSTALL REAR WIPER ARM Operate the wiper motor once and turn the wiper sw...

Page 988: ...9 BODY REAR WIPER AND WASHER 80 37 c Adjust the installation position of the wiper arm at a point in defogger pattern d Tighten the nut Torque 5 4 N m 55 kgf cm 4S in lbl 6 wl Rear spoiler REMOVE REAR SPOILER ...

Page 989: ...B0 38 BODY ROOF DRIP SIDE MOULDING ROOF DRIP SIDE MOULDING COMPONENTS p iJ I RoofDripSideMoulding RoofSideRailWeatherstrip 112516 ...

Page 990: ...MOULDING REMOVAL 1 REMOVE ROOF SIDE RAIL WEATHERSTRIP a Using a clip remover remove the 4 clips b Remove the roof side rail weatherstrip 2 REMOVE ROOF DRIP SIDE MOULDING Remove the 8 screws and roof drip side moulding B0 39 ...

Page 991: ...LDING a Using a heat light heat the moulding to 20 30 nc 68 86 F NOTICE Do not heat the moulding excessively b Remove the adhesive tape from the moulding c Wipe off stains with cleaner d Apply a new adhesive tape to the moulding 3 a INSTALL ROOF DRIP SIDE MOULDING If using a new moulding Securethe roofdrip side moulding withthe c ip fortempo rary attachment b Install the roof drip side moulding wi...

Page 992: ...Butyl T ape 4 Clips H125l BODY ROOFDRIPSIDfMOULDING 4 INSTALL ROOF SIDE RAIL WEATHERSTRIP 80 41 Install the roof side rail weatherstrip with the 4 clips as shown in the illustration ...

Page 993: ...80 42 ROOF SIDE MOULDING COMPONENTS p BODY ROOF IDEMOULDING RoofSideMoulding HI 500 ...

Page 994: ...Using a heat light heat the moulding to 20 30 C 68 86 F NOTICE Do not heat the moulding excessively c Using a scraper pull off the roof side moulding from the front end and rear end HINT Tape the screwdriver tip before use 2 REMOVE MOUlDING AND ADHESIVE a Pull off the moulding by cutting the adhesive with a knife at the front and rear ends b Remove the moulding NOTICE Do not damage the body with t...

Page 995: ...AN MOULDING a Using a heat light heat the moulding surface to 20 30 c 68 86 F NOTICE Do not heat the moulding excessively b Using a knife cut the remaining adhesive from the mould ing NOTICE Be careful not to damage the moulding c Wipe off stains with cleaner 3 COATCONTRACT SURFACE OF BODY WITH PRIMER M Using a brush coatthecontactsurface on the bodywith Primer M as shown in the illustration Front...

Page 996: ...on for both front and rear of the vehicle Front and rear end A 50 mm 1 97 in HINT When removing the moulding apply adtlesive well to the part where the body sealer is removed 5 INSTALL MOULDING Push the moulding to the body NOTICE Make sure that the body and moulding are heated to the proper temperature Do not depress the adhesive coated parts excessive ly but just hold them down with your thumb S...

Page 997: ...B0 46 SIDE MUD GUARD COMPONENTS Side Mud Guard 9Ctips p BODY SIDE MUD GUARD ...

Page 998: ...OMPONENTS w o Sliding roof MapU ghtAssembly i MapLightLens BODY WINDSHIELD w Slidingroof SlidingRoof OpeningTrim RoofHeadlining InnerRearViewMirror WindshieldGlass FrontPillarGarnish WiperArm B0 47 SLJnVisor Stopper ...

Page 999: ...T ASSEMBLY Remove the screw Using a moulding remover remove the cover Remove the screw and map light assembly then discon nect the connector REMOVE SUN VISORS REMOVE SUN VISOR HOLDERS 6 REMOVE INNER REAR VIEW MIRROR Remove the inner rear view mirror as shown in the illustration 7 REMOVE WIPER ARMS Remove the 2 wiper arm head caps 2 nuts and 2 wiper arms 8 REMOVE HOOD TO COWL TOP SEAL 9 REMOVE COWL...

Page 1000: ...bjects c wl Front window defogger Disconnect the connector NOTICE Be careful not to damage the wire harness d Cut the adhesive by pulling the piano wire around it NOTICE When separating the glass take care not to damage the paint and exterior ornaments To prevent the safety pad from being scratched when removing the windshield place a plastic sheet between the piano wire and safety pad HINT Apply ...

Page 1001: ...uch the glass face after cleaning it 3 w No 1 Stopper REPLACE NO 1 STOPPERS a Remove the damaged stoppers b Cut off the old adhesive around the stopper installation area NOTICE Be careful not to damage the body c Clean the installation area d Attach new stoppers to the body so that tho notches on the body will align with the stoppers as shown in the il lustration HINT Make sure that the stoppers a...

Page 1002: ...nce marks on the glass and body Remove the glass 7 CLEAN CONTACT SURFACE OF GLASS Using a cleaner clean the contact surface which is black col ored area around the entire glass rim NOTICE Do not touch the glass face after cleaning it 8 COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a brush coat Primer M to theexposedpart of body on the vehicle side NOTICE Allow 3 minutes or more to dry the prime...

Page 1003: ...use 1 0 APPLY ADHESIVE a Cut off the tip of the cartridge nozzle Part No 08850 00801 or equivalent HINT After cutting off the tip use all adhesive within the time de scribed in the table below Temperature Tacklree time 35 c 95 FJ 1 5 minutes 20 C 6B F 100 minulos 5 C 4 1 F 8 hours b Load the cartndge mto the sealer gun c Coat the glass with adhesive as shown in the i tustration A 12 5 mm 0 492 ln ...

Page 1004: ...e table below Temperalure Minimumtime priortodrivingthe veh ele 35 G 95 F 20 c 68 FJ 5 C 41 F 12 INSPECT FOR LEAK AND REPAIR NOTICE 1 5 hOU S 5 hours 24 llOUfS Conduct a leak test after the hardening time has elapsed 13 INSTALL FRONT SIDE OF ROOF HEADLINING 14 INSTALL COWL TOP VENTILATOR LOUVER HINT Check that the 2 clips on the back side of the cowl louver are surely fixed to the body 15 INSTALL ...

Page 1005: ...B M 17 INSTALL INNER REAR VIEW MIRROR 18 INSTALL SUN VISOR HOLDERS 19 INSTALL SUN VISOR 20 INSTALL MAP LIGHT ASSEMBLY 21 INSTALL FRONT PILLAR GARNISH ...

Page 1006: ...TS FrontSeat OuterBeltShoulderAnchor QuarterTrimPanel DoorScuffPlate RoofDripSideMoulding RearSeatbackRH RearSeatCushion Assembly Y _ l _ _____ __ RearSeatbackLH tJ l_ f_m _ _ I J Spedfiedtorqu p Non reusablepart SeatbackHinge B0 55 DeckTrim SidePanel H12W ...

Page 1007: ...MAT 6 REMOVE REAR DECK TRIM COVER a Remove the 2 bolts and 2 hooks b Remove the 3 clips c Using a screwdriver remove the rear deck trim cover HINT Tape the screwdriver tip before use 7 REMOVE DECK TRIM SIDE PANEL a Remove the screw and No 1 luggage compartment trim hook b RH side HINT Using a screwdriver remove the rear room light then dis connect the connector Tape the screwdriver tip before use ...

Page 1008: ...Torque 42 N m 430 kgf cm 31ft lbf 13 REMOVE ROOF SIDE INNER GARNISH a Using a screwdriver open the cap of coat hook HINT Tape the screwdriver tip before use b Remove the screw and coat hook c Using a screwdriver remove the roof side inner garnish HINT Tape the screwdriver tip before use 14 REMOVE ROOF SIDE RAIL WEATHERSTRIP a Using a clip remover remove the 4 clips b Remove the roof side rail weat...

Page 1009: ...P SIDE MOULDING Remove the 8 screws and root drip side moulding 16 REMOVE QUARTER WINDOW GLASS a Using a knife cut off the moulding as shown in the below illustration NOTICE Do not damage the body with the knife b Remove the remaining moulding b b d c H 5 ...

Page 1010: ...eing scratched NOTICE When separating the glass take care not to damage the paint and exterior e Cut the adhesive by pulling the piano wire around it HINT Cut the adhesive areas as shown in the illustration leaving the adhesive where the clips are f Push the piano wire through as shown in the illustration cut off the adhered part to the clips g Remove the glass NOTICE leave the adhesive on the bod...

Page 1011: ...dy 2 CLEAN CONTACT SURFACE OF NEW GLASS Using a cleaner clean the contact surface which is black col ored area around the entire glass rim NOTICE Do not touch the glass face after cleaning it 3 INSTAll NEW SPACERS Install the new spacers to the quarter window glass as shown in the illustration 4 COAT CONTACT SURFACE OF BODY WITH PRIMER M Using a brush coat Primer M to theexposed part ofbody on the...

Page 1012: ...he glass and the contactsurface with PrimerG as shown in the i lustra tion b When the primer is coated wrongly to the area other than the specified wipe it off with a clean shop rag before the primer dries NOTICE Allow 3 minutes ormore to dry the primer coated sur face Do not keep any of the opened Primer G for later use b b Primer G I J d d ...

Page 1013: ...f the tip use all adhesive within the time de scribed in the table below Temperature Tackflee time 35 C 95 f 15 minutes 20 C 68 F 100 minute s s c 4t F 8 hours b Load the cartndge tnto the sealer gun c Coat the new glass with adhesive as shown in the illustra tion Adhesive height 12 0 mm 0 472 in Adhesive width 8 0 mm 0 315 in Adhesive Tape 3 I c o L e e C C d d Hl CO ...

Page 1014: ...NSTALL ROOF DRIP SIDE MOULDING See page BD 40 10 INSTALL ROOF SIDE RAIL WEATHERSTRIP See page BD 40 11 INSTALL ROOF SIDE INNER GARNISH 12 INSTALL FRONTSEAT OUTER BELTSHOULDER AN CHOR Torque 43 N m 440 kgf cm 32 ft lbf 13 INSTALL QUARTER TRIM PANEL 14 INSTALL REAR SEAT OUTER BELT FLOOR ANCHOR Install the rear seat outer belt floor anchor wlth the bolts as shown in the illustration Torque 43 N m 440...

Page 1015: ...80 64 BACK DOOR GLASS COMPONENTS No 1 Dam BODY BACK OOOfl GLASS BackDoorGrass wl Rearspoiler RearSpoiler Outside Lower Moulding __ _ _ _ _ J DoorPullHandle BackDoorTrimBoard ...

Page 1016: ... b Disconnect the connector and washer hose then remove the center stop tight in order A B as shown in the illustra tion 6 REMOVE BACK WINDOW OPENING TRIM 7 REMOVE BACK DOOR GLASS a Insert a piano wire between body and glass and let it pass through b Tle both wire ends to wooden blocks or similar object HINT Apply protective tape to the outer surface to keep the surface from being scratched NOTICE...

Page 1017: ...en if all the adhesive has been removed clean the body 2 CLEAN REMOVED GLASS a Place marks for installing new clips to the glass b Remove the damaged dips and dams c us lng a scraper remove the adhesive sticking to the glass d Clean the glass with cleaner NOTICE Do not touch the glass after cleaning it Be careful not to damage the glass 3 If reusing the glass INSTALL NEW CLIPS Install new clips on...

Page 1018: ...a brush or sponge coat the edge of the glass and thecontactsurfacewith PrimerG as shown in the illustra tion b When the primer is coated wrongly to the area other than the specified wipe it off with a clean shop rag before the primer dries NOTICE Allow 3 minutes ormore to dry the primer coated sur face Do notkeep any ofthe opened Primer G for later use 7 APPLY ADHESIVE a Cut offthe tip of the cart...

Page 1019: ...he vehicle during the timedescribed In the table below Temperawre Minimum time priortodrivingthevehicle 35 C 95TJ 1 5 hours zo c 68 FJ 5 hours s c 4t FJ 24 hours 9 INSPECT FOR LEAKS AND REPAIR NOTICE Conduct a leak test after the hardening time has elapsed 10 INSTALL BACK WINDOW OPENING TRIM 11 INSTALL CENTER STOP LIGHT 12 INSTALL BACK DOOR TRIM BOARD 13 INSTALL DOOR PULL HANDLE 14 INSTALL REAR WI...

Page 1020: ...time of the slid ing roof Operation time Approx 6 sees b Check for abnormal noise or binding during operation c With the sliding roof fully closed check forwater leakage d Check for a difference in level between the sliding roof weatherstrip and roof panel Except rear end 0 1 5 mm 0 0 059 in Rear end 0 1 5 mm 0 0 059 in 0 1 0 mm 0 0 039 in ...

Page 1021: ...B0 70 COMPONENTS Drain Hose I N mJ 5 9 L cnl t lbf Specifiedtorque p BODY SLIDING HOOF No 1 Sunshade Trim Cable Guide Casing _ No 2 Sunshade Trim LH Roof Drip Channel Drive Cable H12 Ht ...

Page 1022: ...ive gear with the sliding roof fully closed a Remove the 2 screws and room light bracket b Disconnect the connector c Remove the 2 bolts and drive gear Torque 5 4 N m 55 kgf cm 48 tt lbf 4 REMOVE SLIDING ROOF HOUSING a Disconnect the 4 drain hoses from the housing_ b Remove the 12 bolts and 6 brackets Torque 5 4 N m 55 kgf cm 48 tt lbf c Remove the 4nuts then remove the housing Torque 5 4 N m 55 k...

Page 1023: ...E REAR ROOF DRIP CANNEL 5 REMOVE LH AND RH ROOF DRIP CHANNEL 6 REMOVE CABLE GUIDE CASING Torque 2 0 N m 20 kgf cm 17 1n lbf 7 REMOVE DRIVE CABLE a Remove the screw b Slide the drive cable rearward then remove it c Employ the same manner described above to the other side HINT At the time of reassembly please refer to the following items Adjust the drivecable to aclosed and titled down position Slid...

Page 1024: ... ROOF GLASS IN CLEARANCE Difference In left and right clearance a When the front or rear alignment is not correct remove the drive gear and sliding roof glass then adjust the drive cables NOTICE Remove the drive gear with the sliding roof fully closed b Adjust by sliding the cables forward or rearward to align the 2 marks as shown in the illustration c Install the drive gear and sliding roof glass...

Page 1025: ...80 74 BODY SllDlNG ROOr REASSEMBLY Reassembly is in the reverse order of disassembly See page B0 72 ...

Page 1026: ...BODY SLIDINGROOF INSTALLATION Installation is in the reverse order of removal See page B0 88 HINT After installing the sliding roof sliding roof need to be re ini ialized Refer to BE 84 B0 75 ...

Page 1027: ...rontDoorOpeningTrim BODY INSTR MENT PANEL Front PillarGarnish PassengerAirbagAssembly 2 Brace 11 Front Door Cowl SideTrim OpeningTrim LH End Finish Panel DoorScuff Plate HeaterConsoleand AccessoryAssembly Cow SideTrim DoorScuff Plate P __ _g_ 2_cm _ __ f_ J Specifiedtorque ConsoleBox ...

Page 1028: ...rtoRegisterDuct No 1 HealertoRegisterDuct I 1 Elm No 1 Register or Automatic light Console Sensor 1 Pin or No 1 Pin 7 or or Center Bracket l A _ Hazard Switch Po LightControl Rieostat Switch Hole Cover Instrument Panel Wire 60 77 H 3426 ...

Page 1029: ...5 0 59 1 I Shape mm linJ Size 0 6 0 24 L 22 0 87 if lf I I I I t1u I o 6 1 1 o 6 I i _ t o 241 I I 10 241 E L 16 L 18 0 63 0 71 i 0 5 22 0 2055 L 16 0 63 I i 1 i 1 j f _ _ __ 1 j I 1 i 0 5 22 i 0 5 I lo 51 QJJ l lo 2 0 631 I 0 711 CD 0cc 5 0 20 L 16 0 63 L I c r 11 ____ _____ _ 1 I l i II 5 0 20 L 16 0 63 0 e o 5 0 20 1 L 14 v 0 55 i 0 4 0 16 l 16 0 63 i I 1 11 I___ __ _ _ __L_ __J I 0 8 I J 0 32 ...

Page 1030: ...river tip before use 5 REMOVE FINISH PANEL 6 REMOVE COLUMN COVERS See page SR 11 7 REMOVE SPIRAL CABLE See page SR 11 8 REMOVE WIPER AND WASHER SWITCH AND LIGHT CONTROL SWITCH A N D HEADLIGHT DIMMER SWITCH See page SR 11 9 REMOVE CLUSTER FINISH PANEL a Remove the 2 screws b Using a screwdriver remove the cluster finish pane HINT Tape the screwdriver tip before use 10 REMOVE COMBINATION METER 11 RE...

Page 1031: ... harness 13 REMOVE PASSENGER AIRBAG ASSEMBLY Remove the boll 2 nuts and passenger airbag assembly Torque Bolt 20 N m 204 kgf cm 15 ft lbf 14 REMOVE UPPER CONSOLE PANEL a Mff Remove the shift lever knob b Using a screwdriver removethe upper console panel the disconnect the connector HINT Tape the screwdriver tip before use 15 w Power window REMOVE POWER WINDOW CONTROL SWITCH 16 w o Powerwindow REMO...

Page 1032: ...en disconnect the connector HINT Tape the screwdriver tip before use d Remove the 4 screws and clock from the center cluster finish paneL e 20 21 22 23 Remove the 2 screws and heater control name plate from the center cluster finish panel as shown in the illustration w Radio REMOVE RADIO w o Radio REMOVE STEREO OPENING COVER ASSEMBlY REMOVE HEATER CONTROl AND ACCESSORY AS SEMBLY See page AC 66 REM...

Page 1033: ...lamps c Remove the J B set bolts and nuts d Using a screwdriver remove the 4 caps HINT Tape the screwdriver tip before usc e Remove the 2 bolts nut 4 screws and instrument paneL 27 REMOVE NO 1 AND NO 2 BRACE 28 REMOVE REINFORCEMENT a w ASS Remove the 2 nuts and ABS ECU b Remove the 3 bolts 4 nuts and reinforcement ...

Page 1034: ...VE NO 2 HEATER TO REGISTER DUCT 6 REMOVE NO 3 HEATER TO REGISTER DUCT 7 REMOVE AUTOMATIC LIGHT CONTROL SENSOR 8 REMOVE LIGHT CONTROL RHEOSTAT 9 REMOVE HAZARD SWITCH 10 REMOVE WINDOW LOCK SWITCH 11 REMOVE SWITCH HOLE COVER 12 REMOVE NO 1 RESISTER 13 REMOVE NO 2 RESISTERS 14 REMOVE NO 3 RESISTERS 15 REMOVE RH LOWER PAD INSERT 16 REMOVE CENTER BRACKET B0 83 ...

Page 1035: ...B0 84 BODY INSTRUMENT PANEL 10 01 REASSEMBLY Reassembly is in the reverse order of disassembly See page B0 83 ...

Page 1036: ...BODY INSTRUMENT PANEL INSTALLATION Installation is In the reverse order of removal See page B0 79 B0 85 ...

Page 1037: ...60 16 ROOF HEADLINING COMPONENTS Front Pillar Garnish BODY ROOF f EADUNlNG CowlSideTrim RearSeatCushion Front Pillar Garnish Hook Luggage Compartment Mat Hl 633 ...

Page 1038: ...wlo Sliding roof Front Roof Side Rail Pad b Sun Visor SunVisorHolder aoov ROOF HEADLINING MapUghtCover Roof Headlining Front Roof SideRaHPad B0 87 Sliding Roof OpeningTrim Sun Visor ...

Page 1039: ... DECK TRIM COVER a Remove the 2 bolts and 2 hooks b Remove the 3 clips c Using a screwdriver remove the rear deck trim cover HINT Tape the screwdriver tip before use 7 REMOVE DECK TRIM SIDE PANEL a Remove the screw and No 1 luggage compartment trim hook b RH side HINT Using a screwdriver remove the rear room light then dis connect the connector Tape the screwdriver tip before use c Remove the 2 cl...

Page 1040: ...bove to the other side 12 REMOVE FRONTSEATOUTER BELTSHOULDER AN CHOR Torque 43 N m 440 kgf cm 32 ft lbf 13 REMOVE ROOF SIDE INNER GARNISH a Using a screwdriver open the cap of coat hook HINT Tape the screwdriver tip before use b Remove the screw and coat hook c Using a screwdriver remove the roof side inner quarter HINT Tape the screwdriver tip before use d Employ the same manner described above t...

Page 1041: ...Remove the screw b Using a moulding remover remove the cover c Remove the screw and map light assembly then discon nect the connector 19 w Sliding roof REMOVE SUN ROOF OPENING TRIM MOULDING 20 REMOVE SUN VISORS 21 REMOVE SUN VISOR HOLDERS 22 REMOVE ROOF HEADLINING a Using a clip remover remove the 5 clips b Remove the roof headlining 23 REMOVE CLIP STOPPERS 24 REMOVE FRONT ROOF SIDE RAIL PAD a Rem...

Page 1042: ...BODY ROOF HEADLINING INSTALLATION j Installation is in the reverse order of removal See page 80 88 80 91 ...

Page 1043: ...tback Frame Seatback Cover w Sideairbag assembly Hog Ring FrontSeatCushionInnerShield FrontSeatInner Belt SeatTrackHandle 1rimlkg q it lbtYI Specified torque Non reusable Side Airbag Assembly X 7 Hog Ring SeatCushion Cover Seat Cushion Pad Seal Cushion Frame RecliningConnecting Pipe ...

Page 1044: ...ACK COVERS Using a screwdriver remove the seat track covers HINT Tape the screwdriver tip before use 2 REMOVE FRONT SEAT a Remove the 4 bolts b Disconnect the connectors c Remove the front seat NOTICE Be careful not to damage the body B0 93 ...

Page 1045: ... screw and frontseatcushion inner shield as shown in the l lustration 5 REMOVE SEATBACK ASSEMBLY a Remove the hog rings b Zip the seatback cover open c w Side airbag assembly Turn over the wire harness protector as shown in the il lustration d w Side airbag assembly Disengage the side airbag wire harness from the seal cushion frame e w Side airbag assembly f 6 a Pull out the side airbag wire harne...

Page 1046: ...ack cover from the seatback cushion REMOVE FRONT SEAT INNER BELT REMOVE SEAT CUSHION ASSEMBLY Remove the 4 bolts and seat cushion assembly Remove the hog rings Disengage the seat cushion cover t10oks and remove the seat cushion frame d Remove the seat cushion cover from the seat cushion pad 9 REMOVE SEAT TRACK HANDLE Using a screwdriver remove the seat track handle HINT Tape the screwdriver tip be...

Page 1047: ...pect that the outer and Inner recliners are released at the same time HINT When the reclining lock position slips off disassemble the seat to adjust the position b When sliding the seat inspect that the outer and inner tracks are locked at the same time HINT When sliding lock positions slip off loosen the bolts to adjust the position ...

Page 1048: ...r_ 4 INSTALL SEAT CUSHION ASSEMBLY a Install the seat cushion cover to the seat cushion pad with new hog rings HINT When installing the hog rings take care to prevent wrinkles as much as possible b Install the seat cushion frame to the seat cushion cover with pad c Engage the seatcushionhooks and install new hog rings HINT When installing the hog rings take care to prevent wrinkles as much as poss...

Page 1049: ...nstall the 2 nuts then engage the clamp of side airbag wire harness Torque 5 5 N m 56 kgf cm 49 ln lbf 7 INSTALL SEATBACK ASSEMBLY a Install the seatback assembly with the 4 bolts Torque 43 N m 440 kgf cm 32 fUbf b w Side airbag assembly Insert the side airbag wire harness into the slit of seatback cover c w Side airbag assembly Engage the side airbag wire harness to the seat cushion frame d w Sid...

Page 1050: ... I B0 99 BODY FRONTSEAT 8 9 10 11 INSTALL FRONT SEAT INNER SHIELD INSTALL FRONT SEAT CUSHION SHIELD INSTALL RECLINING ADJUSTER RELEASE HANDLE WI Vertical adjuster INSTALL VERTICAL ADJUSTER KNOB ...

Page 1051: ...T SEAT c Slide the front seat to the most front position d Tighten the bolts on the rear side temporarily startingfrom the bolt on the inner side tighten them com pletely Torque 37 N m 375 kgf cm 27 fl lbf e Slide the seat to the most rear position to instal the bolts on the front side Torque 37 N m 375 kgf cm 27 fl lbl f Install the seat track covers ...

Page 1052: ...back Lock Knob __ __ SeatbackLockKnobHolder SeatbackLockStrikerRH If SeatbackFrame RH 1 j f Seatback Lock Striker LH _ p 185 13 _ Seatback Frame LH _ 21 7 A I Seatbacklock Hog Ring j Seat Cushion Pad wtlh Frame ri njk f l_ _ri i t l Specified torque P Non reusable part 1117 _ _ ...

Page 1053: ...he 4 bolts Torque 18 N m 185 kgf cm 1 3 ft lbl c Remove the seatback assembly LH and RH 2 REMOVE SEAT CUSHION ASSEMBLY 3 REMOVE SIDE HINGE LH AND RH Torque 7 8 N m 80 kgf cm 69 ft lbf 4 REMOVE CENTER HINGE Torque 18 N m 185 kgf cm 13 ft lbf 5 REMOVE SEATBACK LOCK STRIKER See page BQ 88 Torque 18 N m 185 kgf cm 13 ft lbf ...

Page 1054: ... cover with pad d Employ the same manner described above to the other side 4 REMOVE SEATBACK LOCK a Remove the 2 bolts and seatback lock b Employ the same mannerdescribed above to the other side 5 REMOVE SEATBACK COVER a Remove the hog rings and seatback cover from the seatback pad b Employ the same manner descr 1bed above to the other side 6 REMOVE SEATBACK CUSHION COVER Remove the hog rings and ...

Page 1055: ... installing hog rings take care to prevent wrinkles as little as possible b Employ the same manner described above to the other side 3 INSTALL SEATBACK LOCKS Torque 21 N m 210 kgl cm 15 11 lbl 4 INSTALL SEATBACK FRAME a Install the seatback frame to the seatback cover with pad b Install new hog rings HINT When installing hog rings take care to prevent wrinkles as little as possible c Install the 5...

Page 1056: ...INSTALLATION BODY REAR SEAT Installation is in the reverse order of removal See page 80 102 B0 105 ...

Page 1057: ... BODY SEAT BELT Roof SideInnerGarnish Quarter Trim Panel RearSeatback Passenger s side only Torque Plate Stopper Door Scuff Plate RearSeatback Side Hinge 1 I 40 32 jl l Front Seal Outer Belt I t I ea us 1on nnerShield RearSeat Cushion uter ...

Page 1058: ...a new belt assembly verify the proper operation before installation o on 2 Driver s Seat Belt ELR STATIC TEST a Make sure that the belt locks when pulled out quickly b Remove the locking retractor assembly c Tilt the retractor slowly d Make sure that the belt can be pulled out at a tilt of 15 de grees or less and cannot be pulled out over 45 degrees of tilt If a problem is found replace the assemb...

Page 1059: ...he whole belt then pull out the belt until 200 mm 7 87 in of belt remains retracted f Tilt the retractor slowly g Make sure that the belt can be pulled out at a tilt of 1 5 de grees or less and cannotbepulled out atover45 degrees of tilt If a problem is found replace the assembly ...

Page 1060: ...E TRAY TRIM 3 REMOVE REAR SEAT See page B0 102 4 REMOVE LUGGAGE COMPARTMENT TRAY a Using a clip remover remove the 2 clips b Using a screwdriver remove the luggage compartment tray HINT Tape the screwdriver Up before use 5 REMOVE LUGGAGE COMPARTMENT MAT 6 REMOVE REAR DECK TRIM COVER a Remove the 2 bolts and 2 hooks b Remove the 3 clips c Using a screwdriver remove the rear deck trim cover HINT Tap...

Page 1061: ...HOR 13 REMOVE FRONT SEAT OUTER BELT FLOOR AN CHOR 14 REMOVE RETRACTOR OF FRONT SEAT OUTER BELT CAUTION Never disassemble the front seat outer belt NOTICE When removing the retractor of front seat outer belt take care not to pull the seat belt pretensloner wire harness a Disconnect the pretensioner connector as shown in the illustration CAUTION When removing the seat belt pretensioner work must be ...

Page 1062: ...uarter trim panel Check for cuts and cracks in wire harness and for chipping in connectors Check for deformation of the quarter panel CAUTION For removal and installation ofthefrontseatouterbelt see page B0 109 and B0 118 2 PRETENSIONER IS ACTIVATED a Perform a diagnostic system check See page Dl 326 b Perform a visual check which includes thefollowing items with the front seat outer belt removed ...

Page 1063: ...r belt which has an in activated pretensioner The seat belt pretensioner produces a sizeable ex plodlng sound when it activates so perform the op eration out of doorand where it will not create a nui sance to nearby residents When activating the seat belt pretensloner always use the specified SST SRS Airbag Deployment Tool Per1orm the operation in a placeawayfrom electrical noise SST 09082 0700 09...

Page 1064: ...low connector which will be connected with the seat belt pretensioner 2 Check functioning of SST CAUTION Press the SST activation switch and check the LED of the SST activation switch lights up Ifthe LED lights up when the activation switch is not being pressed SST malfunction is probable so definitely do not use the SST b Disconnect the pretensioner connector L o 1 Remove the door scuff plate 2 R...

Page 1065: ... red clip to the battery positive terminal and the black clip to the negative termi nal d Activate the seat belt pretensioner HINT 1 Confirm that no oneisinside thevehicleorwithin 1 0 m 33 ft area around of the vehicle 2 Press the SST activation switch and activate the seat belt pretensioner The seat belt pretensioneroperates simultaneously as the LED of the SST activation switch lights up e Dispo...

Page 1066: ...y as the power source when activating the seat belt pretensioner a Remove the front seat outer belt See page 80 109 HINT Cut the belt near the seat belt retractor b Check functioning of SST See step 1 a SST 09082 00700 09082 D0740 c Install the SST 1 Connect the 2 SST then connect them to the seat belt pretensioner SST 09082 0700 09082 0740 NOTICE To avoid damaging the SST connector and wire harne...

Page 1067: ... or H 31 8 R0518l e Dispose of front seatouterbelt with seatbelt pretension er CAUTION The frontseatouterbelt Isveryhot when the seat belt pretensioner is activated so leaveIt alone forat least 30 minutes after activation Use gloves and safety glasses when handling a front seat outer belt with activated seat belt pretensioner Always wash your hands with waterafter completing the operation Do not a...

Page 1068: ...vated If the seat belt pretensioner has been found to be faulty in troubleshooting_ B0 117 If the front seat outer belt has been found to be faulty during checking in items 1 b or 2 b If the front seat outer belt has been dropped CAUTION For removal and installation of the seat belt pretensloner see page B0 109 and B0 118 Be sure to follow the correct procedure ...

Page 1069: ...ractorof front seat outer belt with the 2 bolls Torque Upper bolt 7 5 N m 76 kgt cm 66 ln lbf Lower bolt 43 N m 440 kgf cm 32 ft lbf b Connect the pretensioner connector as shown in the il lustration c Connect the retractor switch connector 2 INSTALL FRONTSEAT OUTER BELT SHOULDER AN 3 4 5 6 7 8 9 10 11 12 13 14 CHOR Torque 43 N m 440 kgf cm 32 ft lbf INSTALL FRONT SEAT OUTER BELT FLOOR AN CHOR Tor...

Page 1070: ...UNIT AC 30 COMPRESSOR AND MAGNETIC CLUTCH AC 35 CONDENSER AC 43 BLOWER MOTOR AC 48 BLOWER RESISTOR AC 49 THERMISTOR AC 50 PRESSURESWITCH AC 51 HEATER MAIN RELAY AC 54 MAGNETIC CLUTCH RELAY AC 55 COOLING FAN RELAY AC 56 CONDENSER FAN AC 57 AIR CONDITIONING AMPLIFIER AC 60 HEATER CONTROL ASSEMBLY AC 65 ENGINECOOLANT TEMPERATURE ECT SWITCH AC 72 AIR REFINER FILTER AC 73 ...

Page 1071: ......

Page 1072: ...T CONTAINER OR EXPOSE ITTO NAKED FLAME 5 BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT 6 DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERATION SYS TEM If there is not enough refrigerant in the refrigerant system oil lu brlcation will be insufficient and compressor burnout mayoccur so that care to avoid this necessary care should be taken 7 DO NOT OPEN PRES...

Page 1073: ...as the driver and front passenger airbag Failure to carry out service operation in the correct sequence could cause the SRS to unexpectedly deploy during servicing possi bly leading to a serious accident Before servicing including re moval or installation of parts inspection or replacement be sure to read the precautionary notices tn the RS section ...

Page 1074: ...present in sight glass None SL H Iefll or too nuch Aerer item 3 and 4 No temperature d1lterence between com 1 Check forgas leakage w th gas leak de 3 pressor miet and ou lel Empty or r1eatly empty lector and repair if necessary 2 Add refrigmanl until bubbles d sappear Temperature between compressorinlet and outlet is noliceabty different Correct or too much Hefer to items 5 and 6 tmmed ately after...

Page 1075: ...l at COOL position HINT It should be noted that the gauge indications may vary slightly due to ambient temperature conditions i Normally functioning refrigeration system Gauge reading Low pressure side 0 15 0 25 MPa 1 5 2 5 kgf cm2 High pressure side 1 37 1 57 MPa 14 1 6 kgf cm21 2 Moisture present in refrigeration system OlJ67 Probable cause Diagnosis Remedy Moisture entered m refligeration Dr er...

Page 1076: ...nt 1n system lngerant Bubbles seen in sigtrt glass con trigeration system Refrigerant leakmg 3 Ifindrcated pressure value rs tinuously near0 when wnnectod to gauge lnsuffrcielll coolingperformance cmale the v Jcuum alter ir1specting and repa r ng tne ocatron ol llle teak 4 Poor circulation of refrigerant Condition Insufficientcooling Symptom seen 10 Probablecause Diagrmsis Remedy refrigeration sys...

Page 1077: ... sides Unable todevelop sufficient per No sir bubbles see11 llrough the formaf ce duo to excessiVe s ghl glass even when the engine Insufficient cooling of condenser rpm is lowered 01449 Dtagnosis Remedy 1 Check expansion valve 2 Clean out dirt in expansion valve by blowing with air 3 Replacecondenser Retngerant does not Circulate 4 Evacuate air and charge new refrigerant to proper onnount 5 hx ga...

Page 1078: ... refriger antchargedwithoutvacuum purging Remedy AC 7 1 Check ompressoroil to see tf Airpresent 1n refrigeration sys it is seo if tl ts dirty orinsufficient tern 2 Evacuale atr and charge new lnsuftioent vacuum purging refrigerant 8 Expansion valve improperly Condilton Insufficientcooling Symplom seen 10 Probable cause Diagnosis Remedy refngeratlon system Pressum too high on both low E cessive ref...

Page 1079: ...tion 1ZZ FE engine models MIT Magneticclutchcondition Idle upspeed Magneticclutch not engagOO 700 50 rpm Maonetic clutch engaoed 900 50 rpm If tdle speed ts not as spectfted check Idle control system 1ZZ FE engine models AJT Magnetic clutch condition Idle upspeed Magnetic clutchnotengaged 750 50 rpm Magneticdutchengaged 900 50 rpm If tdle speed ts not as spectfled check Idle control system 2ZZ FE ...

Page 1080: ...e blower motor stopped leave the cooling unit for more than 15 minutes Expose the gas leak detector sensor the under the drain hose When bring the gas leak detector close to the drain hose make surethat the gas leakdetectordoes not react tothe volatile gases If such reaction is unavoidable the vehicle must be lifted up c If gas leak is notdetected on the drain hose remove the blower resistor from ...

Page 1081: ...ATE AIR FROM REFRIGERATION SYSTEM a Connect the vacuum pump adapter to the vacuum pump b Connect the center hose of the manifold gauge set to the vacuum pump adapter c Open both the high and low handvalvesand run thevacu um pump d After 10 minutes or more check that the low pressure gauge indicates 750 mmHg 30 in Hg or more HINT If the reading 750 mmHg 30 in Hg or more close both hand valves of ma...

Page 1082: ...r CAUTION Do not open both high and low hand valves of manifold gauge set c Open the valve of charging cylinder d Press the valve core on the side of manifold gauge and expel the air inside of the center hose 2 INSPECT REFRIGERATION SYSTEM FOR LEAKS a Open the high pressure hand valve and charge refriger ant b When the low pressure gauge indicates 98 kPa 1 kgf cm2 14 psi close the high pressure ha...

Page 1083: ...valve fully b Charge specified amount of refrigerant then close the high pressure hand valve HINT A fully charged system is indicated by the sightglass being free of any bubbles c Charge partially refrigeration system with refrigerant 1 Set vehicle in these condition Running engine at 1 500 rpm Blower speed control switch HI Temperature control selector MAX COOL Air inlet control selector RECIRC F...

Page 1084: ...nation Meter Engine Room Relay Block No 1 Heater Main Relay NC Unit Evaporator Expansion Valve Heater Radiator Thermistor Engine Room J 8 Magnetic Clutch Relay Cooling Fan Relay No 2 Cooling Fan Relay No 3 Slower Unit Blower Motor Blower Resistor HeaterControl Assembly Blower Speed Control Switch NC Switch ...

Page 1085: ... sensor AC 35 5_ Compressor AC 35 Nocompressor operation 6 Pressure switch AC 51 7 Heater mam relay AC 54 8 Blower spocd control switch AC 68 9 Heater control assembly AC 65 10 Thermistor AG 50 1 1 Wrre hamess L Refrigerant vo ume AC r 3 2 llelrigerant pressure AG 3 3 Drive belt AG 16 Magneticcl tcll AC 35 No cool air comes out 5 Compressor lock sensor AC 35 6 Pressure switch AG 51 7 fhermistor AC...

Page 1086: ...trol 2 Wire harness I Compressor AC r 35 2 Drive belt AC 16 Blinking of NC indicator 3 Compressor lock sensor AC 35 4 Heater control assembly AC 6 1 Headlight and tailligl t system BE 17 Brightness does notchange when light control sw1lch is tumed 2 Heatercontrol assembly AC r 65 ...

Page 1087: ...AG 16 Correct Wrong AIRCONDmONING DRIVE BELT DRIVE BELT ON VEHICLE INSPECTION INSPECT DRIVE BELT S INSTALLATION CONDITION Checkthat the drive belt fits properly in the ribbed grooves ...

Page 1088: ... AC 17 AIR CONDITIONING DRIVEBELT OOOHS REMOVAL REMOVE DRIVE BELT Loosen the drive be t tension by turning the drive belt tensioner arm clockwise and remove the drive belt ...

Page 1089: ...A 18 AIR CONDmONING DRIVE BELT 000145 INSTALLATION 1 INSTALL DRIVE BELT Turning the drive belt tensioner arm clockwise and instal the drive bell 2 CHECK DRIVE BELT INSTALLING CONDITION ...

Page 1090: ...2 CONNECT QUICK DISCONNECT ADAPTER TO CHARGING HOSES Tighten the nuts by hand 3 CLOSE BOTH HAND VALVE OF MANIFOLD GAUGE SET 4 REMOVE CAPS FROM SERVICE VALVE ON REFRIG ERANT LINE 5 CONNECT QUICK DISCONNECT ADAPTER TO SEA VICE VALVES HINT Push the quick disconnect adapter onto the servtce valve then slide then slide the sleeve of the quick disconnect adapter downward to lock it ...

Page 1091: ...S OF MANIFOLD GAUGE SET 2 DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT Slide the sleeve of the quick disconnect adapter upward to un lock the adapter and remove it from the service valve 3 INSTALL CAPSTOSERVICE VALVES ON REFRIGER ANT LINE ...

Page 1092: ...ING REFRIGERANT LINE ON VEHICLE INSPECTION REFRIGERANTLINE 1 INSPECTION HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2 INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector check for leak age of refrigerant AC 21 ...

Page 1093: ...REFR GEflANT LINE LOCATION Liquid Tube SuchanHose Di ch coe Hose Piping Clamp QuickJoint Condenser 1 N m kgf cm ft lbf Specified torque Non reusablepart p Piping Clamp Quick Joint I _ I 11 I i _ j i f i Compressor I l1 90S ...

Page 1094: ...hter than the specified torqued PartH ghtened N m kgh m Condenser x Discharge tube 5 4 55 Condenserx Liquid tube 5 Compressorx Doscharge tube w HJO Compressor x Suctton lube 10 100 Expansion wive x Evaporator 5 4 55 4 EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount 430 30 g 15 17 1 06 oz 5 INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector check for leak...

Page 1095: ...PECT FOR LEAKAGE OF REFRIGERANT a Remove the glove compartment door See page 80 79 b Remove the blower unit c Using a gas leak detector check for leakage of refrigerant If there is leakage check the tightening torque at the joints or check the evaporator expansion valve AJC tube and Q rings ...

Page 1096: ...uidTube Q Rings SuctionTube Reinforcement NCUnit BlowerUnit NCUnitCase pq m kgf crll ff lbt Specifiedtorque Non reusablepart Brace Evaporator Packing EvaporatorCover I T Valve Plate fR Plate I dJ The mislo L Clamp 4ain lb J fevaporatorisreplaced add40cc 1 411 oz ofcompressoroil ND QIL8orequivalent ...

Page 1097: ...RADIATOR HINT It is not necessary to drain out all coolant 3 DISCONNECT LIQUID TUBE AND SUCTION HOSE a Using SST remove the 2 piping clamps HINT SST 0987 0015 Suction 1ube 09870 00025 Liquid tube 1 Insert SST to piping clamp Confirm the direction of the piping clamp claw and SST using the illustration showing on the caution labeL 2 Push down SST and release the damp lock NOTICE Be careful not to d...

Page 1098: ... HEATER RA DIATOR PIPES Second Ridge View _ View Hose Clip Upper Upper RH ffi_ Marking W Lower LH Y Markmg Lower IHDJ c G _ _ HINT Using pliers grip the claw of the hose clip and slide the hose cllp along the hose Disconnect the heater hoses At the time of installation please refer to the following item Push the water hose onto the heater radiator pipe as far as se cond ridge on the pipe and insta...

Page 1099: ...e fins are clogged clean them with compressed air NOTICE Never use water to clean the evaporator b Check fitting for cracks or scratches lf necessary repair or replace 2 INSPECT HEATER RADIATOR Inspect fins for blockage If the fins are clogged Clean them with compressed air AIR CONDITIONING UNIT ...

Page 1100: ...ngine side b Hold the removed heater hose with the end facing up pour LLC into the hose c Pour LLC until itflows into the reverse tankfrom the hose at the bottom d When this happens stop pouring and reinstall the heater hose to the heater pipe e Perform air bleeding in the same manner when LLC is re placed See page C0 2 HINT Note that the amount of LLC removed from the heater parts should be added...

Page 1101: ...AC 30 AIR CONDITIONING BLOWER UNIT BLOWER UNIT COMPONENTS p Blower Unit Blower Unit Case Air Refiner Filter Blower Motor Filter Case Blower Resistor 113S9 ...

Page 1102: ...WER UNIT REMOVAL 1 REMOVE GLOVE COMPARTMENT PARTS See page B0 79 2 REMOVE BLOWER UNIT AC 31 a Disconnect the connector and air inlet control cable b Remove wire harness clamp c Remove the 2 screws 2 nuts and the blower unit ...

Page 1103: ...E BLOWER RESISTOR Remove the 2 screws and blower resistor 2 REMOVE AIR REFINER FILTER a Pull out the filter cover b Remove the filter from the frame 3 REMOVE BLOWER MOTOR a Remove the screw and wire harness clamp b Remove the 3 screws and the blower motor ...

Page 1104: ...AC 33 AIR CONDI110NING BLOWER UNIT REASSEMBLY Reassembly is in the reverse order of disassembly See page AC 32 ...

Page 1105: ...AC 34 INSTALLATION AIR CONDITIONING BLOWEA UNIT Installation is in the reverse order of removal See page AC 31 ...

Page 1106: ...ESIS TANCE a Disconnect the connector_ b Measure resistance between terminals 1 and 2 Standard resistance 165 205 n at 20 c 68 F If resistance is not as specified replace the sensor 5 CHECK FOR LEAKAGE OF GREASE FROM CLUTCH BEARING 6 CHECKFOR SIGNSOFOILON PRESSURE PLATE OR ROTOR 7 INSPECT MAGNETIC CLUTCH BEARING FOR NOISE a Start eng 1ne b Checkforabnormalnoise from the compressor when the AJC swi...

Page 1107: ...AC 36 AlA CONOITIONING COMPONENTS p Cruise Control Actuator Drive Belt Pressure Plate COMPRESSORAND MAGNETIC CLUICH Suction Hose Compressor Stator Compressor ...

Page 1108: ...N SYSTEM 5 REMOVE DRIVE BELT See page AC 17 6 DISCONNECT CRUISE CONTROL ACTUATOR CON NECTOR 7 REMOVE 3 CRUISE CONTROL ACTUATOR SET BOLTS 8 DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 bolts and disconnect the both hoses NOTICE Cap the open fittings immediately to keep moisture or dirt out of the system 9 REMOVE COMPRESSOR a Disconnect the connector b Disconnect the wire harness clamp c Remo...

Page 1109: ...et wrench remove the shaft bolt SST 07112 76060 Torque 13 2 N m 135 kgf cm 9 fl lbf b Install SST on the pressure plate SST 07112 66040 c Using SST and socket wrench remove the pressure plate SST 0711 2 66040 07112 76060 d Remove the shims from the pressure plate 2 REMOVE ROTOR a Using SST remove the snap ring SST 07114 84020 ...

Page 1110: ...CH AC 39 b Using a plastic hammer tap the rotor off the shaft NOTICE Becareful not to damagethe pulley when tappingonthe ro tor 3 REMOVE STATOR a Disconnect the connector from the stator b Using SST remove the snap ring SST 0711 4 84020 c Remove the stator ...

Page 1111: ...03 REASSEMBLY 1 INSTALL STATOR a Install the stator b Using SST install the snap ring SST 071 14 84020 NOTICE The snap ring should be installed so that its beveled side faces up c Connect the connector to the stator 2 INSTALL ROTOR a Install the rotor b Using SST install the snap ring SST 071 14 84020 ...

Page 1112: ...6040 07112 76060 Torque 13 2 N m 135 kgf cm 9 fl lbf 4 INSPECT MAGNETIC CLUTCH CLEARANCE a Set the dialindicatorto the pressure plate ofthe magnetic clutch b Connect the magnetic clutch lead wire to the positive terminal of the battery c Check the clearance between the pressure plate and ro tor when connecting the negative terminal to the bat tery Standard clearance 0 45 0 10 mm 0 018 0 004 in If ...

Page 1113: ...fl lbf NOTICE Hose should be connected immediately after the caps have been removed 3 INSTALL 3 CRUISE CONTROL ACTUATOR SET BOLTS 4 CONNECT CRUISE CONTROL ACTUATOR CONNECTOR 5 INSTALL AND CHECK DRIVE BELT See page AC 18 AC 16 6 CONNECT NEGATIVE H TERMINAL CABLE TO BATTERY 7 EVACUATE AIR FROM REFRIGERATION SYSTEM CHARGE SYSTEM WITH REFRIGERANT Specified amount 430 30 g 15 17 1 06 oz 8 INSPECT FOR L...

Page 1114: ...ed wash them with water and dry with compressed air NOTICE Be careful not to damage the fins If the fins are bent straighten them with a screwdriver or pliers 2 INSPECT CONDENSER AND FITTINGS FOR LEAKAGE Using a gas leak detector check for leakage of refrigerant If there is leakage check the tightening torque at the joints AC 43 ...

Page 1115: ...NENTS 0 Ring I Radiator UpperMounting Hose p Condenser lN _f J k QI J _bf Specified torque P Non reusable part 13905 Compressor oil NO OIL 8orequivalent I1Y JOO CONDENSER Front Bumper Drier Filter o A R 0 v tng Cap i2 3 125 90 e ...

Page 1116: ...QUID TUBE AND DISCHARGE HOSE Remove 2 bolts and both tubes Torque 5 4 N m 55 kgf cm 48 in lbf NOTICE Cap the open fittings immediately to keep moisture out of the system HINT Lubricate 2 new Q rings with compressor oil and install them to the tubes 4 REMOVE RADIATOR UPPER MOUNTINGS Remove the 2 bolts 2 nuts and the 2 upper mountings 5 REMOVE CONDENSER Pull out the condenser HINT Al tho time of ins...

Page 1117: ...ot remove the dryer from a vinyl bag until insert ing it into the modulator Install the dryer with its 2 layered part faced upward to the modulator e Insert the fi ter into the modulator NOTICE Install the filter with Its protrusion faced downward to the modulator f Install the cap to the modulator 1 Apply compressor oil to the a rings and screw part of the cap Compressor oil NO OIL 8 or equivalen...

Page 1118: ...AC 47 AIR CONDITIONING CONDENSE R INSTALLATION J Installation is in the reverse order of removal See page AC 45 ...

Page 1119: ... the 3 screws and motor 3 INSPECT BLOWER MOTOR OPERATION Connect the positive lead from the battery to terminal 1 and the negative leadtoterminal 2 thencheckthatthe motorop erations smoothly If operation is not as specified replace the blower motor 4 INSTALL BLOWER MOTOR a Install the motor and 3 screws b Connect the connector and wire harness clamp 5 INSTALL GLOVE COMPARTMENT PARTS See page B0 85...

Page 1120: ...nector b Remove the 2 screws and the blower resistor 2 INSPECT BLOWER RESISTOR CONTINUITY AC 49 Condition Testerconnection Specifiedcondition Constant 1 2 3 4 Continu y If contmutty IS not as spectfted replace the blower reststor 3 INSTALL BLOWER RESISTOR a Install the blower resistor and 2 screws b Connect the connector ...

Page 1121: ...ermistor_ HINT Tape the screwdriver tip before use 3 INSPECT THERMISTOR a Place the thermistor in cold water and while changing the temperature of water measure resistance at the connec tor and at the same time measure temperature of water with a thermometer b Compare the 2 readings on the chart If resistance is not as specified replace the thermistor 4 INSTALL THERMISTOR a Install the thermistor ...

Page 1122: ...ch control INSPECT PRESSURE SWITCH OPERATION a Connect the positive lead from the ohmmeter to termi nal 4 and the negative lead to terminal 1 b Check continuity between terminals when refrigerant pressure is charged as shown in the illustration It operation is not as specified replace the pressure switch 5 Condenser fan control INSPECT PRESSURE SWITCH OPERATION a Connect the positive lead from the...

Page 1123: ... of refrig erant Specified amount 430 30 g 15 17 1 06 oz 2 REMOVE PRESSURE SWITCH a Disconnect the connector b Remove the pressure switch from the liquid tube Torque 10 N m 100 kgf cm 7 ft lbf HINT Lock the switch mount on the tube with an open end wrench being careful not to deform the tube and remove the switch At the time of installation please refer to the following item Lubricate a new 0 ring...

Page 1124: ...AC 53 AIR CONDITIONING PRESSURE SWITCH _ INSTALLATION Installation is in the reverse order of removal See page AC 52 ...

Page 1125: ...PECTION 1 REMOVE HEATER MAIN RELAY FROM ENGINE ROOM RELAY BLOCK NO 1 2 INSPECT HEATER MAIN RELAY CONTINUITY Cof1dillon Tester connection Specifiedcondition Constant 3 Continuity 2 4 App y B between _ Cont nuily terminals 1and 3 lf contmuity is not as speclfted replace the relay ...

Page 1126: ...LAY INSPECTION 1 REMOVE MAGNETIC CLUTCH RELAY FROM ENGINE ROOM JIB 2 INSPECT MAGNETIC CLUTCH RELAY CONTINUITY ConditiOn Testorconnoction Specifiedcondttion Constant 1 2 Continuity Apply 8 betwoon 3 5 Continuity terminals 1 and 2_ f continuity is not as specified replace the relay ...

Page 1127: ...ECT COOLING FAN RELAY N0 2 CONTINUITY Condition Constant Apply Br be tween terminals 1 and 2_ T esterconnection 1 2 s 3 5 Spedtiedcondition Continuity Continuity If continuity is not as specified replace the relay 4 INSPECT COOLING FAN RELAY N0 3 CONTINUITY Condition Tester connection Specified coOOition Constant _ Continuity Apply B between 3 5 Continuity terminals t and 2_ If conttnUity IS not a...

Page 1128: ...eis less than 1 520 kPa 15 5 kgf cm2 220 psi Refrigerantpressureis 1 520 kPa 15 5 kgf cm2 220 psi or above F lrl0p Fat on Fan speed Rotate low spoed Rotate H1gh speed Rotate low speed Hotate ff1gh speed If operat1on 1s not as spectfJed proceed to the next mspect1on 2 INSPECT CONDENSER FAN MOTOR OPERATION a Disconnect the connector b Connect battery and ammeter c Check that the fan rotates smoothly...

Page 1129: ...AC 58 COMPONENTS Radiator Upper Support N CONDENSER FAN AIR CONDITIONING Upper Front Fender Apron Seal Upper Radiator Support Seal _____ BumperCover lol0818 ...

Page 1130: ...AC 59 AIR CONDITIONING CONDENSER FAN Fan Shroud Fao Nut N ...

Page 1131: ...onnector on the wire harness side as shown in the chart below Test condition Turn ignition switch to ON rf r t i 09 r U l iJ L L l i 2 3 4 5 6 7 ll 1 1 12 1 14151 1 1 1 u Connector A Connector 8 Tester connBction A7 Gwufl l A6 A18 Condition Spec1 iod ccndilion Constant CorJlinuity Evaporator temperature at 25 c 77 F t Skn If c1rcwt IS as spec1hed try replacmg the amphf1er With a new one II the cir...

Page 1132: ... Lto11 t 2 t 3 1 4 1ste17ta q L_ _ rr J 11046 Tesler connection Condition Specifiedcondition BlO Ground 814 Ground 915 Ground A13 Ground NCswitch ON Blower motor operate Below 1 0 V NCSWllch OFF Bat erypositive voltage Mode selector DEF Below 1 0 V ModeSelector Except DEE Ba lery positive voltage NCswitch ON Below 1 0 V NGswitch OFF Battery positive voltago Blower motor Operata Below 2 0 V Blowerm...

Page 1133: ...ngine MagnBtic clutch ON Below 1 0 V Startengine Magneticclulch OFF Batterypositive vOltage Start engine AJCswitch ON Ba tery pos1t ve voltage Start engine AJCSWitch OFF No voltagB Refrigerant pressure 196 1 340 kPa flattery positwe voltnge Refrigerant pressure less than 196 ormore than 1 340 kPa No voltage If CirCUit IS as spec1fied try replacmg the amphher wtth a new one If the circuit is not as...

Page 1134: ...AIR CONDITIONING AIR CONDITIONING AMPLIFIER REMOVAL 1 REMOVE COMBINATION METER See page BE 44 2 REMOVE ECM AC 63 ...

Page 1135: ...AC 64 INSTALLATION AIR CONDffiONING AIR CONDITIONINGAMPLIFIER Installation is in the reverse order of removal See page Ac 63 ...

Page 1136: ...CTION _ INSPECT HEATER CONTROL DIALS OPERATION Turn the control lever and 2 control dials left and right then check that click sound can be heard and recoil is felt If click sound can not be heard or recoil is fell adjust the control cable or check control cable and heater control assembly ...

Page 1137: ...er Finish Panel Air Outlet Control Cable Color Blue Air Mix Control Cable Color Black Switch Circuit Bulb Iii i U _____ J i r cfllr Heater Control Assembly L_ __ jl J C 1 Heatet Contml Panoi C Clamp Air Inlet Control Cable I 1 J Colot Gtay i I Heater Control Assembly Retainer Defroster Mode Switch Heater Control Cover ...

Page 1138: ...HEATER CONTROL CABLES NOTICE When the air mix damper control cables is disconnected should not bend the cable 3 REMOVE HEATER CONTROL ASSEMBLY Release the 2 claws and pull out theA Ccontrol assembly then disconnect the connector 4 REMOVE HEATER CONTROL PANEL a Remove the 2 screws b Slide and remove the NC control assembly ...

Page 1139: ... I continuity exists replace the heater controL II no continuity exists replace the bulb 3 INSPECT AIC INDICATOR OPERATION a Connect the positive lead from the battery to terminal 1 and the negative lead to terminal 3 and 10 b Push the NC button in and then check that the indicator lights up H operation is not as specified replace the switch 4 INSPECT DIMMING OPERATION a Connect the positlve lead ...

Page 1140: ...uity is not as specified replace the bulb 6 INSPECT BLOWER SPEED CONTROL SWITCH CON TINUITY PositioNCircuit T ester connoction Specitred condition OfF NocontirMty LO 8 Contrnuity M 1 6 8 Cominu1ty M 1 5 8 ConttnU1 y 4 8 Cont rwity If continuity is not as specified replace the switch_ 7 INSPECT DEFROSTER MODE SWITCH OPERATION PosihonlCircuit T ester connection Spcdf1edcondition OFF No continuity ON...

Page 1141: ...C CONTROL PANEL Install the AJC control panel and 2 screws 2 INSTALL AIC CONTROL ASSEMBLY a lnstatl the AJC control assembly temporarily b Pass through the AJC control cables as shown in the il lustration c Fit the 2 claws of heater control assembly in the instru ment panel hole ...

Page 1142: ...ile lightly pushing the outercable tothe direc tion shown by arrow in the illustration e Adjust air mix damper control cable HINT Set air mix dampercontrol leverto MAX COOL position and connect the inner cable to lever pin and clamp the outer cable Lockthe clamp while lightly pushing the outercable to the direc tion shown by arrow in the illustration f Adjust air outlet damper control cable HINT P...

Page 1143: ...l the coolant 2 REMOVE ECT SWITCH 3 INSPECT SWITCH CONTINUITY a Using an ohmmeter check that no continuity exists be tween the terminals when the coolant temperature is above 90 c 194 F b Using an ohmmeter check that continuity exists between the terminals when the coolant temperature is below 83 c 181 F If no continuity exists replace the switch 4 INSTALL ECT SWITCH 5 REFILL ENGINE COOLANT _ ...

Page 1144: ... the 2 pins m the glove box and open the glove box widely by pulling it down b c Pull out the filter case Remove the air refiner filter from the filter case 2 INSTALL AIR REFINER FILTER a Install the air refiner filter to filter case b Install the filter case c Close the glove box and install the 2 pins to it ...

Page 1145: ... MEMO ...

Page 1146: ...10 1 ALPHABETICAL INDEX ...

Page 1147: ...1 PP 77 I SS 54 1 BE 1 2 MA 6 1 PP 62 I SS 49 1 BR 13 2 BH 4 2 BR 9 BR 6 2 BR 1 21 IG 13 21 SF 46 2 PP 24 1 SS 27 1 CHARGING SYt TEM _ CHASSIS CIHCUlT INS Io CTION ANTI LOCK BRAKE SYSTEM WHH ELECTRONIC BRAKE FORCE OISTniBUTION EBO DIAGNOSTICS CIRCUH INSP CTION AUTOMATIC TAANSAXl E U240E iDIAGNOS HCS CIRCUIT INSPECTION AUTOMATIC TRANSAXLE U341E DIAGNOSTICS CIRCUIT INSPECTION BODY CONTROL SYSTEM DIA...

Page 1148: ...2 IN 1 0 1 ns 57 2J SA 1 1 Rf1 20 2 Hfl 11 R0 4 121 l 0 10 2 SA 18 2 SA 46 121 FRONT lOWf R SUSPFNSION ARM f ROI JT PASSCNGLR AiRBAG ASSEMHLy FRONT SEAT FRONT SHOCK ABSORREil 1 RONT Sl f ED SENSOR FRONT SlARIUZER BAH f RON WHCEL ALIGNMENI FRONT WHEEL HUB BOI T FRONT WIPEfl AND WASHEn FUEL CUT RPM FUEL PRESSURE REGULA OH FUFL PUMP fUEL TANK AND LINE GFNFRAL NFORMAI ION G HOWTO TROUBLESHOOT ECU CONT...

Page 1149: ...EM WITH ELECTRONIC BRAKE f ORGE DISTRIBUTION EBO DIAGNOSTICS PARTS l OCATION AU OMAliG TRANSAXLE U240E DIAGNOSTICS PAH I S LO CAfiON AU rOMAl iC 1 f1ANSAXLE U341E DIAGNOSTICS PAH1S LOCAl ION BODY CUNlHOL SYSTEM OIAGNOSTICSJ PARTS I OCATION CRUISE CONTROL SYSTEM DIAGNOSTICS PAHl S LOCAriON ENGINE DIAGNOSTICS PARTS LOCATION SUPPLEMENTAL RESTRAINf SYSTEM DIAGNOSTICS POSHIVE CRANKCASE VENTILATION PCV ...

Page 1150: ...6 2 t 10 69 2 BE 82 2 AX 4 2 80 3 2 RS 1 2 SS 1 1 Sf 2 2 ST 17 2 PP 21 1 SS 25 1 ST 1 2 PP 67 1 S 51 1 SR 1 2 SR B 2 HS 12 2 Rf 32 2 Ot 2 1 Pf 74 1 SS 5 1 SUSPENSION AND AXLl PREPAf ATION SUSPENSION AND AXLE SERVICE SPECIFICATIONS T fEHMINALS OF ECM AUTOMATIC TRANSAXLE U240E DIAGNOSTICS fl RMINALS OF ECM AUTOMATIC rRANSAXLE U341Ej DIAGNOSfiGS TEHMINALS OF ECM ENGINE DIAGNOSTICS TERMINALS OF ECU AN...

Page 1151: ... WATER PUMP WINDSHIELD WIPER AND WAStiER SYSTEM w WIRE HARNESS AND CONNECTOR WIRELESS DOORLOCKCONTROlSYSTEM AlPHABETICAL INDEX W W Page Vol CQ 4 2 80 47 2 BE 14 2 R 72 2 BE 7 2 ...

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Toyota Celica 2000, Repair Manual

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